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BACKGROUND
1. Field of the Invention
Embodiments of the invention relates to simulation of an Integrated Circuit (IC) chip for testing of test patterns that are created by Automatic Test Pattern Generation (ATPG) for use with scan circuitry within a physical IC chip.
2. Related Art
Electronic devices today contain millions of individual pieces of circuitry or “cells.” To automate the design and fabrication of such devices, Electronic Design Automation (EDA) systems have been developed. An EDA system includes one or more computers programmed, for use by chip designers, to design electronic devices which may include one or more IC chips. An EDA system typically receives one or more high level behavioral descriptions of circuitry to be built into an IC chip (e.g., in Hardware Description Language (HDL) like VHDL, Verilog, etc.) and translates this behavioral description into netlists of various levels of abstraction. A netlist is typically stored in computer readable media within the EDA system and processed and verified using many well known techniques. The EDA system uses the netlist(s) to ultimately produce a physical device layout in a mask form, for use in fabricating a physical IC chip.
A Design For Test (DFT) process may take a design, for example in the form of a netlist, of an IC chip which implements a desired behavior, for example Digital Signal Processing (DSP), and replace one or more flip-flops 11 - 12 ( FIG. 1A ) with special cells called “scan cells” 21 - 22 ( FIG. 1B ) that are designed to supply test vectors from primary inputs 31 of IC chip 10 ( FIG. 1B ) to one or more portions 13 . Portions 13 of the original IC chip's design typically include combinational logic, which couples flip-flops 11 and 12 . During the just-described replacement of flip-flops with scan cells, portions 13 are typically kept unchanged. Such a modified design has two modes of operation, a mission mode which performs an intended function (e.g. DSP) for which IC chip 10 was designed, and a test mode which tests whether circuit elements in IC chip 10 have been properly fabricated.
Typically, a scan cell 21 ( FIG. 1B ) in such an modified design of IC chip 10 includes a flip-flop 21 F that is driven by a multiplexer 21 M; multiplexer 21 M supplies to a data input (D input) pin of flip-flop 21 F, either a signal SI if operated in test mode (during which time a scan enable signal SE is active) and alternatively supplies another signal MI if operated in the mission mode (during which time signal SE is inactive). A signal which is input to flip-flop 21 F is shown in FIG. 1B as the multiplexer's output signal MO. During scan design, scan cells 21 and 22 may be identified by a chip designer as being intended to be coupled into a scan chain, which involves creation of a scan path 23 (see FIG. 1B ) by coupling scan cells 21 and 22 (e.g. the input pin SI of cell 22 is coupled to the output pin Q of flip-flop 21 F in cell 21 ). Scan path 23 is an alternative to a mission path 13 P through portions 13 , and a signal from one of these two paths is selected by multiplexer 22 M based on its scan enable signal. Chip designer may designate either a common scan enable signal SE or designate different scan enable signals, to operate multiplexers 21 M and 22 M.
An additional step in developing an IC chip's design involves generating test patterns to be applied to IC chip 10 . A computer programmed with ATPG software may analyze one or more representations of the IC design in the form of netlists and may automatically generate test patterns. Such test patterns (also called test vectors) are applied to scan cells in a physical IC chip by a hardware device (called “tester”) to test, for example, whether certain selected portions of circuitry are fabricated correctly.
More specifically, a tester (not shown) tests IC chip 10 by loading one or more test patterns serially into one or more scan cells 21 (also called “input scan cells”) from primary inputs 31 of IC chip 10 during a shifting operation (also called “loading operation”), while activating the scan enable signal. Primary inputs 31 and primary outputs 32 of IC chip 10 are external pins that are accessible from outside of chip 10 , e.g. to any tester. After such a shifting operation, the tester may deactivate the scan enable signal, and operate IC chip 10 for one clock cycle with the test patterns applied to portion 13 (in a “test operation”.)
The test operation is followed by one or more cycles of active scan enable signal(s) in another shifting operation (also called “unloading operation”), wherein results of test operation that were latched by output scan cells 22 are shifted to primary outputs 32 of IC chip 10 . The current inventors note that during both the loading operation and the unloading operation, the selected portions 13 of circuitry between the source and sink scan cells 21 and 22 continue to operate normally in the prior art, i.e. all gates in these portions are evaluated.
Prior to fabrication of the physical IC chip, the test patterns are typically applied to a gate-level computer model of the IC chip. For example, computer instructions 40 ( FIG. 1C ) are obtained by converting an IC design that is expressed in a HDL into software source code (e.g. in programming language C or C++) that is either executed (after compilation) or interpreted (without compilation) in a computer. In the illustration of FIG. 1C , computer instructions 40 include three functions, a first function “Evaluate_Flipflop” simulates a signal at the output pin Q of flip-flop 21 F in scan cell 21 ( FIG. 1B ), a second function “propagate” simulates the propagation of this signal through combinational logic 13 , via mission path 13 P to the MI input pin of scan cell 22 . Finally, a third function “Evaluate_Multiplexer” simulates a signal that is supplied by multiplexer 22 M to the input pin D of flip-flop 22 F. Execution of computer instructions 40 after compilation is faster than interpreted execution, and therefore it is common to compile such software source code into compiled code.
The function “propagate” described in the previous paragraph may or may not simulate a signal's travel on scan path 23 , depending on the configuration. For example, flip-flops typically have another output pin, namely the Q-pin (which is in addition to the Q pin) and in some configurations the Q-pin is used in scan chaining, in which case function “propagate” does not to do any additional simulation. In other configurations, the Q-pin is not used, and instead path divergence happens at cell instantiation. In such configurations, the Q-pin may be simulated, to drive a signal on the scan path 23 .
Simulation based on compiled code is described in, for example, “Ravel-XL: A Hardware Accelerator for Assigned-Delay Compiled-Code Logic Gate Simulation” by Michael A. Riepe et al, published by University of Michigan in March 1994, and incorporated by reference herein in its entirety as background. Moreover, some compiled code simulators of the prior art are also described in U.S. Pat. No. 6,223,141 granted to Ashar on Apr. 24, 2001, which patent is also incorporated by reference herein in its entirety as background. Ashar describes speeding up levelized compiled code simulation using netlist transformations. Specifically, delay-independent cycle-based logic simulation of synchronous digital circuits with levelized compiled code simulation substantially increases speed. Sweep, eliminate, and factor reduce the number of literals. Specifically an eliminate function rids a netlist of gates whose presence increases the number of literals, i.e., collapsing these gates into their immediate fanouts reduces the number of literals. Before collapsing a gate into its fanout, the function estimates the size of the new onset. If the estimated size is greater than a preset limit, the collapse is not performed. Most of the literal count reduction is through the eliminate function.
The current inventors believe that compiled code simulators can become unduly slow. Specifically, the number of test patterns required to achieve high fault coverage increases with circuit size. Moreover, deep sub-micron technology challenges existing fault models with the possibility of more failure mechanisms and more defect types. More fault models, in turn, require more test patterns for the same fault coverage and quality level, which increases the time required to simulate the testing of the test patterns. Hence, the current inventors believe there is a need to further improve the speed of compiled code simulation.
SUMMARY
Embodiments of the invention disclosed herein provide a computer implemented method, apparatus and a computer readable medium to prepare a computer program for simulating operation of an integrated circuit (IC) chip, in order to test scan circuitry therein.
An exemplary embodiment of the invention provides a computer implemented method for to prepare a computer program for simulating operation of an IC chip, in order to test scan circuitry. The method traces a path through combinational logic in a design of the IC chip, creates a first instruction set to simulate propagating a signal through the path; modifies the first instruction set to create a second instruction set, the second instruction set requiring a predetermined condition to be met for execution of the first instruction set; and stores the first instruction set and the second instruction set in a memory.
An exemplary embodiment of the invention provides an apparatus to prepare a computer program for simulating operation of an IC chip, in order to test scan circuitry. The apparatus includes memory encoded with a design describing the IC chip; means for tracing a path through combinational logic in the design; means for checking if the first scan cell and the second scan cell receive a common scan enable signal; means for generating at least a portion of the computer program to conditionally propagate a signal through the path if the common scan enable signal is inactive and to not propagate the signal through the path if the common enable signal is active; and means for storing the portion of the computer program in the memory.
An exemplary embodiment of the invention provides a computer readable medium to prepare a computer program for simulating operation of an integrated circuit (IC) chip, in order to test scan circuitry. The computer readable medium includes instructions to trace a path through combinational logic in a design of the IC chip; instructions to create first instruction set to simulate propagating a signal through the path; instructions to modify the first instruction set to obtain a second instruction set, the second instruction set requiring a predetermined condition to be met for execution of the first instruction set; and instructions to store in a memory of a computer, as a portion of the computer program, the first instruction set and the second instruction set.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A and 1B illustrate a prior art design of an IC chip before and after insertion of scan circuitry.
FIG. 1C illustrates a portion of a prior art computer program for simulation of the design of FIG. 1B , to test the scan circuitry.
FIG. 2A illustrates, in a flow chart, a method used in accordance with an embodiment of the invention, to prepare a computer program that enhances speed of simulation.
FIG. 2B illustrates a portion of the computer program generated in accordance with an embodiment of the invention, to include a conditional statement, by performing the method of FIG. 2A .
FIG. 3 illustrates, in a flow chart, acts performed in an illustrative embodiment of the invention, to implement the method of FIG. 2A .
FIGS. 4A-4C illustrate, in flow charts, acts performed in an implementation of an embodiment of the invention.
FIG. 5 illustrates, in a block diagram, a computer that is programmed in accordance with an embodiment of the invention.
FIG. 6 illustrates a simplified representation of an exemplary digital Application Specific IC (ASIC) design flow in accordance with an embodiment of the invention.
DETAILED DESCRIPTION
A computer 150 ( FIG. 5 ) is programmed, in accordance with an embodiment of the invention, to perform a method 200 ( FIG. 2A ) to create a computer program that enhances speed of simulation of an IC chip in order to test scan circuitry. Specifically, the inventors of the current patent application note that when the scan enable signal SE ( FIG. 1B ) is active, a multiplexer 22 M at the output of combinational logic 13 selects a signal that travels via scan path 23 . Accordingly, the inventors conceived that operation of such a multiplexer (when scan enable signal is active) makes it unnecessary to simulate the propagation of a signal through portions 13 , via mission path 13 P. Based on this conception, the inventors formulated method 200 which enhances speed of simulation, by avoiding unnecessary simulation on path 13 P when the scan enable signal is active, as discussed in the next paragraph. As will be apparent to the skilled artisan, the scan enable signal may be either an active high signal (i.e. active when the signal is high or of value “1”) or alternatively an active low signal (i.e. active when the signal is low or of value “0”), depending on the embodiment.
As illustrated in FIG. 2A , in a first operation 201 , computer 150 initially determines which components of the IC chip form scan cells. In this operation computer 150 also determines for each scan cell, which of its pins respectively carry (1) a scan data signal, (2) a data signal resulting from operation in the mission mode, (3) a scan enable signal, and (4) a clock signal. Computer 150 is further programmed to perform a tracing operation 202 , for example to identify a path 13 P through combinational logic 13 . As shown in FIG. 1B , mission path 13 P starts from an output pin Q of flip-flop 21 F in source scan cell 21 , and ends in an input pin MI of multiplexer 22 M in sink scan cell 22 . Computer 150 is also programmed to perform an operation 203 to create software instructions to simulate the propagation of a signal through the mission path 13 P.
Note that the result of operation 203 is illustrated by prior art computer instructions 40 in FIG. 1C . Note also that computer 150 may be programmed to implement operations 201 - 203 in any manner apparent to the skilled artisan. Hence, specific details of the manner in which operations 201 , 202 and 203 are performed by computer 150 , are not critical to practicing the embodiments of the invention.
Computer 150 is further programmed to check on one or more conditions (in an operation 204 ) and if the condition(s) is/are met, computer 150 performs an operation 205 which is skipped if the condition(s) is/are not met. The condition(s) 997 ( FIG. 5 ) used in operation 204 is/are predetermined, and are stored in a memory of computer 150 . Certain conditions of operation 204 are used to ensure that non-simulation of path 13 P will not change the results of testing one or more test patterns created by automatic test pattern generation (ATPG) for use with scan circuitry. If the conditions are satisfied, then path 13 P is determined to be “optimizable,” thereby making it a candidate for non-simulation.
For example, some embodiments of the invention support use of multiple scan enable signals. Accordingly, such embodiments check a predetermined condition in operation 204 as follows: whether the signal supplied to path 13 P by source scan cell 21 and the signal received from path 13 P by sink scan cell 22 are synchronously used (or not used), i.e. if the multiplexers 21 M and 22 M in the respective scan cells 21 and 22 are operated by the same scan enable signal. If the result is true, then path 13 P is determined to be optimizable. Another such predetermined condition that is checked in operation 204 of some embodiments of the invention is whether path 13 P contains any sequential elements, and only if the result is no then path 13 P is marked by computer 150 as being “optimizable.” Note that some embodiments of the invention treat a path as being optimizable if the path starts in a data pin of a scan cell and eventually ends in a data pin of a scan cell. While tracing such a path, one illustrative embodiment traces through combinational elements but not through other circuit elements. A combinational element's output state is instantly determinable from the state(s) at its input(s). The illustrative embodiment marks a path as being unoptimizable if any circuit element other than a combinational element is encountered during path tracing as described herein.
As noted above, if path 13 P is found by operation 204 to be not optimizable, then computer 150 simply goes to operation 206 wherein computer instructions 40 ( FIG. 1C ) that were created by operation 203 are stored to memory, as one portion of a computer program, for use with other such portions (e.g. created by operation 203 by repetition). Note that the instructions 40 (i.e. software) include a statement 42 whereby the signal's propagation on path 13 P is simulated unconditionally. If path 13 P is found by operation 204 to be optimizable, then an optional operation 205 is performed by computer 150 , as discussed next.
In operation 205 , computer 150 modifies computer instructions 40 that were created in operation 203 by adding therein one or more condition(s) to be checked, to obtain modified computer instructions that avoid simulation of signal propagation along the optimizable path 13 P when unnecessary. For example, as illustrated by statement 252 in modified computer instructions 250 shown in FIG. 2B , the scan enable signal is checked and if it is active then the function “propagate” is not executed, unless path 13 P is not optimizable. Specifically, software statement 252 checks if path 13 P is not optimizable and if not optimizable, then the function “propagate” is executed. On the other hand, regardless of whether or not path 13 P is optimizable, if the scan enable signal is inactive (e.g. when mission mode is being simulated) then function propagate is again executed. Note that instructions 250 include statement 252 whereby simulation of signal propagation is performed conditionally. More specifically, statement 252 is conditioned on the state of the scan enable signal and on whether or not path 13 P is optimizable.
Accordingly, as will be apparent to the skilled artisan in view of this disclosure, simulation of signal propagation through mission path 13 P is eliminated, by checking one or more conditions in such modified computer instructions 250 , which in turn speeds up loading and unloading operations, namely the operations to shift in or shift out test patterns from/to primary inputs/outputs. Hence, simulation of an IC design during testing of scan circuitry therein is speeded up by modified computer instructions 250 as illustrated in FIG. 2B . Therefore, after operation 205 , computer 150 performs operation 206 wherein the modified computer instructions 250 are stored to memory, as a computer program portion (i.e. software) for use with other such portions. After operation 206 , computer 150 goes to operation 207 and checks if all paths starting from all scan cells in the IC chip's design (e.g. in the form of a gate level netlist, see FIG. 5 ) have been traced. If not, then computer 150 returns to operation 202 (described above). If all paths are found in operation 207 as having been traced, then computer 150 has completed this method, and hence it exits (see operation 208 ).
The computer instructions resulting from operation 203 were to have been executed unconditionally (relative to the scan enable signal), as illustrated in FIG. 1C . In accordance with the invention, an operation 205 ( FIG. 2A ) modifies these computer instructions, to make them executable conditionally, as shown in statement 252 ( FIG. 2B ). While certain examples of conditions are shown in statement 252 , other condition(s) may be checked in other embodiments, as will be apparent to the skilled artisan in view of this disclosure.
In some embodiments of the invention, computer 150 implements a process of the type illustrated in FIG. 3 , based on operation 201 in method 200 of FIG. 2A . Specifically, in act 301 , computer 150 identifies one or more User-Defined Primitives (UDPs) in a design of IC chip 10 as being for flip-flop(s). The specific UDPs which are used depend on a number of factors, such as a technology library of cells which is provided by a fabrication facility. Next, in act 302 , computer 150 identifies additional UDPs in the design as being for multiplexer(s). Note that acts 301 and 302 may be implemented in any manner that will be apparent to the skilled artisan in view of this disclosure.
Thereafter, in act 303 , computer 150 obtains from a data model of the IC chip design, a list of all modules that instantiate the flip-flop that was identified in act 301 . Next, in act 304 , computer 150 obtains from the data model, a list of all ports of each module (which when being processed individually, is referred to below as “current module”) that was identified in act 303 . In act 304 , computer 150 also obtains all connections to an input pin of each flip-flop in the data model. Then, in act 305 , computer 150 obtains from the data model, a list of all drivers which drive the data signals to each flip-flop. Then in act 306 , computer 150 checks if any driver in the list obtained in act 305 has been identified as a multiplexer in act 302 . If so, then computer 150 goes to act 307 to further process the multiplexer (which is referred to as the “current” multiplexer), and else goes to act 310 . In act 310 , computer 150 marks a path to the flip-flop's data pin D as being unoptimizable, and then proceeds to act 311 .
In act 307 , computer 150 identifies which pin of the current multiplexer receives scan data (i.e. identifies the SI pin), and which pin receives the mission data (i.e. identifies the MI pin). Next, in act 308 , computer 150 traces back the signals from these two input pins of the current multiplexer (i.e. SI and MI pins), to the input ports of the current module. Then, in act 309 , computer 150 traces forward the signal from the Q pin of the current flip-flop, to the output port of the current module. Next, computer 150 goes to act 311 wherein one or more of the above-described acts are repeated, for example, if there are paths between scan cells which have not been visited, and marked as being one of optimizable and unoptimizable. If there are no unvisited paths, then computer 150 exits this method in act 312 .
Some illustrative embodiments in accordance with the invention perform the acts illustrated in FIG. 4A as discussed next. Specifically, some embodiments enter perform acts 401 - 404 , wherein act 401 implements a “for” loop in which computer 150 individually selects each module ‘m’ in a ‘netlist’ representing the IC design. In act 402 , computer 150 checks if there is a scan cell in module ‘m’. If the answer is ‘yes’, then computer 150 goes to act 403 , and stores information on the scan cell, such as its identity and the components therein, such as a multiplexer and a flip-flop. After act 403 , computer 150 goes to act 404 . Computer 150 also goes to act 404 if the answer in act 402 is no. Act 404 implements loop termination for act 401 , by checking if all modules in the netlist have been visited in which case, computer 150 goes to operation 405 and if not it returns to act 401 . Note that the specific manner in which a scan cell (and one or more of its components, such as multiplexer and flip-flop) is identified is different, depending on the embodiment, although as discussed above in reference to FIG. 3 , some embodiments are based on recognition of UDPs.
In operation 405 , computer 150 checks every pair of scan cell instances (e.g. identified in act 403 ) to see if both instances in a pair are driven by the same scan enable signal, and if so, the identity of such a pair is stored in a data structure (e.g. a two dimensional table may be used, depending on the embodiment). After operation 405 , computer 150 goes to act 406 , as discussed next.
Act 406 implements another “for” loop in which computer 150 individually selects each scan cell instance identified in act 403 and goes to act 407 . In act 407 , computer 150 checks if all paths from the current scan cell instance are optimizable, e.g. by tracing fanouts. If the answer is ‘yes’, then computer 150 goes to act 408 and marks all such paths as being optimizable. After act 408 , computer 150 goes to act 409 . Computer 150 also goes to act 409 if the answer in act 407 is no. Act 409 implements loop termination for act 406 , by checking if all scan cell instances that were identified in act 403 have been visited and if so goes to operation 410 and otherwise returns to act 406 .
In operation 410 , computer 150 generates software instructions to simulate propagation of a signal through combinational logic which include conditions (of the type illustrated in statement 252 in FIG. 2B ) or which are unconditional. As noted above, the conditions used in the software instructions are based on the scan enable signal. Moreover, whether or not the generated software instructions contain such conditions depends on the optimizability of the path. If the path is optimizable, then the software instructions are made conditional. If the path is unoptimizable, then the software instructions are unconditional.
Operation 405 of FIG. 4A may be performed in any manner that will be apparent to the skilled artisan in view of this disclosure, and the detailed implementation of operation 405 is not a critical aspect of the invention. Nonetheless, for purposes of illustration, note that some embodiments implement the acts 411 - 418 illustrated in FIG. 4B to implement operation 405 . Specifically, in act 411 , computer 150 implements a “for” loop by individually selecting each scan cell instance identified in act 403 ( FIG. 4A ) and goes to act 412 . In act 412 computer 150 traces back to identify the root net for the scan enable signal and save the identified root net for the current cell instance. Then, computer 150 goes to act 413 wherein it checks if all cell instances have been visited and if not returns to act 411 . If all cell instances have been visited, computer 150 goes to act 414 , which is discussed next.
In act 414 , computer 150 implements another “for” loop by individually selecting a pair of scan cell instances and goes to act 415 . In act 415 computer 150 checks if the root nets of the scan enable signals of each of the scan cell instances in the currently selected pair are identical. If the answer in act 415 is ‘yes’, the computer 150 goes to act 416 and otherwise goes to act 417 . In acts 416 and 417 , computer 150 stores a flag as being true or false to respectively indicate that the scan enable signals are identical or not. After acts 416 and 417 , computer 150 goes to act 418 which implements loop termination for act 414 , by checking if all pairs of scan cell instances have been visited and if not goes back to act 414 .
Act 407 of FIG. 4A may also be performed in any manner that will be apparent to the skilled artisan in view of this disclosure, and the detailed implementation of operation 407 is not a critical aspect of the invention. Nonetheless, for purposes of illustration, note that some embodiments implement the acts 421 - 427 illustrated in FIG. 4C to implement act 407 . Specifically, in act 421 , computer 150 implements a “for” loop by individually selecting each fanout f of a Q pin of a scan cell whose fanouts are to be traced. Next, in act 422 , computer 150 checks if this fanout f is a simple combinational element which is unidirectional, such as an AND gate or an OR gate, or an inverter. If the answer is ‘no’ in act 422 , then computer 150 goes to act 424 and checks if fanout f is an inferred scan cell instance, and if not then returns ‘false’, meaning the path is not optimizable. If the answer in act 424 is ‘yes’, then computer 150 goes to act 425 to check if fanout f and the scan cell have the same scan enable signal and if not then again returns ‘false’, meaning the path is not optimizable. If the answer in act 425 is ‘yes’, then computer 150 goes to act 426 to check if fanout f is same as scan cells dataNet and if not then again returns ‘false’, i.e. path is unoptimizable. If the answer in act 426 is ‘yes’, then computer 150 returns ‘true’ meaning path is optimizable.
In act 422 , if the answer is ‘yes’, then computer 150 goes to act 423 and makes a recursive call to return to act 422 , but with a new ‘f’ which is the fanout of the old ‘f’ with which act 423 had been entered. When no further fanout can be reached in act 423 , e.g. if primary output is reached, then computer 150 goes to act 427 to implement loop termination for act 421 , by checking if all pairs of scan cells have been visited and if not returns to act 421 . If all pairs of scan cells have been visited, then computer 150 returns from this method, i.e. act 407 ( FIG. 4A ) is completed.
Note that any appropriately programmed computer (hereinafter “compiled code simulator”) that performs method 200 to implement simulation speed enhancement as described above (e.g. in reference to FIG. 2A ) may be used in a digital ASIC design flow, which is illustrated in FIG. 6 in a simplified exemplary representation. At a high level, the process of designing a chip starts with the product idea ( 900 ) and is realized in an EDA software design process ( 910 ). When the design is finalized, it can be taped-out (event 940 ). After tape out, fabrication process ( 950 ) and packaging and assembly processes ( 960 ) occur resulting, ultimately, in finished chips (result 990 ).
The EDA software design process ( 910 ) is actually composed of a number of stages 912 - 930 , shown in linear fashion for simplicity. In an actual ASIC design process, the particular design might have to go back through steps until certain tests are passed. Similarly, in any actual design process, these steps may occur in different orders and combinations. This description is therefore provided by way of context and general explanation rather than as a specific, or recommended, design flow for a particular ASIC. A brief description of the components of the EDA software design process (stage 910 ) will now be provided.
System design (stage 912 ): The circuit designers describe the functionality that they want to implement, they can perform what-if planning to refine functionality, check costs, etc. Hardware-software architecture partitioning can occur at this stage. Exemplary EDA software products from Synopsys®, Inc. that can be used at this stage include Model Architect, Saber, System Studio, and DesignWare® products.
Logic design and functional verification (stage 914 ): At this stage, the VHDL or Verilog code for modules in the system is written and the design (which may be of mixed clock domains) is checked for functional accuracy. Exemplary EDA software products from Synopsys®, Inc. that can be used at this stage include VCS, VERA, DesignWare®, Magellan, Formality, ESP and LEDA products.
Synthesis and design for test (stage 916 ): Here, the VHDL/Verilog is translated to a netlist. The netlist can be optimized for the target technology. Additionally, the design and implementation of tests to permit checking of the finished chip occurs. Exemplary EDA software products from Synopsys®, Inc. that can be used at this stage include Design Compiler®, Physical Compiler, Test Compiler, Power Compiler, FPGA Compiler, Tetramax, and DesignWare® products.
Design planning (stage 918 ): Here, an overall floorplan for the chip is constructed and analyzed for timing and top-level routing. Exemplary EDA software products from Synopsys®, Inc. that can be used at this stage include Jupiter and Floorplan Compiler products.
Netlist verification (stage 920 ): At this step, the netlist is checked for compliance with timing constraints and for correspondence with the VHDL/Verilog source code. Exemplary EDA software products from Synopsys®, Inc. that can be used at this stage include VCS, VERA, Formality and PrimeTime products.
Note that a compiled code simulator 999 (of the type described above that performs the method of FIG. 2A ) can be used during this stage 920 , as shown in FIG. 6 . If the displayed results are not satisfactory, a chip designer may go back to stage 916 to make changes to the IC design as shown in FIG. 5 .
Physical implementation (stage 922 ): The placement (positioning of circuit elements, such as the above-described sequential cells and combinational cells) and routing (connection of the same) occurs at this step. Exemplary EDA software products from Synopsys®, Inc. that can be used at this stage include the Astro product. Although circuitry and portions thereof (such as rectangles) may be thought of at this stage as if they exist in the real world, it is to be understood that at this stage only a layout exists in a computer 150 . The actual circuitry in the real world is created after this stage as discussed below.
Analysis and extraction (stage 924 ): At this step, the circuit function is verified at a transistor level, this in turn permits what-if refinement. Exemplary EDA software products from Synopsys®, Inc. that can be used at this include Star RC/XT, Raphael, and Aurora products.
Physical verification (stage 926 ): At this stage various checking functions are performed to ensure correctness for: manufacturing, electrical issues, lithographic issues, and circuitry. Exemplary EDA software products from Synopsys®, Inc. that can be used at this stage include the Hercules product.
Resolution enhancement (stage 928 ): This involves geometric manipulations of the layout to improve manufacturability of the design. Exemplary EDA software products from Synopsys®, Inc. that can be used at this include iN-Phase, Proteus, and AFGen products.
Mask data preparation (stage 930 ): This provides the “tape-out” data for production of masks for lithographic use to produce finished chips. Exemplary EDA software products from Synopsys®, Inc. that can be used at this include the CATS® family of products. Actual circuitry in the real world is created after this stage, in a wafer fabrication facility (also called “fab”).
The data structures and software code for implementing one or more acts described in this detailed description (e.g. FIG. 2A , 3 , 4 A- 4 C and/or subsection A below) can be encoded into a computer-readable medium, which may be any storage medium and/or any transmission medium that can hold code and/or data for use by a computer. Storage medium includes, but is not limited to, magnetic and optical storage devices such as disk drives, magnetic tape, CDs (compact discs), and DVDs (digital versatile discs). Transmission medium (with or without a carrier wave upon which the signals are modulated) includes but is not limited to a wired or wireless communications network, such as the Internet. In one embodiment, the transmission medium uses a carrier wave that includes computer instruction signals for carrying out one or more steps performed by the methods illustrated in FIG. 2A . Another embodiment uses a carrier wave that includes instructions to perform a method as illustrated in FIG. 2A .
Note that a computer system used in some embodiments to implement a simulation speed enhancer of the type described herein uses one or more linux® operating system workstations (based on IBM®-compatible PCs) and/or unix® operating systems workstations (e.g. SUN Ultrasparc, HP PA-RISC, or equivalent), each containing a 2 GHz CPU and 1 GB memory, that are interconnected via a local area network (Ethernet).
Subsection A of this detailed description section which is located below, just before the claims, is an integral portion of this detailed description and is incorporated by reference herein in its entirety. Subsection A includes pseudo-code and related information for implementing one illustrative embodiment of a simulation speed enhancer in accordance with the invention, for example, to implement the acts illustrated in FIGS. 4A-4C by use of a software product called “VCS” available from Synopsys®, Inc.
Numerous modifications and adaptations of the embodiments described herein will become apparent to the skilled artisan in view of this disclosure. Accordingly, numerous modifications and adaptations of the embodiments described herein are encompassed by the scope of the invention.
SUBSECTION A
/* Pseudo code for an illustrative implementation of the invention is
as follows */
/* top level entry*/
doScanOpt(netlist)
{
/*
* Infer which HDL modules match the template of a Mux-DFF scan
cell
* If successfully inferred, the relevant D/SI/SE/Q nets are in
the module.
*/
foreach modules “m” in the ‘netlist’
{
if (isScanCell(m, &DataNet, &ScanDataNet, &ScanEnableNet,
&Qnet) == true)
{
scanCellModuleTable.append({m, DataNet, ScanDataNet,
ScanEnableNet, Qnet});
}
}
/* collect all instances of a scan cell in the fully expanded HDL
description */
scanCellInstanceTable = {instances of all scan cell modules in
‘scanCellModuleTable’};
/*
* create SE-Equivalence tables to answer if a pair of scan cell instances
* are tied to the same ScanEnable root signal.
*/
SEEquivTable = createSEEquivTable(scanCellInstanceTable, netlist);
/* Identify optimizable scan cell output (Q) signals and mark them for
special processing at code generation */
foreach instance ‘fi’ in ‘scanCellInstanceTable’
{
if (allPathsFromQAreOptimizable(fi, netlist))
{
markOutputAsOptimized(fi);
}
}
}
/* routine to create SE root-net equivalence table */
Table createSEEquivTable(cellInstTable, netlist)
{
foreach instance ‘fi’ in ‘cellInstTable’
{
fi.rootSENet = traceBackAndFindRootNet(fi.ScanEnableNet);
}
foreach pair <fi1, fi2>
{
if (fi1.rootSENet != fi2.rootSENet)
SEEquivTable[<fi1, fi2>] = false;
else
SEEquivTable[<fi1, fi2>] = true;
}
return SEEquivTable;
}
/* routine to check if this instance can have its output optimally
propagated */
ScanCellInstance currentSourceInst;
bool traceFanouts(signal, netlist)
{
foreach fanout ‘f’ of signal
{
if (‘f’ is a simple combinational gate) {
return traceFanouts(f->fanOut); /* recursively call for fanouts */
} else if (‘f’ is an inferred scanCellInstance) {
if (SQEquivTable[<currentSourceInst, f>] == false)
return false;
else if (signal == f.DataNet)
return true;
else
return false;
} else {
return false;
}
}
}
bool allPathsFromQAreOptimizable(SourceScanCellInstance, netlist)
{
currentSourceInst = SourceScanCellInstance;
/* trace forward fanouts of scanCellInstance.Q */
if (traceFanouts(Q,netlist) == true) {
return true;
} else {
return false;
}
/* Routine for scan cell template matching */
bool isScanCell(m, pD, pSI, pSE, pQ)
{
if (m->hasOneSequentialUDP( ) == false)
return false;
pQ = udp.Q;
/* trace back data pport of the UDP through simple gates (if any) */
if ((muxFound = traceBackTillMux(udp.D)) == false)
return false;
else {
D = mux.A; SI = mux.B; SE = mux.C;
}
/* trace back D/SI/SE signals till the module port boundary. Return false
if any loops, complex gates are found in the path */
if ((traceBackTillPort(D, pD, SI, pSI, SE, dSE) == false)
return false;
/* success with template match. return true; */
return true;
}
/* changes to code generation routine */
doCodeGen(netlist)
{
......
/*
* while generating propagation routine of cellInstance.Q, check if it
* was marked to be optimized by doScanOpt( ). If yes, then generate
guarded code.
*/
if (isMarkedAsOptimized(cellInstance.Q))
{
codeGenIfCheck(“if (cellInstance.SE == 0) ”);
}
codeGenPropagate(“propagate(Q);”);
......
} | A computer is programmed to prepare a computer program for simulating operation of an integrated circuit (IC) chip, in order to test scan circuitry therein. The computer is programmed to trace a path through combinational logic in a design of the IC chip, starting from an output port of a first scan cell and ending in an input port of a second scan cell. If the first and second scan cells receive a common scan enable signal, then the computer generates at least a portion of the computer program, i.e. software to perform simulation of propagating a signal through the path conditionally, for example when the common scan enable signal is inactive and alternatively to skip performing simulation when the common scan enable signal is active. The computer stores the portion of the computer program in memory, for use with other such portions of the computer program. | 6 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is entitled to the benefit of Provisional Patent Application Ser. No. 60/798,696 filed May 23, 2006.
FIELD OF THE INVENTION
[0002] The present invention is directed to the reliquefaction of boiloff vapors from liquefied natural gas (LNG) storage tanks. Such storage tanks are used on large ocean-going vessels for transport of LNG, and are in widespread use on land in many applications.
BACKGROUND ART
[0003] This invention is particularly applicable to shipboard re-liquefaction of boil-off natural gas from LNG carriers, where simplicity, weight, energy consumption, cost, and maintenance must strike an economic balance.
[0004] Such systems have typically incorporated a refrigeration cycle, composed of a working fluid such as nitrogen gas in mufti-stage compression and one or two turboexpanders which may drive compressors; and the boiloff gas is typically compressed in two stages. Such prior art is shown in existing patents: WO 98/43029 A1 (Oct. 1,1998), WO 2005/057761 A1 (May 26, 2005), WO 2005/071333 A1 Aug. 4, 2005, each issued to Rummelhoff; and U.S. Pat. No. 6,449,983 B2 (Sep. 17, 2002) and U.S. Pat. No. 6,530,241 B2 (Mar. 11, 2003), each issued to Pozivil; and has also been prominently displayed in publications and web sites. The designs in the prior art include turboexpansion of the refrigerant gas through wide pressure and temperature ranges, considered essential for process efficiency under the selected overall plant design, leading to compression of the refrigerant gas in multistage compressors of increased weight and complexity. None of these patents (and other published material) has openly considered the viability of a single stage of refrigerant compression, though shipboard liquefaction of boiloff gas has been a topic of serious investigation. Hence, the advantages of single-stage compression of a refrigerant gas in a main compressor have not been obvious to practitioners with skill in the specific technology.
[0005] Since these installations are considered primarily (but not exclusively) aboard ship, size and weight, and the number of pieces of equipment, especially machinery, take on great importance. Additionally, requirements for unbroken on-stream time may necessitate full duplication of all rotating equipment, effectively doubling the savings which accrue from a reduction in component machinery and complexity.
[0006] In view of the compound requirements for achieving efficient reliquefaction and reducing the number of components, including their weights and complexity, it would be advantageous to develop a process which achieves both ends.
[0007] It has been determined that under certain design configurations, a refrigeration cycle requiring a main single-stage compressor for the refrigerant, can have high thermodynamic efficiency (low specific power); and have the aforementioned benefits of reductions in component rotating equipment.
[0008] The current invention breaks the state-of-the-art barrier to an efficient refrigeration cycle based on a low compression ratio for the refrigerant gas, and enables employment of a single-stage main compressor for the refrigerant gas. The current system offers attractive alternatives to other proposed and constructed systems.
[0009] This invention achieves the objectives of net capital cost and overall weight reduction by reducing the compression of nitrogen in a main compressor to one centrifugal stage, saving a large investment over a main compressor of multiple stages and its coolers. Further compression may take place in compressors which are shaft-connected to turboexpanders.
[0010] Another aspect of this invention is that the refrigeration cycle is so designed as to efficiently achieve boiloff gas condensation while utilizing only one turboexpander, while maintaining a low compression ratio on the single-stage refrigerant compressor.
[0011] This invention relates to a process and equipment configuration to liquefy natural gas boiloff, wherein gas machinery for the refrigeration cycle is composed of a single-stage main compressor and one or two turboexpanders, which may drive compressors.
[0012] Additional improvements may include, all or individually, a single-stage boiloff gas compressor; an inserted heat exchanger to enable compression of the boiloff gas from an ambient temperature condition; and throttling a small refrigerant sidestream at low temperature in order cover the complete cooling range, while maintaining a low compression ratio on the single-stage main cycle compressor without an increase in energy consumption. This is especially effective when the condensed boiloff gas is brought to a subcooled condition.
OBJECT OF THE INVENTION
[0013] The object of this invention is to provide equipment and process for reliquefaction of LNG boiloff gas which is thermodynamically efficient, in an installation which has a lower capital cost, smaller size (volume, footprint), lower weight, and less need for maintenance than systems utilizing the prior art.
SUMMARY OF THE INVENTION
[0014] Reliquefaction systems for liquefaction of LNG boiloff gas can be composed of a circulating working fluid, such as nitrogen in a closed cycle, which includes compression and machine expansion; as well as compression of the LNG boiloff gas. Such systems are machinery-intensive, i.e. the machinery size, weight, cost, and potential maintenance constitute major factors in the practicality and economy of the installation. This invention directly addresses machinery-intensive systems by means of a reduction in machinery components, i.e. stages of compression, while maintaining, and even improving, the energy requirements for reliquefaction.
[0015] The signal feature of the invention incorporates a single-stage main compressor for the circulating refrigerant fluid (nitrogen). Since each stage of compression in a main compressor requires an aftercooler (intercooler, if followed by another stage of compression), a reduction in stages of compression also reduces the heat exchanger requirements for cooling the compressed gas. Of course, savings are multiplied, if an installation must have a spare compressor.
[0016] Additionally, features can be incorporated in the invention which improve the thermodynamic efficiency (reduction in power consumption) of the reliquefaction process. These features include:
[0017] 1. The cold boiloff gas emerging from the storage tank is warmed to approximately ambient temperature before it is compressed. Compression of cold gas has a thermodynamic penalty and leads to higher energy consumption.
[0018] 2. A small refrigerant stream is liquefied, reduced in pressure, and introduced into the cold end of the main heat exchanger in order to achieve final cooling or subcooling of the reliquefied boiloff gas, as a means of reducing the overall compression ratio required for compression of the refrigerant.
[0019] The invention allows choices for employment of one or two stages of boiloff gas compression; one or two refrigerant turboexpanders; how the turboexpander(s) is loaded, i.e. by compressors, electric generators, mechanical load, and/or dissipative brakes; whether a combination of compressors is in series or parallel; if there are two turboexpanders, whether they operate in series or in parallel; and whether a turboexpander-driven compressor operates over the same pressure range as the main compressor, or a different pressure range.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] The figures show multiple versions of the invention as examples of many alternative arrangements. These configurations are not exhaustive; but serve as a sampling of many possible arrangements which can accompany the externally-driven single-stage compression of the refrigerant gas as the chief element of the process invention.
[0021] FIG. 1 depicts a version of the invention which includes a heat exchanger which recovers boiloff gas refrigeration; a single stage of boiloff gas compression; and a single turboexpander. Turboexpander shaft output could drive an electric generator, a mechanical load, or a dissipative brake.
[0022] FIG. 2 depicts a version of the invention which includes a single stage of boiloff gas compression, which compresses boiloff gas as it emerges cold from the cargo tank; and a single turboexpander. Turboexpander shaft output could drive an electric generator, a mechanical load, or a dissipative brake.
[0023] FIG. 3 depicts a version of the invention which includes a heat exchanger which recovers boiloff gas refrigeration; a single stage of boiloff gas compression; and two turboexpanders. Turboexpanders shaft output could drive electric generators, mechanical loads, or dissipative brakes. The turboexpanders are shown in a series arrangement. The turboexpanders could also be in a parallel arrangement, operating across the same pressure ratio, instead of dividing the pressure ratio between them.
[0024] FIG. 4 depicts a version of the invention which includes a single stage of boiloff gas compression which compresses boiloff gas as it emerges cold from the cargo tank; and two turboexpanders. Turboexpanders shaft outputs could drive electric generators, mechanical loads, or dissipative brakes. The turboexpanders are shown in a series arrangement. The turboexpanders could also be in a parallel arrangement, operating across the same pressure ratio, instead of dividing the pressure ratio between them.
[0025] FIG. 5 (which is quantified in the Example) depicts a version of the invention which includes a heat exchanger which recovers boiloff gas refrigeration; a single stage of boiloff gas compression; and a single turboexpander. Turboexpander shaft output drives a compressor, which further elevates the top operating pressure of the closed refrigeration cycle.
[0026] FIG. 6 depicts a version of the invention which includes a heat exchanger which recovers boiloff gas refrigeration; a single stage of boiloff gas compression; and two turboexpander. Turboexpanders shaft outputs drive compressors, which further elevate the top operating pressure of the closed refrigeration cycle. The turboexpanders could also be in a parallel arrangement, operating across the same pressure ratio, instead of dividing the pressure ratio between them. The compressors are shown in a series arrangement. However, they may also be arranged in a parallel arrangement, each operating over the same suction and discharge pressures; or the compressors may operate over the same pressure range as the main refrigeration compressor.
DETAILED DESCRIPTION OF THE INVENTION
[0027] The drawings show the arrangement of equipment for effecting this process and its modifications.
[0028] ( FIGS. 1 & 2 ) A refrigerant cycle gas 14 , such as nitrogen, is compressed in a single-stage compressor 2 . Through an arrangement of heat exchangers 6 and one turboexpander 8 , refrigeration is delivered to the compressed natural gas boiloff from the cargo of a liquefied natural gas carrier ship, or other liquefied natural gas storage container.
[0029] The compressed nitrogen 3 is cooled in an aftercooler 4 against cooling water or ambient air, and is partially cooled in a heat exchanger 6 against low-pressure returning streams. A first part of the partially-cooled compressed nitrogen 7 is withdrawn from the heat exchanger and is work-expanded in a turboexpander 8 . The exhaust stream 9 from the turboexpander re-enters the heat exchanger 6 and flows countercurrent to the feed streams and exits as stream 14 which returns to the suction side to the aforementioned single-stage nitrogen compressor.
[0030] The second divided stream 10 is further cooled in the heat exchanger 6 . It is removed and passed through a throttle valve 11 and stream 12 exits the throttle valve at the same or nearly the same pressure as the turboexpander exhaust pressure of the first divided stream. The valve-throttled stream 12 also re-enters the heat exchanger 6 and flows countercurrent to the feed streams. Stream 12 may be combined with stream 9 at junction point 13 and also returns to the suction side to the aforementioned single-stage nitrogen compressor. Power recovery from the turboexpander 8 may be by mechanical shaft connection to the single-stage nitrogen compressor or by means of an electric generator. In some cases, power recovery may not be practiced.
[0031] In FIG. 1 , natural gas boiloff 21 is warmed in a heat exchanger 22 and then compressed in either a single stage compressor, or in two stages with intercooling. The compressed boiloff gas 25 is cooled in an aftercooler 26 against cooling water or ambient air, and the cooled, compressed boiloff gas 27 is then cooled in the above-mentioned heat exchanger 22 by refrigeration derived from warming the aforementioned natural gas boiloff. The cooled, compressed boiloff natural gas 28 undergoes further cooling in heat exchange against the refrigerant in heat exchanger 6 . This stream 28 is further de-superheated and then partially or fully condensed. The condensate may be further subcooled. The condensate 29 is returned to the cargo tank of the vessel. The condensate 29 may be flashed to lower pressure with recycle or venting of vapor prior return of the liquid to the cargo tank of the vessel.
[0032] Alternatively ( FIG. 2 ), the cold natural gas boiloff 23 enters the boiloff gas compressor 24 at the temperature it leaves the cargo tank piping, and the stream 25 which exits a one- or two-stage boiloff gas compressor directly enters the heat exchanger 6 for further cooling. Compressed boiloff natural gas undergoes further cooling in heat exchanger 6 against the refrigerant, where the boiloff gas is further de-superheated and then partially or fully condensed. The condensate may be further subcooled prior to cargo tank return. The condensate 29 may be flashed to lower pressure with recycle or venting of vapor prior return of the liquid to the cargo tank of the vessel.
[0033] FIGS. 3 and 4 show arrangements similar to FIGS. 1 and 2 , but incorporating two turboexpanders in the refrigeration circuit. The turboexpanders operate over different temperature ranges, which may partially overlap. These systems consume less energy than single turboexpander systems, at the cost of an additional machine and related complexity.
[0034] FIGS. 5 and 6 show arrangements similar to FIG. 1 and FIG. 3 , respectively, with the exception that the turboexpanders drive compressors. The refrigeration cycle then includes the effects of further compression by these means. The processes represented in FIGS. 2 and 4 could also be modified to include turboexpander-driven compressors as part of the process cycle.
[0035] There are a large number of combinations of how turboexpander-driven compressors are employed in a refrigeration cycle. The common element in each of the figures is the single-stage centrifugal main refrigeration compressor.
EXAMPLE
[0036] kgmoles/hr=kilogram moles per hour (flow)
[0037] ° C.=degrees Celsius (temperature)
[0038] bar=bar (absolute pressure)
[0039] composition %=molar percentages
[0040] FIG. 5 shows a process for the reliquefaction of boiloff gas 21 evolved from the cargo tanks of an ocean-going LNG transport vessel, where the boiloff gas evolution rate is 395.9 kgmoles/hr, reaching the deck at a temperature of −130° C. and a pressure of 1.060 bar. The boiloff gas composition is 91.46% methane; 8.53% nitrogen; and 0.01% ethane. The boiloff gas is warmed in heat exchanger 22 and stream 23 exits at 41° C. and 1.03 bar. Stream 23 enters boiloff gas compressor 24 and is compressed to 2.3 bar and 122° C. Stream 25 is cooled in aftercooler 26 to 43° C. and 2.2 bar. Typically, cooling water is the cooling medium in indirect heat transfer with the boiloff gas for this aftercooler and other aftercoolers in the process. The cooled, compressed gas 27 enters heat exchanger 22 in indirect heat transfer with stream 21 , and exits as stream 28 at −126.7° C. and 2.17 bar. Stream 27 enters heat exchanger 6 for further cooling, condensation, and subcooling. Stream 29 exits heat exchanger 6 at −169.2° C. and 2.02 bar. It then can be re-injected into the storage tank.
[0041] The refrigeration cycle working fluid in this case is nitrogen. A nitrogen stream 3 at 8.73 bar and 43.12° C. is compressed in a single-stage compressor 2 to 16.64 bar and 123.1° C. at a flow rate of 6875 kgmoles/hr. This stream is cooled in aftercooler 4 to 43° C. and 16.50 bar. Stream 41 is further compressed in turboexpander-driven compressor 81 to 18.99 bar and 59.53° C. Stream 42 cooled in aftercooler 82 to 43.0° C. and 18.89 bar, and stream 5 enters heat exchanger 6 , where it is cooled to −142.0° C. A division of nitrogen flow occurs here. Stream 7 is routed to turboexpander 8 at a flow of 6825 kgmoles/hr. The balance of the flow of 50 kgmoles/hr remains in heat exchanger 6 and is cooled to −163.0° C. and 18.49 bar and exits as stream 10 .
[0042] Stream 10 is valve-throttled to 9.00 bar which produces a two-phase mixture 12 at a temperature of −171.0° C., which enters the cold end of heat exchanger 6 and is vaporized and warmed as it further removes heat from the boiloff gas stream.
[0043] Stream 7 undergoes a work-producing turboexpansion which is utilized to drive compressor 81 . The discharged stream 9 is at −167.7° C. and 8.99 bar. This stream enters heat exchanger 6 at a point where the returning cold stream is at that temperature. The returning streams may be combined as they are warmed to 42.19° C. and 8.73 bar leaving the heat exchanger as stream 14 , transferring their refrigerative value to the incoming streams.
[0044] Stream 14 enters the suction side of the single-stage compressor 2 as part of the closed refrigeration cycle.
[0045] While particular embodiments of this invention have been described, it will be understood, of course, that the invention is not limited thereto, since many obvious modifications can be made; and it is intended to include with this invention any such modifications as will fall within the scope of the invention as defined by the appended claims. | A design for equipment and process for reliquefaction of LNG boiloff gas, primarily for shipboard installation, has high thermodynamic efficiency and lower capital cost, smaller size (volume, footprint), lower weight, and less need for maintenance than systems utilizing the prior art. The main refrigerant gas compressor is reduced to a single stage turbocompressor. Optional elements include: compression of boiloff gas at ambient temperature; compression of boiloff gas in one or two stages; turboexpansion of refrigerant gas incorporating one or two turboexpanders; turboexpander energy recovery by mechanical loading, compressor drive, or electric generator; refrigerant sidestream for cooling at the lowest temperatures. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This U.S. non-provisional patent application claims priority under 35 U.S.C. § 119 of Korean Patent Application No. 10-2006-92464, filed on Sep. 22, 2006, the entire contents of which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
The present invention disclosed herein relates to a semiconductor memory device, and more particularly, to a flash memory device capable of reducing charge coupling that occurs between adjacent memory cells coupled to the same row, and a method of programming the same.
A semiconductor memory device is largely classified into a volatile semiconductor memory device and a non-volatile semiconductor memory device. The volatile semiconductor memory device is characterized of fast reading and writing speeds, but has limitations of losing stored content when no power is applied. Contrarily, the non-volatile semiconductor memory device retains the stored content even if no power is applied. Therefore, the non-volatile memory device is used for storing content that must remain regardless of power. The non-volatile memory device includes a mask read-only memory (MROM), a programmable read-only memory (PROM), an erasable programmable read-only memory (EPROM), an electrically erasable programmable read-only memory (EEPROM), etc. Since a flash EEPROM (hereinafter, referred to as a flash memory) among non-volatile semiconductor memory devices has the higher degree of integration, compared to a typical EEPROM, it is advantageous to use the flash memory for a high capacity auxiliary memory device.
FIG. 1 shows an array structure including a conventional flash memory device. FIG. 2 shows a vertical sectional view including memory cells 40 , 50 , and 60 arranged in the same row of FIG. 1 .
Referring to FIGS. 1 and 2 , a memory cell array 10 may include a plurality of memory blocks including a plurality of bit lines BL 1 e, BL 1 o, BL 2 e, . . . BLmo, which are arranged in parallel. Each memory block may include a plurality of NAND strings corresponding to the respective bit lines BL 1 e, BL 1 o, BL 2 e, . . . BLmo. One memory block in the memory cell array 10 is illustrated as an example in FIG. 1 .
Each string may have a string select transistor SST and a ground select transistor GST. A plurality of floating gate transistors M 0 to M 31 (hereinafter, referred to as memory cells) used for memory cells may be coupled in series between the string select transistor SST and the ground select transistor GST. The memory cells M 0 to M 31 included in each string may be formed in the same substrate 80 . The memory cells M 0 to M 31 may include adjacent floating gate transistors and shared source-drain terminals in each string. A plurality of word lines WL< 0 > to WL< 31 > may intersect each string.
Looking at a structure of adjacent memory cells 40 , 50 , and 60 coupled to the same row, floating gates 41 , 51 , and 61 , i.e., charge storage elements of the memory cell, may be spaced a predefined distance apart from each other.
A control gate 70 may be formed on the floating gates 41 , 51 , and 61 of the memory cells 40 , 50 , and 60 . The control gate 70 may also be coupled to the corresponding word line WL< 30 >.
To program the memory cells, an erase process may be performed to have a predetermined threshold voltage (e.g., −3 V) in the memory cells. Then, a high voltage (e.g., 20 V) may be applied to the word line WL< 30 > for a predetermined time, which is coupled to a selected memory cell 50 . To accurately program the selected memory cell 50 , the threshold voltage of the selected memory cell 50 may increase to a higher level, but the threshold voltage of the memory cells 40 and 60 (which are not selected) must stay without change.
When a program voltage is applied to the selected word line WL< 30 >, the program voltage is commonly supplied to the selected memory cell 50 and unselected memory cells 40 and 60 through the control gate 70 . As illustrated in FIG. 2 , a parasitic capacitance Cx may be disposed between the adjacent floating gates 41 , 51 , and 61 . Therefore, when the program voltage is applied to the selected word line WL< 30 >, charge coupling between the selected memory cell 50 and unselected memory cells 40 and 60 occurs due to the parasitic capacitance Cx. Consequently, the threshold voltages of the selected memory cell 50 and unselected memory cells 40 and 60 arise together such that unselected memory cells 40 and 60 adjacent to the selected memory cell 50 are accidentally programmed. At this point, the size of the rising threshold voltage Vth is in proportion to the size (i.e., 2Cx) of the parasitic capacitance Cx between the selected memory 50 and adjacent memory cells 40 and 60 .
Due to the change of a threshold voltage in the memory cell, which is caused by charge coupling, an unintended program operation occurs in the unselected memory cell. This is called program disturb. The program disturb in the flash memory device is disclosed in U.S. Pat. No. 5,867,429, entitled “HIGH DENSITY NON-VOLATILE FLASH MEMORY WITHOUT ADVERSE EFFECTS OF ELECTRIC FIELD COUPLING BETWEEN ADJACENT FLOATING GATES.” A method of reprogramming a part of memory cells after performing a program operation, which prevents the change of a threshold voltage in the memory cell due to charge coupling, is disclosed in U.S. Pat. No. 6,807,095, entitled “MULTI-STATE NONVOLATILE MEMORY CAPABLE OF REDUCING EFFECTS OF COUPLING BETWEEN STORAGE ELEMENTS.” According to the above method, the extensive threshold voltage distribution due to the charge coupling becomes less wide.
However, an additional program operation is required for adjusting the threshold voltage distribution after performing a general program operation disclosed in U.S. Pat. No. 6,807,095. Consequently, a program time lengthens and controls become complicated. To accurately perform a program process, a new method is required to reduce the change of a threshold voltage, which occurs due to the charge coupling caused by adjacent memory cells arranged in the same row, without an additional program operation or an additional circuit.
SUMMARY OF THE INVENTION
The present invention includes a flash memory device capable of reducing charge coupling, which occurs between adjacent memory cells coupled to the same row, and a method of programming the same.
Some embodiments of the present invention include a flash memory device comprising: a memory array intersected by a first even bit line, a first odd bit line adjacent to the first even bit line, a second even bit line, and a second odd bit line adjacent to the second even bit line, and a plurality of word lines; a page buffer circuit including a first latch coupled to an even virtual bit line and a second latch coupled to an odd virtual bit line, the even virtual bit line being coupled to the first and second even bit lines, and the odd virtual bit line being coupled to the first and second odd bit lines; and a select circuit configured to electrically couple one of the first even bit line and the second even bit line to the first latch, and to electrically couple one of the first odd bit line and the second odd bit line to the second latch.
Some embodiments of the present invention include a method for programming a memory cell, comprising: electrically coupling a first bit line to a first latch; electrically coupling a second bit line to a second latch, the second bit line being adjacent to the first bit line; electrically decoupling a third bit line from the first latch, the third bit line being adjacent to the second bit line; and programming adjacent memory cells in a same word line associated with the first bit line and the second bit line responsive to data stored in the first latch and the second latch.
BRIEF DESCRIPTION OF THE FIGURES
The accompanying FIGURES are included to provide a further understanding of the present invention, and are incorporated in and constitute a part of this specification. The drawings illustrate exemplary embodiments of the present invention and, together with the description, serve to explain principles of the present invention. In the FIGURES:
FIG. 1 shows a view of an array structure including a conventional flash memory device;
FIG. 2 shows a vertical sectional view including memory cells arranged in the same row of FIG. 1 ;
FIG. 3 shows a block diagram including a flash memory device according to an embodiment of the present invention;
FIG. 4 shows a block diagram including a flash memory device according to another embodiment of the present invention;
FIG. 5 shows a flowchart including a method of programming a flash memory device according to the present invention;
FIG. 6 shows a flowchart including an LSB program operation of FIG. 5 ;
FIG. 7 shows a flowchart including an MSB program operation of FIG. 5 ;
FIGS. 8 and 9 show views of the result in addressing a page used for a programming method according to embodiments the present invention;
FIG. 10 shows a view of program properties in memory cells according to page addressing of FIGS. 8 and 9 ;
FIGS. 11 and 12 show views of the result in addressing a page used for a programming method according to embodiments the present invention; and
FIG. 13 shows a view of program properties in memory cells according to page addressing of FIGS. 11 and 12 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Preferred embodiments of the present invention will be described below in more detail with reference to the accompanying drawings. The present invention may, however, be embodied in different forms and should not be constructed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the present invention to those skilled in the art. Hereinafter, exemplary embodiments of the present invention will be described in conjunction with the accompanying drawings.
An embodiment of a flash memory device of the present invention simultaneously programs at least two adjacent memory cells (for example, memory cells of the same row respectively coupled to even bit lines and odd bit lines, which are adjacent to each other) arranged in the same row. According to the above program method, a charge coupling effect is drastically reduced in memory cells adjacent to another memory cell that will be programmed. Therefore, the change of threshold voltage in the adjacent memory cells arranged in the same row where the selected memory cell is arranged significantly decreases. A structure of a flash memory device and a method of programming the same will be described in detail as follows.
FIG. 3 shows a block diagram including a flash memory device 100 according to an embodiment of the present invention. The flash memory device 100 is a NAND flash memory device with a single latch structure, which may be used for storing a single bit data, or storing a multi bit data in One-NAND memory having a buffer therein.
Referring to FIG. 3 , the flash memory device 100 may include a memory cell array 110 , a row decoder 130 (X-DEC in FIG. 3 ), a bit line select circuit 140 , a page buffer circuit 150 , and a controller 170 . The memory cell array 110 may include a plurality of memory blocks. Only one memory block among the plurality of memory blocks is illustrated in FIG. 3 . Each memory block may include a plurality of memory cells arranged on intersected regions of word lines WL 0 to WLn and bit lines BL 1 e, BL 1 o, BL 2 e, BL 2 o, and so forth. The memory cells may include a string structure. The string structure of the memory cell was described in detail with reference to FIG. 1 . Thus, the overlapping description will be omitted here for conciseness.
The rows of the memory cell array 110 may be driven by the row decoder circuit 130 , and columns may be driven by a page buffer circuit 150 . The page buffer circuit 150 may be controlled by a controller 170 and may operate as a write driver or a sense amplifier according to an operation mode. Due to the operation characteristics, the page buffer circuit 150 may be called a sense and latch circuit. The page buffer circuit 150 may include a plurality of page buffers 151 , 152 , and so forth, corresponding to the respective bit lines or a pair of bit lines. FIG. 3 illustrates page buffers 151 and 152 corresponding to adjacent two even bit lines BL 1 e and BL 2 e, or adjacent two odd bit lines BL 1 o and BL 2 o.
Still referring to FIG. 3 , the adjacent two even bit lines BL 1 e and BL 2 e may be coupled to the page buffer 151 through an even virtual bit line VBLe. The adjacent two odd bit lines BL 1 o and BL 2 o may be coupled to the page buffer 152 through an odd virtual bit line VBLo. The even bit lines and odd bit lines are alternately arranged. A bit line structure coupled to each of page buffers 151 , 152 , and so forth, may vary within the scope of the present invention. A bit line switching operation of the bit line select circuit 140 may determine which bit line is selected among two bit lines coupled to the page buffers 151 , 152 , and so forth.
The bit line select circuit 140 may include a plurality of switching transistors 141 to 144 coupled to the bit lines BL 1 e, BL 1 o, BL 2 e, BL 2 o, and so forth. The switching transistors 141 to 144 may be turned on/off according to switching control signals D 1 to D 4 generated from the controller 170 , in order to selectively activate the corresponding bit lines BL 1 e, BL 1 o, BL 2 e, and BL 2 o.
At least two adjacent bit lines among the bit lines BL 1 e, BL 1 o, BL 2 e, and BL 2 o may be activated and the activated bit lines may be electrically coupled to the page buffers 151 and 152 . The switching transistors 141 and 142 , or 143 and 144 coupled to the same page buffer (or, the same virtual bit lines) may perform respectively opposite switching operations. For example, when the switching transistors 141 and 142 are turned on, the switching transistors 143 and 144 may be turned off. When the switching transistors 141 and 142 are turned off, the switching transistors 143 and 144 may be turned on. Consequently, when the adjacent bit lines BL 1 e and BL 1 o are electrically coupled to the corresponding page buffers 151 and 152 , other bit lines BL 2 e and BL 2 o may be electrically decoupled from the page buffers 151 and 152 by the turned-off switching transistors 143 and 144 . The memory cell coupled to the bit lines BL 1 e and BL 1 o, which are electrically coupled to the page buffers 151 and 152 , may be simultaneously programmed according to the programming methods of FIGS. 5 through 7 . In this case, charge coupling that occurs between the adjacent memory cells 40 , 50 , and 60 is drastically decreased compared to transitional methods. This will be described in more detail with reference to FIGS. 8 through 13 . Referring to FIG. 3 , a reference number 120 represents simultaneously programmed memory cells and a page buffer corresponding to the memory cells.
FIG. 4 shows a block diagram including a flash memory device 200 according to another embodiment of the present invention, and illustrates a NAND flash memory device 200 with a dual latch structure. The flash memory device 200 with a dual latch structure may be used for storing multi bit data, and the dual latch structure may be modified and changed in diverse forms. For example, one latch among two latches is included in a page buffer, and the other may be disposed outside the page buffer.
Referring to FIG. 4 , the flash memory device 200 is identical to that of FIG. 3 except that the page buffers 251 and 152 have a dual latch structure. Therefore, operations of the bit line select circuit 140 , the controller 170 , and the page buffer 250 may be substantially identical to those of FIG. 3 . Like reference numbers refer to like elements throughout the drawings. Its detailed description will be omitted for conciseness.
FIG. 5 shows a flowchart including a method of programming a flash memory device according to an embodiment of the present invention, FIG. 5 also illustrates a multi bit programming method that can prevent the change of a threshold voltage, which is caused by charge coupling between the memory cells 40 , 50 , and 60 arranged in the same row.
In a case of a multi bit program where one memory cell stores 2 bit data therein, the memory cell may be programmed to have one of states 11, 01, 10, and 00. However, the states are just examples, and may be modified in various forms. The memory cell having a state 11 is an erased memory cell. The threshold voltage of the memory cell having a state 01 is higher than that of the memory cell having a state 11. The threshold voltage of the memory cell having a state 10 is higher than that of the memory cell having a state 01. The threshold voltage of the memory cell having a state 00 is higher than that of the memory cell having a state 10. In the memory cell, one data bit (hereinafter, referred to as a Least Significant Bit, or LSB data bit) among two data bits is programmed first and then another data bit (hereinafter, referred to as a Most Significant Bit, or MSB data bit) is programmed last. The former is called an LSB program operation, and the latter is called an MSB program operation. Generally, the LSB program operation may be substantially similar to the single bit data program operation, but the MSB program operation may be substantially different from the LSB program operation.
Referring to FIG. 5 , the programming method of the present invention may perform the LSB program on the memory cells 40 and 50 of the same row coupled to the plurality of adjacent bit lines (for example, BL 1 e and BL 1 o ) in operation S 1000 . Then, the MSB program may be performed on the memory cells 40 and 50 in operation S 2000 . Although not illustrated in FIG. 5 , adjacent bit lines (for example, BL 1 e and BL 1 o ) may be selected for programming before performing the LSB program and MSB program operations. In this case, the adjacent bit lines (for example, BL 1 e and BL 1 o ) may be activated. Therefore, a voltage difference does not occur between the memory cells 40 and 50 when a program voltage is applied to adjacent memory cells 40 and 50 through the word line.
According to the programming method of the present invention, charge coupling does not occur between the adjacent memory cells 40 and 50 coupled to the activated bit lines (for example, BL 1 e and BL 1 o ). Contrarily, charge coupling occurs between the adjacent memory cell 60 and the selected memory cell 50 coupled to physically adjacent but deactivated bit lines (for example, BL 2 e ). In this case, charge coupling for the memory cells coupled to the same row is not completely eliminated. However, when taking the arbitrarily selected memory cell 50 as a reference, charge coupling occurs on only one side of the memory cell 50 , which occurs on both sides of the memory cell 50 in traditional methods. Consequently, the change of threshold voltage in the memory cell due to charge coupling is reduced by half.
FIG. 6 shows a flowchart including an LSB program operation S 1000 of FIG. 5 . FIG. 7 shows a flowchart including an MSB program operation S 2000 of FIG. 5 . FIGS. 6 and 7 illustrate an LSB program operation on two adjacent memory cells (hereinafter, referred to as first and second memory cells) coupled to the same row.
Referring to FIG. 6 , when a host (not shown) requests an LSB program operation, a plurality of LSB data may be loaded into corresponding page buffers 151 and 152 , respectively, according to the control of the controller 170 in operation S 1100 . The LSB data may be programmed into the first and second memory cells 40 and 50 , which are adjacently arranged on the same row.
Thus, an LSB program may be performed on the first and second memory cells 40 and 50 by using the loaded LSB data in operation S 1200 . The first and second memory cells 40 and 50 may be respectively coupled to the adjacently disposed and activated first and second bit lines BL 1 e and BL 1 o. After a program operation is performed on the adjacent first and second memory cells 40 and 50 , a program verify process may be performed on one of the programmed memory cells 40 and 50 , i.e., the first memory cell 40 in operation S 1300 . Then, a program verify process may be performed on the second cell 50 in operation S 1400 . In operations S 1300 and 1400 , it is determined whether the first and second memory cells 40 and 50 have a required threshold voltage or not.
Next, it may be determined whether all the memory cells 40 and 50 are programmed or not based on the verification result in operation S 1500 . If all the memory cells 40 and 50 are not programmed in operation S 1500 , it may return to operation S 1200 . If all the memory cells 40 and 50 are programmed in operation S 1500 , it may terminate.
The LSB and MSB program operations for a region 120 in FIGS. 3 and 4 are described as an example. However, the example is used for understanding an embodiment of the present invention, and the number of simultaneously programmable adjacent memory cells may vary. The number of program verify operations may vary as frequently as the number of simultaneously programmable adjacent memory cells vary. The LSB program operation of the multi bit flash memory device may be applied to the single bit program operation.
Referring to FIG. 7 , when the host requests the MSB program operation, a plurality of MSB data may be loaded into the corresponding page buffer 151 and 152 . Next, a first pre-read operation S 2200 and a second pre-read operation S 2300 may be performed to read states of the previously programmed data. In the first pre-read operation, the program state of the first memory cell 40 may be confirmed. In the second pre-read operation, the program state of the second memory cell 50 may be confirmed.
The previously performed program state may be confirmed in operations S 2200 and S 2300 , and then the MSB programs for the first and second memory cells 40 and 50 may be simultaneously performed based on the program state and the MSB data loaded in the page buffers 151 and 152 in operation S 2400 . In operations S 2500 and S 2600 , program verify operations may be sequentially performed on the memory cells 40 and 50 . In operations S 2500 and S 2600 , it may be sequentially determined whether the programmed first and second memory cells 40 and 50 have a required threshold voltage or not. Next, it may be determined whether all the memory cells 40 and 50 are successfully programmed or not, based on the verification result in operation S 2700 . If all the memory cells 40 and 50 are not programmed according to the determination result, it may return to operation S 2400 ; and if all the memory cells 40 and 50 are successfully programmed, it may terminate.
The MSB program method for one of states 01, 10, and 00 is described above as an example. As it is well known to those skilled in the art, the operation order of MSB 01, MSB10, and MSB00 programs may vary in diverse forms.
FIGS. 8 through 12 show views of the result in addressing page according to a program method of an embodiment of the present invention.
Referring to FIGS. 8 and 9 , at least two memory cells coupled to the same row may have the same page address. A program or read operation of the NAND flash memory may be performed by a page unit, and an erase operation of the programmed data may be performed by a block unit. The block unit may include a plurality of pages. Therefore, adjacent memory cells having the same address may be simultaneously programmed. The page addressing method of FIGS. 8 and 9 may vary.
FIG. 10 shows a view of program properties in memory cells according to page addressing of FIGS. 8 and 9 . Referring to FIGS. 8 through 10 , when at least two adjacent memory cells coupled to the same row are simultaneously programmed, parasitic capacitance Cx does not occur between the simultaneously programmed memory cells 40 and 50 , and parasitic capacitance Cx occurs between memory cells 50 and 60 that are not simultaneously programmed. If memory cells coupled to the same row are not simultaneously programmed but programmed respectively, charge coupling occurs on both sides of the selected memory cell. Charge coupling that occurs during a program operation according to a program method of the present invention is reduced by half compared to transitional methods. If the number of memory cells that are simultaneously programmed among adjacent memory cells coupled to the same row increases, charge coupling occurring between the memory cells can be even more reduced.
Referring to FIG. 11 and 12 , the number of memory cells with the same page address among memory cells coupled to the same row is not limited to two, and may be a natural number n. The n number of adjacent memory cells with the same page address in the same row may be programmed simultaneously, and the n number of simultaneously programmed memory cells may vary, and may correspond with at least one page buffer. For example, in FIG. 11 , a 1st page may correspond with page address 0 , which may include n number of adjacent memory cells, each having a LSB comprising the same page address 0 . Similarly, a 2nd page may correspond with page address 1 , which may include the n number of adjacent memory cells, each having a MSB comprising the same page address 1 .
FIG. 13 shows a view of program properties in memory cells according to page addressing of FIGS. 11 and 12 . Referring to FIGS. 11 through 13 , a parasitic capacitance Cx does not occur between the simultaneously programmed memory cells 40 , 50 , and 60 . As the number of simultaneously programmed memory cells increases, charge coupling between adjacent memory cells coupled to the same row is reduced. Therefore, according to a structure of the present invention, which may simultaneously program the n number of adjacent memory cells coupled to the same row, charge coupling, which occurs between adjacent memory cells arranged in the same row during a program operation, may reduce the change of a threshold voltage. Accordingly, an additional reprogram operation is unnecessary to correct the change of a threshold voltage of adjacent memory cells, which is caused by charge coupling. The change of a threshold voltage, which is caused by charge coupling that occurs between adjacent memory cells arranged in the same row, can be reduced and a program operation for corresponding memory cells can be performed at high speed without a program operation or an additional circuit.
According to various embodiments of the present invention, the change of a threshold voltage can be reduced without a program operation or an additional circuit. The change of a threshold voltage is caused by charge coupling that occurs between adjacent memory cells arranged in the same row. Consequently, an additional processor for correcting a threshold voltage in adjacent memory cells is omitted such that a program operation for a corresponding memory cell can be performed at higher speeds.
The above-disclosed subject matter is to be considered illustrative, and not restrictive, and the appended claims are intended to cover all such modifications, enhancements, and other embodiments, which fall within the true spirit and scope of the present invention. Thus, to the maximum extent allowed by law, the scope of the present invention is to be determined by the broadest permissible interpretation of the following claims and their equivalents, and shall not be restricted or limited by the foregoing detailed description. | A flash memory device and a method of programming the same are disclosed. The flash memory device includes an array of memory cells intersected by a plurality of bit lines and a plurality of word lines. A page buffer circuit includes a plurality of latches coupled to an even virtual bit line and an odd virtual bitline. The page buffer circuit is configured to load data into the array of memory cells responsive to a select circuit, which is structured to electrically couple at least some of the bit lines to the plurality of latches of the page buffer circuit. | 6 |
FIELD OF THE INVENTION
[0001] This invention relates generally to the field of cable television (CATV) filters, and more particularly to laser marking for identification of a CATV filter.
BACKGROUND OF THE INVENTION
[0002] Cable television (CATV) filters typically block channels from the full spectrum of channels offered to provide a limited or basic service to a subscriber at a lower price. Other CATV filters permit certain channels to pass through the filter while blocking the remainder. Because different models of filters block different groups of premium channels, the model numbers of the CATV filters are permanently printed, typically by roll stamping, into the metal housing of the filter. The filter tube is inserted into a support arbor after which raised hardened metal characters are rolled over the filter tube to leave an impression in the metal filter tube. Printed labels and ink labels are inadequate because of the filters' exposure to the environment and become impossible to read after sufficient exposure to the elements.
[0003] In addition, users are now requesting even more information to be permanently printed onto the filters, e.g., bar codes and/or serial numbers to control better the use of the filters. It is not practical to stamp such information on the filters using roll stamping.
[0004] Furthermore, stamping can deform the housing and change the internal characteristics of the performance of the filter, which fact can cause elaborate work-arounds when fabricating CATV filters.
SUMMARY OF THE INVENTION
[0005] Briefly stated, a CATV filter assembled inside a housing has the housing marked by a laser system with indicia relating to specific characteristics of the filter. The housing is thus not mechanically deformed during the step of marking, resulting in unchanged RF characteristics of the filter as a result of the marking.
[0006] According to an embodiment of the invention, a method includes the steps of providing a CATV filter assembled inside a housing; and marking, with a laser system, an outside of the housing with indicia relating to specific characteristics of the filter, wherein the housing is not mechanically deformed during the step of marking, therein resulting in unchanged RF characteristics of the filter as a result of the step of marking
[0007] According to an embodiment of the invention, a marked device includes a CATV fitter assembled inside a housing; and an outside of the housing being laser-marked by a laser system with indicia relating to specific characteristics of the filter, wherein the housing is not mechanically deformed during the marking, therein resulting in unchanged RF characteristics of the filter as a result of the marking.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 shows a laser system according to an embodiment of the present invention.
[0009] FIG. 2 shows a schematic of the laser and laser control circuitry associated with the embodiment of FIG. 1 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0010] According to an embodiment of the invention, a workpiece such as an outer shell or sleeve of a cable TV system component, which component preferably being a trap or surface mount product, is marked with indicia relating to specific characteristics of the system component such as the part number or other information, with the indicia preferably being a logo, bar-coding, date-coding, 2-D Matrix, or similar.
[0011] The marking is preferably done with a laser, and preferably an excimer laser or pulsed solid state laser such as the VersaScribe GM Laser Marking System manufactured by Alase Technologies, Inc. According to Alase, VersaScribe GM YAG Laser Engraving Systems are designed to bring precision, reliability, versatility, and speed to the most demanding applications, with WinLase Software allowing for applications ranging from deep engraving to fine surface annealing.
[0012] The VersaScribe YAG laser features q-switched, flash lamp technology for high laser energy densities and proven reliability. The laser preferably operates in TEMoo mode. Because the internal Q-switch is software controlled, the operator has the flexibility to change the laser beam power characteristics for marking materials such as steel, aluminum and soft plastics. The VersaScribe laser is a high performance Nd:YAG Laser Marker, with 80 watts CW at 1064 nm.
[0013] The laser marking is preferably done at 90% power, 4 Khz with a marking speed of 500 mm/sec. This setting is used for both the stainless and brass cases. The etch depth is no greater than 0.0002″ so that the base material is not exposed causing corrosion.
[0014] Referring to FIG. 1 , an optically enclosed shroud 10 is preferably placed over a laser 12 and workpiece (not shown) such that an operator can view the workpiece through a viewing window 14 laser safety viewing glass. Multiple interlocks to laser 12 preferably prevent operation of laser 12 with shroud 10 out of position. An “Emergency Stop” (not shown) is preferably located on a laser control box PLC ( FIG. 2 ) within easy reach of the operator at all times. A quick-release latching (not shown) on shroud 10 preferably allows access for maintenance.
[0015] To maintain the focal point of etching on the workpiece, a fixture 16 is preferably of the shuttle type with exchangeable inserts to accommodate various sleeve types, with the diameters of the sleeve types ranging from a trap sleeve to a SMT sleeve. Fixture 16 is connected to a fixture plate 18 . Fixture plate 18 is in turn slideably connected via a shuttle groove 20 to a platform 24 . Fixture plate 18 is slideable in and out through an opening 26 in shroud 10 using a slide handle 22 . A large green LED 28 is preferably mounted in shroud 10 to indicate that laser 12 is inactive, with a red LED 30 to identify the active state.
[0016] The process is as follows. The operator inserts the sleeve by hand into fixture 16 on fixture plate 18 . Fixture plate 18 is shuttled into shroud 10 by the operator via slide handle 22 until fixture plate 18 reaches a shuttle stop 36 . Laser 12 is preferably activated by a sensor such as limit switch 32 detecting the presence of fixture plate 18 and the sleeve. Upon completion of the laser etch, laser control PLC preferably activates a solenoid 34 which returns fixture plate 18 and fixture 16 for another unload/load cycle of the sleeve. A schematic for the laser and control circuitry is shown in FIG. 2 . When the workpiece is a filter assembly which includes a housing and a filter disposed inside the housing, the housing is un-deformed by this laser marking operation.
[0017] While the present invention has been described with reference to a particular preferred embodiment and the accompanying drawings, it will be understood by those skilled in the art that the invention is not limited to the preferred embodiment and that various modifications and the like could be made thereto without departing from the scope of the invention as defined in the following claims. | A CATV filter assembled inside a housing has the housing marked by a laser system with indicia relating to specific characteristics of the filter. The housing is thus not mechanically deformed during the step of marking, resulting in unchanged RF characteristics of the filter as a result of the marking | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention pertains to sealing systems for two part fluid handling couplings, particularly couplings wherein one or more of the parts may be under pressure during connection or disconnection. Couplings of this type are often used with hydraulically powered tools wherein different tools may be selectively attached to a common flexible pressurized medium supply hose.
2. Description of the Related Art
Tools and other devices powered by pressurized hydraulic fluid, or compressed air, normally utilize quick connect and disconnect fittings whereby the tools may be quickly attached to a pressurized supply line, or detached therefrom. It is highly desirable that different types and brands of tools be connectable to standard couplings, and the Hydraulic Tool Manufacturers Association (HTMA) has determined standards for couplings for use with its members' products.
Fluid couplings as used with hydraulic tools may be subjected to fluid pressures of 1800 psi or more and as the coupling parts usually incorporate self-sealing valves to prevent the loss of fluid when the coupling parts are disconnected it is not unusual for at least one of the coupling parts to be under pressure when interconnection of the coupling parts is desired. Pressurizing of a fluid circuit may occur because of weight imposed upon an expansible chamber motor within the circuit, or thermal pressurization, or even hose winding or storage may pressurize a hydraulic fluid circuit which would normally be depressurized.
To produce a leak-proof connection between coupling parts, it has been the practice to utilize a conventional O-ring seal located within a recess defined within the passage of the male coupling part which engages a valve sleeve in the female part when full interconnection is achieved. While such conventional use of an O-ring seal is capable of rendering the coupling fluid tight, the disconnection or connection of coupling parts while one or both parts are under pressure causes a short exposure of the O-ring seal to the coupling pressure when the seal is not internally supported which often results in the seal ring being blown from its recess destroying the sealing ability of the coupling. Also, couplings utilizing only conventional O-ring seals often experience the extrusion of the O-ring from its recess into the space between the parts when directly subjected to high pressures, or into the valve seat of the female part, if any misalignment exists during coupling or uncoupling.
To minimize seal ring blow-out and extrusion it has been proposed to employ a stiff and semi-rigid seal ring, rather than a conventional O-ring, in conjunction with the male coupling part recess. By using a semi-rigid seal ring significantly greater resistance to seal blow-out is achieved. One type of semi-rigid seal ring which may be employed in the environment discussed above is disclosed in the assignee's U.S. Pat. No. 4,614,348 wherein a two part seal ring is disclosed having a body of relatively stiff semi-rigid material used in conjunction with a conventional O-ring to prevent fluid bypassing the stiffer seal material.
While the use of a stiff and semi-rigid seal ring does prevent seal ring blow-out during connection and disconnection of the coupling parts, the stiffer and semi-rigid characteristic of the seal ring makes it difficult to acheive effective sealing and this type of seal ring will often permit leakage or seepage. Such leakage may occur because the surface finish engaged by the semi-rigid seal ring is too rough to provide 100% resistance to leakage.
Further, as the valve parts are subjected to numerous connections and disconnections the sealing surfaces of the seal ring may become scratched, particularly in dirty and gritty environments. Also, seals which are formed of stiff and semi-rigid material do not accommodate themselves to manufacturing tolerances as well as softer and more elastic seal rings, and when using a semi-rigid seal ring the presence of maximum tolerances with one coupling part may cause the seal ring to set at such maximum diameter and use of the coupling part containing the seal ring with another female part of a lesser dimension, still within tolerances, may produce spacing which will permit leakage.
OBJECTS OF THE INVENTION
It is an object of the invention to provide a seal system for interconnectable and disconnectable fluid coupling parts wherein the parts may be interconnected and disconnected while under pressure and dual seals are used intermediate the parts wherein the seals' characteristics augment each other and seal blow-out is prevented while high efficiency sealing is accomplished.
Another object of the invention is to provide a dual seal system for interconnectable fluid couplings wherein one of the seals is of a stiff semi-rigid construction capable of resisting seal blow-out, and the other of the seals is protected against exposure to the high forces present during connection or interconnection by the first seal, and the greater flexibility and elasticity of the second seal achieves superior sealability.
A further object of the invention is to provide a dual seal system for two part fluid couplings wherein a stiff and less resilient seal is used to buffer and protect a more flexible and elastic seal from blow-out and extrusion.
Yet another object of the invention is to provide a dual seal system for interconnectable fluid couplings which may be utilized with fluid couplings constructed in accord with HTMA standards and does not require overall coupling dimensional changes.
An additional object of the invention is to provide a dual seal system for interconnectable coupling parts wherein the seal system includes axially spaced recesses separated from each other in the direction of coupling movement by sufficient distance to permit the stiffer and most rigid of the seal rings to protect the more flexible and elastic of the seal rings from coupling pressures, and the more elastic seal ring is internally supported by coupling structure prior to being exposed to the pressurized medium.
SUMMARY OF THE INVENTION
The invention pertains to a dual seal system for interconnectable male and female coupling parts. The type of fluid coupling with which the invention is particularly advantageous is that standardized by the HTMA, an example being the coupling that is sold by the assignee, Aeroquip Corporation of Jackson, MI, identified as the Series FD49. Such couplings are widely used with power tools selectively interconnected to a hose supplying a pressurized hydraulic or air medium. Pressures as high as 1000 psi may be encountered when using couplings for hydraulically operated tools, and in the practice of the invention seal blow-out is eliminated even though coupling interconnection or disconnection may occur under high pressures.
Couplings incorporating the inventive concepts include male and female parts capable of being separated and selectively latched in an interconnected relationship. Each of the parts includes a self-sealing valve.
The male coupling part includes a poppet valve which is spring biased toward its closed condition wherein the poppet valve is received within a cylindrical sealing surface adjacent the part outer end. As later described, dual seals are mounted within the male coupling part and sealingly engage the poppet valve when located within the sealing surface. Exteriorly, the male part includes an annular groove for receiving locking detents defined upon the female part.
The female coupling part includes a fixed valve stem having a head aligned with the outer end of the female part. An annular valve seat is defined on the head and a valve sleeve is biased into engagement with the valve seat to selectively close the female part passage. An annular detent sleeve circumscribes the outer surface of the valve sleeve and is engageable by the end of the male part during interconnection. Axial displacement of the detent sleeve inwardly a predetermined extent abuts the detent sleeve against a shoulder on the valve sleeve to unseat the valve sleeve from the valve head. An axially biased locking sleeve mounted upon the female coupling part selectively operates ball detents for forcing the detents into the male part groove once the coupling parts are fully connected.
As the coupling parts are interconnected the poppet valve and valve head engage whereby relative axial movement of the coupling parts toward each other removes the poppet valve from association with its seals. As the nose of the male coupling part passes over the exterior sealing surface of the valve sleeve the outermost seal ring located on the male part is received upon the valve sleeve and is inwardly supported thereby. During connection, or disconnection, the axial spacing between the seal rings defined on the male coupling part is such that the seal ring furthest from the male part outer end will be in a sealed relationship with the poppet valve while the seal ring closest to the male part outer end is located on the valve sleeve, and at this time the valves of both coupling parts are closed and no fluid is flowing through the coupling and the seals are not exposed to surges of pressurized medium.
When the coupling parts are fully connected both seal rings will be located on the exterior sealing surface of the valve sleeve and internally supported, and under such conditions seal blow-out cannot occur.
To achieve the desired results of the inventive concept the physical characteristics of the two seal rings mounted upon the male coupling part are different. Each of the seal rings is located within an annular recess defined in the male coupling part intersecting and concentric to the cylindrical surface receiving the poppet valve. The seal ring located in the recess furthest from the outer end of the male coupling part is of a stiff semi-rigid material, such as polytetrafluoroethylene, and is of such rigidity, and dimension, relative to its associated recess, that seal blow-out is prevented. Preferably, the semi-rigid seal is associated with a more elastic O-ring seal to improve the sealing characteristics with respect to the associated recess, and this seal may be of the type shown in the assignee's U.S. Pat. No. 4,614,348.
The second seal of the dual sealing system of the invention is located in a recess located intermediate the semi-rigid seal and the outer end of the male coupling member. A conventional O-ring seal formed of rubber, nitryl, or the like, is located within this recess, and is of such dimension and elasticity as to provide excellent sealability with respect to the female coupling part.
The semi-rigid seal is located closer to the internal passage of the male coupling member containing high pressure medium than is the conventional O-ring seal, and the semi-rigid seal serves as a buffer to protect the O-ring seal against exposure to the high pressure surges that may occur as the coupling parts are connected or disconnected. As the semi-rigid seal significantly reduces the pressure and volume of medium imposed upon the O-ring seal the likelihood of the O-ring seal being blown or extruded from its recess is removed as not enough volume of fluid is exposed to the O-ring seal to flush the O-ring seal from its recess, and further, as the O-ring seal is internally supported by the valve sleeve whenever the coupling part valves are open the likelihood of inadvertent O-ring seal loss is substantially eliminated. Further, as the O-ring seal establishes an effective sealing relationship between the coupling parts prior to the valves thereof being opened, leakage during connection and disconnection is prevented.
BRIEF DESCRIPTION OF THE DRAWINGS
The aforementioned objects and advantages of the invention will be appreciated from the following description and accompanying drawings wherein:
FIG. 1 is a diametrical, elevational, sectional view of a male coupling part in accord with the invention, the poppet valve being shown in the closed position,
FIG. 2 is an elevational, diametrical, sectional view of a female coupling part in accord with the invention, the valve sleeve being closed,
FIG. 3 is an elevational, diametrical, sectional view of the coupling parts as partially interconnected and prior to opening of the valves,
FIG. 4 is an elevational, sectional, diametrical view of the coupling parts as fully interconnected and latched together, with the valves in the fully open position,
FIG. 5 is a perspective exploded view of the male coupling part,
FIG. 6 is a perspective exploded view of the female coupling part, and
FIG. 7 is an enlarged detail view of the dual seal system of the invention of the portion indicated in FIG. 4.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In the drawings a typical coupling 10 is illustrated utilizing the dual seal concept of the invention. It is to be appreciated that the dual seal concept may be employed with a variety of coupling configurations wherein the seal "blow-out" problem exists, and the disclosed relationship of coupling components is illustrative of the environment with which the invention is used, and this general type of coupling is that which is approved by the HTMA.
The coupling 10 includes an interconnectable female part 12 and a male part 14, and with reference to FIG. 1 the particular construction of the part 14 will be appreciated.
The part 14 includes a body 16 formed by the tube 18 and adapter 20 which are threadably interconnected. The body 16 includes the axially extending passage 22 which communicates with the adapter threads 24 and the threads 24 permit a hose connection, or the like, not shown, to be attached to the adapter 20 for supplying pressurized hydraulic fluid, or other compressed medium, to the part 14.
The body outer end 26 is intersected by the passage 22 and a reduced cylindrical diameter nose 28 is defined on the part 14 adjacent the end 26. The annular groove 30 defined in the nose receives the detents of the female part as later described to permit interconnection of the coupling parts.
The cylindrical passage surface 32 adjacent the outer end 26 constitutes a sealing surface for the poppet valve as later described.
A spider 34 is centrally located within the passage 22 having passages defined therein whereby fluid may flow through the spider. The poppet valve 36 is supported within the spider 34, and the poppet valve includes an outer cylindrical surface 38 which is closely slidably received within the sealing surface 32. The poppet valve includes the elongated stem 40 which is received within the spider bore 42 and in this manner the poppet valve 36 is capable of being axially displaced within the passage 22 for movement between open and closed conditions, the closed position of the poppet valve being shown in FIG. 1. The spring 44 biases the poppet valve 36 into the sealing surface 32 and axial movement of the poppet valve is limited by engagement of the enlarged oblique shoulder surface 46 with the complementary shaped passage surface as apparent from FIG. 1.
The dual seal system constituting the crux of the invention is mounted within the nose 28 of the part 14, and the sealing system includes the annular recess 48 having the annular seal ring 50 located therein, and the seal ring receiving recess 52 also located within the nose 28 axially spaced from the recess 48 as to be separate and distinct therefrom which is located between the recess 48 and the outer end 26. The recess 52 includes the O-ring type seal 54. The seals 50 and 54 are described in detail below. The recesses 48 and 52 are concentric to and intersect the sealing surface 32.
The female coupling part 12 includes a body 56, FIG. 2, which is formed by the tube 58 and the adapter 60 which are threadably interconnected to form the body assembly. The body includes the axially extending passage 62 which intersects the body outer end 64 and communicates with the adapter threads 66. The threads 66 permit the part 12 to be threadably connected to a tool fitting or conduit, not shown, for establishing communication with the circuit thereof.
A spider 68 is located within the passage 62 and is provided with openings whereby the fluid may flow therethrough as passing through passage 62. The spider 68 supports the valve stem 70 which terminates at the valve head 72 located adjacent the body outer end 64. The valve head 72 includes the resilient O-ring valve seat 74.
The tubular valve sleeve 76 is reciprocally mounted within the passage 62 and includes an outer end 78 adapted to engage the valve seat 74 when the valve sleeve is in the closed position shown in FIG. 2. The valve sleeve 76 includes an outer cylindrical sealing surface 80, and a radially extending abutment shoulder 82 extends from the surface 80. A compression spring 84 interposed between the adapter 60 and the shoulder 82 biases the valve sleeve 76 toward the right, FIG. 2, to engage the sleeve end 78 with the valve seat 74.
An annular detent sleeve 86 holds the detents retracted and surrounds the valve sleeve sealing surface 80 and includes a radially extending outer head 88. The detent sleeve fills in the annular spacing between the valve sleeve 76 and the tube 58 and also functions as lost-motion means for operating the valve sleeve 76 as later described. A compression spring 90 biases the detent sleeve 86 toward the right, FIG. 2, and such movement is limited by engagement of the valve sleeve stop shoulder 92 with a similarly shaped shoulder formed on the tube 58.
Latching of the parts 12 and 14 together is accomplished by the annular lock collar 94 reciprocally mounted upon the tube 58 which operates in the known manner. The lock collar 94 includes an internal groove defining a cam surface 96 whereby detent balls 98 located within tube holes 100 will be biased inwardly into engagement with detent sleeve 86 due to the biasing force of the compression spring 102 endeavoring to move the lock collar 94 to the right, FIG. 2. As will be appreciated from FIG. 4, when the groove 30 of part 14 is aligned with the detent balls 98 the detent balls are received within the groove 30 and the lock collar will move to its extreme right position as shown in FIG. 4 to maintain the parts interconnected in the known manner.
The construction of the seal 50 is best appreciated from FIG. 7, and it will be noted that the rectangular recess 48 receives the seal body 104 in relatively close confinement. The body 104 is of a generally U-shaped configuration in a transverse cross-section and includes an internal diameter 106 adapted to have a sealing relationship with the poppet valve cylindrical surface 38 when the poppet valve is closed, and with the valve sleeve surface 80 when the coupling parts are fully interconnected as shown in FIG. 7.
An annular recess 108 is defined on the outer portion of the seal body 104 and a resilient O-ring 110 is located within the recess 108, and is under compression to serve to seal the body 104 with respect to the outer diameter of the recess 48.
The seal 50 is preferably constructed in the manner shown in assignee's U.S. Pat. No. 4,614,348, and the disclosure of this patent is herein incorporated. The seal body 104 is preferably formed of a stiff semi-rigid synthetic plastic material such as virgin polytetrafluoroethylene sold under the trademark Teflon by the Dupont Company. Other sealing materials than polytetrafluoroethylene may be used for the body 104 within the concepts of the invention, but it is necessary that the seal body 104 be sufficiently stiff and semi-rigid as to prevent being blown out of the recess 48 by the fluid pressures to which the seal 50 is exposed.
The O-ring type seal 54 located within the recess 52 may be of conventional elastomeric O-ring material such as formed of buna-N rubber or nitryl, but if desired, the O-ring seal 54 may be formed of polyurethane or other material having high resistance to cutting, and yet the seal 54 is soft enough and elastic enough to be capable of forming the desired fluid tight seal between the parts 12 and 14.
In use, the part 14 will be attached to the pressurized medium source fitting, not shown, by threads 24. The part 12 will be attached to the pressurized medium user, not shown, such as a tool, or the like, or, of course, may also be attached to a flexible hose supplying the tool.
To interconnect the parts 12 and 14 the outer ends 26 and 64 are aligned with the axes of the part passages coaxially related. The nose end 26 is of a radial dimension substantially equal to that of the detent sleeve head 88, and these parts will engage upon coaxial alignment of the parts 12 and 14 being achieved. As will be appreciated from FIGS. 2 and 3, the detent balls 98 ride upon the outer diameter of the detent sleeve 86, and the detent balls will be radially retracted so as not to interfere with the interconnection of the coupling parts.
As the parts 12 and 14 are axially moved toward each other the outer end 26 forces the sleeve 86 inwardly upon the valve sleeve 76, and the valve head 72 engages the outer end of the poppet valve 36, these engaging components being of substantially equal diameter.
At this time, while the sleeve 86 is moving inwardly on part 12, and the poppet valve 36 is moving inwardly within part 14, the valve sleeve end 78 remains in engagement with the valve seat 74, and the seal 50 remains in a sealed relationship relative to the poppet valve outer cylindrical surface 38. Accordingly, neither of the coupling parts valves have opened, and no fluid flow through the coupling parts exists.
The axial spacing between the recesses 48 and 52 is such that during partial connection as shown in FIG. 3 the O-ring seal 54 will be located upon the valve sleeve sealing surface 80, and internally supported thereby, while the seal 50 is still in a sealed relationship to the poppet valve 36. As the maximum pressures that normally exist in the system will be within the passage 22 of part 14 the seal 50 acts as a buffer and protects the seal 54 from such high pressures as may exist within passage 22 and the presence of the seal 50 prevents such fluid pressures, and pressurized volumes as might cause the seal 54 to be flushed from its recess 52, from occurring as the seal 54 passes over the joint line between the valve head 72 and the end of the poppet valve 36.
Further axial displacement of the parts 12 and 14 toward each other causes the seal 50 to be received upon the valve sleeve surface 80, and continued movement of the parts causes the detent sleeve head 88 to engage the valve sleeve abutment shoulder 82 and axial displacement of the valve sleeve 76 to the left, FIG. 3, occurs. This valve sleeve movement opens the passage 62 due to the separation of the valve sleeve end 78 and the valve seat 74.
Simultaneously, the poppet valve surface 38 has cleared the sealing surface 32 and fluid may flow through the passage 22 of part 14.
Continued axial movement of the parts 12 and 14 toward each other continues until the groove 30 aligns with the detent balls 98 and the cam surface 96 will force the detents 98 into the groove 30 positioning the lock collar 94 as shown in FIG. 4. Interconnection of the coupling parts is now completed.
During connection and fluid flow through the coupling 10 the seal 50 continues to act as a buffer to protect the seal 54 and any fluid flowing or seeping past the seal 50 is only of low volume so as not to force the seal 54 from its recess 52.
To disconnect the coupling parts 12 and 14 the aforedescribed procedure is reversed. Shifting of the lock collar 94 to the left, FIG. 4, permits the ball detents 98 to be forced outwardly by the beveled edges of the groove 30, and the internal pressure within the parts 12 and 14 will rapidly force the parts apart. During disconnection, the axial spacing between the seals 50 and 54 is such, as described above, whereby the relationship shown in FIG. 3 will instantaneously exist and the seal 50 will continue to buffer and protect the O-ring seal 54 as the parts separate and the seals 50 and 54 are again located upon the poppet valve surface 38 as shown in FIG. 1.
The dual seal system of the invention as described above solves a perplexing problem for the HTMA coupling. The seal between the coupling parts must be resilient enough to provide reliable sealing over a broad pressure range, and yet, the seal must be stiff and rigid enough to resist blow-out or cutting when the parts are connected under pressure. In the sealing art, resiliency and elasticity, and stiffness and rigidity are conflicting requirements. In the practice of the invention the use of the axially spaced stiff and semi-rigid seal 50 as used in conjunction with the resilient O-ring seal 54 solves the dilemma, and the seal 50 protects the seal 54 under those situations which, previously, would have blown out, flushed out or extruded an O-ring seal. Additionally, the O-ring seal 54 acts as a separate interface seal for sealing the parts 12 and 14 relative to each other well before the self-closing valves of either part are open. The invention permits a redundancy to be achieved which provides a sealing efficiency for an HTMA coupling heretofore unachieved.
It is appreciated that various modifications to the inventive concepts may be apparent to those skilled in the art without departing from the spirit and scope of the invention. | A sealing system for high pressure fluid couplings wherein male and female valved coupling parts are interconnected while under fluid pressure, the sealing system including a pair of diverse characteristic seal rings axially spaced in the direction of relative coupling part movement. The seal ring closest to the pressurized medium is semi-rigid to prevent blow-out from its recess during coupling disconnection and interconnection while the second seal ring is of greater elasticity and sealability to prevent leakage. The axial spacing between the seal rings permits adequate internal support for the second seal prior to the opening of the coupling parts' valves. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to a canvas-mounting device and, more particularly, to an apparatus that will provide canvas and like materials with a device to simultaneous stretch and mount the material to any size stretcher-frame structure.
2. Description of the Prior Art
As is well known in the art, various problems and difficulties are encountered in providing suitable means for simultaneously mounting and stretching canvas to a supporting stretcher frame structure, wherein the stretcher-frame structure comprises a generally rectangular framework having four wooden side members.
For years, the mounting and stretching of canvas--both in unpainted and painted form--have been generally accomplished by hand. Thus, many problems existed because the canvas was not stretched sufficiently or evenly along all four sides, creating waves or ripples in the stretched canvas. An artist was usually reluctant to use the framed canvas under such conditions.
Additionally, if a painted canvas was loose or had not been mounted and stretched properly, it could possibly not be sold for its true value.
Various types of mounting and stretching devices have been conceived and utilized, and some are still being used at the present time. However, these devices have features that restrict their use; and they are usually expensive, often complicated, and time-consuming in operation.
Canvas-stretching devices must be provided with means to grab and secure the canvas while it is being stretched and fastened to a frame structure. It has been found in the past that a regulated force must be provided to secure the canvas along its edge without ripping or damaging the canvas. Therefore, machines of this type have been produced with complicated pressure and hydraulic systems, which not only consume much space but are also very costly. Further, the designs of these devices are such that they are generally limited to a very small range of canvas frame sizes.
Accordingly, there is a need for a device of simple construction that is capable of accepting all sizes of frame structures, without damage to the canvas as it is stretched and fixed to the frame member.
SUMMARY OF THE INVENTION
The present invention comprises an apparatus for stretching and mounting canvas and other like materials to a stretcher-frame structure. The apparatus itself comprises an elongated, tubular, structural-beam member that is horizontally disposed and affixed at each end to vertical supports. A spring-loaded, clamping-bar member is hingedly connected to the structural beam so as to be positioned along the top wall of the beam, thus defining a jaw-like member having a longitudinal-securing keeper bar mounted to the underside of the clamping bar. This allows one free edge of the canvas to be releasably secured while tension is being placed on the canvas as it is stretched over the canvas-stretcher frame.
It should be noted that this apparatus is also adapted to stretch needlepoint materials as well as silk-screen materials.
Mounted to one end of the main beam is an operating handle that is spring-loaded whereby the spring-loaded clamping bar can be placed in an open position to receive the free edge of the canvas material. As the clamping bar is opened, it is engaged by an automatic, releasable, locking trigger that prevents the clamping bar from closing until the canvas is ready to be stretched. That is, the locking trigger is pivotally mounted to the main beam and adapted to be longitudinally adjusted thereon. By pressing downwardly on the trigger, the clamping bar along with the keeper bar engage the free end of the canvas and allow the frame to be rotated downwardly over a pair of stretcher-bar holders. The stretcher-bar holder is also slidable along the full length of the main beam member, so as to be adjustable to any particular size of canvas-stretcher frame.
Accordingly, each free edge of the canvas is positioned by the jaw-like operation and then stretched, at which time the secured edge is stapled along the length of the mounting-frame member.
OBJECTS AND ADVANTAGES OF THE INVENTION
The present invention has for an important object a provision wherein the apparatus includes a longitudinal, releasable, locking trigger and a pair of longitudinally adjustable stretcher bar holders, whereby various sizes of canvases can be mounted to corresponding sizes of frame members.
It is another object of the invention to provide an apparatus to stretch and mount canvas or like materials, wherein the apparatus is spring-actuated rather than hydraulically-actuated, whereby the force provided by the spring members is sufficient to firmly secure the canvas within the clamping-jaw arrangement while applying the necessary tension thereto.
Still another object of the invention is to provide a device of this character that is relatively inexpensive to manufacture, and that is simple and rugged in construction.
It is still another object of the invention to provide a canvas-stretching apparatus that includes relatively few operating parts.
Still a further object of the invention is to provide an apparatus of this character that is easily serviced and maintained.
The characteristics and advantages of the invention are further sufficiently referred to in connection with the accompanying drawings, which represent one embodiment. After considering this example, skilled persons will understand that variations may be made without departing from the principles disclosed; and I contemplate the employment of any structures, arrangements or modes of operation that are properly within the scope of the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring more particularly to the accompanying drawings, which are for illustrative purposes only:
FIG. 1 is a pictorial view of the present invention supported by vertical end members and wherein a portion of a stretcher-frame member is shown supported by a pair of stretcher bar holders;
FIG. 2 is an end view of the apparatus shown in a closed mode;
FIG. 3 is an end view similar to FIG. 2 wherein the upper clamping bar is shown in an open mode;
FIG. 4 is a rear-elevational view with the central portion broken out to illustrate both ends thereof, including biased hinge members;
FIG. 5 is a top plan view thereof;
FIG. 6 is a cross-sectional view taken substantially along line 6--6 of FIG. 1, wherein the canvas is shown being stapled to the stretcher frame for the initial mounting step;
FIG. 7 is a cross-sectional view similar to FIG. 6, wherein the canvas is released from the securing keeper after being stapled to the canvas-frame member; and
FIG. 8 is also a cross-sectional view similar to FIG. 6, with the frame being positioned to stretch the canvas across the frame.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring more particularly to FIG. 1, there is shown a canvas-stretching-and-mounting apparatus, generally indicated at 10, having supported thereon a stretch-frame member 11, the apparatus comprising a main, structural, elongated beam member 12. Beam 12 is horizontally mounted at each free end to vertical support members 14. It should be noted that support members 14 represent various types of stands or support structures that would allow apparatus 10 to be mounted horizontally, as herein shown and described.
Beam 12 is further formed as a substantially rectangular tubular member by means of extrusion molding wherein the beam is defined by a rear wall 16 attached directly to the support members 14, a top wall 18, a front wall 20, and a bottom wall 22. Hingedly mounted to the rear wall 16 and longitudinally disposed over the top wall 18 is a clamping bar 24, which is also a hollow tubular member defined by a front wall 26, rear wall 28, and top and bottom walls 30 and 32, respectively.
Thus a hinge means 34 is provided, and is mounted to the rear walls 16 and 28 of beam 16 and clamping bar 24, respectively, whereby clamping bar 24 is spaced upwardly from beam 12. This can be seen in FIGS. 3 and 4; and further in FIG. 4 where at least two hinges are shown employed and appropriately spaced apart evenly so as to carry the loads placed on the clamping bar during the operation thereof.
Included within each hinge 34 is a biasing means 36, illustrated as a coil spring located about the hinge pin 38. (See FIGS. 4 and 5.) Spring 36 creates a downward biasing force on clamping bar 24, thereby providing the necessary engaging force between the clamping bar and the top wall 18 of beam 12, whereby a free edge of a canvas or like material can be readily secured during the stretching and mounting steps. A detailed description of this procedure will hereinafter be described.
To further provide a more positive securing of the edge of a canvas, there is included a keeper means, generally indicated at 40, and shown in FIGS. 2, 3, 6, 7 and 8. Keeper means 40 comprises mainly an elongated securing keeper bar 42 which is mounted along the full length of the bottom leading edge of clamping bar 24; and it includes a band or strip 44 of pliable material attached to the adjacent leading edge of beam 12, wherein the leading edge thereof is defined by a vertical flange 46. Thus, keeper bar 42 directly engages strip 44--providing a jaw-like arrangement.
It should be noted at this time that keeper bar 42 can be arranged in any suitable configuration that will mount canvas or other materials, such as those used in needlepoint and silk-screening. The arrangement and form of keeper bar 42 as shown is designed for canvas material. That is, keeper bar 42 is shown having a substantially "L"-shaped cross-sectional configuration wherein the depending member 48 is provided with a plurality of arcuate teeth members 50 formed along the full length of member 48. This arrangement can be seen in FIG. 4.
Accordingly, during the series of steps in the operation of the apparatus, the jaw-like arrangement of clamping bar 24 must be continuously opened and closed. Thus, to provide this action, a lever-actuating means, indicated generally at 52, is mounted to the apparatus, whereby clamping bar 24 can be opened along the leading edge so as to allow the free edge of the material to be inserted between keeper bar 42 and strip 44, and then closed to secure the material therein. As herein illustrated, lever-actuating means 52 comprises a handle 54 having a gripping, extended free end and a pivoted curved end 55, including an extended neck portion 56 which is tipped with a nylon head member 58.
In this embodiment, actuator means 52 is shown positioned adjacent the left end of the apparatus; however, either end can be used but the left end mounting is preferred for better overall operation of the machine.
In FIGS. 1 and 4, handle 54 is shown in a closed mode whereby biasing means or spring 56, which is attached between handle 54 and beam 12, secures handle 54 in a downwardly released position. It should be noted that neck portion 56 is provided with a plurality of holes 58 through which is located a mounting bolt, providing a pivot point about which handle 54 rotates. Thus, to open clamping bar 24, handle 54 is pulled outwardly, causing head 58 to forceably engage bottom wall 32 of bar 24 and thereby lifting clamping bar 24, as seen in FIGS. 3 and 7. As the handle is rotated, neck 56 abuts a stop means defined by pin 60. At this position, handle 54 is held in an open mode and is retained in that position as head 58 passes the vertical center line a-a, as seen in FIG. 4. Accordingly, handle 54 can be manually returned to a closed mode, allowing clamping bar 24 to again close.
However, for a more complete and safer operation of the clamping action, there is further provided a releasable locking means, indicated generally at 62.
The releasable locking means is arranged to be pivotally attached to beam 12 so as to automatically engage bar 24 as bar 24 is raised to an open position by handle 54. Locking means 62 is also adjustable along the full length of the apparatus; and it comprises a substantially "L"-shaped lever arm wherein the upright member 64 is provided with a protruding latch tongue 66 which engages the leading edge of clamping bar 24 in an open locked mode. The latch member 68 of the lever arm extends outwardly from the apparatus so as to be pressed for releasing of bar 24. That is, the lever arm 62 is provided with a flat spring member 70 that establishes a biasing force to cause the arm to pivot inwardly, thereby automatically engaging clamping bar 24 in a locked open mode when raised, as seen in FIGS. 3 and 7. The locking lever arm 62 includes an annular rib member 72 which is slidably received in a circular longitudinal groove 74 formed along the full length of beam 12, as seen in FIG. 1. Depending upon the operator and the size of frame 11, lever arm 62 can be positioned at a convenient location along the apparatus, either to the left or to the right of the frame 11.
Due to the fact that it is very important to position frame 11 on a level and equal plane relative to the upper leading edge 46 of beam 12 (See FIGS. 6 and 7.), there is included a frame-positioning means represented by a pair of frame holders 76. The frame holders are designed to be adjusted vertically and horizontally along beam 12. Beam 12 is provided with a longitudinal channel 78 having inwardly formed flanges 79 disposed along the lower face of front wall 20, wherein there is slidably received a mounting-lug member 80 formed to fit the configuration of channel 78. Lug 80 includes a keyed face 82 defined by a plurality of teeth members and a threaded pin 84, to which a wing nut 85 is mounted. Coupled to lug 80 is the frame-support holder 76, the holder being adjustable vertically by means of a keyed inner face, represented by matching teeth 88, so as to engage with teeth 82 of lug 80. The frame-support holder further comprises an extended flat body 86 having an elongated slot 90 disposed therein to adjustably receive pin 84. Slot 90 allows holder 76 to be raised or lowered to the proper height for each particular size frame structure. The upper end of holder 76 includes a support head 92 formed having a substantially "C"-shaped configuration, wherein the curved head portion protrudes outwardly from beam 12 and then projects inwardly, providing a substantially flat shoulder member 94 on which one of the frame bars 95 is supported, such as seen in FIGS. 1, 6 and 7.
OPERATION
The following is one example of how the canvas is stretched and mounted to the canvas-frame structure 11.
After the main structure of apparatus 10 is fixedly mounted to a support structure, as indicated by 14, the frame holders 76 are positioned and set to accept a particular canvas frame 11. Thus, each holder 76 is located and positioned longitudinally within channel 78, whereby each holder is adjacent the respective upright frame bars 94a and 95b, as seen in FIG. 1. Once the longitudinal position of holders 76 is set, the vertical position is set by raising or lowering the holder up or down until the stapled edge of frame bar 95 is even with the top of beam 12 (as seen in FIGS. 6 and 7) and tightening nuts 85.
Handle 54 is pulled to open the clamping bar, at which time the releasable locking trigger 62 latches under clamping bar 24, holding it open. Then, a free edge 98 of a canvas 100 is positioned between keeper bar 42 and strip pad 44. The canvas is pressed against the corners of frame bar 95 to determine the alignment of the canvas to the frame. When the canvas is in the proper location, trigger 62 is pressed, allowing clamping bar to close. The operator slides an index finger along the length of the leading edge of bar 95, thereby creasing the canvas at point 102 (FIG. 6). The canvas is now stapled to bar 95, this being done generally with an electric stapler 104.
Handle 54 is again pulled to open clamping bar 24 (See FIG. 7.), thus releasing the edge of canvas 100--clamping bar again being latched by trigger 62.
The canvas together with the stretcher frame 11 is turned around to the opposite side (the unstapled side) and the free edge of the canvas is again positioned under keeper 42. The canvas frame 11 is held against beam 12 above holders 76 at approximately 45 degrees, as indicated in FIG. 8. It should be noted that the higher the frame 11 is held the tighter the canvas is stretched. A 45-degree angle, however, is the preferred angle in most mounting operations.
The trigger is again released and the frame is rotated downwardly, causing bar 94c to engage along edge 97 with the arcuate cam surface of head 92 of holder 76 until bar 95c is flush against beam 12. The canvas is now stretched in one direction and is stapled in place. Canvas 100 is again released, and then the corners are folded on the unstapled side, the unstapled side being again positioned in the machine, as described before, at an approximate angle of 45 degrees and clamped therein. The canvas is stretched against the holders 76 and stapled to the frame bar 95. The remaining free edge of the canvas is stretched and stapled as described, at which time the canvas should be secured to all sides of the canvas-frame structure 11 in a very smooth and tight manner.
The unique arrangement of the elements of the present device allows the use of virtually any stapling device presently available. Thus, manual, electrical or air-gun types are compatible with the present invention.
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; and I do not wish to be restricted to the specific form or uses mentioned, except as defined in the accompanying claims. | An apparatus for stretching canvas and like materials that must be stretch-mounted to a supporting stretcher-frame structure generally comprising a four-sided wooden frame member, whereby the canvas is stapled thereto. The apparatus comprises an elongated, horizontal, tubular, structural-beam member affixed at both ends to vertical supports; and has an elongated, biased, clamping bar member hingedly mounted along the full length of the upper surface of the structural-beam member, the clamping bar being provided with a canvas-securing keeper located thereon to engage, under tension, one edge of the canvas when the canvas is positioned between the clamping bar and the beam member. The operation of the clamping bar is provided by a spring-loaded handle and a trigger-release device, the trigger-release device being adapted to be adjustably positioned on either side of the canvas-stretcher frame during the operation thereof. Further included is a pair of stretcher-bar holders which are arranged to be slidably received on the beam member and to be adjustable to support various sizes of stretcher frames. | 3 |
FIELD OF THE INVENTION
The present invention relates to an image sensing apparatus, that can be connected to an information processing apparatus via a data transmission/reception unit based on the USB (Universal Serial Bus) specification, and that has a function to release a suspended status of the information processing apparatus by transmitting a resume signal, a control method for the apparatus, and a storage medium.
BACKGROUND OF THE INVENTION
In an image sensing apparatus such as a digital camera, an image signal obtained by an image sensing device such as a CCD is converted into a digital image signal by an A/D converter and a signal processing unit. Then compression using the JPEG (Joint Photographic Expert Group) method or the like is performed on the digital image signal by a compression unit. The compressed data is stored as an image file into a recording unit such as a memory card.
In some cases, the image sensing apparatus is connected to a computer via a transmission/reception unit such as a USB unit, and the image file stored in the memory card is transmitted from the image sensing apparatus to the computer. However, when the computer enters a suspended status as a low electric consumption mode, the data transmission/reception unit of the computer is not operative, therefore the image file cannot be transmitted from the image sensing apparatus to the computer. Once the computer has entered the suspended status, to transmit the image file again from the image sensing apparatus to the computer, it is conventionally necessary to bring the transmission/reception unit such as a USB unit into operative status to release the suspended status, by e.g. depressing a particular switch of the computer.
However, in the above-described image sensing apparatus, to restore the computer from the suspended status as a low electric consumption mode and bring the transmission/reception unit such as a USB unit into the operative status, a user, who is even operating the image sensing apparatus, must move the hands off the apparatus and operate the computer. This is troublesome, and further, the user might miss a shutter chance while he/she operates the computer.
SUMMARY OF THE INVENTION
Accordingly, the present invention has been made in consideration of the above problem, and has its object to provide an image sensing apparatus which improves operability in transmission of image data to a computer or the like, a control method for the apparatus, and a storage medium.
To solve the above-described problem and attain the object, an image sensing apparatus according to the present invention has the following construction.
That is, provided is an image sensing apparatus comprising: image sensing unit adapted to sense an object; a signal processing unit adapted to convert an image signal outputted from the image sensing unit into digital image; a communication unit adapted to transmit a resume signal to a computer connected to the image sensing apparatus; and a switch for indicating the image sensing apparatus to transmit the resume signal to the computer, wherein before the resume signal is transmitted to the computer, the image sensing apparatus determines whether the computer is in a suspended state or not, and if it is determined that the computer is in the suspended state, the image sensing apparatus transmits the resume signal to the computer to release the suspended state.
Further, an image sensing apparatus control method according to the present invention has the following construction.
That is, provided is a method used in an image sensing apparatus including (a) an image sensing unit adapted to sense an object; (b) a signal processing unit adapted to convert an image signal outputted from the image sensing unit into digital image; (c) a communication unit adapted to transmit a resume signal to a computer connected to the image sensing apparatus; and (d) a switch for indicationg the image sensing apparatus to transmit the resume signal to the computer, the method comprising the step of: before the resume signal is transmitted to the computer, determining whether the computer is in a suspended state or not; and if it is determined that the computer is in the suspended state, transmitting the resume signal to the computer to release the suspended state.
Further, a storage medium according to the present invention has the following construction.
That is, a computer-reabable storage medium storing a program for providing a method used in an image sensing apparatus, the image sensing apparatus includes (a) an image sensing unit adapted to sense an object; (b) a signal processing unit adapted to convert an image signal outputted from the image sensing unit into digital image; (c) a communication unit adapted to transmit a resume signal for release to a computer connected to the image sensing apparatus, and (d) a switch for indicating the image sensing apparatus to transmit the resume signal to the computer, the method comprising the steps of: before the resume signal is transmitted to the computerm, determining whether the computer is in a suspended state or not; and if it is determined that the computer is in the suspended state, transmitting the resume signal to the computer to release the suspended state.
Further, an image-sensing method according to the present invention has the following construction.
That is, provided is an image-sensing method in an image sensing apparatus comprising: image sensing means for image-sensing an object and outputting an image signal; signal processing means for converting the image signal outputted from the image sensing means into digital image data; transmission/reception means for transmitting/receiving data with an information processing apparatus connected via a cable or wireless communication; and signal generation means for generating a trigger signal to perform image-sensing related operation, the method comprising a step of, if the image sensing apparatus and the information processing apparatus are connected to each other and the information processing apparatus is in a suspended status, transmitting a resume signal from the image sensing apparatus via the transmission/reception means to the information processing apparatus, in accordance with the trigger signal.
Further, a control apparatus according to the present invention has the following construction.
That is, provided is a control apparatus for controlling an image sensing apparatus comprising: image sensing means for image-sensing an object and outputting an image signal; signal processing means for converting the image signal outputted from the image sensing means into digital image data; transmission/reception means for transmitting/receiving data with an information processing apparatus connected via a cable or wireless communication; and signal generation means for generating a trigger signal to perform image-sensing related operation, wherein if the image sensing apparatus and the information processing apparatus are connected to each other and the information processing apparatus is in a suspended status, the control apparatus controls the image sensing apparatus to transmit a resume signal via the transmission/reception means to the information processing apparatus, in accordance with the trigger signal.
Other objects and advantages besides those discussed above shall be apparent to those skilled in the art from the description of a preferred embodiment of the invention which follows. In the description, reference is made to accompanying drawings, which form a part thereof, and which illustrate an example of the invention. Such example, however, is not exhaustive of the various embodiments of the invention, and therefore reference is made to the claims which follow the description for determining the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.
FIG. 1 is a block diagram showing a schematic construction of an image sensing apparatus according to a first embodiment of the present invention;
FIG. 2 is a flowchart showing image sensing operation and image file transmission to a computer by the image sensing apparatus according to the first embodiment;
FIG. 3 is a flowchart showing the image sensing operation and the image file transmission to the computer by the image sensing apparatus according to a second embodiment; and
FIG. 4 is a flowchart showing the image sensing operation and the image file transmission to the computer by the image sensing apparatus according to a third embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Preferred embodiments of the present invention will now be described in detail in accordance with the accompanying drawings.
(First Embodiment)
FIG. 1 is a block diagram showing the construction of the image sensing apparatus according to a first embodiment of the present invention.
As shown in FIG. 1 , an image sensing apparatus 12 of the present embodiment photoelectric-converts an object image formed via an optical system 1 into an electric signal by an image sensing device 2 such as a CCD, and further converts the signal into a digital image signal by an A/D converter 3 and a signal processing unit 4 . The digital image signal is inputted into a memory 5 . The digital image signal inputted in the memory 5 is subjected to compression processing using the JPEG method or the like by a compression unit 8 , and is stored as a file into the memory 5 . The image sensing apparatus 12 of the present embodiment has a control unit 6 and a CPU 7 to control the above-described respective units, a release switch 10 connected to the control unit 6 , and a display unit 11 . Further, the image sensing apparatus 12 of the present embodiment has a USB I/F circuit 9 .
Note that the optical system 1 , comprising a lens, an aperture, an optical filter, a shutter and the like, forms an object image on the image sensing device.
Further, the image sensing device 2 is a CCD or the like which converts the object image formed by the optical system 1 into an electric signal.
The A/D converter 3 converts continuous electric signals outputted from the image sensing device 2 into digital signals.
The signal processing unit 4 generates a digital image signal by performing signal processing on the digitized signal.
The memory 5 is used for temporarily storing the digital image signal outputted from the signal processing unit 4 or storing a file-format digital image signal. The memory 5 comprises an internal memory or an external memory card such as a compact flash memory.
Further, the control unit 6 and the CPU 7 control the overall image sensing apparatus 12 .
The compression unit 8 performs compression processing by the JPEG method or the like on the digital image signal outputted from the signal processing unit 4 and temporarily stored in the memory 5 .
The USB I/F circuit 9 transmits/receives a digital image signal, transmits/receives control commands, and performs transmission/reception to notify statuses of the computer and the image sensing apparatus, with the computer 13 by a data transmission/reception method based on the USB specification.
According to the USB specification, when the computer enters the suspended status as a low electric consumption mode, any data cannot be transmitted/received between the computer and a device connected to the computer via a USB transmission/reception unit. In the USB, data transmission/reception is performed upon reception of command from the computer, therefore, if the computer is in the suspended status, any data cannot be transmitted from the device side to the computer. Once the computer has entered the suspended status, to transmit/receive data again in the USB, it is necessary to operate the computer to release the suspended status or transmit a resume signal from the device side to the computer by using a remote wake-up function defined in the USB specification, to release the suspended status of the computer.
In the image sensing apparatus 12 of the present embodiment, the USB I/F circuit 9 transmits a resume signal under the control of the control unit 6 and the CPU 7 .
The release switch 10 , having at least two contacts, enters any one of two-stepped statuses in accordance with e.g. the amount of depression of the switch. In this embodiment, if the release switch 10 is depressed in part way, a first contact represented as SW 1 is selected, and if the release switch 10 is fully depressed, a second contact represented as SW 2 is selected. When the first contact is selected, image-sensing preparation operation such as AF or AE is performed, while when the second contact is selected, image-sensing operation, and digital image-data formation and recording are performed.
Further, in the image sensing apparatus 12 of the present embodiment, as described later, when the first contact of the release switch 10 is selected, the USB I/F circuit 9 transmits a resume signal.
The display unit 11 displays various statuses of the image sensing apparatus under the control of the control unit 6 and the CPU 7 , or sequentially displays stored image files in accordance with the user's instruction. The display unit 11 comprises an LCD, a TFT liquid-crystal display or the like.
Next, the operation of the image sensing apparatus having the above construction will be described in a case where the image sensing apparatus, connected with the computer via the USB transmission/reception unit, sequentially forms digital images, stores the images into the memory, and at the same time, transfers the image files in the memory to the computer.
FIG. 2 is a flowchart showing the operation according to the present embodiment.
First, the image sensing apparatus and the computer are connected via the USB I/F circuit 9 (S 11 ). Next, when the user depresses the switch 10 to select the SW 1 (S 12 ), the image sensing apparatus performs an image-sensing preparation operation (S 13 ). Next, in preparation for image file transfer to the computer after image sensing, it is examined whether or not the computer is in the suspended status (S 14 ). If the computer is in the suspended status, a resume signal is transmitted via the USB I/F circuit 9 (S 15 ). If the computer is not in the suspended status, the step of transmitting the resume signal is skipped. Next, it is examined whether or not the contact SW 2 has been selected by the user (S 16 ). The checking as to whether or not the contact SW 2 has been selected is performed for a predetermined period. If the SW 2 has not been depressed after the predetermined period, there is a possibility that the user has stopped image sensing operation. The process returns to step S 12 to check whether or not the contact SW 1 has been selected. If it is determined at step S 16 that the contact SW 2 has been selected, image sensing for formation of one digital image is performed, and the image is stored in the memory (S 17 ). Finally, the digital image stored in the memory is transmitted to the computer by using the USB I/F circuit 9 (S 18 ). Thus, the sequence by the image sensing apparatus to form one digital image, store the image into the memory, and transfer the image stored in the memory to the computer, is completed.
Then, the user's instruction for image-sensing preparation is waited again at step S 12 .
That is, in the image sensing apparatus of the present embodiment, when an obtained image is transmitted to the computer at the same time of image sensing by the image sensing apparatus, if the user has depressed the switch to select the contact SW 1 , the image sensing apparatus automatically transmits the resume signal to the computer if the computer is in the suspended status. Accordingly, it is unnecessary for the user to operate the computer to release the suspended status. This user's labor can be removed, and the user can avoid missing a shutter chance.
(Second Embodiment)
In the first embodiment, the image sensing apparatus transmits the resume signal to the computer, triggered by the user's depression of the switch to select the contact SW 1 .
However, the user does not always depresses the switch to select the contact SW 2 to perform image sensing after the depression of the switch to select the contact SW 1 . In cases other than image sensing, the suspended status of the computer is released even though image file is not transferred to the computer.
In a second embodiment, the image sensing apparatus transmits a resume signal to the computer, triggered by the user's depression of the switch to select the contact SW 2 .
The construction of the image sensing apparatus of the second embodiment is the same as that in FIG. 1 .
FIG. 3 is a flowchart showing the operation of the present embodiment.
First, the image sensing apparatus and the computer are connected by the USB I/F circuit 9 (S 21 ).
Next, when the user depresses the switch to select the contact SW 1 (S 22 ), the image sensing apparatus performs image-sensing preparation operation (S 23 ). Next, it is examined whether or not the user has depressed the switch to select the contact SW 2 (S 24 ). The checking as to whether or not the contact SW 2 has been selected is performed for a predetermined period. If the contact SW 2 has not been selected after the predetermined period, there is a possibility that the user has stopped image sensing operation. The process returns to step S 22 , to check whether or not the contact SW 1 has been selected. If it is determined at step S 24 that the contact SW 2 has been selected, in preparation for image file transfer to the computer after image sensing, it is examined whether or not the computer is in the suspended status (step S 25 ). If the computer is in the suspended status, a resume signal is transmitted via the USB I/F circuit (step S 26 ). If the computer is not in the suspended status, the step of transmitting the resume signal is skipped. Then image sensing has performed to form one digital image, the image is stored into the memory (S 27 ). Finally, the digital image stored in the memory is transmitted to the computer by using the USB I/F circuit 9 (S 28 ). Thus, the sequence by the image sensing apparatus to form one digital image, store the image into the memory, and at the same time, transfer the image file stored in the memory to the computer is completed.
Then, the user's instruction for image sensing preparation is waited again at step S 22 .
That is, in the image sensing apparatus of the present embodiment, when an obtained image is transmitted to the computer at the same time of image sensing by the image sensing apparatus, if the user has depressed the switch to select the contact SW 2 , the image sensing apparatus automatically transmits the resume signal to the computer if the computer is in the suspended status. Accordingly, as in the case of the first embodiment, it is unnecessary for the user to operate the computer to release the suspended status.
This user's labor can be removed, and the user can avoid missing a shutter chance.
(Third Embodiment)
In a third embodiment, the image sensing apparatus transmits a resume signal to the computer when the user has depressed the switch to select the contact SW 2 then formed and stored digital image data.
The construction of the image sensing apparatus according to the third embodiment is the same as that in FIG. 1 .
FIG. 4 is a flowchart showing the operation according to the third embodiment.
First, the image sensing apparatus and the computer are connected by the USB I/F circuit (S 31 ). Next, if the user has depressed the switch to select the contact SW 1 (S 32 ), the image sensing apparatus performs image-sensing preparation operation (S 33 ). Next, it is examined whether or not the user has depressed the switch to select the contact SW 2 (S 34 ). The checking as to whether or not the contact SW 2 has been selected is performed for a predetermined period. If the contact SW 2 has not been selected after the predetermined period, there is a possibility that the user has stopped image sensing operation. The process returns to step S 32 , to check whether or not the contact SW 1 has been selected. If it is determined at step S 34 that the contact SW 2 has been selected, image sensing is performed to form one digital image, and store the image into the memory (S 35 ). Next, in preparation for image file transfer to the computer, it is examined whether or not the computer is in the suspended status (S 36 ). If the computer is in the suspended status, the resume signal is transmitted via the USB I/F circuit (S 37 ). If the computer is not in the suspended status, the step of transmitting the resume signal is skipped. Finally, the digital image stored in the memory is transmitted to the computer by using the USB I/F circuit 9 (S 38 ). Thus the sequence by the image sensing apparatus to form one digital image, store the image into the memory, and at the same time, to transfer the image file stored in the memory to the computer is completed.
Then, the user's instruction for image sensing preparation is waited again at step S 32 .
That is, in the image sensing apparatus of the present embodiment, when an obtained image is transmitted to the computer at the same time of image sensing by the image sensing apparatus, if the user has depressed the switch to select the contact SW 2 and performed image sensing to form and store digital image data, the image sensing apparatus automatically transmits the resume signal to the computer if the computer is in the suspended status. Accordingly, as in the case of the first and second embodiments, it is unnecessary for the user to operate the computer to release the suspended status. This user's labor can be removed, and the user can avoid missing a shutter chance.
Note that in addition to the above-described three embodiments, if it is arranged such that the image sensing apparatus automatically transmits a resume signal to the computer if it is in the suspend status when the user depresses an arbitrary switch of the image sensing apparatus, as in the case of the above embodiments, it is unnecessary for the user to operate the computer to release the suspended status. This user's labor can be removed, and the user can avoid missing a shutter chance.
Further, in any of the above embodiments, as information as to whether or not the USB-connected computer is in the suspended status is displayed on the display unit 11 in FIG. 1 , the user obtains information on the suspended status of the computer while operating the image sensing apparatus.
Further, in the above embodiments, the resume signal is transmitted in accordance with manipulation on the shutter button by the user, however, the present invention is not limited to this arrangement. For example, in a case where automatic image sensing is performed intermittently at predetermined intervals, it may be arranged such that the resume signal is automatically transmitted upon each image sensing without the user's manual switch operation.
Further, the image sensing apparatus according to the present invention is not limited to a camera but may be any device to pick up an image and transmits an image signal.
Further, in the present invention, the image-sensing unit and the control device may be provided in one casing or may be provided in separate casings and connected with each other via a cable or wireless communication.
(Other Embodiment)
The present invention can be applied to a system constituted by a plurality of devices (e.g., a host computer, an interface, a reader and a printer) or to an apparatus comprising a single device (e.g., a copy machine or a facsimile apparatus).
Further, the object of the present invention can be also achieved by providing a storage medium storing program code for performing the aforesaid processes to a system or an apparatus, reading the program code with a computer (e.g., CPU, MPU) of the system or apparatus from the storage medium, then executing the program. In this case, the program code read from the storage medium realizes the functions according to the embodiments, and the storage medium storing the program code constitutes the invention. Furthermore, besides aforesaid functions according to the above embodiments are realized by executing the program code which is read by a computer, the present invention includes a case where an OS (operating system) or the like working on the computer performs a part or entire processes in accordance with designations of the program code and realizes functions according to the above embodiments.
Furthermore, the present invention also includes a case where, after the program code read from the storage medium is written in a function expansion card which is inserted into the computer or in a memory provided in a function expansion unit which is connected to the computer, CPU or the like contained in the function expansion card or unit performs a part or entire process in accordance with designations of the program code and realizes functions of the above embodiments.
In a case where the present invention is applied to the aforesaid storage medium, the storage medium stores program code corresponding to the flowcharts ( FIGS. 2 to 4 ) described in the embodiments.
As described above, according to the present invention, it is unnecessary for the user to operate the computer to release the suspended status. This user's labor can be removed, and the user can avoid missing a shutter chance by operating the computer.
The present invention is not limited to the above embodiments and various changes and modifications can be made within the spirit and scope of the present invention. Therefore, to appraise the public of the scope of the present invention, the following claims are made. | An image sensing apparatus comprises an image sensing unit adapted to sense an object; a signal processing unit adapted to convert an image signal outputted from the image sensing unit into digital image; a communication unit adapted to transmit a resume signal to a computer connected to the image sensing apparatus; and a switch for indicating the image sensing apparatus to transmit the resume signal to the computer. Before the resume signal is transmitted to the computer, the image sensing apparatus determines whether the computer is in a suspended state or not. If it is determined that the computer is in the suspended state, the image sensing apparatus transmits the resume signal tothe computer to release the suspended state. | 7 |
BACKGROUND
[0001] The present invention relates generally to gas storage in subterranean formations and, in an embodiment described herein, more particularly provides a gas storage and production system.
[0002] Natural gas stored underground is typically stored in leached out salt dome caverns or in depleted hydrocarbon-bearing formations. Where depleted formations are utilized, the formations are generally unconsolidated or poorly consolidated sandstones, which makes it possible to flow gas into and out of pores of the formations at high flow rates.
[0003] To prevent production of formation sand when gas is withdrawn from the formations, gravel packing is typically used. In a gravel packing operation, gravel (e.g., sand, ceramic or bauxite proppant, etc.) is placed in an annulus between a sand screen and a wellbore intersecting a formation. The gravel provides structure against which the formation sand bridges off, thereby preventing migration of the formation sand through the gravel, while permitting gas to flow therethrough.
[0004] In a common method of injecting gas into, and withdrawing gas from, a storage formation, a single tubing string is used for both the injecting and withdrawing operations. That is, the same tubing string is used to store the gas in the formation as is used to produce the stored gas from the formation. Thus, gas is alternately flowed from the surface through the tubing string into the formation, and from the formation through the tubing string to the surface.
[0005] Unfortunately, several problems are associated with this method. One problem is that only a single wellbore is available for both storage and production operations. Another problem is that when operations shift between storage and production, a flow reversal is experienced at the gravel pack in the wellbore. This flow reversal disturbs the gravel and the formation sand bridges therein, thereby escalating the migration of formation sand through the gravel.
[0006] Yet another problem with gravel packs in gas storage wells has to do with the high flow rates generally used in these wells. Typical gravel packs have an open upper end, and so the gravel is not fully contained. High gas flow rates through these gravel packs cause the gravel to move about, “fluffing” the gravel so that it has more open space between its grains. This makes it easier for formation sand to migrate through the spaces between the grains of gravel.
[0007] When formation sand migrates through a gravel pack, it enters the production flowpath and erodes equipment, plugs passages and must be separated from the produced gas. Each of these undermines the profitability of the operation. Therefore, it may be seen that it would be highly advantageous to provide a gas storage and production system which addresses some or all of the above problems.
SUMMARY
[0008] In carrying out the principles of the present invention, in accordance with an embodiment thereof, a gas storage and production system is provided which enhances the profitability of subterranean gas storage by preventing or at least substantially decreasing migration of formation sand through a gravel pack.
[0009] In one aspect of the invention, a gas storage and production system is provided. The system includes a gas storage formation, a production and storage wellbores and a junction between the storage and production wellbores. The system is of the type wherein gas is stored within pores of formation rock, such as in a depleted hydrocarbon-bearing formation.
[0010] The production wellbore extends into the formation for withdrawing gas from the formation. The storage wellbore also extends into the same formation for injecting gas into the formation. In this manner, it is not necessary for a single wellbore to be used for both injecting and producing the gas.
[0011] In another aspect of the invention, a gas storage and production system is provided wherein production and storage wellbores extend from a wellbore junction at a main wellbore. The main wellbore extends from the earth's surface to the wellbore junction. The storage and production wellbores each extend from the wellbore junction into a gas storage formation. Gas is injected from the main wellbore into the formation via the storage wellbore, and gas is withdrawn from the formation into the main wellbore via the production wellbore.
[0012] In yet another aspect of the invention, various means may be utilized for delivering gas to the storage wellbore for injection into the formation, and for delivering gas from the production wellbore to the earth's surface. For example, a single tubular string may be used to deliver the gas to the storage wellbore, and the gas may be received from the production wellbore into an annulus between the tubular string and the main wellbore for flowing to the earth's surface. As another example, a single tubular string may be used for alternately delivering gas to the storage wellbore and receiving gas from the production wellbore. As yet another example, separate tubular strings may be used for delivering gas to the storage wellbore and receiving gas from the production wellbore.
[0013] Also provided is a method of gravel packing a wellbore, which is particularly useful in high flow rate gas production of the type typically experienced in gas storage and production systems. The method includes the steps of positioning a sand control device in the wellbore, placing gravel in an annulus formed between the sand control device and the wellbore, and flowing a retainer material into the annulus. The retainer material prevents displacement of the gravel in the annulus.
[0014] These and other features, advantages, benefits and objects of the present invention will become apparent to one of ordinary skill in the art upon careful consideration of the detailed description of representative embodiments of the invention hereinbelow and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] [0015]FIG. 1 is a schematic view of a gas storage and production system embodying principles of the present invention, wherein main and storage wellbores have been drilled, and the storage wellbore has been gravel packed;
[0016] [0016]FIG. 2 is a schematic view of the system of FIG. 1, wherein a production wellbore has been drilled and gravel packed;
[0017] [0017]FIG. 3 is a schematic view of the system of FIG. 1, wherein cement has been placed above the storage wellbore gravel pack;
[0018] [0018]FIG. 4 is a schematic view of the system of FIG. 1, wherein a first method of storing and producing the gas has been implemented;
[0019] [0019]FIG. 5 is a schematic view of the system of FIG. 1, wherein a second method of storing and producing the gas has been implemented;
[0020] [0020]FIG. 6 is a schematic view of the system of FIG. 1, wherein a third method of storing and producing the gas has been implemented; and
[0021] [0021]FIG. 7 is a schematic view of the system of FIG. 1, wherein a fourth method of storing and producing the gas has been implemented.
DETAILED DESCRIPTION
[0022] Representatively illustrated in FIG. 1 is a gas storage and production system 10 which embodies principles of the present invention. In the following description of the system 10 and other apparatus and methods described herein, directional terms, such as “above”, “below”, “upper”, “lower”, etc., are used only for convenience in referring to the accompanying drawings. Additionally, it is to be understood that the various embodiments of the present invention described herein may be utilized in various orientations, such as inclined, inverted, horizontal, vertical, etc., and in various configurations, without departing from the principles of the present invention.
[0023] As depicted in FIG. 1, initial steps of a method used to practice the system have been performed. A main wellbore 12 has been drilled, cased and cemented, so that it extends from the earth's surface into a formation 14 in which it is desired to store gas. It is not necessary, however, for the main wellbore 12 to extend into the formation 14 .
[0024] A casing string 16 cemented in the main wellbore 12 includes an orienting latch coupling 18 of the type well known to those skilled in the art. The latch coupling 18 is positioned below a desired exit window 20 through the casing 16 , so that, when a whipstock 22 is latched into the coupling 18 , a window mill (not shown) will be directed to mill through the casing at the desired position and in the desired direction. Note that the window 20 may be preformed, or at least provided for, in the casing string 16 when installed, for example, by including an item of equipment known to those skilled in the art as a window bushing or a window joint in the casing string.
[0025] After the casing string 16 is cemented in the main wellbore 12 , a storage wellbore 24 is drilled as an extension of the main wellbore. Alternatively, the storage wellbore 24 could be drilled as a lateral or branch wellbore from the main wellbore 12 . As shown in FIG. 1, the storage wellbore 24 is deviated, so that it extends substantially horizontally in the formation 14 . This maximizes the surface area of the formation 14 exposed to the storage wellbore 24 to increase the flow rate at which gas may be flowed from the storage wellbore into the formation. However, it is to be clearly understood that it is not necessary for the storage wellbore 24 to be horizontal or deviated in the formation 14 .
[0026] After the storage wellbore 24 is drilled, a sand control assembly 26 is installed in the storage wellbore. The sand control assembly 26 may be conventional and may include a gravel pack packer 28 (which is preferably set in the casing 16 above the storage wellbore), a tubular string 30 and a sand control device 32 . Of course, if the formation 14 is well consolidated, or there is otherwise no need for controlling influx of formation sand into the storage wellbore 24 , then the sand control assembly 26 may not be used.
[0027] The sand control device 32 is representatively illustrated in FIG. 1 as a tubular screen of the kind well known to those skilled in the art. The screen 32 may be any type of well screen, including a wire-wrapped screen, a sintered metal screen, a wire mesh screen, etc. Other types of sand control devices may also be used in the system 10 , such as slotted or perforated liners, etc. Therefore, the terms “sand control device” and “sand control screen” as used herein are to be taken as including any apparatus or device which excludes particulate matter, but permits liquid or gas to flow therethrough.
[0028] After the sand control assembly 26 is positioned in the storage wellbore 24 , the wellbore is gravel packed. That is, gravel 34 is placed in an annulus 36 formed between the sand control assembly 26 and the wellbore 24 . Placement of the gravel 34 is accomplished using techniques well known to those skilled in the art. For example, a workstring (not shown) may be used to flow a gravel slurry from the workstring outward through a crossover tool (not shown) below the packer 28 . Of course, other methods of gravel packing the storage wellbore 24 may be used without departing from the principles of the present invention.
[0029] After the storage wellbore 24 is gravel packed, a plug 38 is installed in the packer 28 . The plug 38 prevents debris from the window milling and cementing operations described below from passing into the sand control assembly 26 . Otherwise, this debris could fully or partially plug the screen 32 , thereby preventing or decreasing the flow of gas therethrough.
[0030] A whipstock 22 , or other deflection device, is then installed in the main wellbore 12 . The latch coupling 18 secures the whipstock 22 longitudinally in the casing 16 and orients the whipstock so that it faces in the desired direction for milling the window 20 through the casing. A window mill (not shown) or other cutting device is then deflected off of the whipstock 22 , so that it cuts the window 20 through the casing 16 .
[0031] At this point, or after passing additional cutting tools, such as one or more drills, through the window 20 , an initial recess 40 is cut into the formation 14 beyond the cemented casing 16 . Preferably, a permeability reducing material 42 is then forced outwardly into the formation 14 surrounding the recess 40 . The material 42 may be, for example, a plastic resin, a polymer, a cementitious material, a material known as PermaSeal™, etc. The main purpose of using the material 42 is to prevent gas in the formation 14 surrounding the window 20 from passing through the window into the casing 16 . However, use of the material 42 is not necessary in keeping with the principles of the present invention.
[0032] Referring additionally now to FIG. 2, the system 10 is depicted with further steps having been performed. The recess 40 has been extended outward into the formation 14 , for example, by deflecting one or more drill bits off of the whipstock 22 and through the window 20 , thereby forming a production wellbore 44 . The production wellbore 44 is preferably deviated or substantially horizontal in the formation 14 to expose a greater surface area of the formation to the wellbore, but this is not necessary in keeping with the principles of the invention.
[0033] Another sand control assembly 46 is installed in the production wellbore 44 . A packer 48 of the sand control assembly 46 is set in the casing 16 above the window 20 , a sand control screen 50 is installed in the production wellbore 44 , and a tubular string 52 extends between the packer and the screen. The sand control assembly 46 is similar to the sand control assembly 26 described above, but may differ in some respects.
[0034] In particular, the sand control assembly 46 may include ported collars 54 , 56 of the type used in cementing operations, interconnected in the tubular string 52 between the packer 48 and the screen 50 . Preferably, the ported collar 54 is positioned between the window 20 and the screen 50 , and the ported collar 56 is positioned between the packer 48 and the window. The use of the ported collars 54 , 56 in the system 10 is described in more detail below.
[0035] After installing the sand control assembly 46 , the production wellbore 44 is gravel packed using techniques well known to those skilled in the art. Gravel 58 is placed in an annulus 60 between the sand control assembly 46 and the production wellbore 44 about the screen 50 . Preferably, the gravel 58 extends somewhat beyond the ports in the lower ported collar 54 .
[0036] One of the inventive aspects of the system 10 is a manner in which the gravel 58 is retained in the wellbore 44 about the screen 50 . Due to high flow rates of gas from a storage formation into a screen through a conventional gravel pack, the gravel is typically made to move about, disturbing any sand bridging that had previously developed, and permitting increased migration of sand through the gravel pack.
[0037] One reason the gravel in a conventional gravel pack is able to move about due to high gas flow rates therethrough is that the annulus above the gravel pack is typically open. That is, the upper level of a conventional gravel pack is typically spaced apart from the packer, leaving the annulus therebetween available for the gravel to displace into.
[0038] An example of this is shown in the accompanying figures wherein the storage wellbore 24 is gravel packed. The gravel 34 spaced apart from the packer 28 , leaving the annulus 36 open therebetween. This does not present a problem of sand migration in the system lo, however, since gas preferably flows outward from the sand control assembly 26 into the formation 14 , and not in the other direction, which is another significant advantage of the system.
[0039] For the production wellbore 44 , wherein gas flows from the formation 14 into the sand control assembly 46 , the problem of gravel movement is reduced or eliminated by retaining the gravel 58 in the annulus 60 about the screen 50 , so that it cannot displace upward in the annulus 60 .
[0040] Referring additionally now to FIG. 3, the system 10 is depicted wherein additional steps have been performed. Specifically, a retainer material 62 has been flowed into the annulus 60 above the gravel 58 . The retainer material 62 is flowed outward into the annulus 60 through the lower ported collar 54 , and is flowed upward through the annulus, until it extends through the window 20 . During this process, returns are taken from the annulus 60 through the upper ported collar 56 .
[0041] Preferably, the retainer material 62 is cement or another cementitious material. In that case, conventional cementing techniques may be used to place the cement 62 in the annulus 60 above the gravel 58 . For example, a workstring, such as a coiled tubing string (not shown), may be inserted into the sand control assembly 46 and used to open the ported collars 54 , 56 prior to pumping the cement through the workstring into the annulus 60 . Withdrawal of the workstring may cause the ported collars 54 , 56 to close.
[0042] Any of the gravel 58 above the ports in the ported collar 54 will be displaced along with the cement 62 as it is flowed into the annulus 60 . This procedure will ensure intimate contact between the cement 62 and the top of the gravel 58 in the annulus 60 . Thus, when the cement 62 sets or hardens in the annulus 60 , it will prevent the gravel 58 from displacing when gas flows therethrough at a high rate. Note that the gravel 34 in the storage wellbore 24 could similarly be retained in keeping with the principles of the invention.
[0043] Of course, materials other than cement may be used for the retainer material 62 . For example, a polymer material may be flowed into the annulus 60 above the gravel 58 . Such a material may gel instead of harden when set. A gelatinous material may be used. In short, any material which may serve to prevent displacement of the gravel 58 in the annulus 60 can be used for the retainer material 62 .
[0044] After the retainer material 62 is permitted to set in the annulus 60 , the packer 48 is retrieved from the main wellbore 12 . Alternatively, the packer 48 could be retrieved before placing the retainer material 62 in the annulus 60 , in which case there would be no need to include the upper ported collar 56 in the tubular string 52 .
[0045] Referring additionally now to FIG. 4, the system 10 is depicted wherein further steps have been performed. The sand control assembly 46 extending inwardly through the window 20 has been milled away, so that the tubular string 52 terminates at the window. Any retainer material 62 left in the casing string 16 has also been removed. The whipstock 22 has been retrieved, for example, by using a washover tool well known to those skilled in the art. The plug 38 has been retrieved from the packer 28 .
[0046] A tubing string 64 having a seal assembly 66 proximate a lower end thereof is installed in the main wellbore 12 . The seal assembly 66 is stabbed into the packer 28 or an associated seal bore extension. The tubing string 64 now provides a conduit for injecting gas from the earth's surface, into the sand control assembly 26 in the storage wellbore 24 , and outward into the formation 14 . The direction of gas flow is indicated by the arrow 68 .
[0047] Another conduit for gas flow is provided by an annulus 70 formed between the tubing string 64 and the wellbore 12 . Gas is received into the annulus 70 from the sand control assembly 46 , which in turn receives the gas from the formation 14 . The gas may be flowed to the earth's surface in the annulus 70 , in the direction indicated by arrows 72 .
[0048] Preferably, the directions of gas flow indicated by arrows 68 , 72 are not reversed in normal gas storage and production operations. Thus, the problems of flow reversal are substantially, if not totally, eliminated. In the storage wellbore 24 , gas is preferably only flowed into the formation 14 . In the production wellbore 44 , gas is preferably only flowed out of the formation 14 . Of course, these flow directions could be reversed if conditions warrant.
[0049] It should also be clearly understood that it is not necessary for the gas to be injected via the tubing string 64 and the gas to be produced via the annulus 70 . The gas could instead be injected via the annulus 70 and produced via the tubing string 64 . For example, the tubing string 64 could extend into the production wellbore 44 , where the seal assembly 66 could be stabbed into a seal bore (not shown) of the tubular string 52 .
[0050] Referring additionally now to FIG. 5, the system 10 is depicted wherein an alternate method of storing and producing the gas in the formation 14 is used. In this version, the tubing string 64 is installed in the main wellbore 12 and a seal assembly 66 is stabbed into the packer 28 , or a seal bore associated therewith, as described above for the version depicted in FIG. 4. However, another tubing string 74 is installed in the main wellbore 12 , and a packer 76 on the tubing string is set in the casing 16 above the window 20 .
[0051] As with the version depicted in FIG. 4, gas is preferably injected into the formation 14 via the tubing string 64 . However, the gas is produced via an annulus 78 formed between the tubing strings 64 , 74 . This method may be more desirable in jurisdictions where an annulus extending to the earth's surface, such as the annulus 80 between the tubing string 74 and the wellbore 12 , must be available for well control and monitoring, and cannot be used for production. Use of the tubing string 74 provides the additional annulus 78 for production of the gas, leaving the annulus 80 available for well control and monitoring.
[0052] As shown in FIG. 5, the tubing strings 64 , 74 are concentric or coaxial, and the flow of gas is as indicated by the arrows 68 , 72 . However, it is to be clearly understood that the tubing strings 64 , 74 could be otherwise positioned, and the gas flow could be otherwise directed, in keeping with the principles of the invention. For example, the tubing strings 64 , 74 could be positioned side-by-side in the main wellbore 12 , the gas could be produced through the interior bore of the tubing string 64 , the gas could be injected through the interior bore of the tubing string 74 , etc.
[0053] Referring additionally now to FIG. 6, the system 10 is depicted wherein another alternate method of producing and storing gas in the formation 14 is used. As with the previously described versions, the tubing string 64 is installed in the main wellbore 12 and the seal assembly 66 is stabbed into the packer 28 . However, in this version, the tubing string 64 includes a packer 82 , which is set in the casing 16 above the window 20 , and a valve 84 , which is positioned between the packers 28 , 82 .
[0054] The valve 84 is of the type well known to those skilled in the art which alternately permits flow through its sidewall and its internal longitudinal bore. That is, the valve 84 has two positions—in the first position the valve permits flow through its sidewall but prevents flow through its internal bore, and in the second position the valve prevents flow through its sidewall and permits flow through its internal bore. Such valves are used in several oilfield operations, including drill stem testing, where the valves are known as “tester” valves. An example is the Omni™ valve available from Halliburton Energy Services, Inc.
[0055] The valve 84 may be of the type which uses pressure in a control line 86 to control its operation, as is commonly used in subsea operations. However, other actuation means may be used, such as acoustic, electromagnetic, etc., telemetry from a remote location, pressure or pressure pulses in the tubing string 64 or annulus 70 , etc.
[0056] When the valve 84 is in its first position, gas is produced from the production wellbore 44 , through the sidewall of the valve, and to the earth's surface via the tubing string 64 above the valve. Flow between the storage wellbore 24 and the tubing string 64 above the valve 84 is prevented by the valve. Thus, when it is desired to produce gas from the formation 14 , the valve 84 is operated to its first position.
[0057] When the valve 84 is in its second position, gas is injected through the tubing string 64 , through the internal bore of the valve, and into the storage wellbore 24 . Flow between the production wellbore 44 and the tubing string 64 is prevented by the valve 84 . Thus, when it is desired to store gas in the formation 14 , the valve is operated to its second position.
[0058] An advantage of this method shown in FIG. 6 is that only a single tubing string 64 is needed to both store and produce gas via the multiple wellbores 24 , 44 , while leaving an annulus 88 extending to the earth's surface above the packer 82 available for well control. No flow reversal occurs in any gravel pack of the system 10 . The valve 84 is merely alternated between its first and second positions as needed to store or produce the gas.
[0059] Referring additionally now to FIG. 7, the system 10 is depicted wherein yet another method of storing and producing the gas is used. This method is similar to the method shown in FIG. 6 except that, instead of the valve 84 , two check valves 90 , 92 are used to control flow between the tubing string 64 and each of the storage and production wellbores 24 , 44 .
[0060] The check valve 90 prevents flow from the interior of the tubing string 64 to the production wellbore 44 , but permits flow from the production wellbore to the interior of the tubing string. The check valve 92 prevents flow from the storage wellbore 24 to the interior of the tubing string 64 , but permits flow from the interior of the tubing string to the storage wellbore.
[0061] When it is desired to produce gas from the formation 14 , pressure in the tubing string 64 is decreased below that in the production wellbore 44 . This pressure differential opens the check valve 90 and gas flows from the production wellbore 44 , through the check valve 90 , into the tubing string 64 , and to the earth's surface. The pressure in the tubing string 64 is also less than pressure in the storage wellbore 24 , which maintains the check valve 92 in its closed position.
[0062] When it is desired to inject gas into the formation 14 , pressure in the tubing string 64 is increased above that in the storage wellbore 24 . This pressure differential opens the check valve 92 , and gas flows from the tubing string 64 , through the check valve, and into the storage wellbore 24 . The pressure in the tubing string 64 is also greater than pressure in the production wellbore 44 , which maintains the check valve 90 in its closed position.
[0063] Biasing devices, such as springs, may be added to the check valves 90 , 92 , so that predetermined pressure differentials are needed to open the valves. This may also ensure more positive closing of the valves 90 , 92 and/or allow greater latitude in the pressures which may be applied to the tubing string 64 to open or close the valves as desired.
[0064] The check valves 90 , 92 are shown schematically in FIG. 7 as being separate valves spaced apart in the tubing string 64 . However, these valves 90 , 92 could be otherwise configured and positioned in keeping with the principles of the present invention. For example, the valves 90 , 92 could be combined into a single assembly, the valves could be retrievable by slickline or coiled tubing, etc.
[0065] Note that the system 10 as depicted in FIG. 7 also has the advantage of using only a single tubing string 64 to inject and produce gas in the multiple wellbores 24 , 44 , while leaving the annulus 88 available for well control. This storage and production of gas through the tubing string 64 is accomplished without requiring flow reversal in any gravel pack of the system 10 .
[0066] In the accompanying FIGS. 1 - 7 depicting several embodiments of the invention, the production wellbore 44 is shown as intersecting the main wellbore 12 at a wellbore junction, and the storage wellbore 24 is shown as being an extension of the main wellbore. The main wellbore 16 is cased, while the production and storage wellbores 24 , 44 are uncased. The production wellbore 44 is above the storage wellbore 24 . However, it is to be clearly understood that these examples of embodiments of the invention are merely used for illustration purposes. The main wellbore 12 could be uncased at its junction with the production and/or storage wellbores 24 , 44 , the storage and/or production wellbores could be cased, the storage wellbore could be above the production wellbore, the storage wellbore could intersect the main wellbore at a wellbore junction, the production wellbore could be an extension of the main wellbore, etc.
[0067] The junction between the main wellbore 12 and the production wellbore 44 has been depicted in the drawings and described above as one in which the tubular string 52 in the production wellbore extends into the main wellbore and is cemented at least up to the window 20 . However, it is to be understood that other types of wellbore junctions may be utilized, without departing from the principles of the present invention. For example, any of the wellbore junctions known to those skilled in the art as Levels 1 - 6 may be used, as well as any other type of wellbore junction.
[0068] Thus, a person skilled in the art would, upon a careful consideration of the above description of representative embodiments of the invention, readily appreciate that many modifications, additions, substitutions, deletions, and other changes may be made to these specific embodiments, and such changes are contemplated by the principles of the present invention. Accordingly, the foregoing detailed description is to be clearly understood as being given by way of illustration and example only, the spirit and scope of the present invention being limited solely by the appended claims and their equivalents. | A gas storage and production system decreases production of formation sand and permits high gas flow rates in storing and producing operations. In a described embodiment, different flowpaths are used for injecting and withdrawing gas from a subterranean formation. In another embodiment, a gravel pack is confined to a set volume, so that it is not expanded when gas flows at a relatively high rate therethrough. | 4 |
FIELD OF THE INVENTION
[0001] The present invention relates generally to ultrasound imaging methods and systems. More specifically, it relates to a method and system for using the computer keyboard and/or speech recognition technology to automatically fill in an image annotation during an ultrasound scan.
BACKGROUND OF THE INVENTION
[0002] During a typical ultrasound scan, the sonographer frequently needs to type in an annotation on the image to indicate the anatomy scanned, probe orientation on the patient, and any abnormal anatomic feature in the image. The image, together with the superimposed annotation, is saved for later review and further diagnosis by a physician. That image and annotation becomes part of the patient's medical record.
[0003] During the scanning process, the sonographer maintains the ultrasound probe on the patient with one hand, while controlling the machine with the other hand. Thus, annotations are typically typed with only one hand. This is a difficult and awkward process at best. For example, it can be difficult for the sonographer to reach the keyboard while keeping the probe properly positioned on the patient, particularly during interventional procedures. Even with the ability to freeze-frame and cine the image, this remains a cumbersome procedure. If less typing would be required, or if typing can be done away with entirely, the situation would be more manageable. What is needed is a method and system whereby the sonographer uses a minimal amount of effort to complete the annotation by means of the computer keyboard during the examination. What is also needed is such a method and system whereby annotations are set according to a pre-programmed scheme depending upon the examination that is being performed.
[0004] In the experience of these inventors, several methods exist for voice-controlling the ultrasound equipment itself. However, previous voice recognition systems are used only to control or to select ultrasound system parameters. What is needed is a voice control method that recognizes common annotations used by ultrasound operators and that can be used in conjunction with or in place of keyboard annotation systems for the ultrasound equipment.
BRIEF SUMMARY OF THE INVENTION
[0005] Currently, to type an annotation, the sonographer types the text he or she wants to appear character by character. These inventors sought to maintain this mental model for the user. To make it simpler for the user, the method of the present invention is used to predict the complete word that the user intended to type. The most likely word to complete the letters already typed is displayed in lighter letters. Additionally, a “drop down” shows other options that the user may intend. To accept the most likely word, i.e. the one displayed in line with the typed letters, the user need only hit the confirmation button. The confirmation button can be the space bar, the return key, the set key, or any other key of the user's choosing. To select one of the “drop down” options, the user must use an arrow key to select one of the options, and then hit the confirmation button. At this point, the user is ready to type the next word. The system will suggest words most likely to follow the previous word selected. The user can either confirm one of the selected words, or continue to type the word he or she wants. The system will function as described previously following each letter typed. To get the system to work, it requires a list of words and associated frequency. Assuming this list is sorted by frequency, to get the algorithm to display the most likely word involves displaying the first word (of highest frequency) that matches all of the letters currently typed. The next best guesses can be added by listing the next x (let's say 4) highest frequency words with matching letters. This frequency list can be updated dynamically based on what annotations are actually typed, or the user can manually update the list. The system should also store a list of word-pairs. It uses this list to suggest the second word. This list can also be updated dynamically based on the user's history.
[0006] In short, the method and system of the present invention enables the keyboard to be used in such a way that the computer software completes the annotation of words by recognizing words of common usage in accordance with a pre-programmed scheme. The method and system of the present invention also enables the ultrasound operator to perform difficult examinations without requiring the operator to use the keyboard to fully type in the annotation in order to annotate images generated by the ultrasound equipment. That is, the operator is not required to type each and every letter of each and every word of the annotation. The method and system instead recognizes words that are frequently used in a particular scan and anticipates the word or words that the operator wants to complete. This capability simplifies difficult examinations, and reduces the occupational health problems from scanning in physically awkward situations. The present invention is also capable of employing both keyboard and speech recognition equipment to automatically fill in the annotation during ultrasound imaging.
[0007] The foregoing and other features of the method of the present invention will be apparent from the detailed description that follows.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] [0008]FIG. 1 is a schematic diagram of the automatic annotation filler method of the present invention.
[0009] [0009]FIG. 2 is an example of a screen display employing the annotation filler of the present invention and showing the first letter completed by the user and the annotation filled by that letter.
[0010] [0010]FIG. 3 is the screen display illustrated in FIG. 2 and showing the second letter completed by the user.
[0011] [0011]FIG. 4 is the screen display illustrated in FIG. 2 and showing the third letter completed by the user.
[0012] [0012]FIG. 5 is the screen display illustrated in FIG. 2 and showing the fourth letter completed by the user.
[0013] [0013]FIG. 6 is the screen display illustrated in FIG. 2 and showing the fifth letter completed by the user.
[0014] [0014]FIG. 7 is the screen display illustrated in FIG. 2 and showing the eighth letter completed by the user.
[0015] [0015]FIG. 8 is the screen display illustrated in FIG. 2 and showing the ninth letter completed by the user.
[0016] [0016]FIG. 9 is the screen display illustrated in FIG. 2 and showing the completed annotation.
DETAILED DESCRIPTION OF THE INVENTION
[0017] Ultrasound image annotation typically uses acronyms and abbreviations to identify or label anatomical landmarks, positions, locations or medical procedures. For example, the letters CBD stand for “Common Bile Duct”, and the letters TRV stand for “Transverse.” In ultrasound imaging, the system parameters are optimized depending on certain applications. Before starting to scan, the user should select the right application by pressing a key or button to preprogram the ultrasound system. For example, when scanning a patient's carotid artery, the user should select the “carotid” application to set the system parameters, and then begin the ultrasound scan. This maximizes system parameters for that particular type of scan.
[0018] In the method and system of the present invention, a keyboard is used to identify certain words that are most often used in ultrasound image annotations. This would include acronyms and abbreviations that are saved in a memory. The words should be grouped under each application. Some words may appear under multiple applications. For example, the abbreviations SAG (for “sagittal”) and TRV appear under almost every type of ultrasound application. The words are listed by frequency. This concept, for example, can be demonstrated in a carotid application where the following Table 1 illustrates some of the words used for annotation purposes. Those words are saved in the memory, and in order, using the hierarchy as described above:
TABLE 1 Art (artery), Aneur (aneurysm), Anast (anastamosis) AoAr (aortic arch), Bifurcation Bulb CCA (common carotid artery), Distal ECA (external carotid arter), EJV (external jugular vein), Graft ICA (internal carotid artery), IJV (internal jugular vein), Innom (Innominate artery) InMam (inferior mammary), Jugular, Left Mid Prox (proximal), Right Sag (sagittal) Sten (stenosis), Subc (subclavian), SupTh (superior thyroid), SV (superior vena cava). Trv (transverse) Thyroid Vert (vertebral), Vein, VertV (vertebral vein).
[0019] It will be observed that the words have been sorted out by their frequency of usage, with higher frequency words being listed first. Words with the same ranking and same initial letters will be saved in alphabetical order. The system will search down the list for the first word matching all of the letters typed by the user. The following Table 2 illustrates how many letters must be keyed in to get certain words:
TABLE 2 Letter typed Word chosen a Artery an Aneur ana Anast ao Aorta b Bifurcation bu Bulb c CCA d Distal e ECA ej EJV g Graft i ICA ij IJV in Innom inm InMam j Jugular l Left m Mid p Prox r Right S Sag St Sten su Subc sup SupTh sv SV t TRV th Thyroid v Vert vei Vein vertv VertV
[0020] Ultrasound imaging systems typically have a “Set” or “Select” key, each of which is used to select certain functions or parameters, much like a left “click” made on a computer mouse. If the user-selected word appears on the screen, the user need only press the “Select” or “Set” key (although the space bar, the “Return” key or any other punctuation key could be used as well) to have the cursor jump to the end of the word. The system is then ready for the next word. The operator needs to keep typing in the letters until the desired word appears on the screen. A space is automatically added between each word.
[0021] The following Table 3 illustrates some of the words used for an abdomen annotation. The words are likewise sorted out in accordance with the order described above.
TABLE 3 Letters typed Chosen word a Aorta ap Appendix b Bladder bo Bowel c CBD. (common bile duct) ca Caudate Lobe Ce Celiac Art d Distal g GDA (gastro duodenal artery) ga Gallbladder h Hepatic Vein hepatic a Hepatic Artery i IVC (inferior vena can) k Kidney l Liver le Left lo Lower lob Lobe m Mid p Pancreas po Portal Vein pr Prox (proximal) r Right s Spleen sa Sag (sagittal) sm SMA (superior mesenteric artery) splen Splenic Vasculature t TRV (transverse) u Upper v Vein
[0022] If the word is not in the memory, then the user has to type the entire word. The annotation automatic fill algorithm can also be turned on or off. When it is off, the screen is going to display whatever is typed on the keyboard. When it is on, the annotation automatic fill algorithm will anticipate the word or words that the operator wishes to insert when he or she types the first one or two letters of the word that is desired. This results in a substantial reduction of the actual amount of typing that the operator needs to perform during the ultrasound scan.
[0023] In application, the sonographer is presented with a screen display 30 much like that illustrated in FIGS. 2 through 9. In this example, the sonographer is attempting to type the annotation “splenic vasculature” 46 , normally a nineteen keystroke entry, in the least number of strokes possible. The annotation 32 appears at the bottom of the display 30 . As shown in FIGS. 2 through 5, the user types 34 the first letter “s” and the highest ranking option to appear is the word “spleen” 36 . The complete word is shown in a lighter background. Since the word “spleen” 36 is not the desired word, the sonographer continues typing the letters “p” 38 , “l” 40 , “e” 42 and “n” 44 . In FIG. 6, it will be seen that the word “spleen” 36 no longer matches, so the highest-ranking word matching the typed letters “splen” is “splenic” 46 . This complete word 46 also displays in a lighter background. In FIG. 7, the user hits the spacebar or the “set” key, which accepts the suggested word and then continues typing the first letter “v” 48 of the next word. The most likely “v” word is “vein” 50 so that is shown in the lighter background. In FIG. 8, the user types the letter “a” 52 and, since “vasculature” 54 is the most likely word matching the letters “va”, that word appears in lighter background. In FIG. 9, the user hits the set key to accept the word “vasculature” 54 and the completed annotation “splenic vasculature” 56 . In summary, the key presses in this example are S, P, L, E, N, space, V, A. The key count is eight, compared to nineteen keystrokes normally required. This results in a 58% reduction in the keystrokes for this example. Of course, expected efficiency and overall reduction will vary from application to application.
[0024] If the preceding example is expanded to include a drop-down box, only four keystrokes are required. After the user types “s”, the most likely word “spleen” is shown as described above, and a drop-down list appears. This list contains the next three most likely matches, namely: “Sag”, “SMA”, and “splenic vasculature”. The user must hit the down arrow three times to highlight the last suggestion (“splenic vasculature”) and then hit the “set” key. This results in a 79% improvement over typing the entire word.
[0025] In accordance with the method of the present invention, the ultrasound operator has four options. The speech recognition apparatus can be activated, the auto annotation filler can be activated, both can be in use or neither can be in use.
[0026] In accordance with the method of the present invention, there are three methods to annotate the image by voice. Two permit free form text entry (dictation) using a general medical dictation vocabulary; one requires the user to enter a dictation mode, while the other adds a keyword before each comment. The third method involves selection from a limited list of terms. Each of these methods assumes that the sonographer is already using speech recognition to control the ultrasound machine.
[0027] There are several features common to all of these methods. First, comments and annotations can be positioned on screen with a command “Move Comment Top Left” or “Move Comment Bottom Center.” The commands “Return” or “New Line” set a carriage return. Words can be deleted with commands like “Word Delete” or all annotations can be erased with “Delete All” or “Clear All.”
[0028] Secondly, spaces are automatically inserted between words; other punctuation must be listed at the point where it should be inserted. The name of the punctuation symbol should be verbalized. A word can be capitalized by preceding it with the command “Capital”, “Cap”, or by saying “Capitalize That” or “Cap That” after it is typed. To capitalize all letters, the caps lock key on the keyboard must be depressed.
[0029] Additionally, words can be spelled instead of spoken. However, in order to avoid confusion with words that sound similar to the name of a letter, the user can precede the letters with the command “Spell” or “Type Letters” followed by all of the letters with little or no time gap between them.
[0030] The first method for verbal annotations involves a medical dictation recognition engine. Generally, the ultrasound machine that operates from speech commands is already listening for system commands and ignores other speech. Therefore, the user must separately issue a verbal command to instruct the machine to take dictation. This command enables the grammar dictionary and instructs the software to transcribe everything the user says. Similarly, a command is required to instruct the machine to stop transcribing. Other commands are required for correcting errors in dictated text, punctuation and spacing. A sample interaction is described in Table 4 below.
TABLE 4 User Says Machine Reaction <keyword> Type Machine enables dictation engine Left Coronary Artery Types “Left Coronary Artery” in last position cursor was in. New Line Moves to next line Note Blockage Exclamation Point Types “Note blockage!” Move Comment to Top Left Positions text on top left side of screen Done Machine disables the dictation engine.
[0031] In the foregoing example, <keyword> refers to a specific word used to identify a command to the machine. This is an optional feature that improves the accuracy of the dictation. In the event the machine transcribes inaccurately, or the user makes an error, the sonographer can say correct <error> to <correction> to have the machine fix the mistake.
[0032] The second method also uses a dictation recognition engine but it does not require the user to enter a special dictation mode. Instead, comments are prefaced with a keyword such as “Type.” This eliminates the need for the user to enter a separate mode to get the machine to transcribe. It also makes use of the correction commands described for method one. A sample interaction using this third method is described in Table 5 below.
TABLE 5 User Says Machine Reaction Type Left Coronary Artery Machine types “Left Coronary Artery” in last position cursor was in. New Line Moves to next line Type Note Blockage Types “Note Blockage!” Exclamation Point Moves Comment to Top Left Positions text on top left side of screen.
[0033] The third method of speech recognition is the restricted list method. It uses a command control recognition engine, and requires every possible annotation word to be in a pre-defined list. This list of words can be user defined and context sensitive to the type of exam being performed. The grammar definition for this method is of the form <keyword> <wordlist> + , where <keyword> identifies the phrase as a comment (for example “Type”), and <wordlist> is one or more words from the list.
[0034] For example, if the sonographer issues a verbal command “Type left coronary artery”, and provided the words “Left”, “Coronary” and “Artery” are in the available word list, the system types them on the screen display. As such, the transcription feature becomes another command in the list of commands that the system understands.
[0035] A partial list of the grammar entries for a general exam are the following words: Right, Left, Top, Bottom, Of, And, etc. If the sonographer wished to perform an examination of the carotid artery, the sonographer would select the carotid wordlist, which could include terms such as: aneurysm, anastamosis, aortic arch, bifurcation, bulb, common carotid artery etc. The sonographer would need to train the system for each such exam before the speech engine would recognize the terms. After the system is trained using the above grammar, the system would respond to the command “Type Left Aneurysm” because each of the terms is within its grammar lists. It would not respond to “Type Left Side Aneurysm” because the word “Side” is not in the list.
[0036] The speech recognition method of the present invention employs several different elements as are well known in the art. For example, any microphone suitable for speech recognition may be used. Additionally, any mounting option for the microphone can be used. Furthermore, the microphone could be either wired directly to the speech recognition system or a wireless connection could be used.
[0037] There are also many types of speech recognitions systems known to the art that could be used in the method of the present invention. For example, the speech recognition system could use a processor embedded within the housing of the ultrasound unit. The speech recognition system could also be installed on a stand-alone processor connected to the ultrasound machine.
[0038] Obviously, the computer must be connected to the ultrasound in some way. These types of connections are also standard and are well known in the art. The present invention is not limited to a certain type of ultrasound or to a specified computer. It is instead recognized that the method of the present invention is designed for use with all types of speech recognition systems and ultrasound machines.
[0039] Referring now to FIG. 1, it shows the flow chart of the automatic annotation filler in accordance with the present invention. As can be seen from FIG. 1, the voice recognition system and the keyboard can work independently and concurrently. The automatic annotation filler is generally identified 10 . The schematic representation includes a keyboard 12 and an ultrasound image display monitor 14 . The first question asked by the method is whether the automatic annotation filler is “on” 22 . If the automatic annotation filler is “off” then the display 14 merely shows what the user types on the keyboard. A second question asked is whether the speech recognition is “on” 28 . If the speech recognition is “on” then the display monitor 14 shows what the user says by voice. If the automatic annotation filler is not on, the display monitor 14 does not automatically show the annotation unless the keyboard 12 is manually operated. If the automatic annotation filler 22 is on, then the application is read in 24 and the search words in the memory 26 are electronically accessed to display the automatic annotation included on the display monitor 14 . In other words, the ultrasound operator can both type and use vocal commands to enter the annotations required for the ultrasound imaging and the display 14 will show the most likely word that the sonographer intends to type based on the keys he or she has already hit or the words he or she has spoken.
[0040] It is to be understood that the invention is not limited to the embodiment set forth herein but that the invention may be carried out in other ways without departure from the spirit of this invention. | The present invention provides a method and system for using the computer keyboard 12 and/or speech recognition technology to automatically fill an image annotation 32 during an ultrasound scan. More specifically, it provides a method and a system for annotating a displayed ultrasound image 30 using commands that is comprised of; providing an annotation vocabulary sorted in descending order of usage frequency providing a method to select a subset of words from the vocabulary that are relevant to the imaged anatomy, detecting the initial command, selecting a suggestion list from the selected sub-vocabulary, and displaying the suggestion list to the user for optional acceptance or further specification. | 6 |
FIELD OF THE INVENTION
[0001] This invention relates to combinations of vasopressin antagonists and diuretic agents for use in treating edematous conditions such as congestive heart failure.
BACKGROUND OF THE INVENTION
[0002] Congestive heart failure (CHF) is a pathophysiological state in which the heart is unable to pump sufficient blood to meet the metabolic needs of the body. The underlying basis of this disorder is a deficiency of myocardial contractility, resulting in a decreased mechanical ability to pump blood and in turn, a decreased cardiac output. Congestive heart failure may result from a number of factors affecting the myocardium, altering systolic and/or diastolic function. As the condition progresses, activation of both the sympathetic nervous system and the renin-angiotensin-aldosterone system lead to an increase in the total peripheral resistance. In addition, elevated levels of arginine vasopressin (AVP) have been reported in some patients with heart failure, although its pathophysiologic role is unknown. It has been postulated that the increase in AVP may provide increased systemic vascular resistance and impaired water excretion as a compensatory mechanism to the low cardiac output associated with CHF.
[0003] Arginine vasopressin, also known as antidiuretic hormone (ADH), is synthesized in the magnocellular neurosecretory cells of the paraventricular and supraoptic nuclei of the hypothalamus and stored in the posterior pituitary. There are 2 classes of AVP receptors. V 1 and V 2 . There are 2 subclasses of V 1 receptors. V 1A and V 1B . V 1A receptors are found in the vasculature, and mediate the pressor response of AVP by increasing the contraction of blood vessels. V 1A receptors are also found on platelets, where they mediate platelet aggregation. V 1B receptors are located in the anterior pituitary, and mediate adrenocorticotropic hormone (ACTH) release. V 2 receptors are located in the collecting ducts of the kidney: they are coupled to aquaporine channels and modulate free water clearance. Arginine vasopressin is released into the circulation in response to an increase in plasma osmolality (mediated by osmoreceptors) or a decrease in plasma volume or blood pressure (mediated by baroceptors). However, there are other stimuli for AVP release, including norepinephrine, angiotensin II, emotion, nausea and vomiting, and fever.
[0004] Heart failure is characterized by increased sympathetic nervous system activity and changes in several neurohormonal factors, such as angiotensin II, aldosterone, endothelin-1, and atrial natriuretic factor. In patients with advanced CHF, plasma levels of AVP are also increased. While the mechanism of AVP release in CHF is not well-understood, infusion of AVP into CHF patients results in an increase in systemic vascular resistance and a redistribution of cardiac output. These observations suggest that the increased levels of AVP observed in patients with severe CHF play a role in the pathogenesis of this disease. Several compounds are known which antagonize the hormonal effects of AVP, for example, the benzazepines disclosed in U.S. Pat. No. 5,723,606.
[0005] The cardiac dysfunction underlying CHF results in a decreased effective tissue perfusion, which in turn stimulates the renin-angiotensin-aldosterone and sympathetic nervous systems to promote Na + retention by the kidney, which can result in the formation of edema. Patients with CHF and evidence of pulmonary congestion or peripheral edema are routinely treated with diuretics. Thiazide diuretics, which act on the distal convoluted tubule of the kidney by inhibiting the Na + -Cl − cotransporter, may initially be employed. However, they produce only a slight increase (5%-8%) in the amount of sodium excretion by the kidney, and subject the patient to risk of hypokalemia (low blood potassium) and hyponatremia. In patients with more advanced heart failure and signs of extracellular fluid accumulation, loop diuretics are generally used. Loop diuretics, such as furosemide, act at the thick ascending limb of the loop of Henle by competing for the Cl − site on the Na + —K + —Cl − transporter. These diuretics are capable of increasing the fractional sodium excretion to more than 20% of the filtered load, albeit at an even greater risk of potassium wasting in the urine and hypokalemia and hyponatremia in the serum.
[0006] We have now discovered that the use of diuretics in combination with compounds which inhibit vasopressin enzymes is surprisingly effective in promoting increased clearance of fluid by the kidney, and decreased excretion of sodium and potassium in the urine, thereby minimizing the risk of electrolyte disturbance such as hypokalemia and hyponatremia. An object of this invention is thus to provide compositions comprising a vasopressin antagonist in combination with a loop diuretic agent, and a method for treating edematous conditions such as CHF using such compositions.
SUMMARY OF THE INVENTION
[0007] This invention provides a composition comprising a diuretic agent and a vasopressin antagonist. The invention also provides a method for treating edematous conditions such as CHF, and promoting increased fluid clearance by the kidney, and maintenance of electrolyte balance in a mammal by decreasing excretion of sodium and potassium in the urine otherwise caused by the diuretic agent alone.
[0008] Any diuretic agent can be used in combination with any vasopressin antagonist according to this invention. In a preferred embodiment, the diuretic agent is a loop diuretic agent. Loop diuretics are compounds that act on the ascending limb of the loop of Henle and on the proximal and distal tubes in the kidneys of animals. The compounds are routinely used to treat edema associated with CHF, cirrhosis of the liver, and renal disease. Typical loop diuretics include bumetinide, ethacrynic acid, furosemide, piretamide, and torsemide. Other diuretics can also be used in this invention, including agents such as chlorothiazide, hydrochlorothiazide, triamterene, spironolactone, eplerenone, metolazone, acetazolamide, amiloride, and polythiozide. A preferred loop diuretic is furosemide (see U.S. Pat. No. 5,256,687).
[0009] The vasopressin antagonist to be employed is any chemical compound that is effective in inhibiting the biological activity of any arginine vasopressin or antidiuretic hormone. Numerous compounds are known to be vasopressin antagonists, and any of such compounds can be utilized in the composition of this invention.
[0010] In a preferred embodiment, the vasopressin antagonist to be utilized is a condensed benzazepine such as those described in U.S. Pat. No. 5,723,606, incorporated herein by reference. In a further preferred embodiment, the vasopressin antagonist is an imidazo benzazepine of the Formula I
[0011] wherein R and R 5 are hydrogen or lower alkyl;
[0012] R 1 , R 2 , and R 3 independently are hydrogen, halo, lower alkly, lower alkoxy, amino, alkylamino, or dialkylamino; and
[0013] R 4 is hydrogen, phenyl or substituted phenyl, and pharmaceutically acceptable salts thereof.
[0014] An especially preferred vasopressin antagonist to be used in accordance with this invention is conivaptan, which is N-[4-(2-methyl-4.5.6-tetrahydromidazo[4,5-d] [1]benzazepin-6-ylcarbonyl)phenyl]biphenyl-2-carboxamide hydrochloride. Conivaptan is also referred to as CI-1025 and YM087, and has the structural formula below
[0015] Other vasopressin antagonists that can be employed accordingly to this invention include the benzoheterocyclic compounds described in U.S. Pat. No. 5,258,510, incorporated herein by reference. Preferred compounds from this class to be used herein include the following:
[0016] 5-Dimethylamino-1-[4-(2-methylbenzoylamino)-benzovl]-2.3.4.5-tetrahydro-1H-benzazepine;
[0017] 5-Dimethylamino-1-[2-chloro-4-(2-methylbenzoylamino)benzoyl]-2,3,4,5-tetrahydro-1H-benzazepine;
[0018] 5-Methylamino-1-[2-chloro-4-(2-methylbenzoylamino)benzoyl]-2,3,4,5-tetrahydro-1H-benzazepine;
[0019] 5-Cyclopropylamino-1-[2-chloro-4-(2-methylbenzoylamino)benzoxyl]-2,3,4,5-tetrahydro-1H-benzazepine:
[0020] 5-Cyclopropylamino-1-[2-chloro-4-(2-chlorobenzoylamino)benzoxyl]-2,3,4,5-tetrahydro-1H-benzazepine;
[0021] 5-Dimethylamino-1-[2-methyl-4-(2-methylbenzoylamino)benzoyl]-2,3,4,5-tetrahydro-1H-benzazepine;
[0022] 5-Dimethylamino-1-[2-methoxy-4-(2-methylbenzoylamino)benzoyl]-1,2,3,4-tetrahydroquinoline:
[0023] 7-Chloro-5-methylamino-1-[4-(2-methylbenzoylamino)benzoxyl]-2,3,4,5-tetrahydro-1H-benzazepine: and 7-Chloro-5-methylamino-1-[4-(2-chlorobenzoylamino)benzoxyl]-2.3.4.5-tetrahydro-1H-benzazepine.
[0024] Other vasopressin antagonists that can be employed according to this invention include those described in U.S. Pat. Nos. 5,225,402; 5,258,510; 5,338,755; 5,719,155; and 5,710,150; all of which are incorporated herein by reference. Specific vasopressin antagonists include YM471, OPC-31260. OPC-21268, OPC-41061, SR-121463, SR-49059, VPA-985, CL-385004, FR-161282, JVT-605, VP-339, WAY-140288, and the like.
[0025] The compositions provided by this invention will contain a diuretic agent, preferably a loop diuretic, and a vasopressin antagonist in a weight ratio of about 0.05:1 to about 1000:1, and typically about 1:1 to about 500:1 and ideally about 1:1 to about 10:1. A typical composition, for example, will comprise about 40 mg to about 80 mg of the loop diuretic furosemide together with about 5 mg to about 40 mg of conivaptan. Such compositions will be administered to adult humans suffering from edematous conditions such as CHF.
[0026] A further embodiment of this invention is a method for treating CHF comprising administering to a patient suffering from CHF and in need of treatment an effective amount of a diuretic agent in combination with an effective amount of vasopressin antagonist.
[0027] Another embodiment is a method for decreasing the excretion of sodium and potassium ions in the urine of an animal comprising administering a diuretic agent in combination with a vasopressin antagonist.
[0028] Still another embodiment of the invention is a method for increasing the amount of fluids secreted by an animal via the kidney comprising administering an effective amount of diuretic agent in combination with a vasopressin antagonist.
[0029] Another embodiment is a method for treating edematous states.
[0030] All that is required to practice the methods of this invention is to administer amounts of a diuretic agent and a vasopressin antagonist that are effective to treat CHF and to reduce electrolyte imbalance in mammals. The agents can be administered individually, or they can be formulated together into a single composition.
DESCRIPTION OF FIGURES
[0031] [0031]FIG. 1 shows the change in urine osmolality (mOsm/kg) in patients receiving various dose combinations of furosemide and conivaptan.
[0032] [0032]FIG. 2 shows the percentage reduction in urine osmolality caused by various dose combinations of furosemide and conivaptan and the synergy between the two agents.
[0033] [0033]FIG. 3 shows the total urine sodium concentration (mEq) following various dose combinations of furosemide and conivaptan (conivaptan antagonizes the excretion of sodium).
[0034] [0034]FIG. 4 shows the total urine potassium concentration (mEq) following various dose combinations of furosemide and conivaptan. Conivaptan antagonizes the urinary excretion of potassium by furosemide.
DETAILED DESCRIPTION OF THE INVENTION
[0035] The ability of a combination of a diuretic agent together with a vasopressin antagonist to reduce electrolyte imbalance and to treat CHF has been established in a controlled clinical trial.
[0036] Preclinical pharmacologic studies have demonstrated potent binding of YM087 conivaptan to AVP receptors and antagonism of the vascular and renal effects of AVP. YM087 has high affinity for V 1A - and V 2 -receptors with pKi (negative log of the binding inhibition constant) of 8.20 for human V 1A -receptors and 8.95 for human V 2 -receptors expressed in COS-1 cells.
[0037] Clinical Pharmacology
[0038] YM087 given orally to rats antagonizes the AVP-induced pressor response (VIA antagonism) in a dose-related manner, with the dose that reduced the AVP response by 50% (ID 50 ) being 0.32 mg/kg: ID 50 for a similar experiment using intravenous (IV) YM087 in dogs was 0.026 mg/kg. In conscious dogs, oral YM087 (0.03 to 0.3 mg/kg) increased urinary output (V 2 antagonism) and reduced urinary osmolality (from 1500 to <100 mOsm/kg H 2 O) in a dose-related manner. Unlike furosemide. YM087 has little or no effect on urinary sodium (Na) or potassium (K) excretion. In dogs with heart failure induced by rapid right ventricular pacing, intravenous administration of YM087 (0.1 mg/kg) significantly improved the depressed cardiac function and produced a water diuresis.
[0039] Oral absorption of YM087 is rapid (peak concentrations reached between 0.5 to 1 hour in the rat and dog, respectively) and occurs predominantly in the small intestine. There is a marked food effect with absorption reduced by >50% in dogs after a meal. The elimination half-life is 1 hour in rats and 2 hours in dogs. Mass balance studies show the majority of radioactive tracer excreted in the feces. The preclinical toxicologic potential of YM087 has been extensively evaluated, and all findings were evaluated for relevance to human risk assessment and impact on clinical trial design. Findings of potential concern were bone marrow changes in dogs and effects on fertility in rats.
[0040] Histopathologic changes in bone marrow were observed in both 2- and 13-week oral studies in dogs with systemic exposures 28- to 87-fold higher than the maximum anticipated human exposure. Decreased peripheral erythrocyte, leukocyte, and/or platelet counts occurred in affected dogs in the 13-week study. Bone marrow and peripheral blood changes were reversible.
[0041] YM087 did not affect reproductive performance of male rats. In the 13-week, repeated oral dose study in rats, more females at 10 mg/kg were in diestrus or proestrus and fewer were in estrus than in controls, and uterine weights were decreased at all doses: associated systemic exposures were 0.06- to 3.2-fold the maximum anticipated human exposure. In the female fertility study in rats, reduced fertility index, increased implantation loss, and decreased live fetuses were observed in females given 100 mg/kg orally for 2 weeks prior to mating with untreated males. Effects on estrous cycle and fertility in female rats may be related to alterations in serum hormone levels resulting from pharmacologic activity of YM087. YM087 was not teratogenic in rats or rabbits.
[0042] Other drug-related effects, including diuresis and hepatocellular hvpertrophy, were of less concern due to the nature of the effects or the high exposures at which the effects occurred compared to exposures anticipated in clinical trials.
[0043] YM087 was not mutagenic in bacteria, and was not clastogenic in human lymphocytes in vitro or in bone marrow of rats. No toxicity was observed in 4-week, IV studies with the glycerin formulation at maximum achievable doses. 2.5 mg/kg in rats and 2 mg/kg in dogs.
[0044] In summary toxicological findings of potential concern for human risk assessment were reversible effects on bone marrow in dogs and reversible effects on estrus cycle and decreased fertility in rats. Findings in bone marrow were observed at exposures in excess of 23 times exposure expected in humans given the maximum dose of 120 mg once daily (QD), while effects on estrus cycle occurred at exposures from 0.05- to 3-fold the expected human exposure at 120 mg QD. Other drug-related findings in toxicology studies were considered secondary to pharmacologic activity or a functional adaptation to exposure to YM087.
[0045] YM087 has been given to approximately 250 healthy patients who participated in a total of 15 Phase 1 studies (8 in Japan and 7 in Europe). Subjects taking oral medication received either a single dose of YM087 (dose range 0.2 through 120 mg) QD or 30 or 120 mg YM087 administered as a divided dose twice daily (BID). Subjects received YM087 as a single IV injection once daily over a dose range of 0.2 to 250 μg/kg or up to a maximum of 50 mg.
[0046] Inhibition of AVP-induced platelet aggregation (evidence of V 1A antagonist activity) was seen among subjects who received YM087 at 20 mg/day orally or 2.5 mg IV. Total inhibition of AVP-induced dermal vasoconstriction was observed among subjects who received YM087 50 mg IV.
[0047] Normal subjects have demonstrated aquaretic action (evidence of V 2 -receptor antagonism) accompanied by a decrease in urine osmolarity starting at 15 mg oral or 50 μg/kg IV. At higher doses aquaretic effects were more pronounced and at 120 mg QD or 60 mg BID given orally or 50 mg given IV were considered too uncomfortable in normal subjects to be tolerable. YM087 at IV doses up to 250 μg/kg and 50 mg/day increased urine production rate for up to 3 and 6 hours postdosing, respectively.
[0048] Under fasting conditions. YM087 is rapidly absorbed, time to maximum plasma concentration (tmax) being reached at around 1 hour. The mean oral bioavailability, of a 60-mg dose is 44% under fasting conditions; bioavailability is decreased after intake with food. A high-fat breakfast reduced bioavailability of single 15- to 90-mg doses of YM087 to 43% to 59% of the fasted value, and peak plasma levels were reduced to 24% to 54% of the fasting value. Oral YM087 demonstrated a nonlinear pharmacokinetic profile. Repeated BID oral doses of YM087. 60 mg, result in unexpectedly high plasma levels after the second dose, possibly caused by reduced first-pass metabolism. YM087 displays 2 compartment pharmacokinetics, with an elimination half-life of 4 to 5 hours. Elderly subjects have a similar elimination half-life as healthy, young volunteers.
[0049] The pharmacokinetics of orally administered YM087 (20 mg) were not affected when combined with either 0.5 mg IV digoxin or 25 mg oral captopril (each given as a single dose).
[0050] Safety
[0051] Among approximately 250 subjects treated, no major safety concerns were identified. One patient with severe CHF who received YM087 80 mg/day for 4 days experienced a generalized tonic clonic seizure, which the investigator could not exclude as related to study drug. The most frequent adverse events regardless of treatment association were mild or moderate thirst and mild headache. Other adverse events included flushes, a sensation of cold extremities, abdominal complaints, abnormal stools, syncope, dizziness, palpitations, and postural hypotension. Three subjects who received YM087 and one subject who received placebo developed minor, reversible decreases in white blood cell counts. No drug-related trend was observed in biochemical or hematological laboratory parameters. At higher doses, urinary osmolarity decreased and plasma osmolarity increased with or without an increase in plasma sodium. These observations were considered related to antagonism of V 2 receptors and not a safety concern. Vital signs (blood pressure and heart rate) were unaffected by YM087.
[0052] Study Rationale
[0053] The edematous condition resulting from CHF develops from a decreased effective tissue perfusion, which in turn stimulates the renin-angiotensin-aldosterone and sympathetic nervous systems to promote Na + retention by the kidney, which can result in the formation of edema. Patients with CHF and evidence of edema are routinely treated with diuretics. Thiazide diuretics, which act on the distal convoluted tubule of the kidney by inhibiting the Na + —Cl − cotransporter, may initially be employed. However, they produce only a slight increase (5%-8%) in the amount of sodium excretion by the kidney, and expose the patient to risk of hypokalemia and other disorders associated with electrolyte disorders. In patients with more advanced heart failure and signs of extracellular fluid accumulation, loop diuretics are generally used. Loop diuretics, such as furosemide, act at the thick ascending limb of the loop of Henle by competing for the Cl − site on the Na + —K + —Cl − transporter. These diuretics are capable of increasing the fractional sodium excretion to more than 20% of the filtered load, albeit at an even greater risk of hypokalemia and other electrolyte disorders.
[0054] At the kidney, AVP acts via the V 2 receptors in the principal cells of the collecting duct to increase water reabsorption. The binding of AVP to V 2 receptors results in an increase in cytosolic cAMP (via a linked G protein) which acts as a second messenger, and results in an increase in the “trafficking” of aquaporin 2 (AQP2) water channels from intracellular vesicles to the apical plasma membrane of the principal cells. While this shuttling of AQP2 occurs shortly following stimulation of the V 2 receptor, longer-term changes also occur in the form of an increase in AQP2 proteins. As YM087 antagonizes the binding of AVP to the V 2 receptor, it is reasonable to postulate that its mechanism of action is via the decrease in the trafficking and production of AQP2 to the plasma membrane of the principal cells of the collecting duct.
[0055] These findings indicate that furosemide and YM087 act at different segments of the nephron, and act via different mechanisms of action. Agents that act at different portions of the kidney can be of importance in patients with CHF and other edematous states who sometimes develop resistance to loop diuretics, especially when they have been used chronically for some time. The addition of a hormone antagonist which would increase the excretion of solute-free water (and thus not increase sodium loss) and simultaneously limit potassium losses, might produce an added benefit in the treatment of CHF patients who are currently on a loop diuretic. Therefore, this study will be conducted to assess the effect of concomitant treatment with the vasopressin antagonist. YM087, and a commonly used diuretic, furosemide, in patients with a prototypical edematous condition, namely CHF.
[0056] STUDY OBJECTIVES
[0057] The objectives of this study are:
[0058] To assess the effect of concomitant treatment with YM087 and furosemide in CHF patients.
[0059] To determine the safety of giving these two agents concomitantly to CHF patients; and
[0060] To assess the pharmacodynamic parameters of oral YM087 when given with furosemide
[0061] Study Design
[0062] This is an open-label, randomized study assessing the effect on the safety and efficacy of oral YM087 (20 or 40 mg QD) when given concomitantly with oral furosemide (40 or 80 mg QD) to patients with CHF.
[0063] This study is comprised of 4 phases: Screening. Furosemide Balance, Baseline and Treatment (Scheme 1, Study Design). Patients will be randomized to 1 of 4 treatment combinations: (a) furosemide 40 mg QD and YM087 20 mg QD: (b) furosemide 40 mg QD and YM087 40 mg QD; (c) furosemide 80 mg QD and YM087 20 mg QD: or (d) furosemide 80 mg QD and YM087 40 mg QD. Patients will be treated on an outpatient basis, and will come for clinic visits at Screening and on Study Days 1, end of Day 4 (beginning of Day 5), and each day of treatment (Days 5 through 9 [beginning of Day 10]). All tests scheduled to be done at the 24-hour time point will be done prior to the next dose of study medication. Urine collections will be done for the 24 hours prior to the visit.
[0064] Study Schedule
[0065] Screening Phase (1 Week)
[0066] The Screening Phase allows the investigator to evaluate patients who qualify for entry into the study and to assess initial values for a number of study parameters (ie. clinical laboratory and urinalysis values including serum and urine electrolytes). An informed consent will be signed and patients will provide medical history, including documentation of N.Y. Heart Association (NYHA) Class II/III CHF. A physical examination will also be performed at this time.
[0067] Furosemide Balance Phase (4 Days)
[0068] This phase allows the patient to achieve sodium and fluid balance on the background dose of furosemide. The patient will be randomized to 1 of the 4 arms of the study, and during this phase, will receive the dose of furosemide (either 40 or 80 mg/day) to which he/she is randomized. The dose should be given in the morning (before breakfast). During this phase and throughout the remainder of the study, patients will monitor their weight daily.
[0069] Baseline Phase (2 Days)
[0070] During the Baseline Phase, the patient will continue to receive the dose of furosemide (either 40 or 80 mg/day) to which he/she has been randomized. Patients will be given their dose of furosemide in the clinic for each of these days. This phase will be used to establish baseline values for a number of study parameters. Various clinical laboratory parameters (eg. serum and urine sodium, and plasma and urine osmolalities), free water clearance, effective water clearance, and safety profiles will be obtained. On Day 6, patients will remain in the clinic during the first 6 hours of the study in order to collect blood and urine samples at various time points. Patients will then be allowed to return home overnight (continuing to collect their urine for the 24-hour urine sample), and will return to the clinic the following morning at their scheduled visit.
[0071] Treatment Phase (3 Days)
[0072] This phase is used to determine the effect of concomitant treatment with furosemide and YM087. In addition to the background dose of furosemide (40 or 80 mg/day), patients will receive YM087 at the dose to which they have been randomized (20 or 40 mg QD) for 3 days (Study Days 7-9). Both drugs will be administered at the same time orally once daily 1 hour before breakfast with 100 mL water. Furosemide and YM087 will be dispensed in the clinic on these days (Study Days 7, 8, and 9). On Day 9, patients will remain in the clinic during the first 6 hours of the study, in order to collect blood and urine samples at various time points. Patients will then be allowed to return home overnight (continuing to collect their urine for the 24-hour urine sample), and will return to the clinic the following morning for their scheduled visit.
[0073] If at any time, the investigator judges the patient's volume status to be abnormally decreased, the next dose of furosemide may be decreased by one-half. The dose of furosemide can be further decreased by one-half at any later assessment in which the volume status is still abnormal.
[0074] Fluid and Sodium Intake
[0075] Patients will have their sodium and fluid intake assessed prior to the Baseline Phase. CHF patients should be maintained on the sodium-restricted diet that is typically prescribed for these patients. A dietician or nurse coordinator % ill determine the contents of diet and daily calorie intake, salt consumption, and volume of water consumed in the diet. These levels will be maintained throughout the study period. Total fluid intake (not including water in food) may not exceed 2.0 L/day. Fluid intake will be assessed on a daily basis.
[0076] Urine Output
[0077] A 24-hour urine specimen will be collected on Study Days 4 through 9. Samples will be collected at intervals on Study Days 6 and 9, and subsequently pooled to obtain the total 24-hour sample. Urine collection will begin following the administration of furosemide alone or furosemide and YM087 (at approximately 7 AM).
[0078] Study Population
[0079] Source and Number of Patients
[0080] Number of Patients: 3 to 6 patients per arm: 12 to 24 patients total
[0081] Source: Outpatients
[0082] Patient-Selection Criteria
[0083] Inclusion Criteria
[0084] These criteria are mandatory and must be met to provide evaluable data.
[0085] Males or females 18 to 85 years of age
[0086] Females must be postmenopausal, surgically sterilized or practicing a barrier method of birth control so that in the opinion of the investigator, they will not become pregnant during the study:
[0087] Congestive heart failure with Class II or III functional impairment by N.Y. Heart Association criteria (Appendix C):
[0088] At screening, current therapy for chronic heart failure consisting of at least 2 months duration of an ACE inhibitor. β-blocker (optional), and digoxin (optional):
[0089] Doses of digoxin. ACE inhibitors, and/or β-blockers, must have been held constant for 7 days prior to the Balance Phase: and
[0090] At screening, patients must have been receiving a dose of furosemide of between 40 and 160 mg/day.
[0091] Exclusion Criteria
[0092] Breast-feeding or pregnant;
[0093] Excessive peripheral edema (>2+, ie. above the knee) or lack of peripheral edema, suggesting volume depletion.
[0094] Significant renal impairment (serum creatinine >2.5 mg/dL or creatinine clearance <30 mL/min); or nephrotic syndrome;
[0095] Known urinary outflow obstruction (eg, stenosis, stone, tumor, etc);
[0096] Alanine aminotransferase (ALT) or aspartate aminotransferase (AST)>3×upper limit of normal (ULN) and/or bilirubin >2.5 mg/dL: or cirrhosis with ascites:
[0097] Active myocarditis, constrictive pericarditis, or active vasculitis due to collagen vascular disease:
[0098] Uncontrolled hyper- or hypothyroidism;
[0099] Adrenal insufficiency (AM cortisol <7 μg/dL);
[0100] Serious hematological diseases (eg, severe anemia. Hgb <10 g/dL: leukopenia, WBC <4000/μL);
[0101] Significant hypotension (SBP <95) or uncontrolled hypertension:
[0102] Concurrent enrollment in a chemotherapy or radiation regimen:
[0103] Unstable angina or acute myocardial infarction within 30 days of the screening visit;
[0104] Treatment with inotropic drugs (eg, dobutamine, dopamine, milrinone, amrinone, etc) within 30 days of the screening visit:
[0105] Participation in another clinical trial of an investigational drug (including placebo) within the 30 days prior to screening for entry into the present study;
[0106] History of current or past use of illicit drugs or alcoholism unless abstinence can be documented for >6 months:
[0107] Other medical conditions, such as significant obstructive cardiac valvular disease and/or hypertrophic subaortic stenosis, obstructive lung disease, dementia, or significant abnormalities that the investigator feels may compromise the patient's safety or successful participation in the study; and
[0108] Inability to understand and sign the Informed Consent to participate in this study.
[0109] Prohibited Drugs
[0110] The following medications may not be taken during this study:
[0111] Any antineoplastic agent:
[0112] Any medication known to cause leukopenia:
[0113] Parenteral inotropic agents;
[0114] Nonsteroidal anti-inflammatory drugs, with the exception of low-dose aspirin (≦325 mg/day); and
[0115] Smoking pattern should not be altered for the duration of the investigation, as smoking has been found to stimulate the secretion of AVP from the posterior pituitary gland. Patients must not smoke immediately prior to blood sampling.
[0116] Allowable Medications
[0117] Digitalis, ACE inhibitors, beta blockers, or other vasodilators are allowed but should be at a stable dose for at least 7 days prior to the Furosemide Balance Phase. The dosage and regimen of any other chronic, permitted concurrent medications (eg. hormone replacement therapy, hormone contraceptives, thyroid replacement therapy, or H2 antagonists) should be stabilized before the Furosemide Balance Phase and held constant throughout the study. Any medications prescribed chronically or intermittently during the study or dose adjustments of these medications must be reported on the concurrent medication Case Report Form (CRF). It is recommended that concurrent medications not be taken at the same time as the study drug (eg. within 1-2 hours).
[0118] Efficacy Assessments
[0119] Primary Efficacy Parameter(s)
[0120] The primary efficacy measure is change in urine output from baseline (obtained on Day 2 of the Baseline Phase [Study Day 6]) to end of treatment (Study Day 9).
Secondary Efficacy Parameter(s)
[0121] Similarly, secondary efficacy parameters will be evaluated:
[0122] Change from baseline in body weight; and
[0123] Change from baseline in free water clearance.
[0124] calculated as
C H 2 O = V ( 1 - Uosm Posm )
[0125] where: V=Urine volume (mL/day):
[0126] Uosm=Urine osmolality, and
[0127] Posm=Plasma osmolality.
[0128] Change from baseline in effective water clearance, calculated as
V−[ 2( U Na +U K )× V/ 2( P Na +P K )]
[0129] where: V=Urine volume;
[0130] U Na =Urine sodium concentration:
[0131] UK=Urine potassium concentration:
[0132] P Na =Plasma sodium concentration; and
[0133] P K =Plasma potassium concentration.
[0134] This formula can be reduced to:
V × ( 1 - U Na + U K P Na + P K )
[0135] Change from baseline in serum and urine sodium:
[0136] Change from baseline in fractional sodium excretion, calculated as:
Fe Na % = CL Na CL CR × 100
[0137] where: CL Na =sodium clearance: and
[0138] CLCR=creatinine clearance.
[0139] Number of back-titrations of furosemide
[0140] Laboratory Evaluation
[0141] Full clinical laboratory assessments will be performed at screening and at the end of Study Days 6 and 9. A clinically significant laboratory abnormality occurring during the study that has been verified by repeat testing will be reported as an adverse event and followed until the abnormality has resolved or a satisfactory explanation has been obtained (see Appendix B for a listing of the clinical laboratory determinations to be performed).
[0142] Urinalysis
[0143] A urinalysis will be performed at screening and at the end of the study (Day 9).
[0144] Other Assessments
[0145] Pharmacokinetic/Pharmacodynamic Analysis
[0146] Plasma concentrations of YM087 and plasma and urine concentrations of furosemide will be determined throughout the study as outlined in Appendix A. YM087 concentrations will be measured using a validated LC/MS/MS method in the positive ionization mode. Furosemide concentrations will be determined using a validated HPLC method. For both assays, sensitivity, specificity, linearity and reproducibility will be determined before analysis of samples.
[0147] A pharmacokinetic/pharmacodynamic analysis will be utilized to evaluate the potential effect of concomitant treatment with YM087 and furosemide in comparison to furosemide alone. In addition, plasma concentrations of furosemide during baseline and treatment phases, will give information about a potential pharmacokinetic interaction between YM087 and furosemide.
[0148] Study Medication
[0149] Description
[0150] Furosemide tablets (40 and 80 mg) and YM087 tablets (10 mg) will be prepared for the study by the Clinical Pharmaceutical Operations Department. Medication for this protocol will be dispensed according to the randomization code. All study medications should be stored in a secure, locked area. A detailed set of dispensing instructions will be included with the drug shipment.
[0151] Data Analysis and Statistical Considerations
[0152] Power and Sample Size
[0153] This is an exploratory study. Patient numbers are not based on considerations of power, but are thought to be adequate to provide preliminary assessment of the safety and tolerability of YM087 when administered concomitantly with furosemide.
[0154] Efficacy Parameters
[0155] The efficacy parameters and changes from baseline will be summarized by treatment group at each collection time. Baseline values are defined as those values obtained at the 24 hour time point of Study Day 6 (end of Baseline Phase). Descriptive statistics will include mean, standard error, median, minimum, maximum, and others as appropriate.
[0156] A urine creatinine will be obtained on all 24-hour urine specimens in order to determine the accuracy of urine collection. Results will be summarized on those urine samples determined to be complete 24-hour collections. Additionally, results from all patients will be summarized.
[0157] Twenty-four patients ranging in age from 41 to 87 with Class II/Class III CHF (as defined by the New York Heart Association) were randomized into 1 of 4 treatment groups. Group I received 40 mg of furosemide alone, once a day for 6 days, followed by concomitant treatment with 20 mg of conivaptan once a day for 3 days. Group II received initial dosing with 40 mg of furosemide, followed by concomitant dosing with 40 mg of conivaptan. Group III received 80 mg of furosemide initially, then concomitant dosing with 20 mg of conivaptan. Group IV received 80 mg of furosemide alone, and then in continuation with 40 mg of conivaptan.
[0158] Baseline measurements of urine volume, osmolality, sodium, and potassium content were obtained on Day 6 (steady state for background furosemide use), and evaluations of the combination therapy were done on Day 9. The data shown in FIGS. 1 and 2 and in Table 1 below establish that the aquaretic effects of conivaptan not only persist but are amplified with concurrent use of a loop diuretic. This surprising result establishes synergism between the two drugs on urinary water excretion. In addition, the results of urinary sodium excretion shown in FIG. 3 and in Table 1 below establish that combination therapy lessens the loss of sodium in the urine, particularly as the dose of furosemide is increased. This surprising result renders the claimed combination particularly useful in treatment or prevention of hyponatremia in edematous states like CHF in which therapy with a diuretic is standard care. Finally, the results on urinary potassium excretion shown in FIG. 4 establishes that the combination substantially reduces potassium loss, particularly as the dose of furosemide is increased. This surprising result indicates the claimed combination is especially useful in treatment or prevention of hypokalemia in edematous states like CHF in which therapy with a diuretic is standard care. In total, the data establish that conivaptan in combination with a loop diuretic such as furosemide can provide increased therapeutic excretion of water in edematous conditions like CHF. Furthermore, the data establish that the deleterious effects of a loop diuretic on electrolyte loss, particularly potassium, can be diminished to a surprising extent by concomitant treatment with a vasopressin antagonist such as conivaptan.
TABLE 1 Change From Baseline in Pharmacodynamic Parameters (0-6 Hours Postdose) Urine Total Urine Total Urine Urine Osmolality Sodium Potassium Volume (mOsm/kg) (mEq) (mEq) (mL) Mean % Mean % Mean % Mean % Treatment Group Change Change Change Change F 40 mg/C 20 mg −25.0 −13.8 −1.3 54.4 F 40 mg/C 40 mg −13.4 27.6 14.0 79.9 F 80 mg/C 20 mg −43.2 −9.2 −23.1 13.7 F 80 mg/C 40 mg −45.5 −32.3 −45.0 −7.8
[0159] The compositions to be employed in the present invention can be prepared and administered in a wide variety of oral and parenteral dosage forms for treating and preventing edematous conditions such as CHF, and promoting electrolyte balance. The compounds can be administered by injection, that is intravenously, intramuscularly, intracutaneously, subcutaneously, submucosally, intraductally, intraduodenally, or intraperitoneally. Also, the compounds can be administered by inhalation, for example, intranasally. Additionally, the compositions can be administered transdermally. It will be obvious to those skilled in the art that the following dosage forms may comprise as the active component, either a compound as a free base, acid, or a corresponding pharmaceutically acceptable salt of such compound. The active compound generally is present in a concentration of about 5% to about 95% by weight of the formulation.
[0160] For preparing pharmaceutical compositions from the compounds of the present invention, pharmaceutically acceptable carriers can be either solid or liquid. Solid form preparations include powders, tablets, pills, capsules, cachets, suppositories, and dispersible granules. A solid carrier can be one or more substances which may also act as diluents, flavoring agents, solubilizers, lubricants, suspending agents, binders, preservatives, tablet disintegrating agents, or an encapsulating material.
[0161] In powders, the carrier is a finely divided solid which is in a mixture with the finely divided active component.
[0162] In tablets, the active component is mixed with the carrier having the necessary binding properties in suitable proportions and compacted in the shape and size desired.
[0163] The powders and tablets preferably contain from 5% or 10% to about 70% of the active compound. Suitable carriers are magnesium carbonate, magnesium stearate, talc, sugar, lactose, pectin, dextrin, starch, gelatin, tragacanth, methylcellulose, sodium carboxymethylcellulose, a low melting wax, cocoa butter, and the like. The term “preparation” is intended to include the formulation of the active compound with encapsulating material as a carrier providing a capsule in which the active component, with or without other carriers, is surrounded by a carrier, which is thus in association with it. Similarly, cachets and lozenges are included. Tablets, powders, capsules, pills, cachets, and lozenges can be used as solid dosage forms suitable for oral administration.
[0164] For preparing suppositories, a low melting wax, such as a mixture of fatty acid glycerides or cocoa butter, is first melted and the active component is dispersed homogeneously therein, as by stirring. The molten homogenous mixture is then poured into convenient sized molds, allowed to cool, and thereby to solidify.
[0165] Liquid form preparations include solutions, suspensions, and emulsions, for example, water or water propylene glycol solutions. For parenteral injection, liquid preparations can be formulated in solution in aqueous polyethylene glycol solution.
[0166] Aqueous solutions suitable for oral use can be prepared by dissolving the active component in water and adding suitable colorants, flavors, stabilizing, and thickening agents as desired.
[0167] Aqueous suspensions suitable for oral use can be made by dispersing the finely divided active component in water with viscous material, such as natural or synthetic gums, resins, methylcellulose, sodium carboxymethylcellulose, and other well-known suspending agents.
[0168] Also included are solid form preparations which are intended to be converted, shortly before use, to liquid form preparations for oral administration. Such liquid forms include solutions, suspensions, and emulsions. These preparations may contain, in addition to the active component, colorants, flavors, stabilizers, buffers, artificial and natural sweeteners, dispersants, thickeners, solubilizing agents, and the like.
[0169] The pharmaceutical preparation is preferably in unit dosage form. In such form, the preparation is subdivided into unit doses containing appropriate quantities of the active component. The unit dosage form can be a packaged preparation, the package containing discrete quantities of preparation, such as packeted tablets, capsules, and powders in vials or ampoules. Also, the unit dosage form can be a capsule, tablet, cachet, or lozenge itself, or it can be the appropriate number of any of these in packaged form.
[0170] The quantity of each active component in a unit-dose preparation may be varied or adjusted from 1 to 1000 mg, preferably 10 to 100 mg according to the particular application and the potency of the active component. The composition can, if desired, also contain other compatible therapeutic agents.
[0171] The following examples illustrate typical formulations that can be utilized in the invention.
Tablet Formulation Ingredient Amount (mg) Conivaptan 25 Furosemide 40 Lactose 30 Cornstarch (for mix) 10 Cornstarch (paste) 10 Magnesium stearate (1%) 5 Total 120
[0172] The conivaptan, furosemide, lactose, and cornstarch (for mix) are blended to uniformity. The cornstarch (for paste) is suspended in 200 mL of water and heated with stirring to form a paste. The paste is used to granulate the mixed powders. The wet granules are passed through a No. 8 hand screen and dried at 80° C. The dry granules are lubricated with the 1% magnesium stearate and pressed into a tablet. Such tablets can be administered to a human from one to four times a day for treatment of CHF and other edematous conditions.
Preparation for Oral Solution Ingredient Amount Conivaptan 40 mg Furosemide 80 mg Sorbitol solution (70% N.F.) 40 mL Sodium benzoate 20 mg Saccharin 5 mg Red dye 10 mg Cherry flavor 20 mg Distilled water q.s. 100 mL
[0173] The sorbitol solution is added to 40 mL of distilled water, and the conivaptan and furosemide are dissolved therein. The saccharin, sodium benzoate, flavor, and dye are added and dissolved. The volume is adjusted to 100 mL with distilled water. Each milliliter of syrup contains 4 mg of invention composition. The composition is administered to animals to treat edematous states such as heart failure, hepatic failure, and venous insufficiency.
[0174] Parenteral Solution
[0175] In a solution of 700 mL of propylene glycol and 200 mL of water for injection is suspended 20 g of conivaptan and 15 g of furosemide. After suspension is complete, the pH is adjusted to 6.5 with 1 N sodium hydroxide, and the volume is made up to 1000 mL with water for injection. The formulation is sterilized, filled into 5.0 mL ampoules each containing 2.0 mL, and sealed under nitrogen. The composition is administered to a patient in order to decrease the excretion of sodium and potassium in the urine, thereby preventing electrolyte imbalance associated with CHF and use of a diuretic agent alone. | Combinations of diuretics and vasopressin antagonists are useful to slow and reverse the symptoms and process of congestive heart failure, to increase the excretion of water in the urine, and to decrease the excretion of sodium and potassium ions in urine. Preferred vasopressin antagonists have the formula
wherein R and R 5 are hydrogen or lower alkyl;
R 1 , R 2 , and R 3 are hydrogen, halo, alkyl, alkoxy, and amino; and
R 4 is hydrogen or phenyl, and a pharmaceutically acceptable salt thereof. | 0 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] Not applicable to this application.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable to this application.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The present invention relates generally to the Internet marketing industry and more specifically to a method to manage the flow of business information based on the Web site user experience.
[0005] 2. Description of the Prior Art
[0006] It can be appreciated that the idea of tracking customer/guest usage on a Website is not new to the Internet community. Several companies track the aggregate browser Web site activity and provide or sell that information in generic form to interested parties and vendors. These companies are interested in the user Web site experience for a number of reasons. For example, the marketing aspect of a business is concerned with the number of visitors, the length of each visit, what was viewed, what links were selected and possibly, how the Web site was navigated. From this data, the business concern may generally infer product interest and how well the architecture and mechanics of the Web site served the browsers. Armed with this group information, the business concern is able to provide a group response. The business may alter the appearance, sound, ability and/or content of the Web site such that it is ideally more appealing to generate higher activity and sales.
[0007] These prior art user tracking methods produce limited information to yield an incomplete response to market the potential client since the information gathered is not specific in nature. The particular interest of the individual browser in the product may not be directly addressed or addressed in way that may lose the sale. It is well known in the marketing industry that personal contact based on personal information yields the best results.
[0008] Also, current Web sites that do capture some personalized information may not profile the user for any effective use. For example, on-line airline/car/hotel reservation Web sites accept the user's name and billing information with a purchase. The use of this information is limited to a first name greeting the next time the user logs on and the occasional bulk e-mail concerning the latest deals. Most users view these general e-mails as a nuisance and take steps to eliminate them because they are rarely consistent with the user's specific interests. In this example, the business is not effectively using the personalized information to develop a more effective marketing method to boost sales.
[0009] What is needed is a method that captures and maximizes the marketing application of user specific information. This information would include the user identity (e-mail, name and telephone number) and a detailed analysis about the type of user and the user's specific interests that may be deduced from data captured of the user's Web site experience. This information provides the necessary elements to support an effective personalized marketing response.
[0010] Also, a method for a marketing network service is needed to apply the user specific information through an interdependent team of trained and managed goods and/or service representatives to address the user in terms the user can appreciate with information specific to the user's interest.
[0011] In these respects, the present inventive solution substantially departs from the conventional concepts, methods of the prior art, and in so doing provides a method to effectively manage the marketing and sales of goods and services based on personalized client data.
SUMMARY OF THE INVENTION
[0012] In view of the foregoing disadvantages inherent in the known types of standard marketing services now present in the prior art, the present invention, hereafter known as the Marketing Network Service (MNS), provides a detailed marketing analysis based on the individual Web site user experience and manages that information in a pertinent and applicable manner to the appropriate network team members. This client specific information is specifically geared towards sales/marketing representatives of goods and services to facilitate a timely and effective interaction with a prospective buyer. The MNS also has the ability to admit interested parties to join as a team member through a member/up-line team member to utilize the offered services and represent their selected goods and/or services. The MNS provides the tools to manage contact data between the networked down-line team members and up-line team members to effect collaboration and support of ongoing marketing and sales activities of the junior member. The MNS also offers training to each member and provides a report of the member's training level to the up-line team member(s) to ensure effective interaction with the prospective client or potential team member.
[0013] The general purpose of the present invention, which will be described subsequently in greater detail, is to provide the e-commerce industry with a marketing and sales tool that includes many of the advantages of the standard Web site monitoring systems mentioned heretofore and many novel features that result in a new method which is not anticipated, rendered obvious, suggested, or even implied by any of the prior art standard telephone appliances, either alone or in any combination thereof.
[0014] There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof may be better understood, and in order that the present contribution to the art may be better appreciated. There are additional features of the invention that will be described hereinafter.
[0015] In this respect, before explaining at least one 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 the description and should not be regarded as limiting.
[0016] A primary object of the present invention is to provide a method that will overcome the shortcomings of the prior art devices.
[0017] An object is to provide a marketing service to capture personal client data and determine a detailed marketing analysis of the Web site user experience.
[0018] Another object is to provide a marketing service that supplies the marketing analysis of the Web site user experience and personal data to the service member and an up-line team member(s) to be used in a collaborative effort to tailor an effective interaction with the Web site user.
[0019] Another object is to provide a marketing service that provides a method for a network member to mentor and track the training of the next successive or other new and existing down-line member(s) to the service.
[0020] Other objects and advantages of the present invention will become obvious to the reader and it is intended that these objects and advantages are within the scope of the present invention. To the accomplishment of the above and related objects, this invention may be embodied in the form illustrated in the accompanying drawings, attention being called to the fact, however, that the drawings are illustrative only, and that changes may be made in the specific construction illustrated and described within the scope of the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] Various other objects, features and attendant advantages of the present invention will become fully appreciated as the same becomes better understood when considered in conjunction with the accompanying drawings, in which like reference characters designate the same or similar parts throughout the several views, and wherein:
[0022] [0022]FIG. 1 illustrates a simplified diagram of the Internet environment to implement the present invention.
[0023] [0023]FIGS. 2A and 2B depict a flow chart of the steps to implement the preferred embodiment of the inventive solution.
[0024] FIGS. 3 A- 3 D is key menu pages of the Contact Manager provided by the MNS.
[0025] FIGS. 4 A- 3 D is the key menu pages for the Teamwork Communication System of the MNS.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0026] The following description is presented to enable any person skilled in the art to make and use the invention, and is provided in the context of a particular application and its requirements. Various modifications to the disclosed embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be applied to other embodiments and applications without departing from the spirit and scope of the present invention. Thus, the present invention is not intended to be limited to the embodiments shown, but is to be accorded the widest scope consistent with the principles and features disclosed herein.
[0027] The data structures and code described in this detailed description are typically stored on a computer readable storage medium, which may be any device or medium that can store code and/or data for use by a computer system. This includes, but is not limited to, an erasable programmable read only memory (EPROM), random access memory (RAM), magnetic and optical storage devices such as disk drives, magnetic tape, CDs (compact discs) and DVDs (digital video discs), and computer instruction signals embodied in a transmission medium (with or without a carrier wave upon which the signals are modulated).
[0028] [0028]FIG. 1 illustrates a simplified diagram 100 of the Internet environment to implement the Marketing Network Service (MNS). The World Wide Web supports 101 the popular e-mail and Web site based services through Internet Service Providers (ISP) 102 between users in a manner well known in the art. The MNS 103 is presented as a Web site typically realized on a computing platform processing a proprietary program supported by a fast data handling database connected in a protected high speed manner to the Internet. The MNS could be any suitable server located in a home or business or split into several physical locations around the world. A business Web site, again usually realized on a server, is shown 104 to represent a typical Web site that presents corporate information and/or a virtual storefront to offer all manner of goods and services. The shown Web browser 105 represents the typical home system or networked business computer that provides individual Web browsing (shopping, research, e-mail etc.) access to the Internet. This browser is one of a billion potential clients or potential team members for the inventive solution. There could be any number of MNS participants, where two are shown 106 that may be located anywhere in the world using any of the commonly known methods to connect with the Internet. These participants are part of the MNS hierarchy to promote the marketing and sales of goods and services. These team members, or users, would typically be a home based concern, common to e-commerce businesses of today.
[0029] [0029]FIGS. 2A and 2B depict a flow chart 200 of the steps to implement the preferred embodiment of the marketing network service. The process begins 201 with a sales/marketing representative, hereafter known as the user, as a mid level representative active in the MNS 202 . The user is linked into the network as a down-line team member just below his up-line team member, the representative that recruited him. The up-line team member is understood to be the user's up-line manager. This staffing chart may take the form of a star or a pyramid where it begins with the first member (a representative of goods and services) and branches to an expanding network of joined users in the ongoing activity of recruiting other interested users as well as the marketing and sales of their own goods and services. The MNS user of the following description could be an effective representative anywhere in the hierarchy since an active flow of marketing data is maintained between the most junior to the most senior member/representative. The user first joined MNS by logging onto the computer network Web site, selecting the join/subscription page and following the instructions on payment for subscription and setup of his own Web site on the network server. His personalized Web site becomes part of the MNS and is now ready to be used to market and promote his goods and services.
[0030] In the normal course of business, the user invites guests or accepts “walk in” business to his Web site 203 . The user can bring business by manual input of the guest's information into a program file, filed under a data management algorithm termed the Contact Manager (CM), or he can upload from various personal types of computer files (electronic address books). The user can also purchase leads from the MNS to be automatically placed in the CM. This information includes the guest's names, emails and other personal or psychological information given or sold to the MNS. The Contact Manager is a powerful tool for the team member to organize and manage client data. The benefit to inviting guests in this manner is that the CM will send the guest a welcome invitation e-mail with a link to the user's site that allows the guest to visit the site without the bother to “sign” a guest book. The user can also advertise his Web site in any effective method to attract the browser. These methods may include newspapers, search engines, flyers, mailings or bulletin board postings. Upon arrival to the Web site by the random browser, the guest is prompted to sign a guest book so the guest's personal information can be attached to the record that is created on them. This personal information needs to include the guest's name and e-mail address but preferably also contains a correspondences address and telephone number.
[0031] Next, the guest tours or experiences the site commensurate with the guest's interest in the content. The MNS tracks the experience or viewing activity 204 for subsequent processing to aid the representative in his follow up efforts. What the guest viewed, how long on any particular page or audio presentation, links selected, questions answered and total time in the Web site are a few of the browser activities that are detected and recorded to comprise the user experience.
[0032] The MNS detects guest departure and performs several functions 205 . First, the MNS attaches the monitored data to the personal data and deposits the information in the guest file under the CM. The MNS determines a neuro dynamic profile and identifies the Web site content the browser showed degrees of interest based on the captured guest experience. This information is also added to the guest file. A contact report is generated of the guest file and may be immediately e-mailed to the user. The user may also be notified of all or any particular guest visit by other methods such as instant message, page or telephone call. The contact report may include, but is not limited to, the pages and page sections of the Web site that the guest visited and how long the guest was on each page. This information is important because many of the pages are multi-media and have a designated viewing length for completion. If the guest stayed on that section for the allotted viewing time, the user can deduce that the guest viewed the whole multi-media presentation. Also, a summary of the user experience with the neuro dynamic profile is provided.
[0033] The neuro dynamic profile (NDP) is an analysis of the personality type, communication style, motivation strategy, decision strategy and other psychological profiled information developed from the data captured during Web site user experience. Basic personality types that can be determined include aggressiveness, patience, intelligence and practicality. A communication style is based on whether the guest shows a predilection to information presented in a visual, auditory, kinetic or analog/digital fashion. A motivation strategy can be deduced from the guest's tendency to move away from pain or to move toward pleasure. A decision strategy is evidenced through the guest's tendency to collect and base a decision based on information from others or internalize the information for self-determination.
[0034] In the next step, the user receives notification 206 of the guest contact and reviews the report. The user can read the e-mail report and/or access his CM and review a detailed report on the guest information. The user could also have the guest receive auto-responder e-mails that are sent out automatically when the guest concludes the Web site visit. Use and content of the auto-responder e-mail are determined by the user based on the report results of the guest visit. These auto-responder emails are neuro dynamically enhanced using the psychological profile established during the tracking procedure. The wording, content, layout, graphics of this follow up email are tailored to the particular profile of the contact. In this way, the follow up response can be tailored to the personality and individual interests of the guest. Guest contact could be provided through whatever means is appropriate and available to investigate the guest's interest in the Web site content. “Next Visit” issues are also addressed. When a contact returns to the site and signs the guest book, the MNS automatically detects who it is, that they have been here before, analyzes the neuro dynamic profile and tailors the content and user experience to best match his/her neuro dynamic profile (his or her buying and decision making strategy) to better elicit a sale or action from them.
[0035] At this point in time, the guest will generally elect 207 to ignore user contact 208 or, in an e-commerce scenario, the user would respond to the contact and pursue his interest in or purchase 209 the user's goods and services. Also, in a participatory scenario, the guest could indicate a real interest in the product and request to become a representative 210 under the MNS. The user responds to the user request by directing the guest to access the user's Web site and begin the subscription process. In the happy event the guest is also interested in purchasing a product; the user can direct the recruit to become his own first customer. In the subscription process, the guest is now “down-line” linked to the user as being referred or recruited by the user to the system and thus “attached” to user in the MNS. With respect to the new relationship of the guest and user, the guest becomes the new member or down-line member and the user is termed the up-line team member.
[0036] With completion of the subscription process, the new member is directed 212 to the Training Manager (TM), an information program governed by the MNS. These steps are carried out on the new member's own Internet linked (home) computer system. The Training Manager is a training system setup where the new user can be trained on-line through multi-media presentations, audio recordings and text material on how to benefit and use the user's (his up-line team member) goods and services and how to use the MNS itself. A report is generated, similar to the guest information report, each time the new member accesses the Training Manager. His training level status is monitored by the up-line team member(s). In this way, the up-line team member(s) is enabled to guide and monitor the new member's training progress so that the new member can be fully trained by the up-line member(s) and MNS. The reporting is handled through the MNS Teamwork Communication System (TCS) program.
[0037] After sufficient training, the new member begins 213 to drive guest traffic to his Web site in the same way as his up-line team member where these Web sites are maintained on the NIS computing platform. The new member receives a contact report with guest information in a manner similar to the up-line team member but the up-line team member(s)' TCS is updated with the new user's contact and guest information 214 . This reporting method allows the up-line team member(s) to monitor the new user's activity and enable the up-line team member(s) to collaborate with an inexperienced or disadvantaged new user on the guest information and follow up together, perhaps a three way telephone call, with the interested guest 215 . If the guest elects to also join the Marketing Network Service, become a representative under the MNS, then the process previously described to create the up-line team member and new member team repeats 216 where the (old) new member becomes an up-line team member to the next member and the up-line team member is now a up-line team member to both the new and next down line members 217 . In this way, a collaborating team is formed within the service network.
[0038] FIGS. 3 A- 3 D show a representation of the main menu pages to provide the team member navigation within the Contact Manager (CM), a key program tool for a participant in the MNS. The CM is accessed through a “link” in the member control panel of the MNS main program menu. The CM records the time of use by the individual team member for evaluation by a senior team member(s) in the network. This information is reported through the Teamwork Communication System. FIG. 3A depicts the first page of the CM. The top frame is a welcome message and identifies that the CM has been accessed. The initial main frame contains the quick launch to the help center, mail manager and information center. The left frame is the launch menu and remains available throughout the CM.
[0039] [0039]FIG. 3B shows the Contact Record page to accept the data for a new contact or to modify an old account. Explanation of several key entries includes:
[0040] Last Date of Activity is the last data of prospect/contact activity, not the team member.
[0041] First Date in System is when the client was entered or last appended. The CM checks, with client information entry on the participants Web site, to see if there is a record with that e-mail address. If none is found, the service adds the name, e-mail and telephone and starts a new record and appends the Pro New Prospect and then subsequently, the tracking to the log (Pro New Prospect is a rating system of the contact).
[0042] Category is the user defined category from the category assignment button. It is default and mandatory category 1.
[0043] Joined Team button puts in the contact log that the client joined MNS and switches category to team member.
[0044] View Profile Script opens a window with the appropriate script for the key code that is in the Neuro Dynamic Profile Box.
[0045] View Profile Description will bring up a window with the prospects description of their particular Neuro Dynamic Profile (NDP).
[0046] View NDP E-mails will bring up a screen that shows the several NDE e-mails that will be sent out over the next several days, months or years.
[0047] Log Phone Call, Log 3-Way and Log Meeting open a corresponding page to manually insert notes or comments.
[0048] View Overall Log shows all entries in the log whether track information, telephone, meeting, e-mail, 3-way or Pro New Prospect. FIG. 3C is an example of the sub menu for the Overall Log. The other view logs show just their particular category.
[0049] System Setup allows access to customize the system default and how it can operate for just this prospect. There will be global settings and individual contact settings.
[0050] Category Assignment is to assign what category this prospect falls into. The default is the category 1 list.
[0051] [0051]FIG. 3D is an example of the Display/Sort Contacts menu page. It provides a configurable way to display a list or group of contacts. In addition to the typical column for the prospect name, e-mail, telephone, and time zone, an option column provides access to any contact information, category assignment, mail preferences or a remove function. The user can click on the name or contact information to link to a detail screen on the contact.
[0052] FIGS. 4 A- 4 D show a representation of the main menu pages to navigate the Teamwork Communication System (TCS), where TCS is a powerful management tool for the team member. The TCS is accessed through a “link” in the Member Control Panel. TCS tracks and manages guest information and member activity information between all successively recruited down line members of the MNS. The individual TCS user is enabled to limit the information viewable to the up-line team member(s). The MNS also tracks the time of use by the team member for evaluation by the appropriate up-line team member(s).
[0053] [0053]FIG. 4A represents the first page of the TCS. The top frame is the welcome message and indication to confirm access to the TCS. The initial main frame contains the quick launch to setup and help areas and the left frame is a launch menu that remains available throughout the TCS.
[0054] [0054]FIG. 4B is a representation of the TCS Log of down-line viewable members. The listing is first sorted by Category then by an alphabetical sort of all the TCS members that are viewable. A button click on a name reveals an individual record. The Quick Activity View button provides access to view members who have had activity today, yesterday, past 7 days or the past 30 days. Activity is anyone who has received a tracking report or other activity within that time.
[0055] [0055]FIG. 4C is an example of a TCS individual log. An explanation of the key sections of the menu is described as follows:
[0056] Team Member TCS Log can display a team member's overall log if authorized (viewable) by the down line team member or, if not authorized, a display of tracking notices and the user's notes or entries.
[0057] Name, E-mail etc. is not editable since it is provided from the team member's record.
[0058] Last Date of Activity is activity from the team member's tracking reports.
[0059] Category is set by the user and the team member in the setup process.
[0060] Training Level is the expected level of training by the team member.
[0061] Training Level Target is a time line to correlate the expected training level with the number of days in the service.
[0062] Team Member Profile Summary shows the information based on the view button selected.
[0063] Set Tracking Notification Level via E-mail is a selectable user set point of the tracking level (1-6) depending on time spent on the site. 1 being 10 minutes or more all the way to 6 being 60 minutes or more. The purpose is to trigger receipt of a notification e-mail. The tracking log will be displayed in the Team Member TCS Log and sent in the form of notifications in two formats:
[0064] Open-meaning the TCS user can see all the detail of their team members tracking report; and,
[0065] Blocked-meaning the TCS user can see only the tracking subject line but when viewing the body of the e-mail the contact information of the prospect is not available.
[0066] Edit Category brings up a screen with a dropped down list to allow the user to manage categories as available in the Contact Manager.
[0067] [0067]FIG. 4D is a representation of a TCS menu page for the user to manage what the up-line manager(s) can view. The first blank is to input the up-line team member identification (ID code) of the up-line team member. The following preferences are set by the TCS user:
[0068] Your Info (drop down list):
[0069] Open-information if full viewable to up line managers
[0070] Limited-personal information is viewable but logs are blocked except the tracking log
[0071] Blocked-personal information, except for name, is blocked, tracking reports are viewable
[0072] Tracking Detail Info:
[0073] Open-tracking report contact information is viewable
[0074] Blocked-the tracking report contact information is not viewable
[0075] Member Profile Info:
[0076] Open-complete profile is viewable
[0077] Limited-all but the time is viewable
[0078] Blocked-profile is completely blocked
[0079] Team View:
[0080] Open-complete team is viewable to this person, based on their team view filter
[0081] Limited-team is viewable only by name and stats, no contact
[0082] Blocked-nothing is viewable
[0083] Team Filter:
[0084] Open-allow anyone in up line who makes team viewable to view user in full
[0085] Limited-no contact info on TCS user or prospects (cannot contact user or prospects)
[0086] Blocked-TCS user not viewable
[0087] Status-request sent or confirmed
[0088] View Contact Info reveals a simple screen with name, e-mail, phone current in service
[0089] Send E-Mail opens an e-mail screen
[0090] It is a second embodiment of the invention to provide the features of the Marketing Network service to reside with the potential client and “follow” the client to any Web site that the client visits on the Wide World Web.
[0091] It is a third embodiment of the invention to provide the features of the Marketing Network Service to expand computing platforms other than the Internet to manage sales/marketing contact data.
[0092] As to a further discussion of the manner of usage and operation of the present invention, the same should be apparent from the above description. Accordingly, no further discussion relating to the manner of usage and operation will be provided.
[0093] 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.
[0094] 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. | A marketing service is provided for e-commerce sales and marketing representatives to generate a contact report and manage the flow of this information between the linked up-line and the down-line network members for the purpose of recruitment to the network service and to facilitate the sales and marketing by the service members. The service captures the Web site user experience to generate a neural dynamic profile and identify the Web browser's specific interests. This information is combined with individual browser identification to form the contact report, filed under a contact management program and passed by a teamwork communication system to the up-line team member for review of the down-line member's activity and to identify any need for collaboration on a business transaction. The information in the contact report is used to tailor a personalized response to better elicit a sale or activity from the interested party. | 6 |
This application is a filing under 35 USC §371 of PCT/SG2007/000133, filed May 11, 2007. This application is incorporated herein by reference.
BACKGROUND OF THE INVENTION
The present invention relates to the production of porcine circovirus type 2 (PCV2). More particularly, the invention relates to continuous cell lines that are highly susceptible to infection with PCV2 and to methods for the production of PCV2 using the cell lines.
Porcine circovirus (PCV) is a small, non-enveloped, circular, single-stranded DNA virus classified in the Circoviridae family. Murphy, F A., Fauquet, C M., Bishop, D H L., Ghabrial, S A., Jarvis, A W., Martelli, G P.; Mayo, M A., Summers, M D. Virus taxonomy. Sixth report of the International Committee on Taxonomy of Viruses . New York, N.Y: Springer-Verlag; 1995. pp. 166-168. It was originally identified and described as a contaminant of a porcine kidney cell line. Tischer, I., Gelderblom, H., Vettermann, W., Koch, M. A. A very small porcine virus with circular single - stranded DNA. Nature. 1982:295:64-66. Recently, PCV has been associated with a disease of pigs, the post-weaning multi-systemic wasting syndrome (PMWS), first observed in Western Canada. Ellis, J., Hassard, L., Clark, E., Harding, J., Allan, G., Willson, P., Strokappe, J., Martin, K., McNeilly, F., Meehan, F., Todd, D., Haines, D. Isolation of circovirus from lesions of pigs with postweaning multisystemic wasting syndrome. Can. Vet. J., 1998; 39:44-51; Harding, J. C. S., Clark, E. G. Recognizing and diagnosing postweaning multisystemic wasting syndrome ( PMWS ). Swine Health Prod. 1997; 5:201-203; Jue Liu, Isabelle Chen, and Jimmy Kwang, J. Virol. 2005: 79(13); 8262-74. PWMS has emerged as a major disease that poses a significant threat to the economics of the global swine industry. After its first appearance in Canada, PMWS has now spread to the United States, Europe and Asia. The syndrome mainly affects pigs between 6 and 14 weeks of age. It tends to be slow and progressive with a high fatality rate in affected pigs. See http:www dot aphis dot usda dot gov/vs/ceah backslash dei/taf backslash emergingdiseasenotice_files/pmws — 0301.htm.
The clinical signs of PMWS are quite variable. Affected pigs may show signs of chronic wasting, respiratory distress, diarrhea, incoordination, paralysis, pale skin color and blue ears. Pigs usually demonstrate a decrease in growth rate and, occasionally, jaundice.
The diagnosis of PMWS is based on the age of affected pigs, typical wasting appearance and necropsy lesions. Microscopic and immunohistochemical examination of tissues reveals unique lung and lymphoid tissue lesions with the presence of PCV2. Id.
Antibacterial medication is usually ineffective in treating PWMS and currently no vaccines are available. Prevention of the syndrome is based on biosecurity precautions and good husbandry practices.
PCV2 has also been found in association with other diseases including porcine dermatitis and nephropathy syndrome (“PDNS”), congenital tremors (CT-All) reproductive disorders, prenatal myocarditis and proliferative and necrotizing pneumonia.
Vaccines employing PCV2 antigens have shown some initial success in preventing the PMWS. Fenaux, M., et al., A chimeric porcine circovirus ( PCV ) with the immunogenic capsid gene of the pathogenic PCV type 2 ( PCV 2) cloned into the genomic backbone of the nonpathogenic PCV 1 induces protective immunity against PCV 2 infection in pigs. J. Virol., 2004. 78(12): p. 6297-303; Blanchard, P. et al., Protection contre la maladie d'amaigrissement du porcelet ( MAP ) par vaccins a ADNet proteines recombinantes. Journees de la Recherche Porcine en France, 2004. 36: p. 345-352; Blanchard, P., et al., Protection of swine against porcine multisystemic wasting syndrome ( PMWS ) by porcine circovirus type 2 ( PCV 2) proteins. Vaccine, 2003. 21: p. 4565-4575; Pogranichniy, R. et al. Efficacy of inactivated PCV 2 vaccines for preventing PMWS in CDCD pigs . American Association of Swine Veterinarians. 2004. Des Moines, Iowa. However, an effective vaccine is not currently available.
The development of vaccines, diagnostic agents and therapies for PMWS and other diseases associated with PCV2 viral infections will require efficient and reliable means for producing the virus in substantial quantities. PCV2 virus stocks have conventionally been produced by culturing the virus in porcine kidney cell-line PK15. The virus titers yielded from PK15 cell cultures, expressed as 50% tissue culture infectious dosage (“TCID 50 ”) per milliliter, usually ranged from 10 4 -10 5 and could never exceed 10 5 . Immunofluorescence stainings of infected PK15 cell cultures have revealed that only about 40% of the cell population is susceptible to the PCV2 infection.
A need exists for a continuous cell line that is highly permissive to PCV2 infection and that reliably produces virus in high titers over extended periods of time.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows immunofluorescence assay results demonstrating percentage infection on uncloned and cloned PK15 cell monolayers infected with PCV2 on 3 days post-infection. A, B, C and D represent mock-infected PK15 monolayer (negative control), infected PK15 monolayer, low-permissive and high-permissive (clone C1) subcloned monolayers respectively.
FIG. 2 shows PCV2 attachment onto surface membrane of PK15 cell line, low- and high-permissive cell clones after 1 hour adsorption at 37° C.
FIG. 3 shows growth curves of PK15 and clone C1 cell populations over 48 hours.
FIG. 4 shows PCV2 virus yields generated in parental PK15 and cloned C1 cell lines over 4 passages.
FIG. 5 shows PCV2 virus genome synthesis in parental PK15 and cloned C1 cell lines.
SUMMARY OF THE INVENTION
The present invention provides a continuous cell line that is highly permissive to PCV2 infection. In another embodiment, the invention provides a method for producing a substantially homogeneous cell line that is highly permissive to PCV2 infection, which comprises (1) cultivating a heterogeneous cell population that contains cells of varying susceptibility to PCV2 infection; (2) diluting the cell culture and placing aliquots of the diluted cells into separate vessels such that each vessel contains about one cell; (3) adding PCV2 to each vessel; (4) culturing the cells and identifying a vessel that contains cells that are susceptible to PCV2 infection; and (5) culturing and maintaining a cell line from such susceptible cells. In a particular embodiment, the invention provides a continuous cell line designated PK15-C1. In yet another embodiment, the invention provides a method for producing PCV2 by cultivating a virus in a cell line of the present invention under conditions suitable for cell growth and recovering virus produced by the cell line.
DETAILED DESCRIPTION OF THE INVENTION
In accordance with the invention, it has been discovered that the population of cells in the PK15 porcine kidney cell line is heterogeneous with respect to permissivity to the PCV2 infection. The cell line has been found to contain cells of both low- and high-permissivity to viral infection. The relatively low virus titers produced by PCV2-infected PK15 are attributable to the heterogeneity of the cell line.
Homogeneous cell lines of this invention may be produced by cloning single cells and identifying resulting cultures that are highly susceptible to PCV2 infection. While the PK15 cell line is a preferred cell line for use in the methods of this invention, other cell lines that are susceptible to infection with PCV2 may also be used to produce homogeneous virus-producing cell lines.
A culture of a heterogeneous cell population is first diluted into aliquots containing single cells. The single-cell aliquots are placed into individual vessels, such as the wells of a microtiter plate, and are suspended in a nutrient medium that contains nutrients, growth factors and buffers necessary for replication of the cells. They are then incubated under thermal and atmospheric conditions conducive to cell growth. Following cell growth, e.g., to a continuous monolayer, an infectious amount of virus is added to each aliquot and the cells are cultured until a suitable phase of virus production is achieved.
Virus titers of each aliquot are determined, e.g., by immunofluorescence assay according to the following protocol: Infected cells are fixed with 4% paraformaldehyde for 15 minutes at 72 hours post-infection (pi), and incubated with PCV2 ORF-1 antibody followed by anti-guinea pig fluorescein isothyocianate (FITC), each for 1 hr at 37° C. with washing of cells one time with phosphate buffered saline between each step. The staining results are observed under an Olympus fluorescent microscope and cells are scored for their ability to produce high virus titers. High virus-producing cell lines are then advantageously re-cloned and highly permissive cells are selected.
A preferred cell line produced in accordance with the invention was derived from cell line PK15 (ATCC® CCL-33™ pig kidney cell line) and has been designated clone C1. It is referred to herein as PK15-C1. The results presented herein show that clonal C1 cell population is more susceptible to PCV2 infection than are PK15 cells. Therefore, PK15-C1 is a more effective cell line for the production of high PCV2 virus yield than the parental PK15 cell line.
PK15-C1 has been deposited with the American Type Culture Collection located at University Boulevard, Manassas, Va. 20110, USA on 20 Mar. 2007 and assigned accession number PTA-8244.
The invention is further illustrated by the following examples, which are not intended to limit the invention.
Example 1
Production of PK15-C1
The PK15 parent cell line was maintained in Eagle's minimum essential medium (MEM), supplemented with 5% fetal bovine serum (FBS), 2.2 g/L sodium bicarbonate, 2 mM L-glutamine, 1.0 mM sodium pyruvate and antibiotics. Cloning of PK15 cells was performed by the limiting-dilution method. The cells were trypsinized, diluted at a mean concentration of 1 cell/well in MEM/20% FBS/60% conditioned media and dispensed into 96-well tissue culture plates. The wells were immediately screened for single cells and marked, and the plates were incubated at 37° C. in an atmosphere of 5% CO 2 . Following the identification of cell monolayers from the initial cloning, these subclones were subjected to another round of further cloning.
The PK15 parent and cloned cell populations were screened by immunofluorescence assay (IFA) for high- and low-permissive cells. The cells were seeded to 70% confluency in 96-well plates and infected with PCV2 with a titer of about 10 5 TCID 50 /ml at 6 hours post-seeding. Glucosamine (300 mM) was added to the infected cells within 24 hours of infection, and the cells were maintained in MEM/5% FBS at 37° C./5% CO 2 . Positive and negative controls used in this experiment were PCV2 virus supernatant (s/n) of 10 5 TCID 50 /ml and MEM/5% FBS respectively. The cells were fixed with 4% paraformaldehyde, and IFA was performed at 72 hours post-infection (pi). IFA results demonstrated highest of 90% PCV2 infection in high-permissive clone C1 cells, compared to only 40% PCV2 infection in PK15 parent cells, and less than 20% infection in the remaining low-permissive cell clones ( FIG. 1 ). In addition, a virus attachment assay was carried out to observe the affinity of PCV2 to the cell surface membrane of each cell clone. Each cell clone was seeded onto chamber slides and incubated overnight as above to obtain 70% confluency. PCV2 of 10 7 TCID 50 /ml was added to the cells for 1 hour adsorption at 37° C. and fixed with 4% paraformaldehyde. IFA was performed as above, however using PCV2 ORF-2 antibody for the primary antibody. After the final washing, the stained cells were mounted with fluorescent mounting media and observed under a Zeiss Meta inverted confocal microscope. Confocal microscopy results demonstrating PCV2 attachment onto cell surface membranes of cloned and uncloned PK15 cells after 1 hour adsorption at 37° C. are shown in FIG. 2 . A, B, C and D represent mock-infected PK15 monolayer (negative control), infected low-permissive, high-permissive (clone C1) subcloned monolayers and infected PK15 monolayer respectively. 1) FITC fluorescent staining image. 2) Overlay of light phase and green fluorescence image. The spread and intensity of fluorescence, indicating PCV2 attachment to the cell surface membrane, was observed most intensely on high-permissive cell clone C1, followed by uncloned PK15 cells and low-permissive cell clones. These results suggested that clone C1 is most susceptible to PCV2 infection, and therefore selected for propagation of PCV2 virus.
Example 2
Characterization of PK15-C1
PK15 parent cells and clone C1 cells were characterized by their mean generation time in hours. Approximately 1×10 5 cells were seeded into 6-well plates, and cultured in MEM/10% FBS. The cells were trypsinized, counted, and underwent DNA extraction and quantitation at 0, 4, 8, 16, 24, 32 and 48 hours post-seeding. From the cell count and DNA quantitation data, the mean generation times of PK15 parent and clone C1 cell populations were determined to be 12.1 and 14.6 hours respectively. The results shown in FIG. 3 and Table 1 suggest that PK15 parent cells doubles faster than that of clone C1 cells.
Following, the titres for released virus in the culture supernatant were compared between virus yields from PK15 parent and clone C1 cells. The cells were seeded to 70% confluency in 150 cm 2 tissue culture flasks and infected with PCV2 (10 4 TCID 50 /ml) at 6 hours post-seeding. The infected cultures were treated with D-glucosamine and maintained in culture media as previously mentioned. Finally, the virus-infected cultures were freeze-thawed three times at 4 days post infection (DPI), cells debris were pelleted at 3500 rpm at 4° C. for 5 minutes and supernatant containing PCV2 virus was retrieved. PCV2 virus was serially passaged in PK15 parent and clone C1 cell lines, harvested and stored at −80° C. until infectivity was determined by IFA using C1 clones. IFA results demonstrated that C1 cell clone produced a maximum virus titer of 10 8 TCID 50 /mL after 5 serial passages compared to a lower titer of 10 5 TCID 50 /mL generated from the parental PK15 cell line ( FIG. 4 ).
TABLE 1
Cell Line
Mean Generation Time (Hours)
PK15
12.1
Clone C1
14.6
DNA replication rates of PCV2 in the parental PK15 and C1 cell clone were also assessed using a real-time PCR method. Two hundred microliters of each PCV2 infected PK15 and C1 cell lysate were harvested at 4 day post-infection (DPI) and DNA extractions were carried out using the QiaAmp DNA Mini kit (QIAGEN, Inc., Valencia, Calif. USA). The purified DNA was then eluted in 200 microliters of sterile distill water. Real-time PCR was carried out using the Roche LightCycler system (Roche Applied Science, Indianapolis, Ind. USA). One microliter of each DNA extract was used as PCR template and a pair of PCV2 specific primers was used for the amplification (Forward primer: 5′ cacctggttgtggtaaaagc 3′, Reverse primer: 5′ ggtctgattgctggtaatcg 3′). A PBluescript plasmid (Stratagene, La Jolla, Calif. USA) containing PCV2 genome insert was used as standard reference. Real-time PCR quantification has shown that the genomic DNA copy number of PCV2 in 1 mL of PK15 and C1 cell lysates are 10 7 and 10 10 respectively ( FIG. 5 ).
Although the invention has been described herein in detail for the purpose of illustration, it is to be understood that variations can be made therein by those skilled in the art without departing from the spirit and scope of the invention except as it may be limited by the claims. | Continuous cell lines that are highly permissive to infection by porcine circovirus type 2 (“PCV2”) are described. PCV2 is the causal agent of post-weaning multi-systemic wasting syndrome (“PMWS”) in pigs. PMWS has emerged as a major disease that poses a significant threat to the economics of global swine industry. The highly permissive cell lines of this invention provide efficient and reliable sources of PCV2 for use in development of vaccines, therapies and diagnostic agents for PMWS. | 2 |
This application is a national stage application of International Application No. PCT/GB95/00156, filed Jan. 25, 1995.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a form of herpesvirus particles suitable for use in vaccination, the preparation of such particles, and vaccines containing them.
2. Description of the Related Art
Herpes simplex virus type 1 (HSV-1) light particles (L-particles) are non-infectious virus-related particles, produced in approximately equal numbers with virions throughout the virus replication cycle in BHK cells (Szilagyi and Cunningham, 1991, J. Gen. Virol. 72, 661-668; Rixon et al., 1992, J. Gen. Virol. 73, 277-284). Similar L-particles have been isolated from pseudorabies virus (PRV); equine herpesvirus type 1 (EHV-1) (McLauchlan and Rixon, 1992, J. Gen. Virol. 73, 269-276); bovine herpes virus type 1 (BHV-1); varicella-zoster virus (VZV) (Dargan and Subak-Sharpe, unpublished) and HSV-2 (MacLean, unpublished). Because of the non-infectious nature of L-particles they have great potential as candidate vaccine materials (PCT Patent Application Publication No. 92/19748).
Comparative analysis of the protein composition of HSV-1, PRV and EHV-1 L-particles and virions show that most or all the virion tegument and envelope proteins are present in L-particles, but the nucleocapsid proteins are not present. Five phosphoproteins not detectable in HSV-1 virions are associated with HSV-1 L-particles (Szilagyi and Cunningham, 1991, J. Gen. Virol. 72, 661-668; McLauchlan and Rixon, 1992, J. Gen. Virol. 73, 269-276).
HSV-1 L-particles have been shown to be as efficient as virions in supplying functional tegument proteins to target cells. Thus, L-particles are biologically competent and have the potential to participate in the early stages of HSV-1 infections (McLauchlan et al., 1992, Virology, 190, 689-688).
Using an HSV-1 ts mutant (ts1201) (Preston et al., 1983, J. Virol. 45, 1056-1064) having a mutation in gene UL26, Rixon et al., 1992, J. Gen. Virol. 73, 277-284, demonstrated that L-particles were generated independently of virion maturation. Under non-permissive conditions ts1201 failed to make infectious virions but produced L-particles which were identical to typical wild-type virus L-particles in appearance and protein composition. Although viral DNA is synthesised normally in cells infected with ts1201 under their non-permissive conditions, viral DNA packaging into virions is blocked (Preston et al., 1983, J. Virol. 45, 1056-1064).
Although L-particles can be prepared to be substantially free of infectious virions, a typical preparation of HSV-1 L-particles containing a ratio of from 3×10 3 :1 to 1×10 4 :1 L-particles: infectious virions, there is a problem to improve on this ratio. Further, although the L-particles lack a capsid and the DNA within it, L-particle preparations still contain some viral DNA present in contaminating virions and/or possibly in the form of free nascent viral DNA. It would be advantageous to reduce the amount of such DNA present in the L-particle preparations, in order more easily to convince regulatory authorities of the safety of a vaccine containing them.
Additional prior art, the relevance of which becomes clear only in the context of the present invention, is referred to below after "Summary of the invention".
SUMMARY OF THE INVENTION
The inventors have now found a new type of herpesvirus particles, which are herein called pre-(viral DNA replication) enveloped particles (PREPS). Like L-particles, they are non-infectious. They can be prepared reliably to have a high ratio, typically for HSV-1 from 6×10 5 :1 to 3.8×10 8 :1 and frequently for HSV-1 of at least 10 7 :1 PREPS:infectious virions. The underlying experimental finding is that HSV-1 PREPS can be produced under conditions where viral DNA replication is blocked either by use of drugs (e.g. Acyclovir [ACV]; Elion et al, 1977, Proceedings of the National Academy of Sciences, USA, 74, 5716); cytosine-β-D-arabinofuranoside [ara C]; (Ward and Stevens, 1975, J. Virol. 15, 71-80) or by using an HSV-1 mutant defective in viral DNA synthesis.
The data reported below show that in the absence of viral DNA synthesis HSV-1 and other α-herpesviruses such as HSV-2 and pseudorabies virus can synthesise PREPS, but not infectious virions, from infected cells. Moreover, PREPS preparations are not expected to contain nascent (=newly synthesised) viral DNA and therefore have the advantage of generating a safer vaccine by virtue of reducing the overall amounts of viral DNA per unit of vaccine. The results indicate that PREPS may be produced by using HSV-1 mutants defective in any of its replication proteins, or in HSV-1 infected cell cultures treated with any inhibitor of viral DNA synthesis or of protein(s) essential to viral DNA replication. Although the invention is illustrated mainly by reference to HSV-1, it is a pioneer invention of general principle which can be expected to be applicable to any virus of the herpesvirus family, especially of the α-herpesvirus family, e.g. to those referred to above in connection with L-particles. Further, the PREPS can be made to incorporate foreign proteins by recombinant DNA techniques.
Important features of the invention are (1) a virus preparation substantially free of virions, based on particles of a herpesvirus which are virus-related, non-infectious particles of a herpesvirus lacking a capsid and viral DNA, characterised in that they are pre-(viral DNA replication) particles (PREPS) lacking or containing only small amounts (smaller by comparison with corresponding L-particles) of at least one of those proteins, called "true late" proteins, which are normally produced only after replication of viral DNA, but containing larger amounts of at least one of the other viral proteins (larger by comparison with corresponding L-particles) and optionally further characterised by having fewer envelope glycoprotein spikes than L-particles, when viewed by electron microscropy; and (2) a method of preparing a virus preparation characterised by comprising infecting host cells with a herpesvirus under conditions effective to prevent replication of viral DNA, allowing the synthesis of viral proteins and PREP formation and recovering from the cells or extracellular medium a substantially virion-free preparation of virus-related, non-infectious, particles.
ADDITIONAL PRIOR ART
Very recently, Morrison and Knipe, 1994 J. Virol. 68, 689-696, have demonstrated immunisation in a mouse model against HSV-1 by direct injection with replication-defective strains of HSV-1. The mutant virus stocks contained less than 1 pfu of wild type virus per 10 7 pfu of mutant virus as determined by assays. The viral DNA content of the mutant virus preparation was equivalent to that of wild type virus. However, these authors have not appreciated that the mutant virus stocks could be used to produce PREPS or that such PREPS could serve as vectors in which foreign proteins could be carried to generate an immune response to those proteins. In other words, these virus stocks have been produced using complementing cell lines and are at the equivalent stage to the starting inoculum used in relation to the method of the invention.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
FIGS. 1(a) to 1(d) show "Ficoll" density gradients containing (1a) wild type control, (1b) amb UL8, (1c) Acyclovir-treated, and (1d) ara C-treated preparations, all of HSV-1. Bands corresponding to virion (V), L-particles (L) and PREPS are indicated.
FIGS. 2(a) and 2(b) show electron micrographs of HSV-1 L-and PREP particles, respectively.
FIG. 3 is a photograph of a silver-stained gel showing SDS-PAGE analysis or protein profiles of virion (V), L-particles (L) and (PREPS) (P) of HSV-1.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the virus particle preparations of the invention, the numerical ratio of PREPS to infectious virions (defined as plaque-forming units) will usually be at least 7×10 6 :1 and more usually at least 1×10 7 :1. The number of PREPS can be determined by electron microscopy. The number of pfu can be determined by plaque assay of virus grown on monolayers of appropriate cells. The greater ratio found in PREPS compared with L-particles probably arises at least in part because no new infectious progeny are made by the PREPS, owing to the DNA synthesis inhibition. (The L-particle/virion ratio of about 10 6 :1 in small scale experiments mentioned in WO 92/19748 is not comparable with the L-particle/pfu ratio).
Considered in terms of the particles per se, these PREPS differ from L-particles in that they lack or contain in reduced amounts "true late" protein(s) (Johnson et al., 1986 J. Gen. Virol. 67, 871-883). True late proteins are made at a late stage in the virus growth cycle and are considered to result from transcription of nascent copies of the original viral DNA. Consequently, when DNA synthesis is inhibited, true late proteins are not made or only made in small amounts, i.e. smaller amounts than present in the corresponding L-particles. The "corresponding" L-particles are those obtainable from wild type virus of the same strain (i.e. disregarding any minor genetic differences).
Important true late proteins in HSV-1 are "82/81K" (VP13/14) (McLean et al., 1990, J. Gen. Virol. 71, 2953-2960), 273K (VP1-2) (McNabb and Courtney, 1992, Virology 190, 221-232) and g C (VP 8) (Peake et al., 1982, J. Virology 42, 678-690). Absence or reduction of the amount of any one or more of these proteins may be called in aid as a distinctive feature of the PREPS of HSV-1. In general, for herpesviruses, it is expected that at least one, and normally at least two true late proteins will be lacking or present in reduced amount in PREPS compared with L-particles.
For many purposes, the absence or reduced amount of true late proteins is sufficient to distinguish PREPS from L-particles. However, this distinction reflects merely the absence of replication of viral DNA by PREPS. PREPS could be made to contain true late proteins in greater amount if the viral genome were altered to put the gene(s) coding for one or more of the true late proteins under control of an "early" promoter, i.e. one which causes mRNA transcription early in the process of particle-formation, so that the true late proteins can be produced in the viral tegument of the particles. The use of an "early" viral promoter to transcribe true late proteins has been described in the literature and is therefore feasible. Since PREPS could be made to include true late proteins, the absence or reduction thereof is not distinctive of all possible PREPS. However, it has further been found that certain other viral proteins are present in increased amounts in PREPS compared with L-particles. In HSV-1, these are the 175K (VP 4, IE 3), 92/91K (VP 11/12) and 38K (VP 22) proteins. In general, for herpesviruses, it is expected that at least one, and normally at least two viral proteins will be produced in increased amounts in PREPS by comparison with L-particles.
In the method of preparation of the invention, the initiating herpesvirus inoculum has to contain DNA, because DNA is required for production of viral proteins involved in producing the particle structure (tegument proteins, envelope proteins etc.). Thus, when a viral DNA replication-negative mutant is used to synthesise PREPS, the viral inoculum itself used to initiate the treatment of cells with the virus has to be produced using some kind of helper specifically complementing for the mutant function, in order to restore full functionality for viral DNA synthesis. For example, engineered cells that express that missing function or a helper virus that expresses the function may be used.
The starting herpesvirus may be disabled in several ways to prevent DNA synthesis. This is readily achieved by introducing a deletion, insertion, variation or stop signal into DNA encoding a protein which is necessary for viral DNA synthesis. For example, in HSV-1 it is particularly effective to mutate the DNA encoding the UL8 protein. UL8, UL5 and UL52 proteins together form a complex which is associated with DNA-helicase-primase activity (Crute et al., 1989, Proc. Nat. Acad. Sci. USA, 86, 2186-2189). While this particular function is supplied by UL5 and UL52 alone (Calder et al., 1992, J. Gen. Virol. 73, 531-538), the complex also acts in some other way to enable DNA replication and UL8 is essential to that function. Other DNA replication-essential proteins in HSV-1 which could be disabled are listed in Example 3. Equivalent genes of VZV or EHV-1 respectively are VZV genes 55, 52, 51, 29, 28, 16 and 6 (Davison and Scott, 1986, J. Gen. Virol. 67, 1759-1816) and EHV-1 genes 57, 54, 53, 31, 30, 18 and 7 (Telford et al., 1992, Virology, 189, 304-316). Genes encoding DNA replication-essential proteins in other herpesviruses are known to those skilled in the art or will be determined in manners analogous to those used for HSV-1, VZV and EHV-1.
Another way to disable the starting herpesvirus is to block replication of its DNA by a specific or general chemical inhibitor of DNA synthesis such as Acyclovir, phosphonoacetic acid (PAA) or cytosine-β-D-arabinofuraroside (ara C). Their respective modes of action are documented in (Elion et al., 1977, above, Mao et al., 1975, J. Virol., 15, 1281-1283 and Mach et al., 1975, J. Virol., 15, 1281-1283).
Other forms of disablement or interference with DNA synthesis can be devised (e.g. removal or inactivation of the relevant promoter of transcription of a gene) and all forms are within the scope of the invention. The essential requirement is that the host cells be infected with herpesvirus virions and particles allowed to be synthesised under conditions effective to prevent viral DNA synthesis. For example, the inhibitory agent could be an anti-sense oligonucleotide or a peptide inhibitor binding to a protein or protein complex required for DNA synthesis; or an agent that prevents the formation of or disrupts a replication-essential protein-protein or protein-nucleic acid complex.
The process of culture includes an appropriate incubation period to allow virus specified products to be synthesised. By transcribing off the input viral DNA, envelope, tegument and various other proteins are produced, resulting in particle assembly and therefore synthesis of PREPS, but true late proteins are either only produced to a very minor (trace) extent or not at all. To reduce further the amount of infectious virions contaminating the PREP preparations, virions from the starting inoculum, which have been adsorbed onto the cells but have not penetrated them, should be removed as thoroughly as possible. Alternatively or additionally, the virions can be inactivated, for example, through an acid glycine wash, as described by Rosenthal et al., 1984, J. Virol., 49, 980-983.
The immune responses to PREP preparations are expected to provide protection against the type of herpesvirus from which the PREPS are derived. It is expected that the PREPS will induce protection against a herpesvirus infection of the strain which provides the relevant proteins of the PREPS, but there will doubtless, in many cases, result a degree of protection against other strains within a serotype or even against strains of a different serotype.
While the invention thus far described relates to PREPS wholly composed of elements of herpesvirus, a wider range of protection could be provided by producing recombinant herpesviruses expressing inserted foreign DNA in such a way as to incorporate the resulting foreign proteins or epitopic peptides from unrelated viruses or other types of herpesvirus or other organisms into the PREPS. (The term "foreign" herein means not native to the strain of herpesvirus from which the PREPS are derived).
Where the foreign DNA is foreign only in the sense that it is derived from another strain or type of HSV, it is expected that a recombinant HSV containing the foreign DNA will express it without difficulty in most cases, so that the protein thus produced becomes incorporated within the PREPS (e.g. in the envelope or in the tegument). Recombinant virus expressing the foreign protein can be constructed by inserting the gene for that protein placed under the control of appropriate HSV signals in the genome of either the wild type HSV-1 virus or the DNA-replication negative HSV-1 using standard techniques (Rixon and McLauchlan, 1993, In: Molecular Virology, A Practical Approach, p. 285-307; ed. Davison A. J. and Elliott, R. M. IRL Press, Oxford). The wild type virus carrying the foreign gene can either be used with DNA-replication inhibitors (see above) or can be engineered further to render it DNA-replication negative. PREPS containing foreign proteins could also be produced by treating cells engineered to express the foreign genes, carrying appropriate herpesvirus signals, with the DNA-replication negative HSV-1 or with wild type HSV in the presence of DNA replication inhibitors.
The cells or specifically constructed HSV mutant complementing cell lines can be any appropriate to vaccine use and approved by regulatory authorities. They may be, for example, baby hamster kidney cells. Complementing cell lines are purely to grow the defective virus to be used as inoculum which in turn is used to infect non-complementing cells for PREP production. The infected culture is then incubated, preferably for at least 24 hours, to produce PREPS containing foreign protein or a peptide expressed from the recombinant herpesvirus DNA, substantially free of virions. The above description applies mutatis mutandis to other herpesviruses.
The particle preparations of the invention are normally produced in a cell-free form. That is, the PREPS are separated from the supernatant of cells from which they have been excreted or recovered from cells containing them. Thus, the preparations are desirably made as far as possible free of whole cells and of cell debris.
To maximise the potential use of PREPS, considerable interest centres on the expression of foreign genes not native to HSV, e.g. of other herpesviruses such as human cytomegalovirus (HCMV) or varicella zoster virus (VZV), or of unrelated viruses, e.g. immunodeficiency group viruses or papillomaviruses, or of bacterial or non-viral parasites. It may be necessary to engineer the foreign DNA to provide it with HSV signals such that the expressed protein is targeted to the PREPS. This engineered foreign DNA can then be incorporated into an appropriately chosen site or region of the herpesvirus genome. Finding the signals for targeting into the PREPS will be a matter of trial and error, but it has already been shown in Example 3 of WO 92/19748 that the virion host shut-off (vhs) protein gene of HSV-1 is capable of providing the requisite signals for targeting into L-particles. Experimentation with marker genes along the lines indicated in that Example will readily provide appropriate herpesvirus genomic sequences for the construction of required recombinants.
Examples of the foreign proteins and peptides or heterologous antigens which can be introduced into HSV-1 PREPS by procedures as described above are any HSV-2 structural proteins, or other proteins, such as gD2, gB2, immediate-early Vmw 183, or HSV-2 equivalent of Vmw 65, etc and proteins of other herpesviruses such as HCMV gB etc., or of unrelated viruses such as human immunodeficiency virus proteins (or peptides), such as of HIV-1 or HIV-2 gp 120 or gp 160, etc., or proteins in nature produced by any prokaryote or eukaryote.
If it is found that the presence of one or more HSV-1 true late proteins is helpful in PREPS to improve their immunogenic or other properties, it would be possible to re-introduce these genes under the control of appropriate early or immediate early promoters into the genome of a viral DNA-replication negative virus. Under such conditions, these true late proteins are expected to be expressed as early or immediate early gene products.
There are several references to work done in putting early genes under control of an immediate-early promoter in HSV-1 and obtaining competent viral particles, see e.g. L. E. Post et al., 1981, Cell 24, 555-565 and 25, 227-232, J. M. Calder et al., 1992, J. Gen. Virol. 73, 531-538 and H. M. Weir et al., 1989, Nucleic Acids Research 17, 1409-1425. Further it is known that true late genes can be put under control of early or immediate-early promoters in bacterial plasmids. The man skilled in the art will therefore be able to combine these technologies and apply them to the present invention.
The vaccine of the invention may be of any formulation by which PREPS can stimulate formation of antibodies to the relevant proteins and/or stimulate cell-mediated immunity. The vaccine will therefore frequently contain an immunostimulant (e.g. adjuvant) or vehicle, as well as a virus particle preparation of the invention. It can, of course, also contain other conventional additives, such as excipients and assistant adjuvants. The PREP particles in the vaccine can be in untreated form or in a form in which they have been irradiated or, treated chemically with agents like formaldehyde. Irradiated or chemically treated PREP vaccines could be used whole or possibly in a disrupted or comminuted form to release proteins from the tegument. The vaccine is desirably made up into unit dosage forms. Appropriate doses can be derived from knowledge of the use of herpesvirus vaccines, e.g. of HSV-1 or VZV virus, but the dose will also depend on whether the PREPS are intended to protect against a herpesvirus infection or mainly to stimulate the immune system with an immunogenic foreign protein or peptide. In the latter case, dosages appropriate to the foreign protein or peptide will have to be calculated, using the existing body of knowledge concerning that protein or peptide.
For administration of the preparations of the invention to the appropriate mammals, any of the conventional routes used in the viral vaccine field can be used. These will be predominantly by subcutaneous or intramuscular injection, but other routes, e.g. oral, intravenal, intravaginal, intraperitoneal and intranasal, may be more appropriate on occasions. They can be administered for the prophylactic or therapeutic vaccination against herpesvirus or, if foreign protein is incorporated in the PREPS to stimulate the immune system to increase an immunoprotective effect against it. In this context, the invention is expected to be useful in the prophylaxis of AIDS in HIV-negative, at risk individuals.
The invention is primarily intended for use in human patients, in which case the herpesvirus is preferably one likely to be tolerated by humans when in the form of non-infectious particles, especially a herpes simplex virus and most especially HSV-1.
However, for use in other animals than humans, other kinds of herpesvirus may be more appropriate, e.g. equine herpesvirus for horses.
The following Examples illustrate the invention. "Ficoll" and "Sorval" are Registered Trade Marks.
EXAMPLE 1
HSV-1 PREPS produced in infected cell cultures treated with inhibitors of DNA synthesis
Confluent roller bottle cultures of BHK-21cells (2×10 8 cells/roller bottle) were infected with HSV-1 strain 17 at a m.o.i. of 5 pfu/cell in 15 ml of Glasgow-modified Eagle's medium supplemented with 5% newborn calf serum (EC 5 ). The cells were allowed 2 h at 37° C. to absorb the virus. The inoculum was then decanted and the cell sheet washed with acidic glycine to inactivate residual input virus. The washing procedure for each roller bottle was as follows (Rosenthal et al., 1984, J. Virol. 49, 980-983):
1. Wash once with 20 ml of 0.14M NaCl.
2. Wash once with 20 ml of 0.1M glycine pH 3.0 in 0.14M NaCl for 1 min.
3. Wash once with 20 ml of EC 5 to neutralise the acid.
The cells were then overlaid with 30 ml/roller bottle of drug-free EC 5 or of EC 5 containing 10 μM Acyclovir (ACV) (Sigma) or 100 μg/ml cytosine-β-D-arabinofuranoside (ara C) (Sigma). The infected cultures were then grown at 31° C. for 48 h before harvesting.
The extracellular material was clarified (4000 rpm for 20 min/4° C.) using a "Sorval" GSA rotor, and pelleted (12000 rpm/2 h/4° C.) using the same rotor (Szilagyi and Cunningham, 1991, above). This provided cell-released particles.
After gentle resuspension of the pelleted material it was separated by density gradient centrifugation using the procedure of Szilagyi and Cunningham (1991, above).
The "Ficoll" gradients containing the drug-free preparation yielded bands of characteristic virions and L-particles, while the gradients containing material produced in the presence of ACV and ara C had no visible virion band, although a diffuse band corresponding to the drug-free "L-particle" band was present (FIGS. 1c and 1d).
These bands were collected by side-puncture, made up to 37 ml with Eagle's medium lacking phenol red (Epr - ), pelleted by centrifugation at 19,000 g for 16 h at 4° C. in a Sorval AH 629 rotor and subsequently resuspended in a small volume of Epr - and stored at -70° C. The material was subsequently examined by electron microscopy, which showed high numbers of particles resembling wild type L-particles (FIGS. 2c and d). The particles made in the absence of viral DNA replication have been designated PREPS. The region of the gradients corresponding to the location of the virion band in the drug-free preparation was similarly removed and analysed. The analysis is presented after Example 4.
Similar results were obtained using infected cell extract material containing intracellular PREPS, released from cells by mechanical breakage with glass beads and purified as described above.
EXAMPLE 2
BHK cells or human melanoma cells (MeWO) were grown in Eagle's medium supplemented with 10% newborn calf serum or Dulbecco's modified Eagle's medium supplemented with 10% foetal calf serum (DMEM 10 ) respectively. The drugs (10 μM ACV, 100 μg/ml Ara C or 300 μg/ml PAA) were added 1 h prior to infection and were present throughout infection with HSV-1. Following incubation at 37° C., PREPS were purified from the medium, as described in Example 1.
It has been found that the temperature at which the infected cells are grown is of minor importance so long as the cells reach the full cytopathic effect (cpe) condition, which is well understood by the person skilled in the art and can be judged visually by the cells losing their stringy appearance and becoming fully round. Either 31° C. for 48 hours or 37° C. for 24 hours was used in this Example.
The resulting PREPS were analysed, as described after Example 4.
EXAMPLE 3
Isolation of a DNA replication-negative amber non-sense mutant of HSV-1
HSV-1 gene nomenclature and DNA sequence are set forth by McGeoch et al., 1988, J. Gen. Virol. 69, 1531-1574.
HSV-1 genes UL5, UL8, UL9, UL29, UL30, UL42 and UL52 encode proteins which are known to be required for viral DNA synthesis in tissue culture cells (Wu et al., 1989, J. Gen. Virol. 62, 435-443; Weller et al., 1991, In: Herpesvirus Transcription and its Regulation, 105-135). Mutations which abolish the function of any one of these genes fail to induce viral DNA synthesis in infected cells. The biochemical functions so far assigned to these replication proteins are as follows. The products of UL5, UL8 and UL52 form a heterotrimer complex which exhibits DNA helicase-primase activities (Crute et al., 1989, Proceedings of the National Academy of Sciences, USA 86, 2186-2189). Gene UL9 encodes an origin-binding protein (Weir et al., 1989, Nucleic Acids Research, 17, 1409-1425); UL29 encodes the major DNA-binding protein (Weller et al., 1983, J. Gen. Virol. 45, 354-366); UL30 and UIL42 respectively encode the viral DNA polymerase and its accessory protein (Dorsky et al., 1987, J. Gen. Virol. 61, 1704-1707; Parris et al., 1988, J. Virol. 62, 818-825; Wu et al., 1988, above; Marcy et al., 1990, Nucleic Acids Research, 18, 1207-1215).
In order to construct a HSV-1 mutant defective in viral DNA synthesis, the serine codon at amino acid position 267 of the UL8 protein was replaced with an in-frame amber stop codon by in vitro site-directed mutagenesis. The mutated gene was then introduced into the wild type virus genome by homologous recombination. The resultant mutant virus, HSV-1 ambUL8, was isolated in a permissive cell line (S22) which was generously supplied by Dr S. Weller (Carmichael et al., 1988, J. Virol., 62, 91-99), but the cell line A26 (below) could equally be used. The amb UL8 mutant failed to produce plaques or synthesise viral DNA when grown in Vero cells, consistent with the observation made previously that UL8 is essential for viral DNA synthesis (Carmichael and Weller, 1989, J. Virol., 63, 591-599). The efficiency of ambUL8 virus production in Vero and S22 cells, as measured by single-step growth analysis, showed that the mutant failed to grow on Vero cells whereas the virus yield on S22 cells was comparable to that of wild type virus. Western immunoblot analysis using monoclonal antibodies specific for UL8 protein failed to detect the UL8 gene product in ambUL8-infected Vero cells. For the work reported herein the virus was propagated in another complementing cell line (A26 cells derived from Vero cells) which was constructed as follows.
Following the procedure of DeLuca et al., 1985, J. Virol. 56, 558-570, Vero cells were co-transfected with a plasmid carrying the Bgl11 k fragment of the HSV-1 genome (co-ordinates 14589 to 25149 containing the complete nucleotide sequences of HSV-1 genes UL6, UL7, UL8, UL9 and UL 10; McGeoch et al., 1988, above) and another plasmid, pSV2neo, containing the neomycin resistance gene under the control of the simian virus 40 (SV40) promoter (Southern and Berg. 1982, J. Mol. Appl. Genet. 1, 327-341). The transfected cells were grown to confluence, trypsinised and plated at 1:25 dilution in medium containing 800 μg/ml of the antibiotic Geneticin (G418, GIBCO BRL). Following incubation at 37° C. for 2 weeks (with periodic change of medium), individual colonies resistant to G418 were visible. These colonies were isolated and amplified. One of the colonies was chosen and found to be able to support the growth of a HSV-1 amb UL8 mutant which formed plaques and displayed cpe on this cell line, which was designated A26. The A26 cell line was also able to support the growth at 38.5° C. of a temperature-sensitive mutant, tsS in UL9, (Marsden et al., 1976, J. Gen. Virol. 31, 347-372; Dargan and Subak-Sharpe, 1983, J. Gen. Virol. 64, 1311-1326).
The ability of ambUL8 virus to synthesise virus-like particles under non-permissive conditions (i.e. under conditions non-permissive for HSV-1 DNA replication, using a non-complementing cell line) was examined. BHK cells in roller bottles were infected with ambUL8 or wild type virus at an m.o.i. of 5 pfu./cell, followed by acid glycine wash as described in Example 1 above. Infected cells were incubated further at 37° C. for 3.5 h in Eagle's medium containing 2% calf serum (EC 2 ). Cell medium was then replaced with methionine-free EC 2 , containing 0.5 mci 35 S-methionine (for purposes of autoradiography, superseded by silver staining: see Example 4) and incubation was continued for a further 43 h. Extracellular matter present in the supernatant medium was pelleted, resuspended and analysed in a 5-15% "Ficoll" gradient as described by Szilagyi and Cunningham (1991, above). The wild type virus preparation gradient contained bands corresponding to virions and L-particles. In the ambUL8 preparation gradient, the virion band was absent, although a diffuse upper band corresponding to the L-particle band of wild type virus was present (FIGS. 1a and b). In the gradient containing ambUL8, material co-migrating with the wild type virion band was also collected. The analysis is described below.
EXAMPLE 4
PREPS from ambUL8 HSV-1 were prepared from virus-treated BHK and MeWO cells, following the conditions of Example 2 for all stages, except that no drugs were used.
Analysis of PREPS
Negative-stain electron microscopy
5 μl samples of L-particles or PREPS were spotted on to a "Formvar"-coated EM grid and allowed to dry. The grid was then treated with 5 μl of phosphotungstic acid (PTA) for 5 seconds and excess PTA was removed by blotting. The samples were examined in a "Jeol" 101 electron microscope.
By electron microscopy, careful study of HSV-1 L-particles has revealed a difference in appearance between L-particles and PREPS: in PREPS the envelope glycoprotein spikes were less numerous per particle. The difference can be seen by careful scrutiny of the EM photographs of FIGS. 2a and 2b, showing the stained L-particles and PREPS respectively (from Example 4, but those from the other Examples are similarly distinguishable). Typical particles in which these spikes are clearly visible are arrowed. Gaps appear between the spikes in FIG. 2b. The bar line shown is a distance of 100 nanometres.
Glycoprotein spikes are carried by all herpesviruses. It is believed and expected that the same trait will be visible in EM photographs of L-particles and PREPS of other such viruses besides HSV-1.
Infectivity
Samples of the collected PREPS were titrated on BHK or A26 cell monolayers to determine the infectivity in pfu/ml. Numbers of particles/ml were determined by electron microscopy.
The results are shown in the Table. Those for the BHK cells in Examples 1 and 2 are the same and those for Examples 3 and 4 are also the same. They are presented in the Table.
Although present in insufficient number to constitute a visible band in PREPS-containing gradients, some virion particles were detected by electron microscopy by sampling in the region corresponding to the WT control virion band. The PREPS were produced in similar numbers to WT control L-particles by both BHK and MeWO cultures, irrespective of whether viral DNA synthesis was blocked biochemically by drugs or genetically. A small amount of infectivity was found in all PREPS preparations but the particle:pfu ratios obtained were routinely 100- to 10,000-fold greater than that of the WT control L-particle preparations. The high particle:pfu ratios obtained for the PREPS band and the EM-detected virions from PREPS gradients indicate that most of the virions present were non-infectious, probably representing adsorbed, acid-inactivated, inoculum virus persisting in the cultures, despite the washing procedures, and later released from the cell surface. Small amounts of infectivity were found in association with the PREPS, but fewer than for L-particles.
TABLE__________________________________________________________________________HSV-1 VIRION, L-PARTICLES AND PREP PARTICLE AND INFECTIVITY MEASURES L-Particle/PREPS Band Virion RegionCells Virus Drug P/ml pfu/ml P/pfu P/ml pfu/ml P/pfu__________________________________________________________________________BHK WT None 9.0 × 10.sup.11 8.2 × 10.sup.7 1.0 × 10.sup.4 6.5 × 10.sup.11 4.9 × 10.sup.9 138 BHK WT ACV 3.6 × 10.sup.11 1.0 × 10.sup.4 3.6 × 10.sup.7 1.1 × 10.sup.9 2.0 × 10.sup.4 5.3 × 10.sup.4 BHK WT Ara C 3.5 × 10.sup.11 1.6 × 10.sup.4 2.2 × 10.sup.7 6.6 × 10.sup.9 1.5 × 10.sup.5 4.4 × 10.sup.4 BHK ambUL8 None 1.8 × 10.sup.11 1.0 × 10.sup.4 1.8 × 10.sup.7 <10.sup.8 3.5 × 10.sup.4 >3 × 10.sup.3 MeWO WT None 2.3 × 10.sup.11 7.4 × 10.sup.7 3.1 × 10.sup.3 1.3 × 10.sup.11 3.4 × 10.sup.9 38 MeWO WT ACV 3.0 × 10.sup.11 5.0 × 10.sup.5 6.0 × 10.sup.5 4.3 × 10.sup.9 4.0 × 10.sup.4 1.1 × 10.sup.5 MeWO WT Ara C 10.0 × 10.sup.11 2.7 × 10.sup.3 3.8 × 10.sup.8 8.7 × 10.sup.8 2.0 × 10.sup.3 4.3 × 10.sup.5 MeWO WT PAA 3.9 × 10.sup.11 1.8 × 10.sup.4 2.1 × 10.sup.7 8.8 × 10.sup.10.sup. 5.4 × 10.sup.5 1.6 × 10.sup.5 MeWO ambUL8 None 9.6 × 10.sup.11 1.3 × 10.sup.5 7.4 × 10.sup.6 5.4 × 10.sup.9 4.4 × 10.sup.6 1.2 ×__________________________________________________________________________ 10.sup.3
Polyacrylamide gel electrophoresis, silver staining of proteins and western immunoblotting
Purified virions, L-particles or PREP particles were solubilised and 2×10 9 equivalents loaded onto 9% SDS PAGE gels (Marsden et al., 1976, J. Gen. Virol. 31, 347-372). Proteins were visualised by silver staining as described by McLean et al., 1990, J. Gen. Virol. 71, 2953-2960.
FIG. 3 shoes the polypeptide profiles as follows:
Track 1 (V) Virions from untreated WF-infected BHK cells (Ex. 2)
Track 2 (L) L-particles from BHK cells (Ex. 2)
Track 3 (P am) PREPS from ambUL8-infected BHK cells (Ex. 4)
Track 4 (P am) PREPS from ambUL8-infected MeWO cells (Ex. 4)
Track 5 (P ACV) PREPS from Acyclovir-treated WF-infected MeWO cells (Ex. 2)
Track 6 (P arc) PREPS from ara c-treated WT MeWO cells (Ex. 2)
Track 7 (P PAA) PREPS from PAA-treated WT-infected MeWO cells (Ex. 2)
Track 8 (L) L-particles from untreated WT-infected MeWO cells (Ex. 2)
Track 9 (V) Virions from untreated WT-infected MeWO cells (Ex. 2)
Key to symbols in FIG. 3:
Filled circles denote L-particle protein bands.
Open circles denote capsid protein bands.
Filled squares denote PREPS protein bands of greater intensity than corresponding L-particle protein bands.
Open diamonds denote PREPS protein bands of less intensity than corresponding L-particle protein bands.
In many respects, the profiles of PREPS and WT L-particles were similar (compare tracks 2 and 3 and also 8 and 4). However, the following significant differences in bands were consistently observed irrespective of whether the preparations were obtained from infected BHK or MeWO cells. Protein bands of 273K (VP1-2), 82/81K (VP13/14), 57K (VP17, gD), and 40K were clearly reduced in amount, although BHK-produced PREPS contained much more 81/82 and gD than those made in MeWO cells. Bands of 175K (VP4, IE3), 92/91K (VP11/12), and 38K (VP22) were increased in amount.
Solubilisation of envelope proteins
Approximately 4×10 10 virions, L-particles and PREPS (as for FIG. 3) were treated with 1% NP40 in EPr - at 0° C. for 30 minutes. Soluble (envelope) supernatant and insoluble pellet (tegument) fractions were then separated by centrifugation at 13,000 rpm for five minutes in an MSE microfuge. After solubilisation in sample buffer (Marsden et al, 1976, Journal of General Virology 31, 347-372) a volume equivalent to 4×10 9 particles was loaded into individual gel tracks.
The following proteins were increased in amounts in the tegument fractions of PREPS; 175K multiple band (VP4; IE3), 120K, 118K, 92/91K (VP11/12), gE (BHK cells only), 67K (VP15) (MeWO), and 38K (VP22), while the 273K (VP1-2) and 82/81K (VP13/14), 40K (MeWO) and 37.5K (MeWO) were decreased. In the envelope fraction the band representing gB and gH, shows little or no difference in the amounts of these proteins in L-particles and PREPS. The amount of gD present in PREPS was, however, reduced. Glycoprotein gE appeared to be either missing or only in trace amounts in all types of particle made in MeWO cells while the amount of gE detected in ambUL8 PREPS produced in BHK cells was clearly increased compared to L-particle control.
For Western immunoblotting, envelope and tegument proteins separated by SDS PAGE were transferred to "Hybond-ECL" nitrocellulose sheets (Amersham), treated with blocking buffer (phosphate-buffered saline containing 0.05% Tween 20 (PBS-T) and 2% "Marvel" milk powder) overnight and, after washing with PBS-T, incubated with test mouse monoclonal, or rabbit-polyclonal antibodies prepared in PBS-T containing 1% bovine serum albumin for two hours at 18° C. After further washes with PBS-T, the blots were treated with anti-mouse or anti-rabbit IgG-horseradish peroxidase (as appropriate), and the tagged proteins detected by enhanced chemiluminescence (Amersham). The antibodies used were monoclonal antibody (MAB) 4846 (anti-gD); MAB 3114/109 (anti-gE); and rabbit polyclonal antibodies 94497 (anti-82/1K).
The main results of the Western immunoblotting were as follows:
The true late protein 82/81K was present in the tegument of virions and L-particles made in the BHK or MeWO cell line but, was absent from all PREPS (however prepared). Another true late protein, gC, was present in substantial amounts in the envelope fractions of both L-particles and virions, but in much lower amounts in PREPS, suggesting either that a small amount of viral DNA synthesis took place, or that some gC was produced from the input genomes. Anti-gD was slightly reduced in amount in PREPS.
Complementation of a HSV-1 cell line defective in Vmw 65K protein production
In this experiment, the ability of PREPS to complement the HSV-1 Vmw65K (α-TIF, VP16) defective mutant in1814 (Ace el al., 1988, J. Gen. Virol. 69, 2595-2605 and 1989, J. Virology 63, 2260-2269). It has been shown already that the Vmw65K tegument protein appears to be present in similar quantities in L-particles and PREPS (FIG. 3, lanes 1-9). McLauchlan et al, 1992, J. Gen. Virol. 73, 269-276 have shown that L-particles are as effective as virions at complementing the in1814 mutant.
Human foetal lung cell monolayers (Flow 202) (propagated in GMEM supplemented with 10% FCS) on 24 well tissue culture dishes were infected with in1814 at 0.1, 1.0 or 10 pfu/well. After a 1 hour absorption period, virus not taken up was removed by washing the cells with containing PBS containing 5% FCS and the monolayers then treated for 1 hour at 37° C. with 0.1, 1.0 10 or 100 particles/cell of either HSV-1 L-particles or PREPS. After three washes with PBS containing 5% FCS to remove unbound particles, the monolayers were overlaid with EC 5 , incubated at 37° C. for 48 hours, then fixed, stained and the numbers of plaques counted.
Neither L-particles nor PREPS by themselves had any detectable infectivity, but each was able to complement the in1814 mutant. However the efficiency of PREPS complementation was about 10-30% that of control L-particles.
EXAMPLES 5 AND 6
These two examples relate to preparation of PREPS of HSV-2 from MeWO cells and pseudorabies virus from BHK cells in the presence of 100 μg/ml of ara-C and L-particles in the absence thereof. The procedure was as in Example 2, the incubation of the infected cells being at 37° C. for 48 hours. The viral strains used were HSV-2 strain HG52 (Tinbury, 1971, J. Gen. Virol. 13, 373-376) used in the MRC Virology Unit at the University of Glasgow, Scotland and a wild type pseudorabies stock also used in the MRC Virology Unit. These and all other starting viral strains and the A26 cell line herein referred to are available from The Director, MRC Virology Unit, Institute of Virology, Church Street, Glasgow G11 5JR, Scotland.
The resultant PREPS and L-particles appeared by electron microcopy to be similar to HSV-1 PREPS, having fewer glycoprotein spikes around the envelope. Polypeptide composition analysis has not yet been done, but it is confidently expected that the PREPS will again be characterised by reduced amounts of true late proteins relative to the corresponding L-particles. | This invention is directed toward a new type of herpesvirus particle (e.g., HSV-1), herein designated pre-viral DNA replication enveloped particles (PREPS), and methods of preparing said particles. These particles are non-infectious and can be prepared reliably to a high ratio of HSV-1 PREPS to infectious virus of at least 10 7 :1. PREPS can be produced under conditions wherein viral DNA replication is blocked through the use of suitable drugs (e.g., acyclovir [ACV]; cytosine-β-D-arabinofuranoside [ara C]) or by using an HSV mutant defective in viral DNA synthesis. Compositions comprising HSV-1 PREPS are disclosed wherein said particles have the following characteristics: a) the PREPS lack a viral capsid; b) the PREPS lack viral DNA; c) the PREPS contain reduced quantities of the proteins 273K (VP1-2), 82/81K (VP13/14), 57K (VP17, gD), and 40K, as compared to HSV-1 L particles; and d) the PREPS contain increased quantities of the proteins 175K (VP4, IE3), 92/91K (VP11/12), and 38K (VP22), as compared to HSV-1 L particles. These particles are useful, inter alia, for the generation of HSV-specific immunological and diagnostic reagents. | 2 |
BACKGROUND OF THE INVENTION
The invention relates to a radiator frame for a cooling module of an internal combustion engine, having a fastening element for fastening the cooling module to/on/in a radiator of the internal combustion engine. Furthermore, the invention relates to a cooling module or a cooling device for an internal combustion engine of a motor vehicle, having a radiator frame according to the invention.
A motor vehicle which can be driven by an internal combustion engine has as a rule a water cooling system which guides a cooling water which is heated by the internal combustion engine through a radiator, the cooling water discharging its heat to a cooling air which flows through the radiator. At a standstill and/or at slow speeds of the motor vehicle, a heat build-up occurs in the radiator which is typically arranged in the frontal region of the motor vehicle. In order to avoid a heat build-up of this type, the radiator is as a rule assigned a cooling module which has a fan and serves to additionally convey the cooling air through the radiator. The fan which has a fan motor and a fan wheel is as a rule accommodated on/in a radiator frame behind the radiator in the direction of the vehicle interior of the motor vehicle, which radiator frame is in turn positioned and fastened with regard to the radiator.
The cooling module of the radiator as a rule has a single fan wheel or a plurality of fan wheels, a number, preferably corresponding to the former, of electric motors (fan motors), and the radiator frame. Furthermore, the radiator frame serves to guide the cooling air in as optimum a manner as possible for cooling the radiator and therefore the internal combustion engine and to secure a unit comprising the electric motor or motors and the fan wheel or wheels. A mechanical attachment of the radiator frame and therefore of the cooling module to the radiator or in the vicinity of the radiator of the motor vehicle usually takes place, depending on vehicle type, by means of from at least four to over six fastening elements. That is to say, in a mounted position of the cooling module, from at least four to over six bearing regions are usually formed between the cooling module and the radiator or the motor vehicle.—The fan wheel has a hub which is preferably produced from plastic, a driver which is preferably sintered, and fan blades which are connected, preferably integrally, to the hub on a radial inner side and, likewise preferably integrally, to a fan belt of the fan wheel on a radial outer side. The fan belt of the fan wheel mainly works as a fluid-mechanical seal with respect to the radiator frame.
The fastening elements of the radiator frame serve to suppress the degrees of freedom (translation and rotation in in each case three spatial directions) between the radiator and the radiator frame and therefore the cooling module, or of an attachment of the radiator frame or the cooling module to the motor vehicle. During operation of the motor vehicle, not inconsiderable forces act on the cooling module and therefore on the radiator frame. That is to say, depending on a shaking or vibratory load, different forces and/or moments which change over time act on the fastening elements of the radiator frame. Loads in a y-direction, that is to say a transverse direction of the motor vehicle, and therefore on a fastening element of the radiator frame which locks the cooling module in these directions at least in a single y-direction are to be considered critically, in particular; that is to say, in particular, therefore a fastening element of a locating or fixed bearing between the radiator frame and its mechanical attachment in the motor vehicle. A fracture of the fastening element can occur here.
SUMMARY OF THE INVENTION
It is an object of the invention to specify an improved radiator frame for a cooling module of an internal combustion engine and an improved cooling module or an improved cooling device for an internal combustion engine of a motor vehicle. Here, the radiator frame is to be improved mechanically, that is to say a premature mechanical failure of the radiator frame is to be prevented effectively; a mechanical durability of a fastening element of the radiator frame is to be improved. Here, a previous design of a radiator frame for a cooling module and/or its mechanical attachment in the motor vehicle are/is to be interfered with structurally as little as possible. Furthermore, the radiator frame according to the invention is to be improved in such a way that it can be mounted in an established interface on a radiator of the motor vehicle or in the motor vehicle. Furthermore, the radiator frame according to the invention is to be capable of being produced simply and inexpensively.
The object of the invention is achieved by means of a radiator frame for a cooling module of an internal combustion engine, having a fastening element for fastening the cooling module to/on/in a radiator of the internal combustion engine; and a cooling module or a cooling device for an internal combustion engine of a motor vehicle.
The radiator frame according to the invention having the fastening element according to the invention or a fastening element according to the invention for a radiator frame has a retaining face, by means of which the radiator frame or a cooling module which has the radiator frame can be locked in a translational and optionally a rotational direction, the individual fastening element having at least two retaining faces in such a way that said fastening element can be seated on preferably two mating faces at/on/in the radiator or on preferably two mating faces in the motor vehicle. The cooling module according to the invention and the cooling device according to the invention have a radiator frame according to the invention or a fastening element according to the invention.
The radiator frame according to the invention is considerably improved mechanically as a result of a homogenization according to the invention of a force on/into the fastening element according to the invention. Here, a bending moment (see below) which occurs in the prior art on the fastening element is reduced considerably or no longer exists, as a result of which the mechanical loading of the fastening element is reduced considerably. This is reduced again considerably by the second retaining face on/in the fastening element. That is to say, according to the invention, a premature mechanical failure of the radiator frame is prevented effectively; the fastening element is improved in such a way that a previous design of the radiator frame and/or its mechanical attachment in the motor vehicle has to be interfered with structurally by the invention as little as possible; the fastening element can be used in an established interface with the radiator or the motor vehicle and, moreover, the radiator frame according to the invention can be produced simply and inexpensively.
In embodiments of the invention, the at least two retaining faces of the fastening element are provided in such a way that a movement of the radiator frame in a transverse direction of the radiator frame or of the motor vehicle can be prevented by means of the retaining faces. Here, a respective surface vector of the at least two retaining faces can point mainly or substantially in a direction of an acceleration, in particular a transverse acceleration, of the radiator frame or of the motor vehicle. Here, two retaining faces of the individual fastening element can be configured so as to be separate from one another spatially or contiguous on the fastening element. Here, an individual retaining face can be configured mainly or substantially as a rectangle or in the manner of an ellipse segment, it being possible for the individual retaining face to be curved.
In embodiments of the invention, the longitudinal extents of two retaining faces of an individual fastening element extend in parallel and/or at an angle, in particular at a right angle, with respect to one another. Furthermore, the transverse extents of two retaining faces of an individual fastening element can be arranged in parallel, in particular on a straight line, or at an angle, in particular at a right angle, with respect to one another. Furthermore, two retaining faces of an individual fastening element can be arranged parallel to one another, in particular lying in one plane, or offset with respect to one another with regard to one plane.
The fastening element according to the invention can have at least two latching devices which are separate from one another or at least two latching devices which are connected to one another, which latching devices enclose or run around a shank of the fastening element at least partially in its circumferential direction. Furthermore, the shank of the fastening element according to the invention can have a head at its free end, which head has the at least two retaining faces at least on two sides so as to point away from the shank. Here, the at least two retaining faces of the head can be provided so as to lie opposite one another and/or so as to be adjacent to one another and preferably so as to face the radiator frame or the shank. Contiguous retaining faces form, in particular, an L-shape or a U-shape. If the retaining faces run completely around the shank, this can result, for example, in an outwardly square, rectangular, elliptical or circular shape.
In preferred embodiments of the invention, the at least two retaining faces of the fastening element are spaced apart from one another at least over a diameter of the shank. Furthermore, at least one retaining face of the fastening element can be provided so as to be adjacent, preferably directly adjacent, to the shaft and so as to lie laterally away from the latter, which preferably takes place at a right angle. According to the invention, the at least two holding faces or an entire retaining face of the fastening element can run around the shank at least partially and optionally in an interrupted manner, it being possible for a coverage in the circumferential direction of the shank to be from approximately 90° to approximately 360°.
In preferred embodiments of the invention, the fastening element is configured in one piece with the radiator frame, in particular in one piece in material terms and preferably integrally. Furthermore, the fastening element itself, in particular the fastening element for an individual bearing region of the radiator frame, can be configured in one piece, in particular in one piece in material terms and preferably integrally. In a case of this type, the fastening element is, for example, not slotted, which would make two resilient brackets out of the fastening element. Here, the shank of the fastening element, in particular of the individual fastening element for an individual bearing region of the radiator frame, is configured mainly or substantially as a solid profile.
The fastening element of the radiator frame for fastening the cooling module can be a fastening element for a locating bearing or a fixed bearing of the cooling module. Furthermore, the fastening element can be the only fastening element for locking the radiator frame in the transverse direction of the radiator frame or of the motor vehicle. For a mounted state of the radiator frame or of the cooling module, a retaining face can be capable of being seated mainly or substantially on a relevant mating face in a plane-parallel manner. Furthermore, it is preferred that the fastening element is configured as a retaining bracket, a fastening bracket or as a latching hook.
BRIEF DESCRIPTION OF THE DRAWINGS
In the following text, the invention will be explained in greater detail using exemplary embodiments with reference to the appended drawing. In the figures of the drawing:
FIG. 1 shows a front view of a cooling module from the prior art which has two fan wheels for a radiator of an internal combustion engine,
FIG. 2 likewise shows a front view of a radiator frame from the prior art for a cooling module having a single fan wheel,
FIG. 3 once again shows a front view of a fastening element of a radiator frame from the prior art,
FIG. 4 shows a view, which is analogous to FIG. 3 , of a first embodiment of a fastening element according to the invention of a radiator frame according to the invention,
FIG. 5 shows a perspective view of a second embodiment of the fastening element according to the invention of the radiator frame according to the invention in a mounted position on a radiator of a motor vehicle, and
FIG. 6 likewise shows a perspective view of a third embodiment of the fastening element according to the invention of the radiator frame according to the invention.
DETAILED DESCRIPTION
In the following text, the invention will be explained in greater detail, starting from disadvantages of the prior art ( FIGS. 1 to 3 ). However, the invention is not restricted here to the exemplary embodiments which are shown or explained, but rather can be applied to all fastening elements 100 of a radiator frame 10 or of a frame basic body 10 or of a frame plenum 10 , as long as a fastening element 100 of this type has at least two retaining faces 123 which are configured so as to be either separate from one another spatially and/or contiguous, and in the process their respective longitudinal extents L or transverse extents Q do not coincide, which is the case, for example, in a retaining face 123 which is L-shaped or U-shaped overall—in the former case there are actually two retaining faces 123 , 123 and in the latter case there are actually three retaining faces 123 , 123 , 123 (cf. FIG. 4 ).
During operation of the motor vehicle, acceleration forces a (see FIGS. 2 to 4 ) act on a cooling module 1 (see FIG. 1 ) for a motor vehicle or a radiator 2 (see FIG. 5 , a small detail) and therefore a radiator frame 10 (see FIGS. 1 and 2 ) of the cooling module 1 , which acceleration forces a can be up to 50 m/s 2 and which acceleration forces, for example in the case of a shaking load in the y-direction, are usually to be absorbed by means of a single fastening element 100 . Here, the y-direction corresponds to a transverse direction y of the motor vehicle, of the radiator 2 , of the cooling module 1 and of the radiator frame 10 . Here, high and, in many cases, impermissible forces on the fastening element 100 are produced, which can lead to a fracture of the fastening element 100 . The fracture of the fastening element 100 is to be attributed to a superimposition of a tensile and flexural load and a resulting overall stress on/in the fastening element 100 .
The tensile load on the fastening element 100 results from a force F from the acceleration a of the radiator frame 10 during operation of the motor vehicle on the only retaining face 123 of the fastening element 100 (see FIG. 3 ). Since the force F can act only on one side of the fastening element 100 , that is to say asymmetrically, a flexural load is produced in addition to the tensile load, which flexural load leads to a mechanical moment on the fastening element 100 . The mechanical stresses from the tensile and flexural load are added, in particular, at an integral connection of the retaining face 123 to a shank 110 of the fastening element 100 and an integral connection between the fastening element 100 and the radiator frame 10 in a surrounding area with respect to the retaining face 123 . At said points, the fastening element 100 tends to become damaged, which damage can lead as far as to the fracture of said fastening element 100 .
The mechanical stress from the force F is a quotient of an active force F (see FIG. 3 ) and a load-bearing cross section of a retaining face 123 . The greater a load-bearing cross section of the fastening element 100 , the smaller the resulting mechanical stress on/in the fastening element 100 . In order to reduce the mechanical stress on/in the fastening element 100 , the load-bearing cross section of the fastening element 100 is increased in such a way that the bending moment M is also preferably reduced here and disappears in a favorable case. According to the invention, this takes place in relation to a fastening element 100 according to FIG. 3 in such a way that a second latching device 122 or a second retaining lug 122 or a second shoulder 122 is provided at a free end of the fastening element 100 or its shank 110 or its limb 110 (see FIG. 4 ).
The invention therefore relates to a design or a layout of one or a plurality of fastening elements 100 of the radiator frame 10 . A fastening element 100 of this type can also be called, for example, a retaining bracket 100 , fastening bracket 100 or latching hook 100 . However, it does not have to be the case here that the load-bearing cross section of the fastening element 100 according to the invention is increased significantly with respect to the prior art; this can also remain identical, for example, that is to say a previous load-bearing cross section is distributed to two retaining faces 123 , the bending moment M disappearing, however, during operation of the motor vehicle. This can be sufficient in the case of certain pairings of cooling modules 1 and radiators 2 .
According to the invention, the force F which results from the acceleration a no longer acts on the fastening element 100 on one side, but rather, in the exemplary embodiments according to the invention which are shown ( FIGS. 4 to 6 ), is distributed to two or more sides of the fastening element 100 , as a result of which a resulting mechanical stress is avoided as a rule. Furthermore, the bending moment M disappears on account of the symmetrical load according to the invention of the fastening element 100 , and this therefore brings about an additional mechanical relief of the fastening element 100 . Furthermore, the interface is likewise loaded symmetrically or more symmetrically on the side of the motor vehicle and the radiator 2 .
In the following text, the embodiments of the invention which are shown in FIGS. 4 to 6 will be explained in greater detail. In all the embodiments of the invention which are shown, the fastening element 100 is configured, in particular, integrally and laterally on the radiator frame 10 and preferably projects away from the latter in the y-direction. A protrusion in another direction, that is to say to the top/bottom or to the front/rear, and possibly an oblique protrusion are also of course possible. The fastening element 100 preferably extends away at a right angle from the radiator frame 10 . Here, a cross section of the shank 110 of the fastening element 100 is shaped in any desired manner, a square or a rectangular cross section being preferred, but it is also of course possible for a circular or elliptic and optionally a cross section composed from these shapes to be used. Here, the diameters of the shank 110 are preferably constant over its entire length as far as a head 120 at a free end of the shank 110 , the head 120 widening the shank 110 . The head 120 can also be configured, for example, as a projection 120 or foot 120 .
The head 120 of the fastening element 100 serves to latch the radiator frame 10 in an apparatus 2 (see FIG. 5 ) for fastening or hooking the cooling module 1 in the motor vehicle or a radiator 2 of the motor vehicle. For this purpose, on its inner side which lies opposite the radiator frame 10 , the head 120 has at least two retaining faces 123 or locking faces 123 which are preferably arranged substantially parallel to a relevant side of the radiator frame 10 . The retaining faces 123 are part of the latching devices 122 or the retaining lugs 122 or the shoulders 122 which are formed on the head 120 of the fastening element 100 and substantially constitute the latter. Between the respective retaining face 123 which is formed as a projection on the shank 110 and the actual radiator frame 10 , the radiator frame 10 has a recess 124 which is firstly accessible from the outside and is secondly delimited by the retaining face 123 , the shank 110 and the actual radiator frame 10 .
A mechanical attachment of the apparatus 2 for fastening the cooling module 1 or a mechanical attachment of the radiator 2 can be received within the recess 124 , which mechanical attachment is configured, for example, in FIG. 5 as a bracket which engages there. A hoop (not shown in the drawing) which reaches around the shank 110 and can optionally be closed can of course be used. In a mounted state of the cooling module 1 in the motor vehicle, the bracket, the hoop and/or some other projection of the apparatus 2 for fastening the cooling module 1 or the radiator 2 is then received in the at least two recesses 124 of the fastening element 100 and, optionally with a mechanical play, is clamped between a lateral boundary of the radiator frame 10 and the retaining faces 123 of the fastening element 100 . Here, in each case one mating face 223 for the relevant retaining face 123 is formed on the bracket, the hoop or the other kind of projection of the apparatus 2 for hooking in the cooling module 1 or the radiator 2 .
The at least two latching devices 122 or their retaining faces 123 are situated on at least two lateral regions of the shank 110 or are formed on at least two lateral regions of the fastening element 100 , that is to say the head 120 projects from the shank 110 at at least two regions. Here, the at least two latching devices 122 can be connected integrally or their retaining faces 123 can merge into one another, or the at least two latching devices 122 or their retaining faces 123 can be spaced apart from one another. Here, in the case of a round cross section, an individual lateral region covers from at least approximately 45° to over approximately 90° of a complete circumference of the shank 110 . In the case of a square or rectangular cross section of the shank 110 , the at least two latching devices 122 or their retaining faces 123 then extend analogously along two regions which in each case can be a section of a side. A region of this type is preferably exactly as long as a side of the cross section.
The embodiment of FIG. 4 shows a fastening element 100 , the head 120 of which has two retaining faces 123 which are arranged opposite one another and in each case face the radiator frame 10 . In the case of a typical and/or critical transverse acceleration a in the y-direction, the result in this embodiment, in comparison with a fastening element 100 from the prior art (see FIG. 3 ), is a halved force on an individual retaining face 123 (see F/ 2 in FIG. 4 ). Here, a mechanical stress from the tensile force F is likewise halved. Furthermore, no moment M occurs on the fastening element 100 , since the two forces F/ 2 in FIG. 4 are introduced symmetrically into the fastening element 100 or its shank 110 and therefore also the radiator frame 10 . As a result, a mechanical stress from the moment M likewise disappears.
The second embodiment (shown in FIG. 5 ) of the fastening element 100 shows a fixed bearing or a locating bearing of the radiator frame 10 on the apparatus 2 for fastening or hooking in the cooling module 1 or the radiator 2 . In the mounted position of the radiator frame 10 , an inner side, facing the radiator frame 10 , of the head 120 of the fastening element 100 , which inner side has the two retaining faces 123 , is seated on two outer mating faces 223 of the apparatus 2 for fastening the cooling module 1 or the radiator 2 . Here, the head 120 is of plate-shaped configuration, the shank 110 (which cannot be seen in FIG. 5 ) of the fastening element 100 engaging into an inner space, accessible from outside and situated between the mating faces 223 , on/in the apparatus 2 for fastening the cooling module 1 or the radiator 2 .
In order to further increase a rigidity or a load-bearing capability of the fastening element 100 , as great an overlap as possible can be aimed for between the fastening element 100 and an interface on the apparatus 2 for fastening or hooking in the cooling module 1 or the radiator 2 . That is to say, the retaining faces 123 which can be used for this purpose are to cover more than 180° here or are to be provided on the shank 110 on more than two sides. For instance, the embodiment of FIG. 6 shows a fastening element 100 , by means of which an all-round overlap is possible between the fastening element 100 of the radiator frame 10 and the interface. That is to say, in the case of the square or rectangular cross section of the shank 110 , the four retaining faces 123 which are connected among one another are situated on all four sides so as to point away from the shank 110 .
As a result, the force F which results from the acceleration a is distributed to the circumferential retaining faces 123 , which results in a homogeneous loading of the fastening element 100 . That is to say, the entire fastening element 100 is load-bearing, and not only a part thereof. The interface which is configured so as to correspond to the fastening element 100 and to its circumferential retaining faces 123 is likewise mechanically loaded more homogeneously. The resulting stresses and strains on/in the fastening element 100 and on/in the interface are likewise smaller and therefore less critical. | A radiator frame ( 10 ) for a cooling module of an internal combustion engine, having a fastening element ( 100 ) for fastening the cooling module to/on/in a radiator of the internal combustion engine, the fastening element ( 100 ) having a retaining face ( 123 ), by which the cooling module ( 1 ) can be locked in a translational and optionally a rotational direction, and an individual fastening element ( 100 ) has at least two retaining faces ( 123 ) in such a way that said fastening element ( 100 ) can be seated on mating faces at/on/in the radiator. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. provisional patent application Ser. No. 60/547,311 filed Feb. 24, 2004, the entire contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present disclosure relates to retroreflector targets which may be used in coordinate metrology for example.
[0004] 2. Discussion of the Related Art
[0005] There is a type of instrument that measures the coordinates of a point by sending a laser beam to a retroreflector target that is in contact with the point. The instrument determines the coordinates of the point by measuring the distance and the two angles to the retroreflector target. A popular type of retroreflector target comprises a cube-corner retroreflector embedded in a metal sphere, with the apex of the cube corner placed at the center of the sphere. This type of retroreflector target is commonly called a spherically mounted retroreflector (SMR). Cube-corner retroreflectors are formed of three mutually perpendicular faces. These faces may be constructed of three perpendicular mirrors (an open cube corner) or of three perpendicular surfaces of a glass prism (a solid cube corner).
SUMMARY OF THE INVENTION
[0006] An embodiment may comprise a method for adjusting a laser retroreflector to compensate for passing laser light through a window of the retroreflector comprising: determining an adjustment factor to compensate for propagation errors due to passing laser light through the window of the retroreflector; and adjusting a location of a reflection point of the retroreflector to minimize the propagation errors based on the adjustment factor.
[0007] An embodiment may comprise a laser retroflector apparatus comprising: a window for passing laser light to the retroreflector; a reflection point located on the retroreflector for reflecting the laser light after the laser light has passed through the window wherein the reflection point is located at a selected location to minimize propagation errors of the laser light due to the laser light passing through the window.
[0008] An embodiment may comprise a system for adjusting a laser retroreflector to compensate for passing laser light through a window of the retroreflector comprising means for determining an adjustment factor to compensate for propagation errors due to passing laser light through the window of the retroreflector; and means for adjusting a location of a reflection point of the retroreflector to minimize the propagation errors based on the adjustment factor.
[0009] An embodiment may comprise a one or more computer-readable media having computer-readable instructions thereon which, when executed by a computer, cause the computer to determine an adjustment factor to compensate for propagation errors due to passing laser light through a window of a retroreflector; and determine a location of a reflection point of the retroreflector to minimize the propagation errors based on the adjustment factor.
BRIEF DESCRIPTION OF THE FIGURES
[0010] Embodiments will now be described, by way of example only, with reference to the accompanying drawings which are meant to be exemplary, not limiting, and wherein like elements are numbered alike in several Figures, in which:
[0011] FIG. 1 ( a ) is a prior art retroreflector.
[0012] FIG. 1 ( b ) is a perspective view of an embodiment of a retroreflector.
[0013] FIG. 1 ( c ) is a cut away view of the retroreflector of FIG. 1 ( b ).
[0014] FIG. 2 ( a ) is diagram of a retroreflector.
[0015] FIG. 2 ( b ) is a diagram of a retroreflector having a window.
[0016] FIG. 3 is graph of radial error verses angle A 1 .
[0017] FIG. 4 is graph of transverse error verses angle A 1 .
[0018] FIG. 5 is graph of radial error verses angle A 1 .
[0019] FIG. 6 is graph of transverse error verses angle A 1 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] The exemplary embodiment may be implemented as any type of open cube-corner retroreflector, of which the spherically mounted retroreflector (SMR) is one example. In many factory environments where metrology measurements are made, large amounts of particulate matter are thrown into the air as a result of machining or other work activities. This matter can coat the glass surfaces of the cube corner or collect in the edges between the glass surfaces. When sufficient material builds up, the laser light beam incident on the retroreflector may reflect with diminished power or with a distorted wave front. The glass surfaces of the cube-corner can be cleaned. However, if the cleaning is done improperly, the glass surfaces may be scratched. In some cases, it may be difficult to clean the matter that accumulates in the vertex where adjacent glass panels meet. The present disclosure reduces these difficulties by placing a flat glass window over the retroreflector. The flat window can be cleaned quickly with a minimum of effort and is readily replaceable if damaged. This increases the likelihood that the retroreflector can be kept clean and thereby reduces the likelihood of a measurement error caused by a dirty retroreflector.
[0021] There are some potential problems that may result from placing a glass window over a cube-corner retroreflector. However, these errors can be minimized with proper design of the retroreflector assembly. These design techniques are discussed below.
[0022] FIG. 1 ( a ) shows a perspective view of the traditional SMR 10 . It comprises the open cube-corner retroreflector 11 , sphere 12 , and lip 13 . The point where the three perpendicular mirror surfaces intersect is referred to as the apex 33 of the cube-corner. In the traditional SMR 10 , the apex 33 is placed as nearly as possible at the center of the sphere 12 . The lip 13 provides protection for the cube-corner retroreflector 11 . It also provides a convenient handhold for the operator.
[0023] The protected SMR is shown in FIG. 1 ( b ) in perspective view and in FIG. 1 ( c ) in sectional view. It comprises the modified SMR body 25 and the protective cover 30 . The modified SMR body 25 comprises the open cube-corner retroreflector 11 , sphere 12 , and lip 13 as in the traditional SMR 10 . However, in the modified SMR body, the apex 33 of the cube corner is shifted away from the center of the sphere for reasons that are explained below. The protective cover 30 comprises the window 31 and the window holder 32 .
[0024] FIG. 2 ( a ) shows a schematic representation of the open cube-corner retroreflector 11 that is a part of the traditional SMR 10 . The incoming laser beam 40 enters the open cube-corner retroreflector 11 at an angle A 1 with respect to the axis of symmetry 41 . It strikes the apex 33 of the cube corner, reflects off the three perpendicular mirrors of the cube corner, and retraces the beam path back out of the retroreflector.
[0025] FIG. 2 ( b ) shows the schematic representation of the open cube-corner retroreflector 11 and the window 31 that are a part of the protected SMR 20 . The thickness T of the window is exaggerated in the figure to show the bending of the light within the glass more clearly. Laser beam 40 enters the window 31 at an angle A 1 with respect to the axis of symmetry 41 . When the laser beam 40 enters the window 31 , it bends inward toward the normal of the window surface. When it has passed through the window and reaches the air, it bends outward away from the normal, back to the original angle A 1 . The path 42 that the laser light would have taken if the window were not present is indicated as a dashed line. When the window 31 is present, the path 40 of the laser beam with the window does not coincide with the path 42 of the laser beam without the window.
[0026] The intersection 43 of the axis of symmetry 41 with the path 42 is marked with an “X.” This point should be kept near at the center of the sphere. This ensures that the tracker measures the same point in space regardless of the orientation of the SMR (i.e., the angle A 1 ). To get the best performance, the apex 33 of the cube corner should be adjusted away from the sphere center, as shown in FIG. 2 ( b ). If the angle A 1 is small, then to a good approximation d=T(1−1/n), where T is the thickness of the window and n is the index of refraction of the window.
[0027] The optimal design for the protected SMR 20 is achieved by adjusting the cube-corner 11 within the sphere 12 to minimize the errors in measured radial and transverse distances. Radial distance is measured along the radial direction, which is the direction from the measurement instrument to the SMR. Transverse distance is measured along a plane that is located at the SMR and is perpendicular to the radial direction. The radial error ΔR for the protected SMR is
Δ R= 2 [nT /cos( A 2 )+ H /cos( A 1 )−( nT+H+L )]. (1)
[0028] The distance L is shown in FIG. 2 ( b ). To find L, draw an arc from point 43 to point G where the laser beam 40 intersects window 31 . Find point F where the arc intersects the normal line 41 . The distance from point F to the window is
L =( T+H−d )/cos( A 1 )−( T+H−d ). (2)
[0029] The optical path length from apex 33 to point F is nT+H+L, which is the final term in equation 1. The round trip optical path length is twice this amount, which accounts for the factor of 2 at the front of equation 1. The optical path length from apex 33 to point G is nT/cos(A 2 )+H/cos(A 1 ). These terms are also found in equation 1. If the window 31 caused no error in the radial measurement, the optical path length from point 33 to G would be the same as from point 33 to F, and the radial error AR in equation 1 would be zero. By selecting the depth d of the apex 33 in relation to the sphere center, the distance L and the corresponding error ΔR in equation 1 can be made to vary. By proper selection of the distance d, the error ΔR can be minimized.
[0030] The transverse error ΔD for the protected SMR is
Δ D=T sin( A 1 −A 2 )/cos( A 2 )− d sin( A 1 ). (3)
The first term in equation (3) represents the bending of the laser beam 40 by the glass window 31 away from the axis of symmetry 41 . The second term represents travel toward the axis of symmetry 41 as a result of the laser beam traveling past point 43 and on to point 33 . The second term in equation (3) tends to cancel the first term. By proper selection of the distance d, the size of the second term can be adjusted to minimize the error ΔD.
[0031] For a given angle A 1 , a particular value of d minimizes radial error and a different value minimizes transverse error. The optimum depth d also changes with the angle A 1 . A graphical approach is helpful in selecting the optimum depth d over a range of angles. For example, suppose that a protected SMR has the following characteristics: T=1 mm, H=21 mm, n=1.5. The clear aperture of the window holder 32 determines the range of possible angles A 1 . In this example, assume that A 1 can vary from 0 and 25 degrees (i.e., a full angle of 50 degrees). By using equations (1), (2), and (3) and Snell's law, sin(A 1 )=n sin(A 2 ), the radial and transverse errors can be found as a function of angle A 1 for different depths d. The depth d is conveniently given in terms of the adjustment factor k:
d=T (1−1/ n ) k. (4)
The optimum adjustment factor k is close to 1 for small angles and is larger for larger angles.
[0032] FIGS. 3 and 4 show the results for the radial and transverse errors, respectively. From the graphs, it can be seen that k=1.09 gives a maximum radial and transverse error of less than 5 micrometers. This is close to the optimum value since it gives a smaller maximum error than either k=1.07 or k=1.11. The corresponding depth d is found from equation (4) to be 0.363 millimeter.
[0033] In another preferred embodiment, T=1 mm, n=1.51509, k=1.0908, and d=0.3708 mm.
[0034] The improvement in the radial and transverse accuracy is shown in FIGS. 5 and 6 . For these figures, the apex 33 is at the center of the sphere 12 as in the traditional SMR 10 . This is the case k=0. FIGS. 5 and 6 show the maximum radial and transverse errors to be approximately 80 and 155 micrometers, respectively. By optimizing the depth d of the apex 33 , the maximum errors have been reduced by more than an order of magnitude.
[0035] The capabilities of the present invention may be implemented in software, firmware, hardware or some combination thereof. As one example, one or more aspects of the present invention can be included in an article of manufacture (e.g., one or more computer program products) having, for instance, computer usable media. The media has embodied therein, for instance, computer readable program code means for providing and facilitating the capabilities of the present invention. The article of manufacture can be included as a part of a computer system or sold separately.
[0036] Additionally, at least one program storage device readable by a machine, tangibly embodying at least one program of instructions executable by the machine to perform the capabilities of the present invention can be provided.
[0037] It will be apparent to those skilled in the art that various modifications and variations can be made to the cube-corner retroreflector covered by window without departing from the spirit or scope of the invention. | Embodiments may comprise methods, apparatuses, systems, and one or more computer-readable media having computer-readable instructions thereon for adjusting a laser retroreflector to compensate for passing laser light through a window of the retroreflector comprising: determining an adjustment factor to compensate for propagation errors due to passing laser light through the window of the retroreflector; and adjusting a location of a reflection point of the retroreflector to minimize the propagation errors based on the adjustment factor. | 6 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation-in-part of co-pending U.S. patent application Ser. No. 11/746,411, filed May 9, 2007, which is herein incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention is generally related design structures, and more specifically, design structures in the field of dynamic random access memory (DRAM) control and more particularly to DRAM paging.
[0004] 2. Description of the Related Art
[0005] The memory controller provides the control logic to orchestrate the movement of data to and from dynamic random access memory (DRAM). In operation, a read command can be issued to a DRAM in order to move a fixed amount of data from the DRAM to a requesting device such as a processor cache in a central processing unit (CPU). In response, a sequence of control signals can move the requested data from the DRAM device to the memory controller and eventually to the requesting hardware. In the course of retrieving the requested data, a chip select signal can select an appropriate DRAM from amongst a set of DRAMs, the selected DRAM being referred to as a “rank”.
[0006] Thereafter, a bank address signal can select the correct array in the selected DRAM, known as a “bank”, as required to satisfy the data request. Finally, an activate signal also referred to as a row access strobe or RAS signal can select a row in the appropriate bank. Notably, the activate signal connects the correct row of bits in the bank to sense amplifiers. The sense amplifiers, in turn, can latch an entire row of bits from the analog domain in the bank into the digital domain. This resulting row of bits is referred to as a “page” of physical memory.
[0007] After a threshold number of DRAM cycles the memory controller can send “read”, “write”, “read with auto pre-charge” or “write with auto pre-charge” signals to the DRAM. These signals either read from a certain portion of the sense amplifiers or write to a certain portion of the sense amplifiers, usually filling a cache line worth of bytes. The auto pre-charge signal, if specified with the read or write command can cause the sense amplifiers to lose latched data after the read or the write operation completes. This has been referred to in the art as “closing” the page or “pre-charging” the bank. In the event that the auto pre-charge signal has not been implicitly requested at the time of the read or the write command, then the pre-charge signal must be explicitly sent by the memory controller to the DRAM devices. Otherwise, the page will remain “open” until the next refresh cycle which will cause the bank to become pre-charged.
[0008] Refreshes are known to be relatively infrequent compared to the request rate, and therefore leaving the page open can be beneficial if there is reason to believe that the next access to the same bank will also be to the same page. Leaving the page open necessarily requires maintaining the charge on the sense amplifiers until explicitly removed by a pre-charge signal at a later time. A pre-charge signal eventually will be required if a different row in the DRAM array is to be read. In this circumstance, the content of the different row must be moved to the sense amplifiers, prior to which a pre-charge operation will be required.
[0009] Micro-architecture designers at design time select one of two modes of computing for a memory controller in a microprocessor system depending upon the nature of the applications expected for operation in the system. Specifically, the modes include an open page mode and a closed page mode. In the open page mode, the memory controller leaves data brought into the sense amplifiers as is after an initial read or write operation. This allows a faster access to the same “page” of data, the next time a read or a write request to the same page is received in the memory controller. Referred to as a “page hit”, such reuse of data in a page is usually expected when there is only one thread of execution running in the CPU at a given time and the data accesses made by that thread are relatively sequential in nature.
[0010] In the closed page mode, by comparison, the memory controller can close the page after handling a read or write command. Consequently, there can never be a “page miss” arising where a page in a bank is open, when a different page in the same bank is required to be opened. A page miss causes a longer delay than a permissible “page idle” condition where no page was open at the outset. In the page miss condition, the open page first must be closed, e.g. pre-charged. Only then can the correct page be opened or activated and a read or write can initiate. While a “page miss” can occur in a memory controller operating in an open page mode, in the closed page mode only “page idles” can occur. As such, memory latency can be better predicted. Accordingly, a closed page mode can be effective in supporting applications having a highly random access pattern with multiple threads of execution sharing a memory controller.
[0011] Notwithstanding, processors exist that intend to support both applications with highly randomized access and applications with sequential access to data in memory. The anticipated applications can run under both types of thread scenarios, sometimes running only one thread of execution and sometimes running multiple threads from multiple users. In the past, memory controller designs allowed moving the memory controller from open page mode to closed page mode depending upon an observed memory access pattern. When detecting changes in access patterns, the memory controller can switch to a closed page mode to reduce page misses or to an open page mode to capitalize upon page hits.
[0012] There are, however, applications that experience both access patterns during different program phases. In search applications, for instance, the same thread of execution jumps seemingly randomly across a large database based upon a search key, and upon locating the key, the execution changes in character to a sequential access pattern for a significant number of accesses. After some time, the execution of the application again changes to random access and so on. With many threads of such an application running, a properly configured memory controller must identify or designate the overall system access as sequential or random, even at a given instant in time.
BRIEF SUMMARY OF THE INVENTION
[0013] Embodiments of the present invention address deficiencies of the art in respect to memory management and provide a novel and non-obvious method, system and computer program product for dynamic optimization of DRAM controller page policy. In one embodiment of the invention, a memory module can include multiple different memories, each including a memory controller coupled to a memory array of memory pages. Each of the memory pages in turn can include a corresponding locality tendency state. A memory bank can be coupled to a sense amplifier and configured to latch selected ones of the memory pages responsive to the memory controller. Finally, the module can include open page policy management logic coupled to the memory controller.
[0014] The logic can include program code enabled to granularly change open page policy management of the memory bank responsive to identifying a locality tendency state for a page loaded in the memory bank. In this regard, the program code can perform a memory management method including identifying a locality tendency state for an existing memory page in a memory bank for a memory array, receiving a memory request for the memory bank, transitioning the locality tendency state responsive to determining either a page hit or a page miss for the memory request, storing the transitioned locality tendency state in association with the existing memory page in the memory array, and closing the memory page in response to a page miss, but leaving open the memory page in response to a page hit.
[0015] The method additionally can include further receiving a memory request for a memory page in the memory array, loading the memory page and an associated locality tendency state for the memory page in the memory bank and accessing the memory page in the memory bank. In response to determining the associated locality tendency state to be a closed state, the memory page can be closed subsequent to accessing the memory page, but otherwise the memory page can be left open in the memory bank and the locality tendency state can be transitioned to a weakly opened state if another request for the memory page is pending, or if the memory page had immediately previously been opened and then closed in the memory bank. By comparison, in response to determining the locality tendency state to be a weakly opened state, the locality tendency state can be transitioned to an open state and leaving the existing memory page open in the memory bank. Finally, in response to determining the locality tendency state to be an open state, the locality tendency state can be transitioned to a strongly opened state and leaving the existing memory page open in the memory bank.
[0016] In another embodiment, a design structure embodied in a machine readable storage medium for at least one of designing, manufacturing, and testing a design is provided. The design structure generally includes a memory module. The memory module generally includes a plurality of memories. Each memory generally includes a memory controller coupled to a memory array of memory pages, and each of the memory pages generally includes a corresponding locality tendency state. The memory module further includes a memory bank coupled to a sense amplifier and configured to latch selected ones of the memory pages responsive to the memory controller, and open page policy management logic coupled to the memory controller, the logic comprising program code enabled to granularly change open page policy management of the memory bank responsive to identifying a locality tendency state for a page loaded in the memory bank.
[0017] Additional aspects of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The aspects of the invention will be realized and attained by means of the elements and combinations particularly pointed out in the appended claims. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention, as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The accompanying drawings, which are incorporated in and constitute part of this specification, illustrate embodiments of the invention and together with the description, serve to explain the principles of the invention. The embodiments illustrated herein are presently preferred, it being understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown, wherein:
[0019] FIG. 1 is a schematic illustration of a memory management data processing system configured for dynamic optimization of DRAM controller page policy; and,
[0020] FIG. 2 is a state diagram illustrating a process for dynamic optimization of DRAM controller page policy.
[0021] FIG. 3 is a flow diagram of a design process used in semiconductor design, manufacture, and/or test.
DETAILED DESCRIPTION OF THE INVENTION
[0022] Embodiments of the present invention provide a method, system and computer program product for dynamic optimization of DRAM controller page policy. In accordance with an embodiment of the present invention, a state can be assigned to each page opened in a bank managed by a memory controller in a memory module. The state can change for each page depending upon whether a page hit or page miss condition arises in the managing memory controller. Thereafter, the state can transition and the page can be closed or remain open as dictated by the state and rules for leaving open or closing pages having particular ones of the states. In this way, the controller page policy can be granularly tuned according to dynamic conditions sensed for the pages of the bank.
[0023] In further illustration, FIG. 1 is a schematic illustration of a memory management data processing system configured for dynamic optimization of DRAM controller page policy. The memory management data processing system can include a memory module 100 including one or more memories 110 , such as DRAMs. Each of the memories 110 can include a set of memory arrays 160 and corresponding sense amplifiers 170 . Address decoding logic 150 further can be provided to receive a row select instruction 150 A and a column select instruction 150 B to retrieve a page of data from a specified one of the memory arrays 160 into a corresponding one of sense amplifiers 170 .
[0024] A memory controller 120 can be configured to manage the movement of data to and from the memory 110 of the memory module 100 . In this regard, data latched in the sense amplifiers 170 further can be shepherded into a data-in buffer 140 A by the memory controller 120 for processing a read operation from the memory module 100 , or into a data-out buffer 140 B by the memory controller 120 for processing a write operation in the memory module 100 . Importantly, whether or not a pre-charge signal is provided subsequent to latching a page in the sense amplifiers 170 and the choice of address hashing scheme utilized during read and write operations can depend on the page policy applied by the memory controller 120 .
[0025] In this regard, open page policy manager 130 can be coupled to the memory controller 120 and can alternately provide for degrees of an open page mode in performing read operations, and write operations in the memory 110 depending upon a tendency of locality detected for a given page of memory. The tendency can be recorded in a locality tendency state 180 B applied to a page 180 A in a bank 180 latched by a corresponding one of the sense amplifiers 170 . Specifically, the locality tendency state 180 B can range from an open state, a weakly open state, a strongly open state and a closed state, and the locality tendency state 180 B can transition from state to state depending upon the occurrence of a page hit or a page miss. In addition, a last page record 180 C can be provided for the bank to indicate a last page opened and then closed in the bank 180 . Notably, when the a page 180 A is written back to a respective one of the memory arrays 160 , the locality tendency state 180 B also can be written back in association with the page 180 A. Consequently, pages 190 in each of the memory arrays 160 can include not only individual pages 190 A of memory, but also corresponding locality tendency states 190 B.
[0026] In operation, when a data request is received in the memory controller 120 , both the requested page 190 A and its corresponding locality tendency state 190 B can be latched into bank 180 as page 180 A and locality tendency state 180 B by a corresponding one of the sense amplifiers 170 . The locality tendency state 180 B can be updated depending upon whether a page hit or page miss has occurred. The locality tendency state 180 B can range from open, to strongly open, to weakly open, to closed. In the open state, if a page hit is generated on an open page 180 A, a strongly open state will result indicating a potential locality of access within the page 180 A that could be exploited by leaving the page 180 A in an open state. In contrast, in the open state if a page miss is generated, a weakly open state can result and the page 180 A can be closed. In the strongly open state, a page hit does not change the locality tendency state 180 B, though a page miss reduces the locality tendency state 180 B to an open state while the page 180 A is closed.
[0027] By comparison, in a weakly open state—the default locality tendency state for a page 180 A—the page 180 A remains open until a page request is received for the bank 180 . Thereafter, a page hit results in a transition to the open state while a page miss results in a transition to the closed state and the closing of the page 180 A. Finally, in a closed state, a page 180 A will be closed immediately after the first access to the page 180 A. In the unlikely event of a page miss, the locality tendency state 180 B of the page 180 A will remain closed, while a page hit will result in a transition to the weakly open state only if additional requests to the request are detected by the open page policy manager 130 in a request queue, or if the page 180 A had previously been opened as indicated by the last page record 180 C for the bank 180 .
[0028] In yet further illustration, FIG. 2 is a state diagram illustrating a process for dynamic optimization of DRAM controller page policy. As shown in FIG. 2 , an initial state of weakly opened 230 can be assigned to a page latched in a memory bank. A page hit promotes the latched page to a state of open 220 , while a page miss demotes the page into a state of closed 240 . In the former circumstance, the page can remain open while in the latter circumstance the page can be closed. When in the state of open 220 , a page hit results in a transition to the state of strongly opened 210 , while a page miss results in a demotion to a state of weakly opened 230 . In the former circumstance, the page can remain open, while in the latter circumstance the page can be closed.
[0029] In the state of strongly opened 210 , a page hit results in no transition and a page miss results in a transition to the state of open 220 . In the former circumstance, the page can remain open, while in the latter circumstance the page can be closed. Finally, in the state of closed 240 , a page miss results in no state transition. However, a page hit unto itself also results in no state transition. Rather, a state transition to the state of weakly opened 230 only arises where a page hit occurs whilst an additional page request for the page exists in a request cache for the memory controller. Alternatively, a state transition to the state of weakly opened 230 can arise where a page hit occurs on a page that had immediately previously been opened.
[0030] The persistence of an indication of locality tendency for each page provides the ability for the memory controller to granularly control the open page policy for memory paging. Whereas conventional memory controllers are configured statically as open page mode controllers or closed page mode controllers, the consideration of locality tendency and the support of the state machine transitioning to different states of locality tendency permit a finer management of open page mode memory control.
[0031] FIG. 3 shows a block diagram of an exemplary design flow 300 used for example, in semiconductor design, manufacturing, and/or test. Design flow 300 may vary depending on the type of IC being designed. For example, a design flow 300 for building an application specific IC (ASIC) may differ from a design flow 300 for designing a standard component. Design structure 320 is preferably an input to a design process 310 and may come from an IP provider, a core developer, or other design company or may be generated by the operator of the design flow, or from other sources. Design structure 320 comprises the circuit described above and shown in FIG. 1 in the form of schematics or HDL, a hardware-description language (e.g., Verilog, VHDL, C, etc.). Design structure 320 may be contained on one or more machine readable medium. For example, design structure 320 may be a text file or a graphical representation of a circuit as described above and shown in FIG. 1 . Design process 310 preferably synthesizes (or translates) the circuit described above and shown in FIG. 1 into a netlist 380 , where netlist 380 is, for example, a list of wires, transistors, logic gates, control circuits, I/O, models, etc. that describes the connections to other elements and circuits in an integrated circuit design and recorded on at least one of machine readable medium. For example, the medium may be a storage medium such as a CD, a compact flash, other flash memory, or a hard-disk drive. The medium may also be a packet of data to be sent via the Internet, or other networking suitable means. The synthesis may be an iterative process in which netlist 380 is resynthesized one or more times depending on design specifications and parameters for the circuit.
[0032] Design process 310 may include using a variety of inputs; for example, inputs from library elements 330 which may house a set of commonly used elements, circuits, and devices, including models, layouts, and symbolic representations, for a given manufacturing technology (e.g., different technology nodes, 32 nm, 45 nm, 90 nm, etc.), design specifications 340 , characterization data 350 , verification data 360 , design rules 370 , and test data files 385 (which may include test patterns and other testing information). Design process 310 may further include, for example, standard circuit design processes such as timing analysis, verification, design rule checking, place and route operations, etc. One of ordinary skill in the art of integrated circuit design can appreciate the extent of possible electronic design automation tools and applications used in design process 310 without deviating from the scope and spirit of the invention. The design structure of the invention is not limited to any specific design flow.
[0033] Design process 310 preferably translates a circuit as described above and shown in FIG. 1 , along with any additional integrated circuit design or data (if applicable), into a second design structure 390 . Design structure 390 resides on a storage medium in a data format used for the exchange of layout data of integrated circuits (e.g. information stored in a GDSII (GDS2), GL1, OASIS, or any other suitable format for storing such design structures). Design structure 390 may comprise information such as, for example, test data files, design content files, manufacturing data, layout parameters, wires, levels of metal, vias, shapes, data for routing through the manufacturing line, and any other data required by a semiconductor manufacturer to produce a circuit as described above and shown in FIG. 1 . Design structure 390 may then proceed to a stage 395 where, for example, design structure 390 : proceeds to tape-out, is released to manufacturing, is released to a mask house, is sent to another design house, is sent back to the customer, etc.
[0034] Embodiments of the invention can take the form of an entirely hardware embodiment, an entirely software embodiment or an embodiment containing both hardware and software elements. In a preferred embodiment, the invention is implemented in software, which includes but is not limited to firmware, resident software, microcode, and the like. Furthermore, the invention can take the form of a computer program product accessible from a computer-usable or computer-readable medium providing program code for use by or in connection with a computer or any instruction execution system.
[0035] For the purposes of this description, a computer-usable or computer readable medium can be any apparatus that can contain, store, communicate, propagate, or transport the program for use by or in connection with the instruction execution system, apparatus, or device. The medium can be an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system (or apparatus or device) or a propagation medium. Examples of a computer-readable medium include a semiconductor or solid state memory, magnetic tape, a removable computer diskette, a random access memory (RAM), a read-only memory (ROM), a rigid magnetic disk and an optical disk. Current examples of optical disks include compact disk-read only memory (CD-ROM), compact disk-read/write (CD-R/W) and DVD.
[0036] A data processing system suitable for storing and/or executing program code will include at least one processor coupled directly or indirectly to memory elements through a system bus. The memory elements can include local memory employed during actual execution of the program code, bulk storage, and cache memories which provide temporary storage of at least some program code in order to reduce the number of times code must be retrieved from bulk storage during execution. Input/output or I/O devices (including but not limited to keyboards, displays, pointing devices, etc.) can be coupled to the system either directly or through intervening I/O controllers. Network adapters may also be coupled to the system to enable the data processing system to become coupled to other data processing systems or remote printers or storage devices through intervening private or public networks. Modems, cable modem and Ethernet cards are just a few of the currently available types of network adapters. | A design structure embodied in a machine readable storage medium for designing, manufacturing, and/or testing a design for dynamic optimization of DRAM controller page policy is provided. The design structure can include a memory module, which can include multiple different memories, each including a memory controller coupled to a memory array of memory pages. Each of the memory pages in turn can include a corresponding locality tendency state. A memory bank can be coupled to a sense amplifier and configured to latch selected ones of the memory pages responsive to the memory controller. Finally, the module can include open page policy management logic coupled to the memory controller. The logic can include program code enabled to granularly change open page policy management of the memory bank responsive to identifying a locality tendency state for a page loaded in the memory bank. | 6 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates generally to television and multimedia devices, and more particularly to a method, apparatus, and system for user based control of video display aspect ratios in response to a channel or input selection.
[0003] 2. Description of the Related Art
[0004] Digital television (DTV) is a telecommunication system for broadcasting and receiving moving pictures and sound by means of a digital signal, in contrast to an analog signal used by analog (traditional) standard definition TV (SDTV). DTV utilizes the digital modulation of analog signal data, which is digitally compressed prior to recording or broadcast. The digitally compressed signal requires decoding by a specially designed receiver within a television set, or a standard receiver with a set-top box, or a PC fitted with a television card. Digital television has several advantages over traditional analog TV, the most significant being that digital channels take up less bandwidth space. The reduced bandwidth of a digital broadcast signal enables digital broadcasters to provide more digital channels in the same space, provide High-Definition (HD) digital service, or provide other non-television services such as pay-multimedia services or interactive services. Digital television also permits special services such as multicasting (more than one program on the same channel), electronic program guides, and program identification.
[0005] In addition, the transition from National Television System Committee (NTSC) SDTV to Advanced Television Systems Committee (ATSC) high definition broadcasting has introduced programming available in widescreen 16:9 aspect ratios versus the traditional 4:3 aspect ratio. Aspect ratio is the measure of an image's width (w) to its height (h) and is generally expressed as (w:h).
[0006] Widescreen television and video display monitors are currently among the most popular components of home entertainment systems. Widescreen monitors are capable of displaying different formats of video broadcasts, particularly “high-definition” (HDTV) signals of extremely clear picture quality. HDTV channels conform to international standards of broadcast transmission of 720 or 1080 scan lines, and generally have a default aspect ratio of 16:9. The 16:9 aspect ratio is the default screen size when a HD channel is selected, and the picture typically fills the entire widescreen. Widescreen displays are also capable of showing standard-definition television (SDTV) in the traditional aspect ratio of 12:9 (4:3). However, the 12:9 aspect ratio does not fill the entire widescreen display of 16:9.
[0007] The Federal Communications Commission (FCC), the branch of the United States (U.S.) government that regulates the television and radio broadcast industries, has mandated that all U.S. television broadcasts will be exclusively digital as of Feb. 17, 2009. Furthermore, as of Mar. 1, 2007, all new television sets that can receive signals over-the-air, including pocket-sized portable televisions, must include digital or HDTV tuners so they can receive digital broadcasts.
SUMMARY OF THE INVENTION
[0008] Embodiments of the present invention include a method, article, and system for viewer based control of video display aspect ratios, the method includes: applying an initial video display aspect ratio to a selected signal source; determining if the selected signal source has a viewer assigned video display aspect ratio; modifying the initial video display aspect ratio of the selected signal source in response to the viewer assigned video display aspect ratio; wherein the viewer assigned video display aspect ratio is a subset of one or more of the viewer assigned video display aspect ratios that are stored in a non-volatile memory medium; wherein the one or more viewer assigned video display aspect ratios are each individually associated with a signal source; and wherein a viewer assigned video display aspect ratio is retrieved from the non-volatile memory medium in response to the selection of an associated signal source.
[0009] An article comprising one or more computer-readable storage media containing instructions that when executed by a computer enables viewer based control of video display aspect ratios; wherein the method further includes: applying an initial video display aspect ratio to a selected signal source; determining if the selected signal source has a viewer assigned video display aspect ratio; modifying the initial video display aspect ratio of the selected signal source in response to the viewer assigned video display aspect ratio; wherein the viewer assigned video display aspect ratio is a subset of one or more of the viewer assigned video display aspect ratios that are stored in a non-volatile memory medium; wherein the one or more viewer assigned video display aspect ratios are each individually associated with a signal source; and wherein a viewer assigned video display aspect ratio is retrieved from the non-volatile memory medium in response to the selection of an associated signal source.
[0010] A system configured for viewer based control of video display aspect ratios, the system includes: a video display configured for showing multiple aspect ratios and a graphical user interface; control logic electrically connected to a non-volatile storage medium; wherein the control logic is configured to: apply an initial video display aspect ratio to a selected signal source; determine if the selected signal source has a viewer assigned video display aspect ratio; modify the initial video display aspect ratio of the selected signal source in response to the viewer assigned video display aspect ratio; wherein the viewer assigned video display aspect ratio is a subset of one or more of the viewer assigned video display aspect ratios that are stored in the non-volatile storage medium; wherein the one or more viewer assigned video display aspect ratios are each individually associated with a signal source; and wherein a viewer assigned video display aspect ratio is retrieved from the non-volatile storage medium in response to the selection of an associated signal source.
TECHNICAL EFFECTS
[0011] As a result of the summarized invention, a solution is technically achieved for a method, article, and system for user based control of video display aspect ratios in response to a channel or input selection.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The subject matter that is regarded as the invention is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other objects, features, and advantages of the invention are apparent from the following detailed description taken in conjunction with the accompanying drawings in which:
[0013] FIG. 1 illustrates an exemplary system for implementing an embodiment of the invention.
[0014] FIG. 2 is a flowchart illustrating the selection of viewer defined display aspect ratios based on predefined parameters in a non-volatile database according to embodiments of the invention.
[0015] The detailed description explains the preferred embodiments of the invention, together with advantages and features, by way of example with reference to the drawings.
DETAILED DESCRIPTION
[0016] Embodiments of the invention provide a method, article, and system for user based control of video display aspect ratios in response to a channel or input selection. When a widescreen display is receiving an SDTV channel, a typical initial display arrangement is for the 4:3 aspect ratio SDTV picture to be centered in the widescreen display with vertical side bars of a neutral color (sometimes called “pillarbox” display) on either side of the SDTV picture. Each side bar is 12.5% of the total horizontal width of the widescreen display. From this initial configuration, various user-selectable display options are available from an on-screen menu, accessible using the remote control. These options include the capability of stretching the 4:3 aspect ratio picture to fill the 16:9 display, or zooming in on the picture in its original aspect ratio, cutting off horizontal sections of the picture at the top and bottom to extend the SDTV picture to the full width of the display. However, with current widescreen display units these selected display options are in effect only for the time the channel is displayed. If another channel is selected, followed by a return to the original channel, the selected display modifications are lost. In addition, when the widescreen display units are turned off, the user settings for the aspect ratios are lost, and have to be reset the next time the user turns on the set.
[0017] Similarly, traditional SDTV and analog television displays supporting the aspect ratio of 4:3 are unable to display a 16:9 aspect ratio without either some loss of picture along the excess length of either side, or the need to display the entire 16:9 aspect ratio signal in what is familiarly known as the “letterbox” format, featuring horizontal bars at the top and bottom of the display, each bar representing 12.5% of the total available vertical height of the display. In addition, some traditional-sized display units provide the ability to adjust display parameters to either vertically stretch the picture to expand to the total height of the standard screen, or to zoom in on the picture, sacrificing vertical strips on either side of the picture to preserve the original aspect ratio of the widescreen picture. Another technique available is known as “anamorphic widescreen adjustment,” a video encoding technique used to optimize the vertical picture resolution of widescreen images by squeezing the images horizontally into a 4:3 native aspect ratio suitable for viewing on standard size television displays. Again, as is the case with widescreen display units, any modifications made to the display parameters of a particular channel on a current SDTV are lost as soon as the channel is changed, or if the television is powered off.
[0018] Embodiments of the invention provide a viewer with the ability to specify aspect ratio display parameters for particular channels and inputs, and to have these parameters remain in effect while other channels or inputs are selected. Embodiments of the invention store user specified aspect ratio settings for individual channels and monitor inputs in a database that is stored in a non-volatile memory. The non-volatile database of display settings remains in effect even when the television is powered off.
[0019] Embodiments of the invention may consist of a logic chip or processor chip coupled to non-volatile memory embedded in a channel tuner of a set top box for over the air signals, cable, or satellite reception. Alternatively, the processor and non-volatile memory for carrying out embodiments of the invention may be integrated with a built-in tuner and input selector of a display unit. User defined parameters for selected channels and inputs are stored in a database held in the non-volatile memory, and the processor contains programming code to facilitate the selection of display aspect ratios based on the user defined parameters. In embodiments of the invention an on screen graphical user interface (GUI) may be implemented to facilitate the selection and setting of user defined display aspect ratios. Subsequently, whenever the particular channel is chosen, the saved user defined display parameters will be applied to the display, overriding the factory-specified default display modes corresponding to the detected type of signal received (HDTV vs. SDTV, and other foreign standards).
[0020] FIG. 1 illustrates an exemplary system 100 for implementing an embodiment of the invention. The system 100 may be part of a set top box, or directly integrated into a display housing. A viewer enters display aspect ratios for individual channels and video inputs utilizing a GUI 104 . The GUI 104 may be displayed on the viewing screen 112 , and accept commands via a remote control device 102 . The GUI 104 interacts with the control logic 106 for deriving available control options including the choices for available display aspect ratios. The control logic 106 may be in the form of firmware, an integrated circuit, or a combination thereof. The control logic 106 interacts with a non-volatile storage medium 108 to store and retrieve viewer parameters that have been entered with the GUI 104 . The non-volatile storage medium 108 may take different forms including magnetic storage, or flash memory. The flash memory may be in the form of insertable memory sticks or may be integrated with the control logic 106 . The control logic 106 provides instructions to a video processor to control the video on the multi-format display 112 . The multi-format display 112 is configured for presenting the various aspect ratios per the stored viewer parameters, default parameters, or an aspect ratio as determined by the broadcaster or the signal source.
[0021] FIG. 2 is a flowchart illustrating the selection of viewer defined display aspect ratios based on predefined parameters in a non-volatile database according to embodiments of the invention. The selection of an aspect ratio starts with the viewer turning on the display monitor, which in this example is a TV (block 200 ). If the TV can not change aspect ratios (decision block 202 is No), the predefined aspect ratio for the TV is displayed and normal TV viewing occurs (block 204 ). However, if the TV is configured to display multiple aspect ratio sizes (decision block 202 is Yes), and the viewer tunes to a desired channel or input from an external video source, for example a DVD player or other player of pre-recorded video content (both are hereafter referred to in combination as a video source) (block 206 ), the video source is initially displayed to a factory default aspect ratio setting (block 208 ). In response to the selected video source, the TV control logic then determines if the viewer has defined an aspect ratio for the selected video source (decision block 210 ). If the viewer has not defined an aspect ratio for the video source (decision block 210 is No), the predefined aspect ratio for the TV is displayed and normal TV viewing occurs (block 212 ).
[0022] Continuing with the example embodiment of FIG. 2 , if the viewer has defined an aspect ratio for the video source (decision block 210 is Yes), the control logic reads the display parameters from a table (block 214 ) stored in non-volatile storage 216 , and sets the display aspect ratio to the viewers customized source setting (block 218 ). If certain content, such as sports, movies, or news, has a user defined aspect ratio in the table (decision block 220 is Yes), the control logic reads the display parameters from a table (block 222 ) stored in non-volatile storage 216 , and sets the display aspect ratio to the viewers customized content setting (block 224 ). TV viewing then proceeds with the customized screen display aspect ratio settings (block 226 ).
[0023] The capabilities of the present invention can be implemented in software, firmware, hardware or some combination thereof.
[0024] As one example, one or more aspects of the present invention can be included in an article of manufacture (e.g., one or more computer program products) having, for instance, computer usable media. The media has embodied therein, for instance, computer readable program code means for providing and facilitating the capabilities of the present invention. The article of manufacture can be included as a part of a computer system or sold separately.
[0025] Additionally, at least one program storage device readable by a machine, tangibly embodying at least one program of instructions executable by the machine to perform the capabilities of the present invention can be provided.
[0026] The flow diagrams depicted herein are just examples. There may be many variations to these diagrams or the steps (or operations) described therein without departing from the spirit of the invention. For instance, the steps may be performed in a differing order, or steps may be added, deleted or modified. All of these variations are considered a part of the claimed invention.
[0027] While the preferred embodiments to the invention has been described, it will be understood that those skilled in the art, both now and in the future, may make various improvements and enhancements which fall within the scope of the claims which follow. These claims should be construed to maintain the proper protection for the invention first described. | A method for viewer based control of video display aspect ratios, the method includes: applying an initial video display aspect ratio to a selected signal source; determining if the selected signal source has a viewer assigned video display aspect ratio; modifying the initial video display aspect ratio of the selected signal source in response to the viewer assigned video display aspect ratio; wherein the viewer assigned video display aspect ratio is a subset of one or more of the viewer assigned video display aspect ratios that are stored in a non-volatile memory medium; wherein the one or more viewer assigned video display aspect ratios are each individually associated with a signal source; and wherein a viewer assigned video display aspect ratio is retrieved from the non-volatile memory medium in response to the selection of an associated signal source. | 7 |
CROSS-REFERENCE TO OTHER RELATED APPLICATIONS
This is a continuation application of U.S. Patent Application Ser. No. 07/967,646, filed on Oct. 28, 1992, now abandoned, which application is a continuation application of U.S. Patent Application Ser. No. 07/607,347, filed on Oct. 30, 1990, also abandoned. Ser. No. 07/607,347 is a continuation of U.S. Patent Application Ser. No. 07/385,986, filed on Jul. 20, 1989, now U.S. Pat. No. 4,994,373 issued on Feb. 19, 1991. Ser. No. 07/385,986 is a continuation of U.S. Patent Application Ser. No. 06/732,374, filed on May 9, 1985, also abandoned, which application is a continuation-in-part of U.S. Patent Application Ser. No. 06/461,469, filed on Jan. 27, 1983, also abandoned.
TECHNICAL FIELD OF INVENTION
The present invention relates generally to the detection of genetic material by polynucleotide probes. More specifically, it relates to a method for quantifiably detecting a targeted polynucleotide sequence in a sample of biological and/or nonbiological material employing a probe capable of generating a soluble signal. The method and products disclosed herein in accordance with the invention are expected to be adaptable for use in many laboratory, industrial, and medical applications wherein quantifiable and efficient detection of genetic material is desired.
BACKGROUND OF THE INVENTION
In the description, the following terms are employed:
Analyte—A substance or substances, either alone or in admixtures, whose presence is to be detected and, if desired, quantitated. The analyte may be a DNA or RNA molecule of small or high molecular weight, a molecular complex including those molecules, or a biological system containing nucleic acids, such as a virus, a cell, or group of cells. Among the common analytes are nucleic acids (DNA and RNA) or segments thereof, oligonucleotides, either single- or double-stranded, viruses, bacteria, cells in culture, and the like. Bacteria, either whole or fragments thereof, including both gram positive and gram negative bacteria, fungi, algae, and other microorganisms are also analytes, as well as animal (e.g., mammalian) and plant cells and tissues.
Probe—A labelled polynucleotide or oligonucleotide sequence which is complementary to a polynucleotide or oligonucleotide sequence of a particular analyte and which hybridizes to said analyte sequence.
Label—That moiety attached to a polynucleotide or oligonucleotide sequence which comprises a signalling moiety capable of generating a signal for detection of the hybridized probe and analyte. The label may consist only of a signalling moiety, e.g., an enzyme attached directly to the sequence. Alternatively, the label may be a combination of a covalently attached bridging moiety and signalling moiety or a combination of a non-covalently bound bridging moiety and signalling moiety which gives rise to a signal which is detectable, and in some cases quantifiable.
Bridging Moiety—That portion of a label which on covalent attachment or non-covalent binding to a polynucleotide or oligonucleotide sequence acts as a link or a bridge between that sequence and a signalling moiety.
Signalling Moiety—That portion of a label which on covalent attachment or non-covalent binding to a polynucleotide or oligonucleotide sequence or to a bridging moiety attached or bound to that sequence provides a signal for detection of the label.
Signal—That characteristic of a label or signalling moiety that permits it to be detected from sequences that do not carry the label or signalling moiety.
The analysis and detection of minute quantities of substances in biological and non-biological samples has become a routine practice in clinical, diagnostic and analytical laboratories. These detection techniques can be divided into two major classes: (1) those based on ligand-receptor interactions (e.g., immunoassay-based techniques), and (2) those based on nucleic acid hybridization (polynucleotide sequence-based techniques).
Immunoassay-based techniques are characterized by a sequence of steps comprising the non-covalent binding of an antibody and antigen complementary to it. See, for example, T. Chard, An Introduction To Radioimmunoassay And Related Techniques (1978).
Polynucleotide sequence-based detection techniques are characterized by a sequence of steps comprising the non-covalent binding of a labelled polynucleotide sequence or probe to a complementary sequence of the analyte under hybridization conditions in accordance with the Watson-Crick base pairing of adenine (A) and thymine (T), and guanine (G) and cytosine (C), and the detection of that hybridization. [M. Grunstein and D. S. Hogness, “Colony Hybridization: A Method For The Isolation Of Cloned DNAs That Contain A Specific Gene”, Proc. Natl. Acad. Sci. USA, 72, pp. 3961–65 (1975)]. Such polynucleotide detection techniques can involve a fixed analyte [see, e.g., U.S. Pat. No. 4,358,535 to Falkow et al], or can involve detection of an analyte in solution [see U.K. patent application 2,019,408 A].
The primary recognition event of polynucleotide sequence-based detection techniques is the non-covalent binding of a probe to a complementary sequence of an analyte, brought about by a precise molecular alignment and interaction of complementary nucleotides of the probe and analyte. This binding event is energetically favored by the release of non-covalent bonding free energy, e.g., hydrogen bonding, stacking free energy and the like.
In addition to the primary recognition event, it is also necessary to detect when binding takes place between the labelled polynucleotide sequence and the complementary sequence of the analyte. This detection is effected through a signalling step or event. A signalling step or event allows detection in some quantitative or qualitative manner, e.g., a human or instrument detection system, of the occurrence of the primary recognition event.
The primary recognition event and the signalling event of polynucleotide sequence based detection techniques may be coupled either directly or indirectly, proportionately or inversely proportionately. Thus, in such systems as nucleic acid hybridizations with sufficient quantities of radiolabeled probes, the amount of radio-activity is usually directly proportional to the amount of analyte present. Inversely proportional techniques include, for example, competitive immuno-assays, wherein the amount of detected signal decreases with the greater amount of analyte that is present in the sample.
Amplification techniques are also employed for enhancing detection wherein the signalling event is related to the primary recognition event in a ratio greater than 1:1. For example, the signalling component of the assay may be present in a ratio of 10:1 to each recognition component, thereby providing a 10-fold increase in sensitivity.
A wide variety of signalling events may be employed to detect the occurrence of the primary recognition event. The signalling event chosen depends on the particular signal that characterizes the label or signalling moiety of the polynucleotide sequence employed in the primary recognition event. Although the label may only consist of a signalling moiety, which may be detectable, it is more usual for the label to comprise a combination of a bridging moiety covalently or non-covalently bound to the polynucleotide sequence and a signalling moiety that is itself detectable or that becomes detectable after further modification.
The combination of bridging moiety and signalling moiety, described above, may be constructed before attachment or binding to the sequence, or it may be sequentially attached or bound to the sequence. For example, the bridging moiety may be first bound or attached to the sequence and then the signalling moiety combined with that bridging moiety. In addition, several bridging moieties and/or signalling moieties may be employed together in any one combination of bridging moiety and signalling moiety.
Covalent attachment of a signalling moiety or bridging moiety/signalling moiety combination to a sequence is exemplified by the chemical modification of the sequence with labels comprising radioactive moieties, fluorescent moieties or other moieties that themselves provide signals to available detection means or the chemical modification of the sequence with at least one combination of bridging moiety and signalling moiety to provide that signal.
Non-covalent binding of a signalling moiety or bridging moiety/signalling moiety to a sequence involve the non-covalent binding to the sequence of a signalling moiety that itself can be detected by appropriate means, i.e., or enzyme, or the non-covalent binding to the sequence of a bridging moiety/signalling moiety to provide a signal that may be detected by one of those means. For example, the label of the polynucleotide sequence may be a bridging moiety non-covalently bound to an antibody, a fluorescent moiety or another moiety which is detectable by appropriate means. Alternatively, the bridging moiety could be a lectin, to which is bound another moiety that is detectable by appropriate means.
There are a wide variety of signalling moieties and bridging moieties that may be employed in labels for covalent attachment or non-covalent binding to polynucleotide sequences useful as probes in analyte detection systems. They include both a wide variety of radioactive and non-radioactive signalling moieties and a wide variety of non-radioactive bridging moieties. All that is required is that the signalling moiety provide a signal that may be detected by appropriate means and that the bridging moiety, if any, be characterized by the ability to attach covalently or to bind non-covalently to the sequence and also the ability to combine with a signalling moiety.
Radioactive signalling moieties and combinations of various bridging moieties and radioactive signalling moieties are characterized by one or more radioisotopes such as 32 P, 131 I, 14 C, 3 H, 60 Co, 59 Ni, 63 Ni and the like. Preferably, the isotope employed emits β or γ radiation and has a long half life. Detection of the radioactive signal is then, most usually, accomplished by means of a radioactivity detector, such as exposure to a film.
The disadvantages of employing a radioactive signalling moiety on a probe for use in the identification of analytes are well known to those skilled in the art and include the precautions and hazards involved in handling radioactive material, the short life span of such material and the correlatively large expenses involved in use of radioactive materials.
Non-radioactive signalling moieties and combinations of bridging moieties and non-radioactive signalling moieties are being increasingly used both in research and clinical settings. Because these signalling and bridging moieties do not involve radioactivity, the techniques and labelled probes using them are safer, cleaner, generally more stable when stored, and consequently cheaper to use. Detection sensitivities of the non-radioactive signalling moieties also are as high or higher than radio-labelling techniques.
Among the presently preferred non-radioactive signalling moieties or combinations of bridging/signalling moieties useful as non-radioactive labels are those based on the biotin/avidin binding system. [P. R. Langer et al., “Enzymatic Synthesis Of Biotin-Labeled Polynucleotides: Novel Nucleic Acid Affinity Probes”, Proc. Natl. Acad. Sci. USA, 78, pp. 6633–37 (1981); J. Stavrianopoulos et al., “Glycosylated DNA Probes For Hybridization/Dection Of Homologous Sequences”, presented at the Third Annual Congress For Recombinant DNA Research (1983); R. H. Singer and D. C. Ward, “Actin Gene Expression Visualized In Chicken Muscle Tissue Culture By Using In Situ Hybridization With A Biotinated Nucleotide Analog”, Proc. Natl. Acad. Sci. USA, 79, pp. 7331–35 (1982)]. For a review of non-radioactive signalling and bridging/signalling systems, both biotin/avidin and otherwise, see D. C. Ward et al., “Modified Nucleotides And Methods Of Preparing And Using Same”, European Patent application No. 63879.
The above-referenced U.S. Patent Application Ser. No. 06/255,223 was abandoned in favor of continuation application, U.S. Patent Application Ser. No. 06/496,915, filed on May 23, 1983, now U.S. Pat. No. 4,711,955. A related divisional application of the aforementioned Ser. No. 06/496,915 was filed (on Dec. 8, 1987) as U.S. Patent Application Ser. No. 07/130,070 and issued on Jul. 12, 1994 as U.S. Pat. No. 5,328,824. Two related continuation applications of the aforementioned Ser. No. 07/130,070 were filed on Feb. 26, 1992 (as Ser. No. 07/841,910) and on May 20, 1992 as (Ser. No. 07/886,660). The aforementioned applications, Ser. No. 07/886,660 and Ser. No. 07/841,910, issued as U.S. Pat. Nos. 5,449,767 and 5,476,928 on Sep. 12, 1995 and Dec. 19, 1995, respectively. The above-referenced U.S. Patent Application Ser. No. 06/391,440, filed on Jun. 23, 1982, was abandoned in favor of U.S. Patent Application Ser. No. 07/140,980, filed on Jan. 5, 1988, the latter now abandoned. Two divisional applications of the aforementioned Ser. No. 07/140,980, U.S. Patent Applications Ser. Nos. 07/532,704 (filed on Jun. 4, 1990 for “Base Moiety Labeled Detectable Nucleotide”) and 07/567,039 (filed on Aug. 13, 1990 for “Saccharide Specific Binding System Labeled Nucleotides”) issued as U.S. Pat. Nos. 5,241,060 (Aug. 31, 1993) and 5,260,433 (Nov. 9, 1993), respectively. The disclosures of the above-identified PNAS article (P. R. Langer et al., “Enzymatic Synthesis of Biotin-Labeled Polynucleotides: Novel Nucleic Acid Affinity Probes,” Proc. Natl. Acad. Sci.(USA) 78:6633–6637 (1981) and U.S. Pat. Nos. 4,711,955, 5,328,824, 5,449,767, 5,476,928, 5,241,060, 5,260,433, and 4,358,535 are herein incorporated and made part of this disclosure.
Generally, the signalling moieties employed in both radioactive and non-radioactive detection techniques involve the use of complex methods for determining the signalling event, and/or supply only an unquantitable positive or negative response. For example, radioactive isotopes must be read by a radioactivity counter; while signalling moieties forming insoluble “signals”, i.e., precipitates, certain fluorescers, and the like [see, e.g., David et al., U.S. Pat. No. 4,376,100] only provide detection not quantitation of the analyte present in the tested sample.
One step toward facilitating rapid and efficient quantitation as well as detection of the hybridization event was the work of Heller et al. in European Patent Applications No. 70685 and 70687 which describe the use of a signalling moiety which produces a soluble signal for measurable detection by a spectrophotometer. These European patent applications disclose the use of two different probes complementary to different portions of a gene sequence, with each probe being labelled at the end which will abut the other probe upon hybridization. The first probe is labelled with a chemiluminescent complex that emits lights of a specific wavelength. The second probe is labelled with a molecule that emits light of a different wavelength measurable by spectrophotometry when excited by the proximity of the first signalling moiety. However, this technique is performed in solution and can generate false positive results in the absence of the analyte if the two probes happen to approach too closely in solution and react with each other.
Similarly, U.K. Patent Application 2,019,408A, published Oct. 31, 1979, discloses a method for detecting nucleic acid sequences in solution by employing an enzyme-labelled RNA or DNA probe which, upon contact with a chromogen substrate, provides an optically readable signal. The analytes may be separated from contaminants prior to hybridization with the probe, or, alternatively, the hybrid probe-analyte may be removed from solution by conventional means, i.e., centrifugation, molecular weight exclusion, and the like. Like Heller's technique, this method is performed in solution.
There remains therefore a need in the art for a reliable, simple and quantifiable technique for the detection of analytes of interest in biological and non-biological samples.
SUMMARY OF THE INVENTION
The invention provides a solution for the disadvantages of presently available methods of detecting analytes by a novel combination of hybridization and immunological techniques. In the present invention, chemically labelled polynucleotide or oligonucleotide probes are employed to detect analytes by having the capacity to generate a reliable, easily quantifiable soluble signal.
Analytes to be detected by the detection processes of this invention may be present in any biological or non-biological sample, such as clinical samples, for example, blood urine, feces, saliva, pus, semen, serum, other tissue samples, fermentation broths, culture media, and the like. If necessary, the analyte may be pre-extracted or purified by known methods to concentrate its nucleic acids. Such nucleic acid concentration procedures include, for example, phenol extraction, treatment with chloroform-isoamyl alcohol or chloroform-octanol, column chromatography (e.g., Sephadex, hydroxyl apatite), and CsCl equilibrium centrifugation. The analyte, separated from contaminating materials, if present, is according to the present invention, fixed in hybridizable form to a solid support.
Analytes in a biological sample are preferably denatured into single-stranded form, and then directly fixed to a suitable solid support. Alternatively, the analyte may be directly fixed to the support in double-stranded form, and then denatured. The present invention also encompasses indirect fixation of the analyte, such as in in situ techniques where the cell is fixed to the support and sandwich hybridization techniques where the analyte is hybridized to a polynucleotide sequence that is fixed to the solid support. It is preferred that the solid support to which the analyte is fixed be non-porous and transparent, such as glass, or alternatively, plastic, polystyrene, polyethylene, dextran, polypropylene and the like. Conventional porous materials, e.g., nitrocellulose filters, although less desirable for practice of the method of the present invention, may also be employed as a support.
It is also highly desirable that the analyte be easily fixed to the solid support. The capability to easily fix the analyte to a transparent substrate would permit rapid testing of numerous samples by the detection techniques described herein.
Chemically-labeled probes are then brought into contact with the fixed single-stranded analytes under hybridizing conditions. The probe is characterized by having covalently attached to it a chemical label which consists of a signalling moiety capable of generating a soluble signal. Desirably, the polynucleotide or oligonucleotide probe provides sufficient number of nucleotides in its sequence, e.g., at least about 25, to allow stable hybridization with the complementary nucleotides of the analyte. The hybridization of the probe to the single-stranded analyte with the resulting formation of a double-stranded or duplex hybrid is then detectable by means of the signalling moiety of the chemical label which is attached to the probe portion of the resulting hybrid. Generation of the soluble signal provides simple and rapid visual detection of the presence of the analyte and also provides a quantifiable report of the relative amount of analyte present, as measured by a spectrophotometer or the like.
The method of the present invention involving the colorimetric or photometric determination of the hybridized probes employs as the signalling moiety reagents which are capable of generating a soluble signal, e.g., a color change in a substrate in solution. Preferable components of the signalling moiety include enzymes, chelating agents and co-enzymes, which are able to generate colored or fluorescent soluble signals. Specifically, certain chromogens upon contact with certain enzymes are utilizable in the method of the present invention. The following Table I lists exemplary components for the signalling moiety of the present invention. Each chromogen listed is reactive with the corresponding enzyme to produce a soluble signal which reports the presence of the chemically-labeled probe analyte hybrid. The superscript notation (*) indicates that the chromogen fluoresces, rather than produces a color change.
TABLE I
ENZYME
CHROMOGEN
alkaline phosphatase
*4-Methylumbelliferyl
or
phosphate
acid phosphatase
*bis (4-Methylumbelli-
feryl phosphate
3-0-methylfluorescein.
*Flavone-3-diphosphate
triammonium salt
p-nitrophenyl phosphate
2Na.
peroxidase
*Tyramine hydro-
chloride
*3-(p-hydroxyphenyl)
Propionic acid
*p-Hydroxyphenethyl
alcohol
2,2′-Azino-Di-3-
Ethylbenzthiazoline
sulfonic acid
(ABTS)
ortho-phenylenedia-
mine 2HCl
0-dianisidine
*5-aminosalicylic acid
p-cresol
3,3′-dimethyloxy-
benzidine
3-methyl-2-benzo-
thiazoline hydra-
zone
tetramethyl benzidine
β-D-galactosidase
0-nitrophenyl β-D-
galactopyranoside
4-methylumbelliferyl-
β-D-galactoside
glucose-oxidase
ABTS
As another aspect of the present invention, the signalling moiety may be attached to the probe through the formation of a bridging entity or complex. Likely candidates for such a bridging entity would include a biotin-avidin bridge, a biotin-streptavidin bridge, or a sugar-lectin bridge.
Once the fixed probe-analyte hybrid is formed, the method may further involve washing to separate any non-hybridized probes from the area of the support. The signalling moiety may also be attached to the probe through the bridging moiety after the washing step to preserve the materials employed. Thereafter, another washing step may be employed to separate free signalling moieties from those attached to the probe through the bridging moiety.
Broadly, the invention provides hybridization techniques which provide the same benefits as enzyme linked immunosorbent assay techniques, i.e, the qualitative and quantitative determination of hybrid formation through a soluble signal. Various techniques, depending upon the chemical label and signalling moiety of the probe, may be employed to detect the formation of the probe-analyte hybrid. It is preferred, however, to employ spectrophotometric techniques and/or colorimetric techniques for the determination of the hybrid. These techniques permit not only a prompt visual manifestation of the soluble signal generated by the signalling moiety on the double-stranded hybrid, but also permit the quantitative determination thereof, i.e., by the enzymatic generation of a soluble signal that can be quantitatively measured.
Yet another aspect of the method of the present invention involves generating the soluble signal from the probe-analyte hybrid in a device capable of transmitting light therethrough for the detection of the signal by spectrophotometric techniques. Examples of devices useful in the spectrophotometric analysis of the signal include conventional apparatus employed in diagnostic laboratories, i.e., plastic or glass wells, tubes, cuvettes or arrangements of wells, tubes or cuvettes. It may also be desirable for both the solid support to which the analyte is fixed and the device to be composed of the same material, or for the device to function as the support in addition to facilitating spectrophotometric detection.
A further aspect of the present invention provides products useful in the disclosed method for detection of a polynucleotide sequence. Among these products is a device containing a portion for retaining a fluid. Such portion contains an immobilized polynucleotide sequence hybridized to a polynucleotide or oligonucleotide probe. The probe, as described above, has covalently attached thereto a chemical label including a signalling moiety capable of generating a soluble signal. Also part of the device is a soluble signal, preferably a colored or fluorescent product, generatable by means of the signalling moiety. The portion of the device for containing the fluid is desirably a well, a tube, or a cuvette. A related product of the invention is an apparatus comprising a plurality of such devices for containing a fluid, in which at least one such device contains the above-described immobilized polynucleotide sequence, polynucleotide or oligonucleotide probe, signalling moiety, and soluble signal. Additionally the present invention provides for the novel product of a non-porous solid support to which a polynucleotide is directly fixed in hybridizable form. Such a fixed sequence may be hybridized to another polynucleotide sequence having covalently attached thereto a chemical label including a signalling moiety capable of generating a soluble signal. As indicated above, the support is preferably transparent or translucent. Such products could be advantageously employed in diagnostic kits and the like.
Other aspects and advantages of the present invention will be readily apparent upon consideration of the following detailed description of the preferred embodiments thereof.
DETAILED DESCRIPTION
The following examples are illustrative of preferred embodiments of the method of the present invention. Specifically referred to therein are methods for fixing the analyte to a non-porous solid support, as well as illustrations of the use of soluble signals in polynucleotide probes as discussed above.
EXAMPLE 1
For purposes of the present invention, an analyte is immobilized on a solid support, preferably a non-porous translucent or transparent support. To effect easy fixing of a denatured single-stranded DNA sequence to a glass support, an exemplary “fixing” procedure may involve pretreating the glass by heating or boiling for a sufficient period of time in the presence of dilute aqueous nitric acid. Approximately forty-five minutes in 5% dilute acid should be adequate to leach boron residues from a borosilicate glass surface. The treated glass is then washed or rinsed, preferably with distilled water, and dried at a temperature of about 115° C., for about 24 hours. A 10 percent solution of gamma-aminopropyltriethoxysilane, which may be prepared by dissolving the above-identified silane in distilled water followed by addition of 6N hydrochloric acid to a pH of about 3.45, will then be applied to the glass surface. The glass surface is then incubated in contact with the above-identified silane solution for about 2–3 hours at a temperature of about 45° C. The glass surface is then washed with an equal volume of water and dried overnight at a temperature of about 100° C. The resulting treated glass surface will now have available alkylamine thereon suitable for immobilizing or fixing any negatively charged polyelectrolytes applied thereto. [See Weetal, H. H. and Filbert, A. M., “Porous Glass for Affinity Chromatography Applications”, Methods in Enzymology, Vol. XXXIV, Affinity Techniques Enzyme Purification: Part B. pp. 59–72, W. B. Jakoby and M. Wilchek, eds.]
Such treated glass could then be employed in the method of the invention. For example, glass plates provided with an array of depressions or wells would have samples of the various denatured analytes deposited therein, the single-stranded analytes being fixed to the surfaces of the wells. Thereupon, polynucleotide probes provided with a chemical label may be deposited in each of the wells for hybridization to any complementary single-stranded analyte therein. After washing to remove any non-hybridized probe, the presence of any hybrid probe-analyte is detectable One then detection - - - technique as described herein involves the addition of an enzyme-linked antibody or other suitable bridging entity of the label for attachment to the probe. Subsequently a suitable substrate is added to elicit the soluble signal, e.g., a color change or chemical reaction, which is then measured colorimetrically or photometrically.
This invention also provides an apparatus comprising a plurality of means for containing a fluid, wherein at least one of the means comprises (i) an immobilized polynucleotide sequence hybridized to a polynucleotide or oligonucleotide probe, the probe having covalently attached thereto, a chemical label comprising a signalling moiety capable of forming a soluble signal, and (ii) a soluble signal generated by means of the signalling moiety.
Also provided by this invention is a non-porous solid support having directly fixed thereto a polynucleotide sequence in hybridizable form. Such a support is characterized in that the polynucleotide sequence is hybridized to a polynucleotide or oligonucleotide probe, the probe having covalently attached thereto a chemical label comprising a signalling moiety capable of generating a soluble signal. Such a support is also characterized in that the support is a transparent or translucent support.
EXAMPLE 2
A glass surface treated as described in Example 1 can be employed in the method of the present invention, wherein glucosylated DNA is employed as the labelled probe, and the signalling moiety comprises the combination of acid phosphatase and its substrate paranitrophenylphosphate.
In this procedure, glucosylated bacteriophage T 4 DNA, isolated from E. coli CR63 cultures infected with phage T 4 AM82 [44 − 62 − ] and purified to be free of chromosomal DNA, or non-glucosylated, highly purified calf thymus DNA is delivered in 100 μl portions to treated glass tubes in triplicate set. After 15–30 minutes at room temperature, the solution is removed and the tubes rinsed generously with PBS·Mg ++ buffer [100 mM Na—K—PO 4 , pH 6.5, 150 mM NaCl and 10 mM MgCl 2 ].
One set of tubes is checked for the presence of DNA by staining with ethidium bromide [100 μl of 1 mg/ml solution, 30 minutes in the dark, at room temperature]. The staining solution is removed and the tubes rinsed and checked by UV light. Both glucosylated labelled and unlabelled DNA “probe” bound to the activated glass surface by the observed red fluorescence characteristic of ethidium bromide.
To another set of tubes is delivered fluorescein-labelled ConA [100 μl of 0.1 mg/ml in PBS·Mg ++ buffer]. The Concanavalin A [ConA] is obtained and solubilized in 2.0 M NaCl at a concentration of 50 mg/ml, and fluorescein-labelled by reacting ConA with fluorescein isothiocyanate at an FITC to protein molar ratio of 3 to 1 in 0.1 M sodium borate solution at a pH of 9.2 and at a temperature of 37° C. for 60 minutes. Any unreacted FITC is removed by gel filtration on Sephadex G-50. After 60 minutes at room temperature, the solution is removed and the tubes rinsed and checked under UV light. ConA bound only to glucosylated DNA in tubes containing T 4 DNA.
To the third set of tubes is delivered 100 μl of unlabeled ConA in PBS·Mg ++ buffer. After 60 minutes at room temperature, the tubes are rinsed free of ConA with 0.2 M Imidazole buffer pH 6.5.
Acid phosphatase is then added [0.005 units in 100 μl at 0.2 percent phosphatase-free BSA] and the tubes are incubated at room temperature for 30 minutes. After rinsing with 0.15 M NaCl to remove any unbound enzyme, 0.1 mM paranitrophenylphosphate in 0.2 M imidazole at pH 6.5 is added and incubation continued for 60 minutes at 37° C. The enzyme reaction is terminated by adding 1.0 ml of 0.5 percent sodium bicarbonate and absorbance is determined at A 300.
The resulting observed test results indicate that acid phosphatase, one component of the signalling moiety gives a positive visible color reaction, upon reaction with its chromogen, only in tubes containing “probe” T 4 DNA and bridging moiety, ConA, but is washed off from the tubes which contain only ConA or ConA and calf thymus DNA.
EXAMPLE 3
In an example of the method of the present invention, phage lambda DNA was employed as the analyte, glucosylated DNA as the labelled probe, ConA as the bridging entity and alkaline phosphatase with paranitrophenylphosphate as the signalling moiety. Bacteriophage lambda, obtained by heat induction of E. coli stain W3350 lysogenic for γC 1 857 phage, was employed for the preparation of phage lambda DNA. In these tests, the analyte, phage lambda DNA, was immobilized on an activated glass surface according to the following procedure. After rinsing with buffer, glass tubes were coated with 100 μl of coating solution [50 percent formamide, 5X SSC, 100 μg salmon sperm DNA 0.2 percent polyvinyl pyrrolidone, 0.1 percent Triton X-100, 0.2 percent BSA and 0.05 percent SDS] at 42° C. for 90–120 minutes. The coating solution was removed and the surface was covered with 100 μl of coating solution containing phage lambda DNA.
Phage lamba DNA employed as the probe is nick translated with maltose-triose dUTP to introduce glucosyl residues into the DNA. The glucosylated minutes and rapidly cooled in ice bath immediately before use. The tubes were then incubated with probe at 42° C. for 24 hours. The solution was removed and tubes were rinsed with PBS·Mg ++ buffer. As described above in example 2, ConA is added to the tubes in PBS·Mg buffer. After 60 minutes at room temperature the tubes are rinsed with 0.2 M Imidazole buffer.
Also as described in Example 2, the signalling moiety components, acid phosphatase and paranitrophenyl phosphate, are sequentially introduced into the tubes, to generate the detectable soluble signal. In these tests, the glucosyl moiety of the DNA probe is one bridging moiety of the chemical label, and reacts with and is strongly attracted to the second bridging moiety, ConA. The results indicated that acid phosphatase was not washed off from the tubes which contained glucosylated probe, whereas tubes containing non-labelled probe did not show any enzyme activity.
EXAMPLE 4
As in the above example employing a glucosylated DNA as the labelled probe, wherein the glucosyl moiety serves as part of the chemical label, comparable results may also be achieved by employing a biotin-labeled DNA probe. When biotin is employed as a bridging moiety of the chemical label of the DNA probe, the presence of the biotin-labeled DNA probe would be elicited or detected by means of an avidin or streptavidin-linked enzyme, since avidin is strongly reactive with or strongly bonds to biotin.
For example, a biotin-labeled DNA probe would readily be detected by an enzyme complex of the character avidin-biotin-alkaline phosphatase. More specifically, the presence of the biotin-labeled DNA probe would readily be detected by contacting the hybrid containing the biotin-labeled probe with the enzyme complex avidin-biotin-alkaline phosphatase, and bringing the resulting probe and avidin-biotin-alkaline phosphatase complex into contact with a suitable substrate which, upon contact with the enzyme, would produce a soluble signal that would be readily noticed or be capable of being determined, both qualitatively and quantitatively, by photometric and/or colorimetric means. If desired, instead of an avidin-biotin-enzyme complex, there could be used an antibody to biotin for attachment to the biotin moiety of the biotin-labeled DNA probe, followed by a complex comprising anti-antibody-enzyme in the manner described above.
EXAMPLE 5
The advantages of this invention are also obtainable when the probe is immobilized on a non-porous plastic surface. When a plastic surface is employed, it is sometimes desirable to increase the effectiveness or uniformity of the fixation by pretreating the plastic surface.
Because polystyrene from various batches or sources exhibits different binding capacities, the adherence or fixing of DNA to a polystyrene surface is improved by treating the surface with an amino-substituted hydrophobic polymer or material. Previous experiments demonstrated that addition of duodecadiamine (DDA) to polystyrene resulted in an uniform binding coefficient of polystyrene plates of different batches. Another technique for improving the fixing or uniformity of the plastic surface for fixing DNA involves treatment of the surface with polylysine (PPL).
In tests involving the fixing of DNA to a plastic surface, biotinylated DNA (b-DNA) was denatured and aliquoted into Dynatech, Immulon II™ removable wells. Samples were allowed to dry onto the plastic surface at 37° C. The amount of bound b-DNA was determined by sequential addition of goat anti-biotin antibody and rabbit anti-goat antibody complexed to the signalling moiety, alkaline phosphatase, followed by development with p-nitrophenyl phosphate in diethanolamine buffer, pH 9.6. Enzymatic activity was monitored at 405 nm utilizing the automatic Dynatech Micro ELISA Scanner. This procedure enables quantitation of the amount of bound DNA and therefore the degree of biotinylation. To increase the sensitivity of detection, a fluorogenic substrate such as 4-methylumbelliferyl-phosphate, or its analogues, with companion enzymes, may be used.
In a further example of the method, denatured adenovirus 2 DNA, the analyte, was bound to polystyrene plates as described above. After blocking with Denhardt's formamide blocking buffer, several biotinylated probes, b-adeno-2-DNA and lambda DNA were hybridized to the immobilized DNA. To one set of immobilized DNA, no probe was added. The extent of hybridization was determined by means of the antibody-enzyme reaction as described above. It was observed that only the homologous adeno-2 probe hybridized. This technique demonstrated that in vitro hybridization under these conditions is specific and can be monitored quantitatively by the method of the present invention.
Other methods for enabling fixation of single-stranded analyte to a solid support for use in the method of the present invention include the following.
EXAMPLE 6
In further tests, radioactively-labeled DNA was prepared by nick translation with [ 3 H]dATP. The labelled, non-biotinylated denatured DNA [2000 ng to 5 ng] was applied to DDA-coated polystyrene plates. The test samples or plates were not allowed to dry. After incubation at 37° C. for periods of 30 minutes, 1 hour, 2 hours, 3 hours, 4 hours, and 18 hours, samples were counted. Binding was maximal after two hours of incubation, however, 50 percent of the originally applied DNA bound regardless of the concentration, thereby indicating that there is an equilibrium between bound and unbound DNA.
In other tests, polystyrene microfilter wells were nitrated using the procedure of Filipsson and Hornby, Biochem. J. 120, 215 (1970). The polystyrene wells were immersed for 20 minutes in a mixture of concentrated nitric and sulfuric acid [41 percent, v/v] cooled to 0° C. The wells were then washed thoroughly with water and subsequently heated to 70° C. in a 6 percent solution of sodium dithionate in 2 M potassium hydroxide. After 4 hours, the wells were washed thoroughly with 0.5 M hydrochloric acid and distilled water.
To produce 6-aminohexane linked polystyrene, 6-amino-caproic acid-N-hydroxysuccinimide ester·hydrobromide [5 mg thereof dissolved in 0.2 M dimethylformamide prepared by reacting 6-aminocaproic acid·hydrobromide with N-hydroxysuccinimide and dicyclohexyl carbodiimide in dimethylformamide and recrystallized from isopropylalcohol] was added to 0.1 M sodium borate [0.4 ml]. Amino-derivitized polystyrene microfilter wells filled with this solution were allowed to react at room temperature for 4 hours and then washed thoroughly with distilled water. The resulting treated wells absorbed H-labeled DNA from aqueous solution at pH less than 9.5.
An improved capability for fixing or immobilization of DNA to non-porous siliceous solid supports, such as glass and plastic, is also provided by treatment with a coating of an epoxy resin. For example, treatment of glass or polystyrene surfaces with commercially available epoxy glues, such as a solution of epoxy glue in ethanol [1 percent w/v] serves this purpose. These epoxy solutions are applied to the surfaces or wells, and the solvent, ethanol, evaporated thereupon at a temperature of 37° C., thereby providing a polyamine polymeric coating on the treated surface. These surfaces were found to absorb 3 H-labeled DNA from aqueous solution at pH less than 9.5.
EXAMPLE 7
Yet another example of the method of the present invention, including fixing the polynucleotide analyte sequence directly to a non-porous solid support, such as a conventional microtiter well, may be performed according to the procedures outlined below.
Conventional microtiter well plates can be pre-rinsed with 1 M ammonium acetate (NH 4 OAc), in an amount of 200 μls/well. Analyte DNA would be diluted to 10–200 ng/50 ul in water or 10 mM Tris-HCl at pH 7.5 and 1 mM EDTA(TE). After boiling for 5 minutes and quick cooling in ice water, an equal volume of 2M NH 4 OAc would be added and 50 ul of analyte DNA is added per well, giving 5–100 ng of analyte DNA per well. After open plate incubation for 2 hours at 37° C., the wells can be sealed and plates stored at 4° C. Alternatively, open plates can be incubated at 37° C. until the wells are dry, at which point the plates can be sealed, and stored at 4° C. for up to one-two months. Single-stranded analyte DNA is now fixed to the wells.
An alternative method to denature and then fix the analyte DNA to the well is to add 50 ul of DNA in TE to wells at a concentration of 10–200 ng/50 ul. After adding 25 ul at 0.9 N NaOH and mixing, the plates can be incubated for 10 minutes at room temperature. After adding 25ul of 4 M NH 4 OAc, the open plate may be incubated at 37° C. for 4 hours or until dry and the plates sealed and stored at 4° C. until ready to use.
To prepare the plates for hybridization, the wells would be rinsed twice with 0.3 m NaCl, 0.03 m sodium citrate (2X SSC) (200 ul/well) buffer regardless of whether the plate was dried or not. Preferably, the wells can be rinsed once with 2X SSC/1% Triton X-100 after the two 2X SSC rinses. Plates should be blotted on absorbent paper before beginning each rinse.
To hybridize the fixed analyte with a probe, the following protocol would be followed. A nick translated probe would be heat denatured and added to a hybridization solution containing 30% formamide (deionized), 2X–4X SSPE (20X SSPE=3.6 M NaCl, 0.2 M NaPO 4 , pH 7.4, 0.02 M EDTA) depending on the GC content of probe, 0.1% SDS, and 5.0% dextran sulfate to give a final concentration of 0.2–1.0 ug probe/ml. An alternative hybridization solution contains 30% formamide (deionized), 2X–4X SSPE, 1.0% Triton X-100, and 5.0% dextran sulfate and 0.2–1.0 ug probe/ml. 100 ul of the selected hybridization mixture is added to each well. After sealing the plates, they are incubated at 37° C. for a desired time.
The hybridization solution is poured out, or collected by aspiration for reuse if desired. The plates are rinsed twice with 2X SSC and 0.1% SDS or 2X SSC and 0.1 0 % Triton X-100 according to whether the first or second hybridization solution identified above was employed. At this point two to four stringency rinses of SSC and detergent are preferably performed by heating the buffer to the desired temperature and adding it hot to the wells. Formamide and low SSC or SSPE can be used at 37–40° C. to achieve the desired stringency. Following stringency washes, wells are rinsed twice with 1X SSC or 1X SSC and 0.1% Triton X-100, and the plates are now ready for detection.
Detection of the fixed hybridized analyte-probe according to the invention may employ the procedure for commercially available ELISA assays using the sensitive DETEK® 1-alkaline phosphatase or DETEK® 1-horseradish peroxidase assays (Enzo Biochem, Inc.). Beginning at the blocking procedure, the standard method is employed except that after blocking, no rinsing step is used. Complex diluted in 1X complex dilution buffer is thereafter added as taught in these commercially available assays.
As will be apparent to those skilled in the art in the light of the foregoing disclosure, many alterations, modifications and substitutions are possible in the practice of this invention, without departing from the spirit or scope thereof. Consequently, only such limitations as appear in the appended claims should be placed upon the scope of the invention. | Nucleic acids are fixed or immobilized to non-porous solid supports (substrates), and include systems containing such supports and arrays with fixed or immobilized nucleic acids. These compositions are useful for nucleic acid analyses and a host of applications, including, for example, detection, mutational analysis and quantification. The non-porous solid supports can be transparent or translucent, and the surfaces can be treated with agents to fix or immobilize the nucleic acids. Such agents include, for example, amine providing compounds, epoxy compounds and acid solutions. The fixed or immobilized nucleic acids can be unlabeled, or labeled with at least one non-radioactive signaling moiety, such as the case when the nucleic acids are double-stranded. | 8 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a construction tool. In particular, a framing guide provides a means for improved construction, including improved wall construction.
[0003] 2. Discussion of the Related Art
[0004] Construction using framing members is an old art. Over hundreds of years, the tools, materials, and methods used for framing structures have improved. Despite these improvements, framing tools used today are little changed from those used hundreds of years ago. The most significant improvements relate primarily to mechanizing a well known tool, such as substituting a nail gun for a hammer and nail.
SUMMARY OF THE INVENTION
[0005] A framing tool comprises a guide used to align a horizontal framing member with a vertical framing member and to facilitate fastening the members together while maintaining the desired relative alignment.
[0006] In an embodiment, an elongated framing guide has a stud side coupled to an opposed nail side by an intermediate side. The stud side, intermediate side, and nail side form a substantially “n” shaped guide cross section with an elongated slot. The elongated slot is for receiving a horizontal framing member.
[0007] The stud side includes a plurality of pockets for receiving respective ends of vertical framing members and each pocket has three sides formed to position opposing major sides of the vertical framing member about perpendicular to the intermediate side. A leveling device is located between each pair of adjacent pockets and is arranged to indicate a level of the guide.
[0008] The nail side includes a plurality of nailing windows and each nailing window is generally opposed to a respective stud side pocket.
[0009] The intermediate side includes a plurality of insets, each inset located between an adjacent pair of the stud side pockets. Each inset has a surface depressed with respect to the intermediate side and about parallel to the intermediate side and a plurality of the depressed surfaces have respective leveling devices, each leveling device located between an adjacent pair of pockets and arranged to indicate a level of the guide. The intermediate side further includes a plurality of viewing windows, each viewing window for exposing a junction between a vertical framing member and the horizontal framing member.
[0010] The guide is movable along an upper horizontal framing member of arbitrary length for aiding alignment and fixation of vertical framing members with the upper horizontal framing member. In addition, the guide is movable along an associated lower horizontal framing member for aiding alignment and fixation of the vertical framing members with the lower horizontal framing member.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The present invention is described with reference to the accompanying figures. These figures, incorporated herein and forming part of the specification, illustrate embodiments of the invention and, together with the description, further serve to explain its principles enabling a person skilled in the relevant art to make and use the invention.
[0012] FIG. 1A shows a first view of a framing guide in accordance with the present invention.
[0013] FIG. 1B shows a second view of the framing guide of FIG. 1A .
[0014] FIG. 1C shows hinged embodiment of the framing guide of FIG. 1A .
[0015] FIG. 2 shows another view of the framing guide of FIG. 1A .
[0016] FIG. 3 shows the framing guide of FIG. 1A alongside framing members to be assembled using the guide.
[0017] FIG. 4A shows a cross-section of a first selected portion of the guide of FIG. 1A .
[0018] FIG. 4B shows a cross-section of a second selected portion of the guide of FIG. 1A .
[0019] FIG. 5A shows a first flowchart depicting an exemplary method of using the guide of FIG. 1A .
[0020] FIG. 5B shows a second flowchart depicting an exemplary method of using the guide of FIG. 1A .
[0021] FIG. 6A shows a first construction of a wall section using the guide of FIG. 1A .
[0022] FIG. 6B shows a second construction of a wall section using the guide of FIG. 1A .
[0023] FIG. 7 shows placement and leveling of a wall section using the guide of FIG. 1A .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] The disclosure provided in the following pages describes examples of some embodiments of the invention. The designs, figures, and description are non-limiting examples of the embodiments they disclose. For example, other embodiments of the disclosed device and/or method may or may not include the features described herein. Moreover, disclosed advantages and benefits may apply to only certain embodiments of the invention and should not be used to limit the disclosed invention.
[0025] FIG. 1A shows a first view of a framing guide in accordance with an embodiment of the present invention 100 A. FIG. 1B shows a second view of the framing guide 100 B. The first view of the guide shows a guide stud side 121 and a guide intermediate side 122 . A second view of the guide 100 B shows a guide nail side 123 and the guide intermediate side. The guide has a generally “n” shaped cross-section formed by the stud side, intermediate side, and nail side. FIG. 1C shows a framing guide embodiment having an articulated joint 100 C.
[0026] FIG. 2 shows an axially rotated view of the guide 200 . In the axially rotated view, the open side of the “n” shaped guide 202 is visible.
[0027] FIG. 3 shows the guide and framing members to be joined 300 . The framing members include a horizontal framing member 302 and a plurality of vertical framing members or studs 304 .
[0028] An orthogonal coordinate system with an origin at a lower, back, left corner of the guide as shown in the first view 100 A places the stud side 121 in a plane parallel to the x-y plane, the nail side 123 in a plane parallel to the x-y plane, the intermediate side 122 in a plane parallel to the x-z plane, and the open side 202 in a plane parallel to the x-z plane.
[0029] Stud pockets 112 are arranged along the stud side 121 of the framing guide. In an embodiment, the framing guide has five stud pockets (as shown). Some embodiments utilize less than five stud pockets while other embodiments utilize more than five stud pockets. Each stud pocket has three sides formed to position opposing major sides of the studs 306 , 307 . Spacing between the stud pocket centerlines 126 , 128 is set to create a desired stud spacing S 1 such as 12 inches on center, 18 inches on center, or another desired spacing.
[0030] FIGS. 4A and 4B show framing guide cross-sections along a plane parallel to the x-y plane 400 A, 400 B. The stud ends 305 are inserted in the stud pockets 112 . As can be seen in the first view 402 , the framing guide aligns the stud major sides 306 , 307 about perpendicular to the intermediate side 122 . In contrast, assembly without the framing guide often leads to misaligned studs as shown in the second view 400 B.
[0031] In an embodiment, one or more bubble tube type levels 108 are fixed to the intermediate side 122 between adjacent stud pockets 112 (as shown). These levels lie along a line parallel to the x axis and are referred to as x-z levels. In some embodiments, one or more bubble type levels 110 are fixed to the stud side 121 between adjacent stud pockets 112 (as shown). These levels lie along a line parallel to the x axis and are referred to as x-y levels.
[0032] In an embodiment, adjacent stud pockets 112 are separated by insets 130 (as shown). Here, each inset has a surface 131 depressed with respect to the intermediate side 122 and about parallel to the intermediate side. Where the framing guide material is chosen for properties other than strength and rigidity, such as in the choice of a light weight polymeric or plastic material, the use of insets improves the rigidity of the guide.
[0033] Nailing windows 118 are arranged along the nail side 123 of the framing guide. In an embodiment, the framing guide has five nailing windows (as shown). Nailing windows correspond to stud pockets 112 as further described below. Each nailing window provides an opening into the interior of the framing guide 119 that aligns with a respective stud pocket and stud face 303 .
[0034] An elongated slot 114 along the length of the framing guide is for interengaging a horizontal framing member 302 . One side of the slot is bounded by the framing guide's nail side 123 and an adjacent side of the slot is bounded by the framing guide's intermediate side 122 .
[0035] In an embodiment, viewing windows 116 are arranged along the intermediate side of the framing guide. The viewing windows are aligned with the stud pockets 112 . When the framing guide interengages a horizontal framing member 302 and a stud 304 , the corresponding viewing window enables a user to view the junction where the stud meets the horizontal framing member. Visual assessments of these junctions enables a user to assure, among other things, that a stud is fully inserted in a respective stud pocket 112 .
[0036] Some framing guide embodiments provide a hand-hold means to facilitate handling the guide. In one embodiment, a hand hold 106 extends from the intermediate side 122 about midway between the ends of the framing guide. And, some framing guide embodiments provide a hinge 150 (See FIG. 1B ) coupling the stud and intermediate sides 121 , 122 , rotation of the stud side with respect to the intermediate side being useful for facilitating sliding the guide along a horizontal framing member. In a hinged embodiment, end walls 152 are separated from the intermediate side by a gap 154 enabling rotation of the end walls and stud side with respect to the intermediate side.
[0037] In various embodiments, the framing guide is made of one or more materials that provide the desired combination of strength, rigidity, light weight, manufacturability, and toughness. Non-metal materials include polymers such as plastics, composites such as carbon composites, and fabric with resin composites such as fiberglass. Metals include ferrous and non-ferrous metals such as steel, aluminum, titanium, and alloys of these metals known to persons of ordinary skill in the art.
[0038] In operation, the framing guide is used to align a horizontal framing member 302 with a plurality of vertical framing members 304 , and to facilitate fastening the members together.
[0039] FIGS. 5A and 5B show exemplary method flowcharts using the framing guide 500 A, 500 B. The method steps may be in the sequence shown, or in another sequence and fewer than all of the steps may be used in various embodiments. Moreover, other steps may be included as will be understood by a person of ordinary skill in the art.
[0040] FIGS. 6A , 6 B show the framing guide in use during wall section construction 600 A, 600 B. View 600 A shows fastening of a bottom horizontal member 622 and view 600 B shows fastening of a top horizontal member 632 . FIG. 7 shows the framing guide in use during wall section placement 700 . The framing guide 702 is located atop the wall section 703 and levels 108 , 110 are available for leveling of the wall section.
[0041] In the exemplary sequence of method steps, beginning with step 5 , a wall is constructed using the framing guide 300 . Framing members are selected and cut to length as needed 300 . Continuing with step 10 , the guide elongated slot 114 is interengaged with a bottom horizontal framing member 612 . Continuing with step 15 , vertical framing members are interengaged with respective stud pockets 624 . Continuing with step 20 , fasteners such as nails, screws, staples, or another fastener known to persons of ordinary skill in the art are used to fasten the horizontal member to the vertical members 606 via the nailing windows 118 . Continuing with step 25 , steps 15 and/or 20 are repeated as needed to fasten each vertical framing member to the horizontal framing member.
[0042] Continuing with step 30 , when the studs 304 in the framing guide are fastened to the bottom horizontal member 622 , the framing guide is removed from the fastened framing members and, continuing with step 35 , the framing guide elongated slot is interengaged with a top horizontal framing member. Continuing with step 40 , the opposite ends of the vertical framing members interengaged with respective stud pockets 634 . Continuing with step 45 , fasteners such as nails, screws, staples, or another fastener known to persons of ordinary skill in the art are used to fasten the horizontal member to the vertical members 606 via the nailing windows 118 . Continuing with step 50 , steps 40 and/or 45 are repeated as needed to fasten each vertical framing member to the horizontal framing member.
[0043] Continuing with step 55 , when the studs 304 in the framing guide are fastened to the top horizontal member 632 , the constructed wall 700 is turned up and located in its intended position in a structure. Continuing with step 60 , the leveling devices 108 , 110 are used to orient the wall with respect to a foundation and/or adjacent structural members. Continuing with step 65 , when the wall is positioned and leveled as desired, the wall is fastened to the foundation and/or adjacent structural members.
[0044] In an embodiment, the framing guide is used to construct a wall section incorporating more studs than can be placed in the framing guide at one time. Here, the framing guide is moved along a horizontal framing member to incorporate additional studs. An exemplary method incorporates additional steps 51 , 52 , and 53 between steps 50 and 55 .
[0045] After step 45 disengage the guide and slide or move it along the horizontal framing member until a guide end stud pocket can be engaged with a vertical framing member adjacent to where the next framing member will be installed 51 . Engage the guide end stud pocket with the vertical framing member and repeat steps 15 - 45 . If vertical members remain to be installed in the wall, go to step 51 ; otherwise, as directed in step 53 , go to step 55 .
[0046] While various embodiments of the present invention have been described above, it should be understood that they have been presented by way of example only, and not limitation. It will be apparent to those skilled in the art that various changes in the form and details can be made without departing from the spirit and scope of the invention. As such, the breadth and scope of the present invention should not be limited by the above-described exemplary embodiments, but should be defined only in accordance with the following claims and equivalents thereof. | A multi-sided framing guide includes a stud side with stud pockets, a nail side with nailing windows, and an intermediate side adjoining the stud and nail sides. | 4 |
FIELD
[0001] The present description relates to a system and method for heating fuel and controlling fuel injection of a fuel injector that operates as part of an internal combustion engine.
BACKGROUND
[0002] Fuel vaporization tends to decrease as ambient temperature decreases. This can make engine starting more difficult at lower temperatures because reduced fuel vaporization can result in an air-fuel mixture near the engine's spark plug that is less than the fuel's lower flammability limit. Further, lower rates of fuel vaporization may make engine starting particularly difficult for certain types of fuels (e.g., ethanol). One example way to improve fuel vaporization is described in U.S. Patent Application 2005/0263136. This patent application describes placing a heating coil around the nozzle of a port fuel injector. The heating coil is supplied electrical energy through an electrical connector that attaches to an engine wiring harness. Heat produced by the heating coil is conducted through the injector to heat fuel that resides within the injector. This heating apparatus purportedly improves fuel vaporization.
[0003] The above-mentioned system can also have several disadvantages. Namely, the system heats the injector through conducting heat from a source outside the injector body. Since the heat source is external to the injector, some energy intended to heat the injector is lost to heating the engine and may therefore be less efficient than is desired. In addition, the heating device requires an additional electrical connector to route power to the heating device. An additional connector increases the number of wires and connections. Therefore, system reliability may be reduced when such a system is used to increase the temperature of fuel injected to an engine. In addition, the system may be difficult to implement on direct injection engine because there may be less space available to place a heating coil around the injector nozzle.
[0004] The inventors herein have recognized the above-mentioned disadvantages and have developed a method that offers substantial improvements.
SUMMARY
[0005] One embodiment of the present description includes a system to heat and inject fuel to an internal combustion engine, the system comprising: an internal combustion engine; a fuel injector capable of delivering fuel to said internal combustion engine, said fuel injector comprising a heating element and a fuel flow control element; and a controller that supplies current to said fuel injector in a first direction to heat fuel that flows through said fuel injector, and said controller supplying current to said fuel injector in a second direction to deliver fuel to said engine without substantially heating the fuel delivered through said fuel injector. This method overcomes at least some disadvantages of the above-mentioned method.
[0006] Fuel vaporization and system reliability can be improved by a system that heats fuel from within the fuel injector and that supplies fuel heating energy through the same conductors that are used to actuate the injector. In one embodiment, a system provides current in a first direction to heat fuel contained or passing through the fuel injector, and the system actuates the fuel injector by providing current in a second direction. In other words, the system controls injector heating and actuation (opening and/or closing) by controlling the direction that current is delivered to the fuel injector. This allows the system to use a single pair of wires to actuate the injector and heat fuel passing through the injector. Consequently, fewer conductors have to be provided, less electrical connections are made, and existing fuel injector connectors can be used to realize the system. Furthermore, the fuel heating and fuel injection elements can be integrated into a small package.
[0007] The present description can provide several advantages. Specifically, the approach can improve system reliability, reduce the cost of heating fuel, and it can be implemented with few changes to existing fuel systems. The system can also be used on a variety of injector designs. For example, the described system can be used to heat fuel flowing through port style injectors, injectors that inject fuel directly into a cylinder, injectors having a single coil controlled pintle, and injectors that use dual coil spool valve operated injectors.
[0008] The above advantages and other advantages, and features of the present description will be readily apparent from the following Detailed Description when taken alone or in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The advantages described herein will be more fully understood by reading an example of an embodiment, referred to herein as the Detailed Description, when taken alone or with reference to the drawings, wherein:
[0010] FIG. 1 is a schematic diagram of an engine configured to operate with heated fuel injectors;
[0011] FIG. 2 is a flowchart of an example fuel injector;
[0012] FIG. 3 is a schematic diagram of an example injector fuel heating circuit;
[0013] FIG. 4 is a schematic diagram of another example injector fuel heating circuit;
[0014] FIG. 5 is a schematic diagram of another example injector fuel heating circuit;
[0015] FIG. 6 is a plot illustrating current control for fuel injector fuel heating; and
[0016] FIG. 7 is a flow chart of an example fuel heating method.
DETAILED DESCRIPTION
[0017] Referring to FIG. 1 , internal combustion engine 10 , comprising a plurality of cylinders, one cylinder of which is shown in FIG. 1 , is controlled by electronic engine controller 12 . Engine 10 includes combustion chamber 30 and cylinder walls 32 with piston 36 positioned therein and connected to crankshaft 40 . Combustion chamber 30 is known communicating with intake manifold 44 and exhaust manifold 48 via respective intake valve 52 and exhaust valve 54 . Intake manifold 44 is shown communicating with optional electronic throttle 62 .
[0018] Fuel is directly injected into combustion chamber 30 via fuel injector 66 . The fuel injector is an example of an electrically operable mechanical valve. Fuel injector 66 receives opening and closing signals from controller 12 . Camshaft 130 is constructed with at least one intake cam lobe profile and at least one exhaust cam lobe profile. Alternatively, the intake cam may have more than one lobe profile that may have different lift amounts, different durations, and may be phased differently (i.e., the cam lobes may vary in size and in orientation with respect to one another). In yet another alternative, the system may utilize separate intake and exhaust cams. Cam position sensor 150 provides cam position information to controller 12 . Intake valve rocker arm 56 and exhaust valve rocker arm 57 transfer valve opening force from camshaft 130 to the respective valve stems. Intake rocker arm 56 may include a lost motion member for selectively switching between lower and higher lift cam lobe profiles, if desired. Alternatively, different valvetrain actuators and designs may be used in place of the design shown (e.g., pushrod instead of over-head cam, electromechanical instead of hydro-mechanical).
[0019] Fuel is delivered to fuel injector 66 by a fuel system (not shown) including a fuel tank, fuel pump, and fuel rail (not shown). Engine 10 may be designed to operate on one or more non-limiting fuel types such as diesel, gasoline, alcohol, or propane.
[0020] A distributor-less ignition system (not shown) may provide ignition spark to combustion chamber 30 via a spark plug (not shown) in response to controller 12 . Universal Exhaust Gas Oxygen (UEGO) sensor 76 is shown coupled to exhaust manifold 48 upstream of catalytic converter 70 . Two-state exhaust gas oxygen sensor 98 is shown coupled to exhaust pipe 49 downstream of catalytic converter 70 . Converter 70 may include multiple catalyst bricks, particulate filters, and/or exhaust gas trapping devices.
[0021] Controller 12 is shown in FIG. 1 as a conventional microcomputer including: microprocessor unit 102 , input/output ports 104 , read-only memory 106 , random-access memory 108 , keep-alive memory 110 , and a conventional data bus. Controller 12 is shown receiving various signals from sensors coupled to engine 10 , in addition to those signals previously discussed, including: engine coolant temperature (ECT) from temperature sensor 112 coupled to cooling sleeve 114 ; a position sensor 119 coupled to an accelerator pedal; a measurement of engine manifold pressure (MAP) from pressure sensor 122 coupled to intake manifold 44 ; engine knock sensor (not shown); fuel type sensor (not shown); humidity from humidity sensor 38 ; a measurement (ACT) of engine air temperature or manifold temperature from temperature sensor 117 ; and an engine position sensor from a Hall effect sensor 118 sensing crankshaft 40 position. In a preferred aspect of the present description, engine position sensor 118 produces a predetermined number of equally spaced pulses every revolution of the crankshaft from which engine speed (RPM) can be determined.
[0022] Controller 12 storage medium read-only memory 106 can be programmed with computer readable data representing instructions executable by processor 102 for performing the methods described below as well as other variants that are anticipated but not specifically listed.
[0023] Referring now to FIG. 2 , a schematic of an example direct injection fuel injector is shown. Fuel injector 200 is designed to inject fuel directly into a cylinder of an internal combustion engine. However, the present description is not restricted to direct injectors or to injectors having the same design as the illustrated injector. For example, the present description may be utilized on port or central fuel injectors, or it may be used with fluid (e.g., oil) assisted intensifier injectors. FIG. 2 is not intended to limit the scope or breadth of the present description.
[0024] Returning to FIG. 2 , fuel is fed to the injector through port 201 . Pressurized liquid fuel occupies reservoirs 250 and 252 until injected to a cylinder. Needle valve 232 regulates the flow of fuel from the injector to the cylinder through nozzle 207 . The needle valve position is controlled by flowing electrical current through coil 203 . The electrical current passing through coil 203 induces a magnetic field around coil 203 that attracts armature 209 toward the coil. As armature 209 approaches coil 203 , spring 221 is compressed, and needle valve 232 lifts from the injector nozzle seat. Fuel then flows to the cylinder.
[0025] Fuel in reservoirs 250 and 252 can be heated by passing current through positive temperature coefficient (PTC) ceramic heating elements 207 and 205 . Alternatively, fuel may be heated using negative temperature coefficient (NTC) heating elements if desired. The heated fuel exits the fuel injector when the armature 209 is attracted to coil 203 .
[0026] Current flows to the injector from electrical connector 210 via two electrical connector pins 211 , one of which is shown. Heating elements 205 and 207 along with actuator coil 203 are electrically connected to pins 211 . Diodes 233 and 231 (or similar current direction controlling devices) are inserted in the electrical path between electrical connector 210 and devices 203 , 207 , and 205 . Diodes 233 and 231 substantially limit the direction of current through coil 203 and heating elements 207 and 205 . That is, the diodes permit substantially full current flow (i.e., current flow is only reduced by a small voltage drop across the diode) in one direction and limit current flow in the opposite direction to a few milliamps. A few circuit examples are illustrated in FIGS. 3 and 4 .
[0027] Referring now to FIG. 3 , an example circuit for bi-directionally controlling current to a fuel injector and heater is shown. Power supply 301 provides current to actuate and heat fuel injector components identified by region boundary 311 . The direction of current supplied to fuel injector 311 is determined by the state of switches 303 , 307 , 305 , and 309 . Current flow can be initiated in a first direction by closing switches 307 and 305 . Current flow in a second direction can be initiated by closing switches 303 and 309 . Switches may be of solid-state (e.g., transistors) or mechanical construction (e.g., relays). Diodes 350 , 352 , 354 , and 356 are included to dissipate inductive energy when switches 303 , 307 , 354 , and 356 are operated.
[0028] Current flows through the fuel injector via pins 323 and 321 . Note that a unique feature over this design is the reduction in pin count over other fuel heating injector designs. In this example, pins 323 and 321 provide power to actuator coil 313 and heater element 317 . Operation of coil 313 and heater element 317 is determined by the direction of current flow because diodes 315 and 319 are biased in different directions.
[0029] If current flows into fuel injector pin 327 from wiring harness pin 323 , and out of fuel injector pin 325 and wiring harness pin 321 , then coil 313 can operate because diode 315 is forward biased. In these conditions diode 319 is reverse biased and substantially stops current flowing to heater element 317 .
[0030] If on the other hand current flows from fuel injector pin 325 to fuel injector pin 327 , heating element 317 can heat fuel because diode 319 is forward biased. Under this condition diode 315 is reverse biased and substantially limits current flow to actuator coil 313 .
[0031] Thus, the circuit illustrated in FIG. 3 provides two separate functions (actuating a fuel injector and heating fuel in the fuel injector via heating elements) by way of a single electrical connector and a single pair of electrical terminals. By simply changing current direction, the fuel injector function is completely changed. Further, the functions are virtually decoupled from each other. That is, the illustrated circuit allows the fuel injector to be actuated and inject fuel to a cylinder without substantially heating fuel in the injector (when current flows to coil 313 only a small amount of current dependant on the diode design passes diode 319 (e.g., a few milliamps) reaches heating element 317 ). Consequently, the present description provides for a fuel injector that functions to inject fuel to a cylinder and heat fuel in the injector by way of a heating element that is distinct and separate from the actuator coil.
[0032] In addition, the illustrated circuit permits various levels of current to be applied to the coil or heater without causing a device to inadvertently operate. For example, 1 amp or 4 amps can be applied to the heater without causing the coil to actuate the fuel injector. This allows coil or heater operation to be adjusted based on engine operating conditions if desired.
[0033] Referring now to FIG. 4 , an alternative circuit for controlling current to a fuel injector and heater is shown. Power supply 401 , switches 403 , 407 , 405 , and 409 are used in the manner described in FIG. 3 to control the direction of current flow into the fuel injector components identified by boundary 411 . Likewise similar to FIG. 3 , diodes 450 , 452 , 454 , and 456 are included to dissipate inductive energy when switches 403 , 407 , 454 , and 456 are operated.
[0034] If current flows into fuel injector pin 427 from wiring harness pin 423 , and out of fuel injector pin 425 and wiring harness pin 421 , then coil 413 can operate because no diode blocks the current flow. In these conditions diode 419 is reverse biased and substantially stops current flowing to heater element 317 .
[0035] If on the other hand current flows from fuel injector pin 425 to fuel injector pin 427 , heating element 417 can heat fuel because diode 419 is forward biased. In one embodiment during these conditions, current flowing into the injector can be kept below a predetermined level at which the fuel injector actuates and injects fuel. This allows the heater to operate without actuating the fuel injector. Alternatively, if desired, current can be increased to a predetermined level at which the fuel injector is actuated and heater temperature increases.
[0036] Thus, this circuit configuration allows the fuel injector to be operated independent of heater operation, or alternatively, it allows the heater to be operated while the injector is actuated. Further, when the level of current is controlled, this circuit permits the fuel injector to heat fuel in the fuel injector without actuating the fuel injector.
[0037] Referring now to FIG. 5 , an example of a fuel heating circuitry integrated into an engine controller is illustrated. Engine controller 12 is comprised of a bank of high-side drivers 505 , low-side drivers 507 , and a relay control switch (e.g., a transistor) 511 . External relay 503 is toggled between a first (lower potential) and second (higher potential) voltage depending on the state of relay control switch 511 . Alternatively, the external relay 503 may be substituted with solid-state circuitry, if desired.
[0038] Circuitry of four heated fuel injectors is within boundary region 501 . This injector circuitry represents an example of circuitry for heating fuel for a four cylinder engine. Cylinder number one fuel injector circuitry is within boundary region 520 , while fuel injectors for cylinders two through four are shown in boundary regions 522 , 524 , and 526 respectively.
[0039] Relay 503 is shown connecting fuel injectors 520 , 522 , 524 , and 526 to a first voltage reference. Relay 503 may also connect the same fuel injectors to a second voltage reference V+. The second voltage reference is at a higher potential than the first voltage reference. The operating state of switch 511 determines whether relay 503 connects fuel injectors 520 , 522 , 524 , and 526 to the first or second voltage reference.
[0040] High-side driver 505 is comprised of individual solid-state switches that are connected to the second voltage reference on one side of the switches and to fuel injectors 520 , 522 , 524 , and 526 on the other side of the switches.
[0041] Low-side driver 507 is also comprised of individual solid-state switches that are connected to the first voltage reference on one side of the switches and to fuel injectors 520 , 522 , 524 , and 526 on the other side of the switch.
[0042] Fuel is heated in the injector by controlling relay control switch 511 and high-side driver 505 . Specifically, relay control switch 511 is set to a state whereby control relay 503 connects the first voltage reference to a terminal of fuel injectors 520 , 522 , 524 , and 526 . In addition, switches internal to high-side injector 505 are closed such that the second voltage reference is routed to a second terminal of fuel injectors 520 , 522 , 524 , and 526 . Current then flows from the second voltage reference to the first voltage reference in a direction that forward biases a diode in an electrical path going to the heating element of each fuel injector.
[0043] On the other hand, the fuel injector is actuated by controlling relay control switch 511 and low-side driver 507 . Specifically, relay control switch 511 is set to a state whereby control relay 503 connects the second voltage reference to a terminal of fuel injectors 520 , 522 , 524 , and 526 . And, switches internal to low-side injector 507 are closed such that the second voltage reference is routed to a second terminal of fuel injectors 520 , 522 , 524 , and 526 . Current then flows from the second voltage reference to the first voltage reference in a direction that reverse biases a diode in an electrical path going to the heating element of each fuel injector. In this way, current is allowed to flow through the injector actuator coils but is limited or blocked from passing through the injector heating element. Thus, current can be driven in one direction to actuated the fuel injector and in a different direction to heat fuel in the injector.
[0044] It should be noted that when current is driven in a direction that forward biases the diodes illustrated in FIG. 5 , the level of current can be restricted or regulated by high-side driver 505 such that the fuel injector is not actuated.
[0045] FIG. 6 is plot of example current supplied to fuel injectors of a four-cylinder engine. Signals INJ 1 - 4 represent current delivered to fuel injectors. The “+” represents current being driven into a fuel injector in a second direction. The “−” represents current being driven into the fuel injector in a first direction, opposite the second direction. The location that is approximately half way between the “+” and “−” represents substantially no current flowing into the fuel injector.
[0046] Engine position relative to top-dead-center compression stroke of cylinder number one is represented by the signal labeled CRK. Engine cranking and starting begins at vertical marker 601 and the sequence flows from left to right.
[0047] Note that the current illustrated in FIG. 6 is not necessarily indicative of the actual current profile. Current is illustrated in FIG. 6 to show an example of when fuel heating may be accomplished relative to fuel injector actuation, the illustration is not meant to illustrate an actual current profile. Also note that fuel heating time may vary from that illustrated without deviating from the scope or breadth of the description. For example, the injector opening timing illustrated at 605 may be increased or decreased or changed with respect to engine position. Further, the amount of current used to open the fuel injector may be increase above the amount of current necessary to open the fuel injector. The resulting additional current can be transformed into heat to further heat the fuel within the injector. Likewise, fuel heating intervals may also vary from those illustrated. For example, between injections at 605 and 619 the heater is shown as being on for the entire interval. However, if desired, the fuel heating may take place for only a fraction of the interval. Furthermore, only a few engine cycles are shown whereas fuel heating may go on for a predetermined period of time or for a specific number of cylinder cycles that exceeds the number illustrated.
[0048] Also note that the present method is capable of heating fuel over the engine operating range if desired. For example, fuel heating can be used during a start as well as during engine operation. Heating fuel during engine operation allows the present method to control the cylinder charge temperature.
[0049] At 603 , current is directed into fuel injector number one in the first direction. This begins heating fuel in the fuel injector. Current flow ceases briefly in region 604 . As the engine begins to rotate, right of vertical marker 601 , the first injector actuation command is issued at 605 . This command directs current into the fuel injector in a second direction. Fuel heating resumes in region 606 when current to fuel injector number one is resumed in the first direction. Fuel is injected to cylinder number one again when current is reversed and sent into fuel injector number one at 619 . The described sequence for heating and injecting fuel at fuel injector number one continues until heating is stopped in region 621 .
[0050] Fuel injector number two follows a similar sequence as fuel injector number one, but fuel heating begins at region 607 , the first injection occurs at 609 and fuel heating is stopped at 623 . The initial fuel heating at 607 is offset in time from the fuel heating in injector one at 603 . This reduces the instantaneous current draw from the vehicle power source before the engine is started. If the vehicle power source has sufficient capacity, fuel in all fuel injectors may be simultaneously heated. In still another embodiment, fuel may be heated at different times in selected groups of fuel injectors. Current at 611 and 615 represents initial fuel heating for cylinders three and four. Fuel injector current at 613 and 617 represents initial actuation current. Fuel injector current at 625 and 627 is substantially zero between injector openings because cylinder temperature has increased to a level that promotes fuel vaporization.
[0051] Referring now to FIG. 7 , a flow chart of an example fuel injector heating method is shown.
[0052] Note that in at least one embodiment, current to actuate a fuel injector (actuation current) enters the fuel injector through an electrical connector having two pins and is delivered in a second direction. Current to heat fuel flowing through the fuel injector is delivered through the same electrical connector and pins but in a first direction, opposite to the second direction described to actuate the fuel injector.
[0053] In step 701 , the routine determines if fuel heating has been requested. A request for fuel heating may come from an external routine or it may result from evaluating the state of sensors and systems. In one example, the states of engine temperature, time since last engine start, oil temperature, desired cylinder charge temperature, and fuel temperature are used to determine if fuel heating is desired. Further, operating conditions can be used to determine the duration of fuel heating. In one example, the fuel heating duration may be determined by retrieving empirically determined heating times from memory. Specific memory locations may be interrogated by indexing arrays that are organized by engine coolant temperature and engine oil temperature, for example.
[0054] In step 703 , the fuel injector heating delivery mode is selected. The heating mode describes how and when the fuel heating is delivered to one or more fuel injectors. For example, during an engine start, heat may be delivered to fuel through a group of injectors in a sequential manner and the amount of heat delivered by each injector can be varied in response to operating conditions.
[0055] In one embodiment, fuel heat delivery mode can be split into two regions. Specifically, the time before the engine is started and the time after the engine is started. Heat may be delivered to the fuel through a fuel injector before a start in a way that may be different from the way that heat is added to fuel after a start. For example, before the engine begins to rotate the heating sequence may be based on time. That is, current can be sent to heat a different individual injector every 2 seconds, for example. After the engine is started, heat may be delivered at predetermined crankshaft intervals for a predetermined time or crankshaft angle.
[0056] Fuel heating by the fuel injector may be delivered to the injectors simultaneously; to groups of injectors where the injectors of a group are simultaneously heated, and where the injector groups are heated at different times; sequentially to all or a group of injectors; or in combinations of the before-mentioned ways. In one embodiment, current is supplied to two or more fuel injectors simultaneously. That is, current for injector heating the injectors is delivered at substantially the same time. Alternatively, it is also possible to deliver current to heat the injectors sequentially. For example, current for injector heating can be supplied to a first injector, stopped, supplied to a second injector, stopped, and continued in the same manner to the remaining injectors.
[0057] In addition, this sequence may be repeated until operating conditions, such as time since key-on has reached a predetermined level or until engine oil temperature reaches a desired level, for example. As mentioned above, after the engine is started, the fuel injector heating may be continued or may be stopped. Further, the amount of heat transferred when the engine is stopped may be different from the amount of heat delivered after the engine is started.
[0058] Engine operating conditions (e.g., engine temperature, fuel temperature, cylinder charge temperature, barometric pressure) may be used to determine when to deactivate injector heating. In addition, the fuel heating mode and the timing when heat is delivered to the fuel may also be varied as the engine begins to rotate.
[0059] FIG. 6 shows one example of a fuel injector heating delivery mode that is available from the present description. Specifically, injector heating is delivered at predetermined crankshaft intervals so that the heating does not interfere with injector operation. Further, it is also possible to briefly deactivate heating to one injector if current is needed to actuate another fuel injector during the same crankshaft interval. For example, if fuel injector heating is scheduled for cylinder number four fuel injector between 540 and 0 crankshaft degrees referenced to top-dead-center of cylinder one, and fuel injection is scheduled for cylinder number one during this same interval, then the heating for cylinder four fuel injector may be deactivated while injection commands are issued to the cylinder number one fuel injector.
[0060] Continuing with step 703 , the heating mode may be determined by assessing engine operating conditions, injector operating conditions including barometric pressure, humidity, cylinder charge temperature, and engine temperature. In one embodiment, the operating conditions may be used to exercise a state machine that can activate different heat delivery modes before and after starting. The selection of these heat delivery modes may be empirically determined, for example. FIG. 6 provides a sample of the available heating modes that may be selected. The routine proceeds to step 705 after the heat delivery mode is selected.
[0061] Referring now to step 705 , the fuel is heated in the injectors. In one embodiment, the fuel heating duration may be reduced or increased based on the type of fuel being heated. Specifically, in one example, a sensor can determine the concentration ethanol in a fuel line leading to the fuel injector. The fuel heating time can be varied as the concentration of ethanol increases in the fuel line. In addition, the rate that heat is delivered to the fuel can be varied as the fuel type varies (e.g., as the concentration of ethanol varies) by varying the amount of current supplied to the heating element. Further, the rate heat is transferred and/or the duration of fuel heating can be varied as the engine's or vehicle's altitude varies. Further still, the rate heat is transferred and/or the duration of fuel heating can be varied as the ambient air humidity varies and/or as engine temperature varies.
[0062] In one embodiment, the heating duration and heat transfer rate are empirically determined and stored in engine controller memory for later retrieval and use. In one embodiment, the amount of fuel heating is reduced as barometric pressure is reduced (i.e., altitude increases).
[0063] As noted above, the present method can also adjust fuel temperature to affect the cylinder charge temperature. In one embodiment, desired cylinder charge temperature is mapped over the engine operating ranges for a particular type of fuel (e.g., ethanol). A model infers cylinder charge temperature from intake air temperature, engine temperature, engine speed, cylinder air charge amount, fuel type, and injection timing. If the inferred cylinder charge temperature deviates from the desired cylinder charge temperature, then heat can be added to the fuel (i.e., the rate of heat addition and/or the amount of time heat is delivered to fuel) or the heater can be deactivated so that the desired temperature is reached.
[0064] Thus, the present method is capable of adjusting the rate of heat transfer from a fuel injector to fuel, as well as the fuel heating duration in response to environmental and vehicle operating conditions.
[0065] In one example, the amount of heat transferred over a period of time to the fuel delivered to the engine after the engine is started may be increased as compared to the amount of heat delivered to fuel before the engine is started. The present method also allows different heat transfer rates to the fuel depending on the power source. When the power to heat fuel comes from a battery, current may be a first amount. When power to heat fuel comes from an alternator, current may be a second amount, different from the first amount.
[0066] As previously mentioned, the fuel may be heated by PTC or NTC devices. Further, the actuator coil may be used to heat the fuel as well. The PTC/NTC heating elements may transfer heat directly to fuel or they may transfer heat to fuel through an intermediate material by conduction. Similarly, the actuator coil may transfer heat to fuel by using the internal resistance of the fuel injector coil to heat the injector components that surround the coil. The coil heat can be transferred to the surrounding material through conduction. The coil resistance transforms the electrical energy entering the coil into thermal energy. By applying a controlled current to the fuel injector coil, the temperature of the injector coil may be regulated so that the coil transfers a desired amount of thermal energy to the surrounding injector while maintaining the temperature of the coil below a predetermined level. In one example, current supplied to the coil is regulated below a predetermined amount so that there is insufficient current to operate the injector, but enough to heat fuel within the injector.
[0067] In addition, eddy current heating may also be used to heat fuel by generating a time-varying magnetic field from varying the current that flows into the actuator coil. The current may be varied in a variety of ways. For example, the current entering the coil may be increased and decreased over a specified time interval, or if the engine is rotating, the current may be increased or decreased over a specified crankshaft interval (e.g., The excitation frequency may be adjusted by a predetermined amount every 3600 crankshaft angle degrees. As the current varies, a magnetic field external to the coil varies and ferrous material in the field resists the changing magnetic field, thereby heating the ferrous material. Heat is conducted from the ferrous material to the fuel.
[0068] The current flow to the fuel injector may be controlled by an H bridge that allows bi-directional current flow, or by other circuitry that provides a similar function.
[0069] Also note that the fuel injection timing may be adjusted as a function of the time fuel injectors are heated or as the amount of heating energy supplied to a fuel injector varies. For example, at a constant engine speed and load, the fuel injection pulse-width may be decreased as the amount of heat energy supplied to a fuel injector increases. This feature allows an engine controller to compensate for the improved response of a heated injector. After the coils start to heat, the routine proceeds to step 707 .
[0070] In step 707 , the routine determines whether or not the engine is ready to start after fuel heating has commenced. In one embodiment, if the fuel has reached a desired temperature or a time since key-on, the engine controller 12 can notify the operator that the engine is ready to start or the engine may be started in other circumstances. In other embodiments, the engine may be considered ready to start after a desired amount of heating energy has been supplied to fuel in one or more injectors. For example, the engine may be considered ready to start if a predetermined number of joules of energy have been dissipated by each fuel injector heating element. Also note that in some embodiments, the engine may be allowed to start as soon as instructed by an operator. That is, fuel heating may be initiated but the engine may be started whether or not fuel has reached a desired temperature. If this mode of operation is selected, the fuel pulse-width may be adjusted to improve starting. If the routine determines that the engine is ready to start the routine proceeds to step 711 . Otherwise, the routine returns to step 705 .
[0071] In step 711 , the injectors are controlled so that the desired amount of fuel is injected to the cylinders at the desired timing. That is, current is delivered in a second direction such that it flows through the actuator coil substantially unencumbered (e.g., a small reduction in current caused by a voltage drop across a diode or similar device is anticipated and permissible). When current is directed in this manner, the fuel injectors are operated in a way that is similar to conditions when injector heating is not desired. That is, current is supplied to the injector at a crankshaft angle and desired duration that delivers the desired amount of fuel to the cylinder.
[0072] In step 713 , the routine determines if fuel heating is desired while the engine is operating. If it is, the routine proceeds to step 715 . If not, the routine proceeds to exit. If no fuel heating is desired during engine operation, current flow is limited to the second direction, and the injectors are operated by the main fuel injection routine and fuel is delivered in response the engine speed, operator demand, and operating conditions.
[0073] In step 715 , the fuel is heated by applying current to the fuel injector in a first direction while the injector is not actuated. That is, as described above, when current flows to the fuel injector in a second direction the injector is actuated. Current flows to the fuel injector in a first direction, different from the second direction, to heat fuel passing through the injector. Accordingly, current is repeatedly reversed as the engine operates. For example, current flows into the coil when it is delivered to the injector in a second direction. When the injector has delivered the desired amount of fuel, the current is reversed and delivered in a first direction to heat fuel passing through the injector. The heating current may be delivered to the fuel injector for the entire period between fuel injections, or it may be delivered for a fraction of the period between injections.
[0074] The rate of heat delivery to the fuel and the duration heat is transferred to the fuel can be an open-loop or closed-loop control process. In one embodiment, fuel heating rate and duration are determined after assessing engine temperature, barometric pressure, and humidity. In this example, fuel heating follows a prescribed schedule that has been programmed into the engine controller.
[0075] In a closed-loop embodiment, engine sensors are repeatedly monitored and used to determine operating conditions so that the heat transfer rate and duration of fuel heating can be revised as engine operating conditions vary. Specifically, the following calculations are one example method to determine the heat transfer rate.
[0000] HeatCur=Basecur( N )·cur h (hum)·cur f tem(fueltemp)·curetem(engtemp)·cur f typ(ftype)·curbar(baro)
[0000] Where HeatCur is the amount of current to deliver in a heating interval, where Basecur is an empirically determined base amount of current that is a function of engine speed N, where curh is a modifier that is a function of humidity hum, where curftem is a modifier that is a function of fuel temperature fueltemp, where curetemp is a modifier that is a function of engine temperature engtemp, where curftype is a modifier that is a function of fuel type ftype, and where curbar is a modifier that is a function of barometric pressure baro.
[0076] The fuel heating duration can be determined from a similar function.
[0000] DurCur=Basedur·dur h (hum)·dur f tem(fueltemp)·dur e tem(engtemp)·dur f typ(ftype)·durbar(baro)
[0000] Where DurCur is the duration current is delivered, where Basedur is an empirically determined base duration of current, where durh is a modifier that is a function of humidity hum, where durftem is a modifier that is a function of fuel temperature fueltemp, where duretemp is a modifier that is a function of engine temperature engtemp, where durftype is a modifier that is a function of fuel type ftype, and where durbar is a modifier that is a function of barometric pressure baro.
[0077] Note as mentioned above, current control can vary depending on the circuitry within the fuel injector. For example, if current is impeded in one direction through the PTC/NTC heating element, and current is not impeded through the actuator coil, it may be desirable to limit current flow to the entire fuel injector (actuator coil and heating element) so that the fuel injector does not actuate when fuel is being heated. On the other hand, if current flow can be impeded through both the actuator coil and the heating element, heating current may not have to be limited to as low of a level as if current where flowing through both the actuator coil and the heating element.
[0078] While the engine is being operated, it is desirable to keep the fuel injectors delivering a commanded amount of fuel. This can be accomplished by heating the injector during the portion of a cylinder cycle where fuel is not injected. For example, the fuel injectors may be heated during the power or exhaust strokes. FIG. 6 shows an example of heating the fuel injectors while the engine is operating. Of course, the fuel injector heating interval may be varied from that which is shown in FIG. 6 , if desired. One convenient way to achieve heating during engine operating is to time the heating period with engine positions. That is, the heating interval can be between bottom-dead-center of the exhaust stroke and top-dead-center of the exhaust stroke of the cylinder associated with the injector being heated, for example. After the coil current sequences are determined and commanded the routine returns to step 711 .
[0079] This concludes the description. The reading of it by those skilled in the art would bring to mind many alterations and modifications without departing from the spirit and the scope of the description. For example, I3, I4, I5, V6, V8, V10, V12, and turbine engines operating on non-limiting fuel types such as ethanol, kerosene, jet fuel, gasoline, propane, proponol, diesel, or other alternative fuel configurations could use the present description to advantage. | A method for improving fuel heating is presented. The method can reduce system complexity and cost when fuel is heated within a fuel injector. In one embodiment, the method independently heats and injects fuel by changing the direction of current flow through a fuel circuit. | 5 |
CROSS-REFERENCE TO RELATED APPLICATION
This Non-provisional Utility application claims priority to U.S. Provisional Patent Application Ser. No. 61/831,319, filed on Jun. 5, 2013.
BACKGROUND
Wind turbines are rapidly becoming a significant source of electrical power throughout the United States and in the world. A typical wind turbine consists of an electrical generator mounted in a nacelle atop a tower that may be 60 or more meters tall. The generator is powered by wind which rotates turbine blades. The turbine blades, which may be up to 50 or more meters in length and weigh upwards of 1900 kg, are mounted to a hub at the forward end of the nacelle. Typically, three blades are used, and a gearbox converts the relatively slow turbine revolution rate to a faster rate of revolutions suitable for the generator.
As with most mechanical machinery, periodic maintenance, refurbishing or repair is needed for wind turbines, including the occasional need to repair or refurbish a blade of the wind turbine. When such refurbishing or repair cannot be administered upon the blade while attached to the hub, it is necessary to remove the blade from the wind turbine and lower it to the ground, where the necessary work may be performed. Upon completion of the work, the blade must be raised to the nacelle and reattached to the hub. The extreme length and weight of a blade, and its aerodynamic shape and structural characteristics, make the job of lowering and raising a blade from a turbine in the field a difficult and exacting task. In addition, blades must be removed from wind turbines situated in areas in which accessibility is limited, and in which the local terrain may not permit the ingress or egress of larger vehicles, such as large cranes. Moreover, because wind turbines are designed to be situated in areas of more-or-less constant prevailing winds, the winds have a tendency to interfere with the raising or lowering of a turbine blade, threatening to knock it against the adjacent tower or to cause the blade to twist and rotate during the lifting process.
Various systems have been developed for performing the task of raising and lowering wind turbine blades for maintenance, refurbishing, or repair. One of these systems is U.S. Pat. No. 7,726,941, Ser. No. 11/738,685 (Pub. No. US-2007-0266538) to Bervang, which describes a method for raising a turbine blade using a rigid yoke that grips the blade to be raised or lowered with a jaw-like structure. The yoke has an integral counterweight which assists in rotating the blade between vertical and horizontal positions, and is raised or lowered by a crane. Tag lines between the yoke and the crane are used to turn or otherwise position or manipulate the blade during raising or lowering. Although this system uses tag lines to prevent the blade from twisting or banging against the tower, its use of a crane hoisting a rigid yoke with a jaw-like structure places extreme pressure point stresses upon interior portions of the blade and requires a suitably smooth or flat area in the vicinity of the base of the tower to support a large crane.
U.S. Pat. No. 8,083,212 discloses a lifting system in which a lifting winch may be mounted in the rotor head, in the nacelle, or on the ground, and that lifts a turbine blade with a cable attached to the winch. A movable sheaf, or pulley, supports a hoisting cable from within the nacelle. A frame structure serves as a harness or yoke to grasp the blade at or near the root, and maintains it in a desired vertical or horizontal orientation as it is suspended from the cable. As the blade is lifted, the frame creates forces on the blade that cause the blade to assume a particular angle with reference to the vertical. Although the harness may be effective in controlling the vertical and horizontal orientation of the blade, this system does not have tag lines that would be necessary to prevent the wind from blowing the blade against the tower or to prevent it from twisting during the hoisting operation.
Canadian Patent CA 2,692,705 to Reed et al. discloses a system in which two winches mounted at ground level on either side of a wind turbine tower each operate a hoisting cable. Each cable extends upward to a pulley that is attached to the rotor hub, which then extends downward to a blade that is to be hoisted up to the hub. A pick crane assists the process by lifting the lower tip of the blade. The use of two cables, one at either side of the blade, provides some protection against the blade's becoming twisted in light winds during hoisting. However, without having taglines to brace the blade against twisting in higher winds, and to hold the blade away from the tower during such winds, this system is limited to being used only in no wind or light wind situations—which are the antithesis of optimal placement for a wind turbine farm.
SUMMARY OF THE INVENTION
The Blade Removal System of the invention overcomes these drawbacks. It is a system and method of lowering a wind turbine blade after it has been removed, and of raising the blade for reinstallation it after repairs have been completed. The system is intended to lower the blade from the hub in a vertical orientation to a point near the ground, and to rotate it to a horizontal position before placing it on a flatbed cradle for maintenance and repair. In an embodiment, the system will operate satisfactorily at temperatures ranging from −10 degrees F. to 120 degrees F., and will hoist blades weighing up to 1900 kg. which may include bearing assemblies of about 270 kg.
The system uses a winch that, in a preferred embodiment, is situated in the nacelle of the wind turbine. A cable extends downward from the winch to the blade root where it may be secured to a load cell. In alternative embodiments, a cable may be threaded through a pulley wheel attached to the root end of the blade, and will extend back to the nacelle where it is secured to a load cell. The slack cable on the other side of the winch is threaded through cable guide pulleys in the nacelle and, in an embodiment, extends to the ground immediately beneath the turbine blade hub. The winch lowers or raises the blade by means of a “lifting yoke,” which is attached to safety cross beams at the root end of the blade. The winch raises or lowers the cable, thereby raising or lowering the blade. In an alternative embodiment, the cable extends through the pulley, and is secured to a load cell in the nacelle. In this alternative arrangement the torque needed to raise or lower the blade is only one-half the weight of the blade being hoisted.
In a preferred embodiment, the winch will have at least two speeds of operation, and the blade will be raised or lowered at 11 m/min. or at 22 m/min., depending upon the winch speed. An operator may select the winch operating speed by means of a controller having “fast” and “slow” speed selections for raising and lowering operations. A cable storage system in the form of a take-up spool may be located within the nacelle or on the ground, and will take up or release cable as necessary as the winch is operated. Take-up spool operation may be manually controlled, possibly using a foot pedal.
In operation, the blade to be removed is turned to the six o'clock position on the turbine hub. A tip end shoe is placed around the blade about 7 meters from the lower tip, and an optional tip sock may be placed at the very tip of the blade. The tip end shoe includes a crane hook receiving component that is used when the blade orientation is being changed. The tip end shoe and tip sock are held vertically in place with a cord that extends vertically upward to the blade root, where the cord is secured.
As the blade is disengaged from the hub, the lifting yoke is attached to the blade root. A cable from the winch runs to the lifting yoke where it is secured to a load cell mounted on the blade root. Tag lines are attached to the tip end shoe at the blade's leading and trailing edges, and extend to points at ground level where technicians hold them to prevent the blade from being blown by any wind that may be present. Two other tag lines are attached to eye bolts or some other suitable fastening mechanism at either side of the blade root, and also extend to the ground where the technicians can hold and manipulate them. The technicians are positioned some distance from the base of the tower, and are able to prevent the blade from blowing or twisting by appropriate manipulation of the tag lines. Without tag lines, the blade is subject to being blown against the tower or being twisted during the blade raising or lowering operation. The system is designed to permit safe operation in winds that may gust up to 12 m/sec.
As the blade is lowered in a vertical orientation and nears the cradle (on the ground), a small pick crane will control a line running from the crane to a crane hook attachment point on the tip end shoe. When this line is tightened, the blade will be rotated to a horizontal orientation, being suspended horizontally by the lifting yoke at one end, and the crane hook attachment at the other. From this position, the blade may be lowered directly onto a blade refitting cradle on a trailer bed for renovation.
As opposed to large cranes which are more expensive and less maneuverable, the pick crane is relatively small, is capable of traversing rough terrain that typically surrounds a wind turbine, and is needed only to lift the lower end of the blade when the blade is to be oriented horizontally while suspended near the ground. The four tag lines extend to the ground from points on either side of the blade, and are controlled by human workers who are able to secure and manipulate the tag lines from positions remote from the base of the tower that may be on uneven or severely sloping ground. After the blade has been repaired or renovated, it will be hoisted back to the hub of the wind turbine in the reverse order of the steps by which it was lowered.
In a preferred embodiment, the blade is raised and lowered by a winch that is located within the nacelle of the wind turbine. In other embodiments the winch may be situated on the ground near the base of the turbine tower. The take-up reel may also be situated in the nacelle or on the ground to take-up or release slack cable and prevent it from becoming tangled or coated with debris from the ground.
The weight of the blade is primarily borne by a lifting yoke that is attached to the blade root. Elsewhere along the blade, the blade is supported by a flexible harness that secures the lower end of the blade with a tip end shoe, which is a belt-type apparatus that wraps around the blade and that provides an attachment point for the lower tag lines and the pick crane cable. In an embodiment, the tip end shoe may also include a tip sock that fits around the extreme lower tip of the blade and that is attached to the tip end shoe by vertical suspenders. The harness may secured at the top (root) end of the blade by a collar that is fastened about the root end. Suspender cords extend down from the collar on either side of the blade to hold the tip end shoe.
It is an object of this invention to provide a method for raising and lowering a wind turbine blade without causing damage to the blade. More specifically, it is an object of the invention to provide a lifting system that allows the use of tag lines to keep a blade from being blown against the tower while being lifted or lowered.
It is an additional object of the invention to provide a lifting system that can safely be used in all terrains.
It is a further object of the invention to provide a lifting system in which inexpensive supporting equipment such as a pick crane or a flat horizontal cradle can be used.
It is another object of the invention to provide a lifting system in which lifting and lowering is provided by a single winch.
It is yet a further object of the invention to provide a lifting system in which tag lines may be manipulated by human personnel from locations in which machinery cannot be situated.
It is another object of the invention to provide a lifting system in which a blade is raised or lowered in a vertical orientation when it is above the ground by a distance greater than its length, and which will be rotated to a horizontal position when it is below that height.
These and other objects of the invention will become evident from the following description of the preferred embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts the system in preparation to lower a blade that has been removed from a wind turbine.
FIG. 2 depicts the system of FIG. 1 when the blade has been lowered a distance from the blade hub.
FIG. 3 depicts the system of FIG. 1 when the blade has been rotated horizontally and lowered to a cradle which will hold the blade during repair.
FIG. 4 a shows an interior view of a preferred embodiment of the system of the invention.
FIG. 4 b shows an interior view of an alternative embodiment of the system of the invention.
FIG. 4 c depicts detail of a portion of what is shown in FIG. 4 .
FIG. 5 shows the attachment of lower tag lines and a pick crane supporting cable to the lower end of a blade being hoisted.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1 , a blade 10 has been detached from a hub 12 and is being supported by main cable 14 which extends downward from a nacelle 16 at the top of tower 20 . Cable 14 is attached to a traction hoist or winch which, in a preferred embodiment, is situated in nacelle 16 . Slack main cable 62 has no tension on it, and feeds down from wind turbine tower 20 where it is taken up by take-up spool 60 . In other embodiments the take-up spool may also be located in the nacelle, or the winch may be situated at ground level rather than within nacelle 16 . To hold the blade and lower it from the hub, the winch is used to provide the hoisting power.
A tip end shoe 22 fits around the lower section of the blade, and is held in place with a suspender cord 52 that extends longitudinally along the blade between the tip end shoe 22 and a collar 54 . The tip end shoe forms the lower part of a harness that holds the blade at a desired orientation. In a preferred embodiment, with a blade of approximately 23-24 meters in length, the tip end shoe is located approximately 5-7 meters from the end of the blade. A cable 24 which is controlled by a pick crane 26 is secured to the tip end shoe, and is used to support the blade against any wind that would cause the blade to knock against the turbine tower 20 , and to rotate the blade to a horizontal position before the blade is set down.
Four tag lines are attached to the blade and are manually controlled by personnel on the ground. Upper tag lines 28 , 30 are attached to the upper (root) end of the blade on either side of the blade. One tag line 28 extends to a first person 36 situated to one side of the tower 20 and pick crane 26 , while the other tag line 30 extends to a second person 38 situated on another side of the tower and pick crane. The positioning of the individuals controlling the tag lines will be based upon the prevailing winds and the location of the pick crane. In a preferred embodiment, the tag line holders will be situated downwind of the tower with the wind direction tending to blow the blade away from the tower and in a direction midway between the two individuals.
Lower tag lines 32 , 34 are attached at either side of the blade at the tip end shoe near the lower end. A pick crane cable 24 is also secured to the tip end shoe. As the blade is being raised or lowered, individuals 36 , 38 manually hold the upper and lower tag lines to prevent the blade from twisting in the wind and to hold it away from the turbine tower if the wind should be blowing in that direction. As the blade is lowered, as shown in FIG. 2 , a flatbed cradle 40 will be situated to receive the blade in a horizontal orientation.
FIG. 2 shows the hoisting system with a turbine blade 10 having been lowered midway from the turbine hub 12 to the ground. Pick crane 26 has released some of cable 24 to permit the blade to be lowered in a substantially vertical orientation. Upper tag lines 28 , 30 maintain the root end of blade 10 in a desired position away from turbine tower 20 and free from twisting. Lower tag lines 32 , 34 similarly hold the lower end of blade 10 at tip end shoe 22 , keeping the blade away from turbine tower 20 and preventing the blade from being twisted by the wind. The winch in the nacelle has lowered cable 14 , thereby permitting the blade to be lowered from the nacelle 16 . Slack main cable 62 is being released from take-up spool 60 , and feeds into the winch to permit continual lowering of the blade 10 . Equipment for receiving the lowered blade is depicted in the form of a flatbed cradle 40 although any suitable cradle for receiving a blade may be used. In some embodiments, when a blade is to be modified, the receiving cradle may also include machining apparatus designed to perform any intended modification or refurbishing of the blade.
In FIG. 3 , the blade 10 has been lowered and reoriented to a horizontal position preparatory to being received in a flatbed cradle 40 . Main cable 14 has been fully extended, and pick crane cable 24 is also near its full extension. Human tag line controllers 36 , 38 are able to manipulate the root end and opposing end of blade 10 to align blade 10 with the receiving cradle 40 . Once the blade has been seated on its cradle, all lines and cables may be removed, and repair or refurbishing may then be done in situ.
FIG. 4 a is a depiction of the hoisting components in the nacelle 16 , and of the main cable and its attachment to the root of the blade being hoisted. In the preferred embodiment, a winch 18 is situated in the nacelle 16 , and is supported by supporting structure 44 that is sufficient to hold the weight of the blade via a single main cable 14 . FIGS. 4 b and 4 c depict an alternative embodiment in which a lifting yoke 64 is attached to the root end of blade 10 , and comprises a pulley arrangement in which a pulley 68 is attached to a swivel 66 that may turn through an arc of 360 degrees. The swivel, in turn, is attached to a supporting arm 70 that extends across the blade root and is firmly secured to the blade root.
As shown in FIGS. 4 b and 4 c , the lifting yoke 64 permits the blade to be hoisted or lowered while winch 18 bears only one-half of the total weight of the blade. Load cell 42 bears the other half of the weight, and provides a method for recording the weight at each moment during the raising or lowering process. In the event of an abrupt change in weight, the winch may be automatically shut down to avoid damage to the blade while the cause of the weight change is investigated. A series of idler wheels comprise a cable guide structure 46 which guide the slack main cable 62 from the winch to a take-up reel (not shown) at the base of the tower 20 . The cable 14 is in tension between load cell 42 and winch 18 , and extends downwardly from winch 18 to the lifting yoke 64 located at the root of the blade 10 .
FIG. 5 depicts detail in the harness used to stabilize the blade during raising or lowering. A collar 54 extends around the blade 10 near the root, and supports suspender cords 52 that run down the blade on either side to support tip end shoe 22 . In embodiments in which a tip sock 50 is used, suspender cords 52 extend to the tip sock and hold it in place at the lower tip of the blade. A tag line support 58 may be attached at either side of tip end shoe 22 , and may comprise a hollow ring through which tag lines 32 , 34 pass. As shown, tag line 34 passes through tag line support 58 and extends upward 56 to the root end of the blade. In an embodiment, tag line 34 forms a continuous line through tag line support 58 , turns upward 56 and passes through an eye bolt (not shown) at the root end of the blade, where it then continues back down to its human controller as tag line 30 . In this embodiment, only two continuous tag lines are required, and are “strung” through tag line supports as indicated. Also shown in FIG. 5 is pick crane 26 with its cable 24 extending to tip end shoe 22 where it may be secured with a cable attachment (not shown). In an alternative embodiment, pick crane cable 24 may extend to tip sock 50 where it may be attached at the extreme end of blade 10 .
In another embodiment, if greater control and stability are desired, a third set of tag lines may be utilized, and would attached to the blade harness at tip sock 50 . Alternatively, lower tag lines 32 , 34 may be attached at tip sock 50 rather than at tip end shoe 22 . Varying circumstances of terrain, wind conditions, and blade size may dictate one or another of the possible configurations for tag line and pick crane cable attachments.
The foregoing description of possible embodiments consistent with the present invention does not represent a comprehensive list of all such embodiments or all variations of the embodiments described. The description of only some embodiments should not be construed as an intent to exclude other embodiments. Artisans will understand how to implement the invention in many other ways, using equivalents and alternatives that do not depart from the scope of the invention. | A method of lowering a wind turbine blade after removal from a wind turbine lowers the blade in a vertical position to a point near the ground, and rotates it to a horizontal position for emplacement on a cradle. A winch is situated in the nacelle of the wind turbine. A cable extends downward from the winch to the blade root where it may be secured to a load cell. A tip end shoe is placed around the lower portion of the blade, and includes a crane hook receiving component that is used when the blade orientation is being changed. Tag lines are attached to the root and the tip end shoe, and extend to points on the ground where technicians manipulate them to prevent the blade from being blown into the tower. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not applicable.
FIELD OF THE INVENTION
[0002] The present invention relates to tools and methods for earth boring, well completion and production. More particularly, the invention relates to apparatus and methods for maintaining downhole tools approximately concentric with a pipe or tubing bore axis.
DESCRIPTION OF RELATED ART
[0003] In the process of well drilling, completion and production, there are numerous tools that require substantial centralization along the axis of a pipe or tube bore. In a frequently arising example, it becomes necessary to cut a pipe or tube at a point deep within a borehole. Such remote pipe cutting is often performed with a shaped charge of explosive.
[0004] Briefly, shaped charge explosives for pipe cutting generally comprise a disc of highly compressed explosive material, such as RDX or HMX, having a V-groove channel formed about the disc perimeter. A thin cladding of metal is intimately formed against the V-groove surface. When ignited at the center of the disc, the opposite flanks of the V-groove expansively explode against each other to produce a rapidly expanding jet of metal material where the impact of this jet material, upon the surrounding pipe or tubing wall, is to sever the pipe wall by hydrodynamically splashing the material out of the way.
[0005] Although reliable and effective when expertly applied, the radial cutting capacity of shaped charge cutters is usually limited to only a few inches from the perimeter of the explosive material disc. Moreover, this radial cutting capacity may be further limited by downhole fluid pressure. When detonated under a downhole fluid pressure of 18,000 psi, the cutting capacity of a shaped charge cutter may be reduced by as much as 40%. If the cutter alignment within the pipe is eccentric with the pipe axis, an incomplete cut may result.
[0006] Other examples of required axial position control for downhole tools include well measurement and logging processes, where the radial proximity of the pipe wall is influential upon the measured data.
[0007] As a functional method, well tool centralizers are known in the prior art. U.S. Pat. No. 7,073,448 to W. T. Bell describes a shaped charge cutter housing having a centralizer comprising four blades in a single plane attached by a single fastener at the distal end of the housing. U.S. Pat. No. 5,046,563 to W. T. Engel et al describes three flat springs formed into bows with one end of each attached to the end of a shaped charge cutter housing. U.S. Pat. No. 4,961,381 to P. D. McLaughlin describes a borehole centering device for blasthole primers comprising a plurality of thin, radially extending spikes secured to a central ring. The spikes are made of a semi-conducting plastic and the central ring is sized to fit over a primer case. A further example of centralizers is disclosed by S. T. Graham et al, in U.S. Pat. No. 3,599,567, including plastic wing members radiating from a drive point for attachment over the end of a stick of explosive. The wing members have the purpose of holding the buoyant explosive down as well as centralizing the charge within a shothole. The explosive casing cutter disclosure of U.S. Pat. No. 3,053,182, to G. B. Christopher, describes a plurality of backswept spring wires secured to the cutter housing in borings directed angularly to the tool axis. Clamping screws engage portions of the spring wires extending into the housing boring
[0008] In adapting prior art centralizing devices to downhole tools, such as pipe and tubing cutters, difficulties arise in the form of excess material usage for forming multiple centering blades from a single sheet of spring steel. Centralizers with elaborate designs present fabrication/assembly difficulties.
[0009] One object of the present invention, therefore, is to provide the art with an inexpensively fabricated and easily attachable well tool centralizer.
SUMMARY OF THE INVENTION
[0010] One embodiment of the present invention comprises two or more thin, resilient metal discs attached to a tool housing end. Each disc is secured, preferably, by a single pin fastener through the disc center. The fastener is placed near the perimeter of the tool housing, whereby only an arcuate portion of a disc projects, substantially normally to the longitudinal tool axis, beyond the tool perimeter to engage a pipe or tubing inside wall surface.
[0011] In another invention embodiment, ends of thin, spring steel wires can be inserted into corresponding apertures in a base of the tool housing and secured by an interference fit or other securing methods. The interference fit may be obtained by swaging or by thermal shrinkage. In an alternative embodiment, the spring steel wires can be inserted into corresponding apertures of a base ring having a different diameter and, then, secured by such methods as interference fit. Alternatively, other securing methods may be used, including, but not limited to, soldering or gluing the spring steel wires directly to the base of the tool housing. Then, the secured spring steel wires can engage the inside of the wellbore during insertion/withdrawal of the tool.
[0012] In another invention embodiment, a plurality of thin, spring steel blades are attached via a plurality of fasteners to the end of the tool housing, the plurality of fasteners acting to prevent rotation of the centralizers during insertion/withdrawal of the tool, and the length of the blades cut to ensure contact with (and thus centralization relative to) the wellbore.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The invention is hereafter described in detail and with reference to the drawings wherein like reference characters designate like or similar elements throughout the several figures and views that collectively comprise the drawings. Respective to each drawing figure:
[0014] FIG. 1 is a longitudinal section of pipe enclosing a shaped charge pipe cutting tool fitted with one embodiment of the present invention.
[0015] FIG. 2 is a cross section of the FIG. 1 illustration showing a plan view of an embodiment of the invention.
[0016] FIG. 3 is a sheet metal die cutting pattern for centralizing discs, illustrating the material utilization efficiency of this invention.
[0017] FIG. 4 is a plan view of an alternative configuration of the invention.
[0018] FIG. 5A is an operative detail of an embodiment of the invention in a tool withdrawal mode.
[0019] FIG. 5B is an operative detail of an alternative embodiment of the invention in withdrawal mode.
[0020] FIG. 6 is a partially sectioned elevation showing an alternative embodiment of the invention.
[0021] FIG. 7 is a plan view of the FIG. 6 invention embodiment.
[0022] FIG. 8A is an enlarged cross-section of one method of fitting the wires of the embodiment of FIG. 6 .
[0023] FIG. 8B is an enlarged cross-section detail of another method of fitting the wires of the embodiment of FIG. 6 .
[0024] FIG. 9 depicts an alternative embodiment of the present invention comprising a plurality of planar, finger-like structures usable for centralizing a tubing cutter.
[0025] FIG. 10 depicts an embodiment of a single blade, from the plurality of blades, for use in centralizing a tubing cutter.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0026] Before describing selected embodiments of the present disclosure in detail, it is to be understood that the present invention is not limited to the particular embodiments described herein. The disclosure and description herein is illustrative and explanatory of one or more presently preferred embodiments and variations thereof, and it will be appreciated by those skilled in the art that various changes in the design, organization, order of operation, means of operation, equipment structures and location, methodology, and use of mechanical equivalents may be made without departing from the spirit of the invention.
[0027] As well, it should be understood the drawings are intended to illustrate and plainly disclose presently preferred embodiments to one of skill in the art, but are not intended to be manufacturing level drawings or renditions of final products and may include simplified conceptual views as desired for easier and quicker understanding or explanation. As well, the relative size and arrangement of the components may differ from that shown and still operate within the spirit of the invention.
[0028] As used herein, the terms “up” and “down”, “upper” and “lower”, “upwardly” and downwardly”, “upstream” and “downstream”; “above” and “below”; and other like terms indicating relative positions above or below a given point or element are used in this description to more clearly describe some embodiments of the invention. However, when applied to equipment and methods for use in wells that are deviated or horizontal, such terms may refer to a left to right, right to left, or other relationship as appropriate. Moreover, in the specification and appended claims, the terms “pipe”, “tube”, “tubular”, “casing”, “liner” and/or “other tubular goods” are to be interpreted and defined generically to mean any and all of such elements without limitation of industry usage.
[0029] With respect to FIGS. 1 and 2 , a special case of the invention is shown as to include a tubing cutter 10 having explosives (not shown) within a housing 12 . The cutter 10 is shown as located within a downhole tube 14 . The cutter 10 is centrally confined within the tube 14 by a pair of centralizing discs 16 having a substantially circular planform.
[0030] As best shown by FIG. 2 , the centralizing discs 16 are secured to the cutter housing 12 by anchor pin fasteners 18 , shown in this embodiment as screws. The disc plane is substantially normally oriented to the housing axis 13 . Since the discs 16 are not expected to rotate about the anchor pins 18 , swage rivets may also serve for securing the discs to the housing 12 .
[0031] In the FIGS. 1 and 2 embodiment, the discs are mounted along a diameter line 20 across the cutter housing 12 , with the most distant points on the disc perimeters separated by a dimension that is preferably at least corresponding to the inside diameter of the tubing 14 . In many cases, however, it will be desirable to have a disc perimeter separation slightly greater than the internal diameter of the tubing 14 . This configuration is illustrated by the upward sweep in the discs in contact with the tubing 14 inside wall.
[0032] Attention is particularly directed to the geometric consequence of two, relatively small diameter discs 16 secured on the diametric centerline of a larger diameter circle with opposite extreme locus points of the disc 16 perimeter coinciding with diagonally opposite locus points on the larger circle perimeter. Any force on the tool housing 12 substantially normal to the diameter 20 can be opposed by a wedging reaction against the inside wall curvature of the tube 14 . This wedging reaction can be applied to the disc 16 perimeters and, ultimately, to the housing 12 by the mounting pins 18 to maintain the axial center of the housing 12 in directions transverse to the diameter 20 .
[0033] In another embodiment of the invention as shown by FIG. 4 , three discs 16 are secured by pin fasteners 18 to the housing at approximately 120° arcuate spacing about the housing axis 13 (shown in FIG. 2 ). In this embodiment, the most distant elements of the disc 16 perimeters from the housing axis 13 at least coincide with the inside perimeter locus of the tubing 14 .
[0034] The FIG. 4 embodiment is representative of applications for a multiplicity of centering discs on a tool housing 12 . Depending on the relative sizes of the tool 10 and pipe 14 , there may be three or more such discs distributed at substantially uniform arcs about the tool circumference.
[0035] Regarding the disc 16 properties, the terms “thin”, “resilient” and “metallic” are used herein to generally describe gage thickness of high carbon and heat treated “spring” steels. Although other metal alloys are functionally suitable, the parameter of economics is a strong driver of the invention, and exotic alloys are relatively expensive.
[0036] Within this triad of material properties for a specific disc 16 application, gage thickness and bending modulus are paramount for the reason best illustrated by FIG. 5A . In the event a well tool 10 must be withdrawn from a downhole location, the projecting arc of the disc 16 can be compressively deformed to reverse the drag sweep against the tubing wall. If the tool 10 is suspended in the tube 14 by the use of a wireline or slick line, not shown, potential exists for exceeding the tensile strength of the support line. A well tool supported by a tubing or pipe string is not as limited. Nevertheless, the disc 16 design limitations of “thin” and “resilient” have particular meaning for specific applications of the invention.
[0037] Furthermore, as illustrated in FIG. 5B , such designs have advantages in that they can be provided in a “stack” configuration, illustrated here as a pair of discs, 16 a and 16 b , each having a thickness less than the thickness of the disc 16 illustrated in FIG. 5A . Such configurations, it has been discovered, provide centralizing force nearly equivalent to a single disc thickness while reducing the force required to insert or withdraw the tool 10 from the tube 14 , due to the reduction in compressive stress along the diameter of the discs 16 a , 16 b.
[0038] While the centralizing force created by the arcuate projection of discs 16 beyond the tool housing 12 perimeter is an operative element of the invention, the economics of fabrication is an equally driving feature. Configurations other than a full circle may also provide an arcuate projection from the tool 12 perimeter. However, many alternate configurations are either more expensive to form or waste more fabrication material. Shown by FIG. 3 is a disc 16 stamping pattern as imposed against a stock sheet of thin, resilient metal material 22 . When compared to single plane cross or star pattern centralizers, the percentage of material waste for a disc pattern is minimal.
[0039] Referring now to FIG. 6 , another economically driven embodiment of the invention is illustrated which includes spring steel centralizing wires 30 of small gage diameter. A plurality of these wires are arranged radially from an end boss 32 , seated within and extending from apertures 34 (shown in FIGS. 8A-8B ). Such wires may preferably be formed of high-carbon steel, stainless steel, or any metallic or metallic composite material with sufficient flexibility and tensile strength.
[0040] The end boss 32 is machined as an integrated part of the tool housing 12 , and the diameter of the end boss 32 will always be smaller than the diameter of the tool housing 12 . Note that the scale and angle of end boss 32 is depicted for clarity; in alternative embodiments, end boss 32 may be any configuration of the distal end of tool housing 12 .
[0041] Referring now to FIG. 7 , a plan view of the configuration in FIG. 6 is shown, with the plurality of centralizing wires 30 projecting outwardly in a radial arrangement from end boss 32 . While the depicted configuration includes a total of eight centralizing wires 30 , it should be appreciated that the plurality may be made up of any number of centralizing wires 30 , or in some cases, as few as two. As can be seen in the plan view, the use of centralizing wires 30 rather than blades or other machined pieces, allows for the advantageous maximization of space in the flowbore around the centralizing system, compared to previous spider-type centralizers, by minimizing the cross-section compared to systems featuring flat blades or other planar configurations.
[0042] As with the configuration in FIGS. 1-5 , the wires 30 are normally oriented to the housing axis 13 and engaged with the sides of the tubing 14 . Wires 30 are sized such that the length of the wires 30 is slightly larger than the length between the inside terminus of apertures 34 and inside diameter of tubing 14 . Thus, wires 30 will exert compressive force to centralize tubing cutter 10 , and flex in the same fashion as the cross-section of discs 16 , shown in FIG. 1 and FIG. 5 a , during insertion and withdrawal. The length of wires 30 may be sized for a specific tubing 14 inside diameter, either before or after attachment to the end boss 32 .
[0043] Referring now to FIG. 8A , the system of FIGS. 6-7 is shown in cross-section, including the end boss 32 having the plurality of apertures 34 formed laterally and penetrating a short distance therein 32 . Apertures 34 are sized to accommodate the diameter of the wires 30 at the surface of the end boss, which are attached within the apertures 34 via glue, soldering, or other methods.
[0044] Referring now to FIG. 8B , an alternative attachment method is shown for the FIG. 6-7 embodiment, in which the diameter of the aperture 34 is slightly smaller than the body of the wires 30 , which enables an interference fit, or press fit, between wires 30 and aperture 34 , where the proximal ends of wires 30 are inserted into the apertures, and then subjected to compressive force and deformed slightly to fit the narrower aperture 34 .
[0045] Referring now to FIG. 9 , a third embodiment of the invention is illustrated herein. This configuration comprises a plurality of planar, finger-like structures (herein “blades”) to centralize a tubing cutter 10 . The plurality 40 of blades 45 a , 45 b are positioned on the bottom surface of the tubing cutter 10 through a plurality of fasteners 42 , projecting outwardly therefrom. The plurality 40 of blades 45 a , 45 b thus flex, against the sides of the wellbore 14 , to exert a centralizing force in substantially the same fashion as the disc embodiments depicted in FIGS. 1 and 5A-5B . Thus, it can be appreciated that the plurality 40 of blades 45 a , 45 b may also comprise a stacked embodiment in which the thickness is reduced to stack multiple blades 45 on the same plurality of fasteners 42 .
[0046] FIG. 10 depicts an embodiment of a single blade 45 from the plurality of blades 40 . Each blade 45 comprises a plurality of attachment points 44 a , 44 b , through which fasteners 42 secure the blade in position. As shown, each respective fastener can extend through a respective attachment point to secure the blade into position. While the embodiment in FIG. 9 is depicted with two blades 45 a , 45 b , and each blade 45 comprising two attachment points, for a total of four fasteners 42 and four attachment points ( 44 a , 44 b are pictured in FIG. 10 ), it should be appreciated that the invention may comprise any number of fasteners and attachment points.
[0047] Significantly, the multiple attachment points 44 on each blade, being spaced laterally from each other, prevent the unintentional rotation of individual blades 45 , even in the event that the fasteners 42 are slightly loose from the attachment points 44 . The fasteners 42 can be of any type of fastener usable for securing the blades into position, including screws.
[0048] Each blade 45 of the plurality 40 of blades 45 can be manufactured at a low cost from a pre-selected width of coil material and simply cut for length, obviating the need in the prior art for specially designed and cut centralizer patterns. As set forth above, the plurality of blades can be spaced laterally and oriented perpendicular to each other, for centralizing a tubing cutter 10 and preventing unintentional rotation of the one or more blades 45 .
[0049] Although the invention disclosed herein has been described in terms of specified and presently preferred embodiments which are set forth in detail, it should be understood that this is by illustration only and that the invention is not necessarily limited thereto. Alternative embodiments and operating techniques will become apparent to those of ordinary skill in the art in view of the present disclosure. Accordingly, modifications of the invention are contemplated which may be made without departing from the spirit of the claimed invention. | An apparatus for, and method of, centering downhole well tools within the wellbore of a pipe comprises at least a pair of discs secured, respectively, to the distal end of a tool in a plane normal to a longitudinal tool axis, with an arc of each disc extended past the outer perimeter of the tool to at least an internal perimeter of an applied pipe bore and flexing to centralize the tool. In alternative embodiments, the discs are replaced by blades that are secured by a plurality of attachment points and fasteners, or by spring steel wires that are secured in radial apertures through an end boss by interference fit, soldering, swaging, or gluing. | 4 |
RELATED APPLICATIONS
This application, which is a national phase filing under 35 USC 371 of PCT international application No. PCT/US2010/000061 filed Jan. 11, 2010, pending as of the filing of the present application, claims the benefit of and priority to provisional application No. 61/144,900 filed Jan. 15, 2009.
BACKGROUND OF INVENTION
The invention relates to a mold seal which allows an improved method of molding a polymeric material onto at least a portion of the periphery of a sheet of substrate material. More particularly, the invention relates to utilizing the subject seal in a molding apparatus to mold a polymeric frame or gasket onto the periphery of a glass window for a vehicle.
It is known to mold an elastomeric gasket or frame member onto the periphery of a substrate such as glass to form products such as vehicle windows. Common molding methods are reaction injection molding (RIM) and injection molding. Such molded-on members have become increasingly complex and, as a result, the molding apparatus used in making such molded-on members have likewise become more complex.
To create the profiles desired in such elastomeric members, it is sometimes necessary to manage the flow of the polymeric molding material within the molding apparatus. Among the methods utilized for such management of liquid polymeric molding material are so-called “soft seals.” In typical known soft seals, it is often necessary to have a soft seal in opposing relationship on each major surface of the substrate onto which the gasket is to be molded. Such seal configurations generally do not permit molding up to the edge of the major surface of the substrate, which can be a detriment, both aesthetically and functionally. Therefore, it would be desirable to have a method of molding requiring a single soft seal that would permit complex molded profiles extending to, and even beyond the edge of a major surface of the substrate.
SUMMARY OF THE INVENTION
The invention relates to a mold seal which allows, in a simple and cost-effective manner, an improved method of molding a polymeric material onto at least a portion of the periphery of a sheet of substrate material. More particularly, the invention relates to utilizing the subject seal in a molding apparatus to mold a polymeric frame or gasket onto the periphery of a glass window for a vehicle. Still more particularly, the invention relates to a dynamic mold seal which, working in cooperation with at least one movable mold portion, permits molding up to the edge of a major surface of a sheet of substrate material, or even beyond the edge of a major surface of a sheet of substrate material if desired.
The dynamic mold seal of the invention includes a base portion, an intermediate portion, a straight arm portion and a flexible arm portion. Preferably, the subject mold seal is an integral assembly including the previously mentioned elements. In any desired configuration, the intermediate portion extends from the base portion, and the straight and flexible arm portions extend from the intermediate portion, but in different directions from one another. The flexible arm is capable of movement due to the presence of an “elbow,” allowing the flexible arm to move into and out of sealing contact with at least a portion of a peripheral edge of the sheet of substrate material. At the same time, the straight arm portion is adapted to sealingly engage at least a portion of a major surface of the substrate material.
The invention also relates in another aspect to the utilization of the previously described dynamic mold seal in a molding apparatus to form an encapsulated substrate, such as a vehicle window having a molded-on frame or gasket.
The molding apparatus in which the dynamic seal is utilized includes upper and lower mold halves, either or both of which may have a mold cavity formed therein. In a mold half containing a mold cavity, a seal cavity will also be formed to receive the base portion of the dynamic seal of the invention. At least one movable mold portion is also included in the mold half having the seal cavity. The at least one movable mold portion is located so that the flexible arm portion of the dynamic seal is within the range of movement of the movable mold portion.
In preparing to conduct a molding operation, the dynamic seal of the invention will have been affixed in the cavity seal. A sheet of substrate material, for example a glass vehicle window, will be placed in the mold cavity such that at least a portion of the peripheral edge of the vehicle window is proximate the dynamic seal of the invention. The straight arm portion of the seal is in sealing contact with a major surface of the vehicle window; that is, the inner major surface of the vehicle window. Closure of the mold halves actuates the movable mold portion, causing it to come into pressing contact with the flexible arm of the seal of the invention. The flexible arm is deflected toward, and into sealing contact with, at least a portion of the peripheral edge of the vehicle window. Then, liquid polymeric material is injected into the molding apparatus to fill the mold cavity. Due to the action of the seal of the invention, such liquid polymeric material is prevented from coming into molding contact with either of at least a portion of the peripheral edge of the vehicle window or a portion of the inner major surface of the vehicle window. A polymeric frame or gasket is formed, however, around the remaining portion of the periphery of the vehicle window.
The liquid polymeric material is allowed to cure in the mold cavity and thus bond to the at least a portion of the periphery of the vehicle window. Once sufficient curing has occurred, the mold halves are opened, and the movable portion of the mold retracts from its extended position, releasing the pressure exerted on the flexible arm of the subject seal. The flexible arm of the seal moves away from the periphery of the now-encapsulated vehicle window, which can be removed from the mold cavity.
BRIEF DESCRIPTION OF THE DRAWINGS
The advantages described herein, as well as other advantages of the present invention, will become readily apparent to those skilled in the art from the following detailed description of the preferred embodiment when considered in light of the accompanying drawings.
FIG. 1 is a perspective view of a lower mold half of the molding apparatus according to the invention.
FIG. 2 is a cross-sectional view of the upper and lower mold halves in molding contact and containing the subject dynamic seal according to the invention.
FIG. 3 is a cross-sectional detailed view of the molding apparatus according to the invention, particularly illustrating the movable mold portion interacting with the dynamic seal.
FIG. 4 a - c are cross-sectional views of the profiles of representative frames or gaskets which can be molded utilizing the seal and method of the present invention.
FIG. 5 is a cross-sectional view of a molding apparatus containing a soft seal typical of those known from the patent literature.
DETAILED DESCRIPTION OF THE INVENTION
Molding of an elastomeric frame or gasket onto the periphery of, for example, a vehicle window to form a so-called modular window assembly, which can then be conveniently installed in an opening in a vehicle body, is well known. Even so, placing a piece of glass into an injection molding apparatus and subjecting it to several thousand pounds per square inch of molding pressure in order to mold on the periphery thereof a polymeric frame or gasket without breaking the glass while obtaining a strong bond between glass and the polymeric frame or gasket, presents a number of technological challenges.
As previously noted, highly complex molding apparatus to create complex molding profiles have been proposed. Typically, such apparatus have one or more means of directing the liquid polymeric molding material to a particular area of the mold, or conversely, preventing the flow of the polymeric material into a particular portion of the mold. As previously noted, movable mold portions and so-called “soft seals” are among these means. An example of a typical known soft seal is illustrated in FIG. 5 . The typical, previously known soft seal illustrated in FIG. 5 requires opposing seals 60 and 62 . The soft seals shown in FIG. 5 do not allow molding up to or even over the edge of a vehicle window during a molding operation. Also, while typical soft seals allow for some variation in glass dimensions and configuration, they are, generally, quite limited in this regard. Typical soft seals are also susceptible to being dislodged from their position in the mold by the pressures in the mold created by the molding operation. This is particularly, an issue with injection molding processes.
The mold seal of the invention, by contrast, is relatively simple in that only a single seal is necessary, rather the two or more as shown in FIG. 5 herein, while allowing molding up to and beyond the peripheral edge of the glass sheet, as well as accommodating significant variations in glass size and shape during the molding process. Further, the cooperation between a movable mold portion and the present mold seal not only causes the effective functioning of the mold seal, by allowing it to move into and out of sealing engagement with the substrate, but the movable mold portion assists in preventing the mold seal from being dislodged from the mold cavity during the molding operation.
FIG. 1 shows a mold half 10 of the invention having a mold cavity 12 which will receive the liquid polymeric molding material. One or more means of conveying the polymeric material (not shown) into the mold cavity 12 will be present, e.g. one or more sprues and a cold/hot runner system, but are well known and not part of the invention. When placed into the mold half 10 , the glass sheet 14 will be supported by one or more resilient support members 16 proximate seal cavity 18 and within the range of movement of movable mold portion 20 . As will be described in more detail, the base of mold seal 22 is configured to be insertable into seal cavity 18 . Lower mold half 10 can be made of steel, aluminum or other suitable material.
FIG. 2 is a cross-sectional view of the lower mold half 10 of FIG. 1 in intimate molding contact with upper mold half 24 . A glass sheet 14 is in the closed molding apparatus ready for the molding operation to occur. Similar to lower mold half 10 , upper mold half 24 may be made from aluminum, steel or other suitable material.
FIG. 3 shows the mold seal 22 of the invention as shown, generally, in FIG. 2 in greater detail. As can be seen, the mold seal 22 of the invention is comprised of a base portion 26 configured to be inserted into seal cavity 18 , an intermediate seal portion 28 which connects the base portion 26 of the seal with the flexible arm 30 , and straight arm 32 . Mold seal 22 can be made from any suitable resilient polymeric material, for example, EPDM, silicone and thermoplastic elastomers (TPE), as well as combinations thereof.
Flexible arm 30 and straight arm 32 extend from the intermediate seal portion 28 in different directions from one another, such that straight arm 32 sealingly contacts a major surface 34 of glass sheet 14 . By contrast, flexible arm 30 , made “flexible” by virtue of an elbow portion, for example, a cut-out 36 or other suitable means, is positioned proximate peripheral edge 38 of glass sheet 14 . Under non-molding conditions, flexible arm 30 is not in contact with peripheral edge 38 . During molding operations, movable mold portion 20 will urge flexible arm 30 into sealing contact with peripheral edge 38 as illustrated in FIGS. 2 and 3 , the direction of movement of the movable mold portion 20 being particularly shown by the arrow. Flexible arm 30 is capable of movement of on the order of 10°-15°. The point at which flexible arm 30 contacts peripheral edge 38 can be adjusted so as to allow the liquid polymeric molding material to bond to varying proportions of the peripheral edge of the glass sheet so as to form different molding profiles, as illustrated in FIG. 4 . Movable mold portion 20 is activated upon the closing of upper and lower mold halves 24 and 10 . After completion of a molding cycle, the mold halves 24 and 10 are opened, the movable mold portion retracts, thus allowing flexible arm 30 to once again move out of molding contact with peripheral edge 38 .
It is within the scope of the invention for mold seal 22 , seal cavity 18 and movable mold portion 20 to be present only in selected portions of the periphery of glass sheet 14 , as well as to be present around the complete periphery of glass sheet 14 as shown in FIG. 1 .
FIG. 4 illustrates some of the versatility of mold seal 22 . FIG. 4 a shows the capability of molding up to the transition between major surface 40 and peripheral edge 38 of glass sheet 14 . FIG. 4 b shows how, with adjustment of the position of mold seal 22 , molding past the transition point between major surface 40 and peripheral edge 38 to an intermediate position on the edge of the glass sheet can be accomplished. Finally, FIG. 4 c shows how the mold seal 22 of the present invention can be utilized to mold a polymeric frame, gasket or the like to form a so-called two-side encapsulation; i.e., a peripheral portion of a major surface and a peripheral edge of a glass sheet.
In accordance with the provisions of the patent statutes, the principles and mode of operation of the present invention have been described in what is considered to represent the preferred embodiment. It should be understood, however, that the invention may be practiced otherwise than as specifically illustrated and described without departing from the scope of the claims herein. | The invention relates to a dynamic mold seal for use in a method of molding apparatus to mold a polymeric frame or gasket onto the periphery of a glass sheet. The seal and method are preferably utilized to form a vehicle window. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a security device for display of electronic hand held items and, in particular, to a device for marketing mobile phones which allows a potential customer to hold a phone at a limited distance from a display stand while automatically retracting and correctly positioning the hand held device on the display stand after its release.
2. Prior Art
With the growth of electronic devices in general and the ability to miniaturize in particular, light weight hand held mobile phones and similar devices have become pervasive. Items, such as cell phones, and hand held computers are sold to the public in a wide range of stores. To properly market such devices, consumers need to assure themselves that they can comfortable be used and manipulated by his/her hands In other words the consumer must be free to hold the device. But by allowing a consumer to inspect the item, the retailer is subjecting themselves to substantial loss through theft and other forms of shrinkage and breakage. It is equally important for marketing of cell phones and hand held computers that they be displayed in an upright position. Various attempts have been made to make retail displays which allow manipulation of displayed items while attempting to prevent theft.
For example U.S. Pat. No. 5,246,183 issued on Sep. 21, 1993 to Leyden discloses a tethering device for use in locations such as motel rooms that allows a remote control to be used but prevents its removal from the room. A spring in combination with a spool and cable allows a user to pull a hand-held remote control from a fixed position and automatically returns a the hand-held remote control back to its original location. It is not a display device for marketing. It does not guide the displayed item after release into a desired upright display position. There is simply no mechanism for turning the hand held remote upright.
While there have been a number of holders for hand held telephone, hand held computers and the like, they have been for the purpose of facilitating carrying and using the device rather than for security in display and marketing. There has been no mechanism as such for securing a mobile phone on a display but rather various devices that achieve the reverse. Such devices come with a variety of quick release mechanisms. See for example U.S. Pat. No. 5,903,645 issued on May 11, 1999 to Tsay; U.S. Pat. No. 5,555,302 issued on Sep. 10, 1996 to Wang.
While U.S. Pat. No. 6,002,921 issued on Dec. 14, 1999 to Pfahlert and Philips discloses a lockable cradle for holding a radiotelephone for use in vehicles it is released by a radio signal. This vehicle mounted device must be of a special construction and size to mate with the security system having grooves. It is neither designed for use in display systems, with existing devices, nor with a retracting and positioning system of the present invention.
SUMMARY OF THE INVENTION
The present invention for displaying mobile phones and other hand-held devices is comprised of three major components: a clamping system, a retracting system and a positioning system.
The clamping system of the present invention comprises two parts which are fastened together around a fitting attached to the end of a cord. The fitting may have a hole drilled through it to allow such a fastening. A security screw or bolt holds the two parts together with a key required to turn the head of the bolt or screw. The clamping system is locked onto the fitting and cannot be removed without the proper key. The clamping system has a lip on two opposite sides which prevents a person from removing the hand held device when the clamping system is fastened to the fitting and the hand held device is within the lips of the clamping system and attaches to a cable with a device also having a positioning guide to assure proper orientation of the hand-held device on display.
The retracting system comprises a coil spring, a spool and a cord mounted in a common decorative housing on which the mobile phone or the like rests. One end of the coil spring connects to the spool and the other end is attached to the housing. The cord is wrapped around the spool with one end attached to the spool and the other end attached to the mobile phone. When the mobile phone is moved from the housing the spool is turned and the coil spring is placed in tension. When the phone is released, the coil spring returns the spool to its original position.
The present invention has a positioning system to bring the cell phone back to its desired display position. The cord attached to the spool and the telephone is made from a relatively stiff material such as braided steel wire or cable. Thus, if the cord is pulled from the display stand and the cell phone is twisted or turned, the cord will develop a counter force to return the cell phone, upon release, to the original, upright position. To guide the hand held device into the proper position, the cord has on the end that emerges from the housing a first half of a positioning system which connects to the clamping system. The positioning system comprises interlocking or complementary male and female fittings. The fitting attached to the end of the cord may be either male or female with a corresponding mating fitting mounted on the housing. The cross-section of the male-female fitting pair may be of any shape other than circular with ovoid shapes preferred and cross-sectional ovoid shapes having guiding ribs contained within the ovoid female cross-section or on the exterior of the male ovoid cross-section most preferred. A non-circular shape, such as an ovoid, along with the ribs will assure that when the male fitting enters its female counterpart, the orientation of the fitting at the end of the cord will be the same as when the fitting, clamping system, or any device held within the clamping system, was pulled. The ribs assist with the guidance of the male fitting into the female fitting and assure that the fitting will return to its intended display orientation. Thus, the security display device of the present invention meets the needs of consumers and merchants by enabling a potential purchaser to conveniently examine a hand-held item such as a cell phone, conventional phone, camera, personal organizer and the like while preventing its theft and guaranteeing its return to a suitable display position when released after examination.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts a version of the cable retracting component of the present invention having a coupling to a clamping device or security claw and a security bolt to fasten the coupling to the clamping device.
FIG. 2 depicts a back view of a version of a clamping device or security claw of the present invention.
FIG. 2 a shows the lower section of a clamping device or security claw of FIG. 2 .
FIG. 3 is a reverse view of the clamping device of FIG. 2 showing the assembly of the clamping device to a connecting cable coupling having a version of a male component of the positioning fitting.
FIG. 4 is a back view of the fully assembled clamping device of FIG. 3 coupled to a connecting cable and secured with a security nut and bolt.
FIG. 5 is a cross-sectional view showing a version of a female component of the positioning fitting having ribs containing the male positioning component depicted in FIGS. 3 and 4 .
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 . shows a version of the retracting mechanism 100 of the present invention. A cord or security cable 101 is wrapped around a plastic double spool 102 having a channel 107 around which the cable 101 is wrapped and an adjacent channel 107 a around which a constant force spring 106 is wrapped. The spool 102 is placed on an axle 110 which allows the spool 102 to rotate on its axis perpendicular to its circumference. The present invention contains a means for mounting the axle 110 to a housing plate 109 . A circular collar or ring 104 attached to one end of cable 101 is used to secure it to spool 102 while a non-circular collar 104 a, preferably of ovoid cross-section is attached to the other end of the cable which is connected to coupling fitting 111 having male positioning component 112 . A channel 120 passes through positioning component 112 which contains cable 101 . Channel 120 has a generally circular cross-section in the general area at which cable 101 enters positioning component 112 but as it continues through, positioning component 112 has a non-circular cross-section 120 a and altered dimensions to snugly retain non-circular collar 104 a within channel 120 and prevent rotation of fitting 111 around cable 101 . The cable 101 is secured to the spool 102 by passing the cable 101 through an opening 103 in the spool 102 and inserting the cable 101 into a clip 105 located on the spool 102 . The clip secures to the cable so that when cable 101 is pulled ring 104 will not pass through clip 105 and will prevent any detachment of the cable 101 from the spool 102 .
A recoil or constant force spring 106 is connected to the spool 102 in spool channel 107 a so as to not interfere with the cable 101 while the cable 101 is being released from or rewound onto the spool 102 . Constant force spring 106 is retained on spool 102 in channel 107 a by means of a slot in the spool core. A length of the constant force spring 106 extends from the reel and coils around rod 122 which is connected to housing plate 109 The constant force spring 106 is arranged so that it is wound onto spool 102 as cable 101 is drawn off the spool, thus exerting a retracting force on cable 101 . The coil of constant force spring 106 is positioned between the walls of channel 107 a of double spool 102 thereby holding spring 106 in place on rod 122 . The constant force spring 106 is arranged so that it is wound onto spool 102 from the coil on rod 122 as cable 101 is drawn off the spool, thus exerting a retracting force on cable 101 . When tension on cable 101 is released spring 106 retracts onto the coil on rod 122 thus rewinding cable 122 onto spool 102 .
When cable 101 is retracted by spring 106 after having been extended, male positioning component 112 enters a female positioning component or fitting 108 , of a male/female positioning fitting couple, that is mounted within flange 121 . The ovoid male positioning component 112 fits into opening 113 , having an ovoid cross-section, on the female positioning component. Flange 121 is attached to housing plate 109 and surrounds an opening in housing plate 121 through which cable 101 passes.
The coupling fitting 111 , having male positioning component 112 , also has incorporated into it the security claw linkage 114 . The security claw linkage 114 has a hole 115 drilled through it so as to allow a security screw 116 to fit through the linkage 114 .
FIG. 2 shows a version of a security claw 201 . The top section 202 connects or locks to the lower section 203 with the use of a security screw 116 which can be opened and closed with security key 216 . The top section 202 has attached to it a tab 204 has an opening that is sufficiently large to allow passage of the shaft but not the head of security screw 116 . The lower section 203 has a threaded tab 205 to receive safety screw 116 . To facilitate opening the security claw to insert or remove display merchandise it is preferred that only one tab be threaded. The tabs themselves may be threaded or, as shown for tab 205 , a threaded nut 206 can be attached to the tab. Both tabs 204 and 205 must be wide enough to allow the security screw 116 to be placed through it so that the security claw 201 is securely fastened to the security claw linkage 114 . Security key 216 has ends 218 that are shaped to fit into a non-conventional opening or slot 220 in the head of security screw 116 . Non-conventional openings or slots 220 on security screw 116 which security key 216 is shaped to fit might for example have star, cruciform, circular or non-circular cross-sections and also have concavities and convexities within the opening 220 . Top section 202 and lower section 203 together comprise a cradle to contain a hand-held device such as a cell phone. Each section may be formed as a complete unit from metal, plastic or any other strong rigid material capable of securely containing a hand held device or as in the version depicted in FIG. 2 it may be formed from more than one piece. As shown in FIG. 2 the upper section has sides 202 a and a bottom 202 b to contain a device on three sides. In the version of the security claw depicted in FIG. 2 each of the two legs of a U-shaped brace 222 is connected to a separate side 202 a of top section 202 to contain a device on a fourth side. Lower section 203 has sides 203 a and a bottom 203 b to contain a device on three sides. As seen in FIG. 2A bottom 203 b extends to form a lip 224 to enclose a device on a fourth side. Lip 224 may extend to brace 223 and be connected to it if necessary to securely enclose a device. Each leg of U-shaped brace 223 is connected to a separate side 203 a forming a bridge over bottom 203 b to secure a device on a sixth side.
FIG. 3 is a back view of the clamping device of FIG. 2 showing the assembly of the clamping device to a version of a coupling fitting 111 having an ovoid version of a male component 112 of the male/female positioning fitting. Security screw 116 is inserted through the unthreaded opening in tab 204 on the back of security claw 201 , through the opening 115 in the security claw linkage 114 of coupling fitting 111 , and into the opening of threaded tab 205 and tightened with security key 218 shown in FIG. 2 . As shown in FIG. 3, coupling fitting 111 is generally arranged so that cable 101 extends from the back of security claw 201 although in other versions fitting 111 may be modified, by means known in the art, to permit security cable 101 to conveniently extend from the side of security claw 201 .
FIG. 4 depicts the version of security claw 201 and coupling fitting 111 shown in FIG. 3 as fully assembled and secured with security screw 116 . In practice, a hand-held device such as a cell phone is inserted into the claw 201 before it is fully assembled and coupled to security cable 101 . For example an appropriately shaped cell phone is inserted into lower section 203 so that the lower part of the phone fits under brace 223 with the face of the phone facing away from bottom 203 b . As shown in FIG. 3 coupling fitting 111 is inserted between top section 202 and bottom section 203 . Top section 202 is then slipped over the top of the cell phone and coupled to bottom section 203 through coupling fitting 111 by means of security screw 116 which is securely tightened into threaded tab 205 . As will be apparent to those skilled in the art the form of upper component 202 and lower component 203 of security claw 201 may be varied depending on the shape and dimensions of the cell phone or other hand-held device to be securely held therein. Regardless of form each security claw will comprise an upper and a lower component having tabs 204 and 205 so that the upper and lower component of the security claw can be coupled by means of coupling fitting 111 and securely held by security screw 116 as illustrated by the example depicted in FIG. 4 .
The retracting system to which cable 101 is attached is typically securely mounted on a display unit. When the displayed cell phone is examined it is pulled away from the retracting unit 100 , but securely held by cable 101 attached to security claw 201 . Upon release the retracting force developed by constant force spring 106 draws the cable back onto spool 102 causing the cell phone to be pulled towards its initial display position. Due to non-circular collar 104 a held in non-circular channel 120 a and the stiffness the cell phone coupled with fitting 111 cannot freely rotate around tethering cable 101 and will also tend to return to its initial rotational orientation upon release. A non-circular, male positioning component such as component 112 of FIG. 1 having an ovoid cross-section is used since it must be properly oriented to enter a corresponding non-circular, female positioning component such as component 108 having an opening 113 with an ovoid cross-section thus insuring that the cell phone returns to its original display position.
Another version of a female positioning component to receive an ovoid cross-section male positioning component is seen in FIG. 5 . Female positioning component 500 generally comprises a tubular structure having walls 501 and 502 enclosing a lumen 513 . Rounded rails 503 , 504 , 505 , 506 , 507 and 508 traverse the length of the interior surface of walls 501 and 502 facing lumen 513 and are substantially parallel and guide male ovoid cross-section positioning component into lumen 513 . Generally, the rounded rails are arranged along the length of lumen 513 so that their rounded surfaces come into generally tangential contact with the sides of the male positioning component having an ovoid cross-section. Female positioning components having rails are preferred as this arrangement reduces friction relative to the female positioning component 108 that has a completely ovoid cross-section thereby facilitating the rapid return of the secured hand-held unit to its initial display position. In another preferred version of female positioning component 500 the rounded rails are slightly recessed from the entrance to lumen 513 to facilitate slight rotation to the initial display position in the event that cable 101 is slightly twisted. Female positioning component 500 is generally formed from two identical segments 501 and 502 , that are joined at seams 511 and 512 generally by press fitting into flange 121 of FIG. 1 . Notches 509 and 510 facilitate press fitting into flange 121 . The positioning and coupling fittings of the present invention may be formed or processed from any rigid material known in the art that may be machined, molded or otherwise formed into a desired shape by means commonly known and practiced in the art. Relatively tough, rigid plastics that may be machined and press fit such as machinable grades of polyvinylchloride (PVC) and other machinable plastics are preferred. Each positioning component may be formed as a single unit or in two or more units that are joined by press fitting, welding and adhesive means as commonly known and practiced in the art. Combinations of materials such as metal and plastic, different metals and different plastics may be used for the female and male positioning components of the present invention.
The apparatus for secure display of hand held items of the present invention may be used singly or in multiple arrays on display structures to securely and attractively display such items for examination by consumers.
It is understood that the present embodiments described above are to be considered as illustrative and not restrictive. It will be obvious to those skilled in the art to make various changes, alterations and modifications to the invention described herein. To the extent that these variations, modifications and alterations depart from the scope and spirit of the appended claims, they are intended to be encompassed therein. | An apparatus for displaying mobile phones and other hand-held devices comprising a clamping system, a retracting system, and a positioning system. The clamping system holds a hand-held device between two parts, which are fastened together by a fitting and a security screw having a head with a slot requiring a special key. The retracting system includes a retractable tethering cable wound on a spool. The positioning system includes a male component, which anchors the tethering cable to the fitting, and a female component, which is mounted on the retracting system. The tethering cable passes through the female component of the positioning system so that when the hand-held device is retracted, the male component of the positioning system is received by the female component thus assuring proper orientation of the hand-held device on display. | 0 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is based upon and claims priority from prior French Patent Application No. 04 08357, filed on Jul. 29, 2004, the entire disclosure of which is herein incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to the amplified reading of analog information with linear decibel (dB) mode gain control. It applies advantageously, but not exclusively, to the processing of signals delivered by a pixel matrix of an image sensor.
2. Description of the Related Art
Analog information from the pixel matrix is read by a reading or processing subsystem, including in particular adjustable gain amplification means.
The gain must be defined accurately to take account of the different colors, so as to balance the colors with the requisite accuracy and restore the latter accurately.
Accordingly, there exists a need for overcoming the disadvantages of the prior art as discussed above.
SUMMARY OF THE INVENTION
An object of the invention is to obtain a linear dB mode gain control which is simple to produce.
The invention therefore proposes an amplified analog information reading device with linear decibel mode gain control, comprising:
an adjustable gain amplification means receiving said analog information and of which the 2 j successive gain values, respectively adjustable by 2 j successive values of a first control word of j bits, follow a geometric progression of ratio a, an analog/digital conversion means connected to the output of the amplification means, having an adjustable input full scale of which the 2 k different values, respectively adjustable, for each gain value, from 2 k successive values of a second control word of k bits, follow a geometric progression of ratio a 1/2 k , said conversion means delivering a digital code corresponding to said analog information amplified by an overall gain, the value of which depends on the gain value of the amplifier and on that of said full scale, and control means designed to deliver the first and second control words.
The amplifier can thus be used to obtain “rough” gains, the rough gain control being provided in the form of a digital word of j bits.
Moreover, adjustment of the input full scale of the analog/digital converter is used to vary the gain of this analog/digital converter, so as to obtain a fine adjustment of the gain of the reading subsystem.
When the control p (rough gain) is incremented by a unit, the gain, expressed in dB, increases by 20.log 10 (a). Since the increment in dB is a fixed value, the result is linear dB mode gain.
Similarly, the input full scale is adjusted so as also to have a linear dB mode progression for the fine gain adjustment.
The invention can thus be used to obtain a fine adjustment of the overall gain of the reading subsystem by using only a single amplifier. This is particularly advantageous from the signal-to-noise ratio point of view.
Moreover, the implementation of such a linear dB mode control law, by using a single amplifier and an analog/digital converter, is differentiated from an implementation of such a control law via another means, for example linear dB mode amplifiers known per se, but which are proving to be far less appropriate to the application of an image sensor.
The device advantageously comprises control means delivering a global control word of j+k bits, of which the j high order bits form said first control word and of which the k low order bits form the second control word.
In other words, the user adjusts the total subsystem gain by a digital word of j+k bits, in which the j high order bits determine the rough gain, in which the k low order bits determine the fine gain, and any incrementation of this word of j+k bits results in an increase in the total subsystem gain (expressed in dB) by a fixed value.
According to an embodiment of the invention, the device comprises generation means designed to generate the 2 k input full scale values, in response to the second control word of k bits, these generation means including an exponential type analog/digital converter having a multiplexer controllable by said second control word, and a potentiometric divider connected between two terminals respectively receiving full scale maximum and minimum values, and the resistances of which follow a geometric progression of ratio a 1/2 k .
Moreover, the device advantageously comprises calibration means designed, for each gain value p, to perform a preliminary adjustment of the full scale maximum value Emax,p and of the full scale minimum value Emin,p, such that Emax,p/Emin,p is equal to a 1/2 k .
The invention also proposes an image sensor including a reading subsystem incorporating an amplified reading device as defined above.
BRIEF DESCRIPTION OF THE DRAWINGS
Other advantages and features of the invention will become apparent on reading the detailed description of embodiments, by no means limiting, and the appended drawings, in which:
FIG. 1 diagrammatically represents an image sensor according to the invention, in which the reading subsystem incorporates a device according to the invention;
FIG. 2 illustrates in greater detail, but still diagrammatically, a part of the device of FIG. 1 ;
FIG. 3 is a table illustrating the trend of the gains obtained by a device according to the invention; and
FIGS. 4 and 5 illustrate means for calibrating the device.
DETAILED DESCRIPTION
In FIG. 1 , the reference CPT denotes an image sensor including in particular a pixel matrix PXA and a reading subsystem CHL incorporating an amplification device DIS according to the invention.
The device DIS includes an adjustable gain amplifier AMP, followed by an analog/digital converter CAN with a resolution of n bits.
Control means MCM deliver a word of j+k bits, in which the j high order bits are used to control the gain of the amplifier AMP. Conventionally, the values of the j bits of the control word are used to switch the transistors on or off to vary the value of the resistive and/or capacitive circuit acting on the gain value of the amplifier AMP.
The gain of the amplifier AMP is expressed by the equation A=A 0 ·a p in which:
A 0 is a constant (minimum gain value); a is a constant greater than 1; p is the gain control value (control on j bits varying from 0 to 2 j −1).
Regarding the analog/digital converter, the result of converting an input voltage V is expressed by:
Code= V· 2 n /E i
in which E i is the input full scale of the converter.
The index i corresponds to a control on k bits, therefore varies from 0 to 2 k −1.
The full scale value E i is defined by generation means MLB from the k low order bits of the control word delivered by the control means MCM.
The total subsystem gain is therefore: Gain=A 0 ·a p ·2 n /E i (expressed in quantum per volt terms).
The 2 k separate values of the full scale of the converter CAN, denoted E i , in which i varies from 0 to 2 k−1 , are obtained by using an exponential digital/analog converter DACX incorporated in the generation means MLB ( FIG. 2 ).
This exponential digital/analog converter includes a potentiometric divider, the resistances of which follow a geometric progression of ratio b. A multiplexer MUX 1 is used to select the corresponding full scale value.
Adjustment of the full scale is used to vary the gain of the analog/digital converter CAN to obtain a fine adjustment of the gain of the reading subsystem CHL. In practice, the range within which the full scale can be adjusted without compromising the performance of the converter is limited. Indeed, this range [E max , E min ] must be such that E max /E min is less than 2. The acceptable ratio of the full scales (E max /E min ) establishes a maximum limit to the parameter a (ratio of the progression of the amplifier gains).
The ratio b of the geometric progression of the resistances of the potentiometric divider of the exponential digital/analog converter is the unitary subsystem gain increment, in other words that by incrementing the word of j+k bits. It can be computed as follows: bearing in mind that after 2 k codes, the rough gain is incremented, the total subsystem gain is multiplied by a. The following therefore applies:
b 2 k =a
or: b=a 1/2 k
Now, the output code is
Code= V· 2 n /E i
in which i is the value of the word of k bits. When this word is increased, the code must be multiplied by b, therefore E i must be divided by b, therefore:
E i+1 =E i /b
The maximum value of E is E max =E 0 (corresponding to the minimum fine gain).
The minimum value of E is E min =E 2 k −1 (corresponding to the minimum gain).
The potentiometric divider can therefore be used to obtain the ratio b between E i+1 and E i .
The rough gain, the fine gain and the total gain of the reading subsystem thus follow a progression partially illustrated in the table of FIG. 3 .
When the control p is incremented, the gain—expressed in dB—increases by 20.log 10 (a). Since the increment in dB is a fixed value, the term “linear dB mode gain” is used.
Similarly, the full scale is adjusted so as also to have a linear progression in dB for the fine gain adjustment.
When the fine gain control reaches its maximum value (that is, when i equals 2 k−1 ), the next gain adjustment position of the subsystem is obtained by resetting i=0 and by incrementing the value of p (rough gain control). The gain increase made in this case must be equal to an increase step of the fine adjustment.
Similarly, the user adjusts the total subsystem gain by a binary word of (j+k) bits, in which the j high order bits determine the rough gain, the k low order bits determine the fine gain, and any incrementation of this code of (j+k) bits results in an increase in the total subsystem gain (expressed in dB) by a fixed value.
In practice, the basic increase in the subsystem gain (factor b) is low with respect to the accuracy that can be obtained for the rough gain adjustment (accuracy on the factor a).
Consequently, the increase in the subsystem gain, when p is incremented, cannot be guaranteed by virtue of the production accuracy of the integrated circuit.
It is therefore essential to adjust accurately the values of E max and E min for each value of p. Thus E max,p and E min,p must be adjustable.
These adjustments will be made using two additional digital/analog converters DAC 1 , DAC 2 ( FIG. 4 ), and must be stored on a calibration procedure, prior to using the device.
It is theoretically necessary to adjust E min,p relative to E max,p+1 such that E min,p /E max,p+1 =b.
This operation, which involves amplifying E max,p+1 by b, therefore necessitates a high accuracy (b possibly being of the order of +1%, for example). However, the problem can be simplified, as explained below.
In practice, the digital/analog converter delivering the values of E has the necessary accuracy. It is therefore easy to provide an additional output, denoted E 2 k , which immediately follows E 2 k −1 in the geometric progression. This position (which can be accessed using the control “CAL”) is supposed to provide a gain of the analog/digital converter CAN of value b 2 k =a. The total subsystem gain is then:
a p ·a=a p+1
Since the same gain can be obtained by a different control word (p+1 and i=0), the procedure works by searching for a match, which is easier to do than amplification by the factor b.
Implementing the calibration procedure requires additional adjustment means ( FIGS. 4 and 5 ).
Thus, in addition to the two digital/analog converters DAC 1 and DAC 2 for adjusting max and E min at each calibration step, storage means MM are provided to store the settings of these two converters DAC 1 and DAC 2 corresponding to each value of b (or 2×2 j values associated with the 2 j values of b).
It is also necessary to provide an additional control (CAL), for accessing an additional output of the digital/analog converter. This additional control is accessible only in calibration mode.
The gain is not a directly accessible quantity, so a calibrated signal must be injected to work on the voltages.
Furthermore, it is essential to take account of the fact that the amplifier has an offset: this is the value of its output when the injected signal is zero.
Since the adjustment consists in searching for a match between two gain positions, it is essential to amplify a calibrated signal in the two agreed positions, and perfect the adjustments of E max and E min so as to obtain identical output codes at the output of the analog/digital converter CAN. This calibration signal must be chosen to produce a sufficiently high voltage (so as not to be limited by the resolution of the analog/digital converter CAN in the case where E=E min .
This calibrated signal depends on the subsystem gain (on the control p), and must be such that the output of the amplifier is sufficiently high (so as not be limited by accuracy problems).
It is desirable to work with constant output amplitude at the output of the amplifier. In this case, the signal to be injected must follow a law of the form 1/c p , with p varying from 1 to 2 j .
There are various methods of calibrating the subsystem.
The proposed method makes it possible to ensure that the gain increase is constant across the entire control range of (j+k) bits.
When the amplifier control (code on j bits) is changed, the gain of the latter is normally controlled by a ratio of resistances or capacitances: the absolute accuracy of this control is not necessarily sufficient compared to the fine adjustment.
The method proposed here to calibrate the subsystem is the “straight line regression” method well known per se to those skilled in the art. The implementation algorithm will now be described below and is implanted in processing means MT ( FIG. 5 ):
1. Measure the gains obtained by modifying only the control p of the amplifier (2 j positions). Throughout this operation,
a) the value of E is held at a typical value E max to obtain the minimum fine gain; b) the injected signal keeps a constant minimum value so as never to saturate the analog/digital converter CAN, whatever the gain of the amplifier; c) for each value of p, it is also essential to extract the offset by injecting a zero signal.
2. Calculate the gains and convert them to dB. 3. Given that the curve gain_db=f(p) is assumed to be a straight line, compute the straight regression line. 4. For each value of p, and starting from the highest value (=2 j −1),
a. set the gain of the amplifier to A 0 ·a p b. inject a signal of the form 1/c p . (By starting from the highest value of p, it is possible to work back to the case of the minimum injected signal, that is, the case used previously (1.b).
i. First adjust E min — p so that the total gain corresponds to the straight regression line. E min — p is obtained by using i=0. ii. Then adjust E max — p (for this use the control CAL) so that the new gain obtained falls on the straight regression line (theoretical ideal value=gain i obtained with E min — p divided by b). iii. While keeping the same injected signal 1/c p , adjust the gain of the amplifier to A 0 ·a p−1 , and adjust E min — p−1 so as to obtain the same subsystem gain as in ii). This is necessary because the two adjustments “ii” and “iii” must give the same gain. iv. Decrement p and now inject a signal 1/c p+1 , without changing the gain setting [this gain is therefore that calibrated in iii]. Record the new useful signal obtained. v. Loop back to ii, until p=0 is obtained.
On leaving this loop, the gain is calibrated.
The invention can thus be used to produce a total subsystem gain with a single analog stage, so as, on the one hand, to favor the signal-to-noise ratio, and, on the other hand, to limit the consumption. The total subsystem gain can be adjusted with accuracy, typically of the order of 1 to 2% for reconstructing a color image.
The gain of the amplifier is roughly adjustable and the full scale of the analog/digital converter is modulated, so as to obtain a fine linear dB mode adjustment.
This structure is associated with a gain calibration method, so as to ensure uniformity of gain control between the rough adjustment (MSB) and the fine adjustment (LSB).
While there has been illustrated and described what is presently considered to be embodiments of the present invention, it will be understood by those of ordinary skill in the art that various other modifications may be made, and equivalents may be substituted, without departing from the true scope of the present invention.
Additionally, many modifications may be made to adapt a particular situation to the teachings of the present invention without departing from the central inventive concept described herein. Furthermore, an embodiment of the present invention may not include all of the features described above. Therefore, it is intended that the present invention not be limited to the particular embodiments disclosed, but that the invention include all embodiments falling within the scope of the appended claims. | An amplified reading device includes an adjustable gain amplifier AMP receiving analog information and of which 2 j successive gain values, respectively adjustable by 2 j successive values of a first control word of j bits, follow a geometric progression of ratio a; an analog/digital converter CAN connected to the output of the amplifier, having an adjustable input full scale, of which 2 k different values, respectively adjustable, for each gain value, from 2 k successive values of a second control word of k bits, follow a geometric progression of ratio a 1/2 k , the converter delivering a digital code corresponding to the analog information amplified by an overall gain, the value of which depends on the gain value of the amplifier and on that of the full scale, and a controller MCM designed to deliver the first and second control words. | 7 |
BACKGROUND OF INVENTION
Polymeric thin film electro-optical (EO) modulator devices based on guest nonlinear optical (NLO) chromophores dispersed in a polymeric material are known. The devices function because the NLO chromophores exhibit a high molecular hyperpolarizabity, which when aligned into an acentric dipolar lattice by an applied poling field, increases the EO activity. The performance of such devices is limited or diminished by the randomizing of the acentric order originally imposed on the lattice due to physical events within the polymeric material. These events include polymer creep, polymer glassy behavior above glass transition state, and chromophore/polymer phase segregation and aggregation.
One approach to surmount these problems includes using a polymeric material exhibiting a relatively high glass transition state well above the operating temperature of the device. However, this strategy has been limited because the NLO chromophore has been found to exert a plasticizing effect on the polymeric material, thereby lowering the glass transition temperature of the composite material relative the undoped polymer.
A second approach employs crosslinking the polymeric material to “fix” the orientation of the poled chromophores. Difficulty in controlling the reaction conditions during device fabrication has limited this approach. To be a viable approach, the crosslinking must not occur before poling is complete. Poling is generally conducted at temperatures at or about the glass transition temperature of the polymeric material. Therefore, the crosslinking needs to occur “on demand”.
There remains a continuing need for still further improvements in the polymeric materials used to maintain the oriented NLO chromophore lattice.
BRIEF DESCRIPTION OF THE INVENTION
In one embodiment, a method for crosslinking a polymer comprises reacting i) a crosslinkable polymeric material comprising olefin groups and ii) a crosslinking agent comprising electron deficient olefin groups, at a temperature at which crosslinking occurs.
In another embodiment, a method of fabricating a crosslinked polymer comprises mixing a crosslinkable polymeric material, a crosslinking agent, and a chromophore to form a mixture; forming a film from the mixture; aligning the chromophore; and heating the mixture to effect crosslinking reactions between the crosslinkable polymeric material and crosslinking agent.
In yet another embodiment, a method for crosslinking a polymer comprises reacting i) a polycarbonate copolymer prepared from a bisphenol compound comprising two olefin groups and a 4,4′-[1-methyl-4-(1-methylethyl)-1,3-cyclohexandiyl]bisphenol and ii) 1,1′-(methylenedi-4,1-phenylene)bismalimide, 1,4-phenylene bismalimide, 1,4-di-1H-pyrrole-2,5-dione)butane, or a combination thereof, at a temperature at which crosslinking occurs.
In another embodiment, a crosslinkable composition comprises a crosslinkable polymeric material comprising olefin groups; a crosslinking agent comprising electron deficient olefin groups; and a non-linear optical chromophore.
BRIEF DESCRIPTION OF DRAWINGS
FIGS. 1 a and 1 b include an idealized thermosetting of DABPA-co-BHPM polycarbonate copolymer via Ene and Diels Alder reactions;
FIG. 2 is a graphical representation of the thermal cure of DABPA-co-BHPM polycarbonate copolymer in the presence of BMI (first heat);
FIG. 3 is a graphical representation of the thermal cure of DABPA-co-BHPM polycarbonate copolymer in the presence of BMI (second heat); and
FIG. 4 includes exemplary NLO chromophores.
DETAILED DESCRIPTION
Described herein are polymeric materials that can be crosslinked to “fix” guest NLO chromophores oriented by electric field poling prior to crosslinking of the polymeric material. The chemical crosslinking reactions subsequent to the induction of acentric order by electric field poling leads to enhanced, long term, thermal stability of the polymeric EO films used to prepare EO devices. The stability is thought to be due to the crosslinks limiting polymer creep and subsequent loss of the chromophores' defined orientation.
Also disclosed herein is a method of crosslinking polymeric materials. The crosslinked polymeric material can maintain an ordered, acentric, dipolar chromophore lattice induced by electric field poling thereby providing both temporal and thermal stability of the EO films when incorporated into EO modulator devices. It has been found that polymeric materials comprising olefin groups can undergo crosslinking under thermal conditions in the presence of an electron deficient olefin-group-containing crosslinking agent. Not wishing to be bound by theory, it is believed that the olefin groups of the crosslinkable polymeric material react with the olefin groups of the crosslinking agent via an ene addition reaction to provide crosslinks. It is further believed that the resulting ene product can undergo a Diels Alder reaction with available olefin groups of the crosslinking agent to provide additional crosslinks.
FIG. 1 a provides an idealized crosslinking reaction scheme between a polycarbonate copolymer and 1,1′-(methylenedi-4,1-phenylene)bis-maleimide (BMI). The exemplary polycarbonate copolymer (DABPA-co-BHPM PC copolymer) shown is prepared from 2,2′-diallyl Bisphenol A (DABPA) and 4,4′-[1-methyl-4-(1-methylethyl)-1,3-cyclohexandiyl]bisphenol (BHPM). As shown in FIG. 1 b, when the resulting Ene reaction product contains an olefin alpha to an aryl group, these groups are thought to further undergo a Diels Alder reaction with the remaining free olefin of the crosslinking agent resulting in a crosslinked polymeric material.
The terms “a” and “an” herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item. All ranges disclosed herein are inclusive and combinable.
The crosslinked polymeric material can be prepared from crosslinkable polymeric material and a crosslinking agent. The crosslinkable polymeric material comprises olefin groups within or pendent from the polymer backbone, and more specifically terminal olefin groups pendent from the polymer backbone (—CH═CH 2 as opposed to —CH═CH—). More specifically, the terminal olefins groups of the polymeric material are pendant from an aromatic group as an allylaromatic. For example, polycarbonates prepared from 2,2′-diallyl Bisphenol A (DABPA) contain allylaromatics having pendent olefin groups.
The crosslinkable polymeric material can include, for example, those of the following class: polycarbonates, polyamides, polyimides, polyetherimides, polyethylene sulfones, polyether sulfones, polyethylene ethers, polyethylene ketones, polyesters, polyacrylates, polyurethanes, polyarylene ethers, copolymers thereof, and the like.
The crosslinkable polymeric material generally comprises 1 to about 50 mole percent olefin functionality, specifically about 2 to about 10 mole percent, and yet more specifically about 2 to about 6 mole percent olefin functionality.
In one embodiment, the crosslinkable polymeric material is a polycarbonate copolymer exhibiting a high glass transition temperature and good film forming qualities. The polycarbonate copolymer can be prepared from a diol comprising at least one olefin group and 4,4′-[1-methyl-4-(1-methylethyl)-1,3-cyclohexandiyl]bisphenol (also identified as 1,3-bis(hydroxyphenyl)monoterpene or BHPM). Exemplary diols comprising at least one olefin group include 2,2′-diallyl Bisphenol A (DABPA), 4-(3-allyl-4-hydroxybenzyl)-2-allylphenol, bis(3-allyl-4-hydroxyphenyl)methanone, 4-(3-allyl-4-hydroxyphenylsulfonyl)-2-allylphenol, 4-(3-allyl-4-hydroxyphenylsulfinyl)-2-allylphenol, and the like.
In an exemplary embodiment, the polycarbonate copolymer is prepared from BHPM and DABPA having a mol fraction of DABPA from about 0.01 to about 1, specifically about 0.05 to about 0.75, and more specifically about 0.1 to about 0.4.
The crosslinking agent includes electron deficient olefin compounds comprising one or more adjacent electron withdrawing groups. Suitable electron withdrawing groups include carbonyl groups such as aldehyde, carboxylic acid, ester, amide, and ketone; nitrile groups; nitro groups; and the like. The crosslinking agent can comprise two, or more electron deficient olefin groups each comprising one or more adjacent electron withdrawing groups.
An exemplary group of crosslinking agents comprising electron deficient olefins include a compound comprising at least two maleimide groups linked via the nitrogen atom to a C 1 -C 30 hydrocarbylene group. Exemplary crosslinking agents include 1,1′-(methylenedi-4,1-phenylene)bismalimide (BMI); 1,4-phenylene bismalimide; 1,4-di-1H-pyrrole-2,5-dione)butane; and the like.
As used herein, “hydrocarbyl” and “hydrocarbylene” refer to a residue that contains only carbon and hydrogen. The residue may be aliphatic or aromatic, straight-chain, cyclic, bicyclic, branched, saturated, or unsaturated. It may also contain combinations of aliphatic, aromatic, straight chain, cyclic, bicyclic, branched, saturated, and unsaturated hydrocarbon moieties. The hydrocarbyl or hydrocarbylene residue, when so stated however, may contain heteroatoms over and above the carbon and hydrogen members of the substituent residue. Thus, when specifically noted as containing such heteroatoms, the hydrocarbyl or hydrocarbylene residue may also contain carbonyl groups, amino groups, hydroxyl groups, or the like, or it may contain heteroatoms within the backbone of the hydrocarbyl or hydrocarbylene residue.
Stoichiometric ratios of the crosslinking agent to the amount of olefin groups from the backbone of the polymeric material can be used. Other amounts include 0.5 to about 10 equivalents of crosslinking agent per olefin group of the polymeric material, specifically about 1 to about 5 equivalents, and yet more specifically about 1 to about 2 equivalents of crosslinking agent per olefin group. Suitable nonlinear optical (NLO) chromophores that can be used to form EO films include those that exhibit good chemical stability under conditions of electric field poling. Exemplary NLO chromophores include so-called high-μβ chromophores comprising and electron donor group bound to a pi electron connective system, which is in turn bound to an electron acceptor group. A suitable NLO chromophore includes LM 46M (4-((1E)-2-(5-(4-(N-ethyl-N-(2-methoxyethyl)amino)styryl)-3,4-dihexylthiophen-2-yl)vinyl)-2-(dicyanomethylene)-2,5-dihydro-5,5-dimethylfuran-3-carbonitrile).
The NLO chromophore can be selected to minimize any potential reaction between the chromophore and the crosslinkable polymeric material and/or crosslinking agent. By selecting, for example, sterically hindered chromophores, it is possible to crosslink the polymeric material without compromising the pi electron connective system of the chromophores. Such a selection can be made by one of ordinary skill in the art without undue experimentation.
The chromophore may be used in amounts of about 10 to about 35 weight percent based on the polymer, specifically about 15 to about 30 weight percent, and yet more specifically about 20 to about 25 weight percent.
Prepared solutions of crosslinkable polymeric material, crosslinking agent, chromophore, and optional solvent can be formed as thin curable films on a substrate, such as polymeric or silicon substrates. The solvent of the solution can be removed by evaporation, optionally with heating and/or vacuum to result in a crosslinkable film. The crosslinkable film can be heated to temperatures sufficiently above the Tg of the crosslinkable polymeric material so that poling can be used to induce the formation of an acentric dipolar lattice while the material is in a glassy state. Once the chromophores have been poled, the temperature is increased to induce crosslinking via Ene or Ene and Diels Alder reactions between the crosslinkable material and crosslinking agent.
The thin crosslinkable films can be formed by spin casting, dipping, spray coating, silk screening, doctor blading, ink jetting, and the like to form a thin film of the composition, more specifically spin casting. Solvents that are suitable for film forming include those that can solubilize the polymeric material, but are inert to the components of the film. Substrates on which the films are form may be of any material including, for example, polymeric or silicon substrates.
In an exemplary embodiment, the crosslinked film can be prepared by mixing a crosslinkable polymeric material comprising pendent olefin groups, a crosslinking agent, and NLO chromophore with a suitable solvent to form a mixture. The mixture is then applied to a substrate, either by spin coating, casting, dipping, etc., and then the solvent is allowed to evaporate to leave a crosslinkable film comprising the crosslinkable polymeric material, crosslinking agent, and chromophore. The crosslinkable film is heated to at or slightly above the glass transition temperature of the film and an electromagnetic field is then applied to the crosslinkable film to cause a poling of the chromophore present therein. The chromophore molecules align relative to the direction of the applied field. While maintaining the electromagnetic field, the crosslinkable film is heated to temperatures sufficient to induce crosslinking of the olefin groups of the polymeric material with the crosslinking agent by Ene and possibly even Diels Alder reactions. The crosslinking fixes the aligned chromophore molecules thereby providing a cured film having non-linear EO properties. It is believed that the crosslinking will provide an increase in the lifetime of the device after poling by maintaining the chromophore orientation longer than the corresponding non-crosslinked polymers.
The crosslinking of the crosslinkable polymeric material and crosslinking agent occurs under mild conditions at temperatures at or just above the glass transition temperature of the crosslinkable film. These temperatures are sufficient to provide cure while at the same time low enough so that decomposition of the other components of the film does not occur. Temperatures suitable to induce crosslinking can be about 150 to about 350° C., specifically about 200 to about 300° C., and more specifically about 200 to about 275° C.
The time of heating to induce crosslinking is dependent upon the crosslinkable polymeric material employed and the crosslinking agent used. Exemplary reaction times to induce crosslinking can be about 2 to about 60 minutes, specifically about 3 to about 20 minutes, more specifically about 4 to about 10 minutes, and yet more specifically about 2 to about 5 minutes.
The crosslinked films comprising oriented NLO chromophores can be used for a variety of applications, including for example, electro-optical waveguide materials, Mach Zehnder modulators, optical switches, variable optical attenuators, narrow band notch and bandpass filters, digitally tuned gratings, optical frequency mixers, and electro-optical devices including organic light-emitting diodes and photo diodes.
In another embodiment, the crosslinkable polymeric material in combination with a crosslinking agent, but without the chromophores, can find use in non-EO applications as a coating material with on-demand cure.
EXAMPLES
Examples 1-4
Synthesis of DABPA-co-BHPM PC Copolymer
DABPA-co-BHPM PC copolymers comprising varying amounts of pendent olefin groups were prepared by reacting a mixture of 1,3-bis(hydroxyphenyl)monoterpene (BHPM, internally prepared), and 2,2′-diallylbisphenol A (DABPA, n=0.1, 0.2, 0.3, and 0.4, Aldrich Chemical Co., purified prior to use) with excess phosgene, and in the presence of pyridine or triethylamine. An amount of 1.5 mol percent of 4-Cumylphenol (Aldrich Chemical Co.) was used as a chain stopper.
Alternatively, the copolymers were prepared under interfacial phosgenation conditions using methylene chloride as the solvent, aqueous sodium hydroxide as the base and (0.1-1 mol %) triethylamine as the catalyst. The processes used for the preparation of the copolymers were not optimized and exhibited a slight excess of BHPM relative to the mole fraction of DABPA, presumably due to a difference in the monomer reactivity ratios under the condensation polymerization conditions used.
Table 1 summarizes the weight average molecular weight (M w ), the number average molecular weigth (M n ), and the polydispersity index (PDI, M w /M n ) for the DABPA-co-BHPM PC copolymers obtained by gel permeation chromatography (GPC).
TABLE 1
Mol
Fraction
M n
M n
Example
DABPA
M w
(Exp)
(Theory)
M w /M n
1
0.1
11664
5598
23383
2.084
2
0.2
15148
5794
23279
2.615
3
0.3
17481
7142
23175
2.448
4
0.4
28354
8677
23071
3.268
A differential scanning calorimetry (DSC) study was undertaken to evaluate the thermal cross-linking of the DABPA-co-BHPM polycarbonate copolymers of Examples 1-4 using 1,1′-(methylenedi-4,1-phenylene)bismalimide as the crosslinking agent. The DSC thermal analysis was completed using a Perkin-Elmer DSC7 differential scanning calorimeter. 1,1′-(Methylenedi-4,1-phenylene)bismalimide (BMI, Aldrich Chemical Co.) was added without further purification to each polycarbonate copolymer formulation to obtain a theoretical stoichiometry of 0.5 allyl equivalents per BMI. All sample copolymer formulations were prepared by evaporatively casting films of filtered (Whatman Uniprep™ syringeless filters, 0.45 micrometer polytetrafluoroethylene membrane) CH 2 Cl 2 solutions containing dissolved copolymer and BMI. All DSC sample measurements were referenced to an indium standard (melting point (mp) 156.60° C., ΔH r =28.45 J/g) using a dual pan configuration under a nitrogen (N 2 ) purge gas. Typical sample masses ranged from 10 to 15 milligrams (mg), and all samples were compressed into pellets sized to fit an aluminum sample pan to maximize heat flow while minimizing thermal lag in the sample. Typical cycles for the first heat and second heat are listed in Table 2 below. DSC scanning kinetics data collection and manipulation was made using the Pyris V5.00.02 software package. No attempt was made to correct the data generated by normalizing it relative to M w , M n , composition, or mass variations between sets of replicate runs.
TABLE 2
Typical DSC experimental heat flow cycles (endothermic event up)
Cycle
Heat
Step
Step Description
1
1
Hold for 2.0 min at 25.00° C.
1
2
Heat from 25.00° C. to 425.00° C. at 10.00° C./min
1
3
Cool from 425.00° C. to 25.00° C. at 10.00° C./min
2
4
Hold for 5.0 min at 25.00° C.
2
5
Heat from 25.00° C. to 425.00° C. at 10.00° C./min
2
6
Cool from 425.00° C. to 25.00° C. at 10.00° C./min
In this screening model study, the thermal cross-linking of DABPA-co-BHPM polycarbonates with BMI was probed in situ using DSC thermal analysis. As indicated in FIG. 1 a, DABPA-co-BHPM polycarbonates are thermoset at temperatures from 130-200° C. as electron deficient BMIs react via an Ene addition to the electron rich diene in the form of an ortho-allylphenyl function. The first and second that for each of the DABPA-co-BHPM/BMI formulations Examples 1-4 is shown in FIGS. 2 and 3 , respectively. The T g for the undoped and uncured polycarbonate copolymers is summarized in Table 3.
TABLE 3
Example
Polymer
Tg (° C.)
Control
BHPM
250
Example 1
DABPA-co-BHPM (n = 0.1
215
DABPA)
Example 2
DABPA-co-BHPM (n = 0.2
185
DABPA)
Example 3
DABPA-co-BHPM (n = 0.3
172
DABPA)
Example 4
DABPA-co-BHPM (n = 0.4
159
DABPA)
An interpretation of the results for the 1 st and 2 nd heat of the DABPA-co-BHPM PC copolymer formulations is as follows. In FIG. 2 , heat flow is seen to increase as the temperature is ramped, consistent with an upward slope of the heating curve. At T=156° C., the unreacted BMI dispersed within cast films of the DABPA-co-BHPM PC copolymer formulations is undergoing an endothermic phase transition as the solid BMI melts. The integrated area under each curve increases roughly in proportion to the concentration of the solid BMI dispersed within the polycarbonate copolymer formulation, that is, the concentration of dispersed BMI increases from heating curve 1 to 4 (n=0.1-0.4 DABPA, respectively). This transition is reproducible between the different polycarbonate compositions, occurring at the reported melting point for 1,1′-(methylenedi-4,1-phenylene)bismaleimide (mp=156-158° C.), and this in turn is consistent with a discrete, low molecular weight component dispersed within the copolymer matrix.
After the BMI has melted, heating continues until the onset of curing at approximately 185° C., as suggested by a broad, shallow exothermic event evident in all of the heating curves. This interpretation is consistent with several additional observations. First, the T g associated with any of the unreacted polycarbonate copolymers (Table 3) were not observed. Secondly, there is no hysteresis observed in the heating curve for the 2 nd heat ( FIG. 3 ), that is, neither an endothermic event associated with the melting of BMI or an exothermic event associated with thermal curing are observed in the 2 nd heat. Indeed, it should also be readily apparent that there are no observable transitions associated with unreacted DABPA-co-BHPM PC copolymers, e.g., T g (Table 3). This result implies that a thermal cross-linking event has occurred, resulting in a cross-linked network. The results further suggest BMI acts as a cross-linking agent to form a polymer network that is distinct from the original starting materials used to form the network. The resultant polymer network does not exhibit any detectable T g under the thermal treatment describe using DSC methods.
Example 5
T g of Doped DABPA-co-BHPM PC
Samples of DABPA-co-BHPM PC containing varying amounts of DABPA were doped with chromophore LM 46M at 25 weight percent loadings and measured for Tg. A distinct trend in the reduction of the glass transition temperature was observed with the incorporation of the chromophore.
TABLE 4
Example 5
Tg (° C.) of copolymer doped with
(Mole fraction of DABPA)
25 wt. % chromophore
0.1
133
0.2
122
0.3
110
0.4
100
While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims. | Crosslinkable polymeric materials are disclosed useful for the temporal stabilization of a poling-induced noncentrosymmetric host lattice containing guest nonlinear optical chromophores. The materials are also suitable as crosslinkable coatings in the absence of chromophores. Also disclosed is a method of crosslinking such polymeric material. | 2 |
FIELD OF INVENTION
This invention relates to shade modification techniques and in particular the use of analytical methods to simulate and increase the amount of sunlight exposure of a golf green.
DESCRIPTION OF THE RELATED PRIOR ART
Proper maintenance of golf greens is essential to the running of a good golf course. A poorly maintained green can unfairly affect scoring while a well maintained green is consistent for all players. A well maintained green can also render putting more predictable and therefore less frustrating. A major component to maintaining a good golf green is having the grass grow evenly across the green and to have the grass grow without any diseases. Unfortunately, given the topography and tree cover that makes golf courses so aesthetically pleasing, sunlight is not evenly distributed throughout the green. A tree adjacent to a green, while pleasing to the eye, may block significant amounts of sunlight from reaching parts of the green throughout the day. This leads to uneven grass growth and makes grass more susceptible to diseases. Shaded parts of the green will have lesser growth and more susceptibility to diseases while unshaded parts would have healthier, better growing grass. Furthermore, players who enjoy being in the sun may find greens that are shaded bothersome for significant parts of the day.
However, even with the problems above, it is difficult to determine the amount of sunlight and, concomitantly, shade that a green receives. In order to do so the interaction between the sun and any trees or features blocking the sun must be studied and analyzed. Such an analysis can only be accomplished if the sun's path across the sky is charted in conjunction with the position of any trees or features that may block sunlight.
While tracking the sun's movement is an eons old occupation and while observing the shadows cast by various objects is also quite old, there are no analytical tools which are specifically tasked to assist an arborist or turf manager in accomplishing these tasks with respects to trees. There have been devices which can track the sun and some that even have been able to give an indication however slight, of the sun's path and its effect on a structure's silhouette.
A patent issued to Gutschick (U.S. Pat. No. 4,678,330) measures the solar radiation in a vegetative canopy by attaching sensors to the leaves of the vegetative canopy. A computer then samples the sensor readings and determines the amount of solar radiation that the canopy receives. While this invention is quite ingenious, it does not accomplish what is required by golf managers and arborists. Gutschick provides data and a data processing capability to determine solar radiation in specific spots but does not provide any means to determine shade data, sunlight exposure analysis, nor a what-if capability to determine which tree, structure, or even tree branch can be modified to provide better light exposure. While this apparatus can be used for this purpose, it would be a time consuming and tedious process to attach a multiplicity of sensors to leaves on each and every relevant tree adjacent the green. Also, Gutschick does not provide any means to determine which trees are the relevant ones in terms of a golf green's light exposure.
Another patent, issued to Dalrymple (U.S. Pat. No. 4,635,371) provides for a device which can be used to determine the path of the sun at any given time and day. The device is a hand-held cylindrical device through which the user can view an area of interest. By viewing the area of interest through the lens of the device and through the markings on the lens, the viewer can see the path the sun would travel at certain times of the year. The markings are graduated to show where the sun would be at certain times of the day and at certain times of the year. Unfortunately, this patent does not show the actual amount of sunlight the sun provides to an area. The device only shows the path the sun would travel. While one can theoretically determine the amount of sunlight an area may get, there is no means to determine the behavior of either the sunlight or of shadows cast because of the sun. To determine the amount of sunlight an area may receive, the user would have to perform a mental projection of how the sun would effect shadows in the area. Also, Dalrymple does not provides any means to model sunlight behavior nor any means to provide a what-if capability to determine the impact of any canopy modification.
A third patent, U.S. Pat. No. 4,288,922, issued to Lewis, is a device which has a wide angle viewer and a transparent screen which has marked on it the paths the sun travels at various times of the year. When the viewer peers through the viewer, the paths of the sun can be determined for different times of the year. Also, by having the area of interest in front of the device, the relevant features, such as a tree or a church, is superimposed on the transparent screen. Thus, by looking through the viewer, the user can then quickly determine how long, per day, the area of interest would be covered in shade at specific times of the year. While Lewis seems to be accomplishing what is required, it runs into problems when there are multiple trees or items that contribute to the shade. If, for example, a clump of trees were providing shade, there is no means to determine which tree contributed most to the combined shade. One may extrapolate by a rough estimate, using this invention, which tree contributes the most to the shade. However, this rough estimate is by no means conclusive of the desired results. The Lewis device, when used with a judicious eye and sound judgment, may provide an approximation of what would happen if a tree or a branch were removed. However, this again depends on the abilities of the user. Human judgment is by definition imprecise and therefore not suitable for determining proper canopy coverage.
A fourth patent, (U.S. Pat. No. 4,186,297) issued to Owner-Peterson et al. is for a sunlight calculator that is comprised of a base portion and two sliding plates. One of the sliding plates is transparent and has a double curve system that allows the plotting of any day/hour combination. A further curve gives an indication of the heating effect of the sun given the relevant data such as the time and sun position. The invention is in effect a large slide rule that allows the user to calculate specific information regarding the sunlight that enters a specific window on a facade. By sliding the plates properly, one can determine the path the sun would take on a specific day, how much heat the sun would generate through square units of window portions of the facade. Clearly, this device was envisioned as a calculator to be used to determine the effect of sunlight entering through a window. Owner-Peterson is directed towards, among other things, determining the amount of heat energy entering through a window. While this invention does track the sun's movement, it does not give an indication of shade or sunlight behavior.
Another patent in this area (U.S. Pat. No. 5,379,215) was issued to Kruhoeffer et al. and related to a weather visualization system. With this system, the user can generate a three dimensional picture, complete with sunlight, shadows, clouds, and other weather effects. Also, the user can generate a simulated “fly-by” of the scene. The invention uses a computer to generate the image and it takes into account all the relevant data such as the date and the time of day. The invention also extracts information from satellites and other sources of real-time information to continually update the image. While Kruhoeffer does provide an image of the general area with an indication of the sun's position and its effects on the landscape, it does not have the capability to project possibilities. Also, the invention provides a macroscopic view of the area whereas what is needed is a more localized view of the area. Furthermore, this invention makes use of a pre-made three dimensional terrain map, requiring large capital outlays to acquire such a map.
A final patent found in this area, U.S. Pat. No. 4,236,313 issued to Griffin, provides an apparatus that determines solar exposure at different locations. The device allows the user to determine the amount of solar exposure an area receives by tracking the sun's path at different times of the year. Griffin is comprised of a base, an elevated sun pointing device, and numerous means to adjust the sun pointing device depending on the date and the time of day. On a theoretical level, this invention allows the user to visually track the sun's path on a specific time of year and, by doing it in front of a tree of interest, determining where the sun would be relative to the tree. However, neither the device nor the method claimed allows the user to project shadows resulting from the sun's position. Also, neither of these two allow the user to automatically determine which obstruction out of many contributes the most to the shade covering an area.
As can be seen, none of the above devices are geared specifically to assist an arborist or turf manager in making canopy pruning or canopy removal decisions. Also, none of these devices can provide recommendations as to which parts of a tree to prune or which tree provides the most shade. Perhaps most importantly, none of these devices can provide an arborist with data as to what effects pruning or tree removal may have on a green's sunlight exposure even before any pruning or tree removal is done.
From the above, it is clear that a tool is needed that can assist an arborist or turf manager in making decisions. The tool must be easy to use, flexible in terms of flexibility and, ideally, provide the arborist with possible shade or sunlight effects of projected canopy modifications.
SUMMARY OF THE INVENTION
The present invention overcomes the deficiencies identified in the prior art. The present invention provides a computer system that can be used to model a sun's path across the sky, model shadows caused by trees and other sunblocking objects, and analyze the sunlight exposure of a golf green.
The above object is achieved by providing a computer system having data storage means and a memory for determining sunlight exposure of an area, said system including:
input means for receiving and storing in memory area data entries which define a size and shape of the area and a first and at least one second predetermined location
input means for receiving and storing in the memory temporal data entries defining a time and date range
input means for receiving and storing in the memory obstruction data entries defining a size and relative position of at least one sunlight obstructing object
processing means for performing sun calculations which determine multiple solar positions of the sun in the sky based on the temporal data entries and the area data entries
processing means for performing shadow calculations for each solar position, said shadow calculations determining a size, shape and position relative to the area of a shadow cast by the or each sunlight obstructing object
processing means for determining for each square unit of the area a sunlight exposure time based on the shadow calculations
output means for generating shadow calculation results and portraying a representation of the shadow calculation results and
output means for generating sun calculation results and portraying a representation of the sun calculation results
Preferably, the area data entries include an earth based latitude of the area, a magnetic declination of the area, azimuth readings of multiple points on a perimeter of the area, and area distance readings of each of the multiple points on the perimeter, wherein said area distance readings are measured between each of the multiple points on the perimeter and the first predetermined location and said area azimuth readings are relative to magnetic north and are determined from said first predetermined location.
More preferably, the first predetermined location is within the area and the area data entries include a longitude of the area.
Most preferably, the area data entries include, for the or each second predetermined location, second location azimuth readings relative to magnetic north and second location distance readings, wherein second location azimuth readings are determined from the first predetermined location and the or each second location distance readings are measured between the or each second predetermined location and the first predetermined location within the area.
Conveniently, the obstruction data entries include obstruction azimuth readings of the or each sunlight obstructing object and obstruction distance readings for the or each sunlight obstructing object, an elevation reading for the or each sunlight obstructing object, wherein said obstruction distance readings are measured between a location of the or each of the sunlight obstructing object and a location chosen from the group comprising the first predetermined location and the at least one second predetermined location and said obstruction azimuth readings are relative to magnetic north and are determined from a location chosen from the group comprising the first predetermined location and the at least one second predetermined location.
More conveniently, the at least one sunlight obstructing object is a tree and wherein the obstruction data entries further include a tree crown shape for the or each tree, a crown upper elevation reading for the or each crown of the or each tree, a crown lower elevation reading for the or each crown of the or each tree, a left crown azimuth reading for the or each crown of the or each tree, and a right crown azimuth reading for the or each crown of the or each tree wherein said crown elevation readings are measured between a location of the or each of the sunlight obstructing object and a location chosen from the group comprising the first predetermined location and the at least one second predetermined location and said crown azimuth readings are relative to magnetic north and are determined from a location chosen from the group comprising the first predetermined location and the at least one second predetermined location.
Most conveniently, the obstruction data entries include at least one growth rate for the or each tree and an aging time span.
Also preferably, the computer system further includes processing means for increasing the crown azimuth readings and the crown elevation readings for the or each tree based on the or each growth rate and the aging time span.
More preferably, the at least one sunlight obstructing object is a block of trees and wherein the obstruction data entries further include tree block azimuth readings of multiple points on a block perimeter of the block of trees, tree block distance readings of each of the multiple points on the block perimeter, an average crown upper elevation reading for the block of trees, and an average crown lower elevation reading for the block of trees wherein said tree block azimuth readings are relative to magnetic north and are determined from a location chosen from the group comprising the first predetermined location and the second predetermined location and said tree block distance readings are measured between each of the multiple points on the block perimeter and a location chosen from the group comprising the first predetermined location and the at least one second predetermined location.
In another embodiment, the invention provides a method of modifying foliage on a golf course to provide more sunlight to a golf green, the method comprising:
determining characteristics of the green including size, shape, and location of the green
determining characteristics of the foliage including size, shape, and location relative to the green
performing a sun simulation of a path of the sun across the sky during a predetermined date and time range
performing a shadow simulation of the shadows cast on the green by the foliage based on the sun simulation and the characteristics of the foliage
performing a unit area calculation for each unit area of the green, said unit area calculation determining an amount of sunlight each unit receives based on the shadow simulation
determining at least one course of action to provide more sunlight to the green based on the unit area calculation, the or each course of action being chosen from a group comprising:
pruning the foliage
removing the foliage
relocating the foliage
performing a modified shadow simulation of the shadows cast on the green by the foliage if the or each course of action were followed, said modified shadow simulation being based on the sun simulation and projected characteristics of the foliage
performing a modified unit area calculation for each unit area of the green, said modified unit area calculation determining a modified amount of sunlight each unit receives based on the modified shadow simulation
In yet another embodiment, the invention provides a method of determining modifications to sunblocking objects on a golf green to provide more sunlight to the green, the method comprising:
a. Determining a size, shape, and geographical location of the green
b. Determining a size, shape, and position relative to a predetermined point of at least one sunblocking object
c. Determining a relevant path of the sun across the sky as observed from the geographical location of the green for a predetermined date and time range
d. Performing a shade calculation resulting in shade results, said shade results determining an amount of shade cast on the green by the or each sunblocking object based on the relevant path of the sun and the size, shape, and position of the or each sunblocking object
e. Performing a modified calculation resulting in modified shade results, said modified shade results determining a modified amount of shade cast on the green by the or each sunblocking object based on the relevant path of the sun and a modification of the or each sunblocking object, said modification being chosen from a modification group comprising:
altering the shape of the or each sunblocking object
removing the or each sunblocking object
altering the size of the or each sunblocking object
a combination of altering the size and the shape of the or each sunblocking object
f. Determining which modification from the modification group provides more sunlight to the golf green based on a comparison of the shade results and the modified shade results
g. Generating a visual representation of the shade results and the modified shade results
Preferably, step e) further includes generating a visual representation of the or each sunblocking object
The advantages of the present invention are numerous. The computer system is flexible in its capabilities as it allows the arborist to generate visual representations of the calculation results. Also, the computer system provides what-if scenarios, allowing the arborist or turf managers to determine which canopy modification strategy works best. Furthermore, the system and the method gives the arborists or turf managers the capability to determine what sunlight cover would be like at any time of the year.
BRIEF DESCRIPTION OF THE DRAWINGS
A better understanding of the invention will be obtained by considering the detailed description below, with reference to the following drawings in which:
FIG. 1 is a block diagram of the components of the invention.
FIG. 2 is a schematic diagram of a golf green as generated by a computer program used to practice the invention.
FIG. 3 shows a measuring instrument that can be used to assist in practising the invention.
FIG. 4 shows a golf green with a plurality of relevant points that must be entered into the computer program used to practice the invention.
FIG. 5 shows a tree with its relevant crown azimuth readings indicated.
FIG. 6 is a sample diagram of the path of the sun on a specific day as observed from the center of a golf green.
FIG. 7 is a sample diagram of the golf green coded to indicate sunlight exposure times.
FIG. 8 is a sample graph that indicates individual tree contribution to green shade.
FIG. 9 is a sample coded diagram of sunlight exposure times calculated with one tree disregarded in the calculations.
FIG. 10 is a sample picture of a tree with skewed images of the golf green superimposed to determine which parts of the tree provide the most shade.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 illustrates the components of the computer system ideally used to practice the invention. The ideal components are a CPU 10 , a memory 20 , a keyboard 30 , a program 40 residing in the memory 20 , and a monitor 50 . A printer 60 can also be attached to provide printouts of the relevant data. Furthermore, have data storage means such as a hard drive 70 is required. The CPU 10 would perform all the calculations required while the keyboard 30 is used to enter the required data.
FIG. 2 shows an overhead schematic view of a sample golf green generated by a program 40 . As can be seen from FIG. 2, the golf green 80 is flanked by the trees 1 , 2 , and 3 . Also, the golf green 80 is flanked by a building B 1 .
Defining the golf green 80 to the program 40 is accomplished by taking azimuth readings of numerous points on the perimeter of the green 80 .
Such measurements, and others that are required by the invention, can be taken by the use of well-known surveying instruments such as the Nikon C-100 Total Station. These measuring instruments, such as the instrument 85 shown in FIG. 3, can take elevation and azimuth readings of sight. Some of these instruments also measure distances. For our purposes, azimuth is the distance from magnetic north as expressed in degrees. For example, 90 degrees=east, 180 degrees=south, 270 degrees=west, and 360 degrees=north. Also for our purposes, elevation is the distance from level as expressed in degrees. For example, level=90 degrees and vertical is 0 degrees.
Referring to FIG. 4, the azimuth and distance of multiple points 90 (marked as black dots around the perimeter of the green) on the golf green 80 are preferably determined from the center of the green 80 . While the green center is the most convenient location for these measurements, other locations not necessarily within the green can be used as well. These azimuth and distance readings are then entered into the program 40 . This method of locating points relative to the center of the green 80 is also to be used in defining the position of the trees 1 , 2 , and 3 . The azimuth of the trees 1 , 2 , 3 are measured from the center of the green 80 along with the distance between the trees and the centre of the green. However, should this method of determining azimuth relative to the center not be practical, such as a blocked line of sight, a secondary locating position can be found. The location of this secondary position must, however, be entered into the program 40 by entering its azimuth and distance as measured from the center. By doing this, any features, such as trees, with its azimuth measured from the secondary position can have its position calculated relative to the center of the green. This is done by using a simple translational calculation with the center as the center of a planar Cartesian coordinate system and the secondary position and the feature as points on the coordinate system. Multiple secondary locations can be used as long as there azimuth, distance readings are entered into the program 40 . Should the secondary locating position have a different elevation from the centre of the green, this elevation, as measured by the instrument 85 , is also entered into the program 40 .
After entering the location, via the azimuth and distance readings, of the trees 1 , 2 , and 3 , other characteristics of these trees are entered into the program 40 . To properly simulate the shadow cast by a tree, its crown shape and the size of the crown must be determined. This is accomplished by choosing a crown shape that fits the tree's crown as closely as possible. Possible crown shapes are umbrella, oval, pyramidal, parabolic, columnar, and round.
After determining crown shape, the characteristics of the crown are then found and, along with the crown shape, entered into the program 40 . To determine the height of the tree, its elevation is measured using the measuring instrument 85 . A proper determination of the crown size requires a reading of the crown's left azimuth, right azimuth, top elevation and bottom elevation. An illustration of these measurements is shown in FIG. 5 .
Further azimuth and distance readings taken from different vantage points can be entered into the program 40 to further define the tree. This will give the program 40 an almost three dimensional view of the tree.
The above steps must be repeated for each tree that is sufficiently close to the green 80 . However, if there is a large block of trees close by, it would be tedious and, in most cases, redundant to repeat the above steps for each and every tree. Thus, a single entry for the whole block can be made to determine the block's contribution to shade, if any. To enter a block into the program 40 , azimuth and distance readings of multiple points on the block's perimeter must be made and entered into the program 40 . These points must be numerous enough to define the shape of the tree block. Such readings can be made relative to either the center of the green 80 or relative to a secondary position as noted above.
After defining the tree block's perimeter, the average upper elevation of the trees in the block is taken and entered into the program 40 . Similarly, an average lower elevation of the trees in the block is measured and entered into the program 40 .
It must be noted that any other sunlight obstructing object, such as building B 1 in FIG. 2, is entered and defined for the program 40 in a manner similar to that of a block of trees.
A blocking horizon, defined as the horizon at the green over which there is no control, such as a building or a hill, must also be entered to give a proper simulation of sunlight and shade.
After entering the relevant data regarding the sunlight blocking objects, the sun's path must be determined so that sunlight coverage can be calculated. To do so, the geographical location of the golf course must be entered. This would include entering the longitude, latitude, and magnetic declination of the course. The magnetic declination, also Known as variance in aeronautical terms, is entered to compensate for the difference between magnetic north and true north. The longitude and latitude can be found through maps, relevant software, or GPF locating devices. With respect to magnetic declination, topographic maps and other software can be used. Also, a specific date, including year, month, and day, must be entered into the program 40 . The program 40 calculates, through well-known astronomical and geographical algorithms, the path the sun will travel on that specific day as seen from that specific longitude and latitude.
A sample print out of the sun's path on a specific day is illustrated in FIG. 6 . This graph illustrates where the sun will be on the date in question relative to the green 80 .
After determining the sun's path, the program 40 simulates the shadow cast on the green 80 by each sunblocking object. By using well-known trigonometric and geometric methods and algorithms, the shadow cast by a sunblocking object, such as a tree, can be determined. Given the sun's position in the sky, the height and shape of the object, the shape of the shadow as projected by the object can be found by the program 40 . This is done by calculating for each of a significant number of points on the silhouette of the object a point on the ground where the silhouette point would cast a shadow, given the sun's position in the sky. With enough points on the object's silhouette an outline of the tree, as projected on the ground, is obtained. This outline is the object's shadow for that specific time of day.
Using the above method for all sunblocking objects, a picture of the green, with appropriate shadows, is composed. Separate trees or objects cast separate shadows and overlapping shadows do not present a problem given that if one shadow covers a specific area, an overlapping shadow does not affect that first shadow.
An analysis of sunlight exposure is therefore now possible. Now that the program 40 knows where the sun will be in the sky at each point during daylight on the specified date, and now that the program 40 can determine where a sunblocking object's shadow will fall given a position of the sun, the program 40 then simulates a day's sunlight exposure of the green 80 . The program 40 , knowing the size and shape of the green 80 , thus divides the green 80 into smaller unit areas. Then, by simulating the shadows falling on the green 80 for each position the sun takes in the sky, a map of sunlight exposure for the green 80 is obtained. This map not only shows which area received sunlight but also how much sunlight it receives during the day. By graphically presenting this map to an agronomist or turf manager, he or she can determine which areas are deficient of sunlight. An example of such a map is shown in FIG. 7 . Portrayed on the figure are a number of zones on the green 80 with each zone marked with an indication of how much sunlight it receives during a specified day. For example, Zone A receives 6-7 hours of sunlight while Zone F receives 11-12 hours of sunlight. The map can be portrayed on either the monitor 50 or printed out on the printer 60 .
A further analysis of which tree contributes most to the shade falling on the green 80 is also performed by the program 40 . This is accomplished by simulating each tree's shadow on the green 80 in isolating from any other sunblocking object. Thus, a tree's shadow throughout the day is simulated and the shadow's total coverage in terms of square foot hours is calculated. The program 40 can easily calculate this for every tree as the green 80 has been subdivided into numerous unit areas. The results for each tree are then graphed to show that tree's contribution to green shading. A sample graph of stand alone tree contribution to green is shown in FIG. 8 .
The above analysis determines which tree contributes the most to green shading. Given that what is desired is an increase in sunlight exposure, the problem tree of trees is identified by observing which tree or trees on the above mentioned graph contributes the most to green shading. The next step is a simulation of possible effects on green shading by projected modification to the canopy. One possible modification is the drastic measure of eliminating the tree. To determine what effect removing a problem tree will have on green shading, the program 40 is told to disregard the problem tree in running a shadow and sunlight simulation similar to that outlined above. By generating a sunlight exposure map with the problem tree disregarded, the effect of removing the problem tree can be seen. An example of such a map is shown in FIG. 9 . This FIG. 9 is similar to FIG. 7 but with tree 3 disregarded in simulating sunlight exposure. Comparing these two figures shows that there is a significant increase in sunlight exposure for most of the green 80 . For example, Zone A 1 now receives 8-9 hours of sunlight compared to 6-7 hours in Zone A in FIG. 7 . Zone E 1 now receives 12-13 hours of sunlight compared to the same area (Zone E and Zone F) in FIG. 7 .
If, on the other hand, removing the problem tree or trees is not an option, pruning the tree to reduce its size or change its shape can be considered. To assist in this, the program 40 will generate a graphical representation of the problem tree with a numerous superimposed images of the green 80 corresponding to each position of the sun. The program 40 projects a shape of the green 80 , skewed based on sun angle, onto a diagram of the tree. Any portion of the tree blocking light has a part of the green shape overlapping it. An example of such an image is shown in FIG. 10. A glance at this image shows which part of the tree blocks the sun and at what time it does so. FIG. 10 shows that it is the top of the tree which blocks sunlight and that pruning is not an option, given the already sparse crown. Furthermore, the path of the sun as viewed from the centre of the green is also shown in FIG. 10 as a number of white dots. This way, the arborist can see how the sun interacts with the shade of the tree at different times of the day.
With another tree, for which pruning is an option, the arborist or turf manager can edit the tree's image by adding or subtracting to the tree's crown. Using a mouse or any other suitable pointing device connected to the system, the arborist adds or subtracts to the tree crown, using the projected green image as a guide. This effectively changes the size and shape of the tree crown and, concomitantly, the tree's shadow. Based on this new size and shape, the program 40 simulates a projected sunlight exposure on the green 80 according to the procedure outlined above. This therefore gives the arborist an idea of the effect of specific projected pruning modifications before any pruning is actually done.
To determine the effect of relocating trees, the arborist tells the program 40 to disregard a certain existing tree from its simulations. The arborist then defines a tree at the projected relocation site to the program 40 using the characteristics of the existing tree. The program 40 them simulates the shade effects of relocating the tree.
To further aid in determining the interaction between the trees and the shadows, the program 40 animates the movement of the shadows cast by trees due to the sun's movement. This is done by calculating for each sky position of the sun the position, shape, and size of each shadow. Each sky position of the sun and the shadows it generates comprises a frame of the resulting animation. This animation is shown to the arborist via the monitor 50 .
It must be noted that to speed up the simulations, the arborist can edit the time increments used by the program 40 . Thus, if an arborist selects 5 minute increments and daylight lasts for 14 hours, 168 separate shadow simulations must be carried out for a complete simulation of the day's shadows. However, if the arborist selects 30 minute intervals, only 28 simulations need to be carried out, one for every 30 minute interval. Lowering the number of shadow simulations by decreasing the number of intervals, however, yields faster but less accurate results.
A further feature of the program 40 that aids the arborist is designed to spot future sunlight problems. By entering a horizontal and a vertical growth rate for every tree of interest, the program 40 calculates a tree's horizontal and vertical growth and its effect on sunlight exposure. This aging process requires that the arborist enter an aging time along with the growth rates. Thus, if a tree has a radial growth rate of 6 inches per year a horizontally and 12 inches per year vertically, aging it by three years will yield a different sunlight coverage. The aged tree will now be 36 inches wider and 36 inches taller. Based on these projected dimensions, the program 40 runs a new shadow simulation. This gives the arborist an idea of what sunlight exposure will be on the green 80 in three year's time.
A person understanding this invention may now conceive of alternative structures and embodiments or variations of the above all of which are intended to fall within the scope of the invention as defined in the claims that follow. | A method and system for determining canopy coverage to a golf green to assist in increasing sunlight exposure of the green. The system allows users to enter data regarding the golf green, surrounding foliage, and other topographical and man-made features surrounding the green. The system can then plot the sun's path for a specific date and simulate shadows cast on the green by the surrounding foliage and features. Furthermore, the system allows the user to generate what-if data, allowing projected effects on canopy coverage to be viewed before any modifications to the canopy are carried out. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority under 35 U.S.C. §119(e) to provisional application Ser. No. 61/041,967 filed Apr. 3, 2008, herein incorporated by reference in its entirety.
FIELD OF THE INVENTION
The present invention generally relates to a back reamer for horizontal directional drilling, and particularly, to a multi-piece, sectional back reamer which can be quickly and easily assembled and disassembled in a safe manner by an operator.
BACKGROUND OF THE INVENTION
Utility lines for water, electricity, gas, telephone, and cable television are often run underground for reasons of safety and aesthetics. Sometimes, the underground utilities can be buried in a trench that is subsequently back filled. However, trenching can be time consuming and can cause substantial damage to existing structures or roadways. Consequently, alternative techniques such as horizontal directional drilling (HDD) are becoming increasingly more popular.
A typical horizontal directional drilling machine includes a frame on which is mounted a drive mechanism that can be slidably moved along the longitudinal axis of the frame. The drive mechanism is adapted to rotate a drill string about its longitudinal axis. The drill string comprises a series of drill pipes threaded together. Sliding movement of the drive mechanism along the frame, in concert with the rotation of the drill string, causes the drill string to be longitudinally advanced into or withdrawn from the ground.
In a typical horizontal directional drilling sequence, the horizontal directional drilling machine drills a hole into the ground at an oblique angle with respect to the ground surface. To remove cuttings and dirt during drilling, drilling fluid is pumped by a pump system through the hollow drill string, over a drill head (e.g., a cutting or boring tool) at the end of the drill string, and back up through the hole. After the drill head reaches a desired depth, the drill head is then directed along a substantially horizontal path to create a horizontal hole. Once the desired length of hole has been drilled, the drill head is then directed upwards to break through the ground surface, completing a pilot bore. Alternatively, the drill head may terminate in a trench.
The diameter of the pilot bore so constructed typically must be enlarged. To accomplish this, a reamer (sometimes called a back reamer) is attached to the drill string which is pulled back along the path of the pilot hole, thus reaming out the hole to a larger diameter. The reamer usually includes a reaming or cutting surface on which is mounted cutting teeth or other cutting or grinding elements. It is also common to attach a utility line or other conduit product to the reamer so that the product is pulled through the hole behind the reamer as the reamer enlarges the hole.
A back reamer, then, may perform several functions including: mechanically cutting, grinding and loosening the soil to enlarge the pilot hole diameter, directing drilling fluid to assist in the cutting action, mixing the loosened soil with the drilling fluid such that the resulting slurry is a consistency that will flow out of the bore when displaced by whatever product is to be pulled in, and transferring the longitudinal force required to pull the product through the hole.
The back reamer is normally constructed of heavy duty steel, and comes in many different sizes to create a bore which accommodates the utility product. The back reamer also has many different configurations according to the type of soil being drilled.
Once the pilot hole is completed, a person removes the drilling head and installs the back reamer. This manual operation is dangerous, since the person typically stands in front of or straddles over the top of the reamer in order to install the reamer on the drill string.
Communication errors are known to occur, with a resulting premature actuation of the back reamer while the installer is still preparing the reamer, thus causing serious injury, and even death, to the installer. The heavy weight of the reamer also results in back problems for the installer, both during attachment of the reamer and detachment of the reamer after the utility hole is formed. Furthermore, attachment and detachment of the reamer normally requires the use of large and heavy wrenches, which also may cause injuries if the wrenches are dropped or slipped.
Therefore, a primary objective of the present invention is the provision of an improved back reamer having components which can be quickly and easily assembled and disassembled by one person.
Another objective of the present invention is the provision of an improved back reaming method of horizontal directional drilling using a back reamer having separable components.
Another objective of the present invention is the provision of an improved back reamer having a main shaft, a reamer head, and a pull tab, each of which include faceted faces to prevent rotation relative to one another after the components are assembled.
Another objective of the present invention is the provision of a back reamer having separable components having faceted surfaces to prevent rotation of the components relative to one another.
A further objective of the present invention is an improved back reamer which can be quickly and easily mounted and dismounted from the drill pipe.
A further objective of the present invention is the provision of a method of horizontal directional drilling wherein the back reamer has components which are fixed against rotation relative to one another.
Still another objective of the present invention is an improved method of horizontal directional drilling which minimizes risk of injury to the operator, while effectively and efficiently enlarging the diameter of a pre-drilled pilot hole.
These and other objectives will become apparent from the following description of the invention.
SUMMARY OF THE INVENTION
The sectional back reamer of the present invention is intended for use in horizontal directional drilling, and comprises three components which can be assembled and disassembled quick and easily by an operator at each end of the drilling operation. The reamer includes a main shaft connectable to the drill string or pipe, a reamer or cutting head mountable on the main shaft, and a pull tab mountable to the reamer. The connections between the main shaft and the reamer cutting head, and between the cutting head and the pull tab include faceted surfaces to preclude rotation of the components relative to one another. The components are assembled sequentially by the installer in the trench or on top of the ground. The smaller size and weight of the components, as compared to the prior art one-piece back reamers, simplifies and greatly improves the safety to the operator driving the attachment and detachment of the reamer's components to and from the drill pipe.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of a conventional horizontal directional drilling operation.
FIG. 2 is a perspective view of one configuration of a prior art back reamer.
FIG. 3 is a schematic view of the reamer of FIG. 2 installed on the drill pipe for horizontal directional drilling.
FIG. 4 is a perspective view of another configuration of a conventional back reamer.
FIG. 5 is a schematic view showing the back reamer of FIG. 4 installed on the drill pipe for horizontal directional drilling.
FIG. 6 is an exploded view of the sectional back reamer of the present invention.
FIG. 7 is a perspective view of the assembled sectional reamer of the present invention.
FIG. 8 is a rear end view of the assembled reamer of the present invention.
FIG. 9 is a side elevation view of the reamer of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a conventional horizontal directional drilling machine 10 having a drill string or pipe 12 to form a pilot hole 14 extending to a trench 16 . The back reamer 18 is attached to the forward end of the drill string 12 in the trench and then pulled backwardly through the pilot hole 14 to enlarge the hole.
Two conventional configurations of back reamers 14 A and 14 B are shown in FIGS. 2 and 4 . As seen in FIGS. 3 and 5 , a utility product 15 is attached to the reamer 14 A, 14 B via a swivel coupling 16 so as to be pulled through the enlarged hole as the reamer 14 A, 14 B is pulled by the drilling machine 10 .
Each of the conventional reamers 14 A, 14 B include a front pipe 20 having internal threads 21 for threadable coupling with the forward end of the drill pipe 12 . The cutting head or body 22 of the reamer 14 A, 14 B includes cutting tools or bits 24 and fluid jets 26 . The rear end of each reamer 14 A, 14 B includes a pulling tab 28 to which the swivel coupler 16 is attached, which in turn connects to the utility product 15 , as seen in FIGS. 3 and 5 .
The conventional reamers 14 A, 14 B are heavy duty, one piece construction with diameters up to 36 inches. The size and weight of these reamers makes their handling and installation difficult and dangerous.
The improved multi-piece, sectional reamer 30 of the present invention is shown in FIGS. 6-9 and includes a main shaft 32 , a reamer head or body 34 , and a pull tab 36 which can be quickly and easily assembled and disassembled to and from one another. More particularly, the main shaft 32 is hollow and includes external threads 33 on the forward end for threadable coupling to the forward end of the drill pipe 12 and an open opposite end 35 . Alternatively, the reamer shaft 32 may have internal threads on the forward end for coupling to the drill pipe 12 , as in the prior art.
The cutting head 34 has a hollow hub 38 which slides on to the rearward end of the main shaft 32 . The head 34 includes a cylindrical shroud 41 surrounding the hub 38 and connected to the hub 38 by a plurality of spokes 43 . The pull tab 36 is slidably received in the rearward end of the hub 38 and includes threads 37 for threaded coupling with the rearward end of the reamer shaft 32 . Preferably, the main shaft 32 , the hub 38 of the cutting head 34 , and the pulling tab 36 each include one or more facets 40 for mating coupling which precludes rotation of the components relative to one another. The components of the reamer 30 can be removably secured to one another in any convenient manner, such as by a bolt 50 extending through bolt holes 42 , 45 on the head 34 and tab 36 , respectively. Thus, the pull tab 36 is fixed to both the main shaft 32 and to the head 34 so as to lock the three components together. The main shaft 32 and/or hub 34 also include a plurality of fluid jets 44 for ejecting fluid to carry the cut soil and material out of the drilled hole. A plurality of cutting teeth or bits 46 are welded or otherwise mounted on the shroud 41 , and a plurality of teeth or cutting bits 48 are similarly attached to the spokes 43 .
In use, after the pilot hole 14 is drilled, the reamer 30 is mounted to the pipe 12 . More particularly, the reamer components are sequentially assembled so as to minimize the weight required to be handled by the installer at any given time. The first step in the assembly sequence is to threadably mount the reamer shaft 32 to the end of the drill pipe 12 . Then, the reamer head or body 34 is slid over the end of the shaft 32 . The pull tab 36 is then inserted into the open end of the head 34 , and the end 37 of the tab 36 threaded onto the main shaft 32 . The bolt 50 is then inserted through the hole 42 on the head 34 and threaded into the hole 45 on the pull tab 36 . As seen in FIGS. 6 and 9 , the faceted surfaces 40 on the shaft 32 , the tabs 36 , and the hub 38 are aligned for assembly of the reamer 30 .
After the pilot hole 14 has been enlarged by the back reamer 30 , the back reamer components 32 , 34 , 36 can be quickly and easily disassembled in the reverse sequence. The smaller, lighter, components of the reamer 10 allow the installer to assemble and disassemble the unit with substantially reduced risk of injury, with reduced coupling forces, and lighter weight tools. Thus, the multi-piece improved back reamer 30 of the present invention inherently improves the safety for the installer or operator, as compared to heavy duty, one-piece prior art reamers.
The invention has been shown and described above with the preferred embodiments, and it is understood that many modifications, substitutions, and additions may be made which are within the intended spirit and scope of the invention. From the foregoing, it can be seen that the present invention accomplishes at least all of its stated objectives. | An improved back reamer for horizontal directional drilling is provided with multiple components which can be assembled and disassembled before and after the back reaming process. The reamer includes a main shaft connectable to the drill string, a reamer head removably mounted on the main shaft, and a pull tab removably attached to the main shaft. Faceted couplings between the reamer shaft and head, and between the reamer head and pull tab preclude rotation between the components. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority to U.S. Provisional Patent Application No. 61/822,109 filed on May 10, 2013 and titled “Non-Lithium Metal Ion Battery Electrode Material Architecture” incorporated herein by reference in its entirety.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable.
BACKGROUND
Field of the Disclosure
This disclosure relates to a secondary or rechargeable battery, specifically to modifying a battery's electrode matrix for use in non-lithium metal ion applications.
Background
Developing high energy, high power, and safe batteries is of great significance so as to address the society's energy needs, such as distributed power sources, electric vehicles, and devices that handle large amounts of power. Among current battery techniques, lithium-ion batteries featuring the highest energy and power density have dominated the portable electronics market. When lithium-ion batteries are to be scaled up, however, the availability of lithium will also become a limitation. The global production of lithium can presently only satisfy half the need to convert the annually produced >60 million cars into plug-in hybrid electric vehicles (EVs) which are powered by both combustion engines and rechargeable lithium batteries. With the continued adoption of EV's, the lithium supply deficit is expected to worsen because these vehicles carry several times more batteries onboard. Although lithium reserves in sea water are rich, exploitation from the sea is presently too expensive to constitute a significant portion of lithium production.
Recent efforts to develop scalable high-energy batteries have turned attention to non-lithium techniques such as room-temperature rechargeable magnesium and sodium batteries which work in a similar way as lithium-ion batteries. Magnesium and sodium are earth abundant elements and are cheaply produced in huge amounts as shown in Table 1.
TABLE 1
Comparison of Key Parameters of
Lithium, Magnesium, and Sodium
Lithium
Magnesium
Sodium
Gravimetric Capacity (mAh g −1 )
3861
2205
1166
Volumetric Capacity (mAh cm −3 )
2066
3833
1128
Potential (V vs NHE)
−3.04
−2.372
−2.71
Global Production (kg yr −1 )
2.5 × 10 7
6.3 × 10 9
10 10
(very low)
(high)
(high)
Price (carbonate; $ ton −1 )
5000
600
200
M n+ Radius (Å)
0.68
0.65
0.95
Polarization Strength (10 5 /pm −2 )
21.6
47.3
11.1
Generally, the electrodes based on light-weight multivalent metals such as magnesium and aluminum provide some advantages over the conventional lithium. For example, they may offer up to seven times higher volumetric specific capacity than lithium-ion battery anodes, including graphite and Li 4 Ti 5 O 12 . In addition, their redox potentials are 0.7-1.4 V higher than lithium, implying potentially better safety; but not too high (e.g. the redox potential of aluminum is lower than the popular anode Li 4 Ti 5 O 12 ) so that the theoretically achievable working potential is not compromised. Studies on the electrochemical deposition of magnesium showed that magnesium can be plated in a uniform dendrite-free manner and will serve as a safe anode material. Rechargeable magnesium batteries are therefore regarded as a potentially low-cost, ultra-high energy, and safe technology for energy storage.
Rechargeable batteries based on non-lithium metals share similar chemistry and fabrication techniques as those for rechargeable lithium batteries, while possessing the advantages of lower costs and better safety. However, most materials used for non-lithium metal storage have met with limited intercalation extent and inferior reversibility. A wide range of intercalation compounds have been screened for magnesium storage, including layered transition metal chalcogenides, transition metal oxides, and polyanionic magnesium salts. All these categories of compounds are established intercalation hosts for lithium battery cathodes. However, when they are directly used in the bulk form as cathodes, only Cheveral phase chalcogenides have exhibited practical magnesium intercalation. Currently, other compounds show continuous capacity fade after the initial activation stage. For oxides, no practical cycling stability has been reported and, to date, there is no cathode material exhibiting practical energy density and cyclability suitable for electrochemical storage of multivalent metal ions. For aluminum batteries, only V 2 O 5 and TiO 2 have been attempted as cathodes but, neither has exhibited practical energy density. Studies on sodium-ion batteries have also revealed intercalation chemistry that is different from their lithium-based counterparts. Many more plateaus are observed in the charge-discharge curves for electrochemical sodium intercalation, implying complex multi-phase reactions with frequent structural transformation which are detrimental to cycling stability.
Generally, the aforementioned disadvantages associated with the intercalation of non-lithium metal cations appear to be related to the fact that all these cations are larger or more polarizing than the Li + ion. Compared to the Li + ion, the Na + ion has the same charge number but a significantly larger ionic radius (0.95 Å, cf 0.68 Å for Li + ). As a result of steric effects, the Na + ion exhibits sluggish intercalation/diffusion kinetics in frameworks commonly employed for Li storage. The Mg 2+ ion has a similar ionic radius (0.65 Å) to Li but double the charge number, hence exhibiting high polarizing ability. The strong interaction of the multivalent Mg 2+ ion with the negatively charged atoms in the host material makes the diffusion of Mg 2+ difficult.
SUMMARY
This disclosure relates to a non-lithium ion metal electrode matrix to increase the multivalent metal-ion batteries' performance. These batteries provide an ultra-high-density energy storage that is aimed at providing substantially higher volumetric energy densities relative to lithium-ion batteries. The intrinsic safety of these batteries adds to the flexibility in packaging battery system, for example in electric vehicle applications. Other applications include energy storage solutions for distributed power source, grid, and EV applications.
In exemplary instances, there is disclosed a method for modifying a battery electrode material comprising introducing insertion species into a composition of A x M y N z and at least one non-lithium metal ion, delaminating the A x M y N z , exposing the delaminated A x M y N z to a solution containing the insertion species, and restacking the delaminated A x M y N z around the insertion species.
Also, there is disclosed a battery electrode material architecture comprising a composition of A x M y N z , a pillaring agent, and at least one non-lithium metal ion X n+ . Configured thusly, A is at least one low-valence element chosen from the group consisting of H, alkaline, and alkaline earth metals, and 0≦x≦1.5, M is at least one metal and 1≦y≦2.5, and N is at least one non-metal element chosen from the group consisting of O, S, Se, N, P, Br, and I, and 1.8≦z≦4.2. In instances, X is at least one non-lithium metal ion chosen from the group consisting of Na, K, Mg, Ca, Al, Ga, and Y, and 1≦n≦3. In further instances, the pillaring agent comprises at least one electrically neutral polymer containing O, N, F, and/or S atoms.
Likewise, there is disclosed a battery having an electrolyte in contact with a battery electrode material architecture comprising a composition of A x M y N z , a pillaring agent, and at least one non-lithium metal ion X n+ . Configured thusly, A is at least one low-valence element chosen from the group consisting of H, alkaline, and alkaline earth metals, and 0≦x≦1.5, M is at least one metal and 1≦y≦2.5, and N is at least one non-metal element chosen from the group consisting of O, S, Se, N, P, Br, and I, and 1.8≦z≦4.2. In instances, X is at least one non-lithium metal ion chosen from the group consisting of Na, K, Mg, Ca, Al, Ga, and Y, and 1≦n≦3. In further instances, the pillaring agent comprises at least one electrically neutral polymer containing O, N, F, and/or S atoms.
Additional features and characteristics of the disclosed embodiments e will be explained in the description which follows and will be apparent to those having ordinary skill in the art upon examination of the following discussion.
BRIEF DESCRIPTION OF THE DRAWINGS
For a detailed description of the disclosed embodiments, reference will now be made to the accompanying drawings in which:
FIG. 1 schematically illustrates the diffusion of non-lithium metal ions in layered materials as facilitated with the increase of interlayer space according to an embodiment of the present disclosure;
FIG. 2 illustrates the diffusion path of a Mg 2+ in MoS 2 and compares the energy change along the diffusion path with two different interlayer distances;
FIG. 3 illustrates a schematic of the method of constructing an electrode according to an embodiment of the present disclosure;
FIG. 4 illustrates the energy barrier for the diffusion of Mg 2+ in MoS 2 as a function of interlayer distance;
FIG. 5 illustrates the X-ray diffraction pattern of MoS 2 samples with different interlayer distances;
FIG. 6 illustrates the discharge-charge profile of magnesium intercalation in MoS 2 samples with different interlayer distance at the tenth cycle;
FIG. 7 illustrates the cycling stability of magnesium intercalation in MoS 2 samples with different interlayer distance;
FIG. 8 illustrates the discharge-charge profile of sodium intercalation in MoS 2 samples with different interlayer distance at the second cycle;
FIG. 9 illustrates the cycling stability of sodium intercalation in MoS 2 samples with different interlayer distance.
DETAILED DESCRIPTION
Overview:
The difficulty in intercalation/diffusion of metal cations in existing materials is induced by strong interactions between metal cations and host materials. These can be alleviated when the lattice of the host materials is enlarged by insertion of additional species including polymers, molecules, and inorganic and organometallic clusters. For example, as shown in FIG. 1 , fine-tuning the interlayer distance D 1 of layered materials according to the specific cation to be intercalated permits implementation of non-lithium metal cations. In FIG. 1 , the interlayer distance or spacing D 1 only permits the passage of lithium but, when expanded, the interlayer spacing shown as D 2 and D 3 no longer restricts the diffusion of non-lithium metal cations. The expansion of the lattice spacing by intercalation of pillaring agents is an efficient and general strategy to modify common electrode materials and matrices for efficient electrochemical storage of non-lithium metal cations. Electrode materials previously developed for lithium-ion batteries may be modified according to the present disclosure to meet the requirements for intercalation of non-lithium metals.
The electrode materials are configured for use in a battery. Generally, a battery comprises an enclosure having an electrolyte therein. The electrolyte may be any material that ionizes in response to an applied voltage, thus converting chemical energy to electrical energy. Further, the electrolyte may be a liquid, a gel, or a polymer electrolyte without limitation. The electrode materials extend into the enclosure and contact the electrolyte. In instances, the electrode materials may be in electrical communication with an electric circuit external to the battery enclosure.
Matrix:
The structural expansion of the electrode materials according to the present disclosure is effective for multiple classes of intercalation hosts and more specifically applicable to layered compounds. In some configurations, the electrode materials have a formula A x M y N z , (0≦x≦1.5, 1≦y≦2.5, 1.8≦z≦4.2). In these configurations, A is one of or a mixture of low-valence elements including but not limited to H (hydrogen), and alkaline and alkaline earth metals. Exemplary alkaline and alkaline earth metals include at least one element chosen from Li, Na, K, Mg, and Ca, without limitation. Further, M is at least one metal chosen from Ti, Zr, V, Ta, Cr, Mo, W, Mn, Fe, Co, Ni, Cu, Zn, Cd, Ga, In, Sn, Pb, Sb, Bi, and Te, without limitation. Also, N is at least one element chosen from O, S, Se, N, P, Br or I, without limitation
Insertion Species:
A controlled amount of electrically neutral pillaring agents is inserted into the lattice spacing of the electrode material intercalation hosts to obtain and stabilize a predetermined interlayer lattice parameter. As used herein, the terms “insertion species,” “intercalation species,” and “pillaring agents” are used interchangeably and have the same meaning Therefore, as disclosed, insertion species, intercalation species, and pillaring agents may be inserted in the interlayer spaces of a layered electrode material, for example having the formula A x M y N z discussed hereinabove. Further, the distance of interlayer lattice parameter is determined at least partially by the specific cation to be intercalated and thus, the amount of pillaring agents is likewise determined. Pillaring agents comprise polymers containing O, N, F, and/or S atoms such as poly(ethylene oxide), polypropylene glycol), poly(vinylpyrrolidinone), methyl cellulose, polyethyleneimine, poly(aniline), and polypyrrole and molecules containing O, N, F, and/or S atoms such as alkylamines comprising diethylamine, dibutylamine, dipentylamine, N-isopropylcyclohexylamine, and dicyclohexylamine and glymes comprising diglyme, triglyme, and tetraglyme. Upon insertion, the pillaring agents show a characteristic lattice expansion of 1-300% in at least one dimension of the layered composite electrode material. Without limitation by any particular theory, controlling the size and amount of the intercalated species likewise controls the interlayer distance of all composites, and thusly can be continuously tuned for the metal ion.
Composite Formation:
The disclosed composite electrode materials are synthesized by a general delamination-adsorption-restacking procedure. This electrode material synthesis method 100 is illustrated in FIG. 3 . The method 100 comprises the steps of delaminating the host material 110 , adsorbing the insertion species 120 , and restacking the host material 130 . In the method 100 , delaminating the host material 110 comprises at least one approach including physical exfoliation, electrochemical reduction/oxidation, chemical reduction/oxidation, or combinations thereof. Without limitation, the host material A x M y N z may be considered delaminated, exfoliated, or opened such that individual layers are not associated. Delaminating the host material 110 further comprises dispersing the exfoliated A x M y N z host material in one or a combination of solvents. In some instances, any inorganic or organic solvent may be used and in certain instances, water may be used as a solvent. Subsequently, adsorbing the insertion species 120 comprises exposing the delaminated host material to a solution containing the insertion species. In certain instances, the insertion species may be dispersed in the solvent for adsorbing the insertion species 120 . Further, the insertion species may be agitated or mixed such that the surfaces of the delaminated host materials are coated in the species. Restacking the host material 130 comprises reforming the layered structure comprising the host material around the insertion species. Generally, restacking the host material 130 comprises solvent extraction. Exemplary solvent extractions may include at least one of the processes chosen from filtration, centrifugation, drying, or combinations thereof. In some instances, restacking the host material 130 comprises a temperature ranging from −80° C. to 150° C. In certain instances, the process for restacking the host material may be predetermined by the solvent used during delaminating the host material 110 .
Electrode Architecture:
The present disclosure relates to expanding the interlayer spacing of intercalation hosts as a general strategy for electrode materials for storage of non-lithium metal cations. The structural expansion is applicable to various intercalation hosts, however the current disclosure specifically relates to layered materials. Layered metal chalcogenides (LMCs) such as MoS 2 is used as a model system because of its established intercalation chemistry and wide deployment as cathode materials in rechargeable lithium batteries. LMCs are typical two-dimensional materials held by strong covalent metal-sulfur bonds within a layer but weak van der Waals force between the layers. Into the weakly held LMC interlayers a range of species including ions, molecules, polymers, and even nanoclusters can be intercalated to form interlayer-expanded composites. By controlling the size and amount of the intercalated species, the interlayer distance is readily tuned.
In some instances, poly(ethyleneoxide) (PEO) is utilized in a configuration of this electrode architecture. The crystal structure and definite chemical composition of a range of LMC-PEO intercalate composite allow for a precise tuning of the interlayer distance over a wide range. In a nonlimiting exemplary configuration using MoS 2 , the interlayer spacings may be controlled in a distance of about 6.1 Å to about 16 Å. Contrary to conventional inert intercalating agents which block the entrance and diffusion of the target cations, the PEO is a solid-state cation conductor that facilitates ion transport within layers. Also, the flexible and mobile segments of PEO also make room for ingressing cations. Recognizing that PEO itself is the major component of solid-state polymer electrolytes, the intercalated PEO may increase the weight to the electrode. However its capability for ion transport lowers the required amount of additional electrolyte, thereby maintaining or improving the energy density of the whole cell.
MoS 2 —PEO intercalate composites with tunable interlayer distances are synthesized following a lithiation-delamination-restacking procedure. Synthetic parameters including particle size of the pristine MoS 2 , molecular weight of PEO, and the mass ratio of MoS 2 to PEO are controlled towards desired lattice spacing of the resulted composite architectures. Electrochemical intercalation of non-lithium ions in these modified MoS 2 are then measured in three-/two-electrode cells.
Further Discussion:
Through the analysis of the intercalation behavior non-lithium cations in expanded structures of MoS 2 , the relationship between interlayer distance of the host and the intercalation kinetics of cations is identified herein. Theoretical modeling has confirmed that as the interlayer space of MoS 2 increases, the energy barrier for Mg 2+ cation diffusion within the host decreases as shown in FIG. 4 . The improved intercalation properties of the host results in increased capacity and/or cycling stability. The unmodified MoS 2 shows a negligible capacity (˜9 mAh/g) in a Mg-ion cell. The insertion of PEO in the lattice increase the capacity by 8 folds to ˜70 mAh/g and stably cycle at a reasonable current density of 33 mA/g as shown in FIG. 7 . This result represents an example that even materials which are usually considered not capable of Mg intercalation can be transformed into a capable material by the interlayer engineering strategy disclosed herein. In another case, MoS 2 with different interlayer distances exhibit comparable initial capacities during sodium (de-)intercalation, but the cycling stability is considerably different, i.e. the larger the interlayer distance is, the better the capacity retention is. This observation can be rationalized as that a more open crystal gallery is less susceptible to structural damage during the (de-)intercalation of large cations and thus makes more suitable intercalation host. The modified MoS 2 represent a new high-performance electrode material for rechargeable magnesium/sodium batteries. Further, the modification of MoS 2 can be readily applied to other LMCs (e.g. TiS 2 and VS 2 ) which feature higher energy densities. Importantly, the interlayer expansion method according to the present disclosure could be extended to other layered materials such as transition metal oxides, leading to a large family of electrode materials.
To further illustrate various exemplary embodiments of the present invention, the following examples are provided.
EXAMPLES
Example 1: Theoretical Demonstration of Enhanced Mg 2+ in Modified MoS 2 with Increased Interlayer Spacing
FIG. 2 shows that regardless of the interlayer distance, the Mg 2+ migrates first from an O h -site to a T h -site then to the other O h site. The binding energy for the Mg—MoS 2 intercalate, defined as the difference between the energy of Mg-intercalated MoS 2 and the sum of those of MoS 2 and Mg atom, changes along the diffusion path. To migrate between two O h -sites, Mg 2+ should first overcome an energy barrier, or diffusion barrier, to diffuse from the more stable O h -site to a semi-stable T h -site, and then overcome another smaller barrier to reach another O h -site. The energy barrier for the diffusion process is 1.12 eV and 0.22 eV for an interlayer distance of 6.75 Å and 9 Å, respectively. This five-fold difference in diffusion barrier that occurred with a merely ˜2 Å increase in interlayer distance indicates that the spacing expansion in the interlayer can effectively improve the Mg 2+ diffusion kinetics. A complete picture of the correlation between diffusion barrier and MoS 2 interlayer distance is shown in FIG. 4 .
Example 2: Synthesis of (PEO—)MoS 2 Composites with Different Interlayer Distance
MoS 2 was soaked in the solution of an excess of n-butyllithium in hexane to form lithiated Li x MoS 2 . The lithiated product was exfoliated in water to form a form a quasi-stable suspension of single-layered MoS 2 sheets. A controlled amount of PEO, 0-200% w/w relative to MoS 2 , was added to the suspension. The mixture was centrifuged, washed with water, and dried to afford the restacked MoS 2 composites with different interlayer distance. FIG. 5 shows the X-ray diffraction patterns of the modified MoS 2 composites as well as a commercial sample without any modification. Among the various PEO—MoS 2 ratios studied (0-2), three ratios, namely 0, 0.25, and 1, are shown as representatives of PEO—MoS 2 composites with zero, one, and two layers of PEO intercalated within two slabs of MoS 2 sheets, respectively. The diffraction peak corresponding to the interlayer spacing shifts to lower angles as the amount of intercalated PEO increases. With the aid of Bragg equation, the interlayer distances of samples are calculated to be 6.14 Å (pristine MoS 2 , or com-MoS 2 ), 6.22 Å (exfoliated MoS 2 restacked in the absence of PEO, or exf-MoS 2 ), 11.42 Å (MoS 2- PEO composite with one layer of intercalated PEO, or peo(1 L)-MoS 2 ), and 15.8 Å (MoS 2 —PEO with two layers of PEO, or peo(2 L)-MoS 2 ), confirming that efficient tuning of the interlayer spacing of MoS 2 is achieved.
Example 3: MoS 2 Composites with Different Interlayer Distance as Intercalation Host for Mg-Ion
The electrochemical performance of MoS 2 composites as intercalation host materials for Mg-ion was demonstrated with three-electrode cells. A slurry of the desired MoS 2 composite (70 wt. %), Super-P carbon (20 wt. %), and polyvinylidene fluoride (10 wt. %) dispersed in N-methyl-2-pyrrolidone was spread on a piece of stainless steel mesh and dried to form the working electrode. Freshly polished magnesium foil was used as both the counter and reference electrodes. A solution of 0.25 M [Mg 2 Cl 3 ] + [AlPh 2 Cl 2 ] − in tetrahydrofuran served as the electrolyte. Three MoS 2 samples, including the commercially available unmodified MoS 2 (com-MoS 2 ), the exfoliated MoS 2 restacked without the addition of PEO (exf-MoS 2 ), and a MoS 2 composite obtained with the addition of 27 wt. % of PEO (relative to the weight of MoS 2 ; peo-MoS 2 ) were compared in this configuration. At the same charge-discharge current density of 33 mA/g, all three samples allow for reversible Mg 2+ (de-)intercalation and exhibit similar cycling stability, but the capacities vary significantly ( FIGS. 6 & 7 ). The unmodified MoS 2 delivers a low specific capacity of ˜9 mAh/g. A slight increase in the interlayer distance from 6.14 Å (com-mos 2 ) to 6.22 Å (exf-MoS 2 ) leads to a three-time increase in capacity to ˜35 mAh/g. The peo-MoS 2 composite containing PEO achieves the highest capacity of ˜70 mAh/g, which is double of that of exf-MoS 2 . The higher capacity for MoS 2 composites with larger interlayer spacing indicates more accessible intercalation sites in the lattice. The high capacity and reversibility observed for the peo-MoS 2 composite confirm that the presence of PEO does not impede but facilitate the intercalation and diffusion of non-lithium cations.
Example 4: MoS 2 Composites with Different Interlayer Distance as Intercalation Host for Na-Ion
The electrochemical performance of MoS 2 composites as intercalation host materials for Na-ion was demonstrated with two-electrode cells. Working electrodes were fabricated with the same method as for those electrodes used in Mg-ion cells. Freshly sliced metallic sodium was used as both the counter and reference electrode. A solution of 1 M NaClO 4 in dimethoxyethane served as the electrolyte. At the same charge-discharge current density of 84 mA/g, the three MoS 2 , i.e. com-MoS 2 , exf-MoS 2 , and peo-MoS 2 , deliver comparable first discharge capacity of 126, 151, and 132 mAh/g, respectively shown in FIG. 8 . All samples experience capacity reduction over cycling but at different rate. The capacity for com-MoS 2 was halved over 2 cycles, while the same degree of fading for exf-MoS 2 and peo-MoS 2 took 8 and 44 cycles to complete, respectively FIG. 9 , indicating improved reversibility of the intercalation process in the host with larger interlayer distance.
Where numerical ranges or limitations are expressly stated in the disclosure of the exemplary embodiments contained herein, such express ranges or limitations should be understood to include iterative ranges or limitations of like magnitude falling within the expressly stated ranges or limitations (e.g., from about 1 to about 10 includes, 2, 3, 4, etc.; greater than 0.10 includes 0.11, 0.12, 0.13, etc.). For example, whenever a numerical range with a lower limit, R l , and an upper limit, R u , is disclosed, any number falling within the range is specifically disclosed. In particular, the following numbers within the range are specifically disclosed: R= l +k (R u −R l ), wherein k is a variable ranging from 1 percent to 100 percent with a 1 percent increment, i.e., k is 1 percent, 2 percent, 3 percent, 4 percent, 5 percent, . . . 50 percent, 51 percent, 52 percent . . . 95 percent, 96 percent, 97 percent, 98 percent, 99 percent, or 100 percent. Moreover, any numerical range defined by two R numbers as defined in the above is also specifically disclosed. Use of the term “optionally” with respect to any element of a claim means that the element is required, or alternatively, the element is not required, both alternatives being within the scope of the claim. Use of broader terms such as “comprises”, “includes”, and “having” means “including but not limited to” and should be understood to also provide support for narrower terms such as “consisting of”, “consisting essentially of”, and “comprised substantially of”. Accordingly, the scope of protection is not limited by the description set out above but is defined by the claims that follow, that scope including all equivalents of the subject matter of the claims. Each and every claim is incorporated into the specification as further disclosure, and the claims are each an embodiment of the present invention. The discussion of a reference in the disclosure is not an admission that it is prior art, especially any reference that has a publication date after the priority date of this application. The disclosure of all patents, patent applications, and publications cited in the disclosure are hereby incorporated by reference, to the extent that they provide exemplary, procedural or other details supplementary to the disclosure. | A method for configuring a non-lithium-intercalation electrode includes intercalating an insertion species between multiple layers of a stacked or layered electrode material. The method forms an electrode architecture with increased interlayer spacing for non-lithium metal ion migration. A laminate electrode material is constructed such that pillaring agents are intercalated between multiple layers of the stacked electrode material and installed in a battery. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to power supplies in general and more particularly to voltage regulating circuits suitable for processing variable a.c. line voltages to generate rectified d.c. output voltages.
2. Prior Art
Most power supplies, especially the ones that are used in computers and other precision electronic devices are required to provide a fixed voltage at a given current. Usually, the allowed deviation at full load, is within the range of ±5%. Preferably, the power supply should be low-cost and consume a relatively small amount of power.
A typical power supply includes a power transformer with a primary winding which is connected to an a.c. input line voltage and one or more secondary windings disposed relative to the primary winding. Rectifying circuits are connected to the secondary windings. The rectifying circuits process the a.c. voltages appearing on the secondary winding to provide a desired d.c. output voltage across a bulk capacitor.
One of the problems which a designer faces is that the input a.c. line voltage varies over a wide range. An obvious solution is to design a regulating circuit which dissipates a relatively large amount of power. Thus, as the input AC line voltage varies from minimum to maximum, more power is consumed within the regulating circuit to provide a desired voltage at a given current. Such a design is unacceptable because the regulating unit usually dissipates a relatively large amount of energy and its cost is also relatively high. It is believed that the high cost stems from the fact that the components which are used in such devices are specified to match the high energy that has to be dissipated rather than the power which the devices output. It is common knowledge that for most designs unit cost and power rating are closely related. Thus, as the power rating increases, the unit cost increases and vice versa. Therefore, it is desirable to design a device with components dissipating close to the output power rating rather than with components rated for higher power due to circuit inefficiency.
The prior art has recognized the problem associated with the above-described design and sets forth alternative designs. U.S. Pat. No. 3,921,059 is an example of the prior art alternative design. In that patent multiple triac taps connected to secondary windings of a power transformer are switched to provide a range of output voltages. A control circuit including a shift register and optical isolator drivers are used to switch the triacs.
U.S. Pat. No. 4,454,466 describes a power supply in which switched primary windings provide a variable voltage which is processed by a series regulator to output a fixed voltage to a load. An up-down counter circuit arrangement is used for driving switches that select the primary windings which are needed to provide a desired output voltage.
IBM Technical Disclosure Bulletin (Vol. 13, No. 6, Nov. 1970, pp. 1516-1517) and U.S. Pat. No. 4,090,234 describe a voltage regulating circuitry in which diodes and SCR taps are made selectively conductive to effectively vary the turn ratio of the secondary winding of a power transformer.
Even though the above devices work well for their intended purpose, they are plagued by problems which adversely affect their use. Probably the most pressing problem is that the automatic tap settings have to be latched. This means that the tap switching to select coils cannot be done instantaneously, since the counters and/or latches which provide the latching function cannot be changed instantaneously. In other words, the rate at which the latching elements are changed is the rate at which the coils can be switched. Counters and other latching elements can only be changed on every clock cycle. Thus, the coils can only be switched on a clock cycle basis only. Any attempt to switch coils during a clock cycle is prohibited. However, there are several sensitive devices (such as computers, etc.) that require regulating circuits in which the coils must be switched instantaneously. As to those devices, the prior art regulating circuits and/or power supplies cannot be used.
It is noted that the regulating circuits of the Technical Disclosure Bulletin and the '234 patent uses SCRs instead of latches. However, one of the inherent characteristics of an SCR is that it must remain in a desired state (i.e., conductive or non-conductive) for a complete clock cycle before it can be changed. Thus, in that regard, the SCR operates as a latch. In addition, the '234 patent requires a separate power supply for driving the SCR. This requirement makes the circuit more complicated and increases its cost. The increased cost also affects the '466 patent since switching is done on the primary side of the transformer and as a result the components are overdesigned in order to handle the high current and/or voltage in the primary windings. Also, some of the prior art references use opto-isolation and/or triacs in the switching circuits. These components are expensive and increase the overall cost of the power supply.
SUMMARY OF THE INVENTION
It is therefore the general object of the present invention to provide a power supply and/or a regulating circuit that is more efficient than was previously possible.
The improved power supply includes a linear regulator connected via a bulk capacitor charged by a plurality of switch circuit arrangements that monitor the voltage level on assigned taps of the secondary windings of a power transformer and as the voltage level changes on respective windings, different ones of the plurality of switching circuit arrangements are automatically selected so that the bulk capacitor is charged by different turn ratio of the secondary windings.
An output capacitor is connected across the output terminals of the linear regulator. The voltage range across the bulk capacitor is controlled by the number of taps on the secondary windings and the number of switch circuit arrangements. Thus, as the number of taps and switch circuits increase, the voltage window across the bulk capacitor decreases and the power which is dissipated in the linear regulator also decreases.
The taps are formed from a plurality of diodes connected to selected points on the secondary windings. A center tap conductor interconnects a center tap of the secondary windings to a ground potential. Each diode is connected to a switch circuit arrangement which includes a switch transistor connected in series with the diode. A differential amplifier means is connected to the switch transistor and a voltage reference generating means is connected to the differential amplifier.
The foregoing and other objects, features and advantages of the invention are more fully described in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The sole FIGURE shows a schematic of the improved power supply according to the teachings of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The sole figure shows an improved power supply according to the teachings of the present invention. The structure and the theory of operation are as follows: a plurality of diode taps (CR1 through CR6) are placed on the secondary windings of a power transformer. The diode taps are connected to a plurality of tap selection circuit arrangements which select a different group of secondary coils to charge capacitor C1 as input a.c. line voltage varies across the primary winding of the power transformer. A linear circuit arrangement (LR1) processes the voltage generated across capacitor C1 to provide a fixed voltage Vout at a desired current across capacitor C2.
Referring to the sole figure, the major sub-assemblies of the improved power supply include an output capacitor C2, linear regulator circuit arrangement LR1, window capacitor C1, power transformer including primary winding 1-2 and a plurality of secondary windings 3-4, 4-5, 5-6, 6-7, 7-8, 8-9, 9-N, a plurality of diode taps (CR1 through CR6) and a plurality of tap selection circuit arrangements 10, 12, 14 . . . N.
The output capacitor C2 provides more filtering for the output voltage. In the preferred embodiment of this invention the fixed output voltage is 5 v ±5% at 0.5 amps maximum load.
Of course, it is within the skill of the art to provide other output power ratings without deviating from the teachings of the present invention. The linear regulator circuit arrangement takes the voltage provided across C1, regulates it and outputs a desired voltage. The linear regulator is a conventional off-the-shelf module which contains the necessary circuit arrangement for regulating the input voltage. In the preferred embodiment of the invention a linear regulator module L7800 manufactured by SGS Corporation was used. Of course, other types of regulating circuit arrangements can be used without departing from the scope of the present invention.
The tap selection circuit arrangements 10, 12, 14-N are identical. Their function is to monitor assigned taps or points on the secondary windings and to select a different set of secondary coils which charge capacitor C1 as the input a.c. line voltage across terminals ACH and ACN fluctuates within preassigned voltage range.
The preassigned voltage range is separated into a plurality of different groups with each group covering an assigned voltage range. Likewise, the secondary windings are separated in a plurality of different groups of windings or coils. Preferably, the number of groupings for the input voltage range and the secondary coils should be identical. Thus, if the variable input voltage range is separated into n groups, the secondary windings should also be separated into n groups. Further, a different group of windings should be selected to charge C1 as the input a.c. line voltage varies within its assigned voltage range.
In the preferred embodiment of this invention the input a.c. line voltage fluctuates between 70 v a.c. and 259 v a.c. The input a.c. line voltage is separated into three equal voltage ranges, namely: 70-107, 107-163 and 163-259 v a.c. Also, the secondary coils are arranged into groups identified by alphabetical characters LL, MM and HH. For this embodiment, the a.c. line voltage and the windings are arranged into like groupings. A center tap conductor 16 interconnects the center tap of the secondary windings to a ground potential. Even though a three-tap winding was used to process the input a.c. voltage, this should not be construed as a limitation on the scope of the present invention since it is within the skill of the art to increase or decrease the number of secondary taps or division of the input line voltage without departing from the spirit and scope of the present invention. As will be explained subsequently, the higher the number of taps, the lower the voltage window on the bulk capacitor C1 and thus less energy will be required to be dissipated across the linear regulator in order to provide a fixed voltage at the output. It should also be noted that N as shown in the sole figure signifies that additional secondary coils with associated taps and selection circuit arrangements can be used.
Still referring to the sole figure, the voltage which is provided across each group of coils is rectified and is switched by one of the tap selection circuit arrangements for charging C1. Thus, the voltage appearing across L6 is rectified by components CR1, CR6 and C3. Likewise, the voltage appearing across terminal M6 is rectified by diodes CR2, CR5 and capacitor C4. Finally, the voltage appearing across terminal H6 is rectified by diodes CR3 and CR4 and C1. It should be noted that when the input a.c. voltage is within its low range (say, 70 v a.c. to 107 v a.c.) the voltage across terminal L6 is selected to charge C1. Similarly, when the input voltage is in its mid-range, say, between 107 v a.c. to 163 v a.c. the voltage across terminal M6 is selected for charging capacitor C1. Finally, when the input a.c. line voltage is within its upper range, say, 163 v a.c. to 259 v a.c., the voltage across terminal H6 is used for charging C1.
As stated above, the tap selection circuit arrangement which selects the set of coils which is used for charging C1 is identical. Thus, only one of these circuits identified by numeral 10 will be described in detail, it being understood that the other circuits (including the one identified by numeral 12) are identical in structure and function in like manner as the detailed circuit.
Still referring to the sole figure, each of the tap selection circuits is comprised of a switching transistor such as Q1 which is coupled to a differential amplifier formed by transistors Q3 and Q4. For brevity, different numerals Q2, Q5, etc. are used to identify components in circuit arrangement 12 that are similar to components in circuit arrangement 10. The emitter terminals of the differential amplifier transistors are connected through resistor R4 to ground. A zener diode CR11 is coupled to a constant current source formed by circuit arrangement 18. The zener diode and its associated current source provide a reference voltage of approximately 5 v to the base of Q3 and the bases of similar situated transistors of differential amplifiers which are attached to node 20.
Still referring to the sole figure, a more detailed description of the improved power system is given. Component CR11 is a 5 v zener diode which provides a 5 v reference signal on node 20. Components CR9, CR10, R1, R2 and Q7 constitute a 6 milliamp constant current source which limits power dissipation in zener diode CR11. The high transformer output voltage which is provided across terminal L-6 is rectified by components CR1, CR6 and C3. Components Q3, Q4 and R4 form a differential amplifier. R5 and R6 form a voltage divider and are selected such that the base of Q4 reaches 5.0 v when VC3 reaches 11.5 v. The emitter-collector voltage of Q1 (VQ1CE) is one volt. For VC3 less than 11.5 v, Q4 is off and Q3 is on. For VC3 higher than 11.5 v, Q4 is on and Q3 is off. It should be noted that Q1 is on whenever Q3 is on and as a result C1 is charged. CR7 is a 7.4 v zener diode and is needed to prevent emitter to base breakdown of Q3. It should be noted that without CR7, VQ4 base would go up to approximately 17 v when VIN reaches approximately 259 v a.c.
The medium transformer voltage across terminal M-6 is rectified by devices CR2, CR5 and C4. A differential amplifier is formed by devices Q5, Q6 and R3. R7 and R8 form a voltage divider. The values of the resistors are selected such that the voltage on the base of Q6(VQ6) reaches 5 v when VC4 reaches 11.5 v. Simultaneously, the voltage across VQ2CE is 1 v. If VC4 is lower than 11.5 v, Q6 is off and Q5 is on. If VC4 is hgher than 11.5 v, Q6 is on and Q5 is off. With Q5 on, Q2 is also on and charges up C1. CR8 is a zener diode which prevents Q5 emitter to base breakdown. Absent the zener diode, VQ5 base would go up to approximately 10.5 v when VIN is approximately 259 v a.c.
For a.c. input voltage greater than 163v a.c., both VC3 and VC4 are higher than 11.5 v. Thus, Q1 and Q2 are off and C1 gets charged through diodes CR3 and CR4. In other words, the voltage across terminals H-6 charges up C1. Operation:
In operation, zener diode CR11 and its associated current source 18 set a reference voltage approximately 5 v on the base of devices Q5 and Q3, respectively. This forces both devices to conduct simultaneously. As a result, Q1 and Q2 also conduct. When the voltage of the primary winding is within a low range, say, between 70 v a.c. to 107 v a.c., a high voltage is reflected across the coils in terminal L-6. Switching transistor Q1 of coil selection circuit means 10 conducts and charges up C1. The diodes CR2-CR5 are reversed biased and, as a result, the voltage across terminals M-6 and H-6 do not charge capacitor C1. When the voltage on the base of Q4 exceeds 5 v, Q1 and Q3 are turned off and Q4 conducts. Similarly, when the input voltage VIN is within the range of 107 v a.c. to 163 v a.c., the voltage generated across terminals M-6 causes current to flow through Q2 and charges up C1. Finally, when the input voltage is within its maximum range, 163 v a.c. to 259 v a.c., the voltage across terminals H-6 charges up capacitor C1.
It should be noted that by arranging the output coils into a plurality of electronically switched center tap outputs and providing tap selection circuit arrangement which selects appropriate taps and group of coils as the a.c. input line voltage varies a power supply is provided which dissipates minimum amount of power across the linear regulator circuit arrangement LR1. It should also be noted that in the preferred embodiment the input a.c. line voltage is separated into three identical voltage ranges, high, medium and low. However, it should be noted that this is only for purposes of explaining applicants' invention and does not limit the invention in any way. Also, the invention may be implemented in a fullwave or halfwave rectifier circuitry.
With the particular arrangement of the circuit in the sole figure, the voltage across capacitor C1 is between 5.7 v to 10.5 v for each voltage range of the input a.c. line voltage. The voltage across C1 is achieved by proper selection and arrangement of the transformer windings. Thus, for an input line voltage which ranges between 70 v a.c. to 259 v a.c., when the line voltage is between 70 v a.c. and 107 v a.c., the voltage across capacitor C1 fluctuates between 5.7 and 10.5 v. Similarly, for line voltage between 107 v a.c. and 163 v a.c. the voltage across C1 fluctuates between 5.7 and 10.5 v and when the line voltage is between 163 v a.c. and 259 v a.c., the voltage across C1 is between 5.7 v and 10.5 v. Thus, since the voltage swing across C1 is relatively low (5.7 v to 10.5 v), the maximum power consumed in the linear regulator LR1 is relatively low. This can be shown mathematically as follows:
P=VI,
where P=power
V=voltage
I=current
With reference to the sole figure,
PLR1=Io(VC1 - Vo) (Equation 1)
where PLR1 represents power consumed by the linear regulator, VC 1 represents voltage on C1; Vo represents Vout and Io represents output current.
Thus, when VC1=5.7 volts, Vo=5 volts and Io=1 amp, only 0.7 watt is dissipated in the linear regulator. Likewise, if 10.5 volts are generated on C1, only 5.5 watts are dissipated in the linear regulator. It should be noted that if additional coils and coil selection circuitry are added to the sole figure the power which is consumed in the linear regulator module will be even less.
In contrast with no switching of transformer taps, the voltage across C1 varies between 5.7 volts and 20.1 volts. When the voltage across C1 is 20.1 volts, 15.1 watts are dissipated in the linear regulator. The wattage is obtained by substituting 20.1 volts in Equation 1 above. Likewise, by comparing the power consumption with tap switching and the power consumption without tap switching, it can be shown that tap switching provides a saving of 9.6 watts. Stated another way, a significant amount of energy is saved when one uses the tap switching topology disclosed above. For the specific example described above, the savings are 9.6 watts.
Several advantages inure to one who uses the teachings of the present invention. Among the advantages are an improved power supply with the following characteristics:
1. Low power dissipation.
2. Low cost due to the fact that the power rating of the components is relatively low.
3. Low failure rate of the components used to manufacture the power supply.
4. No EMC filter or shielding is required because no high frequency switching is needed.
5. No tap selections latching, thus the switching circuits can respond to instantaneous changes occurring at the a.c. input line voltage.
While the invention has been particularly shown and described with reference to the preferred embodiment thereof, it will be understood that various changes in form and details may be made therein without departing from the spirit and scope of the present invention. | Described is a novel power supply for generating a constant d.c. voltage from a variable a.c. voltage supply line. The power supply includes a plurality of switch circuits which monitor voltage levels on respective secondary windings of a power transformer and as voltage levels change, one of the plurality of switch circuits is selected to charge a capacitor which provides a range of d.c. voltages which are processed to provide the constant d.c. voltage. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 11/053,328, filed on Feb. 9, 2005, entitled IMMERSION PHOTOLITHOGRAPHY SYSTEM AND METHOD USING MICROCHANNEL NOZZLES which is also a continuation of U.S. patent application Ser. No. 10/464,542, filed on Jun. 19, 2003, entitled IMMERSION PHOTOLITHOGRAPHY SYSTEM AND METHOD USING MICROCHANNEL NOZZLES, which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to liquid immersion photolithography, and more particularly, to a method and a system for controlling velocity profile of liquid flow in an immersion photolithographic system.
2. Description of the Related Art
The practical limits of optical lithography assume that the medium through which imaging is occurring is air. This practical limit is defined by the effective wavelength equation
Λ eff = λ 2 · n · NA ,
where 8 is the wavelength of incident light, NA is the numerical aperture of the projection optical system, and n is the index of refraction of the medium. Now, by introducing a liquid (instead of the air) between a last lens element of the projection optical system and a wafer being imaged, the refractive index changes (increases), thereby enabling enhanced resolution by lowering the effective wavelength of the light source. Lowering a light source's wavelength automatically enables finer resolution of smaller details. In this way, immersion lithography becomes attractive by, for instance, effectively lowering a 157 nm light source to a 115 nm wavelength, thereby gaining resolution while enabling the printing of critical layers with the same photolithographic tools that the industry is accustomed to using today.
Similarly, immersion lithography can push 193 nm lithography down to 145 nm. In theory, older technology such as the 193 nm tools can now still be used. Also, in theory, many difficulties of 157 nm lithography—large amounts of CaF 2 , hard pellicles, a nitrogen purge, etc.—can be avoided.
However, despite the promise of immersion photolithography, a number of problems remain, which have so far precluded commercialization of immersion photolithographic systems. These problems include optical distortions. For example, during immersion lithography scanning, sufficient g-loads are created that can interfere with system performance. These accelerative loads can cause a vibrational, fluidic shearing interaction with the lens resulting in optical degradation. The up and down scanning motions within the lens-fluid environment of Immersion Lithography can generate varying fluidic shear forces on the optics. This can cause lens vibrational instability, which may lead to optical “fading”. Other velocity profile non-uniformities can also cause optical distortions.
SUMMARY OF THE INVENTION
The present invention is directed to an immersion photolithography system with a near-uniform velocity profile of the liquid in the exposure area that substantially obviates one or more of the problems and disadvantages of the related art.
There is provided a liquid immersion photolithography system including an exposure system that exposes a substrate with electromagnetic radiation, and includes a projection optical system that focuses the electromagnetic radiation on the substrate. A liquid supply system provides liquid flow between the projection optical system and the substrate. A plurality of micronozzles are optionally arranged around the periphery of one side of the projection optical system so as to provide a substantially uniform velocity distribution of the liquid flow in an area where the substrate is being exposed.
In another aspect there is provided a liquid immersion photolithography system including an exposure system that exposes an exposure area on a substrate with electromagnetic radiation and includes a projection optical system. A liquid flow is generated between the projection optical system and the exposure area. A microshower is at one side of the projection optical system, and provides the liquid flow in the exposure area having a desired velocity profile.
Additional features and advantages of the invention will be set forth in the description that follows. Yet further features and advantages will be apparent to a person skilled in the art based on the description set forth herein or may be learned by practice of the invention. The advantages of the invention will be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS/FIGS.
The accompanying drawings, which are included to provide a further understanding of the exemplary embodiments of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the principles of the invention. In the drawings:
FIG. 1 shows a side view of a basic liquid immersion photolithography setup.
FIG. 2 shows a plan view of the setup of FIG. 1 .
FIG. 3 shows the basic liquid immersion photolithography setup with liquid flow direction reversed, compared to FIG. 1 .
FIG. 4 shows additional detail of the liquid immersion photolithography system.
FIG. 5 shows a partial isometric view of the structure of FIG. 4 .
FIG. 6 shows an exemplary liquid velocity profile.
DETAILED DESCRIPTION OF THE INVENTION
Reference will now be made in detail to the embodiments of the present invention, examples of which are illustrated in the accompanying drawings.
One major problem in immersion photolithography is the non-uniformity of the liquid flow, particularly its gradient in the vertical direction. The non-uniformity is due primarily to the fact that near a moving surface, the liquid is in contact with that surface (e.g., a surface of a wafer). For example, during scanning, the wafer moves relative to the exposure system, creating a “dragging effect” near its surface. Thus, the laws of fluid dynamics dictate that the fluid velocity relative to the wafer surface is zero in those areas (or at least close to zero), while fluid velocity is maximum further away from the wafer surface. Similarly, the fluid velocity relative to the bottom surface of the lens is zero. These fluid velocity variations are known as “boundary layer” velocity profiles. The combination of these effects produces a shearing force in the liquid that creates a twofold optical distortion problem: 1) the generation of inertial vibrational forces upon the aperture hardware (resulting in optical distortion), and 2) the formation of velocity striations within the fluid, which cause additional optical distortions.
Additionally, injection of liquid into the exposure area also provides a liquid flow with potential additional non-uniformities in the velocity distribution. For example, a number of striations can exist within the fluid, further degrading exposure quality. Similarly, air bubbles, opto-fluidic vibrations, or turbulence in the liquid flow also can degrade the overall performance of the photolithographic system because of the introduction of optical distortions into the exposure process. Thus, dealing with velocity profile non-uniformities is important from the perspective of the quality of imaging in a photolithographic system. In the ideal case, the velocity profile of the liquid is substantially uniform everywhere.
FIG. 1 illustrates a liquid immersion photolithographic system of the present invention in a block diagram form. As shown in FIG. 1 , a projection optical system 100 of a photolithographic tool includes a lens 102 (which is typically comprised of multiple lens elements). In this figure, the lens 102 has a flat bottom surface 108 , although that need not be the case. Lens height 409 (see FIG. 4 ) may be adjustable to maintain a specific distance to the wafer 101 .
The projection optical system 100 also includes a housing 103 (only the lower portion is shown). The housing 103 includes an annular liquid channel 105 A, and optionally a plurality of other such channels 105 B, etc. Liquid flows through the channels 105 (flowing in through the channel 105 A in this figure, and flowing out through the channel 105 B). The arrows 107 A, 107 B designate the direction of liquid flow over a wafer 101 , as the wafer 101 is being scanned across a field of view of the projection optical system 100 .
FIG. 2 illustrates a bottom-up view of the structure shown in FIG. 1 . As shown in FIG. 2 , a clear aperture area 216 defines an exposure area of the projection optical system 100 and the lens 102 . The various arrows 107 A- 107 D, 211 A- 211 D illustrate possible liquid flow directions at any given time. As may be further seen in FIG. 2 , the housing 103 also includes a number of pressurized chambers 215 A- 215 D. Each pressurized chamber 215 may also be referred to as a “plenum.” The plenum 215 therefore acts as a pressure source, as discussed below. It will also be appreciated that the liquid flow can be turned off completely when no exposure is taking place, or when the wafer 101 is being swapped.
Further, as shown in FIG. 2 , the lower portion of the housing 103 may be divided into a number of sections. In this figure, there are four such sections (quadrants), separated by gaps 217 A- 217 D. It will be appreciated that the number of such sections may be more or fewer than four, although, in most applications, it is expected that four quadrants is an optimal number. For example, for motion only along one axis, dividing the housing 103 into two sections may be sufficient. For X-Y motion, four sections (quadrants) are preferred. For even greater control, eight sections may be needed. This sectioning permits control over liquid flow direction, as also discussed further below. Controlling the direction of liquid flow makes it possible to counteract mechanical strains on the lens 102 , therefore the flow profile in the X direction (especially during a step) may be different from the flow profile in the Y direction (especially during a scan).
FIG. 3 illustrates the same structure as in FIG. 1 , except that the direction of the liquid flow is reversed. As will be appreciated by one of ordinary skill in the art, the ability to reverse the direction of liquid flow is important in a practical photolithographic system, since the direction of wafer motion is normally not limited to just one direction. Similarly, it will be appreciated by one of ordinary skill in the art that, as in FIG. 2 , the wafer 101 can move both in the X direction and the Y direction. Thus, dividing the housing 103 into quadrants permits the direction of liquid flow to be adjusted for any direction of wafer movement.
FIG. 4 illustrates an embodiment of the present invention in additional detail. As shown in FIG. 4 , the lens 102 is mounted in the housing 103 . The housing 103 has the annular channels 105 A, 105 B, through which liquid flows in and out from a liquid supply system (not shown in these figures). From the channel 105 A, the liquid then enters a first large plenum 215 A. It then flows through a diffuser screen 412 A, into a first small plenum 414 A (which is typically smaller than the first plenum 215 A). The diffuser screen 412 A helps remove the turbulence and air bubbles that may be present in the first large plenum 215 A. The diffuser screen 412 also acts as a pressure drop screen.
The first small plenum 414 A also acts as a pressure chamber. From the first small plenum 414 A, the liquid then flows through a plurality of microchannel nozzles (micronozzles) 416 A, arranged in a form of a microshower. Thus, by the time the liquid reaches the micronozzles 416 , the pressure at the entry to all the micronozzles 416 is uniform, and turbulence and gas bubbles have been substantially removed from the liquid. After the micronozzles 416 , the liquid flows into the clear aperture area 216 under the lens 102 , such that the space between the lens 102 and the wafer 101 is filled with the liquid.
In the clear aperture area 216 , the liquid flow is uniform with height, and free of turbulence, bubbles, striations and other imperfections that affect optical image quality.
On the other side of the clear aperture area 216 , the liquid once again flows through a set of microchannel nozzles 416 B, into a second small plenum 414 B, through a diffuser screen 412 B, into a second large plenum 215 B and out through the channel 105 B.
Thus, with the relative motion of the wafer 101 from left to right in FIG. 4 , the wafer 101 creates a “dragging effect” on the liquid. The direction of the liquid flow therefore needs to be from right to left, to counteract the “dragging effect,” and result in substantially uniform velocity profile.
In FIG. 4 , 420 designates effective fluid velocity profile within the clear aperture area 216 as induced by wafer 101 motion. 421 designates counter-injected fluid velocity profile from the microchannel nozzles 416 , yielding near net-zero resultant fluid velocity at the interface between the lens 102 and the liquid in clear aperture area 216 .
The microchannel nozzles 416 also refresh (i.e., replace) the working liquid from time to time (which may be necessary to prevent its disassociation over time, since exposure to intense electromagnetic radiation may break down the molecules of the liquid), so as to preclude thermal gradients from causing refractive distortions and image quality degradation. Avoiding dissociation of liquid (for example water) due to constant flow is another advantage. At the short exposure wavelength, water can dissociate at approximately 2.86 J/cm 2 RT and normal P turns to 4.75*10 −19 J per molecule. At 193 nm with one photon carries 1.03*10 −18 J. Additionally, keeping the liquid refreshed allows to maintain a constant temperature of the liquid. The liquid may be refreshed during exposure, or between exposures.
The micronozzles 416 also act as a buffer against inertial shearing forces between the optics and the liquid. Note that the shearing force is defined by the equation
F = A · μ · ⅆ v ⅆ x ,
where A is the area, is a viscosity parameter, x is a distance variable, and v is the velocity. The shearing force is approximately 1 Newton in the case of a typical 100 micron gap between the wafer 101 and the lens 102 . Neutralizing these shearing forces is accomplished by inertially dampening the relative accelerative motion between the lens 102 and fluid. This is accomplished by simply creating fluidic motion in a direction opposite to scanning. The microchannel nozzles 416 also act as a buffer against inertial shearing forces between the optics and fluid.
Additionally, the housing 103 includes a system for supplying gas to remove any excess liquid from the wafer 101 . The housing 103 includes a supply side annulus 406 A for gas inflow from a gas supply system (not shown in FIG. 4 ), a gas seal 410 A, which bridges the distance to the wafer 101 and makes a “squeegee” so as to contain and remove any excess liquid, and a return side gas outflow annulus 405 A (through which excess liquid is removed). The excess liquid may be removed through the return side gas outflow annulus 405 A, together with the exhausted gas. A similar structure may be found in an opposite quadrant of the housing 103 , as shown on the left side of FIG. 4 . The gas supply system works in conjunction with the liquid supply system, whenever there is liquid flow present, and, consequently, need only be turned on when there is liquid flow in the clear aperture area 216 .
As noted above, in FIG. 4 , with the wafer movement from left to right, the liquid flow is “in” at channel 105 A, and “out” at channel 105 B. When the scan direction is reversed, the liquid flow reverses as well.
FIG. 5 shows a partial isometric view of the micronozzle structure area of FIG. 4 . The channels 105 A- 105 D (not shown in FIG. 5 ) are connected to outer tubes 507 A- 507 D, through which liquid is supplied. Similarly, though not shown in this figure, the annuli 405 , 406 may be connected to tubular gas couplings.
FIG. 6 illustrates an example of a liquid exhaust velocity profile that may be used in the present invention. As will be appreciated by one of ordinary skill in the art, a “natural” velocity profile is not uniform with height in FIG. 4 , but rather may have a vertical gradient, which can cause optical distortion. To compensate for this natural gradient, different lengths of tubes (micronozzles 416 ) may be used, as shown in FIG. 6 . In FIG. 6 , the micronozzle length ranges from a maximum of L 1 to a minimum of L 2 , resulting in approximately the velocity profile at the exit of the micronozzles 416 shown on the left of FIG. 6 . The longer the micronozzle 416 , the lower the output velocity of the liquid from that particular micronozzle. Furthermore, the micronozzles 416 themselves may have different diameters, if needed to further control the velocity profile. Note further that the tubes of the micronozzles 416 need not necessarily be parallel to the wafer 101 , to further control the velocity profile.
The height of the liquid above the wafer 101 , in a typical system, is approximately 100 microns. Greater height generally results in a need for more micronozzles in 416 A due to a larger volume in which velocity profile needs to be controlled.
Thus, with careful selection of the lengths, diameters and orientations of the micronozzles 416 , the velocity profile in the clear aperture area 216 of the wafer 101 may be controlled, resulting in a substantially uniform velocity profile throughout the clear aperture area 216 , thereby improving exposure quality. In essence, the velocity profile generated by a structure such as shown in FIG. 6 may be “opposite” of the “natural” profile that would exist otherwise. Thus, the characteristics of the micronozzles 416 are tailored to result in a substantially uniform velocity profile.
During scanning, the wafer 101 moves in one direction, while the liquid is recirculated and injected in the opposite direction. The effect of the present invention is therefore to neutralize the liquid velocity profile induced by the scanning motion, causing inertial dampening between the lens 102 and the liquid. In other words, the net effect is a “zero” net inertia and velocity profile steering away from motion. Depending on the direction of the liquid flow, either a reduction or elimination of shear forces, or a reduction in optical distortions may result. Thus, the immersion lithographic process is capable of performing at peak levels due to constant fluid refresh, avoidance of gas bubbles, and the buffering of opto-fluidic vibrations.
Note further that while the liquid in the plenum 215 may have turbulence and gas bubbles, by the time it travels through the diffuser screen 412 , the flow is uniform. Therefore, after passing through the diffuser screen 412 , the plenum 414 , and exiting from the micronozzles 416 , the liquid flow has a desired velocity profile, substantially without imperfections caused by striations, opto-fluidic vibrations, turbulence, gas bubbles, and other non-uniformities, resulting in improved image quality.
As noted above, the bottom surface 108 of the lens 102 need not be flat. It is possible to use a lens 102 with a curved bottom surface 108 , and compensate for any induced velocity profile non-uniformities with an appropriate arrangement of micronozzle lengths, diameters, and orientations, to result in a near-uniform velocity profile.
The micronozzles 416 may be constructed using conventional lithographic techniques on silicon material. On a microscopic scale, the micronozzles 416 resemble a honeycomb material composed of tubes that are stacked in a staggered formation that exhibits key characteristic dimensions of hydraulic diameter and length. The micronozzles 416 may be flared out into the clear aperture area 216 .
Typical tubular diameters of the micronozzles 416 may vary, for example, from a few microns to tens of microns (e.g., 5-50 microns), and in some cases, up to 5 mm in diameter, and lengths of between about 10 to 100 diameters. Other lengths and/or diameters may be used. Slits, rather than round nozzles, may also be used. The number of micronozzles per unit area may also be varied.
For 193 nanometer imaging, the liquid is preferably water (e.g., de-ionized water), although other liquids, for example, cycle-octane, Krypton® (Fomblin oil) and perfluoropolyether oil, may be used.
The present invention results in a number of benefits to a liquid immersion photolithographic system. For example, in a step and scan system, transmission is improved, and there is less distortion. Dust particles in the air cannot enter the clear aperture area 216 between the lens 102 and the wafer 101 , since the liquid itself does not contain any dust, and the presence of the liquid acts as a barrier to the dust being present in the clear aperture area 216 during exposure. Preferably, the liquid is brought in after the wafer 101 has been loaded onto a wafer stage, and removed before the wafer 101 is unloaded. This minimizes dust and particulate contamination. Additionally, other ways of keeping the liquid from spilling during wafer exchange are possible as well, and the present invention is not limited to just the approach described above.
The fluid velocity profile induced by the scanning motion is neutralized, causing inertial dampening between lens 102 and the shearing fluid. Aside from acting as inertial dampers, the micronozzles 416 serve to refresh the working fluid volume, thereby eliminating refractive distortions due to thermal gradients created by the light source. A side benefit of the micronozzles 416 is their ability to discourage the formation of gas-bubbles during volume refresh. Also, the size of these micronozzles 416 prevents the formation of gas-bubbles that plague more conventional refresh techniques. All of these benefits allow the use of generally existing photolithographic tools and wavelengths to define much smaller features on a semiconductor surface.
CONCLUSION
While various embodiments of the present invention have been described above, it should be understood that they have been presented by way of example, and not limitation. It will be apparent to persons skilled in the relevant art that various changes in form and detail can be made therein without departing from the spirit and scope of the invention.
The present invention has been described above with the aid of functional building blocks and method steps illustrating the performance of specified functions and relationships thereof. The boundaries of these functional building blocks and method steps have been arbitrarily defined herein for the convenience of the description. Alternate boundaries can be defined so long as the specified functions and relationships thereof are appropriately performed. Also, the order of method steps may be rearranged. Any such alternate boundaries are thus within the scope and spirit of the claimed invention. One skilled in the art will recognize that these functional building blocks can be implemented by discrete components, application specific integrated circuits, processors executing appropriate software and the like or any combination thereof. Thus, the breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims and their equivalents. | A liquid immersion photolithography system includes an exposure system that exposes a substrate with electromagnetic radiation and includes a projection optical system that focuses the electromagnetic radiation on the substrate. A liquid supply system provides liquid flow between the projection optical system and the substrate. An optional plurality of micronozzles are arranged around the periphery of one side of the projection optical system so as to provide a substantially uniform velocity distribution of the liquid flow in an area where the substrate is being exposed. | 7 |
This application is a continuation of application Ser. No. 07/890,030, filed May 28, 1992, now U.S. Pat. No. 5,319,436 and entitled "MICROPLATE FOR ASSAYS USING LIGHT MEASUREMENTS".
FIELD OF THE INVENTION
The present invention relates generally to multi-well staple trays which are commonly referred to as microplates and which are used to hold a large number (e.g., 24, 48 or 96) of samples to be assayed by various techniques such as scintillation counting, luminometry, kinetics etc. This invention is particularly concerned with microplates for use in assaying techniques which require the emission of light from the sample, as occurs in scintillation counting, fluorimetry and luminometry, or the transmission of light through the sample.
BACKGROUND OF THE INVENTION
When microplates are used to hold samples to be assayed by techniques which are dependent on light emissions from the sample, it is important to avoid light transmission between adjacent samples, i.e., "crosstalk." Such crosstalk is extremely undesirable because it means that the photons detected in any particular sample well might not have originated from the particular sample in that well, and the purpose of the assaying technique is to obtain a unique measurement for each individual sample that is representative of only that sample.
In certain applications, it is desirable to have a transparent wall in the bottom of the sample well. For example, when coincidence measurement is used, it is desirable to have a first photodetector at the top of the well, which is normally open, and a second photodetector at the bottom of the well, which is normally closed. Of course, photons can be detected at the bottom of the well only if the wall of the well is transparent. Even when light measurements are not made at the bottom of the well, if is often desirable to have a transparent well wall to allow microscopic viewing of adherent cells within the well.
SUMMARY OF THE INVENTION
It is a primary object of the present invention to provide an improved microplate which includes a transparent wall which permits viewing of the sample and/or the measurement of light emissions from the sample, and yet avoids crosstalk between adjacent wells.
It is another important object of this invention to provide such an improved microplate which can be rapidly and efficiently manufactured.
Other objects and advantages of the invention will become apparent upon reading the following detailed description and upon reference to the accompanying drawings.
In accordance with the present invention, the foregoing objectives are realized by providing a microplate comprising an upper plate forming the side walls of the sample wells, the side walls being opaque so that light cannot be transmitted between adjacent wells through the side walls; a lower plate forming the bottom walls of the sample wells, the bottom walls being transparent to allow the transmission of light therethrough; and bands of opaque material within the lower plate and surrounding each well to block the transmission of light between adjacent wells through the lower plate. In a preferred embodiment, the bands of opaque material are formed by melting together the opaque material of the upper plate and the transparent material of the lower plate in preselected regions.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded perspective view of a microplate embodying the present invention:
FIG. 2 is a top plan view of the upper portion of the microplate of FIG. 1;
FIG. 3 is a bottom plan view of the upper portion of the microplate of FIG. 1;
FIG. 4 is a top plan view of the lower portion of the microplate of FIG. 1;
FIG. 5 is an enlarged section taken generally along line 5--5 in FIG. 1 and showing the two parts of the microplate before they have been joined to each other;
FIG. 6 is an enlarged section similar to FIG. 5 but showing the two parts of the microplate after they have been joined; and
FIG. 7 is an enlargement of a portion of FIG. 6.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
While the invention is susceptible to various modifications and alternative form, specific embodiments thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that it is not intended to limit the invention to the particular forms disclosed, but on the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the invention as defined by the appended claims.
Turning now to the drawings and referring first to FIG. 1, there is shown a microplate 10 formed from two molded plastic plates 11 and 12. The upper plate 11 forms the side walls 13 of the multiple wells of the microplate, and in the illustrative example the wells are arranged in an 8×12 or 4×6 matrix. The bottom plate 12 forms the bottom walls 14 of the web, and is attached to the lower surface of the upper plate 11 by fusing the two plates together. As will be described in more detail below, the fusion is preferably effected by ultrasonic bonding.
In order to confine light emissions to the well in which they originate, i.e., to prevent light transmission between adjacent wells, the upper plate 11 is formed from an opaque polymeric material so that light cannot be transmitted therethrough. For assaying techniques which require the detection of very small amounts of light, as in liquid scintillation counting, the pigmentation used to render the polymeric material opaque is preferably light in color so as to be highly reflective in order to ensure high counting efficiency with respect to the radioactive samples. To form an opaque light colored plate, a pigment having a high Albedo, preferably white, is added to the resin in an amount from about 2 to about 20 weight percent. If a greater amount of pigment is added, the resin becomes too viscous for injection molding. The white pigment is selected from the group consisting of titanium dioxide, zinc oxide, zinc sulfide and thithopone. Titanium dioxide is generally more chemically resistant to scintillation cocktail solvents.
In certain types of luminescence and fluorescence assays it is preferred that the side walls 13 of the sample wells be non-reflective, in which case the upper plate 11 is preferably formed from a black or dark-colored polymer. The dark polymer may be formed by the addition of carbon black in mounts ranging from about 0.5 weight % to about 15 weight %.
In contrast to the upper plate 11, the lower plate 12 is formed of a transparent polymeric material so that it forms a transparent bottom wall 14 for each sample well. This permits viewing of sample material through the bottom wall 14, and also permits light emissions to be measured through the bottom wall. The transparent bottom walls 14 may also be used to expose the sample to light from an external excitation source, while leaving the tops of the wells unobstructed for maximum detection area. Examples of suitable transparent polymers are clear polystyrene, polyacrylonitrile, polycarbonate, polyester, polymethyl pentene and acrylic materials.
The transparent bottom walls of the wells are desirable in assaying techniques that measure light emitted from, or transmitted through, the sample in each individual well. Examples of such techniques are liquid scintillation counting, which counts light emissions produced by a radioactive sample in a liquid scintillator, and techniques which measure light emitted by luminescent labels, such as bioluminescent or chemiluminescent labels, fluorescent labels, or absorbence labels. These techniques use various types of light detectors, such as one or more photomultiplier tubes per well, solid state imaging devices with either lenses or fiber optic couplers, and fiber optic devices.
For any given assaying technique, the polymeric material chosen to form the plate must be nonreactive with, insoluble in, and impervious to the materials contained in the samples to be used in the assay. One particularly preferred resin is a copolymer containing at least 50 weight percent of an unsaturated nitrile monomer and a second monomer which is capable of being copolymerized with the unsaturated nitrile monomer. These high nitrile resins have excellent transparency, rigidity, processability and gas barrier resistance to oxygen, carbon dioxide and other gases. The resins are highly chemically resistant to solvents such as benzene, toluene, xylene, 1,2,4-trimethylbenzene (pseudocumene), alkobenzenes, diisopropyl napthalene, phenylxylylethane (PxE), heptane and ethyl acetate. One or more of the aforementioned solvents are usually present in liquid scintillation cocktails. Additionally, these resins form a microplate that does not deteriorate when exposed to ultraviolet light during storage.
Preferably, the unsaturated nitrile monomer of the above resins is selected from the group consisting of acrylonitrile and methacrylonitrile. The monomer capable of being copolymerized with the unsaturated nitrile is an ethylenically unsaturated copolymerizable monomer selected from the group consisting of alkyl acrylates, alkyl methacrylates, acrylic acid or methacrylic acid. According to one embodiment of the invention, the resin is a rubber modified acrylonitrile-methylacrylate copolymer containing about 75 weight percent acrylonitrile and about 25 weight percent methylacrylate. Such a rubber modified copolymer resin is commercially available under the trademark Barex 210-I® resin manufactured by British Petroleum Chemicals Corporation.
For applications where the solvent resistance of the above-described copolymers is not required, polystyrene is a very cost-effective polymer that can be readily molded to form the plates 11 and 12.
To form a barrier to the transmission of light between adjacent wells via the transparent bottom plate 12, a downwardly protruding bead 20 is formed around the entire circumference of each well opening on the bottom surface of the upper plate 11. As can be seen in FIG. 4, this bead 20 has a tapering cross-section, so that it is narrower at its bottom than at the top. When the two plates 11 and 12 are pressed together, each bead 20 fits into a circular groove 21 formed in the top surface of the lower plate 12. The vertical dimension of each bead 20 is at least as great as the depth of the groove 21, so that when the two plates are pressed together, the lowermost surfaces of the beads 20 are pressed into firm contact with the lower surfaces of the grooves 21.
The two plates 11 and 12 may be joined together by various processes, but the preferred process is ultrasonic bonding. In this process the two plates are held firmly pressed together while they are bonded by the application of ultrasonic energy which causes the contacting surfaces to fuse together. Because of the shape of the beads 20, they function as energy directors, causing the energy to be concentrated at the interface between the beads and the corresponding grooves and thereby ensuring that the beads 20 are melted within the grooves 21. This melting fusion causes the opaque polymer of the beads 21 to penetrate beneath the upper surface of the transparent lower plate 12. This forms a circular band 23 of opaque polymer around the transparent bottom wall of each well, thereby blocking the transmission of light between adjacent wells via the transparent bottom plate 12.
The beads 20 and grooves 21 should penetrate through 25% to 75% of the thickness of the transparent bottom plate 12 for effective reduction of optical cross talk. In a preferred embodiment, the bead and groove have a vertical dimension of 0.025 inch and the bottom plate 12 has a thickness of 0.060 inch. The inner edge of each groove is spaced 0.010 inch from the side wall of the corresponding wall.
Microplates formed in this manner have been found to significantly reduce optical and liquid crosstalk. For example, when used in liquid scintillation counting, liquid crosstalk is eliminiated and optical crosstalk is reduced from 2% or more to about 0.2% by the addition of the non-transmissive bands 23.
For the purpose of attaching the two plates 11 and 12 to each other, while at the same time forming an effective said against liquid cross talk, a grid 30 of beads 31 is formed on the top surface of the lower plate 12. A similar grid 32 of grooves 33 is formed in the bottom surface of the upper plate 11 for receiving the bead grid 30. The height of the beads 31 is made substantially greater than the depth of the grooves 33 to ensure that the beads 31 are thoroughly melted to fill the grooves 33. For example, in a preferred embodiment the vertical dimensions of the beads 31 and the grooves 33 are 0.026 inch and 0.007 inch, respectively. With these dimensions, the application of ultrasonic energy thoroughly melts the beads 31.
The preferred ultrasonic bonding process may be effected by applying the energy to the lower plate 12 through a transducer or "horn" having a fiat surface of about the same dimensions as the plate 12, with multiple recesses located in the same regions as the well holes in the upper plate 11. The recesses help to concentrate the ultrasonic energy in the regions between the wells.
An alternative to the ultrasonic bonding process described above is to mold the opaque upper plate 11 with the depending beads 20, and then mold the transparent lower plate 12 directly onto the bottom of the upper plate 11. The opaque beads 20 are thus embedded in the lower plate 12 to form the desired non-transmissive bands 23 between adjacent wells. It is also possible to use solvent or adhesives to fuse the two plates together.
While the invention has been described with particular reference to certain specific embodiments, it will be understood that various modifications may be made without departing from the spirit or scope of the invention. For example, the grooves in the top surface of the lower plate may be filled with opaque material from a source other than the beads on the lower surface of the upper plate. For example, the grooves could be filled with particulate or liquid opaque material. Also, in cases where a rigid bottom plate is not required, transparent bottom walls may be formed by applying a sheet of transparent film, such as polyester film, to the lower surface of the top plate 11 from which the beads 21 have been omitted. Such a film may be attached to the top plate 11 by means of adhesive, for example. Alternatively, the upper surface of the transparent film may be coated with another polymer such as polyethylene that will melt into the top plate. | A microplate forms a multiplicity of sample wells for holding samples to be assayed by light emissions or light transmission. The microplate comprises a unitary upper plate and a unitary lower plate. The unitary upper plate forms the side walls of the sample wells, while the unitary lower plate forms the bottom walls of the sample wells. The side walls are opaque so that light cannot be transmitted between adjacent wells through the side walls. The bottom walls are transparent to allow the transmission of light therethrough. Bands of opaque material surround the bottom wall of each well and are located below a level of an upper surface of, the bottom wall of each well. The bands of opaque material are constructed and arranged to block the transmission of light between adjacent wells through the lower plate. | 1 |
This application is a division of application Ser. No. 403,628 filed Oct. 4, 1973, now abandoned, which is a continuation-in-part of application Ser. No. 193,632 filed Oct. 29, 1971, which is incorporated herein by reference and has matured into U.S. Pat. No. 3,779,064.
BACKGROUND
In the parent application internal and/or external surfacing of tubes having as cross section any closed ring and of calibration from the inside or from the outside of said tubes is described characterized by the fact that there is used to work, a tool or mandrel of which one part at least of the external surface, harder than the metal to be worked, is defined by the displacement of a meridian curve resting on a closed directrix approximately identical with the border corresponding to the surface to be worked of the cross section of the tube. The profile of the tool along a meridian curve generating its external surface is such that, when passing from the first end plane of the tool, which corresponds to the point at which the tool enters in contact with the tube, to the second end plane of the tool, which corresponds to the plane at which the end of the contact occurs between the tool and the tube, there is made to vary in a continuous manner the distance to the axis of the tube, increasing it when work is done on the internal surface of the tube, and decreasing it when work is done on the external surface. The maximum variation of said distance is greater than the maximum depth of the faults which the tube presents on the surface to be worked on, and smaller than the value which corresponds, to insure the displacement of the tool along the axis of the tube, with a force applied on the tube which exceeds the mechanical resistance of said tube, and in that there is insured a relative displacement in translation along the axis of the tube between the above defined tool and the tube to be worked on.
In a preferred mode of operation defined in the parent application, it has been suggested to perform the calibrating and the internal surfacing of a tube having a circular section by means of a mandrel having the shape of a toric ring with a half round section. It has been indicated that, in the case when work is done on cold drawn steel tubes, the radius of the cross section of the toric mandrel had to be, for the first run of the work preferably between 3 and 6 mm, but could be more, for example, 10 mm, for the finishing run. It has also been indicated that the tube to be worked is preferably subjected to a preliminary run through a drawplate to perform a shaping of the tube. It has finally been indicated that at the time of the running of the toric mandrel inside the tube, it is necessary generally to lubricate the inside of the tube and/or the mandrel. The suggested lubricating is performed, generally, with a brush prior to the setting into place of the tube to be worked on the machine meant for the carrying out of the process.
It has now been observed that it could prove advantageous to lubricate and to cool the inside of the tube to be worked on, and the toric mandrel which performs the work in situ during the work.
OBJECTS
The present invention, consequently, has as its object a surface-finishing process and an internal calibrating process for tubes, according to the parent application, characterized by the fact that the tool, which makes possible the internal tube work, is sprayed during work on the tube by means of a lubricating jet directed on the work zone ahead of the passing of the tool.
In one preferred mode of carrying out the process according to the present invention, the lubricating agent used is a water soluble lubricating agent, the rate of flow of the lubricating agent ranges between 10 and 30 liters per minute.
It is advantageously possible to use as a water soluble oil the water soluble oil found on the market under the brand name "Wynns" used in a concentration of approximately 20% in water.
The present invention also has as its object a machine for the calibrating and the surface finishing of the inside of tubes, making it possible to use the above defined process, said machine having on one part a fixed frame or casing, on the other part a stem movable in translation on which there can be fitted a tool or mandrel such as defined in the parent application, and finally, means for holding the tube to be worked on, with respect to the frame or casing, and means which insure the displacement of the tool with respect to said tube, characterized by the fact that the stem on which the tool is fitted preferably has, internally, a duct or channel to feed the lubricating agent, which communicates with the outside of the stem by at least one boring the axis of which is directed in the direction of the work edge of the tool.
In one preferred mode of operation, the tool is fixed by screwing, for example, to the end of a carrying stem for tools, fastened to the rod of a piston of a hydraulic jack; the tool carrying stem has an external diameter slightly less than the internal diameter of the unfinished tube to be worked on; the tool carrying stem is constituted in the first place, by a head along the end axis of which there has been formed a threaded portion for the fixation of the tool, said head being perforated with several borings which are oblique with respect to the axis of the stem, distributed, for example, along the generatrices of a cone and all of them opening into a central duct or channel; in the second place, a tubular cross piece along the axis of which there is placed, preferably, a tube connected to the central duct of the head; and in the third place, by a fixation base fastened to the cross piece, which makes it possible to insure the solidarity of the tool carrying stem with the stem of the movable piston of the hydraulic jack, said fixation base optionally having running through it a tube which is connected to the central duct of the head.
The apparatus which has just been described for the tool carrying stem at the end of which the tool is placed, is especially important because the arrival of the lubricating and cooling fluid may be provided for, from a pump of the conventional type, directly on the end of the piston rod of the hydraulic jack, so that when it is necessary to change the tool carrying stem, it is sufficient to unscrew said stem to disconnect it from the piston rod, without there being any need to touch the piping through which comes the lubricating and cooling fluid.
The lubrication in the course of the work, such as just defined, in no way prevents a preliminary lubricating of the tool or mandrel prior to the start of the work on the tube. In that case, it is possible advantageously to choose as lubricating agent to apply on the tool, by immersion for example, a lubricating oil such as the one known under the name of "Tubanor A 6 N P" supplied by the French firm Rhone-Poulenc.
It has been observed, moreover, that in order to render easier the introduction of the tool into the tube to be worked on, it might prove desirable to provide for, at the intake of the tube, a chamfer which insures the perfect centering of the tool with respect to the tube.
The present invention, therefore, also has as its object a process for the surface finishing and for the internal calibrating of tubes having a circular section, such as defined above, characterized by the fact that, on the side where the introduction of the tool into the tube takes place there is provided, on the internal edge of the tube, a cone shaped chamfer which increases, at the entrance, the internal radius of the tube. In one preferred mode of operation, the intake radius of the tube is increased by 0.5 to 1.5 mm, and the angle of the cone-shaped chamfer, with respect to the axis of the tube, ranges between 10° and 20°.
It has been observed that the process according to the present invention makes it possible to obtain especially advantageous results for cylindrical tubes of steel, the wall thickness of which ranges between 8 and 16% of the internal diameter. It has been indicated, in the parent application that it was advantageously possible to cause the tubes to be worked on to undergo, in a drawplate, a shaping up, then a passage of the toric tool for surface finishing and for calibrating, and finally a passage of a second toric tool which insured the finishing. It has now been observed, moreover, that in that case, the best results were obtained when the passing of the tool in the finishing phase gave the tubes a diameter increase ranging between 0.10 and 0.25 mm, approximately.
The present invention, therefore, has as its object a process such as defined above, applied to cylindrical tubes of steel having a circular section, characterized by the fact that the thickness of the walls of said tubes ranges between 8 and 16% of the initial internal diameter of the tubes.
In one preferred mode of operation of the above defined process, which includes a shaping in a drawplate, a first passage of the toric shaped tool, and a second passage, called finishing passage, of the toric shaped tool, the increase in internal diameter of the tube, during the finishing passage, ranges between 0.10 and 0.25 mm.
In the parent application it has been indicated that the too was limited, for at least part of its external surface, by a revolution surface such that the angle formed with the axis by the straight line which joins the point at which the tool comes in contact with the tube, and the corresponding point at the end of the contact of the tool with said tube, approximately ranges between 12° and 20°. In the case when a tool is used with a toric external surface with a circular section, it has been found to use a torus radius ranging between 3 and 6 mm for the first work passage, and a greater radius 10 mm, for example, for the finishing passage. The radius of the torus section which seemed to be the best suited for the work in first passage had been indicated, in the example of operation, as being 4 mm. It has been observed that the radius of the cross section of the torus which corresponds to the optimum could vary as a function of the heterogeneity of the metal of the tube to be worked on. In the case when the tube is a welded tube having a welding line where there may be found hard grains spread throughout a less hard metal, the use of a torus with too small a section radius may lead to tearings of the metal along the heterogeneity line. In order to prevent those tearings, it has been observed that it was especially important to increase the radius of the cross section of the torus, the optimum range being between 5 and 7 mm, approximately. Good results have been obtained on electrically welded tubes, using a torus with a radius of 6 mm.
The present invention therefore has as its object a process for the surface finishing and for the calibrating of cylindrical tubes of steel having a circular section and which have a zone of heterogeneity, for example, a soldering or welding line, said process being such as above defined, and making use of a tool having a toric shaped external surface with a circular cross section, characterized by the fact that the radius of the circular cross section of the torus of the tool ranges between 5 and 7 mm for the first passage tool and, preferably, is equal to 6 mm.
It has also been observed that it was advantageous, in order to obtain a perfect surface finishing of the tube, to increase the hardness of the tool or mandrel which works on the tube. From this point of view, good results have been obtained by using, for the composition of the tool, alloyed steels subjected to a thermal treatment so that they have a Vickers hardness of more than 800, but results are even better when there are used as tools toruses made of annealed tungsten carbide. Of course, the tool has a life which is the longer as its hardness is farther removed from the hardness of the tube to be worked on.
The present invention therefore has as its object a machine for carrying out the process such as defined above, for the surface finishing and for the calibrating of the inside of mild or of semi-hard steel tubes, characterized by the fact that the tool is made of hard treated steel which possibly has been alloyed, or of tungsten carbide.
In one preferred mode of operation, when the tool is made of hard alloy steel, the thermal treatment is performed to obtain a surface hardness which is greater than 800 Vickers; the steel contains from 0.7 and 9.9% of carbon, and from 15 to 20% of tungsten; or the steel contains 0.8% of carbon; 18% of tungsten, 4.7% of chromium, 1.15% of vanadium, and 0.7% of cobalt.
It has therefore been observed that, in the case when there was a danger of tearing of metal because of a heterogeneity in one zone of the tube, the increase in hardness of the tool made it possible to improve results. However, it has also been found that an improvement could be obtained in the same case by reducing the speed of displacement of the tool inside the tube. In the case when the internal surface finishing and the calibrating are performed on tubes of semi-hard steel or of mild steel, it is possible advantageously to use a speed of displacement of the tool inside the tube ranging between 1 and 2 meters per minute and, preferably, a speed of displacement close to 1.50 meters per minute. On the contrary, when the tube presents a zone or a line of heterogeneity, as is the case for electrically welded tubes, it proves advantageous to lower the speed to a range of 0.50 meter per minute to 1.50 meters per minute, and preferably to a speed of 1 meter per minute.
The present invention therefore has as its object a process such as defined above, used for the internal surface finishing and calibrating of steel tubes, characterized by the fact that the speed of displacement of the tool, with respect to the tube, ranges between 0.5 and 2 meters per minute.
In one preferred mode of operation, when the tubes have a zone of structure heterogeneity, the speed of displacement of the tool with respect to the tube ranges between 0.5 and 1.5 meters per minute and, preferably, it is near 1 meter per minute.
It is suitable to mention that there exists an interaction for the work on a same steel tube, between the optimum speed to use for the displacement of the tool with respect to the tube, and the ratio chosen between the hardness of the tool and the hardness of the tube.
As indicated in the parent application, there is generally used a preliminary passage through a drawplate to obtain a shaping, the importance of which is first of all a function of the state of the internal surface of the unfinished tube on which it is desired to work. For a tube the internal surface of which is in a relatively mediocre state, it is possible advantageously to choose a theoretical shaping of 0.75 mm, the value of said shaping also having to take into account, when it is desired to work on a series of tubes, the tolerance which exists on the external diameter of the tubes to be worked on, so that it will be possible, with the same drawplate, to apply a sufficient shaping for all of the tubes in the series.
The present invention therefore also has as its object a process such as defined above, in which there is used a preliminary passage of the tube through a shaping drawplate, characterized by the fact that the shaping of the tube decreases the external diameter of the tube by a value ranging between 0.5 and 1 mm, approximately.
The use of a preliminary passage through a drawplate brings about the necessity of setting the drawplate into place at the time of said passage, and of removing it in the phase which corresponds to the internal work on the tube. Said handling of the drawplate is greatly eased by placing, according to the present invention, the drawplate in a support mounted in a pivoting manner with respect to the frame or casing, the axis of pivoting being approximately parallel to the direction of displacement of the tool of the machine, one of the extreme positions of the support corresponding to the complete disappearance of the drawplate away from the axis of work of the tool and the other extreme position, set by a lug piece, corresponding to the setting into place of the drawplate for the preliminary passage through said drawplate.
For the passage through the shaping drawplate, the speed of displacement of the tube with respect to the drawplate preferably is appreciably lower than the speed which has been advocated above for the displacement of the tool with respect to the tube. Especially, in the case when the machine which makes it possible to carry out the process according to the present invention includes a double action hydraulic jack which in one direction insures the passage of the tube through the shaping drawplate and, in the other direction, insures the passage of the tool inside of the tube which has first been shaped, it is arranged, according to the present invention, to choose for the section of the piston of the jack, a surface which is approximately double the section of the piston rod. In that case, for a constant rate of flow of the hydraulic group, the speed of displacement of the piston in the direction of the passage through the drawplate shall be half the speed of displacement of the piston in the direction of the passage of the tool through the tube.
The present invention, therefore, also has as its object a process such as defined above, which includes a preliminary passage of the tubes through a shaping drawplate, characterized by the fact that the passage through the drawplate takes place at a speed ranging between 0.25 and 1 meter per minute, approximately.
Finally, it has been observed that it was necessary to maintain a uniform displacement of the tube, with respect to the shaping drawplate, or of the tool with respect to the tube. Since the internal diameter of the tube to be worked on may undergo slight variations over the whole length of the tube, and since the effort for the forward motion of the tool in the tube is not of necessity strictly constant, it is suitable, in order to insure a progressive continuous displacement of the piston of the jack of the machine used, to place, on each one of the pushing chambers of said jack, a counter-pressure valve which, at the time of the entrance of the pushing fluid into the jack, will offer no restriction to the entrance of said fluid but which will offer such a restriction, by means of a diaphragm, for example, at the time of the exit of the fluid. Said dispostion makes it possible to render more uniform the displacement of the piston of the jack, in spite of the variation of the resistance in the course of the work.
The present invention therefore has as its object a machine, for the purpose of carrying out a process of internal surface finishing and of calibration of tubes, such as above defined, said machine including a double action hydraulic jack which makes possible, in the one and in the other direction, to push the tube through a drawplate for shaping and, in the other direction, to pull the tool inside the tube in order to increase the latter's diameter while calibrating it and while internally finishing its surface, characterized by the fact that on each pushing member, on each side of the piston of the jack (double action jack), there has been placed a check valve which lets the pushing fluid enter freely but which restrains the speed of exit of said fluid.
In order to better help understand the objects of the present invention, there will now be described, as examples which in no way are limitative, several modes of operation represented in the drawings.
THE DRAWINGS
FIG. 1 represents a plan view of a machine according to the present invention, usable for the operation of the process of the process of calibrating and surface finishing of steel tubes, with a preliminary passage through a shaping drawplate;
FIG. 2 represents, in section, the detail of the tool carrying stem, connected to the rod of the jack's piston;
FIG. 3 represents, in section, the detail of a device which makes it possible to regulate the movement of the piston of the jack; and
FIG. 4 represents, in section, the tool used for the calibrating and for the surface finishing of the inside of the tubes.
BRIEF SUMMARY OF THE INVENTION
The invention provides an improvement in a process and apparatus of the type described in the parent application for internal finishing and calibrating tubes in which the internal surface of the tube is sprayed in situ during the work on the tube with at least one lubricating jet directed to the work zone ahead of the passage of the tool.
DETAILED DESCRIPTION OF THE INVENTION
Referring to the drawing, it is seen that there have been designated by 41a and 41b two porticoes, separated by 1.45 meters, approximately, and connected together by 4 rigid rods 42 which form a parallelepipede with a square base. The whole constituted by porticoes 41a, 41b and by rods 42 constitutes the frame of the machine. Said frame carries a double action hydraulic jack 43, a jack the moveable piston of which has been indicated by 44 and the axis of which is placed, approximately, in the same direction as the axis of the parallelepipede having a square base, formed by rods 42. The run of the jack is approximately 1.20 meters.
Hydraulic jack 43 is fed by a motor pump which is not represented in the drawing. The operation of jack 43 is obtained by means of a distributor (not shown) which the user controls by means of a handle. The rate of flow of the motor pump fluid is 7.85 liters per minute and the section of the piston of the jack is 122.71 square centimeters, while the section of the piston rod 44 is 50.27 centimeters square. The operating pressure of the jack ranges between 100 and 180 atmospheres approximately. There is obtained a speed of displacement of the piston rod 44 of 1.084 meters per minute from the left to the right in FIG. 1, and of 0.64 meter per minute from the right to the left in FIG. 1.
Rod 44 of jack 43 carries at its end a connection tip 44a which has an internally threaded boring where it is possible to screw the threaded end of a tool carrying stem 51. Tip 44a laterally has a piping 44b on which there is affixed a flexible duct 44c. Piping 44b is connected with the inside of the boring, inside which there is screwed the tool-carrying stem 51. The diameter of rod 51 is slightly less than the diameter of the tube which it is desired to calibrate and to surface finish the inside by means of the machine according to the present invention. Facing the free end of the tool carrying stem 51, which is placed along the axis of jack 43, there is formed in portico 41a an opening 52. Forward from portico 41a, on the side where there is located jack 43, there has been placed a drawplate support 54 which can move in the transverse direction in the the zone limited by the four rods 42. The drawplate support 54 is mounted in a pivoting manner on a shaft carried by portico 41a said shaft being parallel with rods 42. The transverse pivoting motion of support 54 is obtained by operating a handle and it makes it possible for said support 54 either to open up opening 52 between two rods 42, or to come to the position of work represented in FIG. 1, then taking its support on a lug piece solidary of portico 41a. Said arrangement makes possible a fast maneuver of support 54 of the drawplate.
Drawplate support 54 has in its central zone a cone shaped hollowed out part inside which there has been placed a drawplate 55 the external shape of which is a cone, of which the angle at the summit corresponds to the conicity of the central cone shaped hollowed out area of the drawplate support 54. Drawplate 55 has a shape identical to that which has been described for drawplate 15 in the parent application. It is made of "Sancy" type steel, subjected to a thermal treatment to have a rupture limit of 200 kg/mm 2 . Said steel contains 1.70% of carbon, 13% of chromium, 0.50% of molybdenum, and 0.50% of tungsten.
On the side of portico 41a where there is not located the drawplate support 54, there are placed two movable jaws 58, each one of them movable around an axis parallel with the longitudinal axis of the machine. Jaws 58, when they are in the closed position, limit between them a cylindrical hollowed out part. They have in the median part of their thickness a groove inside which there has been placed a bronze segment 61. When jaws 58 are in the closed position, the two segments 61 of bronze are in a position of support on stem 51 when the latter is in a position forward enough to be at a right angle with jaws 58.
In order to execute the calibrating and the surface finishing of a tube, said tube is placed on stem 51 by making it slide on that stem through opening 52. At that time, piston 44 of jack 43 is placed in its position the most remote from portico 41a. Between piston 44 and the tube, there have been placed on stem 51 for one thing a ring 63 which approximately has in diameter the dimensions of the tube end, for the other thing, two half shells 64 which approximately result from the sawing of a ring 63 along an axial plane. There is then caused, by acting on the distributor associated with jack 43, a forward motion of piston 44 after there has been placed the drawplate support 54 and its drawplate 55, in the position represented in FIG. 1. The tube pushed by the frontal face of ring 63 then runs through drawplate 55.
There have been recorded, in the third and fourth columns of Table I, the results obtained after the running through a drawplate for tubes of different diameters and made of different qualities of steel. It is observed that, depending on the diameters and on the steel qualities, the real shaping of the internal diameter of the tube is more or less important. All of the shapings obtained a range between 0.5 and 1 mm.
The advantages of this preliminary passage through a drawplate for shaping have been indicated in detail in the parent application.
When piston 44 of jack 43 has covered a sufficient run, the tube carried by stem 51 escapes from drawplate 55 and it continues its forward motion. At that moment, jaws 58 still are open. There are then removed the two half shells 64, leaving between the tube to be worked on and the tip 44a, only ring 63, and pushing said ring back toward the piston of the jack. When the piston has moved forward in a sufficient manner, the rear part of the tube to be worked on reaches beyond jaws 58, the end of stem 51 nevertheless being beyond the fore part of the tube. At that moment, the jaws 58 are closed in a manner such that segments 61 come into contact with stem 51, in the rear of the tube to be worked on. The internal diameter of jaws 58 is less than the external diameter of the tube to be worked on.
With reference now to FIG. 2, it can be seen that the tool carrying stem 51 consists of three parts made solidary of one another. At one end there is a head 80, at the other end there is located a fixation base of seating flange 81, and between them there is placed a tubular cross piece 82. Head 80 bears, on its end face, an internally threaded boring 83, where there comes to place itself a screw 84 (FIG. 1) the head of which tightens against the end of head 80 a torus-shaped tool indicated as a whole by 65 (FIG. 1). On the side of head 80, which has no boring 83, there has been formed a central duct 85 into which there open six borings 86, evenly distributed around the axis of head 80 along the generatrices of a cone having 60° as its half angle at the summit.
In the zone where central duct 85 opens to the outside of head 80, there is welded a tube 87 which is placed approximately along the axis of the cross piece tube 82. Cross piece tube 82 is then assembled to head 80, and there is presented, at the other end of cross piece tube 82, the base of flange 81 which has, along its axis, a boring which allows for the passage of tube 87.
Base of flanged end 81 is screwed inside cross piece 82 by means of threading 88 and when solidarization has been completed, tube 87 is welded on the end face of base or flange 81.
Base of flanged end 81 includes an external thread 89 which makes it possible to screw it inside the threaded boring which is in tip 44a, so that, when stem 51 is assembled on tip 44a as already described, the flexible piping 44c can feed liquid lubricant to tube 87, to the central duct 85 and to the borings 86. There is used, to feed these borings 86, a water soluble oil sold under the trade name of "Wynns", at a concentration of 20% in water, and with a rate of flow of 20 liters per minute.
Tool 65, which is affixed by means of screw 84 to the end of head 80 of the tool carrying stem 51, has been represented in detail in FIG. 4. Said tool is made of "high speed" steel subjected to a thermal treatment, so as to have a Vickers hardness of 890, approximately. The steel used contains 0.8% of carbon, 18% of tungsten, 4.70% of chromium, 1.15% of vanadium, and 0.70% of cobalt. It appears in the form of a thick washer having a central boring 90 which makes possible the passage of screw 84 the head of which blocks the tool at the end of head 80 of the tool carrying stem 51. The face of the tool which is located near stem 51 has a chamfer 92 with a 30° half angle at the summit, said chamfer having a width of 7 millimeters. On its other face, tool 65 has a chamfer 91 with a 45° half angle at the summit, and a width of 2 mm. The zone of the tool which works on the inside of the tube is torus 93 the section of which is constituted by the arc of a circle. For the tool which corresponds to the first passage inside the tube, the radius of the arc of circle is 4 millimeters for steel tubes drawn under cold conditions, without any welding, and it is 6 millimeters for the steel tubes which have a welding line. For the tools which correspond to the work in the second passage, the radius of the arc of circle is approximately 10 millimeters.
Once there has been placed at the end of stem 51 a tool 65 such as the one above described, which corresponds to the work of a first passage, there is caused the displacement of piston 44 from the left toward the right in FIG. 1. Tool 65 is centered in chamfer 92, inside the tube to be worked on. In order to improve the centering, it is provided to practice in the internal border of the tube a chamfer having a 15° half angle at the summit, and which widens the entrance diameter of the tube by 2 millimeters. The tool then moves inside the tube, and the torus 93 causes a calibrating and a surface finishing, as indicated in the parent application. The results obtained after the passage of tool 65 through the tube are recorded in columns 5 and 6 in Table I.
The figures, which are recorded in Table I, correspond to electrically welded tubes and to a speed of displacement of the tool, with respect to the tube, which was approximately 1 meter per minute. However, it would be possible to increase that speed, when treating tubes which do not have any line of heterogeneity (soldering or welding line). The sprinkling of soluble oil through borings 86 which are directed toward tool 65, is done during the entire work period on the tube performed by the tool, as indicated above. It can be seen that there exists a difference between the internal diameter of the tube after the passage of the tool, and the maximum external diameter of the tool said difference being variable as a function of the dimensions of the tubes and of the quality of the steel of the tube.
Of course, it is desirable to lubricate torus 93 prior to its introduction into the tube, by means of an application by soaking of an oil of the "Tubanor A6NP" type, supplied by the firm Rhone Poulenc
Once a tool 65 has run the whole length of the tube, the tube escapes from the machine, and jaws 58 are opened. Screw 84 is unscrewed in order to release tool 65 and said tool is replaced by a similar tool, the torus 93 of which has a section, the arc of circle of which corresponds to a radius of 10 millimeters. There is again performed, after stem 51 has been brought back toward the left in FIG. 1, a passage of the tool through the inside of the tube. That second passage, called the finishing passage, is performed with a torus 93 of which the maximum external diameter is greater than the maximum external diameter of torus 93 of the tool corresponding to the first passage. Spraying through borings 86 takes place as in the course of the first passage. The results relative to that second passage of the tool are recorded in columns 7 and 8 of Table I. The diameters of the drawplate and of the two tools used in succession have been chosen for all of the examples in Table I so as to bring the tubes back to approximately the internal diameter which they had to start with.
It will be seen that the tubes which are thus treated are calibrated with an accuracy of 0.02 mm on their internal diameter, and that they have a perfectly polished internal appearance. It is thought that the surface state which is thus obtained is better than 0.5 micron. All of the imperfections which were initially present inside the tube have disappeared.
In order to insure a uniform displacement of the tool in the tube, and of the tube in the drawplate, there has been associated with each one of chambers of the double action jack 43 a counterpressure check valve indicated by 94 in its whole. Check valve 94 is represented in detail in FIG. 3. It includes a body 95 inside which there is formed a boring 26, into which there penetrate two ducts 97 and 98. Duct 98 is connected to the pump, duct 97 is connected to the push chamber of the jack. At the point where duct 98 opens into boring 96, there is placed a ring 99 pushed in the direction of boring 98 by means of a spring 100. A central shaft 101 runs through ring 99 and its position in height inside said ring is adjustable. Central shaft 101 approximately occupies the whole central zone of ring 99, but there has been provided for a slanted trench 102 which allows the passage of the fluid between the central shaft 101 and ring 99, said passage being the more important as the central shaft 101 is less deeply pushed into ring 99. The adjusting of the apparatus is done by working on the pushing of shaft 101 into ring 99. When the pushing fluid reaches apparatus 94 by means of duct 98 it lifts rings 99 by compressing spring 100 and it enters without any hindrance into the corresponding push chamber of the jack. On the contrary, when the fluid is pushed back outside the push chamber of the jack, it enters into the apparatus through duct 97 and it can be ejected through duct 98 only after it has run through trench 102 which constitutes a diaphragm and which consequently limits the speed of ejection of the fluid. There is thus created inside the jack chember which does not cause the push, a counterpressure which prevents jerks in the displacement of the tool. That disposition makes it possible greatly to improve the quality of the surface finishing and of the calibrating obtained by means of the machine according to the present invention.
It is of course understood that the modes of operation which have been described above are in no way limitative, and that they can be subject to any desirable modification, without departing from the scope of the present invention.
TABLE I__________________________________________________________________________ 8 7 Internal1 2 3 4 5 6 Diameter DiameterSize of Tubes Rupture limit Diameter of Internal Dia- Diameter of Internal Dia- torus of tubein mm. of the steel the neck of the meter of tube torus shaped meter of tube tool, after 2ndInternal diam./ of tube in drawplate after draw- tool, 1st after 1st pas- passage passageExternal diam. kg/mm.sup.2 in mm. plate in mm. passage - mm. sage in mm. mm. in__________________________________________________________________________ mm.60,325/69,85 40 69,25 59,65 60,10 60,13 60,35 60,30 52 69,25 59,75 60,27 60,18 60,44 60,3069, 85/82,55 40 81,80 68,90 69,65 69,69 69,90 69,83 52 81,80 69,20 69,86 69,76 70,00 69,8382, 55/95,25 40 94,70 81,62 82,21 82,23 82,58 82,52 52 94,70 81,84 82,50 82,38 82,66 82,5376, 20/95,25 40 94,40 75,35 76,04 76,02 76,26 76,29 52 94,40 75,60 76,04 75,93 76,26 76,15__________________________________________________________________________ | An improvement in a process and apparatus for internal finishing and calibrating tubes is provided in which the internal surface of the tube is sprayed during the work on the tube with at least one lubricating jet directed to the work zone ahead of the passage of the tool. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims priority to U.S. Provisional Application No. 60/752,961, filed Dec. 23, 2005, the contents of which are hereby incorporated by reference.
FIELD OF THE INVENTION
This invention relates to novel compounds isolated and purified from the herb medicine Garcinia hanburi and their medical applications, and it further relates to a method of separating epimers of the compounds.
BACKGROUND OF THE INVENTION
Gamboges, the resin from various Garcinia species including G. morella and G. hanburyi , is rich in anti-tumor gambogic acid (GA, CAS No. 2752-65-0) [1-7]. Gambogic acid was always isolated as an inseparable C(2) epimeric mixture whose structure could not be determined completely until the (R)-epimer was obtained by recrystallization of the pyridine salt of GA and identified by single crystal X-ray diffraction [8], [9]. As different epimers of the same compounds can have significantly different biological effects and different interactions with other therapeutic agents when used in combination, a common practice in chemotherapy, it is of great importance to be able to separate the epimers of the compounds naturally occuring in the herb gamboges that have anti-tumor effects.
Additionally, MDR in cancer cells is a significant factor for the failure of chemotherapy in many patients. It is very important to find and develop new anticancer drug that can overcome MDR of cancer cells, because MDR transporters contributed significantly to the pharmacokinetic disposition of anticancer drugs. Knowledge of substrates, inducers and inhibitors of these transporters is necessary to ensure optimal clinical outcomes [10]. In addition, chemotherapy often requires multidrug combination, and most anti-cancer drugs are metabolic substrates of cytochrome P450s. Therefore, understanding of drug-drug interactions is important for the combination use of anti-cancer drugs. The likelihood of drug interactions with combination therapy will be very high, if these combined drugs are substrates and potent inhibitors or inducers of the cytochrome P450 (CYP) system [11].
SUMMARY OF THE INVENTION
Accordingly, as an object of the present invention, there is provided a number of novel chemical compounds which are isolated in a pure state for the first time from the herb gamboges. The compounds of the present invention are useful for their anti-tumor effects, particularly when they come with a good understating of their potential interactions with other anti-cancer drugs in terms of their being non substrates of multi-drug resistance (MDR) transporter and their inhibitory effects on various human cytochrome P450 (CYP) systems.
As another object of the present invention, there is provided a method for efficiently separating epimers of xanthone compounds of the herb gamboges. This method greatly facilitates the studies of the active ingredients of gamboges in the effort to provide a better understanding of these compounds' therapeutic applications.
In a particular embodiment, the present invention provides three pairs of C-2 epimeric xanthones from Garcinia hanburyi , which are useful for their anticancer effects. The structures of the compounds are shown as follows:
Gambogic acid (GA, CAS No. 2752-65-0) which was previously isolated as an inseparable stereomeric mixture of C-2 epimers, were separated into two epimers (gambogic acid and epigambogic acid, referred to as 1 and 2) according to the present invention. In the HPLC analysis, GA presented as one peak (m/z 628) on C 18 column (Alltima C 18 , 5μ, 4.6×250 mm) eluted with CH3CN/0.1% acetic acid (90:10). When the fraction corresponding to the single peak was then subject to C 8 column (Alltima C 8 , 5μ, 4.6×250 mm), eluted with CH3CN/0.1% acetic acid (75:25), two completely separated peaks appear. These two peaks were isolated by HPLC under the same analytical condition with each injection of 20 μL acetone solution of gambogic acid (35 mg/mL), yielding 1 (12 mg) and 2 (10 mg). The two peaks being two C-2 epimers of GA was clearly confirmed by extensive spectroscopic analysis and direct comparison of NMR and HPLC data with those of the known R-epimer. In addition, two similar pairs of C-2 epimeric xanthones were also isolated from this plant by the same method. They were identified to be isogambogic acid, epiisogambogic acid, 30-hydroxygambogic acid, and 30-hydroxyepigambogic acid by extensive spectroscopic and chromatographic analysis including HRMS, 2D NMR, and HPLC techniques. All of these epimers except gambogic acid (R-epimer which had been reported by American scientists using single crystal X-ray diffraction) were isolated and separated for the first time, and 30-hydroxygambogic acid and 30-hydroxyepigambogic acid were previously unknown compounds.
In another aspect of the present invention, both C-2 epimers (Epimers 1 and 2) of gambogic acid were examined for their cytotoxicities against human leukemia K562(K562/S) and doxorubicin-resistant K562 (K562/R) cell lines. Different from doxorubicin (IC50=10.78 for K562/R and 0.66 μM for K562/S), epimers 1 and 2 exhibited similar activities against both cell lines (IC50=1.32 and 0.89 μM for 1, IC50=1.11 and 0.86 μM for 2). These results indicated that both epimers were not multidrug resistance (MDR) substrates. Furthermore, epimers 1 and 2 (R-epimer and S-epimer, respectively) were tested for their inhibitory effects against six human cytochrome P-450 enzymes. Epimers 1 and 2 showed little inhibitory effects toward five of the enzymes except CYP2C9. Furthermore, when tested against CYP2C9, S-epimer had inhibitory effect 20 folds stronger than R-epimer.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 shows HPLC chromatograms of gambogic acid, the mixture of compound 1, the known R-epimer, and compound 2. Compounds 1 and 2 were identified as R- and S-epimers of gambogic acid in the present invention.
FIG. 2 shows 1 H (400 MHz) and 13 C (100 MHz) NMR spectra of compound 1 and compound 2 (in CDCl 3 , TMS as internal standard).
FIG. 3 shows a comparison among the cytotoxic activities of doxorubicin, compound 1, and compound 2 (μM).
DETAILED DESCRIPTION OF THE INVENTION
Example 1
R- and S-Epimers of Gambogic Acid
(A) Isolation and Identification
The resin (0.1 g) of Garcinia hanburyi was purchased from National Institute for the Control of Pharmaceutical and Biological Products (NICPBP), P. R. China. A voucher specimen (CMS-0283) is deposited in the Herbarium of Hong Kong Jockey Club Institute of Chinese Medicine, Hong Kong, China.
The resin (90 mg) was dissolved in 2 mL acetone, and loaded on the preparative HPLC system (Agilent 1100, Alltima C 18 , 10μ, 22×250 mm) to give GA. The mobile phase was MeOH/0.1% H 3 PO 4 (90:10). The flow rate was 1 mL/min. UV detection wavelength was set at UV 360 nm. After the isolation of GA with prep-HPLC, the GA fraction was condensed to remove most of CH 3 CN, and the condensed acidified solution was diluted with a large amount of water and loaded on a Sephadex LH-20 CC to remove the acid by eluting with H 2 O. The subsequent Me 2 CO elution was condensed to dry, and GA was obtained (35 mg). In the HPLC/ESIMS analysis, GA presented as one peak (m/z 628) on C 18 column (Alltima C 18 , 5μ, 4.6×250 mm) eluted with CH 3 CN/0.1% acetic acid (90:10). However, it presented as two completely separated peaks on C 8 column (Alltima C 8 , 5μ, 4.6×250 mm) eluted with CH 3 CN/0.1% acetic acid (75:25). These two peaks were isolated by HPLC under the same analytical condition with each injection of 20 μL acetone solution of GA (35 mg/mL), yielding 1 (12 mg) and 2 (10 mg). Gambogic acid (1): a bright yellow amorphous powder. [α] D 20 =−578° (c=0.201, CHCl 3 ). UV (MeOH): λ max =290 (log ε4.24), 360 (log ε4.18). IR (KBr): λ max =2970, 2928, 1736, 1690, 1632, 1593, 1435, 1331, 1177, 1138, 1049, 810, 671. ESIMS: m/z=628 (M + ); HRESIMS: m/z=obsd. 628.3046 [M] + , calcd. 628.3036. Epigambogic acid (2): a bright yellow amorphous powder. [α] D 20 =−486° (c=0.197, CHCl 3 ). UV (MeOH): λ max =290 (log ε4.24), 360 (log ε4.18). IR (KBr): λ max =2971, 2930, 1736, 1691, 1633, 1593, 1435, 1332, 1177, 1138, 1048, 810, 671. ESIMS: m/z=628 (M + ); HRESIMS: m/z=obsd. 628.3042 [M] + , calcd. 628.3036. Copies of the original spectra are obtainable from the author of correspondence.
Optical rotations were measured with a Jasco P-1010 Polarimeter. 1H-(400 MHz) and 13C-(100 MHz) NMR spectra were recorded on Brucker DRX-400 spectrometer using TMS as an internal standard. The LC/MS analysis was performed using an Agilent 1100 series combined with MICROMASS Q-TOF-2 spectrometer.
TABLE 1 1 H and 13 C NMR data of 1 and 2 a . 1 2 No. 1 H 13 C 1 H 13 C 2 81.27 s 81.13 s 3 5.35, d, 10.0 124.46 5.39, d, 10.0 124.81 d d 4 6.57, d, 10.0 115.88 6.57, d, 10.0 115.91 d d 5 102.72 102.91 s s 6 157.55 157.61 s s 6-OH 12.73 s 12.76 s 7 100.43 100.51 s s 8 178.86 178.92 s s 9 133.36 133.24 s s 10 7.53, d, 6.8 135.30 7.53, d, 6.8 135.50 d d 11 3.46, m 46.81 d 3.47, m 46.84 d 12 203.34 203.27 s s 13 83.81 s 83.68 s 14 90.93 s 90.96 s 16 157.35 157.33 s s 17 107.58 107.82 s s 18 161.48 161.37 s s 19 1.26, 3H, s 27.69 q 1.32, 3H, s 26.96 q 20 1.59, m 41.98 t 1.64, m 41.71 t 1.76, m 1.75, m 21 1.39, m 25.18 t 1.34, m 25.23 t 2.20, dd, 12.8, 2.28, dd, 12.8, 4.0 4.0 22 2.49, d, 9.2 49.01 d 2.50, d, 9.2 49.01 d 23 83.88 s 83.95 s 24 1.27, 3H, s 28.86 q 1.27, 3H, s 28.83 q 25 1.67, 3H, s 29.87 q 1.68, 3H, s 29.92 q 26 2.93-2.98, 2H, 29.27 t 2.80-3.00, 2H, m 29.29 t m 27 6.08, t, 7.0 138.17 6.09, t, 7.0 137.54 d d 28 127.64 127.87 s s 29 171.33 170.34 s s 30 1.71, 3H, s 20.73 q 1.73, 3H, s d 20.77 q 31 3.09, m 21.61 t 3.14, m 21.63 t 3.25, m 3.27, m 32 5.02, m 122.26 5.00, t, 7.0 122.22 d d 33 131.48 131.45 s s 34 1.69, 3H, s 18.07 q 1.72, 3H, s d 18.16 q 35 1.62, 3H, s b c 25.66 1.64 3H, s e f 25.72 q q 36 1.93-2.04, 2H, 22.74 t 1.97-2.18, 2H, m 22.76 t m 37 5.02, t, m 123.85 5.07, t, 7.0 123.83 d d 38 131.77 132.08 s s 39 1.52, 3H, s 17.62 q 1.56, 3H, s 17.62 q 40 1.60, 3H, s b c 25.65 1.62, 3H, s e f 25.65 q q a 1 H-NMR, 400 MHz; 13 C-NMR, 100 MHz; CDCl 3 (δ H 7.24, δ C 77.23); δ in ppm (J in Hz). b–d Exchangeable signals.
(B) Biological Effects
Both doxorubicin-resistant (K562/R) and -sensitive K562 (K562/S) cell sublines, purchased from Tianjin Instute of Hematopathy, the Chinese Academy of Medical Sciences, China, were cultured in PRMI1640 (Gibco, USA) medium and supplemented with 10 fetal bovine serums at 37° C. in a humidified incubator with 5% CO 2 . MTT assay was performed using a reported method [12]. Cell lines were seeded into 96-well plates at 6000 viable cells per well. The test chemicals (ADR, DMSO, Th1 and Th2) with different concentrations were loaded in a final volume of 200 μL per well. After 44 hours of incubation, MTT (5 g/L) was added to each well in a volume of 10 μl and incubated for 4 hours. Afterwards, the medium was removed and 200 μl of Me2SO (37° C.) was added and shaken for 5 minutes. A 96-well microtiter plate reader was used to determine absorbance values at 570 nm. Mean value of each concentration (n=3 wells) was obtained. Absorbance of untreated controls was taken as 100%. Survival rate was calculated as follows: Cell survival rate (%)=(T−B)/(U−B)×100%, T (treated) is absorbance of chemically treated cells, U (untreated) is the absorbance of untreated cells, and B (blank) is the absorbance when neither cells nor chemicals was added. Human liver tissue was obtained from au autopsy sample (male, aged 37) from Dalian Medical University, with the approval of the ethics committee of Dalian Medical University. HLM were prepared from liver tissue as described in the literature [13]. Protein concentrations of the microsomal fractions were determined by the Lowry method using bovine serum albumin as a standard. The inhibition effects of compounds were characterized using HLM toward six human cytochrome P-450 enzymes based on their probe reaction. Each incubation was performed in a 100 mM phosphate buffer at pH 7.4 containing human microsomal protein, 10 mM glucose 6-phosphate, 1 mM NADP + , 4 mM magnesium chloride, 1 unit/ml of glucose 6-phosphate dehydrogenase, and various probe substrates of CYPs and tested compounds (previously dissolved in methanol, whose final concentration was 1%, v/v) with a range of concentrations in a total volume of 400 μL. The selective inhibitors of each CYP isoform [Furafylline (1A2), 8-Methoxypsoralen (2A6), Sulphaphenazole (2C9), Quinidine (2D6), Clomethiazole (2E1), Ketoconazole (3A4)] were selected as the positive control. There was a 3 minutes preincubation step at 37° C. before the reaction was started by the addition of NADP + . After 10 min, the reactions were quenched by adding the same volume of CH 3 CN or MeOH and an internal standard. The incubation mixtures were then centrifuged for 10 minutes at 20,000×g. An aliquot of the supernatant was analyzed by HPLC. The HPLC system (SHIMADZU, Japan) consisted of an SCL-10A system controller, two LC-10AT pumps, a SIL-10A auto injector, a SPD-10AV UV detector or a RF-10A XL fluorescence detector. The supernatant was analyzed using a SHIMADZU C 18 column (4.6×150 mm, 5μ) at a flow rate of 1 mL/min. IC 50 values (concentration of inhibitor causing 50% inhibition of original enzyme activity) were calculated by Microsoft Excel software (Microsoft Inc, USA).
TABLE 2
The in vitro reaction and detection conditions for CYP-isoform bioassay.
Concentration
Concentration
of
of
Substrate
microsomes
Time
Internal
CYPs
Substrate
Reaction
(μM)
(mg/ml)
(min)
Standard
Detection of HPLC
1A2
Phenacetin
O-
40
0.2
30
7-
A (methanol):B(phosphate
deethy-
Hydroxy-
buffer, pH = 3.0, 50 mM) =
lation
coumarin
34:66, UV 245 nm
2A6
Coumarin
7-
1
0.1
10
—
A (acetonitrile):B water/acetic
hydroxy-
acid (70:0.1, v/v) = 30:70, Fluo
lation
Ex 340 nm, Em 456 nm
2C9
Diclofenac
4′-
10
0.3
10
Coumarin
A (acetonitrile):B (phosphate
hydroxy-
buffer, pH = 7.4, 100 mM) =
lation
32:68, 0-9 min, B 68%-32%, UV
280 nm
2D6
Dextrometh-
O-
25
0.3
20
—
A (acetonitrile):B (phosphate
orphan
demethyl-
buffer, pH = 3.0, 0.12%
ation
Triethylamine) = 25:75, Fluo Ex
235 nm, Em 310 nm
2E1
Chlorzoxazone
6-
120
0.4
30
Phenacetin
A (acetonitrile):B (0.5% acetic
hydroxy-
acid) = 22:60, 0-10 min, B 78%-
lation
40%
UV 287 nm
3A4
Testosterone
6β-
50
0.5
10
Corticosterone
A (methanol):B (water) = 52:48,
hydroxy-
0-15 min, B 48-30, 15-20
lation
min 30-20, UV 254 nm
Example 2
30-Hydroxygambogic Acid and 30-Hydroxyepigambogic Acid
(A) Isolation and Identification
Plant Materials: The resin of Garcinia hanburyi was purchased in Guangzhou, P. R. China. A voucher specimen (CMS-0283) was deposited in the Herbarium of Hong Kong Jockey Club Institute of Chinese Medicine, Hong Kong, China.
Extraction and Isolation: The resin (1 g) was dissolved in 10 mL acetone, and loaded on the preparative HPLC system (Agilent 1100, Alltima C 18 , 10μ, 22×250 mm) to give the mixture (40 mg, t R =8.5 min). The mobile phase was MeOH/0.1% H 3 PO 4 (90:10). The flow rate was 1 mL/min. UV detection wavelength was set at UV 360 nm. The isolated mixture was further loaded on C 8 column (Alltima C 8 , 5μ, 9.2×250 mm) eluted with CNCH 3 /0.1% acetic acid/50% 1,4-dioxan (65:25:10) to yield compound 1 (6 mg) and compound 2 (8 mg), which was subsequently identified as 30-hydroxygambogic acid and 30-hydroxyepigambogic acid, respectively.
1D and 2D NMR spectra: Brucker AM-400 and DRX-500 spectrometers; δ in ppm, J in Hz, Me 4 Si as internal standard, measured in C 5 D 5 N. MS spectra: VG Autospec-3000 spectrometer; m/z (rel. %). LC/MS analysis was performed using an Agilent 1100 series combined with MICROMASS Q-TOF-2 spectrometer.
30-hydroxygambogic acid (1): A yellow amorphous powder with little sublimability. [α] D 28.0 =−500.64° (c=0.314, CHCl 3 ). Positive ESI-MS: 645 [M+H]+; positive HRESIMS: 645.3059 (C 38 H 45 O 9 ; calc. 645.3063). 1 H-NMR (CDCl 3 , 400 MHz) and 13 C-NMR (CDCl 3 , 100 MHz): see Table 3.
30-hydroxyepigambogic acid (2): A yellowish amorphous powder with a little sublimability. [α] D 28.0 =−405.57° (c=0.288, CHCl 3 ). Positive ESI-MS: 645 [M+H] + ; positive HRESIMS: 645.3054 (C 38 H 45 O 9 ; calc. 645.3063). 1 H-NMR (CDCl 3 , 400 MHz) and 13 C-NMR (CDCl 3 , 100 MHz): see Table 3.
TABLE 3 1 H-(400 mhz) and/or 13 C-(100 mhz) NMR Data of 30-Hydroxygambogic Acid and 30-Hydroxyepigambogic Acid 1 2 HMBC HMBC δ H δ C (position) δ H δ C (position) C (2) 81.4 3, 4, 19, 20, 36 81.3 4, 19, 20, 36 CH (3) 5.36 (d, J = 10.0) 124.7 4, 19, 20 5.44 (d, J = 10.0) 125.0 4, 19, 20 CH (4) 6.57 (d, J = 10.0) 115.7 3 6.62 (d, J = 10.0) 115.8 3 C (5) 102.8 3, 4 103.0 3, 4 C (6) 157.4 4 157.5 4 C (7) 100.5 100.5 C (8) 179.0 10 179.1 10 C (9) 133.2 10, 11 133.1 10, 11 CH (10) 7.53 (d, J = 6.8) 135.8 11, 21 7.56 (d, J = 6.8) 135.8 11, 21 CH (11) 3.48 (m) 46.8 10, 21, 22 3.49 (m) 46.9 10, 21, 22 C (12) 203.2 10, 11, 26 203.1 10, 11, 26 C (13) 83.7 11, 21, 26, 83.6 11, 21, 26 27 27 C (14) 90.9 10, 26 90.9 10, 26 157.3 157.3 C (16) 157.3 31 157.4 31 C (17) 107.7 31, 32 108.0 31, 32 C (18) 161.6 4, 31 161.5 4, 31 Me—C (19) 1.36 (s, 3H) 27.7 3, 20 1.35 (s, 3H) 27.6 3, 20 CH 2 (20) 1.57, 1.74 (m, 41.9 3, 19, 36, 1.57, 1.74 (m, 41.7 3, 19, 36, each 1H) 37 each 1H) 37 CH 2 (21) 2.34, 1.40 (m, 25.1 10, 11, 22 2.34, 1.40 (m, 25.1 10, 11, 22 each 1H) each 1H) CH (22) 2.52 (d, J = 48.9 11, 21, 24, 2.53 (d, J = 48.9 11, 21, 24 9.2) 25 9.2) 25 C (23) 84.1 21, 22, 24, 84.1 21, 24, 25 25 Me—C (24) 1.24 (s, 3H) 28.8 22, 25 1.29 (s, 3H) 28.8 22, 25 Me—C (25) 1.67 (s, 3H) 29.9 22, 24 1.70 (s, 3H) 29.9 22, 24 CH 2 (26) 3.00 (d, J = 29.1 27 2.98 (d, J = 29.1 27 6.8, 2H) 6.8, 2H) CH (27) 6.39 (t, J = 140.5 26, 30 6.39 (t, J = 140.5 26, 30 7.6) 7.6) C (28) 131.0 26, 27, 30 131.2 26, 27, 30 C (29) 169.9 27, 30 169.9 27, 30 CH 2 (30) 4.09, 4.01 (d, 64.7 27 4.13, 4.04 (d, 64.7 27 J = 13.2) J = 13.2) CH 2 (31) 3.27, 3.14 (m, 21.6 32 3.30, 3.16 (m, 21.6 32 each 1H) each 1H) CH (32) 5.01 (t, J = 122.0 31, 34, 35 5.04 (t, J = 122.0 31, 34, 35 7.6) 7.6) C (33) 131.8 31, 32, 34, 35 131.7 31, 32, 34 35 Me—C (34) 1.70 (s, 3H) 18.1 32, 25 1.74 (s, 3H) 18.2 32, 25 Me—C (35) 1.61 (s, 3H) 25.6 32, 34 1.64 (s, 3H) 25.7 32, 34 CH 2 (36) 2.00 (m, 2H) 22.7 20, 37 2.08 (m, 2H) 22.5 20, 37 CH (37) 5.01 (t, J = 123.7 20, 36, 39, 5.10 (t, J = 123.7 20, 36, 39 7.6) 40 7.6) 40 C (38) 131.8 36, 37, 39 132.3 36, 37, 39 40 40 Me—C (39) 1.52 (s, 3H) 17.6 37, 40 1.59 (s, 3H) 17.6 37, 40 Me—C (40) 1.62 (s, 3H) 25.6 37, 39 1.67 (s, 3H) 25.7 37, 39 OH—C (6) 12.74 (s) 12.77 (s)
(B) Biological Effects
Cytotoxicity Assay: Both epimers were tested for their cytotoxicities against human leukemia K562 (K562/S) and doxorubicin-resistant K562 (K562/R) cell lines, using the SRB method previously described with doxorubicin being the positive control. The OD data were recorded in X±S, and the IC 50 values were calculated with sigmoidal plot. The result is presented in Table 4.
TABLE 4
Cytotoxicities (IC 50 , μM) of GA derivatives against K562 cell lines
Doxorubicin a
Gambogic acid a
Epigambogic acid a
Doxorubicin
1
2
K562/R
10.78
1.32
1.11
1.79 ± 0.17
2.89 ± 0.35
4.49 ± 0.31
K562/S
0.66
0.89
0.86
0.11 ± 0.01
1.27 ± 0.15
3.61 ± 0.17
Example 3
Isogambogic Acid and Isoepigambogic Acid
This pair of epimers was isolated in the same way as above described. Specifically, the resin (90 mg) was dissolved in 2 mL acetone, and loaded on the preparative HPLC system (Agilent 1100, Alltima C 18 , 10μ, 22×250 mm) to give GA. The mobile phase was MeOH/0.1% H 3 PO 4 (90:10). The flow rate was 1 mL/min. UV detection wavelength was set at UV 360 nm. After the isolation with prep-HPLC, the fraction (isogambogic acid and epiisogambogic acid) was condensed to remove most of CH 3 CN, and the condensed acidified solution was diluted with a large amount of water and loaded on a Sephadex LH-20 CC to remove the acid by eluting with H 2 O. The subsequent Me 2 CO elution was condensed to dry, and the mixture of isogambogic acid and epiisogambogic acid was obtained (35 mg). In the HPLC/ESIMS analysis, the mixture presented as one peak (m/z 628) on C 18 column (Alltima C 18 , 5μ, 4.6×250 mm) eluted with CH 3 CN/0.1% acetic acid (90:10). However, two completely separated peaks appeared with C 8 column (Alltima C 8 , 5μ, 4.6×250 mm) eluted with CH 3 CN/0.1% acetic acid (75:25). These two peaks, which were subsequently identified as isogambogic acid and epiisogambogic acid, respectively, were isolated by HPLC under the same analytical condition with each injection of 20 μL acetone solution of the mixture.
Isogambogic acid (1) obtained was a bright yellow amorphous powder. [α] D 20 =−660° (c=0.321, CHCl 3 ). ESIMS: m/z=629 ([M+H] + ); (+)FABMS: m/z=629 ([M+H] + ); HRESIMS: m/z=obsd. 629.3133 [M+H] + , calcd. 629.3114. Epiisogambogic acid (2) was also a bright yellow amorphous powder. [α] D 20 =−587° (c=0.261, CHCl 3 ). ESIMS: m/z=629 ([M+H] + ); (+)FABMS: m/z=629 ([M+H] + ); HRESIMS: m/z=obsd. 629.3101 [M+H] + , calcd. 629.3114. More analytic data are shown in the following table 5:
TABLE 3 1 H- (400 mhz) and/Or 13 C- (100 mhz) NMR Data of Isogambogic Acid and Epiisogambogic Acid Isogambogic acid Epiisogambogic acid No. 1 H 13 C 1 H 13 C 2 81.43 s 81.27 s 3 5.43, d, 10.0 124.87 5.44, d, 10.0 124.79 d d 4 6.65, d, 10.0 116.03 6.66, d, 10.0 115.97 d d 5 102.89 102.91 s s 6 157.71 157.60 s s 6-OH 12.75 s 12.74 s 7 100.47 100.46 s s 8 178.90 178.85 s s 9 133.44 133.39 s s 10 7.54, d, 7.2 135.40 d 7.53, d, 6.8 135.50 d 11 3.49, m 46.95 d 3.49, m 46.94 d 12 203.13 202.99 s s 13 b 83.74 s e 83.61 s 14 90.80 s 90.60 s 16 157.43 157.34 s s 17 108.00 107.88 s s 18 161.52 161.29 s s 19 1.38, 3H, s 27.61 q 1.37, 3H, s 27.34 q 20 1.61, m 41.98 t 1.60, m 41.87 t 1.78, m 1.80, m 21 1.40, m 25.18 t 1.34, m 25.47 t 2.31, dd, 2.32, dd, 12.8, 12.8, 4.0 4.0 22 2.52, d, 9.2 49.01 d 2.52, d, 9.2 49.02 d 23 b 83.85 s e 83.67 s 24 1.28, 3H, s 29.03 q 1.27, 3H, s 29.05 q 25 1.70, 3H, s 30.02 q 1.70, 3H, s 30.02 q 26 2.64, m 29.03 t 2.60-2.62, 29.05 t 2.55, m 2H, m 27 6.63, t, 7.2 137.15 d 6.51, t, 7.0 136.79 d 28 128.62 s 128.86 s 29 171.82 s 171.47 s 30 1.34, 3H, s 11.48 q 1.35, 3H, s 11.39 q 31 3.23-3.26, 21.71 t 3.26-3.28, 21.64 t 2H, m 2H, m 32 5.09, t, 7.0 122.24 d 5.12, t, 7.0 122.10 d 33 c 131.87 f 131.76 s s 34 1.71, 3H, s 18.19 q 1.73, 3H, s 18.17 q 35 1.63, 3H, s d 25.74 q 1.64, 3H, s g 25.74 q 36 2.00-2.05, 22.86 t 2.03-2.09, 22.75 t 2H, m 2H, m 37 5.04, t, 7.0 123.91 d 5.06, t, 7.0 123.75 d 38 c 131.93 f 131.96 s s 39 1.53, 3H, s 17.71 q 1.55, 3H, s 17.63 q 40 1.63, 3H, s d 25.66 1.64, 3H, s g 25.66 q q a 1 H-NmR, 400 MHz; 13 C-NMR, 100 MHz; CDCl 3 (δ H 7.24, δ C 77.23); δ in ppm (J in Hz). b~g Exchangeable signals.
Manufacturing Pharmaceutical Compositions Containing Individual Epimers:
As shown in the foregoing, three pairs of epimers were isolated from the herb were separated from the herb gamboges, and were separated from each other. The biological assays showed that each epimer may have useful effects in treating diseases. It is contemplated, as people with ordinary skill in the art would do, that the newly separated compounds may be each individually or in combination used as an ingredient to prepare a pharmaceutical composition for a particular treatment purpose. As it is the status of the art in the pharmaceutical industry, once substantially pure preparations of a compound are obtained, various pharmaceutical compositions or formulations can be prepared from the substantially pure compound using conventional processes or future developed processes in the industry. Specific processes of making pharmaceutical formulations and dosage forms (including, but not limited to, tablet, capsule, injection, syrup) from chemical compounds are not part of the invention and people of ordinary skill in the art of the pharmaceutical industry are capable of applying one or more processes established in the industry to the practice of the present invention. Alternatively, people of ordinary skill in the art may modify the existing conventional processes to better suit the compounds of the present invention. For example, the patent or patent application databases provided at USPTO official website contain rich resources concerning making pharmaceutical formulations and products from effective chemical compounds. Another useful source of information is Handbook of Pharmaceutical Manufacturing Formulations, edited by Sarfaraz K. Niazi and sold by Culinary & Hospitality Industry Publications Services.
It is further contemplated that the novel compounds of the present invention may be modified in various ways which are known in the art. Therefore the compounds of the present invention encompass all the compounds which are obvious derivatives of the specific compounds disclosed herewith.
The term “pharmaceutical carrier” means an ingredient contained in a drug formulation that is not a medicinally active constituent. The term “an effective amount” refers to the amount that is sufficient to elicit a therapeutic effect on the treated subject. Effective doses will vary, as recognized by those skilled in the art, depending on the types of diseases treated, route of administration, excipient usage, and the possibility of co-usage with other therapeutic treatment. A person skilled in the art may determine an effective amount under a particular situation.
A “pharmaceutically acceptable carrier” is determined in part by the particular composition being administered and in part by the particular method used to administer the composition. A wide variety of conventional carrier may be suitable for pharmaceutical compositions of the present invention and can be selected by people with ordinary skill in the art.
While there have been described and pointed out fundamental novel features of the invention as applied to a preferred embodiment thereof, it will be understood that various omissions and substitutions and changes, in the form and details of the embodiments illustrated, may be made by those skilled in the art without departing from the spirit of the invention. The invention is not limited by the embodiments described above which are presented as examples only but can be modified in various ways within the scope of protection defined by the appended patent claims.
REFERENCES
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13 Sanderink G J, Bournique B, Stevens J, Petry M, Martinet M. Involvement of human CYP1A isoenzymes in the metabolism and drug interactions of riluzole in vitro. J Pharm Exper Therap 1997; 282: 1465-72 | Three pairs of C-2 epimeric xanthones isolated from Garcinia hanburyi and method for efficiently separating the xanthone compounds into individual epimers, each of which possesses varying biological effects. The compounds are useful for their anticancer effects, particularly because they are shown to be non-substrates of the multidrug-resistance transporter. Some of the epimers have significant inhibitory effects on cytochrome P450 systems. The xanthone compounds of the present invention are gambogic acid, epigambogic acid, isogambogic acid, isoepigambogic acid, 30-hydroxygambogic acid and 30-hydroxyepigambogic acid. | 2 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims the benefit of prior U.S. Provisional Application No. 61/003,748, filed Nov. 20, 2007.
FIELD OF THE INVENTION
[0002] The present invention relates generally to self-standing riser systems used during energy exploration and production, and in a particular though non-limiting embodiment, to a system useful for deploying self-standing risers and associated buoyancy devices in a variety of operating conditions.
BACKGROUND OF THE INVENTION
[0003] Over the past decade, there has been an increasing worldwide demand for oil and gas production. At present, however, oil and gas supply continues to lag far behind demand, a situation which has at times contributed significantly to worldwide economic difficulties and could well present a major concern for many years to come.
[0004] In an effort to balance supply and demand, companies and governmental entities have begun to explore and develop relatively marginal fields in the deeper offshore waters of the Gulf of Mexico, West Africa and Brazil. However, due to high construction costs and limited manufacturing facilities, only a small number of mobile offshore drilling units (MODUs) are being manufactured each year, thereby resulting in escalating “per day” unit costs and a shortage of associated offshore drilling, completion and workover equipment.
[0005] Moreover, even though the cost differential between drilling operations and completion or workover operations is relatively modest (since MODUs usually perform all of these functions during a typical operation), most such projects are still inefficient, because a MODU actively performing one function (e.g., drilling) is generally not able to accomplish any other functions (e.g., completion or workover).
[0006] In other applications by this inventor, it has been shown that a self-standing riser system can be safely and reliably installed in communication with a well head or production tree. Such risers by design are self-supporting, and provide all of the necessary risers, casing, buoyancy chambers, etc., required for exploration and production and of oil, gas and other hydrocarbons. Self-standing risers also provide the requisite safety features required to ensure that the produced hydrocarbons do not escape from the system out into surrounding waters. For example, self-standing riser systems fully support both surface-based and semi-submersible platform interfaces, blow-out preventers, production trees, and other common exploration and production installations.
[0007] Known self-standing riser systems require either a number of different surface vessels or a MODU for installation, due to the size and weight of riser stacks, drilling pipe, buoyancy devices, etc. For many installations, expensive hull and deck modifications also have to be made. Accordingly, few improvements in associated per-day costs have been realized.
[0008] There is, therefore, a need for a more cost-effective method of installing self-standing riser systems, which does not require the use of MODUs.
SUMMARY OF THE INVENTION
[0009] A water-borne vessel for deploying a self-standing riser system is provided, wherein the vessel hull is configured to receive, transfer and deploy components of a self-standing riser system. The vessel hull includes at least a landing platform, a component transfer means, and a deployment platform suitable for deploying the riser components into associated surrounding waters. Various means of assisting the process whereby self-standing riser components are loaded onto the vessel and stored; transferred from receiving to deployment platforms; and deployed from the vessel into surrounding waters are also considered.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1A is a side view of a self-standing riser deployment vessel, according to example embodiments.
[0011] FIG. 1B is a schematic diagram depicting the submersion of a self-standing riser system, according to example embodiments.
[0012] FIG. 1C is a schematic diagram of a deployment vessel positioning a completed self-standing riser system, according to example embodiments.
[0013] FIG. 1D is a schematic diagram of a deployment vessel releasing from a completed self-standing riser system, according to example embodiments
[0014] FIG. 2A is a side view of a self-standing riser system deployment vessel, according to example embodiments.
[0015] FIG. 2B is top view of a self-standing riser system vessel equipped with a buoyancy device loading bay, according to example embodiments.
[0016] FIG. 2C is a schematic diagram depicting a buoyancy device being lowered into a buoyancy device loading bay, according to example embodiments.
[0017] FIG. 2D is a schematic diagram of a deployment vessel beginning its release of a deployed buoyancy device stack, according to example embodiments.
[0018] FIG. 2E is a schematic of a deployment vessel having released its load, and leaving the site prior to commencement of drilling operations.
DETAILED DESCRIPTION
[0019] The description that follows includes exemplary systems, methods, and techniques that embody various aspects of the presently inventive subject matter. However, it will be readily understood by those of skill in the pertinent arts that the described embodiments may be practiced without one or more of these specific details. In other instances, well-known manufacturing equipment, protocols, structures and techniques have not been shown in detail in order to avoid obfuscation in the description.
[0020] Referring now to FIG. 1A , an example embodiment of a self-standing riser deployment vessel 6 is depicted, comprising a plurality of buoyancy devices 2 temporarily attached to the bottom of the hull. In exemplary embodiments, deployment vessel 6 is a workboat, anchor handling boat, or any other available vessel of suitable size and configuration; the lengths of such vessels might range, for example, from around 150 ft. to around 300 ft., though these size estimates should not be deemed as limitative.
[0021] Other embodiments of deployment vessel 6 comprise enough deck and storage space to carry associated riser tubing 4 , and additional buoyancy devices 2 . Still further embodiments employ dynamic positioning equipment (e.g., a spar), which facilitate efficient and reliable riser stack deployment and installation on the sea floor.
[0022] In one embodiment, an entire string of risers is assembled with one or more buoyancy devices interspersed as needed in order to provide sufficient buoyancy for the entire system. The string is then deployed as a continuous structure and lowered to the sea floor in a controlled manner. The top of the string is then secured and lifted so that it can be moved over the drilling site and attached to the well. In other embodiments, the system is deployed in a piecemeal fashion, with sections of a desired length being individually deployed and mechanically joined as the assembly is completed.
[0023] In the example embodiment illustrated in FIG. 1A , deployment vessel 6 further comprises a hoisting frame 3 disposed near a moon pool 5 . The hoisting frame permits riser 4 stored within the vessel to be loaded and lowered or held in position. In various embodiments, the lowering, raising and holding of riser 4 is facilitated using conveyor belts, chains, rollers, etc. In one example embodiment, riser 4 is transferred from a storage container towards the moon pool 5 using a conveyor belt, and subsequently connected to a fastening device affixed to hoisting frame 3 . The riser can then be deployed or held in a desired position in a safe and reliable manner.
[0024] Consistent with the example deployment vessel 6 illustrated in FIG. 1A , further embodiments also comprise loading mechanisms (e.g., frames, rails, etc.) used to load, guide and control the buoyancy devices 2 . FIG. 1A , for example, depicts two buoyancy devices 2 disposed in mechanical communication with the bottom of the hull of the deployment vessel 6 . The buoyancy devices 2 are affixed to a carrying frame 1 configured to reliably accommodate large, heavy loads. Carrying frame requirements will vary by project, but each such device should, at minimum, be capable of supporting the weight of one or more buoyancy devices. Electric, hydraulic or pneumatic lifts can be used to raise and lower the buoyancy devices, and ropes, chains, and tension lines reeled out from strategically placed winches can assist in the fine control necessary to ensure safe and controlled deployment of the buoyancy devices.
[0025] In some embodiments, each of said buoyancy devices 2 further comprises a connector 14 (i.e., a flange or receptive housing, etc.) that allows for attachment of additional buoyancy devices 2 or riser assemblies 4 .
[0026] In the example embodiment depicted in FIG. 1B , each of the buoyancy devices further admit to the passing of riser 4 through a void space in the buoyancy devices by means of a hoisting frame 3 , so that the riser 4 can subsequently be attached to a subsurface wellhead 8 installed atop a well bore 9 . A flanged member 18 can be used to help capture descending riser and assist in connection of the riser to the wellhead.
[0027] In the example embodiment illustrated in FIG. 1C , deployment vessel 6 is used to lower a fully assembled self-standing riser system into position for attachment with wellhead 8 . Guide frame 1 assists in the controlled deployment of the riser near the surface, and a flanged member 14 assists in capture of the lowered riser. In other embodiments, deployment vessel 6 utilizes dynamic positioning equipment (or alternatively, light equipment such as ropes, chains, winch lines, etc.) to lower, raise and support the riser stack as it is position above the wellhead. Further embodiments utilize buoyancy devices to tension the stack as deployment is carried out, and to dynamically position the riser between the vessel and the well.
[0028] As seen in FIG. 1D , once the self-standing riser system is deployed and attached to the well, the surface vessel releases its hold and the vessel can be used for other operations on a cost-effective basis. In some embodiments, the vessel deploys the self-standing riser and leaves the site so that other vessels (e.g., vessels with testing packages, separators, or even MODUs when one becomes available) can interface with the system and initiate completion, testing or workover operations.
[0029] Referring now to FIG. 2A , a side view of a deployment vessel is illustrated, comprising a plurality of buoyancy devices 2 and a reliable means for deployment thereof. Some embodiments comprise one or more of a loading crane, a hoisting frame, buoyancy device transmission and positioning means 5 , etc., disposed near a moon pool.
[0030] As seen in FIG. 2B , it may be convenient that the moon pool is formed at the aft end of the vessel. In an especially novel approach, the aft end is open, and the moon pool has only three sides 6 , so that greater flexibility in position is achieved. In still further embodiments, the buoyancy devices 2 are loaded onto the deployment vessel from a neighboring service vessel, whereafter operations are carried out as described above.
[0031] In the example embodiment depicted in FIG. 2A , a plurality of buoyancy devices 2 are loaded onto the deployment vessel from a neighboring vessel, positioned for deployment from the deployment vessel by a transmission means 5 , and then deployed into a body of water in a safe and controlled fashion that ensures efficient operations and maintenance of the buoyancy devices' structural integrity.
[0032] In some embodiments, a neighboring crane is used to lower the buoyancy devices onto a deployment vessel landing platform, as depicted in FIG. 2A . The landing platform can be either flooded (in the event the devices are intended for immediate deployment), or dry (in the deployment is intended for a later time, or if access is needed so as to permit outfitting or maintenance). If the landing platform is dry, intake ports are provided so that it can later be flooded, allowing easier transportation and deployment of the devices at or near the drilling site (see, for example, FIG. 2C ). Such embodiments would likely utilize winches, fastening mechanisms, etc., to secure and facilitate safe and reliable control of the devices. The deployment vessel can then transport and deploy the devices as described above.
[0033] In the example embodiment depicted in FIG. 2C , a barge or other transport vessel is used to transfer additional buoyancy devices to the landing platform of a deployment vessel by means of a rope, chain, winch line, etc. In one particular embodiment, the buoyancy devices are moved via roller tracks toward an overhead gantry, hoisted by a crane or other hoisting device, and lowered into the deployment pool.
[0034] In the example embodiment depicted in FIG. 2D , the buoyancy devices have been landed from a service vessel and lowered into the water. The devices are then towed in by a second deployment vessel and attached to its hull via winches, hooks, fastening mechanisms, etc., disposed in mechanical communication with the second deployment vessel. In FIG. 2E , the second deployment vessel has captured and secured the devices, and the service vessel has released its line. The service vessel can then repeat the process until the desired number of buoyancy devices has been transferred to a desired number of deployment vessels.
[0035] The foregoing specification is provided for illustrative purposes only, and is not intended to describe all possible aspects of the present invention. Moreover, while the invention has been shown and described in detail with respect to several exemplary embodiments, those of ordinary skill in the art will appreciate that minor changes to the description, and various other modifications, omissions and additions may also be made without departing from the spirit or scope thereof. | A water-borne vessel for deploying a self-standing riser system is provided, wherein the vessel hull is configured to receive, transfer and deploy components of a self-standing riser system. The vessel hull includes at least a landing platform, a component transfer means, and a deployment platform suitable for deploying the riser components into associated surrounding waters. Various means of assisting the process whereby self-standing riser components are loaded onto the vessel and stored; transferred from receiving to deployment platforms; and deployed from the vessel into surrounding waters are also considered. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
The present invention is related to U.S. patent application Ser. No. 08/868,426 filed Jun. 3, 1997, entitled "Continuous Tone Microfluidic Printing" to DeBoer, Fassler, and Wen; U.S. patent application Ser. No. 08/868,416 filed Jun. 3, 1997 entitled "Microfluidic Printing on Receiver", to DeBoer, Fassler, and Wen; U.S. patent application Ser. No. 08/868,102 filed Jun. 3, 1997 entitled "Microfluidic Printing with Ink Volume Control" to Wen, DeBoer, and Fassler; U.S. patent application Ser. No. 08/868,477 filed Jun. 3, 1997 entitled "Microfluidic Printing with Ink Flow Regulation" to Wen, Fassler, and DeBoer, all assigned to the assignee of the present invention. The disclosure of these related applications is incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates to printing high quality images by microfluidic pumping of colored inks onto a receiver.
BACKGROUND OF THE INVENTION
Microfluidic pumping and dispensing of liquid chemical reagents is the subject of three U.S. Pat. Nos. 5,585,069, 5,593,838, and 5,603,351, all assigned to the David Sarnoff Research Center, Inc. The system uses an array of micron sized reservoirs, with connecting microchannels and reaction cells etched into a substrate. Microfluidic pumps comprising electrically activated electrodes within the capillary microchannels provide the propulsive forces to move the liquid reagents within the system. The microfluidic pump, which is also known as an electroosmotic pump, has been disclosed by Dasgupta et al., see "Electroosmosis: A Reliable Fluid Propulsion System for Flow Injection Analyses", Anal. Chem. 66, pp 1792-1798 (1994). The chemical reagent solutions are pumped from a reservoir, mixed in controlled amounts, and them pumped into a bottom array of reaction cells. The array may be decoupled from the assembly and removed for incubation or analysis. When used as a printing device, the chemical reagent solutions are replaced by dispersions of cyan, magenta, and yellow pigment, and the array of reaction cells may be considered a viewable display of picture elements, or pixels, comprising mixtures of pigments having the hue of the pixel in the original scene. When contacted with paper, the capillary force of the paper fibers pulls the dye from the cells and holds it in the paper, thus producing a paper print, or photograph, of the original scene. One problem with this kind of printer is the control of the liquid inks. If the printer is held upside down, gravitational forces may cause the inks to flow and bleed together, destroying the integrity of the printed image. If the printer is moved during the printing operation, acceleration forces may make one side of the printed image darker than the other.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a compact, low powered printer which could rapidly print a high quality image without artifacts caused by changes in the printer position or orientation or acceleration.
These objects are achieved by a microfluidic printing apparatus comprising:
a) at least one ink reservoir;
b) a structure defining a plurality of chambers arranged so that the chambers form an array with each chamber being arranged to form an ink pixel;
c) a plurality of microchannels connecting the reservoir to a chamber;
d) a plurality of microfluidic pumps each being associated with a single microchannel for supplying ink from an ink reservoir through a microchannel for delivery to a particular chamber;
e) means for providing an electrical signal representing the orientation of the printing apparatus; and
f) control means responsive to the electrical signal and for controlling the microfluidic pumps for causing an array of pixels to be printed when the microfluidic pumps supply ink through the microchannels to the chambers so that the correct amount of ink is delivered into each chamber.
ADVANTAGES
An advantage of the present invention is the provision of high quality ink images, regardless of changes in microfluidic printing apparatus position or orientation.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial schematic view showing an apparatus for pumping, mixing and printing pixels of ink onto a reflective receiver;
FIG. 2 is a top view of the pattern of the color pixels described in the present invention;
FIG. 3 is a top view of a second pattern of the color pixels described in the present invention;
FIG. 4 is a cross-sectional view taken along the lines 4--4 of the microfluidic printing apparatus in FIG. 3;
FIG. 5 is another cross-sectional view taken along the lines 5--5 of the microfluidic printing apparatus in FIG. 3;
FIG. 6 is an enlarged view of the circled portion of FIG. 4;
FIG. 7 is a top view of the micronozzles shown in FIG. 6;
FIG. 8 is a top view of the microchannel and showing conducting circuit connections in FIG. 6; and
FIGS. 9A, 9B, 9C, and 9D are schematic diagrams of an embodiment of this invention shown in different operating orientations.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is described in relation to a microfluidic printing apparatus which can print computer generated images, graphic images, line art, text images and the like, as well as continuous tone images.
Referring to FIG. 1, a schematic diagram is shown of a printing apparatus 8 in accordance with the present invention. Reservoirs 10, 20, 30, and 40 are respectively provided for holding colorless ink, cyan ink, magenta ink, and yellow ink. An optional reservoir 80 is shown for black ink. Microchannel capillaries 50 respectively connected to each of the reservoirs conduct ink from the corresponding reservoir to an array of ink mixing chambers 60. In the present invention, the ink mixing chambers 60 delivery the inks directly to a receiver; however, other types of ink delivery arrangements can be used such as microfluidic channels, and so when the word chamber is used, it will be understood to include those arrangements. The colored inks are delivered to ink mixing chambers 60 by microfluidic pumps 70. The amount of each color ink is controlled by microcomputer 110 according to the input digital image. For clarity of illustration, only one set of microfluidic pumps is shown for the colorless ink channel. Similar pumps are used for the other color channels, but these are omitted from the figure for clarity. Finally, a reflective receiver 100 is transported by a transport mechanism 115 to come in contact with the microfluidic printing apparatus. The receiver 100 receives the ink and thereby produces the print. Receivers may include common bond paper, made from wood fibers, as well as synthetic papers made from polymeric fibers. In addition receiver can be of non-fibrous construction, provided they absorb and hold the ink used in the printer.
FIG. 2 depicts a top view of an arrangement of mixing chambers 60 shown in FIG. 1. Each ink mixing chamber 60 is capable of producing a mixed ink having any color saturation, hue and lightness within the color gamut provided by the set of cyan, magenta, yellow, and colorless inks used in the apparatus.
The inks used in this invention are dispersions of colorants in common solvents. Examples of such inks may be found is U.S. Pat. No. 5,611,847 by Gustina, Santilli and Bugner. Inks may also be found in the following commonly assigned U.S. patent application Ser. No. 08/699,955 filed Aug. 20, 1996; Ser. No. 08/699,962 filed Aug. 20, 1996; and Ser. No. 08/699,963 filed Aug. 20, 1996 by McInerney, Oldfield, Bugner, Bermel and Santilli; and in U.S. patent application Ser. No. 08/790,131 filed Jan. 29, 1997 by Bishop, Simons and Brick; and in U.S. patent application Ser. No. 08/764,379 filed Dec. 13, 1996 by Martin. In a preferred embodiment of the invention the solvent is water. Colorants such as the Ciba Geigy Unisperse Rubine 4BA-PA, Unisperse Yellow RT-PA, and Unisperse Blue GT-PA are also preferred embodiments of the invention. The colorless ink of this invention is the solvent for the colored inks in the most preferred embodiment of the invention.
The microchannel capillaries, ink pixel mixing chambers and microfluidic pumps are more fully described in the references listed above.
FIG. 3 illustrates the arrangement of a second pattern of color pixels in the present invention. The ink mixing chambers 60 are divided into four groups cyan ink orifice 200; magenta ink orifice 202; yellow ink orifice 204; and black ink orifice 206. Each chamber is connected only to the respective colored ink reservoir and to the colorless ink reservoir 10. For example, the cyan ink orifice 200 is connected to the cyan ink reservoir and the colorless ink reservoir so that cyan inks can be mixed to any desired lightness. When the inks are transferred to the reflective receiver 100 some of the inks can mix and blend on the receiver. Inasmuch as the inks are in distinct areas on the receiver, the size of the printed pixels should be selected to be small enough so that the human eye will integrate the color and the appearance of the image will be that of a continuous tone photographic quality image.
Cross-sections of the color pixel arrangement shown in FIG. 3 are illustrated in FIG. 4 and FIG. 5. The colored ink supplies 300, 302, 304, and 306 are fabricated in channels parallel to the printer front plate 120. The cyan, magenta, yellow and black inks are respectively delivered by colored ink supplies 300, 302, 304, and 306 into each of the colored ink mixing chambers.
A detailed view of the cross-section in FIG. 4 is illustrated in FIG. 6. The colored inks are delivered to the ink mixing chambers respectively by cyan, magenta, yellow, and black ink microchannels 400, 402, 404, and 406. Microchannels 404 and 406 are not shown in FIG. 6, but are illustrated in FIG. 8. The colored ink microchannels 400, 402, 404, and 406 are respectively connected to the colored ink supplies 300, 302, 304, and 306 (FIGS. 4 and 5). The colorless ink is supplied to the ink mixing chamber, but is not shown in FIG. 6 for clarity of illustration.
A cross-section view of the plane containing the micronozzles in FIG. 6 is shown in FIG. 7. The cyan, magenta, yellow, and black ink micronozzles 600, 602, 604, and 606 are distributed in the same arrangement as the colored ink micro channels 300-304 and the colored ink mixing chambers 200-206. The column electrodes 650 are shown connected to the conducting circuit 550, which is further connected to microcomputer 110.
A cross-section view of the plane containing the microchannels in FIG. 6 is shown in FIG. 8. The color ink channels 400-406 are laid out in the spatial arrangement that corresponds to those in FIGS. 3 and 7. The lower electrodes in the microfluidic pumps for delivering the colored inks are not shown for clarity of illustration. The row electrodes 670 are connected to lower electrodes of the microfluidic pumps. The row electrodes 670 are shown connected to the conducting circuit 500, which is further connected to microcomputer 110.
FIGS. 9A, 9B, 9C, and 9D are diagrams of an embodiment of this invention shown in different orientations. High quality reproduction of digital images requires uniform printing performance across the printer front plate 120. There should be minimal variation in the pumping efficiencies of the microfluidic pumps (not shown) which deliver the ink to the colorant delivery chambers 60 in the printer front plate 120. An important factor that effects the pumping efficiency of an microfluidic pump is the hydrostatic pressure and forces acting on the colorant fluid in the microfluidic pump. The variability of hydrostatic pressure or acceleration forces caused by the moving printer need therefore to be properly controlled.
The operation of the microfluidic printer 8 includes the steps of activating the microfluidic pumps 70 to pump the correct amount of each color ink to the mixing chambers 60 to provide a pixel of the correct hue and intensity corresponding to the pixel of the scene being printed. A receiver 100 is then contacted to the ink mixing chambers 60 and capillary or absorption forces draw the ink from the mixing chambers to the receiver 100. The receiver is then removed from contact with the mixing chambers and allowed to dry. Timing of the removal of the receiver is critical to prevent excess ink to be drawn from the microchannels 400, 402, 404, and 406 that feed the ink mixing chambers 60.
The microfluidic printer 8 is shown in horizontal (which refers to the position of the printer face 120 being horizontally orientated with the printer face 120 being in the top position) (FIG. 9A). In FIG. 9B, the printer face 120 is also horizontal but it is in the bottom position. In FIG. 9C, the printer face 120 is in a vertical orientation facing to the left, whereas in FIG. 9D, the printer face 120 is also vertically orientated but faces to the right. In all these views, the force of gravity is shown by the arrow labeled "g". A preferred orientation for the microfluidic printer 8 is that shown in FIG. 9B and having an "upside-down" orientation in which the front plate 120 is level and facing down. In this orientation, the hydrostatic pressure due to the gravitation force is uniform across the printer front plate 120. The pump efficiencies are essentially uniform if the microfluidic printer 8 is not subject to acceleration movement during printing. When the orientation is different from the level "upside-down" direction or when there is acceleration during printing, the variability in the pumping efficiencies need to be compensated, or in extreme situations, the printing operation needs to be terminated.
In FIGS. 9A-D, a sensor 700 detects orientation and the acceleration in the microfluidic printer 8. The detected orientation and acceleration are communicated to the microcomputer 110. The microcomputer 110 then controls the microfluidic pumps 70 to compensate for the variations in the hydrostatic pressure caused by the differences in the gravitational potential and by the accelerations of microfluidic printer 8. The sensor 700 can, for example, be a ball on an electrically sensitive membrane may be used, or a weight arm on a potentiometer. When the sensor 700 produces a signal which indicates that the orientation or acceleration are too excessive, or outside the range of compensation, the microcomputer 110 communicates a signal which causes the microfluidic pumps 70 to stop the printing operation until the conditions are again within the acceptable printable range.
The operation for the different orientations of the printer will now be discussed. In FIG. 9A, colored inks are delivered vertically upwardly to the ink mixing chambers 60 and are transferred to receiver sheet 100. In FIG. 9B, the colored inks are pumped downwardly to the ink mixing chambers 60.
The invention has been described in detail with particular reference to certain preferred embodiments thereof, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention.
PARTS LIST
8 microfluidic printer
10 colorless ink reservoir
20 cyan ink reservoir
30 magenta ink reservoir
40 yellow ink reservoir
50 microchannel capillaries
60 ink mixing chambers, or printing nozzles
70 microfluidic pumps
80 black ink reservoir
100 receiver
110 microcomputer
115 transport mechanism
120 printer front plate
200 cyan ink orifice
202 magenta ink orifice
204 yellow ink orifice
206 black ink orifice
300 cyan ink supply
302 magenta ink supply
304 yellow ink supply
306 black ink supply
400 cyan ink microchannel
402 magenta ink microchannel
404 yellow ink microchannel
406 black ink microchannel
500 conducting circuit
550 conducting circuit
600 cyan ink micro-orifice
602 magenta ink micro-orifice
604 yellow ink micro-orifice
606 black ink micro-orifice
650 column electrodes
670 row electrodes
700 sensor | A microfluidic printing apparatus includes at least one ink reservoir; a structure defining a plurality of chambers arranged so that the chambers form an array with each chamber being arranged to form an ink pixel; a plurality of microchannels connecting the reservoir to a chamber; and a plurality of microfluidic pumps each being associated with a single microchannel for supplying ink from an ink reservoir through a microchannel for delivery to a particular chamber. The printing apparatus provides an electrical signal representing the orientation of the printing apparatus; and control circuit responsive to the electrical signal and for controlling the microfluidic pumps for causing an array of pixels to be printed when the microfluidic pumps supply ink through the microchannels to the chambers so that the correct amount of ink is delivered into each chamber. | 1 |
FIELD OF THE INVENTION
[0001] This invention relates to insulated concrete wall systems, and more particularly to poured concrete wall systems in which a thermal insulation panel is joined to the concrete wall by an elongate retaining strip having edges engaging grooves formed in opposing vertical edges of the insulating panels.
BACKGROUND OF THE INVENTION
[0002] Poured concrete walls are formed by pouring or pumping uncured concrete between rigid planar forms generally made of wood, aluminum, steel or a combination of these materials. Two series of coplanar forms are typically held in spaced-apart, parallel relationship by retaining ties to create a cavity in which the poured concrete wall is formed.
[0003] Poured concrete walls can be constructed more quickly and at a lower cost than comparable alternative wall structures, while providing excellent durability, structural integrity, and other aesthetic and functional characteristics. However, poured concrete walls have relatively poor thermal insulating properties, and methods for incorporating insulative material in a poured concrete wall often have been difficult, requiring excessive time, labor and cost. Some of these methods require unconventional wall forms which are more costly to obtain and use than conventional wall forms.
[0004] U.S. Patent Application Publication No. U.S. 2001/0000844 A1 (incorporated in its entirety herein) describes an insulated concrete wall structure having embedded wall ties and a series of elongate retaining strips positioned between vertically spaced wall ties. Insulating panels are located between the horizontally spaced wall ties and are retained in position by the retaining strips. An advantage of this system is that an insulated poured concrete wall can be constructed using conventional wall forms in approximately the same amount of time as conventional uninsulated poured concrete walls. The resulting insulated poured wall system can be constructed at a lower cost than other known insulated poured concrete wall systems. Additionally, it is disclosed that the retaining strips allow building material such as drywall or paneling to be attached to the face of the insulating panels once the wall forms are removed and the wall is completed. However, this wall system is deficient is certain respects. First, the elongate retaining strips are not secured directly to the concrete wall, but instead are secured at opposite ends of the retaining strip to wall ties by notches formed in the wall ties. As a result, the elongate retainers are retained along their vertical edges between adjacent insulation panels and at their upper and lower edges between the notches in the vertically spaced-apart ties. This can allow some freedom of movement of the elongate retaining strips when building materials, especially heavy objects such as cabinets, are attached to the elongate retainers. In extreme cases, this can cause structures supported on the elongate retainers to pull away from the wall. Accordingly, there is a need for a more rigid insulation panel retainer that is capable of securely supporting heavier loads.
[0005] Another problem with the insulated concrete wall system disclosed by Patent Publication No. U.S. 2001/0000844 A1 is that it requires a plurality of elongate retaining strips between adjacent insulation panels. More specifically, one retaining strip is located between each set of vertically spaced-apart ties. The publication states that the height or length of the retaining strips is dependent upon the distance between adjacent ties, but is typically about one foot in length. Thus, for a typical poured concrete basement wall, eight retaining strips aligned vertically between adjacent insulation panels are needed. To reduce construction costs, it would be desirable to reduce the number of retainers that are required. Because the retainers are vertically spaced-apart, there are areas along the seam between adjacent insulation panels, in the vicinity of the ties, that are unavailable for engagement with a fastener to allow building materials to be attached. As a result, care must be taken to avoid locating fasteners in the area between vertically spaced-apart retaining strips when securing building materials such as drywall or paneling to the insulation panels.
[0006] Another disadvantage with the insulated concrete wall system described in U.S. Patent Application Publication U.S. 2001/0000844 A1 is that the flat surface of the elongate retaining strips can make it difficult to insert fasteners through the retaining strip. In particular, it can be difficult to initiate penetration of a drywall screw through the flat surface of the retaining strips.
SUMMARY OF THE INVENTION
[0007] The present invention provides an improved method of forming an insulated poured concrete wall, a system for forming an insulated poured concrete wall, and an insulated poured concrete wall. The invention allows insulated concrete walls to be formed more efficiently and at a lower cost by using fewer components. The invention also allows building materials such as drywall, siding, paneling, and the like, as well as heavier objects, such as cabinets, to be more stably and durably secured to the wall.
[0008] In accordance with one aspect of the invention, there is provided a system for forming an insulated poured concrete wall. The system includes spaced-apart wall forms forming opposing wall surfaces that define a cavity, a plurality of insulating panels arranged adjacent at least one of the opposing wall surfaces, and a plurality of elongate retaining strips between adjacent insulating panels, wherein each of the elongate retaining strips includes a portion that projects into the cavity.
[0009] In accordance with another aspect of this invention, a method of forming an insulated concrete wall is provided. The method includes arranging a plurality of wall forms in spaced relationship to form opposing wall surfaces defining a cavity, arranging insulating panels adjacent at least one of the opposing wall surfaces, arranging elongate retaining strips between adjacent insulating panels, wherein the elongate retaining strips engage edges of the insulating panels, and wherein a portion of each retaining strip projects into the cavity.
[0010] In accordance with another aspect of the invention, there is provided an insulated poured concrete wall comprising a concrete wall having opposing wall surfaces, a plurality of spaced-apart, elongate retaining strips, the elongate retaining strips having a portion embedded in the concrete wall with the length direction of the retaining strips extending vertically. A plurality of insulating panels is provided, with each panel being held between laterally spaced-apart retaining strips.
[0011] In accordance with another aspect of the invention, a system for forming an insulated poured concrete wall includes spaced-apart wall forms forming opposing wall surfaces that define a cavity, a plurality of vertically and horizontally spaced-apart wall ties extending between the opposing wall forms, a plurality of insulating panels arranged adjacent at least one of the opposing wall surfaces, and a plurality of elongate retaining strips between adjacent insulating panels, with each elongated retaining strip having at least one notch through which a wall tie passes.
[0012] In accordance with another aspect of the invention, there is provided a method of forming an insulated poured concrete wall using a plurality of elongate retaining strips, wherein each elongate retraining strip includes at least one notch that allows a wall tie to pass through.
[0013] Another aspect of the invention provides an insulated poured concrete wall comprising a concrete wall having opposing wall surfaces, a plurality of vertically and horizontally spaced wall ties contained within the concrete wall and extending between the opposing wall surfaces, a plurality of insulating panels arranged adjacent at least one of the opposing wall surfaces, and a plurality of elongate retaining strips between adjacent insulating panels, each elongate retaining strip having at least one notch through which a wall tie passes.
[0014] These and other features, advantages and objects of the present invention will be further understood and appreciated by those skilled in the art by reference to the following specification, claims and appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] [0015]FIG. 1 is a perspective view of an insulated concrete wall system in accordance with the invention.
[0016] [0016]FIG. 2 is an elevational view of the wall system shown in FIG. 1.
[0017] [0017]FIG. 3 is a front view of a retaining strip used in the wall system of this invention.
[0018] [0018]FIG. 4 is a side view of the retaining strip shown in FIG. 3.
[0019] [0019]FIG. 5 is a cross-sectional of the retaining strip shown in FIGS. 3 and 4.
[0020] [0020]FIG. 6 is a horizontal cross-sectional view of a poured concrete wall in accordance with this invention.
[0021] [0021]FIG. 7 is a transverse cross-sectional view of an alternative-retaining strip in accordance with this invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0022] In FIG. 1, there is shown a perspective view of a portion of a poured wall forming system 10 embodying the present invention. The system includes a plurality of wall forms 12 which are arranged to form two series of coplanar wall forms held in opposing spaced-apart, parallel relationship. Adjacent wall forms 12 are held in a coplanar relationship by connecting pins 14 , and the two series of coplanar wall forms are held in opposing spaced-apart parallel relationship by wall ties 16 . Wall forms 12 may be constructed of wood, aluminum, iron, steel, or various other materials or combinations thereof.
[0023] The forms 12 are typically from about 2 to 6 feet wide and from about 2 to about 10 feet high. Connecting pins 14 are well known in the art. Insulating panels 18 are positioned adjacent the interior surfaces of at least one of the series of wall forms 12 . Grooves 20 are formed in opposing vertical edges of insulating panel 18 . A long edge 28 of a T-shaped retaining strip 22 is received in groove 20 . Insulating panels 18 are held in place at their edges between laterally spaced-apart retaining strips 22 . As shown in FIG. 2, rather than extending between vertically spaced-apart ties 16 , retainer 22 may extend the full height of the poured wall, e.g., such as 8 or 9 feet. This is achieved by providing a series of vertically spaced-apart notches 24 through which ties 16 pass. Thus, rather than extending between ties 16 , retaining strip 22 extends uninterrupted past wall ties 16 . Retaining strips 22 are temporarily held in place by engagement of notches 24 with notches in the edges of wall ties 16 until the concrete has been poured and cured. This reduces the number of retaining strips 22 which are needed, thus simplifying installation and reducing construction costs. While it is preferred that a single retaining strip 22 extend from floor to ceiling, i.e., the full height of a poured concrete wall, the benefits of the invention can be achieved using a plurality (e.g., two or three) of retaining strips 22 which together extend the full height of the poured concrete wall. In other words, notches 24 which allow ties 16 to pass through the retaining strip 22 facilitate a reduction in the number of retaining strips needed and thereby simply and reduce the costs associated with installation of the insulated poured wall system.
[0024] In addition to reducing the number of retaining strips needed, the retaining strips 22 provide a continuous strip or stud that allows building materials such as drywall or paneling to be attached with fasteners such as screws or nails at any elevation, including an elevation at which a wall tie 16 is present.
[0025] A preferred embodiment of a retaining strip 22 in accordance with the invention is shown in further detail in FIGS. 3 - 5 . As shown in FIG. 5, retaining strip 22 has a T-shaped cross-sectional profile, including a web portion 30 , an enlarged (e.g., flared or bulbous) anchor portion 32 at one end of web 30 , and a flange portion 34 at the other end of web 30 .
[0026] Flange portion 34 is at a right angle with respect to web portion 30 and includes a left (with respect to the drawing shown in FIG. 5) side 36 and a right side 38 . The left side (or half) of flange 34 constitutes a continuous, uninterrupted, rectangular strip, whereas the right side (or half) of flange portion 34 includes spaced-apart notches 24 for accommodating wall ties 16 , i.e. for allowing wall tie 16 to pass through or around the retaining strip 22 .
[0027] As shown in FIG. 6, which is a vertical cross section of a finished wall after concrete 40 has been poured between wall forms 12 but before the forms 12 have been removed, anchor portion 32 of retaining strip 22 is embedded within the concrete wall 40 . The T-shaped profile provides improved rigidity and strength for hanging wall coverings such as drywall, paneling, siding (when the insulation is on the exterior side of the wall), etc. Improved rigidity and strength is also achieved by embedding a portion 32 of the retaining strip 22 in concrete wall 40 . The resulting structure shown in FIG. 6, in addition to accommodating wall coverings, can support relatively heavy loads such as large wooden cabinets and the like without warping, buckling, distorting or pulling away from the wall on account of the additional rigidity and strength provided by web 30 and by embedding the anchor portion 32 of retaining strip 22 in concrete wall 40 .
[0028] In order to facilitate easier insertion of fasteners into flange portion 34 of retaining strip 22 , flange portion 34 is provided with a serrated surface as shown in FIG. 5. The serrations help guide a fastener into the flange portion 34 making it easier to initiate penetration of a threaded fastener through flange portion 34 .
[0029] The wall structure shown in FIG. 6 is constructed by first assembling the wall forms 12 with the connecting pins 14 and wall tie 16 as shown in FIG. 1. Thereafter, a plurality of insulating panels 18 and retaining strips 22 are positioned inside the wall forms 12 and along one of the two parallel wall surfaces. The retaining strips 22 are temporarily held in place by the grooves 20 in insulation panels 18 .
[0030] Insulating panels 18 can be made of generally any relatively rigid insulating material, such as rigid polyurethane foam or rigid polystyrene foam. Panels 18 can be of generally any width, typically from about 2 feet to about 6 feet, and generally any height, typically from about 2 feet to about 10 feet, and can have any desired thickness, typically from about 2 to about 3 inches.
[0031] The retaining strips 22 can be made of any of various suitable materials such as wood, plastic or metal. The web portion 30 and flange portion 34 of retaining strips 22 are relatively thin, typically about ⅛ inch in thickness. The width of the web portion 30 and the flange portion 34 is typically from about 1-½ inches to about 4 inches. Preferably, the retaining strips 22 are made of a material to which conventional fasteners such as screws and nails can be secured.
[0032] To create the insulated poured concrete wall, uncured concrete is poured into the cavity formed between the two series of coplanar wall forms 12 . The expression “poured” includes any method or manner in which uncured concrete can be deposited into the cavity between wall forms 12 , whether by hand, from the concrete truck chute, from a pumping system, etc. Once the concrete has set (typically from about 12 to about 24 hours), the forms 12 are removed by releasing the connecting pins 14 from the holes of the walls ties 16 . The forms are then pulled away from the concrete wall. Once the pins and forms are removed, the concrete wall remains with the wall ties 16 embedded within the concrete wall, with insulating panels 18 secured to at least one side of the concrete wall. A portion of wall ties 16 that extends outwardly from the wall surface is typically broken or snapped off.
[0033] Although the wall structure shown in the drawings includes insulation panel 16 on only one side of concrete wall 40 , the method of this invention can be employed to provide insulation on both sides of concrete wall 40 . An insulating surface may be provided on only the exterior side of the poured concrete wall such as to facilitate use of flange 34 of retainer 22 to attach exterior siding to the wall. Insulating panels can be provided only on the interior side of the wall with flange portion 34 of retaining strip 22 used for attaching interior drywall, paneling, or the like. When the wall system and method of this invention is used for insulating both sides of a poured concrete wall, the retaining strips on the exterior side of the wall can be used for securing exterior siding to the wall, and the retaining strips on the interior side of the wall can be used for securing drywall or the like.
[0034] In FIG. 7, there is shown an alternative embodiment of the retaining strip 122 . Retaining strip 122 includes a segmented web portion including a web portion segment 130 A extending between an exterior flange 134 and a parallel interior flange 135 , and a second web portion segment 130 B extending from interior flange 152 to an enlarged anchor portion 132 . Depending on the dimensions of retaining strip 122 , and the dimensions of insulating panel 18 , insulating panel 18 may be retained between flanges 134 and 152 , or flanges 134 and 152 may engage parallel grooves in the edges of adjacent panels 18 . As another alternative one or the other of flanges 134 and 152 may be engaged in a groove formed in the edge of an insulating panel 18 , while the other flange engages one or the other side of panel 18 . The parallel flange arrangement of retaining strip 122 allows a fastener such as a screw or nail to penetrate two parallel structures (flanges 134 and 152 ), whereby improved strength, rigidity and stability are provided for supporting objects, especially heavy objects such as cabinets and the like.
[0035] Web 30 may be scalloped (e.g., have a width that varies along the length of web 30 ) to provide a control joint that limits cracking of concrete wall 40 in a limited area.
[0036] The above description is considered that of the preferred embodiments only. Modifications of the invention will occur to those skilled in the art and to those who make or use the invention. Therefore, it is understood that the embodiments shown in the drawings and described above are merely for illustrative purposes and not intended to limit the scope of the invention, which is defined by the following claims as interpreted according to the principles of patent law, including the doctrine of equivalents. | An improved method of forming an insulated poured concrete wall, a system for forming an insulated poured concrete wall, and an insulated poured concrete wall are provided. The system includes spaced-apart wall forms defining a cavity, a plurality of insulating panels adjacent at least one of the opposing wall surfaces, and a plurality of the elongate retaining strips between adjacent insulating panels, wherein each of the elongate retaining strips includes a portion that projects into the cavity and/or each of the elongate retaining strips has at least one notch through which a wall tie passes. The system allows building materials such as drywall, siding, paneling, and the like, as well as heavier objects, such as cabinets to be more stably and durably secured to an insulated poured concrete wall, and facilitates construction of an insulated concrete wall using fewer components and less labor. | 4 |
TECHNICAL FIELD
[0001] The present invention relates to gantry apparatuses, and more particularly to a rotatable supporting module for a gantry apparatus and a gantry apparatus having the rotatable supporting module that can prevent a cross bar thereof from being damaged.
DESCRIPTION OF RELATED ART
[0002] Gantry apparatuses are becoming widely used. Referring to FIG. 8 , a gantry apparatus 1 in accordance with a related art is shown. The apparatus 1 includes a left guideway 2 , a right guideway 3 , a cross bar 4 having two opposite ends, a left slider 5 arranged on the left guideway 2 , a right slider 6 arranged on the right guideway 3 , a left driver 7 , and a right driver 8 . One end of the cross bar 4 is mounted on the left slider 5 and the other end of the cross bar 4 is mounted on the right slider 6 . The left slider 5 is driven by the left driver 7 thereby moving the cross bar 4 along the left guideway 2 . The right slider 6 is driven by the right driver 8 thereby moving the cross bar 4 along the right guideway 3 . When the left slider 5 moves non-synchronously with the right slider 6 , the cross bar 4 will tilt and be damaged.
[0003] What is needed, therefore, is a rotatable supporting module and a gantry apparatus having same that can prevent a cross bar thereof being damaged.
SUMMARY
[0004] In an embodiment, a rotatable supporting module configured (i.e., structured and arranged) for a gantry apparatus includes a rotary plate, a base, and a bearing. The rotary plate has a through hole. The base is arranged in the through hole. The bearing is arranged between the rotary plate and the base. The bearing includes an inner race and an outer race rotatable relative to the inner race. The inner race is securely coupled to the base and the outer race is securely coupled to the rotary plate, thus allowing the rotary plate to be rotatable relative to the base.
[0005] In another embodiment, a gantry apparatus includes a first guideway and a second guideway arranged parallel with each other, the rotatable supporting module mounted on the first guideway, a slidable and rotatable supporting module slidably mounted on the second guideway, and a cross bar having opposite ends mounted on the rotatable supporting module and the slidable and rotatable supporting module. The slidable and rotatable supporting module includes the rotatable supporting module, and a slidable plate, and a sliding bearing. The sliding bearing includes a first elongated part and a second elongated part juxtaposed with each other. The first elongated part is slidably engaged with the second elongated part and the first elongated part is securely coupled to the rotary plate. The second elongated part is securely coupled to the slidable plate, whereby the slidable plate is slidable along a lengthwise direction of the sliding bearing.
[0006] Other advantages and novel features will become more apparent from the following detailed description of the present rotatable supporting module and gantry apparatus having same when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The components in the drawings are not necessarily drawn to scale, the emphasis instead being placed upon clearly illustrating the principles of the present invention. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views.
[0008] FIG. 1 is an isometric view of a rotatable supporting module in accordance with a first embodiment.
[0009] FIG. 2 is a cross-sectional view of the rotatable supporting module, taken along the line 11 - 11 shown in FIG. 1 .
[0010] FIG. 3 is an exploded isometric view of the rotatable supporting module shown in FIG. 1 .
[0011] FIG. 4 is an isometric view of a slidable and rotatable supporting module in accordance with a second embodiment.
[0012] FIG. 5 is a cross-sectional view of the slidable and rotatable supporting module, taken along the line V-V shown in FIG. 4 .
[0013] FIG. 6 is an exploded isometric view of the slidable and rotatable supporting module shown in FIG. 4 .
[0014] FIG. 7 is an isometric view of a gantry apparatus in accordance with a third embodiment.
[0015] FIG. 8 is an isometric view of a typical gantry apparatus.
DETAILED DESCRIPTION OF EMBODIMENTS
[0016] Reference will now be made to the drawing figures to describe the embodiments of the present rotatable supporting module and gantry apparatus with same in detail.
[0017] Referring to FIGS. 1 to 3 , a rotatable supporting module 10 in accordance with a first embodiment is shown. The rotatable supporting module 10 includes a rotary plate 11 , a base 12 , a bearing 13 , a first holder 14 , a second holder 15 , a cover 17 , and two connecting blocks 19 .
[0018] The rotary plate 11 includes a through hole 110 defined therein, an inner flange 111 , and two opposite step portions 112 . The inner surface of the rotary plate 11 that defines the through hole 110 extends radially to form the flange 111 . Two opposite ends of the rotary plate 11 respectively define the two step portions 112 .
[0019] Each connecting block 19 has a plurality of bolt holes 191 . One of the connecting blocks 19 is mounted on one step portion 112 and the other connecting block 19 is mounted on the other step portion 112 . One end of a cross bar 43 having opposite two ends (shown in FIG. 7 ) is connected to the rotary plate 11 through the connecting blocks 19 and some screws screwed into the bolt holes 191 .
[0020] The base 12 is a cylinder shape and is arranged in the through hole 110 . The outer surface of the base 12 extends radially to form a flange 121 .
[0021] The bearing 13 is arranged between the rotary plate 11 and the base 12 . The bearing 13 includes an inner race 131 and an outer race 132 . The inner race 131 is coaxially aligned with the outer race 132 . The inner race 131 is rotatable relative to the outer race 132 . The inner race 131 is arranged on the flange 121 and mounted on the base 12 through engagement between the first holder 14 and some screws 141 . The outer race 132 is arranged on the flange 111 and mounted on the rotary plate 11 through engagement between the second holder 15 and some screws 16 . Therefore, the rotary plate 11 can rotate around the base 12 . Thus, the cross bar 43 can rotate around the base 12 .
[0022] The cover 17 is held on the second holder 15 by some screws 18 . The cover 17 can prevent the dust outside falling into the rotatable supporting module 10 .
[0023] Referring to FIGS. 4 to 6 , a slidable and rotatable supporting module 20 in accordance with a second embodiment is shown. The slidable and rotatable supporting module 20 includes a rotary plate 21 , a base 22 , a bearing 23 , a first holder 24 , a second holder 26 , a sliding bearing 28 , a slidable plate 29 , and a locking plate 32 .
[0024] The rotary plate 21 includes a through hole 210 defined therein and has a flange 211 . The inner surface of the rotary plate 21 that defines the through hole 210 extends radially to form the flange 211 .
[0025] The base 22 is a cylinder shape and is arranged in the through hole 210 and has a flange 221 .
[0026] The bearing 23 is arranged between the rotary plate 21 and the base 22 . The bearing 23 includes an inner race 231 and an outer race 232 . The inner race 231 is coaxially aligned with the outer race 232 . The inner race 231 is rotatable relative to the outer race 232 . The inner race 231 is arranged on the flange 221 and mounted on the base 22 through engagement between the first holder 24 and some screws 25 . The outer race 232 is arranged on the flange 211 and mounted on the rotary plate 21 through engagement between the second holder 26 and some screws 27 . Therefore, the rotary plate 21 can rotate around the base 22 .
[0027] The sliding bearing 28 is arranged between the slidable plate 29 and the rotary plate 21 . The sliding bearing 28 includes an inner member 281 and an outer member 282 . The inner member 281 is slidable relative to the outer slidable member 282 . The inner member 281 is mounted on the rotary plate 21 by some screws 30 . The outer member 282 is mounted on the slidable plate 29 by some screws 31 . Therefore, the slidable plate 29 can move lengthwise along the sliding bearing 28 . The inner member 281 does not touch the slidable plate 29 , thus there is little friction force between the inner member 281 and the slidable plate 29 .
[0028] The slidable plate 29 has a plurality of bolt holes 291 thereon and an inner sidewall 292 at the end thereof. The locking plate 32 locks the outer member 282 to the inner sidewall 292 , thus securely mounting the outer member 282 on the slidable plate 29 . The other end of the cross bar 43 (shown in FIG. 7 ) is connected to the slidable plate 29 by some screws screwed into the bolt holes 291 . This allows the cross bar 43 to slide lengthwise along the sliding bearing 28 and rotate around the base 22 .
[0029] Referring to FIG. 7 , a gantry apparatus 40 in accordance with a third embodiment is shown. The apparatus 40 includes the rotatable supporting module 10 , the slidable and rotatable supporting module 20 , a left guideway 41 , a right guideway 42 parallel with the left guideway 41 , and the cross bar 43 .
[0030] A left slider 44 is arranged on the left guideway 41 and the slidable and rotatable supporting module 20 is mounted thereon. A left driver 46 moves the slidable and rotatable supporting module 20 through the left slider 44 . One end of the cross bar 43 is mounted on the slidable and rotatable supporting module 20 .
[0031] A right slider 45 is arranged on the right guideway 42 and the rotatable supporting module 10 is mounted thereon. A right driver 47 moves the rotatable supporting module 10 through the right slider 45 . The other end of the cross bar 43 is mounted on the rotatable supporting module 10 .
[0032] The cross bar 43 can rotate around the rotatable supporting module 10 and slide along the sliding bearing 28 of the slidable and rotatable supporting module 20 . When the slidable and rotatable supporting module 20 moves with the rotatable supporting module 10 non-synchronously, the cross bar 43 slides a distance along the sliding bearing 28 of the slidable and rotatable supporting module 20 and rotates a small angle around the base 12 of the rotatable supporting module 10 . A torsion force that can damage the cross bar 43 is thus released. Thus, the cross bar 43 cannot be damaged.
[0033] Although the present invention has been described with reference to specific embodiments, it should be noted that the described embodiments are not necessarily exclusive, and that various changes and modifications may be made to the described embodiments without departing from the scope of the invention as defined by the appended claims. | An exemplary rotation module configured for a gantry apparatus includes a rotary plate, a base, and a bearing. The rotary plate has a through hole. The base is arranged in the through hole. The bearing is arranged between the rotary plate and the base. The bearing includes an inner race and an outer race rotatable relative to the inner race. The inner race is securely coupled to the base and the outer race is securely coupled to the rotary plate, whereby the rotary plate is rotatable relative to the base. A gantry apparatus are also provided. | 5 |
RELATED APPLICATIONS
[0001] This application claims the benefit of priority to U.S. Provisional Patent Application No. 61/793,584, filed Mar. 15, 2013 and incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] New approaches to data organization, such as Hadoop's HDFS, or MongoDB, implement a highly distributed file or document-oriented database system on commodity servers, and support parallel processing. The number of entities (documents, files, directories, collections) in these systems can be in the millions. The present invention proposes a method that organizes this data into logical subsets, and then secures each subset and enables its movement to another location, either in the same big data system or a different big data system.
BACKGROUND OF THE INVENTION
[0003] Big data systems are employed by enterprises for large-scale data storage and management. Typically they are large distributed file systems like Hadoop HDFS, document-oriented database systems like MongoDB or Couchbase, or distributed key-value stores such as HBase. In this paper we refer to all of the above as “Distributed Data Stores” (DDS). DDSs provide the ability to store huge amounts of data on commodity hardware. In addition, DDSs provide multiple features such as parallel processing, restricted access to data, transparent replication, and fault tolerance. These features enable multiple concurrent users to use DDSs to access large quantities of data for data mining and analysis, which are the typical usage areas for DDSs.
[0004] DDSs are often used to store data collected from the web, such as Twitter feeds and Facebook conversations, call records from call centers and telephones, transaction data for financial institutions, and weather data. DDSs generally house a wide variety of information, and are accessed by a variety of end users within enterprises. Managing this large quantity of information, especially with a view towards securing it, is a challenge.
[0005] For example, in a large enterprise, subsets of a DDS may be marked for use by different departments. Each of these subsets may have completely different requirements for security and access controls to be maintained, whether the data can be copied, and what kind of policies need to be in place to ensure that the integrity of the data is not compromised. Some subsets may be open to the public, whereas other subsets may have information that only a select few can access.
[0006] There is therefore a need for a method and system for dividing data in DDSs such as the ones mentioned above into logical subsets, which can then be managed from the security and operational point of view.
BRIEF DESCRIPTION OF THE FIGURES
[0007] The accompanying figures, where like reference numerals refer to identical or functionally similar elements throughout the separate views, and which together with the detailed description below are incorporated in and form part of the specification, serve to further illustrate various embodiments and to explain various principles and advantages all in accordance with the invention.
[0008] FIG. 1 , illustrates a view of a large DDS 100 with multiple domains 102 , 104 , 106 , 108 , 110 & 112 . Each domain 102 , 104 , 106 , 108 , 110 & 112 in turn will contain multiple directories, files, or collections of documents.
[0009] FIG. 2 illustrates a copy action whereby one domain 106 (including its subdomain 112 ) is copied 206 (& 212 ) to another location in the same DDS 100 .
[0010] FIG. 3 illustrates copying between multiple DDS's 100 & 300 , including a copy action whereby one domain 304 (including its subdomains) from a first DDS 100 is copied 306 to a second DDS 300 .
[0011] FIG. 4 . Illustrates a system 400 for managing domains in a DDS 100 & 300 .
[0012] Skilled artisans will appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of embodiments of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0013] Before describing in detail embodiments that are in accordance with the invention, it should be observed that the embodiments reside primarily in combinations of method steps and system components related to a method and system for managing subsets of data in a large distributed data store (DDS.) Accordingly, the system components and method steps have been represented where appropriate by conventional symbols in the drawings, showing only those specific details that are pertinent to understanding the embodiments of the invention so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein.
[0014] In this document, relational terms such as first and second, and the like may be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. The terms “comprises,” “comprising,” or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, or apparatus. An element preceded by “comprises . . . a” does not, without more constraints, preclude the existence of additional identical elements in the process, method, or apparatus that comprises the element.
[0015] Generally speaking, pursuant to various embodiments, the invention provides a method and a system for managing subsets of data in a large DDS 100 . A domain, such as domain 102 , 104 , 106 , 108 , 110 or 112 is defined as a set of one or more directories, files, collections, documents, or other logical units of data in one or more DDSs 100 & 300 . The example system utilizes an application programming interface (API) or other available means of communicating with a DDS cluster, e.g., DDS cluster 100 or 300 , in order to obtain information about the components of the DDS 100 , such as directories, files, and collections. The example system also uses the same means for performing operations such as, but not limited to, discovering sensitive data items, quarantining, masking, or encrypting sensitive data in domains, and for copying domains. The example system stores metadata information about domains 102 , 104 , 106 , 108 , 110 & 112 in its repository (which is typically outside the DDS 100 , but can also be inside the DDS 100 ), and maps the information about components of the DDS 100 such as directories, files, collections, and documents, to the domain metadata information to manage the domains 102 , 104 , 106 , 108 , 110 & 112 .
[0016] Referring to the drawings and in particular to FIG. 1 , an exemplary logical diagram of a DDS 100 containing a hierarchy of domains, for example domains 102 , 104 , 106 , 108 , 110 and 112 is disclosed. HR-World 102 , for example, is a root-level domain, and HR-Europe 104 and HR-Asia 106 are also domains, which happen to be subdomains of root level domain HR-World 102 . In an embodiment, HR-World 102 need not exist, in which case, HR-Europe 104 and HR Asia 106 are root-level domains. HR-Western-Europe 108 and HR-Eastern-Europe 110 are subdomains of HR-Europe 104 , and HR-South-Asia 112 is the single subdomain of HR-Asia 106 .
[0017] Properties may be assigned to the domains 102 , 104 , 106 , 108 , 110 & 112 through the system described in later sections, and depicted in FIG. 4 . All the constituents of a domain, e.g., domain 102 , (i.e., all directories and files marked as being part of the domain 106 in the case of a Distributed File System) are also assigned the properties of the domain 106 . By default, a subdomain, e.g., domain 112 , and its constituents will also be assigned the properties of the respective parent domain, e.g., domain 106 . Examples of such inheritable properties include an encryption key to be used for security, categories of data that are considered sensitive, policies to mask specific types of sensitive data, business tags to be attached to the data in the domain 106 , access rights to groups of users over the constituents of the domain 106 (files and directories in the case of a Distributed File System, collections and documents in the case of a Distributed Document-oriented Database.) The set of properties listed above is purely exemplary, and does not limit other properties from being attached to the domain.
[0018] In an embodiment, constituent of a DDS 100 (for example a directory or a file) may belong to multiple domains, with rules governing which policies are in effect where the policies of the multiple domains are in conflict. In a scenario, subdomains 112 may have some or all relevant policies that are different from those of their parent domains 106 . This change from the usual norm of having subdomains possess the same properties as their parent domains is selected in an explicit manner. But by default, subdomains 112 inherit the policies of the parent domain 106 .
[0019] In an example embodiment, a directory in Hadoop Distributed File System (a type of DDS 100 ) may be assigned as the root 102 of the domain, and all subdirectories automatically become part of that domain 102 . In another embodiment, subdirectories do not automatically become part of the root domain 102 unless explicitly marked as member of the domain 102 . In yet another embodiment, subdomains (e.g., 104 ) of a main domain (e.g., 102 ) may be restricted to being subdirectories of the root directory of the main domain 102 . In yet another embodiment, this restriction may not be there. In the most general case, a domain is simply a set of entities (for example, files, directories, collections, documents) that is marked as being part of the domain, irrespective of their location within the structure of the DDS 100 .
[0020] Once one or more domains are marked, policies can be attached to them. The policies may include but are not limited to sensitive data policies, backup and restore policies, access policies, and others that may affect the constituents of the domain in any way.
[0021] In the case of sensitive data policies, in an embodiment, the enterprise may select a set of sensitive data types it needs to protect within the DDS 100 . Examples of such data types include, but are not limited to, credit card numbers, social security numbers, medical record numbers, addresses, names of patients, names high net-worth individuals, driver's license numbers, and bank account numbers. There can also be policies controlling how exactly the sensitive data, once found, is treated. For example, one policy could say that credit card numbers should be masked with a format-preserving masking. The same policy may say that social security numbers need to be encrypted with a particular encryption key. A different policy may say that telephone numbers need to be masked consistently, where consistency means that identical masked values replace originally identical sensitive values, in this case telephone numbers. The same policy may say that any file containing email addresses needs to be quarantined, i.e., access to it should be restricted. Once the policies relating to data security are defined, tasks run for detecting and sensitive data on constituents of the domain 102 will need to adhere to those policies.
[0022] Another example of security related policies assignable to a domain 102 is the management of encryption and decryption keys to be used in encryption sensitive items in a domain. In an embodiment, policies can be set to use a particular encryption key for a particular period of time in a domain. Policies can also be set for when the key would expire, and a new key would be used. Key strength and key type may also be set at domain level.
[0023] In another scenario, backup policies can be assigned to a domain 102 , whereby the time of incremental and full backup can be set at the domain level. Other scenarios include assignment of different fine-grained access rights to the constituents of a domain to various users. Some users may have read access to all files containing social security numbers, whereas others may not. The user who has access to social security numbers in one domain 102 may not have access to the same in another domain.
[0024] In yet another scenario, business or other tags may be applied to an entire domain 102 , so that reporting systems such as a dashboard may analyze the information about sensitive data using the tags as filters. Tags may indicate that the domain belongs to a particular region, division, or department of the company; they may also indicate that the domain has data of a particular classification level, or the data pertain to a particular region or language.
[0025] FIG. 2 depicts the copying of a domain 106 , including its subdomain 112 to another location (e.g., 206 & 212 ) within the same DDS 100 . In a scenario, the new domain 206 may be automatically be given a new name, which can be modified. The new domain 206 will initially have the properties of the source domain 106 , and these can also be modified. In another scenario, the data in the new domain 206 may be created after masking all sensitive data from the source domain based on certain policies. Therefore, in this case, the source domain 106 , has the sensitive data, but the new domain 206 has only de-identified data. In yet another scenario, the sensitive data from the source domain 106 may be encrypted before copying to a new domain 206 . The same source domain 106 may be used for multiple of such transformations.
[0026] FIG. 3 describes another embodiment of copying domains 304 , but this time between two DDS clusters 100 and 300 . The source domain 304 is in one DDS 100 , and the new copied domain 306 is another DDS 300 . In the most general case, the second DDS 300 may be of a completely different type. In an embodiment, the connectivity software required for this copy between DDS clusters may be part of an example system described in FIG. 4 . In another embodiment, the transfer of domains may apply connectivity software that is part of a third-party tool. From the user viewpoint, copying within a DDS 100 and between multiple DDS's 100 & 300 is substantially identical in terms of steps to follow, resulting in a very easy to use interface.
[0027] FIG. 4 describes an example system 400 for managing domains in one or more DDS clusters 100 & 300 . FIG. 4 describes one embodiment of such an example system 400 , other configurations are possible and can be built to achieve the same effect in managing domains. A user interface 402 enables each end-user to perform operations on domains such as, but not limited to, creation of a domain 102 and association of the domain 102 with various constituents of the DDS 100 ; creation of policies for sensitive data discovery, masking, quarantine, and encryption, and association of those policies with the domain 102 ; creation and management of policies for backup and association of those policies with one or more domains 102 ; creation and management of encryption and decryption key policies and association with one or more domains 102 ; creation of subdomains 104 within domains 102 ; creation of policies to be used while copying domains 106 ; actual copying of the domains 206 either within a DDS 100 or to another DDS 300 . The user interface 402 is also used to start discovery, masking, encryption, or quarantine tasks on one or more domains 102 , and to view the results of these tasks. Further, the user interface 402 may be used to create tags, and associate these tags with one or more domains 102 .
[0028] An example controller 404 interacts with the user interface 402 , and packages requests to an example agent 406 , which interacts with the DDS 100 . The controller 404 has access to a repository 408 where information created and managed through the user interface 402 is stored. Therefore, the repository 408 contains comprehensive metadata about domains 102 , 104 , 106 , 108 , 110 & 112 in the given DDS 100 .
[0029] The agent 406 interacts with the DDS 100 and performs actions initiated in the user interface 402 , such as searching for sensitive data, masking, quarantining, encryption, copying of domains, on the DDS 100 . The agent 406 interfaces and performs actions using either the application programming interface (API) of the DDS 100 or by other means.
[0030] An example dashboard 410 processes data from the results of sensitive data scans, masking operations, quarantining operations, encryption operations, which are stored in the repository 408 , and presents the data in aggregate form to an end user, for example in various visual forms. The example dashboard 410 may display the information filtered for specific domains 106 and subdomains 112 . The dashboard 410 may also use the tags, and therefore may show the data partitioned, narrowed, or filtered by the tag values. The dashboard 410 also offers drill-down review, so that a user may examine constituents of a domain 102 to see what operations were performed on the domain 102 .
[0031] The various embodiments of the invention provide an efficient method for managing and securing data in subsets of a large DDS 100 & 300 .
[0032] Those skilled in the art will realize that the above-recognized advantages and other advantages described herein are merely exemplary and are not meant to be a complete rendering of all of the advantages of the various embodiments of the invention.
[0033] In the foregoing specification, specific embodiments of the invention have been described. However, one of ordinary skill in the art appreciates that various modifications and changes can be made without departing from the scope of the invention. Accordingly, the specification and figures are to be regarded in an illustrative rather than a restrictive sense, and all such modifications are intended to be included within the scope of the invention. The benefits, advantages, solutions to problems, and any element(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as critical, or required. | A system groups multiple entities in a large distributed data store (DDS), such as directories and files, into a subset called a domain. The domain is treated as a unit for defining policies to detect and treat sensitive data. Sensitive data can be defined by enterprise or industry. Treatment of sensitive data may include quarantining, masking, and encrypting, of the data or the entity containing the data. Data in a domain can be copied as a unit, with or without the same structure, and with transformations such as masking or encryption, into parts of the same DDS or to a different DDS. Domains can be the unit of access control for organizations, and assigned tags useful for identifying their purpose, ownership, location, or other characteristics. Policies and operations, assigned at the domain level, may vary from domain to domain, but within a domain are uniform, except for specific exclusions. | 6 |
RELATED APPLICATIONS
[0001] This application is a Section 371 conversion of PCT Application No. PCT/US2013/71092, filed on Nov. 20, 2013, which in turn is a conversion of Provisional Patent Application Ser. No. 61/728,756, filed Nov. 20, 2012. The present application claims the benefit of priority of each of the foregoing applications, all of which are incorporated herein for all purposes.
FIELD OF THE INVENTION
[0002] The present invention relates generally to medical devices and methods for assisting during delivery, and more particularly relates to medical devices affixed to the pregnant mother during delivery, and methods therefor.
BACKGROUND OF THE INVENTION
[0003] Perineal tearing has long been an issue that pregnant mothers face during childbirth. Delivery can lead to overstretching of the vagina, causing tears in the perineal tissue between the vagina and the rectum, as the vagina of the mother stretches to accommodate the passage of the baby's body through the birth canal. In some instances, an episiotomy is performed as a prophylactic measure, to prevent uncontrolled tearing between the vagina and the anus.
[0004] Perineal tears or lacerations are typically classified to indicate the severity of the trauma to the perineum, as follows:
[0005] First degree tear: laceration is limited to the fourchette and superficial perineal skin or vaginal mucosa.
[0006] Second degree tear: laceration extends beyond fourchette, perineal skin and vaginal mucosa to perineal muscles and fascia, but not the anal sphincter.
[0007] Third degree tear: fourchette, perineal skin, vaginal mucosa, muscles, and anal sphincter are torn. Third degree tears are further characterized as “ 3 a”, “ 3 b”, and “ 3 c”, where 3 a is characterized by partial tear of the external anal sphincter involving less than 50% thickness, 3 b is characterized by greater than 50% tear of the external anal sphincter, and 3 c is characterized in that the internal sphincter is torn.
[0008] Fourth degree tear: fourchette, perineal skin, vaginal mucosa, muscles, sphincter, and rectal mucosa are torn.
[0009] Such tearing can cause significant post-delivery complications for the mother. As a result, there has long been a need to reduce the rate and nature of perineal tears without hindering or preventing the vaginal stretching needed to facilitate delivery.
SUMMARY OF THE INVENTION
[0010] The present invention comprises a device that provides support to the tissues comprising and bordering the line between the bottom of the vagina and the anus, and methods relating thereto. A component of the support, which can be a large component in some embodiments, is oriented in a direction perpendicular to the line between the vagina and the anus.
[0011] In an embodiment, the support is not uniform, with comparatively greater support being provided near the anus, and less near the vagina. In an embodiment, the increase in support can be linear. The support near the vagina can, in an embodiment, be smaller to allow for some tearing near the vagina, while providing greater support near the anus with the objective of making tears near the anus unlikely.
[0012] In an embodiment, the support can comprise a force that acts on the skin and, directly or indirectly, the underlying tissues, or can be elastic, to generate a force that resists stretching and tearing of the tissue. The desired support can be provided by any of a group of methods including a variable stiffness material or plurality of materials, a fixed or variable spring constant, an elastic members with variable spring constants, or by a material which applies variable force curves to the skin as the device is stretched.
[0013] The device can be secured to the skin bordering the ano-vaginal line using methods taken from a group comprising: adhesives suited for use on skin, high friction materials, hooks, clips, pins, protrusions, sutures, staples, straps, external members, or any other method that suitably increases the friction or sheer force of the device against the skin.
[0014] These and other aspects of the invention can be appreciated from the following Detailed Description of the Invention, taken together with the appended Figures, described below.
THE FIGURES
[0015] FIGS. 1-8 show a generalized embodiment and a plurality of alternative embodiments of a perineal support device in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0016] Referring first to FIG. 1 , a generalized embodiment of a perineal protection device 100 can be appreciated. The device 100 comprises two halves 110 - 115 , joined near the anus. In an embodiment, each half can be relatively rigid on its own, and joined by a hinge 120 or other connector. The hinge can be a multi-part hinge with a pin connecting the two halves. In such an arrangement, the two halves are pulled toward the center line by a spring component in order to limit tearing. The spring component can be provided by any suitable means, for example a torsional spring at the pin. The hinge can alternatively be monolithic, and integrated with the device halves, with the monolithic hinge being a thinner part of the same material as the two halves, and thus more flexible. This results in the monolithic hinge acting both as a flexible member to allow the two halves to move apart as needed, and also to provide a spring force holding the two halves together to reduce tearing of the tissues. In an embodiment, the two halves are both relatively rigid such that the majority of the flexing occurs at the hinge. The amount of skin separation (stretching and tearing) in such an arrangement is generally proportional to the distance from the hinge axis. In a different embodiment, the two halves can be flexible, and, in a still further embodiment, can be more flexible as they get closer to the vagina, to allow for more stretching at the vagina while providing increasing stiffness as the distance from the anus decreases.
[0017] Referring next to FIG. 2 , the embodiment shown therein illustrates an alternative method of achieving variable elasticity, with stiffness increasing along the line toward the anus. In particular, halves 200 are connected by one or more tensile or elastic members 205 A-B. The members 205 can be of varying stiffness, with the member having the greatest stiffness being proximate to the anus, and the member having the least stiffness being proximate to the vagina. The members 205 A-B can be metal springs, rubber bands, elastic fibers, flexible plastic, textiles, or monolithic springs formed integrally with the two halves 200 . Each of the members flexes to allow the two halves to separate. The members can be “U” shaped as shown in FIG. 3 for members 300 A-C, but can also be any other convenient shape known to those skilled in the art; for example, each elastic member can have a different thickness to provide varying resistance to the separation of the two halves.
[0018] Referring next to FIG. 4 , the use of elastic members having variable elasticity can be better appreciated. In particular, elastomers 400 , 405 and 410 are each connected to halves 415 A-B, with elastomer 400 , nearest the vagina, having the lowest modulus of elasticity or cross sectional area, and elastomer 410 , nearest the anus, having the highest.
[0019] Referring next to FIG. 5 , a monolithic embodiment of the invention is illustrated. A stretchable center patch 500 is formed integrally with two halves 505 and 510 . The stretchable center patch 500 comprises a plurality of stretchable members 515 A-n, with the rigidity of the center patch increasing as the distance to the anus decreases. The rigidity of the center patch can be increased either by increasing the rigidity of the individual members, or by increasing the density (i.e., the number per area) of stretchable members as the distance to the anus decreases.
[0020] Referring next to FIG. 6 , a still further alternative approach can be better appreciated. In some births, tearing is unavoidable. In such circumstances, the objective is to limit the tearing and to prevent the tear from propagating along the centerline from the vagina to the anus. The embodiment shown in FIG. 6 achieves this by directing the tear along the edge of a triangular shaped element 600 , whereby the tear is directed away from the anus. In the embodiment shown, the triangular element 600 is applied to the perineal area with the point of the triangle 605 directed toward the posterior of the vagina. The element 600 is applied by any suitable method, including adhesives and the other methods mentioned hereinabove. By having the narrow, pointed portion nearest the bottom of the vagina, stretching of the vagina is allowed. Should a tear occur, the perineal tissue is supported by the device 600 , which directs the tear along an edge 610 of the device rather than along the centerline, since the key stresses on the perineal tissue form at the edge of the device 600 .
[0021] In some instances, it may be desirable not merely to direct the tear away from the anus, but also to support the skin sufficiently that the redirected tear is stopped. An embodiment for achieving this result is shown in FIG. 7 , where the substantially triangular device 600 of FIG. 6 now includes a pair of V-shaped notches 705 - 710 , one on either side of the centerline.
[0022] It will be appreciated that a caregiver can apply pressure to help hold the device of the present invention in place. The present invention, at the least, helps regulate the amount of inward/medial pressure exerted on the skin and underlying structures. Many embodiments can also have tactile or other features on the surface to help guide the caregiver's fingers to the optimal points to apply a force normal to the surface of the skin.
[0023] In another embodiment, shown in FIG. 8 , the device can comprise primarily a single pad of elastomeric material, indicated at 800 . In an embodiment, the pad can vary in thickness over the area of the patch. In areas where the skin will be allowed to stretch more, such as near the vagina, the pad can be configured to be thinner, as shown at 805 . In areas where more support is needed to prevent excessive stretching, such as near the anus, the pad can be configured to be thicker, as shown at 810 . The pad may aid the user in holding onto or connecting the skin and tissue with the pad. In one embodiment, an adhesive can be used to provide adhesion to the skin and this adhesive can be flexible to allow stretching of the underlying skin while still maintaining adhesion. In other embodiments, hooks, needles, high friction surfaces, and other suitable means can be used to help hold the pad onto the skin and reduce sliding of the skin and tissue under the pad. Note that for those embodiments which use an elastomeric material can also use other materials for the pad that stretch and provide more resistance when stretched. In another embodiment, the pad material may also vary to achieve varying resistance when stretched.
[0024] In one embodiment, the desired varying resistance under stretch is determined via an analysis of the stretching of the perineal skin during birth that yields a model of typical elongation of the skin. This model of elongation can be used to optimize the thickness, shape, density and/or material composition of the pad in different areas of the pad.
[0025] In one embodiment, the pad can be designed to provide a constant support force in reaction to the typical stretching, and areas that typically do not stretch much, such as near the anus, will be supported more when they are stretched beyond the typical amount. In an embodiment, the pad can be made of silicone, though any suitable elastomeric material can be used. In another embodiment the pad can contain other materials. These materials, which can be chosen from a group comprising filaments, threads, fabrics, textiles, wires, different elastomeric materials, other plastics, and springs, can affect the support forces provided by areas of the pad and help better control or vary these forces. For example, threads may be added to the pad to increase the support around the anus. These threads can be selectively aligned within the pad to customize the support in different directions. Different pads can be made for different perineal shapes and sizes. There may be a number of common sizes available. Custom pads can be made for a given user as well. Although a single pad design is mentioned above, other embodiments can have multiple pads connected together by elastic or non-elastic members.
[0026] In an embodiment, any of the above designs can be modified to provide the ability for a doctor or midwife to adjust the support provided by the device during childbirth. Such an adjustment method can be achieved by providing an elastic layer that can be attached to the device at some point, and can also be peeled off, either to cause the device to provide more support, or to allow the device to become more flexible. The device itself can be designed to be easily peeled from the skin.
[0027] From the foregoing, it can be appreciated that a new and novel perineal protection device has been disclosed. Having fully described several embodiments in detail, it will be apparent to those skilled in the art, given the teachings herein, that numerous alternatives and equivalents exist which are within the scope of the invention. Therefore, the foregoing description is not to be interpreted as limiting, and the scope of the invention is to be limited only by the appended claims. | A perineal protection device for use during childbirth comprises one or more pads configured to be placed on the perineum and having a varying level of resistance to stretch along the anterior-posterior axis between the vaginal opening and the anus. The device further includes attachment means in the form of adhesives, hooks, sutures, or other suitable means, for adhering the pad to the skin during childbirth, with the result that stress on the perineum is reduced during childbirth, thus reducing tearing during childbirth. The resistance to stretch is relatively lower near the vaginal opening, and relatively greater near the anus. The increase can be linear or nonlinear. The pad can be formed monolithically or in multiple portions. The resistance to stretch can be varied by varying the modulus of elasticity, varying cross-sectional area, or other suitable mechanical or materials-based techniques. | 0 |
PRIORITY
[0001] This application claims the benefit of co-pending provisional patent application 61/813,289 filed Apr. 18, 2013 entitled “A System To Disperse Luminance” by the same inventor which is incorporated by reference as if fully set forth herein.
BACKGROUND
[0002] The present invention relates generally to a luminaire and with more particularly to a modular lighting system, comprising a plurality of lighting system components, which can be designed in a variety of different ways. With even more particularity, the invention appertains to a system to distribute light.
[0003] Lighting fixtures are one of the basic lighting devices used in homes, offices and a variety of industrial settings. A typical lighting fixture may be mounted on a wall, at a position above a desk, in a corridor, a door entrance, or a garage door such that the lighting fixture can illuminate the area. There are many factors that control the market for luminaires and lighting systems. A few important factors are the ability to create a well-lit hospitable environment, cost efficiency such as operating cost and other associated costs, code compliance, and more particularly the distribution of light and shadows. Traditional luminaires create shadows, specifically hard shadows. Hard shadows are crisply defined and have sharp edges, which can produce a harsh or inhospitable environment. Theses shadows have an umbra, a completely dark shadow cast by an object. Hard shadows lack a penumbra, which is a partial shadow between the complete shadow and complete luminance, where part of the light source is visible. Hard shadows have a sharp transition between complete luminance and umbra, which creates distinct lines. This issue is magnified when luminance is needed for highlighting an article or specific area, such as a display on a table. In this instance, the hard shadows may cast lines onto the article thus masking features, changing the appearance of the article and altering the intended viewed composition. Additionally lighting designers have the task of positioning luminaires to distribute the light to a specific location. To make the environment's luminance more comfortable and make articles in the surrounding area look more natural, a reduction of bold shadows and control of luminance placement is needed.
SUMMARY
[0004] Disclosed herein is a device comprising: a housing with a compartment formed with a first channel abutting one side of said compartment and a second channel, disposed opposite said first channel and abutting said compartment. A first light control is disposed in the first channel and has a portion extending from the first channel over the compartment and a second light control with a portion extending from said second channel over said compartment. A light source is disposed in the compartment and shines light through said first and second light control. The light source may be either a light emitting diode or a fluorescent lamp. The second light control may include a pattern disposed on said second light control which operates to disperse the light.
[0005] The construction and method of operation of the invention, however, together with additional objectives and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 depicts certain aspects in an exploded view of one embodiment of a system to distribute luminance.
[0007] FIG. 2A and FIG. 2B show two alternate embodiments of a system to distribute luminance without secondary light controls.
[0008] FIG. 3 illustrates one embodiment of a system to distribute luminance according to aspects of the current disclosure.
DESCRIPTION
[0009] Specific examples of components and arrangements are described below to simplify the present disclosure. These are, of course, merely examples and are not intended to be limiting. In addition, the present disclosure may repeat reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed.
[0010] Read this application with the following terms and phrases in their most general form. The general meaning of each of these terms or phrases is illustrative, not in any way limiting.
[0011] Lexicography
[0012] The term light source generally includes conventional light sources such as incandescent bulbs, fluorescent lamps, light emitting diodes (LEDs), halogen lamps and the like.
[0013] The term “luminaire” generally refers to a lighting unit consisting of a light source such as a lamp or light emitting diode (LED) together with the parts designed to distribute the light, to position and protect the light sources, and to connect the light sources to a power supply. In some instances a luminaire may not include a light source, but may be operable to
[0014] The term “luminance” generally refers to the brightness of a light source or an object that has been illuminated by a source.
[0015] The term “translucent” generally refers to permitting light to pass through an object while diffusing the light.
[0016] Detailed Description
[0017] FIG. 1 depicts certain aspects in an exploded view of one embodiment of a system to distribute luminance 100 . The system to distribute luminance 100 has a housing 110 . The housing 110 is formed having a pair of channels 112 running along the walls of the housing 110 . In between the channels 112 is a compartment for housing lighting components, such as a lamp or LED (not shown). The inventor contemplates using extruded plastic or metal to form the housing 110 . However, one skilled in the art would recognize the use of other suitable materials that can provide the material strength required for supporting a luminaire. This embodiment of a system to distribute luminance 100 allows for use of a single extruded housing 110 , in place of multiple extrusions.
[0018] Primary Light Control
[0019] The housing 110 is coupled to a primary light control 114 . The primary light control 114 is formed having a complimentary shape to that of the channels 112 to effectuate coupling of the primary lighting control 114 to the housing 110 . Adjoining the complimentary shape of the primary lighting control 114 is an overhang. The overhang, when coupled to the housing 110 , covers a portion of the housing's 110 compartment. As such, the primary lighting control 114 acts to shield light emitted from a light source. Depending on the type of shielding necessary, the primary lighting control 114 can be modified. One possible embodiment of a modification is shown as 116 . The primary lighting control 116 couples to the housing 110 via the channels 112 , in the same manner that the primary lighting control 114 would be coupled.
[0020] Certain embodiments include a light source (not shown) placed on the housing 110 such that the light source is placed between the channels. The light source may be one of more LEDs mounted on a circuit board or a lamp affixed to the housing 110 . The primary light control is shaped to have part of the light control extending over the space where the light source is positioned. In some embodiments the light control may extend all the way over a light source. As shown in FIG. 1 the lighting controls 114 and 116 may be asymmetrical having the effect that light will be directed out of the compartment at differing angles in response to the shape of the lighting controls 114 and 116 . Moreover a lighting designer may employ different shapes to create a desired lighting pattern by modifying the lighting controls 114 and 116 . For example and without limitation, lighting controls may be employed to compensate for bright regions (hot spots) emanating from light sources such as LEDs to create the impression of uniform lighting.
[0021] Secondary Light Control
[0022] A secondary lighting control 118 is also coupled to the housing 110 . The secondary lighting control 118 is formed having a size and shape complimentary to that of the coupling side of the housing 110 . When coupled to the housing 110 , the secondary lighting control 118 provides for bending or diffusing of the light, which affects the pattern of luminance and shadow pattern in the surrounding area. The inventor contemplates using a transparent material but one having skill in the art will appreciate that results of the secondary lighting control 118 may be effectuated using other materials. The secondary lighting control 118 may have a pattern 120 , also used to bend or diffuse the light.
[0023] References in the specification to “one embodiment”, “an embodiment”, “an example embodiment”, etc., indicate that the embodiment described may include a particular feature, structure or characteristic, but every embodiment may not necessarily include the particular feature, structure or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one of ordinary skill in the art to effect such feature, structure or characteristic in connection with other embodiments whether or not explicitly described. Parts of the description are presented using terminology commonly employed by those of ordinary skill in the art to convey the substance of their work to others of ordinary skill in the art.
[0024] FIG. 2 shows two alternate embodiments of a system to distribute luminance 200 without secondary light controls. The system to distribute luminance 200 is shown in FIG. 2A to have a housing 210 coupled to a primary light control 212 . When coupled, the primary light control 212 fits snugly within the channels of the housing 210 . In operation, the primary light control 212 blocks part of the housing's 212 open compartment. The placement of primary light control 212 shields light emitted from the lamp (not shown). When the light is shielded, an altered path for a beam of light 214 is created. FIG. 2B shows a different angle and path of a beam of light 214 . The cut-off angle is changed when the primary light controls 212 are modified. The primary light controls 212 may be formed using a metal or plastic but one having skill in the art will appreciate that other materials may be used to mask light. In some embodiments the primary light control 212 may employ surfaces with different reflectivity to achieve desired lighting affects.
[0025] FIG. 3 illustrates one embodiment of a system to distribute luminance 300 according to aspects of the current disclosure. The system to distribute luminance 300 is shown having a housing 310 coupled to a primary light control 312 and additionally coupled to a secondary light control 314 . The secondary light control 314 , when coupled to the housing 310 , is positioned over the primary light control 312 to further control the dispersion of light from the light source (not shown). The altered path for a beam of light 316 resulting from the secondary light control 314 is shown. The secondary light control 314 may have a pattern to help diffuse the light. The inventor contemplates utilizing silkscreen printing or ink jet printing to apply the pattern. However one having skill in the art will appreciate that other methods to apply patterns may be used to mask light.
[0026] Depicted in FIG. 3 is one embodiment of a pattern, a soft-shadow pattern. This soft-shadow pattern shown in the figure has a gradient of a highly dense layer of marks to a sparse layer of marks. When placed in front of a lamp, the soft-shadow pattern affects the pattern of luminance and shadow pattern in the surrounding area. As light from the lamp passes through the pattern, the percentage of visible portions of the lamp and the light distributed as it shines through the sparse layer of marks is larger than when passing through the highly dense layer of marks, which allows no light to pass. The soft-shadow pattern diffuses the light from the lamp. The intensity of the light passing through the soft-shadow pattern smoothly varies from no shadow to a complete shadow. This shadow pattern created from the soft-shadow pattern generates regions of umbra and penumbra. As suggested above, the penumbra of the shadow allows for more visible luminance than the umbra of the shadow. This type of light pattern is diffuse and creates no visible hard lines. Thus employing the soft-shadow pattern in a luminaire casts a soft shadow. This type of luminance is optimal to eliminate lines and edges caused from light and shadows and alleviate glare issues. The soft-shadow pattern may be translucent, have different colors, or have a regular or randomized pattern, and is not limited to the features show in the figure.
[0027] In operation the embodiments shown and described herein act to direct light from any light sources attached to a housing through the first and second light control to create a desired lighting effect. In some embodiments multiple LED light sources may be employed. Light controls may be constructed using the elements described herein to provide more uniformity to the radiated light pattern or to direct tha light pattern to a certain area or direction. Diffusion patterns may be printed on the second light control to give the appearance of a uniform light source. Moreover, lamps often have hot-spots of intense lighting which may be mitigated using one of more of the light controls described herein.
[0028] The above illustration provides many different embodiments or embodiments for implementing different features of the invention. Specific embodiments of components and processes are described to help clarify the invention. These are, of course, merely embodiments and are not intended to limit the invention from that described in the claims.
[0029] Although the invention is illustrated and described herein as embodied in one or more specific examples, 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. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the invention, as set forth in the following claims. | A device with a housing with a compartment formed with a first channel abutting one side of said compartment and a second channel, disposed opposite said first channel and abutting said compartment. A first light control is disposed in the first channel and has a portion extending from the first channel over the compartment and a second light control with a portion extending from said second channel over said compartment. A light source is disposed in the compartment and shines light through said first and second light control. The light source may be either a light emitting diode or a fluorescent lamp. The second light control may include a pattern disposed on said second light control which operates to disperse the light. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. Ser. No. 10/252,115 filed on Sep. 23, 2002, which is a continuation-in-part of U.S. Ser. No. 09/464,132 filed on Dec. 16, 1999, now U.S. Pat. No. 6,455,321, which claims the benefit of provisional application U.S. Ser. No. 60/117,880 filed on Jan. 30, 1999 the disclosures of which are hereby incorporated by reference in their entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a high throughput, cost-effective, and low false-positive method of genetic screening, capable of performance over a wide range of metabolite groups, using electrospray tandem mass spectrometry. Efficient sample preparation and stringent quality controls are implemented as critical keys in maintaining consistency and accuracy in the resulting data for use in medical diagnosis.
[0004] 2. Description of Prior Art
[0005] Mass spectrometry has been making significant contributions to the diagnosis of metabolic diseases for over 20 years. Fast Atom Bombardment Tandem Mass Spectrometry (FAB-MS/MS) analysis of acylcarnitines in very small volumes of whole blood or plasma has been previously made routine. See Millington, et al., Mass Spectrometry: Clinical and Biomedical Applications, 1, ch. 8, 299-318. It had been a very satisfactory biochemical method for the differential diagnosis of disorders of fatty acid catabolism, and the instrumental method recognized numerous defects of branched-chain amino acid catabolism. The frequency of occurrence of these diseases and their association with sudden, unexplained deaths has generated a great medical interest in the development of neonatal screening tests.
[0006] Routine analysis of amino acids and acylcarnitines by Liquid Secondary Ion Tandem Mass Spectrometry (LSIMS/MS) from blood spots on filter paper has been demonstrated previously as well. See Chace et al., “Neonatal Screening for Inborn Errors of Metabolism by Automated Dynamic Liquid Sewary Ion Tandem Mass Spectrometry New Horizons in Neonatal Screening, 1994. To increase the number and rate at which samples can be analyzed, the development of automated sample preparation, instrumental analysis, and data interpretation was required. The increase in sample throughput and the ease of sample preparation allows for the more efficient and exacting diagnosis of a great number of metabolic disorders, a process necessary in determining the health of a newborn baby, or, for that matter, anyone in clinical care. The ranges of clinical symptoms and abnormalities in simple blood tests are so extreme that extensive biochemical investigation is warranted whenever metabolic disease is suspected, as noted in Millington, et al., “Diagnosis of Metabolic Disease,” from Biological Mass Spectrometry: Present and Future, 3.15, 1994.
[0007] Metabolic profiling of amino acids and acylcarnitines from blood spots by use of automated electrospray tandem mass spectrometry (ESI-MS/MS), is a more powerful diagnostic tool for inborn errors of metabolism. See Rashed, et al., Clinical Chem. 43:7, 1129-1141. New approaches to sample preparation and data interpretation have helped establish the methodology as a robust, high-throughput neonatal screening method. Compared with older methods, ESI-MS/MS is much more versatile and less labor intensive, because most of the steps can be automated.
[0008] Inborn errors of metabolism usually result from defective enzymes or cofactors. Medium-chain acyl-CoA dehydrogenase (MCAD) deficiency is a very common disorder of fatty acid oxidation. As seen in Chace et al., Clin. Chem., 43:11, 2106-2113, MCAD deficiency is diagnosed on the basis of the increase of medium chain length acylcarnitines, as identifiable by isotope dilution mass spectrometry methods. Butyl esters of acylcarnitines share a similar fragmentation pattern with a common fragment ion at 85 Da after collision-induced dissociation using a mass spectrometer. The fragmentation pattern differences are compared to known spectra of healthy individuals and thereby can be diagnosed. In a clinical setting, analysis of acylcarnitines by tandem mass spectrometry is possible as their associated methyl esters allow the diagnostic recognition of all patients with MCAD deficiency, regardless of the underlying mutation, symptomatic state, or treatment Also, the analysis of amino acids as their associated butyl esters has been validated for newborn screening of phenylketonuria (PKU), tyrosinemia, maple syrup urine disease, and homocystinuria, all of which, among others, are detected by mass spectrometry.
[0009] The most selective and sensitive spectrometry, as it relates to genetic disorders, is performed by the automated, electrospray tandem mass spectrometer. The use of ESI-MS/MS has been presented to successfully and quickly provide a specific and accurate screening method (Rashed, et al.). The method itself, however, must be complemented with an efficient sampling procedure and optimized injection and scan function mode to accommodate, with utmost accuracy, many samples at one time, thereby maximizing throughput while maintaining sensitivity and accuracy.
[0010] The efficiency of the ionization of the compounds is very high with the implementation of electrospray ionization. As seen in U.S. Pat. No. 5,352,891, Monning et al., the high ionization efficiency allows useful spectra required for even very small quantities of material. In other words, electrospray tandem mass spectrometry is very sensitive and specific in regards to its compound injection systems, thereby allowing a more broad spectrum of diseases to be covered, a lower false positive rate to be achieved, high specificity to be obtained, and shortened analytical time permitted. The use of the electrospray tandem MS/MS has been shown to increase throughput. Moreover, the technique has been successfully applied to prenatal diagnosis (Rashed, et al., 1130) and other screening processes. However, optimization of the method of screening newborns must be achieved by maximizing sample throughput in the most efficient and accurate way, beginning in the sample preparation, and culminating with the quality assurance. The overall process lends itself to parental peace-of-mind, and expedient and cost-effective results.
[0011] Sample preparation in support of the genetic screening of an individual for carnitines and .alpha.-amino acids (genetic markers for inborn errors in metabolism) for use in mass spectrometry is seen in the art. The standard method of collecting samples for neonatal screening is a heel prick followed by depositing the whole blood on special filter paper (or Guthrie cards) as a series of spots. See Millington, et al., International Journal of Mass Spectrometry and Ion Processes, 111,212, 1991. The latest developed method of preparing the butyl ester derivatives of acylcamitines and amino acids from the blood spots consists of processing samples in microplates. An automated blood-spot puncher punches a single blood spot from each Guthrie card directly into the individual wells of the microplate. To the blood spot punch in each well a methanolic solution containing known concentrations of stable isotope-labeled standards is added. The label standards might include glycine and alanine; valine, methionine, and phenylalanine; leucine and tyrosine; ornithine; carnitine; acetylcarnitine; propionylcarnitine; octanoylcarnitine; and palmitoylcarnitine, all in combination in some concentration as to enhance the sensitivity for particular compounds, as required by respective testing protocol. The samples are extracted and the extracts are then transferred to another microplate where the methanol is removed through evaporation. To the residue in each well, butanolic HCl or other chemical modifiers are added and the derivatization is completed by heating. Final residues are reconstituted and placed in an autosampler tray for introduction into the MS.
[0012] The incorporation of isotope-dilution techniques as standards provides quantitative information for specific components of each sample. There is the need for an optimal concentration of a combination of 12 amino acid standards and 8 acylcarnitinelcarnitine standards to improve accuracy and provide for quality control, as well as to provide for a number of scan functions that maximize metabolite information with high-throughput. Quality control and quality assurance in a clinical environment is of utmost importance because of the method and instrumentation that has evolved for the optimization of sample throughput. It is especially important as mass spectrometry results are correlated to the general populations of newborns so as to show accurate results in demographic trends.
[0013] The advantages of ESI-MS/MS over alternative methods of analysis are its high specificity and accuracy of quantification through use of the isotope-dilution technique, plus its speed and amenability to automation See Chace et al., Clin. Chem. Vol. 39, No. 1, 1993. Coupling the sensitivity in detection with the requirement that newborn screening requires rapid throughput, high accuracy, high precision, high selectivity, and a high value to low cost ratio, there is now a need in the clinical environment, now satisfied by the present invention, for an accurate means of assuring the quality of data for genetic disorder diagnosis is obtained in an organized and accurate manner. This quality can be coupled to the most efficient method of preparing and scanning samples, so as the number of false-positives and false-negatives are reduced, and sample throughput is necessarily maximized in the diagnostic clinical setting.
[0014] 3. Prior Art
[0015] U.S. Pat. No. 5,538,897, Jul. 23, 1996 (Yates, III et al.) shows a method for correlating a peptide fragment mass spectrum with amino acid sequences derived from a database. A peptide is analyzed by a tandem mass spectrometer to yield a peptide fragment mass spectrum. A protein sequence database or a nucleotide sequence database is used to predict one or more fragment spectra for comparison with the experimentally derived fragment spectrum. The various predicted mass spectra are compared to the experimentally derived fragment spectrum using a closeness-of-fit measure, preferably calculated with a two-step process, including a calculation of a preliminary score and, for the highest-scoring predicted spectra, calculation of a correlation function.
[0016] U.S. Pat. No. 5,206,50 Apr. 27, 1993 (Alderdice et al.) teaches a tandem mass spectrometry system, capable of obtaining tandem mass spectra for each parent ion without separation of parent ions of differing mass from each other. This system would in addition provide the capability to select a particular ion prior to excitation.
[0017] U.S. Pat. No. 5,352,891, Oct. 4, 1994 (Monning et al.) demonstrates the production of mass spectra of chemical compounds of high molecular weights having a multiplicity of peaks is improved by generating an enhanced mass spectrum from the observed mass-to-charge spectrum. Signal to noise ratio can in some applications be improved by including in the product all portions within the discrete peaks in the mass-to-charge spectrum, which are contained within a window around each of the discrete peaks.
SUMMARY OF THE INVENTION
[0018] It is the objective of the present invention to improve the method of screening newborns by implementing efficient sampling protocols and data quality controls. As initial and final steps to the use of electrospray tandem mass spectrometry for inborn metabolite error screening, the sample efficiency and quality assurance will complement a more rapid sample throughput method with a high value to low cost ratio. All values are compared to known thresholds as a means for evaluating the contents of the sample. High accuracy and high precision found in a large number of samples will quickly provide consistent diagnosis at the clinical level.
[0019] Electrospray tandem mass spectrometry is very sensitive and specific and can detect a broad spectrum of disorders at the genetic level. The already shortened analytical time and high specificity increases the rate at which samples that can be analyzed. Including internal standards in the sample preparation that decrease extraction error and allow for mixed mode scan functions further increases sample throughput The internal standards are used to provide the quantitative information needed to detect specific components. Use of proper ratios of each particular ion enables the detection of many metabolites at one time, thereby eliminating duplicate analysis, allowing secondary runs to be used for quality assurance and proficiency testing rather than for detection of preliminary compounds.
[0020] It is a secondary objective of the present method to include EDTA standards that can determine whether or not the blood was collected properly. Contaminated blood or blood collected from tubes rather than a heel prick spot is improper and identifiable by this standard.
[0021] It is a third objective of the present method to include quality assurance standards such as 2 H 3 -Serine (deuterium 3 labeled Serine) to show the computer is recognizing normally unfounded compounds. Serine is an amino acid that is not included or recognized in a normal scan, so 2 H 3 -Serine is added to an acylcarnitine scan to show that, when this compound is detected and shown as a peak, the computer is capable of detecting foreign compounds. In effect, drug-ridden or contaminated samples may be flagged.
[0022] It is a fourth objective of the present method to include proper correction factors, mass values, quality assurance flags, and sample preparation flags as input values, complementing a database that is used for checking calculations as produced using a spreadsheet, thereby insuring accurate data reduction. This provides enhanced quality assurance. When an abnormal sample is noted, a recommended action is to be taken. Database storage of values facilitates disease rate data reporting, trend generation and analysis, total sample-per-day values, and QA/QC analyses.
[0023] It is a fifth objective of the present method to include a quality control step that uses unlabeled standards and control blood standards to assure the consistency and accuracy in the detection of the twenty metabolites.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] Accordingly, the method generally comprises, after receiving a plurality of blood spots, combining an amino acid standard and a free carnitine/acylcarnitine standard to form an internal standard containing a plurality of labeled compounds. A plurality of samples are prepared wherein each of said samples comprise the internal standard, methanol, and a blood extract from one of the blood spots taken from the newborn baby. The samples are scanned using the electrospray tandem mass spectrometer to produce scan results. Control blood samples are then prepared and scanned, wherein each of said control blood contain hemolyzed blood, EDTA, 2 H 3 -Serine. A plurality of standards having hemolyzed blood, EDTA, 2 H 3 -Serine, and one of the labeled compounds is also prepared and scanned. Ultimately, the control sample results obtained for each of the quality control samples is compared to the plurality of standard results obtained for each of said standards. In this way, the data obtained for each newborn scan result is assured accuracy and consistency for any further action such as diagnosis or re-testing.
[0025] FIG. 1 is a simplified block diagram showing the overall methodology. Five principle processed are correlated from sample preparation to system diagnostics.
[0026] FIG. 2 is a block diagram showing in more detail the steps involved in preparing the sample.
[0027] FIG. 3 is a block diagram showing in more detail the steps involved in the automated use of an electrospray tandem mass spectrometer to include the use of proper scan functions to maximize accurate output.
[0028] FIG. 3 a is a spreadsheet showing the possible upper or lower thresholds used to determine which samples are to be flagged for further decision-making or re-testing.
[0029] FIG. 3 b is an example of a Free Carnitine MRM scan, showing the pertinent peaks and values for quality assurance.
[0030] FIG. 3 c is an example of an Acetylcamitine MRM scan, showing the pertinent peaks and values for quality assurance.
[0031] FIG. 3 d is an example of a full scan Acetylcamitine profile, showing the pertinent peaks and values for quality assurance.
[0032] FIG. 3 e is an example of a full scan Amino Acid profile, showing the pertinent peaks and values for quality assurance.
[0033] FIG. 3 f is an example of a basic Amino Acid MRM scan, showing the pertinent peaks and values for quality assurance.
[0034] FIG. 4 is a block diagram showing in more detail the steps involved in processing the data after acquisition of the values, which have been produced from the spectrometer.
[0035] FIG. 5 is a block diagram showing in more detail the steps involved in interpreting the data as it relates to demography and decision making.
[0036] FIG. 6 is a block diagram showing in more detail the steps involved in monitoring system diagnostics and implementing quality controls.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0037] The method will now be described in detail in relation to a preferred embodiment and implementation thereof, which is exemplary in nature and descriptively specific as disclosed. As is customary, it will be understood that no limitation of the scope of the invention is thereby intended The invention encompasses such alterations and further modifications in the illustrated device, and such further applications of the principles of the invention illustrated herein, as would normally occur to persons skilled in the art to which the invention relates.
[0038] FIG. 1 represents an overview of the method of screening newborns in the clinical diagnostic setting involving five main steps, each of which are important for rapid, automated, and accurate sample analysis. Efficient sample preparation 10 is necessary to insure accurate derivatization of the metabolites, and certain additives or internal standards are implemented and important to provide quantitative information for specific components of each sample. After sample preparation 10 , the samples are loaded into the electrospray tandem mass spectrometer 12 , which implements many automated features to insure the speed and consistency of sample scanning. Data is then acquired and processed to a reduced and organized form as seen in box 14 . Values produced from the scan of the mass spectrometer are processed and printed into spreadsheet form to further allow checking of the calculations, a means of assuring accurate number production and quality. Acquired data is then interpreted by an assisted diagnostic interpretation system 16 which integrates the results with the demographic data related to the baby and allows for correlation to a specific disorder based on any noted peaks. The process, working in conjunction with software, allows for data reporting which is a way of monitoring daily output and assisting in necessary decision making for further action, such as follow-up, or re-testing. All spectra data is kept accurate using system diagnostic checks and quality control samples as seen in step 18 . To assure diagnostic accuracy and sample quality, periodic system integrity checks and control samples that include specific additives are employed. In combination, the above-mentioned steps maximize the rate and quality at which newborn blood samples are screened for metabolic disorders, which is necessary in the clinical setting.
[0039] FIG. 2 shows an overview of the sample preparation procedure (step 1 of FIG. 1 ). An initial sample login 20 is performed by coding each sample, thereby associating the sample to a specific location in a microtiter well. The samples consist of blood spots placed on designated areas of filter paper. The spots are punched with a diameter in the range of 3/16 in. to ⅛ in. and placed into the designated microtiter well. Internal standard preparations 22 are prepared in methanol to produce an extraction solvent, which is added to the dry blood spot in each well. Extraction solvent additions 24 are performed using automated sample handling equipment.
[0040] The methanol serves as the solvent extraction medium while the internal standards serve to quantify the metabolites in the dry blood matrix The internal standard preparations 22 comprise an ideal mix of twenty stable isotopes—twelve amino acid standards and eight acylcarnitine/carnitine standards. A list of the amino acid standards can be found in FIG. 2 a the left column shows the standard concentrations of the concentrated working stock 20 a . The stock solution is diluted 1:100 v/v with methanol to produce concentrations of daily working standards 22 a . The concentrations of the daily working standards 22 a can be adjusted to analyze two 3/16″, two ⅛″ or a single ⅛″ dried blood spots by adjusting the volume of the extraction solvent additions 24 ( FIG. 2 ) or the concentration of the working stock 20 a . The daily working standards 22 a serve as both the extraction solvent and the means for internal standardization of the analysis.
[0041] Free Carnitine and Acylcarnitine internal standards are listed in FIG. 2 b . Again, the left column lists the concentrations of the working stock 20 b used in the dilution with methanol 1:100 v/v, to produce the daily working standards 22 b . Also, the daily working standards 22 b can be adjusted as described above for the blood spot analysis.
[0042] Both groups of standards are provided in the extraction medium for the optimum mixed mode scan functions, which maximize metabolite detection. The metabolite groups detected include the .alpha.-amino acids—alanine, phenylalanine, tyrosine, glutamic acid, ornithine, citrulline, arginine—and the carnitines—free carnitine, acylcarnitines, acetylcarnitine, octanoylcarnitine, palmitoylcarnitine.
[0043] Now following FIG. 2 , after extraction solvent addition 24 , the solvent is transferred at step 26 to a plate, or microtiter plate, having rounded-bottom wells where the solvent is removed using a nitrogen drying system at step 27 . The blood extract then undergoes esterification and is chemically modified and heated at step 28 to become a derivative. Excess derivative is removed at step 29 and a mobile phase solvent is added using an automated sample handling system. Plate seals retard any solvent evaporation.
[0044] FIG. 3 shows the steps involved after the sample is prepared and standards are included and made ready for introduction into the automated electrospray tandem mass spectrometer. Optimization of the MS/MS systems 30 is achieved by using a tuning solution, and the electrospray MS/MS system 32 is a low flow rate system employing the use of a fused silica line displaced to the tip of the electrode. Automated injection systems 34 use the fused silica line to directly connect the injector to electrode tip to minimize dead space. The scans implemented to detect the necessary fragments of the ions consist of five mixed-mode scan functions 36 for maximizing metabolite and quality assurance information. The mixed-mode scan functions 36 include free camitine MRM, acetylcarnitine MRM, fill scan acylcarnitine, fill scan amino acids, and basic amino acid MRM, whereas a full scan covers a wider range of mass to charge ratios, thereby a wider range of peaks can be compared. Each peak corresponds to a concentration or threshold number and compared to a known upper or lower threshold.
[0045] Examples of the values of the thresholds can be seen in FIG. 3 a . It should be understood that all sample values necessary in metabolic error determination or quality assurance falling above or below a certain threshold are flagged, or identified, for diagnostic purposes, re-testing, or other clinical decision-making.
[0046] FIG. 3 b demonstrates a Free Carnitine MRM implementing quality assurance. An MRM is a scan for a particular compound showing dual masses 401 (parent mass and daughter mass respectively). A first peak 403 is detected as the free carnitine fragments. The resulting concentration of Free Carnitine 405 is then given Quality is assured in this scan by looking at the d 3 free CN (deuterium 3 free carnitine) peak 404 which comes from the hydrolysis of d 3 labeled acylcarnitines. The resulting “hydrofree” concentration value 409 is a quality assurance flag for acylcarnitine hydrolysis and is also a correction for true concentrations of Free Carnitine 405 .
[0047] FIG. 3 c demonstrates an Acetylcarnitine MRM. Peak 501 is the acetylcarnitine (acetylCN) peak and peak 503 is a quality assurance (QA) peak manifesting the hydrolysis of glutamate. The resulting glutamate concentration 505 shows the amount of interference from a glutamate, which is corrected for in the acetylCN concentration 504 determination Other QA checks for propionyl CN are implemented in this scan as duplicate peaks 507 and 509 .
[0048] A profile of the Acylcarnitine full scan is shown in FIG. 3 d . Added internal standards are fragmented and revealed as peaks 601 , 602 , 603 , 604 , 605 . A list of the concentrations of the detectable metabolites 610 is then provided as well as the molar ratios 612 . A QA test is included in this scan as a bad derivative value 614 which stems from any peak found around a m/z, amu value of 403. The bad derivative value 614 would reveal poor sample preparation if elevated. An EDTA QA flag 616 is also implemented to reveal sample collection method. Elevated values of the EDTA QA flag 616 manifest samples drawn from tubes rather than heel pricks, or reveal lengthy preservation maintenance.
[0049] Another QA method is used in this scan, revealed by an intensity value 618 . An elevated intensity value shows the sample was scanned with adequate sensitivity. If the intensity value 618 is too low, the sample will be flagged (noted), and the sample may be re-tested depending on the protocol.
[0050] FIG. 3 e is an example of a full scan Amino Acid analysis. Amino acids in the internal standards fragment and are shown as peaks 710 , 711 , 712 , 713 , 714 , 715 , 716 , 717 . Amino Acid concentration values 701 are listed, along with a QA flag value 703 at around a m/z, amu value of 165. The QA flag value 703 would most likely be produced from the addition of 2 H 3 -Serine, which would be added in a sample to manifest proper detection of compounds normally not found in a routine sample, as Serine is an amino acid not included in the list of amino acids relevant to any disorders. An intensity flag 705 is also implemented to show adequate sensitivity in detection.
[0051] FIG. 3 f is an example of a basic Amino Acid MRM. The QA flag occurs at peak 802 , and the scan includes duplicate Citrulline analysis 804 , normally peaking around a m/z value of 215 and 232.
[0052] FIG. 4 describes the processing of the data acquired from the scan functions used for the mass spectrometer. Step 40 is the input of all mass values, constants for concentration calculations, correction factors for extraction efficiency, ratios of concentration data, and cut-off values. Quality assurance flags, sample preparation flags, and sensitivity flags are also inputted. The flags include the above described peaks, intensity values, bad derivative values, and EDTA values, and are important because they reveal whether or not the samples are contaminated or drug-ridden, and they are very telling of how the samples were contained, or from where the samples were drawn. Also, they assist in maintaining instrument accuracy and consistency. The results are processed and printed for step 42 . The scan functions described for FIGS. 3 a - 3 e can detect multiple diseases based on the fragments of the metabolites detected The revealing peaks will eventually lead to the profiles noted in boxes 43 a and 43 b . The profiles may include the noting of peaks picked up using the quality assurance or quality control standards as well.
[0053] FIG. 5 shows the steps involved in interpreting the organized data. The spreadsheet data is inputted to a database module for recognition of the file and sample types. As seen in step 50 , the data is interpreted so parameters can be assigned to the particular sample, and the results given. The results are then integrated in step 52 with demographic data of the newborn. The demographics may include age, type of specimen, or other notation such as whether or not the baby is premature, etc. Samples that show an abnormality, or seem to show a revealing peak, are flagged to be interpreted using a reference guide and decisions are made on the next course of action as step 54 . Referencing the decision tree and recommending action would be the next step as step 56 . The flagged samples are correlated with the database module used to distinguish abnormal peaks, and a decision to re-test or diagnosis is made. In step 58 , as a measure of quality assurance and quality control, the days mean sample and trend generation is recorded to follow the statistical occurrences of diseases, and to maintain high-throughput sampling. This includes automated data reporting and internet communication reporting.
[0054] FIG. 6 shows the steps involved in further maintaining quality assurance using quality control samples and maintaining system integrity. Quality control samples are prepared as step 60 . The samples consist of QA blood spots and liquids prepared as unlabeled standards at the same concentrations as the internal standards, and scanned The control blood standards implemented in this step 60 consist of hemolyzed blood, EDTA, and 2 H 3 -Serine, or some other recognized marker. These are run and compared to standards that consist of hemolyzed blood, EDTA, 2 H 3 -Serine, and one of the twenty compounds that are the same as those used in the internal standards, but unlabeled. The computer is properly set up to recognize and interpret the results. Another step in maintaining quality assurance is provided as step 61 . Systems are monitored in a database program to detect changes in system integrity or sensitivity. A final step in maintaining system diagnostics is included as step 63 . Maintenance methods and schedules are constantly followed and monitored through archival systems and via the Internet through ongoing monitoring of mass spectrometry data. | A method for screening newborns using electrospray tandem mass spectrometry. The method improves the current protocols that use tandem mass spectrometry by assuring accurate and consistent results at the clinical level through enhanced quality controls and quality assurance protocols as applied to the scan profiling and sample preparation of blood spots from newborns. Specific additives are used in precise concentrations of internal standards, employing detailed controls adapted to distinguish twenty metabolites, which are scanned and vigorously compared to known spectra results. Revealing peaks, metabolite concentration, and scan intensities in the quality assurance steps are then compared to a range of thresholds to determine whether or not the sample is contaminated, drug-ridden, diagnosable, or unacceptable. All spectra results and quality assurance flags are organized in spreadsheet form and exported to a database where values are compiled and stored for daily output results and trend analysis. The method provides for high-throughput and quality results, having a consistent predictability for genetically testing newborns efficiently and accurately. | 6 |
The present invention relates to a post protector used in storage warehouses and the like and, more particularly, to an anchor structure for use in a post protector system.
The invention is particularly applicable to and will be described with specific reference to preventing impacts from warehouse vehicles and other objects to structural columns within a warehouse system. However, it will be appreciated that the invention is applicable to a post protector for any type of structural column or as temporary protection to certain columns during construction or as an anchor structure for any column not requiring a rigid connection.
BACKGROUND OF THE INVENTION
A post protector is a term commonly used in the art to define any system or method in which a structural column is protected from shock or impact loading, such as when a column is rammed by forklift trucks in a warehouse setting. As used herein, post protector includes not only protection of such warehouse structural columns but includes protection for any columns in which it is desired that the column be protected from shock or impact loading,
Post protectors typically consist of any intermediate object between a column and the object which may produce an impact load such as a forklift truck. Traditionally, such intermediate objects have consisted of curbs or "stops" placed on the floor or formed in place to prevent the wheels of a vehicle from impinging upon the space where the structural column is located. Typically, the "stops" are not anchored in place and thus do not effectively control the vehicle's movement. Where the post protector consists of a curb, a warehouse floor is typically constructed at different elevations, thereby hindering any flexibility as to arrangement within the warehouse. Additionally, such curbs can serve to reduce access to a rack as they not only protect the zone around a column but serve to protect a zone surrounding the entire rack system. Finally, while such systems may prevent a vehicle from entering a specified zone by prohibiting tires from traversing further, the forks on a forklift truck typically extend beyond the low stops or curbs, thereby negating any advantage gained with stops or curbs.
Further improvements in post protectors have resulted in structures specifically made for the purpose of wrapping partially around a column and extending upward from the base of a column to protect the column from the wheeled vehicle and from the forks of a forklift truck. Such prior art post protectors are either anchored to the floor or placed on the floor in front of a column without anchorage. However, it has been found that post protectors without anchors are of little use.
Post protectors without anchors easily move upon the force of impact, and hence do not adequately perform the intended function. While large, heavy, unanchored post protectors may protect a post and not move upon impact, such protectors, such as concrete posts, have the effect of damaging any vehicle or object upon impact. Therefore, it has been found that the most desirable post protectors are anchored to the floor in the vicinity of the column. Such protectors protect the column without reducing flexibility or access to a structural rack.
A typical prior art post protector is made of steel for its strength and rigidity and relatively lightweight properties. Post protectors are typically anchored to a concrete floor by placing an anchor bolt through a flange of the post protector. While such a protector serves the intended purpose of preventing impact to a column for small impact loads, there are a number of disadvantages. An impact on the upper portion of a post protector forces the post protector to rock or pivot about the flange portion, causing the steel protector to cut into the concrete. Additionally, this pivoting action places tensile forces on the anchor bolts and the concrete. Since concrete has very low strength properties in tension, the concrete will crack, loosen and, in extreme cases, pop out of the floor. The structural integrity of the post protector is thereby diminished.
Once the concrete has been weakened or destroyed, it is virtually impossible to repair the concrete to its prior strength. Concrete patches do not adequately bond to the concrete already in place. Therefore, once the anchorage of a post protector has been damaged, it is not possible to re-anchor the post protector with the same strength as when originally placed.
Where the post protector rocks or pivots upon impact with a forklift truck either due to lack of anchorage, or when the anchorage is damaged, the protector hits the column of which it is intended to protect. Such an impact has all the disadvantages of impacting an unprotected column. It may result in damage to the column, reducing the structural integrity, or inducing vibration, causing side sway. Side sway to a loaded rack, upon which pallets are placed may damage the pallet loads or induce loads in the structural rack for which it was not designed, causing catastrophic failure of the entire rack system.
Further, even when the post protector is rigidly anchored and the anchorage does not fail upon impact, the post protector is not allowed to "float" or move to absorb an impact. Therefore, impact upon the post protector can result in damage to either the post protector or the forklift truck. Additionally, the prior art post protector allows dirt to accumulate between the flanges of the post protector itself and between a column and the post protector. In certain industries, especially where food may be stored or spillage is common, such accumulation of dirt and/or spillage is highly undesirable.
SUMMARY OF THE INVENTION
Accordingly, it is a principal object of the invention to provide a post protector which overcomes the disadvantages of prior art post protectors and post protector anchor structures in that an anchor structure for a post protector is provided which safely protects the column while absorbing impact or shock loads.
The present invention overcomes the disadvantages of prior art post protectors by providing a post protector having an elongated portion which is placed adjacent to at least one portion of a column. Further the post protector has a flange portion which extends from the elongated portion and which is placed flush with the floor. The flange portion has a number of openings and further includes an elastic membrane which allows the post protector to move laterally or pivotally in an elastic manner. Finally, the post protector includes fasteners which protrude through openings in the flange and holes in the elastic membrane and anchor the post protector to the floor.
The elastic membrane is comprised of a rubber or plastic material which elastically deforms when subjected to outside forces. The elastic membrane is either mechanically or integrally attached to the flange portion. Preferably, the post protector is located in a position adjacent to a column of a structure. A post protector may be adjacent to all sides of a column or only a portion of all of the sides, but is preferably orientated in a position adjacent the outside edges of a structure where the post protector will best protect the structure from outside shock or impact forces. The post protector is anchored to the floor of a warehouse using concrete drive anchors which are placed through the holes in the flange portion. Thus, when a moving object, such as a forklift truck, is in the vicinity of a structural column, the post protector acts as a buffer between the truck and the structural column. Instead of the truck or other object hitting the structural column, it instead strikes the post protector. This advantageously protects the structural column and thus an entire structural rack from being damaged. Such damage can occur when a column is deformed due to impact or when the force of impact causes the entire structure to shift due to side sway. Damage to one structural column may affect the structural integrity of the entire support structure. Inducing side sway in a structure can result in the collapse of the entire structure.
The prior art shows post protectors anchored within a concrete floor which are easily damaged when hit by an object or piece of moving equipment. The impact upon a prior art post protector rocks the post protector toward the structural column. This causes an uplifting force which has the tendency to pull the concrete anchor free of the concrete. The resulting uplifting force pulls up large chunks of concrete which are greater shaped and can be up to six times the size of the original concrete drive anchor. As the post protector has now lost its structural integrity, it is useless. It is nearly impossible to try to re-anchor a post protector where the concrete has been removed. The present invention solves these problems by providing an elastic membrane at the flange of the post protector. The elastic membrane allows the post protector to elastically move upon impact from an object or equipment. The elastic membrane has the ability to absorb impacts from objects without damaging its structural integrity while continuing to prevent an impact with a structural column.
In accordance with the present invention the elastic membrane is located between the flange of the post protector and the floor. In such a position, the post protector can rock or pivot upon impact, thereby allowing the post protector to elastically crush the elastic membrane at a side closest to the structural column.
Further in accordance with the present invention the elastic membrane includes an elastic cylinder, homogeneous with at least the bottom portion of the elastic membrane. The elastic cylinder is located within the openings of the flange. When the post protector is installed, concrete drive anchors pass through the hole in the elastic cylinder as they are placed in the floor. Preferably, the elastic cylinder has an outside diameter substantially equal to the diameter of the flange opening, and an inside diameter of the hole which is equal to one-half of the outside diameter. Thus, when an object strikes the post protector, the post protector is allowed to pivot due to the bottom portion of the elastic membrane and is also allowed to "float" or elastically and laterally move. Therefore, when an object strikes the post protector, the post protector can simultaneously move laterally toward the structural column and pivot toward the structural column without damaging the concrete anchor.
Preferably, the elastic membrane includes a top portion which is homogenous with the elastic cylinder and bottom portion already described. The elastic membrane thus forms an outer surface of the flange. The concrete drive anchor passes through the elastic cylinder portion as the post protector is mounted to the floor. Preferably, both the top and bottom portions each have a thickness which is substantially the same thickness as the flange leaf encased within the elastic membrane. Therefore, the total thickness of the flange is three times that of the flange leaf.
The elastic membrane which forms the outer surface of the flange allows greater flexibility in elastic movement of the post protector when it is impacted by an object. The top portion of the elastic membrane allows the head of the concrete anchor to deform the upper flange portion as the post protector pivots upon impact. This gives added flexibility to the post protector in combination with the elastic lateral and elastic pivot movement given by the elastic cylinder portion and the bottom portion of the elastic membrane. Further, the top portion of the elastic membrane reduces the tensile stresses upon the drive anchor and thus the tensile stresses upon the concrete to which the post protector is anchored. The elastic membrane serves as a "boot" to give the post protector maximum cushion upon impact. The post is thus protected and the post protector structural integrity preserved to provide a long useful life.
Further in accordance with the present invention the post protector is provided with an elastic post cushion along the upper portion of the elongated portion. Therefore, a structural column is protected from any pivoting of a post protector that is the result of an impact with the post protector. Should the post protector pivot to such an extent that it may contact the structural column, the elastic post cushion prevents metal-to-metal surface contact by elastically softening any impact. Such a post protector in combination with the elastic membrane at the flange has the ability to elastically pivot toward the structural column in a manner greater than heretofore conceived in the prior art. Therefore, any impact not previously dissipated by the elastic membrane on the flange portion is dissipated by the post cushion. Additionally, the elastic post cushion will prevent metal-to-metal contact between the post protector which does not make use of an elastic membrane, as shown in the prior art, and a structural column.
In accordance with another aspect of the present invention, the elastic membrane has a footprint on the ground which comprises a smooth, non-angular, outside footprint. Thus, any spaces between adjacent flange leaves are filled with elastic material. Such a footprint adds to the elasticity of the post protector as a whole and has the added advantage of preventing dirt from being trapped between adjacent flange portions, thus providing a cleaner and more efficient work space,
Thus, it is a principal object of the invention to provide an improved post protector and anchor structure which enables elastic and non-destructive movement of the post protector upon impact with moving equipment or the like.
It is another object of the invention to provide a post protector which prevents moving equipment from impacting upon a structural column.
Still another object of the invention is to extend the useful life of a post protector which is anchored to the floor.
Yet another object of the present invention is to provide a post protector which does not damage the floor upon impact with moving equipment.
Still another object of the present invention is to provide a post protector which can elastically pivot upon impact without affecting the structural integrity of the post protector anchor structure.
Further, another object of the present invention is to provide a post protector which is allowed to elastically and laterally move upon impact without damage to the anchor structure.
Still further, another object of the present invention is to provide a post protector and anchor structure which does not damage the concrete floor in such a manner that re-anchorage is prevented.
It is still another object of the present invention to provide a post protector with a post cushion which prevents metal-to-metal contact between the post protector and the structural column.
Another object of the present invention is to provide a post protector with an outer flange surface which prevents the accumulation of trapped dirt between adjacent flanges thus enabling easy cleanup in a warehouse environment.
BRIEF DESCRIPTION OF DRAWINGS
The foregoing and other objects of the invention will become apparent to those skilled in the art upon reading and understanding the following detailed description of preferred embodiments of the invention shown in the accompanying drawings in which:
FIG. 1 is a pictorial view illustrating the use and preferred orientation of a post protector according to the present invention;
FIG. 2 is a cross-sectional plan view taken along line 2--2 of FIG. 1 showing a post protector as placed adjacent a structural column;
FIG. 3 is a cross-sectional view taken along line 3--3 of FIG. 2 showing in detail a post protector according to the present invention as anchored to the floor; and
FIG. 4 is an elevation view of a post protector taken in cross-section showing how the post protector elastically moves when an outside force is applied.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring now to the drawing, wherein the showings are for the purpose of illustrating preferred embodiments of the invention only and not for the purpose of limiting same, FIG. 1 shows a plurality of post protectors 10 each adjacent a structural column 11 and anchored to a concrete floor 12. As can be seen, post protectors 10 in this embodiment have a four-sided angular C-shape. The shape has the ability to protect the three sides of 11a, 11b, and 11c of structural column 11 leaving a fourth side 11d exposed. The C-shape allows post protector 10 to be installed at any time about structural column 11 of a structure such as the structural rack 13 shown in FIG. 1. Since the C-shaped post protector 10 has an open end 19, post protector 10 can be placed around any existing or in-place structural column 11 and then anchored to floor 12.
As best shown in FIG. 2, post protector 10 is comprised of an elongated portion 14 further comprising four planar sections 15, 16, 17 and 18. Each individual planar section has two longitudinal edges. For instance, planar section 15 has longitudinal edges 21a and 21b, planar section 16 has longitudinal edges 21c and 21d, planar section 17 has longitudinal edges 21e and 21f, and planar section 18 has longitudinal edges 21g and 21h. At least one longitudinal edge 21a-21h of each planar section 15-18 is joined to another longitudinal edge 21a-21h of an adjacent planar section 15-18. For example, planar section 15 is adjacent to planar section 16 at abutting longitudinal edges 21b and 21c. Longitudinal edges 21d and 21e join adjacent planar sections 16 and 17, while abutting longitudinal edges 21f and 21g join adjacent planar sections 17 and 18. The C-shape formed by abutting longitudinal edges 21b-21g may be formed by any number of manufacturing processes including welding separate plates or rolling a homogenous sheet. As such, abutting longitudinal edges are preferably indistinguishable from other exposed surfaces of post protector 10.
Each of planar sections 15, 16, 17, 18 includes a corresponding respective upper transverse edge 22a, 22b, 22c and 22d, and a lower transverse edge 23a, 23b, 23c and 23d. Each planar section 15, 16, 17, 18 has a corresponding respective column side surface 25, 26, 27 and 28. Further, each of planar sections 15, 16, 17 and 18 contain an included angle between adjacent planar sections. In the preferred embodiment each of column side surfaces 25, 26, 27, 28 is at an obtuse angle to an adjacent column side surface 25, 26, 27, 28, thus forming the C-shaped post protector 10. For example in the preferred embodiment shown, column side surface 25 is at an angle of 115° from column side surface 26, column side surface 26 is at an angle of 120° from column side surface 27 and column side surface 28 is at an angle of 115° from column side surface 27. However, it will be appreciated that the included angles between column side surfaces may take any shape, including 180° or an acute angle. In the preferred embodiment each of planar sections 15, 16, 17 and 18 include a corresponding respective exposed surface 35, 36, 37, 38. Exposed surfaces 35, 36, 37, 38 are capable of withstanding severe impacts from moving equipment such as forklift trucks and the like. As such, elongated portion 14 is preferably made of structural steel.
Extending from elongated portion 14 is flange portion 41. Specifically, flange portion 41 consists of the flange leaves 45, 46, 47 and 48. Extending from each of lower transverse edge 23a, 23b, 23c, 23d is a corresponding respective flange leaf 45, 46, 47, 48. Each flange leaf 45-48 includes a floor side 51a, 51b, 51c, 51d and an upper side 52a, 52b, 52c, 52d. Each of flange leaves 45, 46, 47, 48 are relatively orthogonal to each of the respective planar sections 15, 16, 17, 18. Each flange leaf, further, has a respective opening 55, 56, 57, 58 therethrough. A concrete drive anchor 61 is placed through each of openings 55, 56, 57, 58 so that post protector 10 may be secured to concrete floor 12. Flange leaves 45, 46, 47, 48 shown in the preferred embodiment are each separate and distinct from the adjacent flange leaf. As such each flange leaf includes lateral edges. For example flange leaf 45 includes lateral edges 45a, 45b and 45c. In a like manner, each of flange leaves 46, 47 and 48 include three lateral edges. For example flange leaf 46 includes lateral edges 46a, 46b and 46c. Separate and distinct flange leaves 45, 46, 47, 48 function independently from each of the other flange leaves, allowing greater non-destructive movement of post protector 10 upon impact. For example, upon impact, post protector 10 can rock up upon any one of flange leaves 45, 46, 47, 48. Additionally, if necessary, post protector 10 is able to bend elastically or plastically at any of axes 65, 66, 67, 68 when a force F is placed upon post protector 10. The design using separate flange leaves 45, 46, 47, 48 allows post protector 10 to bend at one of more axes 65, 66, 67, 68 instead of lifting or rocking post protector 10. Such lifting or rocking results in concrete drive anchor 61 being destructively pulled from concrete floor 12. While bending is not shown, the bending hereinbefore described would occur, for example, at either or both of axes 65 and 68 due to a force F shown in FIG. 4.
Post protector 10 is further comprised of an elastic membrane 70. In the preferred embodiment, elastic membrane 70 includes a bottom portion 72, a top portion 73 and an elastic cylinder portion 74. Bottom portion 72 underlies flange portion 41 and, specifically, each of flange leaves 45, 46, 47, 48 and is located between floor 12 and each one of flange leaves 45, 46, 47, 48. Top portion 73 overlies flange portion 41 and, specifically, each one of flange leaves 45, 46, 47, 48, and is in abutting surface-to-surface contact with each of upper sides 52a, 52b, 52c, 52d. Bottom portion 72 is in abutting surface-to-surface contact with both floor side 51a, 51b, 51c, 51d of respective flange leaves 45, 46, 47, 48 and with floor 12.
Elastic membrane 70 also includes a flange filler portion 75 adjacent bottom portion 72 and top portion 73. Substantially, flange filler portion 75 of elastic membrane 70 occupies the spaces between adjacent flange leaves 45 and 46, between 46 and 47 and between 47 and 48. Further, as shown in FIG. 2, flange filler portion 75 is located adjacent and substantially between lateral edges 45c and 46a, between lateral edges 46c and 47a and further between lateral edges 47c and 48a. Providing elastic membrane 70 with flange filler portion 75 serves at least two advantageous purposes. Flange filler portion 75 allows post protector 10 greater ability to elastically respond to an impact with a moving object. Further, flange filler portion 75 eliminates cracks and crevices between adjacent flange leaves 45, 46, 47, 48 where dirt can collect and is difficult to remove. This is a distinct advantage in certain warehouse settings where spillage easily occurs or alternatively in warehouse environments which must be kept especially clean.
Elastic membrane 70 further includes outer edge portions 76 and outer end edge portions 77. Outer end edge portions 77 extend between bottom portion 72 and top portion 73 of flange leaves 45 and 48. Further, outer end edge portions 77 are in abutting side-by-side contact with lateral edges 45a and 48c.
Outer edge portions 76 also extend between bottom portion 72 and top portion 73. Outer edge portions 76 are in abutting side-by-side contact with lateral edges 45b, 46b, 47b and 48b. Further, at flange leaves 45 and 48, outer edge portion 76 is bounded between outer end edge portions 77 and flange filler portion 75, while at flange leaves 46 and 47, outer edge portions 76 are bounded by adjacent flange filler portions 75. Both outer edge portions 76 and outer edge end portions 77 provide added flexibility to the elastic membrane 70 as a whole, and provide the means for completely enclosing each of flange leaves 45-48 within elastic membrane 70.
In the preferred embodiment, therefore, elastic membrane 70 forms an elastic boot which comprises the entire outer surface of flange portion 41. The outer surface of elastic membrane 70 is comprised of surface edge 81, surface end edges 82, top membrane surface 83 and bottom membrane surface 84. Surface edge 81 is relatively adjacent to outer edge portions 76 and flange filler portions 75. Surface end edges 82 are relatively adjacent to outer end edge portions 77, while top membrane surface 83 is adjacent to top portion 73 and bottom membrane surface 84 is adjacent to bottom portion 72.
Elastic membrane 70 works to provide the means for allowing post protector 10 to elastically move in response to an impact or shock load placed upon post protector 10. As best shown in FIG. 4, a force is placed upon post protector 10. In response post protector 10 rocks towards structural column 11. However, the force F is dampened by elastic membrane 70 in order that tensile forces are not induced in concrete anchor 61 to cause anchor 61 to pull up from concrete floor 12.
In the preferred embodiment shown, each of top portion 73 and bottom portion 72 has a thickness of 1/4" extending orthogonally from the upper sides 52a-52d to top membrane surface 83 and from the floor sides 51a-51d to bottom membrane surface 84, respectively. Further, lateral edges 45a-45c, 46a-46c, 47a-47c, and 48a-48c have a thickness of 1/4" between floor sides 51a-51d and upper sides 52a-52d. Therefore, the total thickness of surface edge 81 and surface end edge 82 of elastic membrane 70 between top membrane surface 83 and bottom membrane surface 84 is 3/4".
Preferably, each opening 55, 56, 57, 58 within each of corresponding respective flange leaves 45, 46, 47, 48 are 1" in diameter. However, each elastic cylinder portion 74 located within each of openings 55, 56, 57, 58 has an outside diameter of 1" for snugly fitting within openings 55-58 and an inside diameter of 1/2" defining cylinder holes 78. Concrete drive anchor 61 has a head 62 having a diameter of 11/2" and a shank 63 having a diameter of 1/2" and a length of 4". Therefore, shank 63 fits snugly within elastic cylinder portion 74 and specifically within cylinder holes 78. Further, head 62 engages top membrane surface 83 of elastic membrane 70. Since the diameter of head 62 is larger than the diameter of openings 55-58, concrete anchor 61 will not tear membrane 70 since anchor 61 cannot be pulled through openings 55-58 when force F impacts post protector 10.
The dimensional relationship between elastic cylinder portion 74 and cylinder holes 78, openings 55-58 and concrete drive anchor 61, including the dimensions of head 62 and shank 63, uniquely provide an anchor structure for post protector 10 which is anchored to concrete floor 12. With further reference to FIG. 4, force F impacts post protector 10. In response, post protector 10 will elastically move from its anchored position. Specifically, flange portion 41 exerts both tensile forces T and shear forces S upon concrete drive anchor 61. The concrete drive anchor closest to the impact point of force F will be subject to the greatest forces, T and S, since the structure of post protector 10, including elastic membrane 70, dampens the effects of force F further from the impact point.
As noted in FIG. 4, tensile force T is caused by the moment arm bending stress induced by force F. As flange portion 41 exerts tensile force T on the underside surface 64 of head 62 tensile force T is transmitted to concrete anchor 61. Tensile force T is further transmitted to the concrete by concrete anchor 61. Each concrete anchor is preferably made of steel. Since steel is generally at least twelve times stronger in tension than is unreinforced concrete, tensile force T causes concrete floor 12 to fail. This results in concrete anchor 61 pulling up from concrete floor 12. It has been found that a 1/2" diameter concrete anchor 61 will form a 3" diameter greater in concrete floor 12. However, the present invention prevents tensile force T from being transmitted to concrete floor 12 by dampening force T. Top portion 73 comes into direct side-by-side contact with underside surface 64 and force T is dampened and dissipated as it is distributed by elastic membrane 70. Further, the tensile force T is also dissipated as bottom portion 72 is deformed between flange leaves 45, 46, 47, 48 and concrete floor 12.
Concrete anchor 61 is also subject to shear force S. This force pushes along the length of shank 63 which is above concrete floor 12. The preferred embodiment of the present invention allows that shear force S is transmitted to shank 63 by elastic cylinder portion 74. Thus, shear force S is dampened and dissipated as elastic cylinder portion 74 is deformed. Shear force S is prevented from weakening the connection between concrete anchor 61 and concrete floor 12.
The anchor structure of the present invention uniquely prevents damage or failure of the connection between anchor 61 and concrete floor 12 by reducing the forces T and S transmitted by concrete anchor 61 to concrete floor 12. The reduction of forces T and S is uniquely provided by the elastic membrane 70 which allows post protector 10, and specifically flange leaves 45, 46, 47 and 48, to "float" or move within elastic membrane 70.
Since post protector 10 elastically rocks or pivots in response to force F while secured to concrete floor 12 by concrete drive anchors 61, elongated portion 14 may still come into contact with structural column 11. While flange portion 41 is elastically anchored in place, and moves only slightly in a lateral direction due to impact, elongated portion 14, which is preferably 12" in length, and specifically upper transverse edges 22a, 22b, 22c, 22d displace a relatively large distance in comparison with flange portion 41. The present invention seeks to prevent elongated portion 14 from metal-to-metal contact with structural column 11, which could damage column 11 or induce rocking or side sway of structural rack 13. Thus, post protector 10 is provided with an elastic post cushion 91.
Elongated portion 14 includes an inside surface 14a consisting of column side surfaces 25, 26, 27 and 28, and an outside surface 14b consisting of exposed surfaces 35, 36, 37 and 38. Each of surfaces 14a and 14b extending between upper transverse edges 22a, 22b, 22c, 22d and corresponding respective lower transverse edges 23a, 23b, 23c, 23d. Further, inside surface 14a includes an inside top portion 97 and an inside bottom portion 98. Elastic post cushion 91 is located substantially in abutting side-by-side contact with inside top portion 97. In the preferred embodiment, the elastic post cushion 91 extends between longitudinal edges 21a and 21h and is substantially adjacent to each of upper transverse edges 22a, 22b, 22c, 22d. Elastic post cushion then extends downward along inside top portion 19 and specifically extends downward 1" from each of upper transverse edges 22a, 22b, 22c, 22d. Thus, elastic post cushion 91 is in substantial side-by-side contact with planar sections 15, 16, 17 and 18.
In further detail, elastic post cushion 91 has a post surface 92, a column surface 93, an inner surface 94 and an outer surface 95. Post surface 92 is in substantial side-by-side contact with inside surface 14a and specifically inside top portion 97. In the preferred embodiment, each of inner surface 94 and outer surface 95 extending between post surface 92 and column surface 93 is 3/8" thick. Post surface 92 and column surface 93 is a 1" wide band extending downward from each of upper transverse edges 22a, 22b, 22c, 22d and extending along each planar section 15, 16, 17 and 18.
Elastic post cushion 91 prevents metal-to-metal contact between elongated portion 14 and structural column 11. As best shown in FIG. 4, when post protector 10 slides and rocks or pivots toward structural column 11 due to force F, elastic post cushion 91 and specifically column surface 93 can impact structural column 11 if force F has not been completely dissipated by elastic membrane 70 at flange portion 41. Thus, the remaining force F which has not been dissipated is further dissipated by elastic post cushion 91. Additionally, elastic post cushion 91 serves another purpose in that any non-destructive contact between elongated portion 14 and structural column 11 does not mark or mar any of surfaces 11a, 11b, 11c, 11d of structural column 11. Therefore, elastic post cushion 91 prevents the stripping away of paint on structural column 11. The paint serves both an aesthetic purpose and prevents corrosion which could structurally weaken column 11.
In the preferred embodiment, both elastic membrane 70 and elastic post cushion 91 comprise a rubber material. The specific type of rubber used may vary significantly. For example, a stiffer rubber material may be required for applications where it is contemplated that there will be large impact loads and it is required that impact forces be dampened quickly. A softer rubber may be used in applications where, for example, only the use of small pieces of equipment are used. Obviously, the use of the softer rubber increases flexibility thereby decreasing the ability of the rubber to dissipate the impact force.
The invention has been described with reference to preferred embodiments. Obviously modifications and alterations other than those discussed herein will occur to those skilled in the art upon reading and understanding the invention. For example post protector 10 and specifically elongated portion 14 may comprise less than the four planar sections 15, 16, 17 and 18 which are part of the preferred embodiment. Elongated portion 14 may consist of one or two planar sections strategically placed adjacent to structural column 11 to protect the structural column from impact. Additionally, elongated portion 14 may not comprise planar sections at all. For example, elongated portion 14 may instead comprise a section having a semi-circular cross-section.
Flange portion 41 may alternatively be comprised of more or less than the four flange leaves 45, 46, 47, 48 of the preferred embodiment. However, it is preferred that at least one flange leaf correspond to each planar section. Therefore, if elongated portion 14 only consists of two planar sections, two flange leaves, one each extending from a planar section should comprise flange portion 41. Alternatively, flange portion 41 may be comprised of only one flange leaf, for example, in a semi-circular shape corresponding to a semi-circular shaped elongated portion 14.
It is further contemplated that elastic membrane 70 and/or elastic post cushion 91 may be comprised of a different elastic component other than rubber. For example, either of elastic membrane 70 or elastic post cushion 91 may be of a stiff plastic material or of a foam material which is capable of elastic bending.
Finally, it is contemplated that elastic post cushion 91 need not function in conjunction with elastic membrane 70. For example, elastic post cushion 91 may function to dissipate force F on a structural column 11 to impact on any post protector without an elastic membrane 70, such as those in the prior art.
It is intended to include all such modifications, including preferred alternative embodiments, insofar as they come within the scope of the invention. | A post protector which is placed around a portion of a column to be protected from impact or shock loading. The post protector is fastened to the floor and non-destructively absorbs impacts from objects which would otherwise impact the column. The post protector comprises an elongated portion which is placed adjacent and around the column. A flange is also provided which extends from the elongated portion and is fastened to the floor via openings through the flange. Fasteners are inserted through the openings which anchor the post protector to the floor. The flange also includes an elastic membrane which allows the post protector to elastically move upon impact whereby the post protector non-destructively absorbs the impact force of an object. | 4 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation of my earlier application Ser. No. 239,931, filed Mar. 31, 1972 entitled "Method and Means of Tufting."
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to tufting of rugs, carpets and the like and utilizes a pneumatic system which may be used in various types of tufting systems, however, it has particular utility in the Spanel et al multi-color selection system described below.
2. Prior Art
The present invention offers modifications to some embodiments disclosed in U.S. Pat. No. 3,554,147 which issued to Abram N. Spanel and George J. Brennan on Jan. 12, 1971 and U.S. Pat. No. Re 27,165 which issued Aug. 10, 1971 to Abram N. Spanel and Loy E. Barton, Abram N. Spanel being the inventor of the subject matter of the present application.
U.S. Pat. No. Re 27,165 discloses a pneumatic system in which yarn strands and/or discrete bits of yarn are transported pneumatically to a loading station where they are applied by a bit-applying element to the backing layer. Here, multi-color selection of yarn bits is enabled by a magazine thus offering a varied color selection to each of the guide tubes through which yarn is transported to the bit-applying elements in their loading position.
The aforementioned U.S. Pat. No. 3,554,147 shows an alternative system to U.S. Pat. No. Re 27,165 which provides for the simultaneous selection of bit-lengths of yarn of different colors for each tufting cycle at each individual needle station. This is accomplished by having yarn from as many sources of color as desired fed through channels which lead into a common channel adjacent the loading station. The capability of cutting a bit-length of yarn before, during or after threading of the bit-applying means and before or during tufting is disclosed. Since the cutting function may take place in close proximity to the loading station and after a particular yarn strand has been fed into the common channel, U.S. Pat. No. 3,554,147 discloses a pull-back system to remove at will, the strand of yarn from the common channel leading to the loading station when a color change is desired.
The system disclosed in some embodiments of aforementioned U.S. Pat. No. 3,554,147, wherein yarn was severed into yarn bits while in tubes or channels when under the influence of pneumatic pressure, was found lacking in some aspects when employed with multi-color selection systems. Accordingly, it is one of the objectives of this invention to provide for increased utility when so employed, as will be clear from the following. To admit a cutting element into pneumatic passageway, it is necessary to have an opening through which the cutting element may operate. This very opening will diminish the efficiency of the pneumatic system, if allowed to remain open during the transport of the yarn. Further, in the Spanel et al multi-color, cut-pile systems, it is desirable to have cutting means adjustable to produce variable pile heights in the manufactured rugs, such adjustment tending to also diminish pneumatic efficiency.
Pneumatic tufting systems such as contained in U.S. Pat. No. 3,216,387 issued Nov. 9, 1965, U.S. Pat. No. 3,217,675 issued Nov. 16, 1965 and U.S. Pat. No. 3,386,403 issued June 4, 1968, all to Joe T. Short, are directed to continuous tufting methods without the multi-color capability of changing yarns prior to each tufting cycle. Such system do not provide a cutting-before-tufting operation comparable to that disclosed in the Spanel et al systems.
U.S. Pat. No. 3,389,667 which issued June 25, 1968 to Helmet C. Mueller discloses the transportation of yarn by positive pressure through hollow needles which are similar to those used in the Short patents and are to be distinguished from the Spanel et al needles which are not hollow and are transversely threaded through needle eyes. Mueller cuts the yarn while it is still in the hollow tube-like needle, and further he neither shows nor teaches a means to prevent pneumatic pressure loss at the cutting station.
The Stanley Shorrock U.S. Pat. No. 3,595,186 issued July 27, 1971 also discloses the use of hollow needles as do the aforementioned Short and Mueller patents whereas the Spanel tufting systems use needles that clearly are not hollow, and moreover are transversely threaded through needle eyes.
Furthermore, Shorrock's arrangement is dependent upon a combination of mechanical and pneumatic feeding means whereas the Spanel et al system utilizes solely pneumatic feeding means.
Also, Shorrock provides yarn bits of uniform length and does not show nor teach the capability to provide variable lengths of yarn bits as is clearly and fully disclosed in the teachings of Spanel in the present application.
A need is thus present for an integrated, highly efficient system for placing a discrete bit in a loading position relative to a tufting member which includes: cutting the yarn into a yarn bit with a cutting means and preserving the efficiency of the pneumatic system while performing such a cutting function, such means being additionally adjustable to provide yarn bits of varying lengths; improving the efficiency of the pneumatic system at the needle station and at the same time providing means to positively control the yarn before and after tufting.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a tufting machine with yarn guide passageways which are free of any substantial pneumatic leaks during the transportation of the yarn yet which will permit the yarn to be cut while in the passageways by yarn-severing means to provide discrete bits of yarn.
It is another object of the present invention to provide a tufting machine in which the efficiency of the pneumatic system may be maintained while introducing the ability to control the cutting means to provide yarn bits of different lengths thereby allowing for varying rug pile heights.
Another object of the present invention is to provide a tufting machine in which the flow of the backing is arranged to improve the efficiency of the pneumatic yarn transportation system.
Yet another object of the present invention is to provide a tufting machine with an improved means of positively controlling yarn bits both before and after tufting.
In accordance with the present invention, there is provided a pneumatic tufting machine in which yarn is transported through passageways via pneumatic gas flow and can be cut while in said passageways by an arrangement in which gaps in the passageways are closed during yarn transfer to prevent the loss of pneumatic efficiency and opened for access of the cutting means. In one embodiment, the gap is provided by an axially reciprocable section of the yarn passageway system to provide access openings for the rapid movement of the yarn-severing means across the yarn passageways to cut the yarn into discrete bits. After completion of the cutting operation, and withdrawal of the cutting member, the reciprocable passageway section closes the access opening and the pneumatic system is once again intact for the transportation of the next bit-length of yarn. Both the cutting member and the abutting sections are adjustable in position relative to each other to give the machine the capability of providing yarn bits of varying lengths. To achieve continuous operation with a minimum of shutdowns of the system, a durable long-lasting cutting member is called for and such is provided. Once the yarn has been cut into discrete bits, positive control is continued by a clamping arrangement at each needle station.
Pneumatic efficiency within the system is further increased by the manner in which the backing moves to and from the tufting position. The mechanism utilized is also designed to keep tufted yarn free from yarn entanglement during the next tufting stroke.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more detailed understanding of the invention, reference is made in the following description to the accompanying drawings in which:
FIG. 1 is a schematic view of a tufting machine;
FIG. 1A is a partial sectional view of an alternate embodiment of a portion of FIG. 1;
FIG. 2 is an isometric view of the tufting element loading station showing the cutting member gap in open position;
FIG. 3 is an isometric view similar to FIG. 2 except showing the cutting member gap in a closed position;
FIG. 4 is a cross-sectional side view of the tufting element loading station showing a bit-length of yarn which has been transported into loading position and clamped;
FIG. 5 is a cross-sectional side view of the tufting element loading station showing the cutting of a yarn bit;
FIG. 6 is a cross-sectional view of the tufting element loading station showing the tufting needles in their down position with the yarn bit deposited in the backing layer;
FIG. 7 is a cross-sectional side view of the tufting element loading station showing the comb support member starting its rearward motion (rearward in relation to the tufting station);
FIG. 8 is a cross-sectional side view of the tufting station and shows a tuft guided to the rear of the tuft retaining bar;
FIG. 9 is a cross-sectional side view similar to FIG. 8, but shows the tuft retained by the tuft retaining bar as the comb support goes forward (here is also shown the backing advanced to its next tufting position);
FIG. 9A is a cross-sectional side view similar to FIG. 9, but showing a modified tuft-retaining bar;
FIG. 10 is a cross-sectional side view of the tufting element loading station showing the cutting machine adjusted to increase at will the length of the yarn bit; and
FIG. 11 is an isometric view of the tufting element loading station showing a different means for adjusting the cutting and anvil means.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In general, the subject tufting machine shown in FIG. 1 comprises a creel 10 having three spools 10R, 10W, 10B, each of differently colored yarn, a yarn metering system 12, a collator 16, a cutting station generally denoted by the cutting blade 30 and anvil 36, an axially reciprocating passageway section 34, a loading or needle station 20, a vacuum source 24, and a tuft guiding means comb member 52. The operation of the tufting machine is controlled by cam shafts generally designated by dotted lines 25 and 25' and various camming members located thereon. In the operation of a preferred embodiment of the tufting machine, yarn from a creel is passed through the metering system 12 which releases a specified length of one of the yarns to collator 16 so that it passes by the cutting station and blade 30 to the loading station. At this point, tufting elements shown as needles 22 have been inserted through the backing to be tufted, and up into the loading station. The eyes of needles 22 are aligned with the passage in the loading station 20 so that when the yarn is fed into the loading station 20, it threads needles 22. The metering system 12 operates so that the travel of the yarn into loading station 20 is limited insofar as the portion extending beyond the cutting means 30 is a specified bit-length. When the yarn is in place in loading station 20, it is clamped by the descent of clamping means 56 to prevent lengthwise movement of the yarn bit once cut. Passageway section 34 is reciprocated in a leftward direction by a rocker arm assembly 47 and cutting blade 30 descends against anvil 36 to cut the yarn. After the cutting, the yarn remaining to the left of blade 30 is withdrawn into collator 16 by part 12y of the yarn metering system 12. The withdrawal of the yarn into collator 16 allows a change of color in the yarn, if desired for the next tufting cycle. The yarn on the right which has been cut into a discrete bit is tufted by needles 22 and comb member 52 acts in concert with tuft retaining means 62 to clear the path for the needles during the subsequent tufting operation.
In more detail and again with reference to FIG. 1, creel 10 is shown having three spools 10R, 10W, 10B, respectively providing for example, a supply source of red, white, and blue yarn. While yarn sources for three different colors are shown, it is to be understood that any number of additional yarn colors may be supplied as desired. Also, yarns differing in other than color may be employed.
The yarn strands R, W, and B are led into metering device 12 which comprises a plurality of brakes 12A, 12B, and 12C and yarn pulling devices 12X and 12Y.
Briefly, puller 12Y is shown at the bottom of a stroke with brakes 12A and 12C closed and brake 12B open. In its descent, puller 12Y draws yarn from the left without restraint by opened brake 12B, but is precluded from drawing yarn from creel 10 by closed brake 12A and is precluded from withdrawing yarn from the right by closed brake 12C. Thus, yarn loops formed at the second pulling station by puller 12Y are from yarn temporarily stored at the first pulling station 12X and are available for use when the closed brake 12C is released.
A yarn strand may thus be procured from any of the sources by the release of the brake 12C for the particular strand desired. The remainder of the yarn strand after a bit-length has been removed may be pulled back from the right by closing 12B and actuating yarn puller 12Y. Thus, the yarn metering and feed system has the capability to both supply yarn and to pull part of it back from the pneumatic passageway area 18, 34, 37. For a more detailed description of the yarn feed system and the manner in which colored, pattern-tufting is accomplished, reference should be made to aforementioned U.S. Pat. No. 3,554,147.
For each yarn supply there is a tube or passageway 16R, 16W, and 16B each forming an input passage of collator 16, the tubes of which lead into a common passageway 18 which extends by way of flexible portion 37 and passageway sections 34 and 35 into the needle loading station 20.
In one embodiment, negative pressure for transporting the yarn strands from yarn-metering device 12 through the collator 16 to loading station 20 may be provided by a pneumatic source 24 shown as a suction device connected to the passageways 18 on the far side of the loading station 20 from the yarn supply to apply a vacuum to the yarn passageways 16, 18, 37. The use of positive pressure or a combination of positive and cooperatively applied negative pressure may be employed to produce a flow of gas to transport the yarn. When double needles 22--22, 22'--22' and 22"--22" (FIG. 2 and FIG. 3) are in their threading positions, the eyes of each pair of needles are in alignment with their respective loading passageways, as shown in FIG. 2. Thus, the eyes 27, 27 of double needle 22, 22 are in alignment with common passageway 18.
The row of needles 22 are secured to a needle bar 23, the reciprocation of which may be produced by cam device 28 which is shown operating from shaft 25'. The needle bar 23 and its drive means may be of a conventional design.
The backing feed elements for the backing B include a supply roll 31 an idler roll 33 and a drive roll 34a. A ratchet and pawl mechanism 36a may be used to drive the drive roll 34a intermittently to advance the backing as the tufting is produced by the reciprocation of needles 22.
Motor 70 is shown as driving the entire device through a suitable transmission 72 which may be a train of gears, timing chain, or the like. The metering mechanism 12 is shown as operating from shaft 25. Thus, with clock pulses shown schematically by reference numeral 71 generating a pattern read-out, yarn can be supplied to loading station 20 in the manner more fully described in U.S. Pat. No. 3,554,147.
With reference to FIG. 2, yarn is shown feeding into three of the many loading stations which extend across the width of the tufting machine. The cutting member or knife 30 which operates from shaft 25, FIG. 1, is shown as slightly penetrating into a knife gap or access opening 32 which is between passageway section 34 and passageway loading section 35 (FIGS. 2 and 3) which includes a continuation of passageway 18. Anvil 36 extends beneath part of passageway 18 of passageway section 34 protruding into gap 32 and is aligned with knife member 30. Passageway section 34 which includes both top wall 38 and bottom wall 40 as well as side walls 42 is laterally reciprocable or shiftable as a unit by means of shaft 44 through rocker arm 46 connected to fixed stud 48. This mechanism 47 is shown in FIG. 1 as operating from shaft 25. The access opening 32 may accommodate other cutting means such as oscillating knives or laser cutters, the use of each being contemplated as within the scope of the present invention.
To permit the axial shifting or reciprocation of section 34, passageway 18 is shown with a flexible portion 37 (FIG. 1). This is relatively straight when the access opening 32 is closed and slacks as section 34 shifts preparatory to the thrust of knife 30. An alternate embodiment to the flexible portion 37 is shown in FIG. 1A in which flexible portion 37 is replaced by telescoping members 37A and 37B. Section 34 is permitted to shift as member 37A slides into member 37B. Although not shown in FIG. 2, and succeeding Figures, the yarn is in guide tubes continually from the collator 16 to the common passageways 18 which are continuous through flexible portion 37, shifting section 34 and needle loading section 35. From its entry into the collator tubes 16R, 16W, and 16B to its placement in section 35, the yarn is under the influence of pneumatic gas flow. The embodiment using, telescoping tubes 37A and 37B (shown in FIG. 1A) permit the increase and decrease in total effective passageway length as section 34 reciprocates.
Intermediate rollers 50 and 51 guide the backing in the proximity of needles 22, 22. A reciprocating comb 52 with apertures 53 for the needles 22 is shown between rollers 50 and 51 to support the backing layer B and may be itself supported by columns (not shown). The comb 52 further serves to drag tufted yarn to the right by means of end bar 60 as the comb 52 shifts to the right to cause the tufts to be retained behind a tuft-retaining bar 62 as will be described. Comb member 52 is shown in FIG. 1 as operating from shaft 25'. The rollers 50 and 51 may be replaced by a shelf or guiding means (not shown) which may project from frame 49 (FIG. 1) and may also serve to raise the level of the backing in the vicinity of the needles. As is shown, bottom wall 54 forming a part of passageway 18 cannot extend between and below the double needles 22, since this space must be clear for a bit of yarn to be drawn into tufting relationship with the backing. Any opening to that space is kept very slight by the close proximity of the backing. The efficiency of the pneumatic flow thus is not significantly lessened by gas leaks which otherwise could interfere with the smooth feeding of the yarn. Yarn clamping devices 56 are designed to hold the bit-lengths of yarn in place once they have been cut by knife 30 despite continued application of pneumatic gas flow. Clamp member 56 is shown in FIG. 1 as operating from shaft 25. To further increase pneumatic efficiency, tolerances resulting in voids between needles 22 and walls of the loading station 35, are kept minimal to minimize gas turbulence. Yarn is only transported into the loading station 35 when the needles 22 are in these loading positions making a substantially streamlined channel, since the needle eyes 27 substantially correspond in size to passageway 18.
With reference to FIG. 3, it will be seen that knife gap 32 (which is open in FIG. 2) is closed and axially shifting section 34 abuts against passageway portion 35 effectively closing the system throughout in preparation for the yarn feed.
In operation, a yarn strand of the desired color is chosen by a pattern read-out process which may follow the teaching of aforementioned U.S. Pat. No. 3,554,147 and aforementioned U.S. Pat. No. Re 27,165. The strand is advanced from the yarn-metering device 12 by pneumatic gas flow produced either by positive pressure or negative pressure or a combination of both. The pneumatic gas flow moves the strand through the needle eyes 27 as shown in FIG. 4 with the length being predetermined and set by the yarn-metering device 12 to provide a bit-length of yarn in the loading station area 35 which will provide a discrete bit of the desired length when cut. At a time prior to cutting, clamp member 56 descends to clamp the yarn as shown. Otherwise, when the yarn is cut it could be influenced by the continuing pneumatic gas flow. A yarn-bit stop described subsequently may be used in place of the yarn-clamp member 56. It will be noted that yarn metering device 12 allows the length of yarn to be released so that equal amounts of the yarn extend from the right yarn end to the right member of the double needle as from the left member of the double needle to the cutting means. This is necessary if the pile height is desired to be equal for each leg.
When the yarn is in position, reciprocating section 34 shifts to the left to open gap or access opening 32, and knife 30 descends through that gap to make contact with anvil 36 disposed there below as shown in FIG. 5. The yarn is thus effectively severed into a yarn bit in its threaded position.
As needles 22 descend, they pull the yarn bit down through the backing layer placing it in tufting relationship with the backing. At this time the knife 30 may return to removed position, and reciprocating section 34 may shift to the right thereby closing gap 32 in preparation for the next cycle. Needles 22 release the yarn as shown in FIG. 6 and the tufting step is completed. In this position, the tuft legs or ends extend down through apertures 53 (FIGS. 2 and 3) between the teeth 52' of comb member 52 which aids in supporting the backing layer B.
With reference to FIG. 7, reciprocating member 52 shifts to the right causing end bar 60 of the comb device 52 to come into contact with the tuft legs.
As shown in FIG. 8, both of the tuft legs are pulled by end bar 60 to a point to the right of tuft-retaining bar 62 which is a stationary member positioned downwardly and to the right of the needle tufting station. Once comb device 52 has shifted to its far right position, clamp 56 is released.
As seen in FIG. 9, comb member 52 reciprocates back to the left as shown by dotted lines, leaving the tuft legs to the right of tuft-retaining bar 62. At this time, the backing layer B is shifted to the right the distance that is desired for the next tufting cycle. The needles 22 then ascend to their loading position as shown in FIG. 3, and the feeding of the next bit-length of yarn may commence. FIG. 9A shows the tuft-retaining bar 62 of the earlier figures replaced by a preferred wedgeshaped retaining means 62A.
After the yarn bit is severed and in preparation for the next tufting cycle, the yarn color selection process as described in aforementioned U.S. Pat. No. 3,554,147 will select the next yarn color and if change is to be made the yarn strand presently in common passageway 18 from which a yarn bit has just been severed, will be pulled back by the yarn pull-back mechanism 12Y at least far enough to clear the common passageway 18 and the yarn strand from the newly selected color will be fed into the needle loading position through passageway 18.
The machine as described produces cut-pile rugs with the pile heights being determined approximately by the distance that the yarn bit extends on each side of the needles 22, the distance on each side being kept equal if pile legs of the same height are desired. On the other hand, a rug may be obtained which for each needle stroke a short and long pile is produced by setting the yarn-metering device 12 to supply lengths of yarn which will extend a distance beyond needles 22 different than the distance between the cutting member 30 and the needles 22.
The tufting machine also may be controlled to produce pile heights that differ from one operation of the machine to the next. With reference to FIG. 10, cutter 30 may be shifted laterally to the left by means of an adjustment means shown generally as 75. An accompanying adjustment means 76 is provided for anvil 36. These are shown as simple screw-set block devices or they may be more on the order of screw means 77 and 78 shown for the cutter 30 and anvil 36 respectively in FIG. 11. As is shown in FIGS. 10 and 11, the shifting block 34 must be set to shift further to the left to create a larger knife gap 32 thereby permitting the knife 30 and anvil 36 contact to be further to the left of loading portion 35 of the passageways 18. Thus, the distance between knife 30 and needle 22 will be increased and yarn-metering device 12 can be set to provide sufficient yarn to give an identical increased length on the far side of needle 22 from the yarn supply. A rug having a greater pile height will thus be produced.
As shown in FIG. 11, screw means 77 is threaded into adjustment block 80 which is inserted into a grooved portion 81 of cutter body 30 by means of base 82 to allow cutter 30 to reciprocate vertically. The reciprocating motion of the cutter may be transferred from shaft 25 (FIG. 1) through shaft 83 and adjustment block 84 locked in place by base 85, but designed to allow cutter 80 to slide lengthwise therealong, to cutter 30. Thus, cutter 30 reciprocates vertically through access opening 32 which separates passageway 18 and may be laterally adjusted by means of screw 77 which is connected to appropriate control means (not shown) to control pile height. A similar lateral adjustment means is provided for anvil 36.
The present system may be modified to have the yarn bits applied adhesively as is disclosed in aforementioned Reissue Patent No. 27,165. A sealing flap valve as shown in FIGS. 23A and 23B of aforementioned U.S. Pat. No. 27,165 may be used to minimize loss of air or other gas.
Advantages may be taken of some of the features of this invention in a further embodiment wherein the yarn is severed at cutting station 90 positioned remotely from the needle loading station and operable from shaft 25 by cam means as shown schematically in FIG. 1. Since in this embodiment, the yarn is cut into bits before the yarn is threaded and is then transported pneumatically to the needle station, it is desirable to have a stop means (not shown) to stop the movement of the yarn bit within the eye of the needle on the order of that which is shown in aforementioned U.S. Pat. No. Re. 27,165. The cutting also can occur during threading which allows additional flexibility in providing yarn bits of varying lengths. In a wellsynchronized operation, the beginning of the yarn strand to be cut is beyond the cutting station when the gap 32 is created for use of the cutting means, thus the yarn transportation is not unduly affected by the gap creation.
While various embodiments of the invention have been shown and described, it will be understood that various modifications may be made. The appended claims are, therefore, intended to define the true scope of the invention. | A tufting machine having multi-color selection capability for each tufting cycle which utilizes pneumatic pressure either positive or negative, or a combination of the two, to transfer the yarn or other tufting material to tufting elements, the yarn being severed before, during, or after threading, for subsequent placement into tufting relationship with a backing layer. The system comprises yarn guide passageways having abutting sections which are relatively movable to create an opening through which a yarn-severing means severs the yarn into selectively-sized bits. The relative positions of the yarn-severing means and the abutting sections of the passageways are adjustable to provide yarn bits of selected varying lengths. Clamping means may be used to clamp the yarn at the tufting needles until tufting occurs. After tufting the tufted yarn is moved away from the needle position to avoid entanglement by the succeeding motions of the tufting. | 8 |
This application is a continuation of Appln. Ser. No. 08/295,077, filed Aug. 26, 1994, now abandoned, which is a continuation of Appln. Ser. No. 08/170,908, filed Dec. 21, 1993, now abandoned, which is a continuation of Appln. Ser. No. 08/068,287, filed May 28, 1993, now U.S. Pat. No. 5,294,960, which is a continuation of 07/785,401, filed Oct. 30, 1991, now abandoned, and which is a continuation-in-part of Appln. Ser. No. 07/689,517, filed Apr. 23, 1991, now U.S. Pat. No. 5,208,634.
FIELD OF THE INVENTION AND RELATED ART
The present invention relates to a process cartridge ahd an image forming apparatus to which the process cartridge is detachably mountable. The image forming apparatus may be in the form of an electrophotographic machine, electrostatic recording machine such as a copying machine or laser beam printer.
Image forming machines such as copying machine require maintenance and servicing operations after they are operated for a long period of time, including replacement of an image bearing member (photosensitive drum), replacement of the developing device or replenishment of the developer (toner), cleaning of a discharging wire of a charging device, replacement of a, cleaning device filled with the residual toner and adjustment or replacement of some elements around the photosensitive drum.
However, the maintenance and servicing operations require expert knowledge and skill, and therefore, have not been easy for ordinary users.
In consideration of the situation, a process cartridge structure has been proposed in which a process cartridge contains as a unit the photosensitive drum and process means such as a developing device, a charging device, the cleaning device or the like. The process cartridge as a unit is detachably mountable to a main assembly of the image forming apparatus. If the maintenance or servicing operations are necessary in the process means, the entire process cartridge is replaced with a fresh cartridge so that the necessity for the maintenance and servicing operations are eliminated.
Referring first to FIG. 17, there is shown a structure of such a process cartridge. It comprises a photosensitive drum 10, and a cleaning device 13 and a developing device 11 which sandwich the photosensitive drum 10. Substantially above the developing device there is a toner container 110 which is coupled with the developing device 11. Substantially above the photosensitive drum 10, there is a charging device 12. The cleaning device 13 functions to remove the residual toner from the peripheral surface of the photosensitive drum 10 so as to prepare the photosensitive drum 10 for the next image forming operation. The cleaning device 13 comprises a cleaner container 13a for accommodating removed residual toner, a cleaning blade 131 for scraping the residual toner off the peripheral surface of the photosensitive drum 10, a toner receiving sheet 132 for receiving the toner scraped by the cleaning blade 131 and for directing it into the cleaner container 13a, and a stirring member (not shown) for conveying the toner received by the cleaner container 13a to the inside thereof.
The developing device 11 functions to supply the toner to the electrostatic latent image of the photosensitive drum 10 to visualize it. The developing device 11 comprises a developer container 11a, a developing sleeve 112 for supplying the toner to the peripheral surface of the photosensitive drum 10, a developing blade 11b in sliding contact with the developing sleeve 112 to triboelectrically charge the toner and to form on the developing sleeve 112 a toner layer having a constant thickness. A wall of the developer container 11a remote from the photosensitive drum 10 is provided with an opening 11c which communicates with an unshown opening of a toner container 110 for containing the toner, so that the developer container 11a and the toner container 110 communicate with each other.
When the toner in the toner container 110 is used up, the process cartridge has to be replaced. The service life of the process cartridge has to be changed in accordance with the types of the image forming apparatus with which the process cartridge is used. For example, in the case of a high speed copying machine, the number of produced copies in a month is large, and therefore, the frequency of the process cartridge replacements is high. Therefore, it is desirable that the process cartridge has a larger capacity toner container to increase the service life thereof. On the other hand, in the case of a small capacity copying machine, the number of copies produced in a month is small. In addition, the reduction of the weight and the size of the main assembly of the image forming apparatus is desired. To meet this desire, the size of the process cartridge is reduced with the reduction of the toner capacity. Thus, different process cartridges are to be prepared for different main assemblies of the image forming apparatus.
SUMMARY OF THE INVENTION
Accordingly, it is a principal object of the present invention to provide a process cartridge and an image forming apparatus usable therewith in which when a process cartridge is manufactured in a factory, the process cartridge may be easily assembled with a different service life.
It is another object of the present invention to provide a process cartridge and an image forming apparatus usable with the process cartridge in which the process cartridge can be easily assembled.
It is a further object of the present invention to provide a process cartridge and an image forming apparatus usable with the process cartridge which the process cartridge is easily disassembled.
It is a further object of the present invention to provide a process cartridge and an image forming apparatus usable with the process cartridge in which the process cartridge can be easily assembled or disassembled, so that various parts are reusable, by which environmental contamination can be reduced.
These and other objects, features and advantages of the present invention will become more apparent upon a consideration of the following description of the preferred embodiments of the present invention taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view of a process cartridge according to an embodiment of the present invention.
FIGS. 2A, 2B and 2C are sectional views taken along lines a--a, b--b and c--c, respectively, of FIG. 1.
FIG. 3 is a sectional view of an image forming apparatus to which the process cartridge according to the present invention is detachably mountable.
FIG. 4 is a sectional view of a process cartridge according to another embodiment of the present invention.
FIG. 5 is a sectional view of a process cartridge according to a further embodiment of the present invention.
FIG. 6A is a perspective view of an upper body.
FIG. 6B is a perspective view of a bottom body.
FIG. 7 illustrates disassembling of the process cartridge.
FIG. 8 is a sectional view of a process cartridge to which the present invention is applicable.
FIG. 9 is a perspective view of the process cartridge when liquid elastomer is injected to a joint in a cartridge frame.
FIG. 10 is a perspective view of a cartridge after liquid elastomer is injected to the joint surface of the toner container.
FIG. 11 is a sectional view after the liquid elastomer is injected.
FIG. 12 is a sectional view of a process cartridge according to an embodiment of the present invention.
FIG. 13 is a sectional view when the process cartridge is divided into an upper body and a lower body.
FIG. 14 is a perspective view when liquid elastomer is injected to the joint of the upper body.
FIG. 15 schematically illustrates an injection system for the liquid elastomer.
FIG. 16 is a schematic view of a liquid elastomer injection system.
FIG. 17 is a sectional view of a conventional process cartridge.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the accompanying drawings, the embodiments of the present invention will be described.
Referring to FIG. 3, there is shown an image forming apparatus usable with a process cartridge according to an embodiment of the present invention. Designated by a reference numeral 10 is an image bearing member in the form of a photosensitive drum, for example. Around the photosensitive drum 10, there are disposed image formation process means such as a developing device 11, a charger 12 or a cleaning device 13. The photosensitive drum 10 and such process means are constituted into a unit on process cartridge frames 14a and 14b of plastic material. The process cartridge 14 thus constituted is detachably mountable to the main assembly 1 of the apparatus. Thus, the maintenance or servicing operation is made easier. The structure of the process cartridge casing will be described in detail hereinafter. When the process cartridge 14 is mounted in the main assembly, a transfer charger 15 is below the photosensitive drum 10. At the sheet supply side of the transfer charger 15, there are a sheet feeding tray 16, a pick-up roller 17 and registration rollers 18. On the other hand, at the sheet discharge side thereof, there are a sheet guide 19, an image fixing device 20, sheet discharging rollers 21 and a sheet discharge tray 22.
Above the process cartridge 14, there is disposed a short focus optical element array 24 for imaging on the photosensitive drum 10 the light which is emitted from an original illumination lamp 23 and is reflected by the original O. At the top of the main assembly 1, there is an original carriage 25 reciprocable in the directions A. Designated by a reference numeral 26 is an original cover.
The photosensitive drum 10 is uniformly charged by a charger and is exposed to the light from the original O through the optical element array 24, so that an electrostatic latent image is formed on the photosensitive drum 10 in accordance with the information of the original. The electrostatic latent image is carried by the rotation of the photosensitive drum 10 to the developing device 11 where the latent image is developed with toner t into a toner image. Then, the transfer sheet P is fed to the registration rollers 18 from the sheet tray 16 through the sheet feeding roller 17. Then, it is fed to between the photosensitive drum 10 and the transfer charger 15 in timed relation with the latent image by the registration roller 18. The toner image is transferred from the photosensitive drum 10 onto the transfer sheet P by the transfer charger 15. The transfer sheet P carrying the transferred toner image is fed to the fixing device 20 where the toner image is fixed into a permanent image. Then, the transfer sheet P is discharged onto the tray 22 by the discharging rollers 21. The photosensitive drum 10, after the completion of the image transfer, is cleaned by the cleaning device 13 for removing the residual toner, so that the photosensitive drum 1 is now prepared for the next image forming operation. Designated by reference numerals 30a and 30b are mounting means in the form of guides for facilitating mounting of the process cartridge 14 to the main assembly of the image forming apparatus.
Referring to FIGS. 1, 2A, 2B and 2C, the process cartridge 14 of this embodiment will be described in detail. The casing of the process cartridge 14 in this embodiment comprises upper casing A (14a) and a lower casing B (14b). The casings A and B can be joined to or disjoined from each other.
The casings A and B are of molded plastic material having elasticity. At the right side of the casing A, a toner container 110 functioning as the developer container is integrally formed. A plug 111 is fused to seal the container. The opening 111a of the toner container 110 which communicates with the developing device 11 is closed by a bonded sealing member 113, as shown in FIG. 2C. An end of the sealing member 113 is folded and is projected to the outside of the casing A. A grip 114 is connected to the end. When the operator pulls the grip 114, the sealing member 113 is removed from the opening 111a so as to permit supply of the toner t to the developing sleeve 112. Below the toner container 110, there is a hook 27 for coupling the casings A and B. By the engagement between the hook 27 integrally formed on the casing A and an opening 28 formed in the casing B, the upper and lower casings A and B can be coupled with a simple structure. Four of such hooks 27 and corresponding openings 28 are arranged in a direction perpendicular to the sheet of the drawing. More particularly, each opening 28 is engaged by a hook 27 at the inclined surface 27a, and an end 28a of the opening 28 is locked by the bottom surface (barb) 27b of the hook 27. The hook 27 has such an elasticity that the engagement with the opening 28 and the disengagement therefrom can be smoothly carried out and that coupling the opening 28 is assured. At the left side of the casing A, as shown in the FIG. 1, a residual toner container 130 (developer container) is formed. An end of the casing A is folded to form a part 14a1 of the bottom surface of the container 130. The bottom casing B is extended to the position overlapping with the bottom surface 14a1, where they are threaded at the overlapped portion by screws 29. Therefore, the bottom surface of the container 130 is constituted by the parts of the casings A and B. A part of the casing A faced to the upper part of the photosensitive drum 10, is provided with an opening 141 for permitting passage of light for the image exposure. Around the openings in the toner container and the cleaner container, there are sealing members 26a and 26b made of foamed polyurethane material to prevent leakage of the toner from the container.
As shown in FIG. 2A, the casing B covers the bottom part of the process cartridge 14, and from the side surface, walls 102a and 102b are raised and are extended to the bottom surface of the casing A. To the walls 102a and 102b of the casing B, supporting shafts 103a and 103b for rotatably supporting the photosensitive drum 10 are securedly mounted by screws 106a and 106b below the photosensitive drum 10, the casing B is provided with an opening 101 for permitting transfer of the toner image from the photosensitive drum 10 to the transfer sheet P and for receiving an unshown driving device of the main assembly of the image forming apparatus. Above the side wall 102a of the casing B, a charger case 122 is supported by a fixing pin 125. At the other end of the charger casing 122, a pin 128 is integrally formed and is engaged in and supported by a hole 129 formed in the side wall 102b of the casing B. In the charger casing 122, bearings 123a and 123b, which support a shaft 130 of the charging roller 121 while urging the charging roller 121 to the photosensitive drum 10. An end of the charger case 122 extends to the outside of the casing B and contains electrode plate 126 for supplying electric power to the charging roller 121. The electrode plates 126 are connectable with power supply contacts (not shown) of the main assembly of the image forming apparatus.
Referring to FIGS. 1 and 2B, the cleaning device 13 and the developing device 12 will be described in detail. The casing B is provided with seats 133a and 133b for mounting the cleaning blade 131 for contacting to the photosensitive drum 10 to scrape the residual toner off the peripheral surface of the photosensitive drum 10. The cleaning blade 131 is fixedly mounted on the seats 133a and 133b by screws 135. Adjacent a longitudinal end of the opening 101 formed at the lower side of the casing B, a receiving sheet 132 is bonded. The side wall of the casing B is bent toward inside adjacent the toner container 110. The bent portion functions to support through springs 118a and 118b sleeve bearings 117a and 117b for supporting the developing sleeve 112. The developing sleeve 112 has spacers 116a and 116b for maintaining a constant clearance between the surface of the developing sleeve 112 and the photosensitive drum 10. The spacers 116a and 116b are urged to the photosensitive drum by the springs 118a and 118b. To one of the ends of the developing sleeve 112, a gear 119 is mounted which meshes with a drum gear 104 mounted to the drum 10. With the rotation of the photosensitive drum 10, the gear 119, and therefore, the developing sleeve 112 is rotated in the direction indicated by an arrow in FIG. 1. In the developing sleeve 112, a cylindrical magnet roller 115 is disposed. It is provided with plural magnetic poles. The end pins thereof are supported by the casing B. Above the developing sleeve 112, a blade 120 is mounted on an unshown seat projected from the side walls 102a and 102b of the casing B.
The lower casing B contains the photosensitive drum 10, the cleaning blade 131, the receiving sheet 132, the charger 12, the developing sleeve 112 and the blade 120 for the developing sleeve 112. Therefore, the positional accuracies of various elements relative to the photosensitive drum 10 are assured by the accuracy of the casing B, and therefore, correct positioning is made easier.
In addition, the process cartridge 14 of this embodiment can be disassembled into the upper casing A and the lower casing B. The process cartridges 14 from which the toner has been used up, are collected. The collected cartridge 14 is disassembled into the casings A and B. Then, the casing A is cleaned, and a fresh sealing member 113 is bonded. An unshown toner cap is removed from a filling opening, and the toner is supplied through the opening. Thereafter, the opening is plugged by the toner cap, again. In addition, worn parts and creeped rubber elements or the like which are not reusable, are replaced with new ones. Then, the casings are joined together. The process cartridge 14 is now distributed from the factory.
Casing B containing the process means may be joined with another casing 14c which has the shape as shown in FIG. 1 and which has a larger toner capacity and a larger residual toner capacity than those of the casing B. Then, another process cartridge having a longer service life and usable with a different type main assembly, can be easily manufactured.
FIG. 4 shows a process cartridge according to another embodiment of the present invention. A pipe 138 is provided for permitting discharge of the residual toner from the process cartridge 14. The pipe is connected to an unshown residual toner bottle (not shown) in the main assembly of the image forming apparatus. The residual toner container is provided therein with a helical residual toner conveyer 139 for supplying the residual toner to the discharge pipe 138. An end of the residual toner conveyer 139 is coupled with a driving gear (not shown). The driving gear is meshed with the drum gear 104. In this example, it will suffice if the upper casing A is provided only with the toner container 110. The residual toner container is not necessary. Then, it is not necessary that the residual toner capacity is dependent on the toner capacity. In this embodiment, the residual toner container is formed by the coupling between the casing A and the casing B.
A phantom line 14c illustrates a configuration of another example of the casing A. In the case of the casing 14c, the toner container 110 is disposed at a lower side. The toner container 110 is provided therein with toner conveyer means (not shown). To both sides of the toner container 110, the casing B is extended and is engaged with coupling pawl 27 formed on the ends of the toner container 110 of the casing A.
In the foregoing embodiments, the process cartridge has the developing means. However, the present invention is applicable to the process cartridge not having the developing means. In this case, the present invention is applied to the residual toner container for the cleaning means.
Referring to FIGS. 5, 6A and 6B, a further embodiment of the present invention will be described. FIG. 5 is a side sectional view of a process cartridge according to this embodiment, FIG. 6A is a perspective view of an upper casing, and FIG. 6B is a perspective view of a lower casing.
In the foregoing embodiments, the upper and lower casings A and B are joined not only by the engagement between pawls and openings but also by screws. In the present embodiment, however, the casings A and B can be joined only by engagement between pawls and openings. In the description of this embodiment, the same reference numerals as in the foregoing embodiments are assigned to the elements having the corresponding functions, and the detailed description thereof are omitted for simplicity.
Sectional views taken along lines a--a, b--b and c--c in FIG. 5 are as shown in FIGS. 2A, 2B and 2C, respectively, which have been described hereinbefore. The process cartridge of this embodiment is also detachably mountable to the main assembly of the image forming apparatus, as shown in FIG. 3.
In this embodiment, the casing A and the casing B are securedly joined by engagement between pawls 27b and the openings 29 in place of the screws 29 in the above-described embodiment. In the present embodiment, four pawls 27b are formed on the bottom outside surface 14a1 of the residual toner container 130 formed at the left side of the casing A. Correspondingly, the casing B is provided with four openings 29 in the wall overlapped with the bottom surface 14a1 of the casing A. Similarly to the toner container 110 side, the pawls 27b of the casing A and the openings 29 of the casing B are engaged with each other at the residual toner container 130 side, so that the casings A and B are joined together. Designated by a reference 27c is an inclined surface of the pawl 27b, and 29 is an engaging end of the opening 29. In this embodiment, the pawls 27 at the toner container 110 side and the pawls 27b at the residual toner container 130 side are inclined outwardly, in other words, they are inclined away from each other. By doing so, the elasticity of the casings A and B of plastic material, more particularly, the elasticity of the pawls 27 and 20b cooperates to enhance the fastening engagement when they are engaged with the associated openings 28 and 29.
In this embodiment, the process cartridge can be easily disjoined. As described above, the upper and lower casings A and B are joined by the pawls 27 and 27b. When the process cartridge is to be disjoined, the process cartridge 14 is put on a disjoining device 200. Then, rods 201 and 202 are pushed to push the pawls 27 and 27b. Thus, the upper casing A can be easily disjoined from the lower casing B.
Without use of the device 200, the casings A and B can be disjoined from each other by properly pushing the pawls 27 and 27b. However, in this case, it is preferable to push the plural pawls simultaneously, and therefore, it is easier if the device 200 is used.
A further embodiment of the process cartridge will be described. In this embodiment, additional sealing members are employed to further prevent the leakage of the developer to the outside of the cartridge.
Referring to FIGS. 8, 9, 10 and 11, the description will be made as to the cartridge of this embodiment having the sealing members. FIG. 8 is a sectional view of the process cartridge according to this embodiment. The process cartridge 201 contains an image bearing member in the form of a photosensitive drum 202 and process means disposed therearound. The process means includes a cleaning device 203, a developing device 204 and a charger 205 supported on a cartridge frame 201a. They constitute a unit which is detachably mountable to a main assembly of the image forming apparatus, as a unit. When the photosensitive drum 202 and/or the developing device 204 comes to an end of the service life, when the cleaning device 203 is filled with the residual toner or when the toner in the developing device 204 is used up, the entirety of the process cartridge 201 is replaced with a new process cartridge. Thus, the maintenance or servicing operations are easy. In this embodiment, the charger 205 is in the form of a well-known corona charger, but it may be replaced with a contact type charger as disclosed in U.S. Pat. No. 4,851,960.
The cleaning device 203 comprises a cleaning blade 230 for removing the residual toner (residual developer) from the surface of the photosensitive drum 202, a toner receiving sheet 231 for preventing leakage of the residual toner to the outside, and a residual toner container 232 for containing the residual toner. The residual toner container 232 is constituted by connecting through sealing members 213 the cleaning container 203a, the blade holder 230a and the cartridge frame 201a. The sealing members 213 are effective to prevent leakage of the toner through the joint portions.
The developing device 204 comprises a developing sleeve 240 rotatable in a constant direction and effective to supply the toner (developer) from its outer periphery to the photosensitive drum 202, a regulating blade 241 for regulating a thickness of a layer of the developer on the developing sleeve 240, and a toner container 242 for containing the toner and for supplying the developer to the developing sleeve 240. The toner container 242 is constituted by the toner container 212 and the developer container 204 which are coupled by screws or the like with a sealing member 214 therebetween so that they can be disjoined and cleaned. The sealing member 214 is effective to prevent leakage of the toner through the joint portion.
In the process cartridge having the structure described above, the photosensitive drum 202 is uniformly charged by a charger 205 and is exposed to image light, so that an electrostatic latent image is formed on the photosensitive drum 202. With the rotation of the photosensitive drum 202, the electrostatic latent image reaches the developing device 204, where the latent image is supplied with the toner from the developing sleeve 240 of the developing device 204 so as to be developed into a toner image. The toner image is transferred onto the transfer sheet through an unshown transfer charger or the like. After the completion of the image transfer action, the photosensitive drum 202 is cleaned by the cleaning blade 230 so that the residual toner is removed from the photosensitive drum 202. Then, the photosensitive drum 202 is prepared for the next image forming operation. The residual toner removed by the cleaning blade 230 is collected into the residual toner container 232 of the cleaning device 203 by way of receiving sheet 231 contacted to the photosensitive drum 202.
Referring to FIGS. 9 and 10, the description will be further made as to the sealing members 213 and 214. The sealing members of this embodiment are provided by injecting from a nozzle 215 two-liquid urethane rubber material R to a coupling surface 201b (FIG. 9) of the cartridge frame 201a and to a coupling surface 212a (FIG. 10) of the toner container 212. The material R is a foaming material, and therefore, it is foamed and solidified into elastomer on the coupling surfaces 201b and 212a approximately 20 sec.-10 min. after the injection.
In FIG. 9, the material R extends from point (a) along arrows 216 and 217 and returns to the point (a), thus constituting a closed loop. As regards the sealing member 214 shown in FIG. 10, the injection starts at point (b) and proceeds along the direction of arrows 218 and 219 and returns to the original point (b). The coupling surfaces 20lb and 212a are provided beforehand with grooves 211 as shown in FIG. 11. Therefore, the material R ultimately becoming the sealing member flows into the groove and then is solidified into an elastic elastomer. Therefore, the sealing member is not easily removed or easily deviated.
With the solidified sealing members 213 and 214 on the cartridge frame 210a and the toner container 212, the cartridge frame 201a and the toner container 212 are coupled with the cleaning container 203a and the developing container 204a, respectively, by which the toner leakage through the connecting portions can be properly prevented. The height h (FIG. 11) of the elastomer members 213 and 214, after solidification, is larger than the clearance C (FIG. 8) after the containers are coupled, and therefore, the sealing members are pressed down to the height which is equal to the clearance C, thus filling the clearance.
In this embodiment, the material R injection or dispensing from the injection nozzle, the injection speed, and the injection rate, can be completely automatically controlled, so that the sealing members can be formed along the connecting surface with certainty. Therefore, the system conveniently meets the complicated shape as shown in FIG. 9.
In the foregoing description, the foaming polyurethane rubber is used as the sealing member material R. However, the material is not limited to this, and another material such as soft rubber or plastic material such as silicone rubber or another elastomer (elastic high polymer material) may be used with the same advantageous effects.
Thus, the sealing members are provided by solidifying liquid elastomer such as foaming polyurethane rubber or the like to seal the coupling portion of plural members such as the developing device 204 in the process cartridge, the toner container of the cleaning device 203 and the residual toner container. Therefore, the toner seal can be easily accomplished in the coupling portions of the containers having complicated structure. In addition, the closed loop can be easily formed, and therefore, the toner leakage through a sealing member connecting portion can be prevented.
Referring to FIGS. 12, 13 and 14, there is shown a process cartridge according to a further embodiment of the present invention. As shown in FIG. 12, the process cartridge is constituted by an upper frame A and a lower frame B. In this Figure, the same reference numerals as in FIG. 8 are added to the elements having the corresponding functions.
As shown in FIG. 13, the process cartridge of FIG. 12 has the upper and lower frames A and B which are coupled by pawls 250 and openings 251. The pawls 250 of the upper frame A are elastically engaged with associated openings 251 formed in the lower frame B, by which the upper frame A and the lower frame B are coupled. The upper and lower frames A and B sandwich sealing members 213b and 214b. The toner container 242 is constituted by coupling the upper and lower frames A and B and by coupling the upper frame A and a blade holder 241a for supporting a regulating blade 241. The coupling portions are provided with a sealing member 214a to prevent leakage of the toner. The residual toner container 232 of the cleaning device 203 is constituted by coupling the upper and lower frames A and B and by coupling the upper frame A and a cleaning holder 230a for supporting a cleaning blade 230. The coupling portion is provided with a sealing member 213a to prevent the toner leakage.
FIG. 14 shows the view in the direction I in FIG. 13. In this embodiment, as shown in FIG. 14, the two-liquid urethane rubber material R is dispensed from the nozzle 215 to the coupling surfaces between the upper and lower frame portions of the toner container and the residual toner container. Since the material is of foaming nature, it foams and becomes elastomer on the coupling surfaces 201b and 212a in approximately 30 sec.-10 min. after injection or dispense. The injection path starts at (a) and extends in the directions of arrows 216 and 217 to return the position (a), so that a closed loop is formed. The surfaces receiving the material R (coupling surfaces 201b and 212a) are formed into grooves beforehand, and therefore, the material R easily flows into the grooves, and then solidifies into an elastomer. Therefore, the sealing member is not easily removed or deviated. In this manner, with the solidified sealing members 213 and 214 on the upper frame A, it is coupled with the lower frame B, so that the sealing members 213 and 214 function to prevent leakage of the toner from the toner container and from the residual toner container. The height h (FIG. 11) of the sealing members 213 and 214, after solidification, is higher than the clearances C1, C2, C3 and C4 (FIG. 12) after the frames are coupled, and therefore, the elastomer is pressed to the heights equal to the clearances C1-C4, thus filling the clearances.
Similarly to the foregoing embodiment, in the present embodiment, the injecting path, speed and rate can be completely automatically controlled, so that the sealing member can be provided along the coupling surfaces with certainty. In addition, the injecting portions are concentrated on one of the frames, and therefore, the injecting or dispensing operation can be completed after only one positioning of the frames. This is advantageous in that the number of manufacturing steps can be significantly reduced.
Similarly to the foregoing embodiment, the material R may be soft rubber, soft plastic or the like.
In this embodiment, the liquid elastomer is dispensed to the coupling surface. Referring to FIG. 15, the description will be made as to the system for mixing the two-liquid-active material (liquid elastomer) and ejecting it through a nozzle 215.
In FIG. 15, liquid A and liquid B are contained in containers A60 and B61. They are metered by precise metering pumps 262 and 263 to a mixing and stirring station 264 so that the mixture ratio thereof are proper for the two-liquid reaction. In the mixing and stirring station 264, the liquid A and liquid B are uniformly mixed by the motor. It requires at least 30 sec approximately for the mixed liquid to solidify into an elastic elastomer, and therefore, the mixed liquid is ejected through a nozzle 215 of the ejector 265 in the middle of the reaction. The mixing and stirring station 264, the ejector 265 and an injection head including a nozzle 215 are moved along X-, Y-, and Z-axes to meet the configuration of the containers or the like, while the liquid elastomer is being ejected.
The metering by the metering pumps 262 and 263, the mixing and stirring speeds, movement of the ejecting head along the three axes, the ejecting speed or the like, are properly controlled in accordance with a program set in a controller of an unshown industrial robot. Therefore, the injecting operation is carried out automatically.
The materials used are as follows.
TABLE 1______________________________________ FoamingLiquid A Liquid B Rate (Vol.) Solidified Elastomer______________________________________Ex. 1Polyol Isocyanate 2-5 Foaming PolyurethaneMix. ratio: 10:2-3 (ISOACK Corporation)Ex. 2(--OH) (--H) 2-10 Foaming SiliconeSilicone Silicone (TORAY SILICONE)Mix. ratio: 1:1______________________________________
Referring to FIG. 16, the description will be made as to a system in which single-liquid reaction type liquid is used. A N 2 gas is injected into the liquid to foam it, and it is ejected through a nozzle 16.
In FIG. 16, a liquid elastomer mainly comprising polyurethane material is heated by a heater to 70° C.-100° C. in a container 266. It is supplied by a pump to a foam mixing machine 268. In the foam mixing machine 268, the liquid supplied from the container 266 is mixed with N 2 gas so as to be foamed. Before the liquid elastomer is solidified, it is ejected to the member such as the toner container or the like through the nozzle 215 of the ejection 270.
Similarly to the case of the two-liquid type material, an unshown industrial robot is used, so that the controller thereof properly controls the mixture of the N 2 gas, the supply of the material, the movement in the three axes directions of the injecting head and the injection speed or the like. Therefore, the injecting or dispensing operations are automatic.
The elastomer in this embodiment preferably has an elongation of 100-200%, a hardness (Asker C) hardness of 4-15, and a compression-restoration of not less than 90%.
In the foregoing, the description has been made as to the case of the process cartridge having both a residual toner container for the cleaning means and a toner container for the developing means. The present invention is not limited to this, and the present invention is applicable to a process cartridge having at least one of these containers.
As described in the foregoing, according to the embodiments of the present invention, the sealing member is constituted by solidifying the dispensed liquid elastomers for the plural connecting portions of the process cartridge developer container, and therefore, the leakage of the developer can be prevented more positively than in conventional devices, and in addition, the present invention is advantageous in that the sealing can meet complicated connecting portions.
In addition, automatic control for the liquid elastomer injection is possible, and therefore, the assembling operation of the process cartridge is made easier.
The process cartridge described in the foregoing may contain an image bearing member and at least one process means actable directly or indirectly on the image bearing member. More particularly, the process cartridge may contain as a unit an electrophotographic photosensitive member and a charging means, developing means and/or cleaning means. The cartridge thus constituted is detachably mountable to an image forming apparatus such as a copying machine or a laser beam printer.
As described in the foregoing, according to the embodiments of the present invention, the process cartridge is divisible into frames, one of which contains an image bearing member and process means actable thereon, and the other of which contains a toner container having toner particles and/or residual toner container. They are assembled by putting them together, and thereafter, they may be disassembled.
Therefore, the present invention provides the following advantageous effects:
1. By selecting the frame containing the toner container (developer container), process cartridges having different service life and cross-sections can be easily produced:
2. The frame containing the image bearing member and the process means can be made the same so that the manufacturing management is made simpler; and
3. The process cartridge can be reused by collecting the used process cartridge (empty toner container), disassembling the frames, replacing worn parts and coupling the toner container refilled with the fresh toner.
According to the present invention, a process cartridge having the feature of easy assembling and an image forming apparatus usable therewith, can be provided.
While the invention has been described with reference to the structures disclosed herein, it is not confined to the details set forth and this application is intended to cover such modifications or changes as may come within the purposes of the improvements or the scope of the following claims. | A process cartridge detachably mountable to a main assembly of an image forming apparatus, the cartridge comprising a photosensitive member, a developing means for developing a latent image formed on the photosensitive member, a first frame containing the developing means; and a second frame coupled with the first frame, the second frame including a developer containing portion for containing a developer to be supplied to the developing means to develop the latent image, wherein the second frame is a selected one of plural secondary frames engageable with the first frame and having different developer containing capacities. | 8 |
FIELD OF THE INVENTION
The present invention relates to a breathing valve and more specifically to a lung-governed breathing valve for excess pressure operation in the interior of a breathing mask.
BACKGROUND OF THE INVENTION
A breathing mask is a device used to enable breathing in environments where such would be difficult or impossible without mechanical aid. Typically, a breathing mask incorporates an inlet valve which controls the flow of gas for breathing between a supply of breathing gas and the user of the breathing mask. A lung-governed valve controls the flow of gas through the inlet valve via the respiration of the user.
A diaphragm divides the lung-governed valve into an inner chamber at a pressure corresponding to the pressure within the breathing mask and an outer chamber at a pressure corresponding to the pressure in the environment. The diaphragm is coupled to a mechanism which opens and closes the inlet valve. The user's respiration creates a pressure differential between the inner and outer chambers of the valve which, in turn, causes displacement of the diaphragm thereby controlling the inlet valve closure mechanism.
A lung-governed valve of this type is described in German Patent No. DE 35 39 669 A1. In that device, the diaphragm controlling the inlet valve lever has at its central point a cam projecting outwardly into the outer chamber. A tilt lever is pivoted to the outer chamber casing and is clamped by transversely tensioned spring elements to the outer chamber so that the tilt lever is movable in a tilting joint. The tilt lever is movable out of an idle position into a first pressure position, exerting force on the diaphragm, and into a second stand-by position, lifting the diaphragm off the valve lever by engaging the cam and moving it and the diaphragm through a predetermined stroke. Because of the transversely tensioned spring elements, which are pivoted to the shorter end of the tilt lever, the end position of the tilt lever may be unstable. Subjection of the valve to external stress may cause the tilt lever to tilt from one position to the other. This instability is particularly disadvantageous when the control diaphragm is in the stand-by position. In this position, external vibration could tilt the lever, entraining the control diaphragm and opening the inlet valve via the valve lever. The limited amount of breathing gas available to the person using the apparatus can thus be inadvertently lost.
It would be desirable, therefore, to develop a lung-governed valve with an improved structural design wherein the valve is protected from accidental release or switching on when in the stand-by position.
SUMMARY OF THE INVENTION
Generally, the present invention relates to a lung-governed valve comprising a casing with a nozzle for supplying breathing gas, a nozzle for discharging breathing gas to a breathing mask, a pressurized control diaphragm and a releasable actuating button. The control diaphragm divides the lung-governed valve into an outer chamber at environmental pressure and an inner chamber at a pressure corresponding to the pressure within the mask. The control diaphragm controls a breathing-gas inlet valve through a lever system and the releasable actuating button.
The present invention is particularly advantageous in several respects First, the lung-governed valve can be firmly held in the stand-by position by a simple mechanical means and remains in that position when subjected to external vibration. Inadvertent loss of the limited supply of breathing gas is thereby prevented. Another advantage of the present invention is the controllability, independent of the direction of switching, of the control diaphragm when it is in the operative position. Additionally, manual control, by depressing the actuating button and maintaining it in the on position, enables a continuous supply of breathing gas to be provided for a second person, for cleaning of the mask from dangerous pollutants, and for relief of pressure from the supply nozzle after use. Finally, the user of the breathing mask is made aware that the lung-governed valve is in the operative mode by the visibility of the actuating button when the lung-governed valve is in that mode.
To achieve these advantages, the central region of the control diaphragm has a resilient raised portion formed integrally thereon with a recess therein. When the actuating button is released, a push-rod integrally molded on the actuating button is positively engageable in the recess of the raised portion of the control diaphragm. Furthermore, the raised portion of the control diaphragm closely abuts and is contained within a recess in an insertion member disposed above the control diaphragm.
Other details, objects and advantages of the present invention will become more readily apparent from the following description of a presently preferred embodiment thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings, a preferred embodiment of the present invention is illustrated, by way of example only, wherein:
FIG. 1 is a partial section of the lung-governed valve of the present invention with the actuating button completely depressed;
FIG. 2 is a close-up view of the raised portion of the control diaphragm which is engaged by the push-rod;
FIG. 3 shows the lung-governed valve of the present invention in the on position;
FIG. 4 shows the lung-governed valve of the present invention in the stand-by position; and
FIG. 5 shows the lung-governed valve of the present invention in the operative position.
DESCRIPTION OF THE PREFERRED EMBODIMENT
As shown in FIG. 1, the present invention provides a lung-governed valve 1 comprising a casing 2 with a nozzle 4 for supplying gas for breathing, a nozzle 3 for discharging gas to a breathing mask (not shown), a pressurized control diaphragm 8 and a releasable actuating button 11. The supply nozzle 4 preferably contains a spring-loaded control piston 6 formed with a through bore 6a disposed to be axially movable in an inlet valve member 5 and in operative connection with valve seat 7.
The control diaphragm 8 divides lung-governed valve 1 into an outer chamber 16 at environmental pressure, typically atmospheric pressure, and an inner breathing chamber 17 at a pressure corresponding to the pressure within the breathing mask. The outer chamber 16 is preferably connected to the atmosphere through a number of openings 18 in a pot-like insert 10. The periphery of control diaphragm 8 is preferably clamped on all sides between the inlet valve body 5 and the pot-like insert 10 in the valve casing 2.
The control diaphragm 8 is formed with a means for engaging the actuating button 11 when the actuating button 11 is depressed. Preferably the center region of the control diaphragm has a resilient raised portion g integrally formed thereon (hereinafter referred to as nipple member 9) with a recess 9a formed therein such that an extension of the actuating button 11 is positively lockable in the recess 9a. In the preferred embodiment, the extension of the actuating button 11 is in the shape of a push-rod 12 which positively enters and entrains the nipple member 9 as shown in FIG. 2.
As FIG. 1 shows, when button 11 is completely depressed, the push-rod 12 engages positively in the resilient nipple member 9 of the control diaphragm 8. The inlet valve body 5 preferably contains two spacers 25 against which the nipple member 9 of the control diaphragm 8 firmly rests when the button 11 is depressed into the engagement position. These spacers 25 secure the control diaphragm 8, enabling the push-rod 12 to enter the nipple member 9. Because of the matching geometrical shape of the push-rod 12 and the protecting, screen-like nipple member 9, the control diaphragm 8 is firmly held and entrained by the actuating button 11.
In the operative position, the push-rod 12 and the nipple member 9 are separated, such as shown in FIG. 5, when the person wearing the breathing mask and the lung-governed valve 1 draws his first breath. Preferably, the nipple member 9 has two opposite slots 27 (see FIG. 2) which enable the push-rod 12 of the actuating button to unlock easily when the first breath is drawn, but not when the lung-governed valve is subjected to external vibrations in the stand-by position. As a result, switching to the operative position is experienced as pleasant by the person wearing the breathing mask.
In the preferred embodiment, the pot-like insert 10 is preferably constructed as a guide part for the axially movable actuating button 11, as a bearing part for receiving a means for returning the actuating button 11, and a means for maintaining excess pressure on the control diaphragm 8. Additionally, the pot-like insert 10 preferably has a recess 24 into which the nipple member 9 enters and is abuttingly contained therein when the lung-governed valve 1 is in the stand-by position. The stand-by position is shown in FIG. 4.
Preferably, excess pressure is maintained on the control diaphragm 8 by an adjustable excess-pressure spring 23 disposed centrally on the control diaphragm 8. The excess-pressure spring 23 by pressing with the appropriate force, determines the amount of excess pressure in the breathing chamber 17 and consequently the desired excess pressure inside the breathing mask.
The inlet valve body 5 has a means for opening and closing the through bore 6a in the control piston 6 by actuation of the control diaphragm 8. In the preferred embodiment, a tilt lever 13 is connected to one side of the inlet valve body 5 and cooperates with a counterpoise 14 and a closure part 15 to control the opening and closing of the through bore 6a.
The valve casing 2 is preferably closed by a tubular member 19 which acts as a shock absorber. The top of the tubular member is preferably formed with a through opening 28 for the actuating button 11. Window-like openings 20 are preferably distributed around the periphery of tubular member 19, enabling optical visibility of the actuating button 11 when the lung-governed valve 1 is in the operative position.
The actuating button 11 is preferably returned by a return spring 22. The return spring 22, which is disposed in the pot-like insert 10, is connected to the actuating button 11. When the lung-governed valve enters the operative position, the actuating button 11 moves outwards via expansion of the return spring 22, coming to rest against the abutment 26. In this position, the actuating button 11 is visible through the window-like openings 20. The actuating button 11 is preferably of a contrasting color to facilitate visibility.
To activate lung-governed valve 1 and place it in the on position, the tension-loaded actuating button 11 is depressed completely, causing the control diaphragm 8 to come to rest on the two spacers 25 and allowing the push-rod 12 to engage the nipple member 9. In this process, the tilt lever 13 revolves around its center of rotation and the closure part 15 of the counterpoise 14 lifts off the through bore 6a in the control piston 6 so that breathing gas can flow through. The breathing gas will continue to flow only so long as the actuating button 11 remains depressed. In this manner, the delivery of gas can be advantageously controlled by hand, allowing use by a second person, cleaning of the mask from pollutants, and relief of pressure from the supply nozzle after use.
FIG. 4 shows the inoperative position or the "stand-by" position of lung-governed valve 1. The stand-by position is automatically brought about by the expansion of the abutment spring 21 and the return spring 22 when the actuating button 11 is released from its fully depressed position. The abutment spring 21 is fairly strong while the return spring 22 is relatively weak. This is because the return spring 22 only needs to return actuating button 11 once the push-rod 12 has been disengaged from the nipple member 9 whereas abutment spring 21 pushes against actuating button 11 and the pot-like insert 10 such that the nipple member 9 of the control diaphragm 8 fits securely into and abuts the annular recess 24 in the pot-like insert 10. It also provides a strong force to release push-rod 12 when there is a negative pressure caused by the first inhaled breath. In this position, the push-rod 12 of the actuating button 11 cannot escape upwards any farther. If the lung-governed valve 1 is subjected to impact, the compressive effect intensifies, preventing the push-rod 12 from disengaging from the nipple member 9 and thereby switching the lung-governed valve 1 to the operative position.
When a breathing mask is connected to the delivery nozzle 3, the first inhalation of the user creates an excess negative pressure inside the mask and consequently an excess negative pressure in the breathing chamber 17. This excess negative pressure, which is produced only during the first breath, causes the control diaphragm 8 and the engaged push-rod 12 to be pulled downwards from the position shown in FIG. 4. The actuating button 11 and the push-rod 12 press against the abutment spring 21 and the return spring 22 until the resulting excess negative pressure combined with the force of the excess-pressure spring 23 release the nipple member 9 from the annular recess 24 and the push-rod 12 disengages the nipple member 9. The lung-governed valve 1 is now in the operative position as shown in FIG. 5. The return spring 22 pushes the actuating button 11 as far as the upper abutment 26 of the tubular member 19. In this position, the actuating button 11 becomes visible through the window-like openings 20, showing the user or a third person that the valve is in the excess-pressure or operative position. In the operative position, the control diaphragm 8, can move freely during subsequent breathing. The control diaphragm 8 controls the opening of the inlet valve by rotating the tilt lever 13 and consequently raising the control piston 6 from the valve seat 7.
To switch off the lung-governed valve 1, the actuating button 11 must be fully depressed as shown in FIG. 3, enabling the push-rod 12 to engage the nipple member 9 and move to the stand-by position shown in FIG. 4.
While a presently preferred embodiment of practicing the invention has been shown and described with particularity in connection with the accompanying drawings, the invention may be otherwise embodied within the scope of the following claims. | A lung-governed breathing valve used in a breathing mask for excess pressure operation. The valve has a casing with a spring-loaded control diaphragm which divides the casing into an outer chamber connected to the outside environment and a breathing chamber for conveying the gas for breathing. The control diaphragm controls a breathing gas inlet valve via a lever system and a manually released actuating button. The control diaphragm has a resilient raised portion formed integrally thereon with a recess therein. A push-rod integrally molded on the actuating button is positively engageable in the recess of the raised portion to prevent the lung-governed valve from being accidentally released or switched from the stand-by to the operative position. | 0 |
This application is a division of application Ser. No. 07/493,896, filed Mar. 15, 1990.
BACKGROUND OF THE INVENTION
The present invention relates to water treatment systems, sometimes commonly known as water softening systems, and more particularly to a unique system comprising a water softening unit, a control system therefor, and its use in commercial/industrial settings.
Resin-type ion exchange devices have many uses, such as the softening of water. As the water to be processed is passed through the resin-filled tank, ions in the fluid to be processed, e.g. calcium, is exchanged with ions found in the resin, e.g. sodium, thereby removing objectionable ions from the water and exchanging them for less objectionable ions found in the resin. During this ion exchange process, the ability of the resin to exchange ions gradually is reduced. That is, the resin bed becomes exhausted and, thereafter, water will flow therethrough in unprocessed form.
The capacity of the ion exchange resin bed can be determined from the volume of resin used and the particular type of resin. The concentration of contaminant(s) in the water to be processed can be determined, at least on an average basis. Thus, the volume of water that can be processed by a particular water treatment unit is known. Once that capacity of water has been treated, the bed must be regenerated.
Regeneration of the ion exchange resins typically involves chemically replacing the objectionable ions from the resin with less objectionable ions, c.g. replacing calcium with sodium ions. This regeneration process requires the suspension of the treatment process, thus necessitating the water to by-pass the ion exchange resin tank. At the same time as the ion exchange resin is regenerated, the bed can be backwashed in order to remove trapped particulate matter, the resin tank can be rinsed to remove objectionable soluble materials, an application of sterilization agent to prevent bacterial growth can be accomplished, etc. All of these operations are known in the art.
In the regeneration of resin beds used to treat hard water, a variety of control modes have been employed commercially. For example, some water softening units function on a timer which necessitates regeneration at specified time intervals. This mode of operation has the disadvantage that the resin bed may have sufficient capacity remaining to continue for quite a time thereafter. Another mode of control involves monitoring the volume of water treated and provoking regeneration once a set point has been reached. Unfortunately, regeneration cycles can be triggered undesirably at just the time when demand for water is high under this mode of operation.
One overriding condsideration regardless of the mode of control employed involves exhaustion of the resin bed. If the resin bed is permitted to become completely exhausted of its capability of exchanging ions, a single regeneration cycle will not be sufficient to establish the original capacity of the bed. Instead, several regeneration cycles often will be required. Moreover, if the bed is near its exhaustion point and a high demand for water is made, present commercial systems cannot provide the capacity to soften the extra water demand without risking total exhaustion of the resin bed. Accordingly, new water treatment systems including the mode of operation thereof are in demand in this field.
BROAD STATEMENT OF THE INVENTION
The present invention has many aspects. In its broadest aspects, a method for the cyclic regeneration of a water softening system is disclosed. The water softening system comprises an exchange medium in a tank which is in fluid communication with a brine storage tank. This method comprises the steps of filling the brine storage tank with refill No. 2 of softened water in a quantity sufficient to create sufficient brine for said exchange medium, said brine storage tank already containing refill No. 1 of softened water from a later step of the method. The exchange medium is subjected to backwashing No. 1 with water flowing counter the direction of water flowing therethrough during water softening operations. Next, brine from the brine storage tank is passed through the exchange medium. Water then is passed through the brine exchange tank. The exchange medium thereafter is subjected to backwashing No. 2 with water flowing counter to the direction of water flowing therethrough during the water softening operation. Finally, the brine tank is refilled with refill No. 1 of softened water to create brine in a quantity insufficient for completely brining the exchange medium.
Another aspect of the present invention is an improved valve assembly which is designed to implement the novel method disclosed above. The improved valve assembly comprises a valve body having a drain port, an inlet water port, softened water outlet port, an injector port, first and second exchange medium tank ports, and first and second injector ports. A piston valve assembly comprises a piston bearing the first and second valve, and is disposed within the valve body. A drive assembly is connected with the piston for reciprocatingly moving the piston within the valve body for the valves to determine the flow of fluid within the valve body. A flow meter is associated with the valve body for measuring water passed through the exchange medium tank. An injector assembly has a first port in fluid communication with the valve body first port which provides fluid communication with the valve body softened water outlet port; a second port in fluid communication with said valve body second port which provides fluid communication with said valve body inlet water port; and a brine storage tank port. The injector second port is in fluid communication with the injector second port through a nozzle whereby water flowing from said injector second port to said injector first port through said nozzle creates a pressure reduction in the injector assembly between said injector second port and said brine storage tank port for drawing brine from said brine storage tank to within said injector assembly and out said injector second port. The piston is movable from a first position wherein water flows from said valve body inlet port to said second exchange medium tank port, and from said exchange medium tank through said first exchange medium tank port and outsaid softened water outlet port; to a second position wherein said valves close fluid communication between said valve body inlet water port and said valve body second exchange medium tank port, opens fluid communication between said valve body second exchange medium tank port and said valve body drain port, and opens fluid communication between said valve body inlet water port and said first exchange medium tank port and said injector second port for water to backwash said exchange medium tank; to a third position wherein said valves only permit fluid communication between said valve body inlet port and said injector second port for water and brine from said brine storage tank to flow from said injector first port to said valve body first exchange tank port, and from said valve body exchange medium tank second port to the valve body drain port; and reciprocatingly movable back to said second and first positions sequentially.
The piston of the novel valve assembly can be driven by a unique helix drive disclosed herein. The helix drive comprises a stationery drive axle bearing a longitudinally slotted sleeve; a piston having an apertured end and being disposed within said drive axle sleeve; a transverse pin, having ends fitted with guide shoes, disposed through said piston aperture and located within said axle slot; and a drive gear having a pair of helix paths within said pin guide shoes are disposed, whereby rotation of said drive gear results in reciprocating longitudinal movement of the pin within the axle slot and, thus, said drive axle.
Advantages of the present invention include a mode of operation that prevents the exchange medium from becoming exhausted by always forcing regeneration when the reserve setting is reached. Another advantage is the ability to soften water on an emergency basis when high demand is specified by always keeping brine in the brine tank. Another advantage is an emergency mode whereby service water bypasses the unit so that the exchange bed can be regenerated prior to its becoming completely exhausted. Yet another advantage is a unique valve assembly system for implementation of the method disclosed herein. Yet a further advantage is a unique helix drive system that can be adapted for use in the novel valve assembly disclosed herein. These and other advantages will be readily apparent to those skilled in the art based upon the disclosure contained herein.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective elevational view of the ion exchange resin system including a cabinet which houses the ion exchange resin bed tank and the valve assembly of the present invention;
FIG. 2 is a sectional view taken along line 2--2 of FIG. 1;
FIG. 3 is an elevational view of the components comprising the exchange medium tank and their assembly;
FIG. 4 is a perspective view of the assembly of the valve body, piston valve assembly, injector assembly, and by-pass assembly of the present invention;
FIG. 5 is a detailed drawing of the components and their assembly for the injector assembly and valve body of FIG. 4;
FIG. 6 is a detailed drawing of the components and their assembly of the piston valve assembly of FIG. 4;
FIG. 7 is a detailed drawing of the components and their assembly of the bypass assembly of FIG. 4;
FIG. 8 is a sectional view taken along line 8--8 of FIG. 1;
FIG. 9 is a side view of the helix drive components which provide reciprocating longitudinal movement of the piston set forth in FIG. 8;
FIG. 10 is a cut-away view of the valve control assembly showing the flow of water and brine therethrough;
FIG. 11 is a flow diagram for the electronic control means used in conjunction with the water softening system of the present invention;
FIG. 12 is an alternative flow diagram to that set forth at FIG. 11; and
FIG. 13 is a schematic representation of a plurality of water softening units and their mode of operation in a single system.
These drawings will be described in detail in connection with the following Detailed Description of the Invention.
DETAILED DESCRIPTION OF THE INVENTION
The water softening unit of the comprehensive water treatment system of the present invention is depicted at FIG. 1. Housed within cabinet 10 is ion exchange medium tank 12. (See FIGS. 2 and 3). Mounted atop tank 12 is valve control assembly 14 which will be described in detail in connection with FIGS. 4-9). Line 16 is for connection to brine storage tank 18 and line 20 is the connection to a drain. Water enters the comprehensive water treatment system through inlet 22 and softened water is withdrawn through outlet 24. Frame 26 (see FIG. 2 also) mounts atop cabinet 10 and retains cover 28 which hides valve control assembly 14.
While exchange medium tank 12 can be made in one or more sections, FIG. 3 depicts it as formed from upper tank section 30 and lower tank section 32. This arrangement permits the insertion of central annular sections to increase the height of tank 12 should it be necessary, desirable, or convenient. Tank 12 is shown fitted with upper screen/distributor 34, center screen/distributor 36, and lower screen/distributor 38. The use of three screen/distributors as shown at FIG. 3 permits different resins or exchange medium beds to be established between distributors 34 and 36, and 34 and 38. Exchange beds also can be located atop distributor 34 and beneath distributor 38, if necessary, desirable, or convenient. It will be appreciated that center screen/distributor 36 may be omitted to establish a single bed. Alternatively, with additional centrally-disposed tank sections with associated screen/distributors, additional beds could be established as is necessary, desirable, or convenient. Head space 35 is provided between upper screen/distributor 34 and the spherical top of upper medium tank section 30. Preferably, head space 35 is filled with media (e.g. 60/80 mesh garnet) capable of filtering particulate contaminants from water passed therethrough. Mounting brackets 40 retain valve control assembly 14. Fill aperture 42 in upper medium tank section 30 can be used to add resin to tank 12 for filling the upper section housed within upper medium tank 30 and can be used for withdrawal of resin by inversion of tank 12. Fill plug 44 and O-ring 46 fill aperture 42 when access thereto is not required. Similarly, lower medium tank section 32 has drain plug 48 which retains lower fill plug 50 and O-ring 52.
Upper medium tank section 30 further has inlet aperture 54 and outlet aperture 56 disposed about its spherical top. Flange 58 (see FIG. 2) projects downwardly from the top of upper medium tank section 30 and provides communication between outlet aperture 56 and center flow tube 60. Apertured plate 62 and associated O-ring 64 mate with flange 58 to provide a cavity in communication with center flow tube 60 that fits through the aperture in plate 62 and, thus, provide an outlet for softened water separate from the head space within upper medium tank section 30 which is filled with service water to be softened as it enters tank 12 via inlet aperture 54. The flow of water admitted via inlet aperture 54 passes sequentially through the garnet media in headspace 35 wherein particulate matter is filtered, through upper screen/distributor 34 through upper resin bed 66, through center screen/distributor 36 and through lower resin bed 68, and finally through lower screen/distributor 38. The water then flows up through center flow tube 60 and into the chamber created by flange 58 and plate 62 for being withdrawn from tank 12 via outlet aperture 56.
Control of the flow of water between exchange medium tank 12, brine storage tank 18, and within exchange medium tank 12 is controlled by valve control assembly 14 which is depicted at FIG. 4. This assembly is composed of valve body 70, injector assembly 72, helix drive assembly 74, and bypass assembly 76. This component and assembly drawing will be referred to in connection with the detailed drawings of each of these assemblies as depicted in other figures.
Referring to FIG. 5, valve assembly 70 and injector assembly 72 are seen in detail. Valve body 71 is seen to have eight ports: water inlet port 78, softened water outlet port 80, helix drive port 82, drain port 84, first exchange medium tank port 86, second exchange medium tank port 88, first injector port 90, and second injector port 92. End cap 94, with O-ring 96 and cylinder insert 98 connects to flange 100, which retains threaded inserts 102a-102e, by bolts 104a-104e. Line 20 (FIG. 1) connects to end cap 94.
Injector assembly 62 is seen to be comprised of injector housing 106 which has internally threaded end 108 into which fits throat 110, nozzle 112, screen 114, O-ring 116, and threaded plug 118. Injector housing 106 further has first ports 120 and second port 122. First injector port 120 mates with first valve body port 90 with intervening O-ring 124 therebetween. Second injector port 122 mates with second valve body port 92 with O-ring 126 disposed therebetween. Threaded sleeve 128 is connected to elbow 130 which serves as the brine tank port for injector 72 and is connected to line 16 (see FIG. 1). Disposed within injector housing 106 and in the aperture formed by threaded sleeve 128 is spring 132, poppet 134, and O-ring 136. This spring assembly is inserted into injector housing 106 via elongate aperture 138 and is sealed to the outside by elongate cover 140 with intermediately disposed O-ring 142. Cover 140 is retained to injector housing 106 by threaded bolts 144a-144f.
Referring to valve assembly 70, cylinder insert 144 (FIG. 5) fits into aperture 82 which is surmounted by flange 146 which contains threaded inserts 148a-148e. Valve assembly 150 is comprised of piston 152 which retains first valve 154 and second valve 156. One end of piston 52 is terminated by crucifix 158 which fits into valve body end cap 94 and is terminated at the other end by transverse aperture 160. Drive axle 162 bears longitudinally slotted sleeve 164 and has mounts for mounting motor 166 with screws 168a and 168b. Drive axle 162 itself is mounted to valve body flange 146 by bolts 170a-170e. The apertured end of piston 152 fits through drive axle 162 and slotted sleeve 164. Cross pin 172 with guide shoes 174 and 176 fits through aperture 160 and rides in the longitudinal slot in slotted sleeve 164. Slotted sleeve 164 permits piston 152 to move in a longitudinal direction only.
The helix drive unit (FIG. 6) that provides reciprocating movement of piston 152 includes bushing 178, helix drive gear 180, helix drive center 182, and helix drive end 184. Switch ring double 186, switch ring single 188, and bushing thrust washer 190 complete the helix drive assembly. Referring to FIG. 4, motor cover 192 attaches to the motor mount flange of drive axle 162 with screws 194a and 194b. Junction printed circuit board (PCB) 196 similarly is attached with screws 198a and 198b. O-ring 200 completes the waterproof seal established between helix drive assembly 74 and valve body 70.
Referring now to bypass assembly 76 depicted in detail at FIG. 7, bypass housing 202 has water inlet port 204 that connects to valve body inlet port 78 and water outlet port 206 that connects to valve body outlet port 80. O-rings 205 and 207 seal port 204 to valve body inlet port 78 and port 206 to valve body outlet port 80, respectively (see also FIG. 4). Turbine 208 is retained in port 206 by flow director 210. Mounted in conjunction therewith is pressure differential switch 212, mounted with screws 214a-214d and O-rings 216a and 216b, and turbine sensor PCB 218 retained by sensor cap 220 and screw 222. Switch 212 permits the pressure drop across the resin beds to be monitored based on the inlet and outlet water pressures. If this value is too great, likely the resin bed(s) is clogged and the water softening system is shut out, i.e. full by-bass mode is established. The turbine sensor assembly provide flow metering of the softened water exiting the system. Full bypass of water is achieved using bypass assembly 76 by activating rotating handle 224 which is affixed to bypass housing 202 by screw 226. Handle 224, in turn, is attached to drive shaft 228 which accommodates O-ring 230 therebetween. Drive shaft 228, in turn, screws into piston assembly 230 which is connected at its other end to end cap 232. End cap 232, in turn, retains valve test port 234. End cap 232 is attached to bypass housing 202 by screws 236a-236h which screw into threaded inserts 238a-238h which are retained by bypass housing 202. O-ring 240 completes the seal established between end cap 232 and bypass housing 202.
Finally, O-rings 242 and 244 provide sealing engagement between first and second tank ports 86 and 88, and inlet 54 and outlet 56, respectively, of upper medium tank section 30. Injector assembly 72 is affixed to also to upper medium tank section 30 by screws 246a and 246b. Bypass housing 76 is retained by screws 248a-248c. Thus, completes the assembly of valve control assembly 14.
As to operation of valve control assembly 14, reference is made to FIGS. 8-10. Piston valve assembly 150 disposed within valve body 70 has three distinct positions to which valves 156 and 154 are brought. Junction PCB 196 in conjunction with switching 186 and 188 provides a stopping point when each of these three positions is reached and, thus, permits motor 166 to be deactivated, as will be more particularly described below. The position of piston valve assembly 150 depicted in FIG. 8 is the normal operational mode wherein service water to be softened enters valve body 70 via inlet port 78 and passes through second tank port 88 into tank 12 to be softened. Valve 154 is in contact with valve seat 252 and, thus, prevents the water from flowing past first valve 154. Similarly, drain line 20 is blocked by O-ring 230 at the crucifix end of piston 152. Softened water is withdrawn from exchange medium tank 12 via first tank port 86 and out of valve body 70 via outlet port 80, first valve 154 again preventing the water from flowing therepast due to its seating against valve seat 252. In this normal operational mode, second valve 156 performs no function. Motor 166 causes center helix drive 182 to rotate its valve actuating surface (e.g. by camming action) into contact with poppet valve 134 to open elbow 130 and permit softened water to flow out threaded sleeve 128, elbow 130, into line 16, and finally into brine storage tank 18. All brine created in tank 18 is with softened water. Next, motor 166 drives piston 152 to a position whereat second valve 156 seats against valve seat 250. This opens drain line 20. First valve 154, however, still is in contact with valve seat 252. The new position of second valve 156 prevents service water entering valve body inlet port 78 from flowing to valve body second tank port 88. Instead, the position of first valve 154 permits service water to now flow out valve body second injection port 92 and thence into injector housing 106. A portion of the water also flows out injector first port 120 into valve body 70 and out valve body first tank port 86 into exchange medium tank 12, but in the direction opposite the normal flow established during softening of inlet service water. This is the so-called "backwash" that is conventionally known in the art. The backwash cycle permits suspended solids and foreign matter to be washed from the garnet bed and ion exchange resin housed within exchange medium tank. This backwash of water passes through valve body second tank port 88 and out drain line 20. Double switch ring 186 and single switch ring 188 permit timing by the controls for the duration of all cycles by carrying seven three-bit binary numbers that provide feedback to the microprocessor establishing the precise position of piston 152 and, hence, the precise cycle and flow of water in valve control assembly 14. Detents in switchings 186 and 188 engage switches on junction PCB 196 and form the binary number, though lands or other indicia could be used.
When this cycle has been completed, piston 152 again traverses to a position whereat second valve 156 still retains contact with valve seat 250, but now first valve 154 is seated against valve seat 254. In this position, the flow of service water entering valve body inlet port 78 and out valve body second injection port 92 is of such a sufficient velocity as it passes through nozzle 112, that a partial vacuum is established within injector housing 106 in communication with threaded sleeve 128. Poppet 134 is moved to an open position by the camming action of drive 182 so that this partial vacuum sucks brine water from brine tank 18 back through line 16 and into injector housing 106 to be mixed with service water passed through injector first port 122 into valve body 70 and thence out valve body first tank port 86. This "brining" or reverse ion exchange refreshes the ion exchange resin and restablishes its initial capacity for softening water. The effluent is withdrawn from exchange medium tank 12 through valve body second tank port 88 and out drain line 20. Again, when the timer indicates that this cycle has been completed, piston 152 reciprocates in the opposite direction and each of these operations sequentially is conducted again, but now in the reverse order. That is, at the next or middle position, the ion exchange resin is backwashed. Thereafter, piston 152 is moved back to the position depicted at FIG. 8 and water softening is recommenced. Finally, softened water again is permitted to flow into brine storage tank 18. During the brining operation, a flow of water directly between valve body inlet port 78 and outlet port 80 is established so that no loss of service is experienced.
The reciprocating movement of piston 152 is determined by helix drive assembly 74, particularly as it relates to helix drive gear 180, helix drive center 182, and helix drive end 184. Referring more particularly to FIG. 9, it will be observed that guide shoe 176 is disposed in the helix path canted in one direction. Not shown in FIG. 9 is guide shoe 174 that is disposed opposite guide shoe 176. These guide shoes follow the double helix path. Since, however, cross pin 176 has only one degree of freedom of movement, viz. in the slot of slotted sleeve 164, cross pin 172 guided by guide shoes 174 and 176 can only move longitudinally in the direction of piston 152 as the helix drive rotates powered by motor 166. A simple, yet highly efficient and reliable reciprocating motive system for piston 152, thus, is disclosed.
The operation of valve control assembly 14 is controlled by a microprocessor that contains a program that will be described below in connection with FIG. 11. Initially, however, data must be entered into the program in order to calculate the RESERVE for the system. The water treatment system of the present invention maintains a reserve capacity in order to prevent the resin bed from becoming completely exhausted. Preferably, this reserve is equal to one day's average use of water, though other time periods can be selected as in necessary, desirable, or convenient. In order to calculate the RESERVE, the "grain capacity" of the resin tank must be entered (this is dependent upon the quantity of resin in the tank and the composition of the resin), the hardness of the water to be treated is entered; the number of people in the family being served by the water treatment system is entered; the average consumption of water, gallons/day, is embedded in the software, though it could be a variable which also is entered; and the computer then calculates the RESERVE. As an example, assume that the capacity of tank 12 is 23,000 grains, the hardness of the water to be treated is 10 grains/gallon, the family comprises four persons, and the average comsumption is 75 gallons/day/person. The total capacity of tank 12 is 2300 gallons and one day's RESERVE is equal to 300 gallons. The volume of water intended for softening prior to regeneration, V s , then is equal to 2,000 gallons. The time of day that the computer samples the status of the system additionally can be a variable, or it can be preset in the computer, e.g. conveniently to 12 o'clock p.m.
With the foregoing information entered into the computer, the computer program starts at block 256. Since the system is designed to prevent complete exhaustion of the resin bed in tank 12, the initial step of the computer program at block 258 looks to see whether the volume of water softened exceeds the calculated capacity, V s , of the resin bed(s) in tank 12. In the hypothetical set forth above, the capacity has been calculated to equal 2,000 gallons. If the program determines that this capacity has been exceeded, the program proceeds to block 260 wherein regeneration of the resin bed is commenced immediately, regardless of time of day. The computer program at block 261 also looks to see the pressure differential, P, between the incoming hard water and the outgoing softened water. If P exceeds a given value for the system, it is assumed that the resin beds are clogged and emergency regeneration also is required. The regeneration of the resin bed is accomplished with the water treatment system as described in connection with the previous drawings. These are override situations that occur at blocks 258 and 261 in the program and are unique features of the present invention.
If the volume of water softened, V s , has not exceeded the capacity of the system and the pressure differential has not exceeded the target value, the computer program proceeds to block 262 wherein the time of day, T d , is sampled. As noted above, this time can be set by the user, or can be embedded in the computer program. Midnight is a convenient time for sampling the system since it is a likely time that no water demand is made on the water treatment system. If the set time of day has not been reached, then the program returns to block 258. If, however, the sample time of day has been reached, then the computer program continues to block 264 wherein the program again looks to see whether the design capacity of the system, viz 2,000 gallons in the example above, has been reached. In other words, the program looks to see whether the water treatment system has entered the RESERVE capacity set for the resin bed. If this value has not been reached, then the program returns to block 258.
If the program determines that the resin bed is operating in the RESERVE portion of the bed, then the computer program continues to block 266 wherein the computer calculates the volume of water required to be added to brine storage tank 18 in order to make sufficient brine to regenerate the resin bed and re-establish its initial capacity. Since the volume of water passed through the resin bed can vary, this step of the computer program ensures that only the minimum amount of brine required to exchange with the resin bed is used. Since the regeneration sequence of the present invention always retains a fraction of the brine performed in brine storage tank 18, only the volume of water needed to bring the brine up to the required volume needs to be added. Once the volume of water is calculated at block 266, the computer program proceeds to block 268 wherein motor 166 is actuated for rotating the helix drive so that the camming action of center helix drive 182 activates poppet 134 to permit the computed volume of water to flow into brine storage tank 18. Next, motor 166 is actuated for moving piston 152 disposed in valve body 70 to backwash the resin in exchange medium tank 12. The program then proceeds to block 270 wherein a time pause or delay, T p , is encountered. This delay permits sufficient time for the water passed into brine storage tank 18 to dissolve sufficient brine to establish a brine solution adequate for treatment of the resin in exchange medium tank 12. A conventional time pause is two hours, which means that the regeneration of the resin bed normally will occur at 2:00 a.m. in accordance with step 272 of the computer program. It will be observed that under the emergency regeneration mode of operation at block 260, the time pause at block 270 also is encountered. Following regeneration of the resin bed, the program proceeds to step 274 wherein the accumulated volume of water softened is reset to zero. The program then returns to block 258 of the program.
The emergency regeneration carried out at block 260 of the computer program calls for the bed to be regenerated with the brine present in brine storage tank 18 by virture of refill No. 1. Following this partial regeneration of the resin bed, refill No. 1 is set for the full capacity of the resin bed and refill No. 2 is omitted. At T d , the full amount of brine in brine storage tank 18 then is used to regenerate the bed. Depending upon the amount of water that has been used between the time at which the emergency regeneration was executed and the normal regeneration time, T d , this sequence under emergency regeneration may result in the overbrining of the bed. Alternatively, an extra demand of water thereafter could result in the capacity of the resin bed being exceeded again before reaching the appropriate standard regeneration time of day, T d . Accordingly, the alternative computer program depicted at FIG. 12 modifies the emergency regeneration sequence. Following the emergency regeneration at step 260, the program proceeds to block 276 wherein the volume of water softened again is monitored to see whether it has exceeded the capacity of the system, viz 2300 gallons in the example used herein. If this capacity again has been exceeded, then the program returns to step 260 wherein emergency regeneration again is executed. If, however, the full capacity of the resin bed has not been exceeded, the computer program continues to block 278 wherein the time of day again is sampled. This time of day may or may not be the same time that standard regeneration at block 262 utilizes. If this sample time of day at block 278 has not been reached, then the program returns to block 276 for monitoring the capacity of water passed through the water treatment system again. If the sample time of day has been reached, then the program continues to step 280 wherein valve control assembly 14 is activated for filling brine storage tank 18 with sufficient water to completely brine the resin bed and the program continues to block 270.
When a plurality of the comprehensive water treatment systems are to be used in a commercial or industrial setting wherein large capacities of water need to be softened, the operational sequence as illustrated at FIG. 13 may be used. Merely for illustrative purposes, five units were chosen to be depicted at FIG. 13. It will be appreciated that a greater or lesser number of units may be combined in parallel operation as illustrated at FIG. 13. Again, it is mandatory that none of the units have a quantity of water passed therethrough so that the resin bed is completely exhausted. Since no two water treatment units will express the same pressure differential thereacross, and hence the same volumetric flow of water, it is not safe to assume that one-fifth of the flow of water will be passed through each of the five units when they are operated in parallel. If this assumption were made, the operator takes a definite risk that one of the units will preferentially exhibit a lower pressure differential thereacross and, hence, it could be operated to exhaustion. Thus, this operational mode of the present invention always ensures that no tank will be depleted. As an alternative, the regenerated tank, for example, could be held off-line which would provide at least one tank in reserve should an emergency situation arise.
With the four water softening units illustrated at FIG. 13 at the top, each unit starts with a complete resin bed as illustrated at A. Five regeneration cycles then are depicted at C-G. In order to establish the sequence for the meter demand set point, the capacity of the smallest of the four units is divided by the number of units. In the illustration at FIG. 11 with equal capacity units, the capacity of any one unit would be divided by four. Say, that each unit is capable of softening 120 gallons of water. This capacity divided by the number of units makes the set point at 30 gallons. This means that units 1-4 on the average will soften each 30 gallons. One or more of the units may be above or below this average figure. When this capacity has been first reached by any of the units, unit 1 then is regenerated. The choice of tank 1 is arbitrary. Any unit could have been selected, not necessarily the unit that triggered regeneration. When unit 1 has been regenerated, it is immediately placed back in service. The counter is reset to zero at the onset of regeneration. Monitoring of when any unit reaches 30 gallons again is commenced. At cycle D when 30 gallons again is first reached by any unit, sequentially tank 2 is regenerated and the remaining units continue to soften the water. By the time that cycle E is reached, the only unit not to be regenerated, unit 4, has run through four cycles of water softening. Since on the average each cycle involves the softening of 30 gallons, its capacity has not been reached and at cycle F, it is withdrawn for regeneration. The cycle then commences again at G. While this example is based on 4 units, it will be understood that other numbers could be used to calculate the regeneration set point. Of importance is the operation in a mode whereby complete exhaustion of any one unit is avoided. By basing regeneration on the smallest capacity unit, uneven capacity units also can be used as is necessary, desirable, or convenient. | In its broadest aspects, a method for the cyclic regeneration of a water softening system disclosed. The water softening system comprises an exchange medium in a tank which is in fluid communication with a brine storage tank. This method comprises the steps of filling the brine storage tank with refill No. 2 of softened water in a quantity sufficient to create sufficient brine for said exchange medium, said brine storage tank already containing refill No. 1 of softened water from a later step of the method. The exchange medium is subjected to backwashing No. 1 with water flowing counter the direction of water flowing therethrough during water softening operations. Next, brine from the brine storage tank is passed through the exchange medium. Water then is passed through the brine exchange tank. The exchange medium thereafter is subjected to backwashing No. 2 with water flowing counter to the direction of water flowing therethrough during the water softening operation. Finally, the brine tank is refilled with refill No. 1 of softened water to create brine in a quantity insufficient for completely brining the exchange medium. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Patent Application No. 60/563,806 filed Apr. 21, 2004, hereby incorporated by reference in its entirety.
BACKGROUND OF INVENTION
[0002] a. Field of Invention
[0003] The invention relates generally to moisture management structured fabrics, and more particularly to fabrics and garments produced by the use of such moisture management structured fabrics and including predetermined hydrophilic and hydrophobic layers for facilitating absorption and evaporation of moisture, and for further facilitating printing on one or both sides of the fabric.
[0004] b. Description of Related Art
[0005] As discussed in co-pending U.S. patent application Ser. No. 10/112,957, filed Apr. 2, 2002, titled “Composite Yarns and Moisture Management Fabrics Made Therefrom,” and U.S. patent application Ser. No. 10/113,286, filed Apr. 2, 2002, titled “Elastic Hydrophobic/Hydrophilic Composite Yarns and Moisture Management Elastic Fabrics Made Therefrom,” owned by Assignee herein and the respective disclosures of which are incorporated herein by reference, in recent years, “structured fabrics” (also referred to as “engineered fabrics”) have become very popular in many application areas of commercial interest. A particularly important subclass of such structured fabrics is referred to commonly as “moisture management” fabrics.
[0006] An effective class of moisture management fabrics utilizes two or more fiber types in layered structures formed so that the two sides of the fabrics are distinctly different in character. In particular, each side of the fabric exhibits different performance characteristics and properties with regard to water and water vapor. The innermost layer, or the fabric side that comes into contact with the body of the wearer, is comprised substantially of hydrophobic fibers, while the outer layer is made up substantially of hydrophilic fibers.
[0007] The principal end use application areas for moisture management fabrics are in active sportswear garments, work clothing, intimate apparel, exercise garments, and footwear. For uses in garments that contact the body of a physically active wearer, the moisture management fabrics act to prevent or minimize the collection of perspiration as a liquid against the body and in the interstices of the fabric layer next to the body of the wearer. The perspiration, in liquid or vapor form, leaves the skin surface and diffuses, or wicks, through the hydrophobic fibers and is absorbed by the hydrophilic fibers in the outer fabric layer. The perspiration that passes from the skin surface through the hydrophobic fibers is absorbed by the outer layer of hydrophilic fibers and, then, evaporated into the ambient atmosphere away from the body. The transport of moisture from the body of the wearer to the atmosphere in this manner increases the comfort level of the garment to the wearer by preventing or minimizing the formation of wet areas at the skin surface or in the fabric layer nearest the skin. Further, by avoiding the collection of liquid perspiration at the body surface and in the fabric next to the body, the insulating value of the garment is improved so that it feels warmer at low temperatures and cooler, due to an evaporative cooling effect, at higher ambient temperatures to the wearer.
[0008] For many moisture management fabric applications, particularly in the areas of active sports and physical exercise wear, it is desirable that the moisture management garments exhibit a certain degree of printability for printing of patterns, text and various other designs thereon.
[0009] Presently, as discussed above, most moisture management fabrics are structured so that the hydrophobic yarn is against the skin of the wearer and hydrophilic yarn (e.g., a hydrophilic fiber made from a modified nylon and marketed under the trade name, “Hydrofil”) is to the outside. Thus, hydrophobic yarns such as nylon and/or polyester yarns are disposed against the skin of the wearer and “Hydrofil” (a modified nylon) yarns are disposed to the outside, either alone or intermingled with a hydrophobic yarn.
[0010] Nylons, and particularly a modified nylon (e.g., “Hydrofil”) generally make very poor substrates for printing. The pigments and dyes used in printing—particularly so, in transfer printing by sublimation—simply do not adhere very well to nylons or to many other natural and synthetic fibers. However, as discussed in the aforementioned '957 and '286 Applications, polyester can serve as an excellent substrate, and the composite yarns recited in the '957 and '286 Applications provide excellent printability. Printability in such fabrics is assured due to the embedded hydrophilic yarn within a matrix of hydrophobic filaments. Consequently, a fabric made using the composite yarns described in the '957 and '286 Applications, comprised of a “Hydrofil” (with or without spandex) yarn and a polyester yarn (i.e., a collection of polyester filaments), would always have polyester against the skin, and at the outside of the fabric, where it can serve as a stable substrate for prints.
[0011] Although the composite yarn approach disclosed in the '957 and '286 Applications enables excellent printability, there remains a need for an economically cheaper alternative for producing excellent printing on moisture management fabrics for a variety of applications for which the costs associated with the composite yarn approach disclosed in the '957 and '286 Applications may be prohibitive.
[0012] Referring now to the related-art fabrics of U.S. Pat. Nos. 4,530,873 ('873 Patent) and 5,486,500 ('500 Patent), while the fabrics disclosed in the noted U.S. Patents are well known in the industry, none of the fabrics per the aforementioned U.S. Patents provide the advantages and benefits of the fabric structure according to the present invention.
[0013] For example, as illustrated in FIGS. 7 and 8 of the '873 Patent, the fabric includes outer cloth layer 2 made of polyester or nylon, water absorbent fabric layer 5 made of cotton and water permeable fabric layer 4, (Col. 10:44-57). Thus, while the '873 Patent describes a conventional fabric structure having moisture management capabilities, based upon the written description of the '873 Patent, the fabric structure is however not printable as is the case for the present invention.
[0014] Referring to FIG. 1 of the '500 Patent, the '500 Patent discloses a printed towel including a first face 20 formed of a material able to receive printing and being generally non-absorbent, and a second face 30 formed of an absorbent material. As discussed above for the '873 Patent, while the '500 Patent describes a conventional printable fabric structure having moisture management properties, the fabric structure of the '500 Patent however also does not provide the various benefits of the present invention fabric structure, as described in detail below.
[0015] It would therefore be of benefit to provide a fabric including excellent printability and moisture management capabilities, and the capabilities of being manufactured in an economical and efficient manner.
SUMMARY OF THE INVENTION
[0016] The invention solves the aforementioned exemplary drawbacks and deficiencies of the prior art moisture management fabrics by providing a fabric structure including excellent printability and moisture management capabilities, and a variety of other benefits as discussed below.
[0017] The present invention thus provides a printable moisture management fabric including one or more hydrophilic yarn layers, one or more first and second hydrophobic yarn layers. The first and second hydrophobic yarn layers may be respectively disposed against opposing faces of the hydrophilic yarn layer to sandwich the hydrophilic yarn layer between the respective first and second hydrophobic yarn layers. The first and second hydrophobic yarn layers may be printable on outer surfaces thereof.
[0018] For the printable moisture management fabric defined above, the hydrophilic yarn layer may be made of polyester, and the hydrophobic yarn layer may be made of nylon. The fabric may be wearable by the first and/or second hydrophobic layers disposed against the skin of a wearer. The fabric may be double knit, wrap knit or woven. The first and/or the second hydrophobic yarn layers may include printing on the respective outer surface. The first and/or second hydrophobic yarn layers may include a flat or textured continuous filament yarn of polyester fiber. The hydrophilic yarn layer may include a flat or textured continuous filament modified 6-nylon or a spun staple yarn of a modified 6-nylon.
[0019] Alternatively, the first and/or second hydrophobic yarn layers may include a flat or textured continuous filament yarn of polyester fiber. The hydrophilic yarn layer may include a flat or textured continuous filament or spun staple yarn of a modified 66-nylon.
[0020] Yet further, the first and/or second hydrophobic yarn layers may include a staple yarn of polyester fiber. The hydrophilic yarn layer may include a flat or textured continuous filament modified 6-nylon or a spun staple yarn of a modified 6-nylon.
[0021] Additional features, advantages, and embodiments of the invention may be set forth or apparent from consideration of the following detailed description, drawings, and claims. Moreover, it is to be understood that both the foregoing summary of the invention and the following detailed description are exemplary and intended to provide further explanation without limiting the scope of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate preferred embodiments of the invention and together with the detail description serve to explain the principles of the invention. In the drawings:
[0023] FIG. 1 is an illustrative view of a printable moisture management fabric according to the present invention, illustrating the various layers of the fabric.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] Referring now FIG. 1 , there is illustrated a printable moisture management fabric according to the present invention, generally designated DRI-LEX fabric 10 (DRI-LEX being a registered Trademark of Faytex Corp.).
[0025] As shown in FIG. 1 , fabric 10 according to the present invention may include at least three sandwiched layers, which in the particular embodiment of FIG. 1 includes hydrophilic (e.g., “Hydrofil”) yarn layer 12 sandwiched between hydrophobic (e.g., polyester) yarn layers 14 , 16 . Those skilled in the art would appreciate in view of this disclosure that since hydrophobic yarn layers 14 , 16 are disposed symmetrically about hydrophilic yarn layer 12 , garments and the like produced by fabric 10 may be worn with hydrophobic yarn layers 14 or 16 disposed against the skin of a wearer. The aforementioned configuration of fabric 10 thus provides hydrophobic yarn (i.e. layers 14 or 16 ) against the skin, backed up by a layer of hydrophilic yarn (i.e. layer 12 ). Accordingly, while hydrophobic yarn layers 14 or 16 absorb moisture passing through inner hydrophilic layer 12 , this moisture is evaporated through the outer hydrophobic yarn layer 16 or 14 to the atmosphere. The outer layer ( 14 or 16 ) thus allows moisture vapor to escape easily to the atmosphere, but also serves as a good substrate for printing.
[0026] For manufacturing garments and the like, fabric 10 may be knit either with double knit circular knitting machines or with wrap knitting machines having three or more needle bars, or woven as needed. Moreover, as illustrated in FIG. 1 , fabric 10 may be printed on either or both surfaces of hydrophobic yarn layers 14 , 16 , at 20 , 18 respectively.
[0027] Fabric 10 according to the present invention thus provides a variety of advantages over conventional moisture management fabrics. For example, as discussed above, fabric 10 may be printed with equal ease on either or both surfaces of hydrophobic yarn layers 14 , 16 . Fabric 10 also provides effective moisture management, irrespective of which side of the fabric is in contact with the skin of a wearer.
[0028] With regard to printability on hydrophobic yarn layers 14 , 16 , fabric 10 according to the present invention also provides a variety of advantages over conventional moisture management fabrics. For example, fabrics in which both nylon and polyester yarns are at the surfaces can be somewhat difficult to dye to even colors. In such fabrics, two dyestuffs must be utilized in a two-step dyeing process, one dye for the polyester (e.g., a disperse dye) and another dye for the nylon (e.g., an acid dye). Since fabric 10 according to the present invention includes polyester on both sides (see FIG. 1 ), the fabric may be readily dyed with only one dyestuff in a single dyeing step.
[0029] Fabric 10 according to the present invention is also advantageous over conventional moisture management fabrics in the final appearance thereof. For example, with regard to nylon yarns, it is known that nylon yarns are much more subject to yellowing than are polyester yarns. The yellowing is caused by atmospheric conditions such as UV-light, nitrogen oxides generated by burning coal, gas, and other fuels, active chlorine (i.e. as present in swimming pools and bleaches), and other factors. For the fabric according to the present invention, since the nylon hydrophilic (i.e., “Hydrofil”) layer 12 is beneath the more resistant hydrophobic (i.e. polyester) yarn layers 14 , 16 , any slight yellowing is hidden from view by the layers of hydrophobic (i.e. polyester) yarn 14 , 16 .
[0030] As discussed above, various modifications may be made to fabric 10 without departing from the scope of the present invention. For example, fabric 10 may include a plurality of layers of hydrophilic (i.e., “Hydrofil”) yarn, so long as the hydrophilic yarn layers are sandwiched between hydrophobic yarn layers. Additionally, instead of nylon and polyester, a variety of other known hydrophilic or hydrophobic yarn layers may be utilized.
[0031] From the foregoing it can be seen that a simple and economical moisture management fabric has been devised having excellent printability for a variety of applications.
[0032] Although particular embodiments of the invention have been described in detail herein with reference to the accompanying drawings, it is to be understood that the invention is not limited to those particular embodiments, and that various changes and modifications may be effected therein by one skilled in the art without departing from the scope or spirit of the invention as defined in the appended claims. | A printable moisture management fabric including a hydrophilic yarn layer, and first and second hydrophobic yarn layers. The first and second hydrophobic yarn layers may be respectively disposed against opposing faces of said hydrophilic yarn layer to sandwich said hydrophilic yarn layer between said respective first and second hydrophobic yarn layers. The first and second hydrophobic yarn layers may be printable on outer surfaces thereof. | 3 |
RELATED APPLICATIONS
This application is a division of application Ser. No. 07/420,337, filed 10/12/89, now U.S. Pat. No. 4,949,549, which is a continuation-in-part of U.S. application Serial No. 208,371, filed June 22, 1988, now U.S. Pat. No. 4,907,535 which is a continuation-in-part of U.S. application Ser. No. 070,973, filed July 7, 1987, now U.S. Pat. No. 4,759,191.
BACKGROUND OF THE INVENTION
The invention relates to temperature changing devices and, in particular, to portable or disposable food or beverage coolers.
There are many foods and beverages that may be stored almost indefinitely at average ambient temperature of 20°-25 °C. but that should be cooled immediately before consumption. In general, the cooling of these foods and beverages is accomplished by electrically-run refrigeration units. The use of these units to cool such foods and beverages is not always practical because refrigerators generally require a source of electricity, they are not usually portable, and they do not cool the food or beverage quickly.
An alternate method for providing a cooled material on demand is to use portable insulated containers. However, these containers function merely to maintain the previous temperature of the food or beverage placed inside them, or they require the use of ice cubes to provide the desired cooling effect. When used in conjunction with ice, insulated containers are much more bulky and heavy than the food or beverage. Moreover, in many locations, ice may not be readily available when the cooling action is required.
Ice cubes have also been used independently to cool food or beverages rapidly However, utilization of ice independently for cooling is often undesirable because ice may be stored only for limited periods above 0°C. Moreover, ice may not be available when the cooling action is desired.
In addition to food and beverage cooling, there are a number of other applications for which a portable cooling device is extremely desirable. These include medical applications, including cooling of tissues or organs; preparation of cold compresses and cryogenic destruction of tissues as part of surgical procedures; industrial applications, including production of cold water or other liquids upon demand; preservation of biological specimens; cooling of protective clothing; and cosmetic applications. A portable cooling apparatus could have widespread utility in all these areas.
Most attempts to build a self-contained miniaturized cooling device have depended on the use of a refrigerant liquid stored at a pressure above atmospheric pressure, so that the refrigerant vapor could be released directly to the atmosphere. Unfortunately, many available refrigerant liquids for such a system are either flammable, toxic harmful to the environment, or exist in liquid form at such high pressures that they represent a explosion hazard in quantities suitable for the intended purpose. Conversely, other available refrigerant liquids acceptable for discharge into the atmosphere (such as carbon dioxide) have relatively low heat capacities and latent heats of vaporization. As a result, some cooling devices which release carbon dioxide are more bulky than is commercially acceptable for a portable device.
An alternate procedure for providing a cooling effect in a portable device is to absorb or adsorb the refrigerant vapor in a chamber separate from the chamber in which the evaporation takes place. In such a system, the refrigerant liquid boils under reduced pressure in a sealed chamber and absorbs heat from its surroundings. The vapor generated from the boiling liquid is continuously removed from the first chamber and discharged into a second chamber containing a desiccant or sorbent that absorbs the vapor.
The use of two, chambers to produce a cooling effect around one chamber is illustrated in U.S. Pat. No. 4,250,720 to Siegel and Great Britain Patent No. 2,095,386 to Cleghorn, et al. These patents disclose a two-chamber apparatus connected by a tube. The Siegel patent uses water as the refrigerant liquid, while the Cleghorn, et al. patent is not limited to water. The Siegel patent envisions the use of such a cooling device to cool food or beverages.
However, in the Siegel and Cleghorn, et al. patents, the rapid initial cooling effect gradually slows as a result of the both decrease in temperature of the object to be cooled and decrease in the heat transfer area of the first chamber. The decrease in heat transfer area is due to the fact that the portion of the first chamber in contact with the liquid decreases as the liquid vaporizes and the liquid level drops. Moreover, in these systems, the evaporation process is limited by the surface area from which the liquid can boil. In addition, the systems do not effectively minimize the amount of liquid which is entrained in the vapor phase caused by uncontrolled boiling of the evaporating liquid.
Our parent U.S. Pat. No. 4,759,191 discloses a refrigeration system employing a desiccant to absorb the refrigerant vapor. In that refrigeration process, the desiccant evolves heat both from the latent heat of vaporization of the refrigerant and from the chemical reaction heat produced as the liquid condensed from the vapor reacts with the desiccant. Since all desiccants so far found satisfactory for this application deteriorate in their absorptive capabilities as the temperature increases, it is of advantage to refrigeration system compactness to limit the temperature rise of the desiccant to as low a value as possible by removing the chemical reaction heat transferred from the condensed liquid to the dessicant.
Accordingly, one objective of the present invention is to provide a self-contained sorption cooling device with a means to alleviate the decrease in heat transfer as the liquid vaporizes and therefore speed the cooling process.
Another object of the present invention is to accelerate the evaporation process by increasing the surface area from which the liquid can evaporate. As a result, the cooling process will be accelerated as well.
Another object of the present invention is to collect and store heat transferred by the vaporized liquid by the use of a heat sink.
Other objectives will become apparent from the appended drawing and the following Detailed Description of the Invention.
SUMMARY OF THE INVENTION
The present invention is a miniaturized cooling device comprising a first chamber containing a liquid which preferably has a vapor pressure at 20° C. of at least about 9 mm Hg, a second chamber containing a sorbent for the liquid, a conduit connecting the first and second chambers, a valve in the conduit for preventing flow through the conduit between the chambers and means for opening the valve. The second chamber is initially evacuated. Thus, when the valve is opened, the first and second chambers are connected and fluid communication between them is possible. This causes a drop in pressure in the first chamber because the second chamber is evacuated. The drop in pressure causes the liquid in the first chamber to vaporize, and, because this liquid-to-gas phase change can occur only if the liquid removes heat equal to the latent heat of vaporization of the evaporated liquid from the first chamber, the first chamber cools. The vapor passes through the conduit and into the second chamber where it is absorbed and adsorbed by the sorbent. The sorbent also absorbs all of the heat contained in the absorbed or adsorbed vapor, and, if the absorption-adsorption process involves a chemical reaction, the sorbent must also absorb the reaction heat. The heat absorbed and adsorbed by the sorbent is in turn collected by a heat sink material in association with the sorbent, thereby slowing the temperature rise of the sorbent.
In a preferred embodiment, the liquid is water, and the first chamber's interior surface may be provided with a wicking material for the liquid. It is preferred that the wicking material lines the interior surface of the first chamber and consists of a highly hydrophilic material such as gel-forming polymers and water-wicking polymers capable of coating the interior of the first chamber.
In one embodiment of the invention, the liquid is mixed with a nucleating agent that promotes ebullition of the liquid. A phase separator for preventing unvaporized liquid from the first chamber from passing through the conduit into the second chamber may advantageously be included in the device. The sorbent material may be an adsorbent or absorbent, and the second chamber preferably contains sufficient sorbent to absorb or adsorb substantially all of the liquid in the first chamber.
The heat sink material, in association with the sorbent material within the second chamber, then collects heat transferred to the sorbent by the vaporized liquid. The heat sink material may be disposed throughout the chamber, or localized in one area of the second chamber. Preferably, the material is disbursed throughout the chamber and so most preferably compartmentalized to prevent nucleation of the entirety of the material. The entire device is preferably disposable.
In use, the vaporization process causes the level of the liquid in the first chamber to drop, but, in the preferred embodiment, the wicking material retains the liquid on the interior surface of the first chamber. This maintains a substantial area of contact between the liquid and the interior surface of the first chamber to avoid a reduction in the effective heat transfer area of the first chamber and a resultant slowing of the cooling process.
The present invention provides a self-contained rapid cooling device that cools a food, beverage or other material or article from ambient temperature on demand in a timely manner, exhibits a useful change in temperature, retains a significant portion of the heat produced from the cooling process can be stored for unlimited periods without losing its cooling potential, and is able to meet government standards for safety in human use.
BRIEF DESCRIPTION OF THE DRAWING
The FIGURE is a schematic representation of a cooling device according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
In FIG. 1, the cooling device 10 has a first chamber 12 lined on the interior surface 14 with a wicking material 16, which, in a preferred embodiment, could be accomplished by flocking or spraying the interior surface 14 with the wicking material -6 and the first chamber 12 is filled with a refrigerant liquid 18. The cooling device 10 also includes a second chamber 20 surrounded by a thermal insulator 22 which is at least partially filled with a sorbent 24 and a heat sink material 40. The second chamber may also advantageously be evacuated to the extent that it contains only the vapor of the refrigerant liquid.
Connecting the first and second chambers 12 and 20 is a conduit 28 and a valve 30 interposed in the conduit 28, allowing fluid communication between the chambers 12 and 20 through the conduit 28 only when the valve 30 is open.
The operation of the cooling device is suspended (i.e., the system is static and no cooling occurs) until the valve 30 is opened, at which time the conduit 28 provides fluid communication between the first and second chambers 12 and 20. Opening the valve 30 between the first and second chambers 10 and 20 causes a drop in pressure in chamber 12 because the second chamber 20 is evacuated. The drop in pressure in the first chamber 12 upon opening of the valve 30 causes the liquid 18 to boil at ambient temperature into a liquid-vapor mixture 32. This liquid-to-gas phase change can occur only if the liquid 18 removes heat equal to the latent heat of vaporization of the evaporated liquid 18 from the first chamber 12. This causes the first chamber 12 to cool. The cooled first chamber 12, in turn, removes heat from its surrounding material as indicated by the arrows 33.
The liquid-vapor mixture 32 is directed through a liquid-vapor collector and separator 34 of conventional design, which separates the liquid 18 from the vapor, allowing the separated liquid 18 to return to the first chamber 12 through the liquid return line 38 and allowing the vapor to pass through the conduit 28 into the second chamber 20. Once inside the second chamber 20, the vapor is absorbed or adsorbed by the sorbent 24. This facilitates the maintenance of a reduced vapor pressure in the first chamber 12 and allows more of the liquid 18 to boil and become vapor, further reducing the temperature of chamber 12. The continuous removal of the vapor maintains the pressure in the first chamber 12 below the vapor pressure of the liquid 18, so that the liquid 18 boils and produces vapor continuously until sorbent 24 is saturated, until the liquid 18 has boiled away or until the temperature of the liquid 18 has dropped below its boiling point.
During the vaporization process, the level of the liquid 18 in the first chamber 12 drops. The wicking material 16 retains the liquid 18 on the interior surface 14 of the first chamber 12 to prevent a reduction in the area of contact between the liquid 18 and the interior surface 14 which would cause a reduction in the effective heat transfer surface area of the first chamber 12 and would thus slow the cooling process.
Four important components of the present invention are the evaporating liquid, the sorbent, the heat sink material and the wicking material. The liquid and the sorbent must be complimentary (i.e. the sorbent must be capable of absorbing or adsorbing the vapor produced by the liquid), and suitable choices for all of these components would be any combination able to make a useful change in temperature in a short time, meet government standards for safety, and be compact.
The refrigerant liquids used in the present invention preferably have a high vapor pressure at ambient temperature, so that a reduction of pressure will produce a high vapor production rate. The vapor pressure of the liquid at 20° C. is preferably at least about 9 mm Hg and more preferably is at least about 15 or 20 mm Hg. Moreover, for some applications (such as cooling of food products), the liquid should conform to applicable government standards in case any discharge into the surroundings, accidental or otherwise, occurs. Liquids with suitable characteristics for various uses of the invention include: various alcohols, such as methyl alcohol and ethyl alcohol; ketones or aldehydes, such as acetone and acetaldehyde; water; and freons, such as freon C318, 114, 21, 11, 114B2, 113 and 112. The preferred liquid is water.
In addition, the refrigerant liquid may be mixed with an effective quantity of a miscible boiling agent having a greater vapor pressure than the liquid to promote ebullition so that the liquid evaporates even more quickly and smoothly, and so that supercooling of the liquid does not occur. Suitable boiling agents include ethyl alcohol, acetone, methyl alcohol, propyl alcohol and isobutyl alcohol, all of which are miscible with water. For example, a combination of a boiling agent with a compatible liquid might be a combination of 5% ethyl alcohol in water or 5% acetone in methyl alcohol. The boiling agent preferably has a vapor pressure at 25° C. of at least about 25 mm Hg and, more preferably, at least about 35 mm Hg. Alternatively, solid boiling agents may be used, such as the conventional boiling stones used in chemical laboratory applications. However, the choice of boiling agent when used in conjunction with a heat sink material such as sodium acetate will be such that the nucleation source compatible with the refrigerant liquid will be incompatible with the heat sink material as to initiate a phase change of the heat sink material. Alternatively, the heat sink material will be packaged or contained within the instant invention as to prevent possible contact with a nucleation source.
The sorbent material used in the second chamber 20 is preferably capable of absorbing and adsorbing all the vapor produced by the liquid, and also preferably will meet government safety standards for use in an environment where contact with food may occur. Suitable sorbents for various applications may include barium oxide, magnesium perchlorate, calcium sulfate, calcium oxide, activated carbon, calcium chloride, glycerin, silica gel, alumina gel, calcium hydride, phosphoric anhydride, phosphoric acid, potassium hydroxide, sulfuric acid, lithium chloride, ethylene glycol and sodium sulfate.
In selecting the wicking material 16, any of a number of materials may be chosen, depending upon the requirements of the system and the particular refrigerant liquid 18 being used. The wicking material may be something as simple as cloth or fabric having an affinity for the refrigerant liquid 18 and a substantial wicking ability. Thus, for example, when the refrigerant liquid is water, the wicking material may be cloth, sheets, felt or flocking material which may be comprised of cotton, filter material, natural cellulose, regenerated cellulose, cellulose derivatives, blotting paper or any other suitable material.
The most preferred wicking material would be highly hydrophilic, such as gel-forming polymers which would be capable of coating the interior surface of the evaporation chamber. Such materials preferably consists of alkyl, aryl and amino derivative polymers of vinylchloride acetate, vinylidene chloride, tetrafluoroethylene, methyl methacrylate, hexanedoic acid, dihydro-2,5-furandione, propenoic acid, 1,3-isobenzofurandione, 1 h-pyrrole-2,5-dione or hexahydro-2 h-azepin-2-one.
The wicking material may be sprayed, flocked, or otherwise coated or applied onto the interior surface of the first chamber. In a preferred embodiment, the wicking material is electrostatically deposited onto that surface. In another embodiment, the wicking material is mixed with a suitable solvent, such as a non-aqueous solvent, and then the solution is applied to the interior surface of the first chamber.
In another preferred embodiment the wicking material is able to control any violent boiling of the evaporator and thus reduce any liquid entrainment in the vapor phase. In such an embodiment, the wicking material is a polymer forming a porous space-filling or sponge-like structure, and it may fill all or part of the first chamber.
The total volume of sorbent 24 rises with increasing temperature. The total volume of heat sink material 40 decreases with temperature. There is, therefore, an optimum temperature rise providing minimum system volume, which is dependent upon the thermal properties of the sorbent 24 and heat sink material 40. The thermal insulator 22 may be any conventional insulation material, but is preferably an inexpensive, easily-formed material such as a low-cost polystyrene foam.
The heat transferred to the sorbent 24 is in turn collected in a phase change heat sink material 40 in association with the sorbent 24. In such materials, temperature change is discontinuous in relation to the temperature of the phase or structure change, and heat is stored in latent form. Latent heat absorption is generally accompanied by sensible heat storage in such materials.
Heat sink materials 40 with appropriate melting points absorb sensible heat in the solid phase as the materials 40 temperature rises to the melting point, absorb latent heat as the phase transformation occurs from solid to liquid, and then absorb sensible heat in its liquid phase as the temperature continues to rise.
Certain crystalline solids, when cooled from above their melting point under appropriate conditions, can be subcooled as liquids to temperatures far below the melting point of the solid, yet no phase change from liquid to crystalline solid will occur. A preferred material is sodium acetate trihydrate (CH 3 COON a . 3H 2 O), a white crystalline solid with a melting point of 136° F. Sodium acetate trihydrate requires a nucleation source in order to change phase upon cooling from a liquid to a solid. In the absence of a nucleation source, the material can be cooled to below 32° F. without exhibiting the liquid to solid phase change.
For example, in the instant invention, if the operating temperature rise of the sorbent/heat sink combination is from 72° F. to 150° F., a temperature interval of 78° F., the sodium acetate absorbs 149 BTU per pound, of which 97 BTU per pound is stored in the change of phase (crystal melting) process. Additionally, if the sodium acetate storage medium is properly packaged to eliminate nucleation, thereby preventing stored heat release by the initiation of recrystallization of the sodium acetate, the capture of the 97 Btu of the total 149 Btu of heat absorbed by each pound of sodium acetate is irreversible. The absorbed heat is captured in the suspended recrystallization process, the recrystallization prevented from being initiated by protection from nucleation.
Other inorganic crystalline materials with various melting points and heat capacities also exhibit this behavior, and are also contemplated for use in the instant invention.
In order to eliminate nucleation, in a preferred embodiment, the present invention entails packaging the sodium acetate to prevent its contact with any nucleation source. In one embodiment, this involves the separation of the sodium acetate into distinct groups or pockets of crystals, each of a sufficient size to absorb a fair proportion of the heat evolved from the process, yet physically separated so that in the event that any of the groups of crystals should not fully melt and/or have the recrystallization process initiated, the recrystallization process will be limited to within the isolated group of sodium acetate crystals, thereby not spreading throughout the entirety or other portions of the heat sink material. For instance, the heat sink material used may be localized one distant area in thermal contact with the second chamber 20, yet be physically divided in some manner, such as through use of plastic or metal dividers, which serve to isolate each individual pocket of heat sink material. Alternatively, such "pockets "or containers of heat sink material may surround the perimeter of the inside of the second chamber 20. Alternatively, individual packets or beads of the heat sink material may be dispersed throughout the sorbent contained within the second chamber 20, in discrete, heat-permeable containers. In yet another alternative embodiment, the heat sink material may be located outside of the second chamber 20 in one or a plurality of chambers, which are thermally coupled to the sorbent material, again providing isolation of the heat sink material to prevent the initiation of nucleation throughout the heat sink material, either by an outside agency or by incomplete melting of a portion of the heat sink material.
The valve may be selected from any of the various types shown in the prior art.
The invention also includes a method of using the cooling device described herein. This method includes the step of providing a cooling device of the type set forth herein; opening the valve between the first chamber 12 and the second chamber 20, whereby the pressure in the first chamber is reduced, causing the liquid to boil, forming a vapor, which vapor is collected by the sorbent material; and removing vapor from the second chamber by collecting the same in the sorbent and collecting heat from the sorbent in a meltable phase change heat sink material, and maintaining a portion of the collected heat in said phase change material by preventing change of phase form a liquid to a solid upon cooling. The process is preferably a oneshot process; thus, opening of the valve 30 in the conduit 28 connecting the first chamber 12 and the second chamber 20 is preferably irreversible. At the same time, the system is a closed system; in other words, the refrigerant liquid does not escape the system, and there is no means whereby the refrigerant liquid or the sorbent may escape either the first chamber 12 or the second chamber 20.
Although the invention has been described in the context of certain preferred embodiments, it is intended that the scope of the invention not be limited to the specific embodiment set forth herein, but instead be measured by the claims that follow. | Disclosed is a self-contained, rapid cooling device that can be stored for indefinite periods without losing its cooling potential. A liquid in a first chamber undergoes a change of phase into vapor which cools the first chamber. A sorbent in a second chamber is in fluid communication with the vapor and removes the vapor from the first chamber. A heat sink material thermally coupled to the sorbent collects and irreversibly captures heat transferred from the vapor to the sorbent. | 5 |
BACKGROUND OF THE INVENTION
[0001] Tantalum is a highly corrosion resistant, bio-friendly metal. As a result it finds wide use in reactors, heat exchangers, piping and the like in the chemical and pharmaceutical processing industries. Because tantalum is very expensive often the structural components used in this equipment are made up of a steel or stainless steel section for strength purposes that is clad with a thin sheet of tantalum to prevent interaction with the process fluid. In order for the tantalum sheet to provide corrosion protection for a whole vessel many such sheets must be joined together into a single impermeable piece. Many techniques have been used but all of them are costly, have severe deficiencies, and cause the cost of the basic tantalum clad steel section to be higher than necessary. This invention provides a low cost, chemical resistant, material and manpower efficient means of joining the tantalum sheets together.
[0002] Cold spray or kinetic spray (see U.S. Pat. Nos. 5,302,414, 6,502,767 and 6,759,085) is an emerging industrial technology that is being employed to solve many industrial manufacturing challenges (see, e.g., U.S. Pat. Nos. 6,924,974, 6,444,259, 6,491,208 and 6,905,728). Cold spray employs a high velocity gas jet to rapidly accelerate powder particles to high velocity such that when they impact a surface the particles bond to the surface to form an integral, well bonded and dense coating. The cold spraying of tantalum powders onto a variety of substrates (including steel) has been suggested (see, e.g., “Analysis of Tantalum Coatings Produced by the Kinetic Spray Process,” Van Steenkiste et al, Journal of Thermal Spray Technology, volume 13, number 2, June 2004, pages 265-273; “Cold spraying—innovative layers for new applications,” Marx et al, Journal of Thermal Spray Technology, volume 15, number 2, June 2006, pages 177-183; and “The Cold Spray Process and Its Potential for Industrial Applications,” Gärtner et al, Journal of Thermal Spray Technology, volume 15, number 2, June 2006, pages 223-232). This is all accomplished without having to heat the tantalum powder to a temperature near or above its melting point as is done with traditional thermal spray processes. The fact that dense coatings can be formed at low temperatures present many advantages. Such advantages include reduced oxidation, high density deposits, solid state compaction, the lack of thermally induced stresses and particularly, in this case, the lack of substrate heating. This is critical because at elevated temperatures, such as in a molten Ta weld pool, Ta can dissolve the elemental components of steels and stainless steels with the result that brittle and non corrosion resistant phases form in the tantalum.
[0003] As mentioned above, tantalum is a preferred corrosion resistant material in industries that process chemically aggressive liquids. Because of tantalum's high cost rather than being used as a thick structural member, it is frequently used in thin layers as a protective cladding on steel or stainless steel. Many techniques have been developed to attach tantalum clad to the substrate material such as high temperature brazing (U.S. Pat. No. 4,291,104), low temperature soldering (U.S. Pat. No. 4,011,981), diffusion bonding (U.S. Pat. No. 5,693,203), explosive bonding (U.S. Pat. No. 4,291,104), and flouroelastomers (U.S. Pat. No. 4,140,172).
[0004] The fabrication problem becomes difficult and expensive however when the individually clad components must be joined together to form a fully functional vessel such as a process reactor. The clad must be fused together to prevent the process liquid from contacting the steel, the steel must also be fused to provide strength to the entire structure. Dissolution of the steel into the tantalum during either fusion process would immediately destroy the desirable properties of tantalum. Thus, all high temperature fusion processes require and use elaborate joint designs and fabrication techniques in order to prevent the tantalum from reaction with the steel during the fusion process.
[0005] U.S. Pat. No. 4,073,427 solves the problem of joining the sheets by providing a machined groove around the entire perimeter of all of the structural parts to be joined. The structural steel is then welded and a machined tantalum batten is inserted in the groove to isolate the tantalum from the steel when the tantalum is welded. The tantalum sheet can then be bent flat (it has to be bent up initially to allow insertion of the batten) and the final tantalum weld performed. Further due to the high temperatures involved purge holes must be provided in the steel element to allow for the introduction of inert gases to protect the final tantalum weld.
[0006] U.S. Pat. No. 4,818,629 provides a similar approach except that three battens are used, one steel and two tantalum battens. This approach requires two welds as well as multiple purge holes drilled in the steel backing sheet.
[0007] U.S. Pat. No. 5,305,946 attempts to improve on the above processes by providing a wide single batten that completely fills the gap between the two tantalum sheets and then double welding a tantalum closure across the top of the tantalum sheets. All of the references discussed so far are done so in terms of joining flat sections. The problems become far more difficult when welding rings to rings to form long vessels, or domes to rings to provide a pressure closure or even vessel penetrations for piping. Bending the tantalum sheet in a circular pattern, then bending 90 degrees out of the plane of the circle, inserting the batten and bending the two tantalum sheets flat again is time consuming and difficult.
[0008] U.S. Pat. No. 4,459,062 describes a process using a plasma arc spray overlay to cover the contaminated weld of the tantalum protective layer. First the steel is welded to itself and then the tantalum is welded to itself. Because the tantalum is in intimate contact with the steel, the steel contaminates the tantalum weld and the corrosion resistance of the weld is greatly reduced. A high temperature plasma arc spray is used to provide a protective layer of tantalum over the contaminated weld. Because these joints are used on large structures they usually must be made in air, thus the hot plasma arc causes both the tantalum sheet and the tantalum powder to oxidize due to the plasma's very high temperature. The result is a porous, lamellar structure in the deposit that is high in oxygen content. The porosity and porous grain boundaries greatly reduce the corrosion resistance by percolation effects and the high oxygen content results in a less ductile (than the tantalum sheet) deposit that is prone to cracking and can fail during operation. Additionally, because the coating is put down hot, and because the coefficient of thermal expansion for tantalum is almost double that of steel, as the structure cools the brittle plasma spray deposit is put in a state of tensile stress, a stress that potentially can lead to cracking and failure of the coating.
[0009] U.S. Pat. No. 6,749,002 describes a method of spray joining articles. The patent indicates that cold spray as well as the many types of hot spray forming techniques (such as plasma and twin wire arc spraying) could be used. However, the method is severely limited in that at least one of the articles must be a spray formed steel article and the sprayed particles must be steel particles. Clearly this method is used for making structural steel joints involving at least one steel component. In the invention described below the structural steel joint is provided by traditional welding techniques. In fact there is no desire or requirement that the sprayed material join to the steel. In the present invention, the cold sprayed material, in this case tantalum, is used to join the tantalum surface coating and to provide an impermeable corrosion resistant layer of tantalum between two or more co-existing Ta sheets.
[0010] U.S. Pat. No. 6,258,402 is even more limited in that it describes a method for repairing spray formed steel tooling. It too requires a steel spray formed part on which a steel spray formed coating will be used to fill a region which has been damaged or somehow eroded away. Additionally, once the spray forming is complete, the spray formed filler is melted and fused using conventional electric welding processes. The purpose of the invention below is to avoid heating and especially melting of the tantalum during the joining processes.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 shows the tantalum clad sections before joining.
[0012] FIG. 2 shows the sections joined together.
[0013] FIG. 3 shows another embodiment of the invention where a lap joint is used.
[0014] FIG. 4 shows another embodiment of the invention where a double lap joint is used.
[0015] FIG. 5 is a micrograph of a cross section of a tantalum cold sprayed joint that has been etched to reveal prior particle boundaries.
[0016] FIG. 6 shows the same cross section as shown in FIG. 5 after annealing at 1150° C. for one and a half hours.
DESCRIPTION OF THE INVENTION
[0017] The present invention is broadly directed to a process for joining tantalum clad steel structures comprising:
a) providing a first tantalum clad section, said first tantalum clad section comprising a tantalum layer over a steel layer, with a bonding layer optionally therebetween, with a portion of said steel layer in an edge region not being covered by said tantalum layer or said bonding layer, b) providing a second tantalum clad section, said second tantalum clad section comprising a tantalum layer over a steel layer, with a bonding layer optionally therebetween, with a portion of said steel layer in an edge region not being covered by said tantalum layer or said bonding layer, c) locating said steel edge regions adjacent each other, d) welding the steel edge regions together, e) cold spraying a tantalum powder onto the welded edge regions and over the tantalum layers adjacent said edge regions thereby joining the tantalum clad steel sections.
[0023] The invention is also directed to a tantalum weld or joint, wherein the weld or joint is formed by cold spraying tantalum powder and consists of elongated tantalum powder particles, elongated normal to the direction of the spray direction, and wherein the powdered particles have a random crystallographic orientation. The invention is also directed to a tantalum weld or joint, wherein the weld or joint is formed by cold spraying tantalum powder followed by heta treatment and consists of equiaxed grains of approximately the same size as or smaller than the sprayed powder and wherein the grains have a random crystallographic orientation.
[0024] In one embodiment, a double sided lap joint may be used, although a single sided lap joint may be employed as well.
[0025] In one preferred embodiment, each tantalum clad section is produced by cold spraying tantalum powder directly onto the respective steel layer in a pattern such that a portion of each steel layer in an edge region is not sprayed and is thus left exposed. This embodiment does, not require the use of a bonding layer.
[0026] Local failures can develop in tantalum clad vessels and do occur frequently. A local failure is when the bulk of the cladding is fine, but a small crack or pinhole may have developed in the clad. This can result from a manufacturing defect (e.g., a gouged tantalum layer, a weld defect or an inclusion), a local hot spot or improper process chemistry. The normal procedure is to enter the vessel, cut out the defect and then weld a patch on top. Of course in doing this there is the risk of overheating the tantalum layer and oxidizing it or causing an undesirable reaction with the steel below the weld. Although not a part of this invention, cold spray could be used to repair these defects without incurring any of the risks just mentioned.
[0027] As used herein, the term “steel” is intended to include both steel and stainless steel.
[0028] This invention, the cold welding of the tantalum sheet using cold spray technology, forms a high density, low cost, corrosion resistant joint free from the deleterious phase mentioned above. It further allows the joining of clad steel parts where the tantalum clad to steel bonding agent is a low melting temperature solder, brazing material or even a structural adhesive.
[0029] By following the present invention, the tantalum layer and the steel substrate require no special machining to provide locations for the insertion of protective battens, since battens are not used. Obviously, machining of battens or other protective strips is not required.
[0030] In the preferred embodiment, the protective cladding can be simply cut with either a straight or beveled edge such that the desired amount of steel substrate is left exposed prior to bonding of the cladding to the plate. This eliminates the many folding and unfolding operations used with cladding that must be joined by elevated temperature processes such as welding. A separate bonding or brazing layer may or may not be present depending on how the tantalum is bonded to steel. The clad sections may simply be placed together and the structural steel butt welded to form a single unit. The resultant seam is then filled, and cold welded together by cold spraying tantalum powder into the seam and over the edges of the tantalum clad layer.
[0031] Because the cold spray process is done at low temperatures, there is no harmful dissolution of the steel into the cold sprayed tantalum joint. The tantalum joint is fully dense with no porosity or oxygen pick up which would impair the joints performance. Furthermore, there are no thermally induced stresses at the joint after fabrication that could lead to separation, buckling or cracking. Stress is an issue with all high temperature joining processes due to the large differences in thermal expansion between tantalum (LCTE=6.5×10 −6 cm (cm ° C.) −1 and steel (LCTE=11.7×10 −6 cm (cm ° C.) −1 In fact to completely eliminate thermal stress during operation, the spraying could be done while the components are held at operational temperatures of less than 250° C.
[0032] The present invention also raises the potential for greatly decreasing the cost of the basic tantalum clad steel component. Since the joining of the tantalum layer is done at low temperatures, there is no potential for burn through of the cladding as with high temperature processes that melt the clad to form a fusion joint. Thus, reliable cold joining on tantalum cladding of very low thicknesses is possible. By following the present invention, it is possible to use thickeness of the tantalum clad as low as about 0.005 inches (preferably from about 0.005 inches to about 0.040 inches, more preferably from about 0.005 inches to about 0.020 inches, and most preferably from about 0.005 inches to about 0.010 inches). This can result in the use of substantially thinner cladding and a proportionate cost savings when compared to welding techniques that require substantially thicker cladding for reliable “in the field” welds (normal welding techniques require that the clad be around 0.02 inches, while explosive bonding requires thicknesses of 0.04 inches).
[0033] Since the process operates at relatively low temperatures, low cost techniques can be employed to bond the clad to the steel substrate, such as using structural adhesives and non-noble metal low temperature solders. Both of these approaches eliminate the need for large high temperature (˜1000° C.) vacuum furnaces, the attendant energy and labor costs of heating large structural pieces to high temperature and the use of expensive noble metal brazes or silver solders. Structural adhesives decompose around 300° C. and low temperature solders melt around 400° C. The need to weld, i.e., exceed the melting point of tantalum (2998° C.), or to use plasma arc spray (the lowest temperatures are typically in excess of 3000° C.) precludes the use of low temperature bonding of the cladding to the steel since the high temperature process for the clad to clad joint would destroy the bond. Cold spray does not have this problem and could be used to join an entirely new class of low cost clad materials. Most tantalum process applications operate at temperatures of less than 250° C. and thus allow for the use of the above discussed bonding agents.
[0034] As is known in the art, various gas/powder velocities can be used in the cold spray process. Generally these velocities are in the range of from 300 to 2,000 meters/second. It is generally advantageous for the powder particles to be available in an amount in the stream, which guarantees a flow rate density of the particles from 0.01 to 100 grams/(second cm 2 ) preferably from 0.01 grams/(second cm 2 ) up to 20 grams/(second cm 2 ) and most preferably from of 0.05 grams/(second cm 2 ) up to 17 grams/(second cm 2 ). The flow rate density is calculated according to the formula F=m/[(π/4)*D 2 ] with F=flow rate density, D=nozzle diameter in cm and m=powder delivery rate (in grams per second).
[0035] Generally, a stable gas such as nitrogen, or an inert gas such as argon or helium is used as the gas with which the metal powder forms the gas/powder mixture.
[0036] Finally, the process may be used to join many types of metals used as protective cladding such as niobium, titanium, zirconium, molybdenum and tungsten.
[0037] In the Figures, the same numbers are used to identify the same element. In FIG. 1 , two sections, 1 and 2 , are placed adjacent each other. Each section has a tantalum layer 3 , over a steel layer 4 , with a bonding or brazing layer 5 therebetween. Each section has a portion ( 6 and 7 ) of the steel layer that is not covered (these exposed sections are only identified by number in FIG. 1 —but are shown in each figure). In the left hand section, the portion is exposed via a beveled edge 8 , while in the right section, the portion is exposed via a straight edge 9 . The beveled edge embodiment is generally preferred.
[0038] Processes for the production of tantalum clad steel are known in the art. If desired, tantalum could be cold sprayed onto the steel (thus eliminating the need for a bonding or brazing layer). The spray configuration could be such that edge portions of the steel would be left uncoated. Alternatively, portions of the tantalum layer and, if present, the bonding or brazing layer could be removed to expose the steel edge portions.
[0039] As shown in FIG. 2 , the exposed portions of the steel are welded 10 and a tantalum powder, 11 , is sprayed over the welded edges as well over the tantalum layer adjacent to the exposed portions.
[0040] FIG. 3 shows a single lap weld ( 12 ). This approach has the advantage of requiring less Ta powder to make the weld (there is no gap to fill) but has the disadvantage that once the steel structure is welded, the larger (upper) piece of tantalum has to be bent and hammered down flat over the lower (smaller) piece of tantalum (another labor operation).
[0041] FIG. 4 shows another embodiment wherein a double lap weld ( 15 ) is employed. This approach eliminates the bending and hammering operation required by the embodiment shown in FIG. 3 , but does use more powder and requires a tantalum batten, 13 , to fill the gap formed by the exposed steel portions and a tantalum sheet, 14 , to join the two tantalum sections.
[0042] To simulate the joining of two tantalum clad steel plates in a reactor vessel, a 0.020″ thick tantalum sheet was bonded to a nominal ⅜″ steel plate, using a high temperature, silver-copper eutectic braze (Bag-8, commercially available from Lucas Milhaupt of Cudahy Wis.). Then a groove was milled approximately 0.022″ deep and nominally 0.20″ wide down the length of the tantalum cladding to simulate the gap that would be left between the tantalum sheets after welding of the steel plate. Next using nitrogen gas preheated to 600° C. at a stagnation pressure of 3 MPa, tantalum powder 15-30 microns in size (Amperit #151, special grade, commercially available from H.C. Starck Inc.) was deposited. Standoff distance of the nozzle was 30 mm and the powder feed rate was approximately 50 g/min. A cold sprayed weld of approximately 0.040 to 0.060″ thick was used to coat the steel, and seal the gap between the tantalum cladding. The cold sprayed tantalum completely filled the gap between the two sheets providing a continuous protective layer of tantalum over both the steel and the tantalum sheet. The cold spray nozzle or gun used was a Kintetiks 4000 commercially available from Cold Gas Technology GmbH, Ampfing, Germany.
[0043] While it is well known that sheet tantalum will provide an impervious, protective barrier, this is not always true of powder based coatings. In order for the powder based coating to be protective, it must not only in itself resist corrosive attack but it must also be sufficiently dense (with no interconnected porosity) to prevent percolation by the acids through the coating. Typically for a coating to prevent percolation via interconnected porosity, the coating must be greater than 95% dense. In the tests conducted, the cold sprayed tantalum coating densities were typically greater than 97.5%.
[0044] To further prove the impervious nature of the coating, an approximate 0.015″ thick tantalum coating was sprayed on nominal 2″×2″ mild steel sheet. The same process parameters and equipment used above were used to make these coatings, with the exception that the final coating was approximately 0.014″ thick. The tantalum coated side of the steel was then exposed to a 20% hydrochloric acid solution maintained at 70° C. for a period of 4 weeks. When compared to a tantalum sheet that was exposed to the same acid for the same period of time, the cold sprayed tantalum coating resisted the acid as well as the tantalum sheet. In fact in both cases the measured corrosion rates for both the sheet and the coating were less than 0.01 mm/year. After exposure to the acid test, porosity was almost nonexistent, was certainly not interconnected and the coating acted as an impervious barrier to the acid as is evidenced by the complete lack of corrosion build up between the coating and the steel.
[0045] Further, the cold sprayed joint is unique in that it produces no heat affected zone (“HAZ”) around the weld compared to thermally induced fusion processes. HAZ is well known and understood by those skilled in the art. In thermally induced fusion bonding, the practice is to carefully minimize potential deleterious effects associated with the HAZ such as excessive directional and crystallographically preferred grain growth. FIG. 5 is a micrograph of a cross section of a tantalum cold sprayed joint that has been etched to reveal the prior particle boundaries (“PPB”). The powder that was used in the spray process was made by the hydride/dehydride process which produces a blocky approximately equiaxed powder (defined as powder having an aspect ratio of approximately 1). The PPBs in FIG. 5 are not equiaxed. In fact they are typically elongated in shape with an aspect ratio of 2 to 3 normal to the direction of spray (it is expected that in the future, as higher gas velocities and higher particle and gas temperatures are used, aspect ratios up to 6 may be obtained). Additionally by using electron beam back scattered diffraction (“EBSD”), it can be shown that the crystallographic orientation of the weld material is completely random. The combined properties of the complete absence of a HAZ with elongated shaped grains, normal to the direction of spray, having a completely random crystallographic orientation are a unique characteristic of a cold sprayed joint.
[0046] There may be some circumstances in which it is desirable to heat treat an as sprayed joint post spraying either to relieve some of the mechanical stresses or to improve interparticle bond strength. This heat treatment can result in recrystallization which results in equiaxed grains of approximately the same size as the original powder particles. FIG. 6 is a micrograph of the same joint as shown in FIG. 5 that has been annealed at 1150° C. for 1.5 hours. The new equiaxed grains retain the near perfect random crystallographic orientation displayed in the original as sprayed structure as can be shown by EBSD analysis. Again the joint has a unique structure of fine, non-directional equiaxed grains that have a random crystallographic orientation.
[0047] While certain procedures have been illustrated or described herein, it will be recognized that variations can be used without departing from the basic teachings herein. | In various embodiments, protective layers are bonded to a steel layer, overlapped, and at least partially covered by a layer of unmelted metal powder produced by cold spray. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of priority under 35 U.S.C. §119(e) of U.S. Provisional Application No. 61/385,275 filed on Sep. 22, 2010, which is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present application generally relates to compositions for coating metallic components, and in particular, relates to thermal barrier coatings that can be used for aircraft engine components.
2. Description of the Related Art
Thermal barrier coatings are commonly applied to aircraft engine components and other metallic parts that operate at elevated temperature conditions. The coatings insulate the aircraft engine components from heat, thus allowing the components to operate under higher temperatures, which in turn can improve engine efficiency. Thermal barrier coatings also protect the engine components, such as turbine blades and combustion chambers, from oxidation and thermal fatigue that may be caused by prolonged thermal exposure. For example, yttria modified zirconia is commonly used as a thermal barrier coating because of the favorable heat insulating properties of zirconia. While a number of different thermal barrier coating materials have been developed for aircraft engine components, there is a continuing need for coatings that are stable at higher temperature conditions.
For military aircrafts, it may also be desirable to apply a radio frequency (RF) absorber material on the engine components to evade radar detection. A layer of RF absorber such as Ferrite 50 or TT2-111R, available from Trans-Tech Inc. of Adamstown, Md., is often applied to the turbine blades in addition to the thermal barrier coating. However, the additional layer adds weight to the aircraft and requires an additional manufacturing step. As such, there is a need to find an effective thermal barrier coating that can operate at higher temperature conditions and there is also a need for reducing the layers of coating on aircraft engine components.
SUMMARY
The compositions, materials, methods of preparation, devices, and systems of this disclosure each have several aspects, no single one of which is solely responsible for its desirable attributes. Without limiting the scope of this invention, its more prominent features will now be discussed briefly.
Any terms not directly defined herein shall be understood to have all of the meanings commonly associated with them as understood within the art. Certain terms are discussed below, or elsewhere in the specification, to provide additional guidance to the practitioner in describing the compositions, methods, systems, and the like of various embodiments, and how to make or use them. It will be appreciated that the same thing may be said in more than one way. Consequently, alternative language and synonyms may be used for any one or more of the terms discussed herein. No significance is to be placed upon whether or not a term is elaborated or discussed herein. Some synonyms or substitutable methods, materials and the like are provided. Recital of one or a few synonyms or equivalents does not exclude use of other synonyms or equivalents, unless it is explicitly stated. Use of examples in the specification, including examples of terms, is for illustrative purposes only and does not limit the scope and meaning of the embodiments herein.
In one aspect, embodiments disclosed herein include compositions that serve, among other things, the dual function of a thermal barrier and an RF absorber. The compositions can be applied as a single layer to an aircraft engine component, thus reducing the weight of the aircraft and eliminating an extra coating step in the manufacturing process. Coating materials comprising the compositions can be applied to metals, such as engine components. The coating materials are designed to protect the metal underneath from the high temperatures generated during engine operation, and also to absorb or scatter radiation which may incumbent on the metal during operation.
Some embodiments include a thermal barrier and RF absorber composition having magnetic activity, such as paramagnetic, ferromagnetic, or ferromagnetic, at temperatures in the range of about 800° C.-1,000° C. The composition may have strain tolerance when applied as a coating on a metallic turbine blade. The composition may have a thermal expansion coefficient of about 10×10 −6 /° C. or above. In some embodiments, the thermal expansion coefficient of the material may match or be similar to that of the metal of the aircraft engine turbine blades to which it may be applied. The material may melt congruently so that it may be plasma sprayed in the molten phase and cooled to form the desired phase assemblages. The material may have a thermal conductivity similar to or less than that of yttria stabilized zirconia.
In various embodiments, the dual function thermal barrier coating material generally comprises a Lanthanides (Ln)—Aluminum (Al)—Iron (Fe)—Oxygen (O) system. In one embodiment, the thermal barrier coating material comprises a composition that is represented by the formula LnAl 1-x-y Fe x M y O 3 or the formula LnAl 11(1-x-y) Fe x M y O 18 , where 0<x<1 and 0<y<0.5. In one implementation, Ln can be Lathanum (La), Praseodymium (Pr), Neodymium (Nd), Samarium (Sm), or a combination thereof; M can be Cobalt (Co), Nickel (Ni), or Copper (Cu), or a combination thereof. In another embodiment, the dual function thermal barrier coating material may comprise a two-phased composite of LnAl 1-x-y Fe x MO 3 and LnAl 11(1-x-y) Fe x M y O 18 .
In another aspect, embodiments disclosed herein include metal substrates that incorporate the dual function thermal barrier of certain preferred embodiments. In some embodiments, the metal substrates can be part of an aircraft engine component such as the turbine blades.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates an aircraft component incorporating the thermal barrier coating with RF absorbing capabilities in according to one embodiment of the present invention; and
FIG. 2 is a flow chart illustrated a method of manufacturing a thermal barrier coating material with RF absorbing capabilities according to one embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Aircraft engine components, such as turbine blades and combustion chambers, are typically coated with a layer of thermal barrier coating. The thermal barrier coating serves to prevent the metallic components from heating past its melting point during engine operation. A coating such as yttria modified zirconia can be applied to the turbine blades as a thermal barrier. In addition to the thermal barrier layer, another coating having RF absorbing capabilities is also typically applied to the engine component to prevent radar detection.
Disclosed herein are coating compositions that have both thermal barrier and RF absorbing properties such that a single layer of the coating composition would be sufficient for protecting aircraft engine components or other metallic parts that operate under high temperature conditions and that may require RF absorption or scattering.
Dual Function Coating Composition
Preferred embodiments of the dual function coating composition generally comprise one or more crystalline structures of the Lanthanide-Aluminum-Iron-Oxygen (Ln—Al—Fe—O) system. The crystalline structures may include, for example, perovskites and magnetoplumbites. These crystalline structures are preferably compatible with one another and may be used individually or may be combined as a two phase mixture. The crystalline structures are preferably selected for their ability to preserve the paramagnetic behavior at high temperatures, which makes them good high temperature RF absorbers. For example, in the perovskite structure, both Fe and Co show octahedral co-ordination and may show multiple oxidation states, each with an unfilled 3 d electron shell which enhances the magnetic properties. Cobalt, in particular, may show a variety of different oxidation states (+2, +3, and +4) each with a high spin, a medium spin, and a low spin state.
The variety of spin states and oxidation states may cause magnetic interactions well above the ferromagnetic Curie temperature in these crystalline structures. Additionally, in some embodiments, the magnetoplumbite structure has crystallographic sites available which show diverse co-ordination spheres. Hexahedral, tetrahedral, and octahedral sits are available for Fe and Co in some embodiments of the magnetoplumbite structure, which leads to a variety of magnetic interactions.
In one embodiment, the coating composition may be represented by the formula LnAl 1-x-y Fe x M y O 3 or LnAl 11(1-x-y) Fe x M y O 18 , where 0<x<1 and 0<y<0.5. In one implementation, Ln can be Lathanum (La), Praseodymium (Pr), Neodymium (Nd), Samarium (Sm), or a combination thereof; M can be Cobalt (Co), Nickel (Ni), or Copper (Cu), or a combination thereof. In one implementation, the dual function coating material may comprise a two-phased composite of LnAl 1-x-y Fe x M y O 3 and LnAl 11(1-x-y) Fe x M y O 18 . Although the parent aluminate structures LnAlO 3 and LnAl 11 O 18 have been used as thermal barrier coating materials, the two-phased composite of LnAl 1-x-y Fe x M y O 3 and LnAl 11(1-x-y) Fe x M y O 18 surprisingly shows exceptional strain tolerance. It is believed that the magnetoplumbite would form needle like crystals that can bridge cracked columns of the perovskite phase, which increases strain tolerance of the material, Another advantage to the two-phased composite of LnAl 1-x-y Fe x M y O 3 and LnAl 11(1-x-y) Fe x M y O 18 is that it improves compatibility with the thermally grown aluminum oxide on bonded nickel based superalloys which are used in some aircraft engine components.
Furthermore, La, Pr, Nd and Sm are selected to be included in embodiments of the above crystalline structures because each does not form an aluminate garnet (Ln 3 Al 5 O 12 ) which is intermediate in alumina content between the perovskite and the magnetoplumbite phases and decomposes by undesirable peritectic melting. The LnAlO 3 and LnAl 11 O 18 phases each show congruent melting both individually and in a two phase assemblage which is desirable for plasma spraying.
Preferred embodiments of the dual function coating compositions advantageously provide both thermal barrier and RF absorber properties. Some embodiments of the coating composition have magnetic activity, such as paramagnetic, ferromagnetic, or ferromagnetic, at temperatures in the range of about 800° C.-1,000° C. The compositions may have strain tolerance when applied as a coating on a metallic turbine blade. The composition may have a thermal expansion coefficient of about 10×10′ 6 /° C. or above. In some embodiments, the thermal expansion coefficient of the material may match or be similar to that of the metal of the aircraft engine turbine blades to which it may be applied. The material may melt congruently so that it may be plasma sprayed in the molten phase and cooled to form the desired phase assemblages. The material may have a thermal conductivity similar to or less than that of yttria stabilized zirconia.
Preparation of the Modified Synthetic Garnet Compositions
The preparation of the dual function coating composition can be accomplished by using known ceramic techniques. A particular example of the process flow is illustrated in FIG. 1 .
As shown in FIG. 1 , the process begins with step 100 for weighing the raw material. The raw material may include oxides and carbonates such as Iron Oxide (Fe 2 O 3 ), Lanthanum Oxide (La 2 O 3 ), Aluminum Oxide (Al 2 O 3 ), Cobalt Oxide (CoO x ) or combinations thereof. In addition, organic based materials may be used in a sol gel process for ethoxides or and acrylate or citrate based technique may be employed. Co-precipitation of hydroxides may also be employed as a method to obtain these materials by one skilled in the art. In addition, a glycine nitrate or spray pyrolysis technique may be used for blending and simultaneously reacting the materials.
After the raw material is weighed, they are blended in Step 102 using methods consistent with the current state of the ceramic art, which can include aqueous blending using a mixing propeller, or aqueous blending using a vibratory mill with steel or zirconia media.
The blended oxide is subsequently dried in Step 104 , which can be accomplished by pouring the slurry into a pane and drying in an oven, preferably between 100-400° C. or by spray drying, or by other techniques known in the art.
The dried oxide blend is processed through a sieve in Step 106 , which homogenizes the powder and breaks up soft agglomerates that may lead to dense particles after calcining.
The material is subsequently processed through a pre-sintering calcining in Step 108 . Preferably, the material is loaded into a container such as an alumina or cordierite sagger and heat treated in the range of about 1100-1300° C., preferably below the solidus temperature indicated on the relevant phase diagram.
After calcining, the material is milled in Step 110 , preferably in a vibratory mill, an attrition mill, a jet mill or other standard comminution technique to reduce the median particle size into the range of about 0.5 micron to 10 microns. Milling is preferably done in a water based slurry but may also be done in ethyl alcohol or another organic based solvent. In addition, dry milling techniques such as a jet mill may be used as well. Milling may be done by any technique available to those skilled in the state of the art in ceramic processing.
The material is subsequently spray dried in Step 112 . During the spray drying process, organic additives such as binders and plasticizers can be added to the slurry using techniques known in the art. The material is spray dried to provide granules amenable to pressing, preferably in the range of about 10 microns to 150 microns in size.
The spray dried granules are subsequently pressed in Step 114 , preferably by uniaxial or isostatic pressing to achieve a pressed density to as close to 60% of the x-ray theoretical density as possible. In addition, other known methods such as tape casting, tape calendaring or extrusion may be employed as well to form the unfired body. Other heat treatment techniques such as induction heating may also be employed by one skilled in the art. After sintering, the bars will be crushed into a powder using a jaw crusher or muller or a similar technique known to those skilled in the art.
The pressed material may be heated on a setter plate in a periodic kiln or a tunnel kiln in air or pressure oxygen in the range of 1100° C.-1400° C. to obtain a dense ceramic compact. Other known treatment techniques such as induction heat may also be used in this step.
The dense ceramic compact is sieved can classified in Step 116 in which the powder will be sort into the appropriate particle size range using a air classifier or a similar instrument known to those skilled in the art.
Components Incorporating the Dual Function Coating Compositions
The dual function coating compositions made in accordance with the preferred embodiments in this disclosure can be utilized on various metallic parts that are subject to high temperature conditions and require some form of RF absorption or scattering.
FIG. 2 schematically shows a substrate 200 incorporating a layer of the dual function coating composition 202 . The substrate 200 can be part of a military aircraft engine component such as the turbine blades. Advantageously, the single layer of dual function coating composition 202 not only serves as a thermal barrier for the substrate 200 but also absorbs and/or scatters RF, which in turn reduces the overall weight of the engine component. It will be appreciated that in various embodiments, the coating compositions can also serve other functions in addition to the dual functions described herein.
While certain embodiments of the inventions have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the disclosure. Indeed, the novel compositions, methods and systems described herein may be embodied in a variety of other forms; furthermore, various omissions, substitutions and changes in the form of the compositions, methods and systems described herein may be made without departing from the spirit of the disclosure. The accompanying claims and their equivalents are intended to cover such forms or modifications as would fall within the scope and spirit of the disclosure. | Embodiments disclosed herein include compositions that serve, among other things, the dual function of a thermal barrier and an RF absorber. The compositions can be applied as a single layer to an aircraft engine component, thus reducing the weight of the aircraft and eliminating an extra coating step in the manufacturing process. The coating materials are designed to protect the metal underneath from the high temperatures generated during engine operation, and also to absorb or scatter radiation which may incumbent on the metal during operation. In some implementations, the compositions comprise a two phase mixture of perovskite and magnetoplumbite. | 2 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention generally relates to electrical connector, and more particularly to a shielded electrical connector for high-speed transmission.
[0003] 2. Description of Related Art
[0004] TW patent No. 239609 issued to Huang on Jan. 21, 1995 discloses an electrical connector. The electrical connector includes a first connector and a second connector interconnected each other via plurality of wires. The wires with opposite ends thereof are soldered to corresponding contacts of the first connector and the second connector, respectively. The electrical connector may result in lower productive efficiency and higher productive cost. With development of an electronic development, the aforementioned electrical connector is unable to meet complex and powerful function requirement. So an improved electrical connector (adaptor) is emerged in the market. The adaptor includes a first connector and a second connector connected together via a printed circuit board, and some other electronic elements, IC chip, resistor, capacitor etc. are also mounted to the printed circuit board. However ever, those electronic elements are delicate and unable to bear high thermal environment and easily to be damaged.
[0005] Hence, an improved electrical connector is highly desired to overcome the disadvantages of the related art.
SUMMARY OF THE INVENTION
[0006] Accordingly, an object of the present invention is to provide a shielded electrical connector.
[0007] In order to achieve the object set forth, an electrical connector in accordance with the present invention comprises a first connector and a second connector electrically connected together by a printed circuit board assembly; a tubular shaped first shielding member enclosing the printed circuit board assembly, partial of the first and second connector; a second shielding member assembled to first shielding member and retaining the first connector and the second connector.
[0008] Other objects, advantages and novel features of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is an assembled, perspective view of an electrical connector;
[0010] FIG. 2 is a view similar to FIG. 1 , but viewed from another aspect.
[0011] FIG. 3 is an exploded, perspective view of the electrical connector;
[0012] FIG. 4 is a view similar to FIG. 3 , but viewed from another aspect.
DETAILED DESCRIPTION OF THE INVENTION
[0013] Reference will now be made in detail to the preferred embodiment of the present invention.
[0014] Referring to FIGS. 1-4 , an electrical connector 100 in accordance with the present invention includes a first connector 1 , a second connector 2 , a printed circuit board assembly (PCBA) 3 for connecting the first connector 1 and the second connector 2 , a first shielding member 4 enclosing outside of the PCBA 3 , a second shielding member 5 . The first connector 1 is compatible with Displayport connector transmitting, and the second connector 2 compliance with HDMI connector transmitting.
[0015] The PCBA 3 has a number of IC chip, resistors and capacitors (not shown) mounted thereon. Furthermore, a plurality of conductive pads (not shown) are formed on a front and rear ends of the PCBA 3 , respectively. The first connector 1 is disposed in front of the PCBA 3 and with terminals (not numbered) being soldered to the corresponding conductive pads on the front ends of the PCBA 3 . The second connector 2 is located behind the PCBA 3 and with contacts (not numbered) being soldered to the corresponding conductive pads on the rear end of the PCBA 3 .
[0016] The first shielding member 4 is one-piece typed tubular member, which has a top wall 41 , a bottom wall 42 and a pair of lateral walls 43 , 44 joined with each other to form a hollow 45 . The PCBA 3 , a rear segment of the first connector 1 , a rear segment of the second connector 2 are accommodated in the hollow 45 .
[0017] A first channel 411 is defined in a middle segment of the top wall 41 , an ellipse shaped cavity 412 is located in a front part of the first channel 411 . The cavity 412 further communicates with the hollow 45 . Two elongated first positioning slots 413 are defined in laterals part of the top wall 41 and communicate with the first channel 411 , respectively. A second channel 421 is defined in a middle segment of the bottom wall 42 . Two elongated second positioning slots 423 are defined in laterals part of the bottom wall 42 and communicate with the second channel 421 , respectively.
[0018] The second shielding member 5 includes an upper cover 51 and a lower cover 52 . The upper cover 51 has a first main portion 511 and two first engaging portions 512 projecting downwardly from front and rear ends of the first main portion 511 . Each first engaging portion 512 respectively defines a crushing rib 515 and a positioning hole 514 on/in free ends thereof A pair of first flange 513 are formed at two lateral sides of the first main portion 511 . An ellipse shaped through hole 516 is defined in a front segment of the first main portion 511 .
[0019] The lower cover 52 has a second main portion 521 and two second engaging portions 522 projecting upwardly from front and rear ends of the second main portion 521 . Each second engaging portion 522 respectively defines a crushing rib 525 and a positioning hole 524 on/in free ends thereof A pair of second flanges 523 are formed at two lateral sides of the second main portion 521 .
[0020] The upper cover 51 is assembled to the first shielding member 4 , with the first main portion 511 accommodated in the first channel 411 , the first flanges 513 received in the first positioning slots 413 . An identifying member (logo) 6 is arranged in the cavity 412 and exposed outside via through hole 516 . The lower cover 52 is assembled to the first shielding member 4 , with the second main portion 511 accommodated in the second channel 421 , the second flanges 513 received in the second positioning slots 423 . The first engaging portion 512 is combined with the second engaging portion 522 , with the crushing rib 515 / 525 inserted into the corresponding positioning hole 524 / 514 . The first connector 1 and the second connector 2 are held/retained by the first and second engaging portions 512 , 522 . The lateral walls 43 , 44 are exposed outward.
[0021] The PCBA 3 snuggly lies in the hollow 45 of the first shielding member 4 , and IC chips, resistors and capacitors thereof are well protected by the first shielding member 4 .
[0022] It is to be understood, however, that even though numerous characteristics and advantages of the present invention have been set forth in the foregoing description, together with details of the structure and function of the invention, the disclosure is illustrated only, and changes may be made in detail, especially in matters of shape, size, and arrangement of parts within the principles of the invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed. | An electrical connector ( 100 ) comprises a first connector ( 1 ) and a second connector ( 2 ) electrically connected together by a printed circuit board assembly ( 3 ); a tubular shaped first shielding member ( 4 ) enclosing the printed circuit board assembly ( 3 ), partial of the first and second connector; a second shielding member ( 5 ) assembled to first shielding member and retaining the first connector and the second connector. | 7 |
BRIEF DESCRIPTION OF INVENTION
This invention is that of glass fiber filter mats applicable to separate from fluids, and particularly from gases and vapors, specific other gases which may be undesirable and to coalesce entrained liquid droplets, and particulates from liquids, which filters have enhanced tensile strength when wetted by the resulting liquid contacting them. These filter mats (briefly called enhanced wet strength filter mats for fluids) in addition have good tensile strength (e.g. when dry as unrolled from a reel), high porosity providing maintained good flow-through rates and yet sufficient density enabling filtering out from liquids finely divided solid particles of even as low as 0.5 micron and less in size and such particles and/or entrained liquid droplets from aerosols or gaseous and/or vapor streams, as well as to coalesce entrained liquid droplets and remove them, and also to adsorb other gases from such streams. The preparation of these mats is included.
The enhanced wet strength glass fiber filter mats of this invention are prepared by use of paper-making equipment and procedure as a wet laid, porous, non-woven matrix composed of randomly arranged haphazardly intersecting and overlapping glass fibers (beneficially of two different dimensions) admixed as at about 80% of the mat content and with considerably smaller amounts of a cobeat (composed of cellulose and of polymer micro-bits, and with added polyester fibers) and of additional polymer micro-bits alone, and a minimum amount of about 3.3% of a cationic melamine-formaldehyde resin apparently chemically bound at least to the cellulose.
The polymer micro-bits, the polyester fibers, and the melamine-formaldehyde resin are more fully described further below. The cobeat contributes to the structural integrity of the mat. The polyester fibers contribute in part to the tensile strength in development of the web on the Fourdrinier screen. The polymer micro-bits (derived from an expanded, thermoplastic styrene-polymer or lower polyolefin or a flexible foam polyurethane) contribute to the enhanced porosity of the filter mat. The cationic melamine-formaldehyde resin enhances the wet strength of the finished filter mat.
BACKGROUND OF THE INVENTION
U.S. Pat. No. 2,559,220 issued July 3, 1951 shows that the wet strength of cellulose paper can be improved by adding to an aqueous suspension of cellulose paper-making fibers a suitable quantity of an aqueous colloidal solution of a cationic melamine-formaldehyde resin as a binder, the preparation and constitution of which resin is shown in the U.S. Pat. No. 2,345,543 of Mar. 28, 1944.
Attempts were made to produce a glass fiber paper by adding such aqueous colloidal solution of that cationic melamine-formaldehyde resin to an aqueous dispersion of paper-making glass fibers to try to provide a glass paper by wet lay procedure.
However, that was found to be ineffective because that aqueous binder solution was unable to wet the glass fibers to adhere to them, so that most to all of melamine-formaldehyde resin binder solution drained out from the glass fibers through and down out of the Fourdrinier screen. Attempts were made to overcome that difficulty by admixing cellulose fibers with the glass fibers and using the same melamine-formaldehyde resin, but the difficulty was not overcome. Apparently, the resin binder caused the cellulose fibers to agglomerate with the result that it was impossible to obtain a useful uniform web.
Urea-formaldehyde and phenol-formaldehyde resin systems are used as binders in the dry lay method of making glass paper, by spraying a solution of the prepolymer (i.e. uncured) stage of the resin onto a dry layer of glass fibers as formed on the moving Fourdrinier screen. A phenol-formaldehyde prepolymer system has been sprayed onto a glass fiber layer formed from an aqueous slurry on a Fourdrinier screen.
In both of the foregoing cases the concentration of the prepolymer resin used exceeded 12% of the weight of the glass fiber layer, and the curing or cross-linking temperature zone was held at 248° C. in a hot air oven about 200 feet long or in a high temperature curing heating zone with the curing temperature provided by direct heat from an open flame into the inner surface of a steel roller contacted by passage of the glass layer over it in an oven held at about 260° C. In those cases the evolution of obnoxious and dangerous vapors of formaldehyde and phenol from the curing zone was very apparent.
Emulsions of polystyrene, polyacrylates, and of polyvinyl chloride, each separately, are used in making glass webs, but to be effective each has to be applied at a concentration exceeding 20%. Then after spraying the glass paper web, hot calendaring is required to attain significant wet strength. As a result the glass matrix is extensively blinded with consequent little or no utility as a filter.
The foregoing difficulties, shortcomings and disadvantages of these various foregoing efforts are overcome by the provision of the glass fiber filter mat of this invention.
DESCRIPTION OF THE INVENTION
This invention, by the components used in providing its glass fiber filter mats, avoids agglomeration of the small percentage of cellulose used. This invention also avoids the loss of the cationic colloidal melamine-formaldehyde resin down from the matrix during its formation on the Fourdrinier screen and in addition provides a final filter mat with a high level of porosity and yet enhanced tensile strength when wetted.
Considered broadly, the glass fiber filter mats of the invention are a wet laid, non-woven matrix of randomly arranged, haphazardly intersecting and overlapping fibers and comprising in percent, by weight of the mat, about 73.6% (from about 64.1 to about 83.5%) of glass fibers (for example, in equal parts of one inch length Owens-Corning's K fiber of 12 micron diameter and three-eighths inch DE fiber of 6 microns diameter).
about 9.16% (from about 5.5 to 12.8%) of polymer micro-bits (further below described),
about 5.13% (from about 2.8 to about 8.1%) of polyvinyl alcohol (98% hydrolyzed) in powder form or as fibers,
about 8.1% (from about 6.6 to about 9.5%) of a cobeat composed of one part of polymer micro-bits to from about one to two parts of cellulose and with up to about 7% of their joint weight being non-shrinkable, non-slip polymer fibers (e.g. of a polyethylene terephthalate polyester); and
about 4.5% (from about 3.35% to about 5.5%) of a melamine-formaldehyde resin component provided by a colloidal cationic melamine-formaldehyde resin, as a binder.
While the use of equal parts of the DE and K glasses presently appears to be desirable, the ratio may be varied even to using in some formulations varying ratios to all of one or the other of them. Also, the use need not be limited to merely the DE and K fibers, as glass fibers from one source, for the current corresponding sizes of like fibers from any other source may be used.
The cobeat is so-called because, after dispersing each of the paper-making cellulose fibers and polymers micro-bits (in the ratio of one part of the latter to from about one to two parts of the cellulose) to uniform dispersion in a paper-making pulper, that dispersion then is fed into the beater and subjected to beating action until the freeness is 400 or more but not over 450. The beater dispersion then is transferred to the beater chest where there is admixed into that dispersion fibers of one or more of a non-shrinkable, non-slip fiber-forming polymer in an amount up to about 7% of the total of the cellulose and micro-bits. The resulting dispersion then can be put through the usual paper-making steps and dried over drum dryer cans and through an Overly drier (of the Overly Corporation, Ramsey, New Jersey, U.S.A.) to a storable product containing little if any water and thus available for use when needed.
The cellulose fibers are those of paper, and better yet writing paper, grade such as cotton fibers (from cotton rags or linters). These cellulose fibers for convenience are prepared in the form of the so-called wet lap cotton fibers as those commonly used in writing paper making to provide its cotton rag content. The wet lap is prepared for the most part from cotton fiber cuttings and cotton linters which are washed (bleached if necessary), separated (as in a hollander) into fibers of from about 4.23 mm. to about 1.27 cm. in length and fed to a wet lap-making machine and passed from it as a web between pressure rolls and leaving them as a web about 2.1 mm. thick (containing about 80% moisture). They then may be dried as shown shortly above through passage over drum dryer cans, and lapped up and back over and over on a pallet usually to a pile of about 363.8 kilos gross weight and containing in equilibrium about 6% moisture.
The micro-bits constituent of the gas-vapor treating mats of the invention are micro-bits of any of an expanded, thermoplastic styrene-polymer or lower polyolefin, non-brittle in expanded form, or of a flexible foamed polyurethane likewise non-brittle in expanded form. These micro-bits of an expanded, thermoplastic styrene-polymer or lower polyolefin are more fully described (in my copending U.S. patent application Ser. No. 833,644 filed Sept. 15, 1977, now U.S. Pat. No. 4,207,378 issued on June 10, 1980.) as an expanded, thermoplastic, non-brittle in expanded form polymer selected from a styrene-polymer and a lower polyolefin from polyethylene to poly-methylpentene.
These micro-bits are (a) from about 40 to about 325 microns long and from about 20 to about 320 microns wide, (b) from substantially completely to entirely completely free of intact cells of the expanded polymer bit-pieces from which they were produced, (c) substantially without any uniformity in outline of the individual micro-bits particles, and (d) in density from about 85 percent of, to about substantially the same as, the specific unexpanded polymer from which there was provided the aforesaid expanded polymer.
These micro-bits of an expanded, thermoplastic styrene-polymer or a lower polyolefin are produced from so-called bit-pieces of any of the expanded thermoplastic, non-brittle in expanded form styrene-polymers or lower polyolefins as starting material. The term "styrene-polymer" is explained in the aforementioned application Ser. No. 833,644. Their content and all other parts of that application referred to in this application are incorporated herein by reference as if actually recited herein.
The foamed polyurethane micro-bits are obtained from flexible polyurethane foam, the preparation and properties of wich foams are described, for example, in the "Handbook of Foamed Plastics", Bender, Rene J., Section X, pp. 173-236, Lake Publishing Corporation, Libertyville, Illinois, U.S.A. (1955), "Polyurethanes: Chemistry and Technology," Saunders & Frisch, Chapter VII, Part II, Interscience Publishers, New York, N.Y., U.S.A. (1964), and "The Development and Use of Polyurethane Foams", Doyle, E.N., pp. 233-256, McGraw Hill Book Company, New York, N.Y., U.S.A. (1971).
The flexible polyurethane foams useful to provide foamed polyurethane micro-bits preferably should be no greater than 72.14 gm. (i.e. grams) per liter in density, beneficially ranging from about 360 to about 120 gm. per liter, and show excellent recovery after 75% deflection with approximately less than 1% loss in height (as determined by American Society of Testing Materials D-1564-64T).
The flexible foam polyurethanes are not obtained in the foregoing same bit-pieces form as are the styrene-polymers and lower polyolefins, but rather in continuous foamed blocks as a result of the reaction that provides the polyurethane. Accordingly, the foamed polyurethane blocks first are shredded into bit-pieces (for example, similar to how they may be prepared for use in stuffing into various articles).
The foamed polyurethane micro-bits are more fully described (as in my copending U.S. patent application Ser. No. 833,643 filed Sept. 15, 1977 now U.S. Pat. No. 4,200,679 issued on Apr. 28, 1980.) as comprising broken and interconnected strand portions from adjacent cells of the flexible foam, which strand portions show substantially total absence of intact cells and cell windows and are tripodal particles with generaly uneven length legs, the strand portions having hook-like projections, indentations and flutes resulting from destruction of the cells and cell windows of the starting flexible foam, and being substantially without uniformity in outline as to their individual particles. The contents of that application referred to in the specification of this application are incorporated herein by reference as if actually recited herein in full.
The micro-bits of any expanded thermoplastic, non-brittle in expanded form styrene-polymer or lower polyolefin or flexible foamed polyurethane are prepared by disintegrating the respective starting expanded polymer bit-pieces (which as to polyurethanes are pieces of shredded flexible polyurethane foam) in a comminuting machine such as that described in the aforesaid patent application Ser. No. 833,644 and by the method described in that application and illustrated buy its examples.
The herein applicable non-shrinkable, non-slip fiber-forming polymers are exemplified by, but not limited to, the fiber-forming polyethylene terephthalate polyesters such as the TREVIRA polyethylene terephthalate polyester used and identified in Example 2 below, the FORTREL polyethylene terephthalate polyester and the KODEL dimethyl 1,4-cyclohexane dimethanol terephthalate polyester, as well as fiber-forming polyacrylate fibers and polyvinylnitrile fibers.
The melamine-formaldehyde resin component of the filter mat of the invention is provided by using in the production of the filter mat (as illustrated in Example 2 below) an aqueous colloidal suspension of a cationic malamine-formaldehyde with two moles of formaldehyde linked to the melamine moiety, in the form of methylol groups, and being in equilibrium with one mole of the formaldehyde which is dissolved in the acid aqueous medium; the resin being cationic by the condensation of its two reactants in an acid aqueous medium, all as specifically described, explained and illustrated in the earlier above mentioned U.S. Pat. Nos. 2,345,543 and 2,559,220.
Lower cost favors using the melamine-formaldehyde resin prepared by use of hydrochloric acid rather than any of the other applicable acids disclosed in those two patents. It is also better to use the colloidal solution of the resin in its diluted, longer time stable concentration.
The invention is illustrated by, but not restricted to, the following examples, the first of which concerns preparation of the polyester-containing cobeat:
EXAMPLE 1
Preparation of Polyester-containing Cobeat
318 kg. (dry basis) of cellulose (from 632 kg. wet lap cotton rag fibers of 50% moisture) and 159 kg. (dry basis) of polystyrene micro-bits were charged into 11,455 liters of water in the pulper and agitated by its defibering rotor for 10 minutes to uniform dispersion which then was transferred to the beater. There this dispersion was subjected to beating action for 4 hours when it attained a freeness of 425.
190 liters of that slurry of cellulose and micro-bits were uniformly admixed into 22,710 liters of water in the beater chest. Into that diluted slurry there was admixed 32 kg. of the (just below identified) TREVIRA polyethylene terephthalate polyester. The resulting uniform mixture then was pumped to the machine chest. From there it was pumped to the head box, diluted as customary to a consistency for the screen and discharged as usual (in paper-making) onto the Fourdrinier screen.
The resulting web than was fed to pass over 2 dryer cans heated to 116° C. and then through the Overly dryer (10 feet long) at 205° C. at a speed of 16.3 meters per minute as the dry polyester-containing cobeat to be held in stock available as needed.
The TREVIRA polyethylene terephthalate polyester is semi-dull, optically whitened, available as 1.27 cm. long fibers (of 1.5 denier) spun by conventional melt spinning process, having a special finish compatible with most anionic, cationic or nonionic binders (and providing rapid and excellent dispersion with a wide variety of furnish systems and furnish additives) and solution viscosity of 770±20 of 1/2 gram dissolved in 50 ml. of solvent (by weight, 40 parts tetrachloroethane and 60 parts phenol) at 25° C. (solution viscosity is the viscosity of the polymer solution divided by the viscosity of the solvent, with the result minus one multiplied by 1000); melting point 494° F., non-shrinkable in boiling water, and elongation at break 45% (available as TREVIRA 101 product of American Hoechst Corporation, Fibers Division, Spartenburg, S.C. 29301, U.S.A.). Additional information relating to TREVIRA 101 polyester fibers may be found in U.S. Pat. Nos. 4,137,181 and 4,179,543.
The enhanced wet strength filter mats (for fluids) of the invention are illustrated by, but not restricted to, the following example:
EXAMPLE 2
Filter Mat Produced by Paper-Making Steps on Paper-Making Equipment
Into a paper-making pulper (e.g. E. D. Jones, Pittsfield, MA, U.S.A., No. 3HI-LOW) containing 13,250 liters of water, equipped with its defibering and circulating rotor running at 800 r.p.m., there was charged 10 kilos (kg.) of the foregoing polyester-containing cobeat, 11.4 kg. (dry basis) of polystyrene micro-bits, 6.4 kg. of polyvinyl alcohol (98% hydrolyzed) powder, 3.8 liters of technical grade concentrated sulfuric acid (98.6%) and 9.1 kg. of sodium hexametaphosphate, to continue in a circular path for the period of 3 minutes for the defibering rotor to disperse the solids as separated fibers into homogeneous slurry in clump-free state.
With the rotor stationary there was admixed 45.4 kg. each of 1.27 cm. length type K fiber (of 12 microns diameter) and 49.53 mm. long DE fibers (of 6 microns diameter) and the mixing then resumed for 17 minutes. The resulting glass fiber-containing dispersion then was transferred to the beater chest.
Into 1890 liters of water in the pulper there was admixed while stirring 91 liters of the 6% solids containing aqueous collodial solution of the cationic melamine-formaldehyde resin (the specifications of which are given shortly below). The mixing was continued for half a minute and the resulting diluted melamine-formaldehyde resin dispersion was admixed into the beater chest content. The pulper then was flushed with 1890 liters of water and the resulting wash water also was admixed into the beater chest.
The beater chest content at a dispersed solids consistency of 0.6% as a homogeneous dispersion was transferred to the machine chest (used in paper-making to hold stock to be fed to the head box from which the furnish is to be fed onto the Fourdrinier).
From the machine chest the slurry on its way to the head box was passed through a stock pump which at 1170 r.p.m. propelled the slurry past an electonic in-line consistency sensor equipped to send a signal to a controller, which by initiating a current to a pneumatic transducer, controls the dilution water valve at the stock pump suction point to enable supplying the needed dilution water prior to passing another consistency sensor.
The slurry then continued through an in-line magnetic flow meter associated with a magnetic current converter providing a signal to a controller which, by a current to an activator transducer, serves to activate a flow valve to regulate flow of a slurry to the fan pump box. The fan pump, at 1750 r.p.m. and with facilities for temperature control, raised the temperture of the slurry to 48.5° C. and conveyed it at that temperature through a magnetic flow meter (similar to a gate flow meter) at 340.7 liters per minute to a Rice Barton open head box.
From there the slurry, passed under the head box slice bar, was distributed (at a consistency of 0.05% and pH of about 3.5) in uniform spread and flow over the traveling Fourdrinier screen, having 78 strands in the travel direction and 50 strands across, and 18.47 meters (m.) long by 2.72 m. wide.
In addition to drainage through the screen, water was removed from the slurry as the screen passed over 5 Rice Barton friction boxes operated at 7.62 cm. Hg. The slurry now as a web (at about 50% dryness) continued at the same speed onto an endless belt conveyor and after about 1.5 meters beyond the end of the screen passed about 10 cm. below a battery (about 60.5 cm. long) of infrared laps (52.4 kilowatts, at 3.8 amperes, 480 volts, single phase 60 cycle) providing at the mat surface a rheostat set temperature of possibly 649° C. The exposure of the wet mat to that temperature thus for about 2.4 seconds quickly caused solution of the PVA.
The partially dry web continued on through a tunnel dryer (about 3.67 meters long by 1.83 meters wide) providing a temperature of about 121° C. and then alternated in sequence over one and then under the next of each of a series of six dryer drums (the first drum providing a temperature of 113° C. with the temperature increased at each of them that followed with the last drum maintained at 127° C.), and on through the Overly dryer maintained at a drying atmosphere of 177° C. The finished filter mat web leaving the Overly dryer (at 99% dryness) then was collected on a web collecting reel.
This end product filter mat basis weight was 15.1 kg. per 100 square meters and its porosity from about 77.65 to 82.2 cubic meters per square meter per minute at 2.54 cm. of water pressure drop. The tensile strength of this mat in the direction of the web is 5.55 kg. per cm. and crosswise of the web is 2.95 kg. per cm. That is very considerably greater than the tensile strength of mats made without using the melamine-formaldehyde resin.
The wet strength of this mat of this example is 2.4 kg. per cm. which also is very much higher than the wet strength of filter mats made without using a melamine-formaldehyde resin and at least about a dozen times the wet strength of a glass fiber filter mat made by spraying a phenol formaldehyde resin binder onto dry laid glass fibers.
A sample of this web taken before it entered the Overly dryer, wetted for wet strength test, showed a wet strength of 0.72 kg. per cm. That compared with the wet strength after leaving that dryer (2.4 kg./cm.) shows the added advantage (3 times) of that final drying.
The enhanced wet strength filter mats of the invention can be folded and pleated without breaking.
The rag cotton fibers cellulose used in the examples may be used from any other practical cotton fibers source even from cotton linters. Cellulose from wood pulp, such as that used in preparing writing paper, also may be used. While the wet lap rag cotton fibers were used, the cellulose also may be taken as in the dry state when thus readily available or desired for any particular reason, although the use as wet lap provides a desirable economy.
The cellulose fibers provide initial wet strength to the matrix during the wet state stages in the filter mat production to retain the integrity and continuity of the web in passing over the suction boxes and on to the drying cans from the Fourdrinier screen.
For initial ready dispersion of the cellulose fibers and to enhance the integrity of the web, it is beneficial as an initial step physically to combine the cellulose fibers and micro-bits jointly as the cobeat, by ramdomly and intimately intermixing them in the beater thereby breaking open the cellulose fibers, apparently enhanced by action of the micro-bits on those fibers, and resulting in interlocking the micro-bits particles or parts of them in the thus extended fibrillar features of the cellulose. The micro-bits enhance the dispersion of the cellulose fibers during the intermixing and interlocking of those fibers and the micro-bits in the water, and serve to keep the cellulose fibers free of clumps and clusters. Similarly, use of the cobeat enables readily dispersing the other added fibrous constituents also free of clumps and clusters, while each of them is being intimately intermixed in the water into the developing matrix.
The polystyrene micro-bits in the cobeat of Example 1 as well as the additional separate micro-bits used in Example 2 can be replaced in each example by a respectively equivalent amount of any of the other herein described applicable polymer micro-bits to provide respective additional separate examples which are to be considered as if written out in full herein.
The separate micro-bits used in Example 2 also enhance the dispersion of the other fibrous substances added to provide the furnish for preparing the mats of the invention and particularly the glass fibers. As a result, while the sulfuric acid and the sodium hexametaphosphate are included (as in Example 2) for dispersing the glass fibers, the amounts of each of those two can be reduced and even eliminated with reliance on the micro-bits adequately to disperse the glass fibers.
While the separate amount of either one of the two different sizes of glass fibers can be increased to the corresponding reduction and even exclusion of the other one, increasing the content of the larger dimensin glass fibers increases the porosity (and so also decreased the capability of the filter mat to coalesce entrained droplets from air streams) and should not go to complete elimination of the smaller dimension glass fibers if the resulting porosity of the mat will be too large to enable retaining the size particles which it is desired to have the mat remove.
Increasing the ratio of the smaller dimension glass fibers tends to decrease the porosity to the extent that their reduction may need to be avoided. Instead one might increase the micro-bits content for they enhance porosity and can be used in an amount sufficient to provide the mat with the degree of porosity and flow-rate level required for the specific application wherein the mat is to be used.
The powdered polyvinyl alcohol used in Example 2 can be replaced by the less costly PVA fibers. However, the mat of Example 2, has greater wet strength than the corresponding mat, in the preparation of which PVA fibers are used. Thus, use of the PVA powder is preferred in spite of its difference in cost for actually on the average the cost of the PVA amounts to only about one-twentieth of the total cost of all of the materials used to provide the filter mat.
The TREVIRA polyethylene polyester fibers of Example 2 contribute to the initial wet strength in the web formed on the Fourdrinier screen. The polyester fibers can be replaced by a functionally equivalent amount of any of the other applicable non-shrinkable, non-slip, fiber-forming polymer fibers such as ay other fiber-forming terephthalate polyester as any other polyethylene terephthalate polyester or dimethyl-1,4-cyclohexane terephthalate dimethanol. Thus, each such additional example resulting from the just suggested replacement of the TREVIRA polyester of Example 2 is to be considered as if written out in full herein to avoid unduly extending this specification.
The separate range recited earlier above for each one of the substances used in the preparation of the mats of the invention is not to be considered as rigidly specifically limited to its respective specific minimum and maximum. That is so because each different replacemet of each specific one of the constituents may not necessarily behave exactly quantitatively in its functon as does the initial substance thus replaced. Accordingly, the maximum and minimum in each of the ranges for the different constituents in the preparation, and final constitution, of the mats is to be considered as involving adequate quantitative tolerance in relation to its respective function in the production and use of the mats.
For example, the amount of the fiber-forming polyester should be below that at which the polyester fibers are seen to begin to agglomerate during the mixing. Thus, the individual range of content of each of the different components is to be considered as being only rough, with the recognition that the functin which each of them serves in producing the mat and its planned application influences the respective possible respective minimum and maximum of each of them.
The aqueous colloidal solution of the cationic melamine-formaldehyde resin used in Example 2 (in preparing the furnish) contains this resin colloidally dispersed as 6% of solids in water as diluted by addition of water to the commercially readily obtained aqueous dispersin containing about 12.5% of the resin (as solids) resulting from the condensation in water of 3 mols of formaldehyde with one mol of melamine in the presence of 0.677 mol of hydrogen chloride, and having a pH of 1.4 and specific gravity of 1.052 at 25° C. and a hazy light blue color.
The hydrochloric acid (condensation agent) may be replaced by any other water-soluble acid that will not precipitate the colloidal resin (as does sulfuric acid) or adversely affect any of the substances to be used in preparing the furnish for the desired mat. Phosphoric acid, sulfurous acid, formic acid, and oxalic acid have been used successfully, and acetic acid may be used. However, hydrocloric acid is the least costly and most convenient.
The colloidal melamine-formaldehyde resin includes those with from 1 to 6 methylol substituents, but the most commonly used are the di- or trimethylol substituted and particularly the dimethylol, as used in Example 2, with the third mol of formaldehyde dissolved in the water.
The amount of cationic melamine-formaldehyde resin to use is influenced by the overall composition of the furnish and the level of wet strength to be provided.
The wet strength mats of the invention serve, for example, to eliminate undesired particles from waste water effluent streams. The Pittsfield, Massachusetts drinking water was clear to the eye, but after passage through a cartridge containing the filter mat of Example 2, a greasy-oily looking residue collected on the filter mat.
While the invention has been explained by detailed description of certain specific embodiments of it, it is understood that various substitutions or modifications can be made in any of them within the scope of the appended claims which are intended to cover also equivalents of these embodiments. | A glass fiber filter mat possessing excellent wet strength which is in the form of a non-woven matrix of glass micro-fibers including polymer micro-bits derived, for example, from a non-brittle expanded, thermoplastic styrene polymer or a flexible foamed polyurethane, the micro-bits being substantially free of intact cells. Also included in the filter mat is a cobeat or intimate blend of cellulose fibers and the polymer micro-bits, which may additionally contain polyester fibers, as well as a combination of binders, viz., polyvinyl alcohol and a melamineformaldehyde resin. | 3 |
BACKGROUND OF THE INVENTION
[0001] Manufacturers ship certain types of systems for controlling devices in an “unprogrammed” or “uncommissioned” state. That is, until the control system has been commissioned or programmed after installation, it will not function to properly control the device it is intended to control. The main reason for this is that many classes of controlled devices have such a large number of unique configurations or requirements that it is not possible to provide a preprogrammed control system for each possible configuration.
[0002] To deal with this situation, various methods for programming or commissioning such control systems during installation have been developed. Where the control system is electromechanical, programming can be as simple as positioning cams or stops appropriately. A very simple example of such a system is any of the light/appliance timers available at hardware stores. The user positions or activates cams or levers on a dial face of the timer to select the on and off times. Although very simple, this example is typical of many types of controller programming.
[0003] Where the control system is electronic, one needs a different approach. It is easy to provide these systems with one or more control switches for reset, startup, error or status readout, etc. and one or more indicator lights that signal mode, status, error, etc. These switches can be used for commissioning or programming these systems. U.S. Pat. No. 6,175,207 teaches one type of controller using an already present reset switch to select one of a number of preprogrammed operating modes as the one for the particular installation. Other systems have dedicated switches for programming input. It is possible to provide a standard keypad such as on a calculator, but this occupies scarce space, adds cost and tempts users to alter settings that an installer had previously recorded.
[0004] It is important in some applications to prevent reprogramming of control systems after initial programming. One of these situations (and the one concerning the inventors) involves the use of a mechanical actuator as the control device for opening, modulating, and (most importantly) closing a fuel valve of a burner. The mechanical actuator is controlled by an electronic controller that receives sensor data and commands from higher-level controllers or even users. A typical actuator can operate the fuel valve between closed and maximum openings with a smaller modulation range between closed and maximum which is active during the Run phase of the burner. Once the fuel control system has been professionally installed and configured, it is important that the user does not alter these installed settings for the fuel valve actuator. However, experience shows that one cannot rely on users to follow this rule. It is possible that user tampering with these settings can inadvertently create an unsafe or inefficient operating mode for the fuel control system.
[0005] User tampering is a serious concern for manufacturers of safety-related equipment of all types. On the one hand, users and manufacturers alike strongly desire that equipment shipped in an uncommissioned state be easily commissioned during installation. On the other hand, it is very important that tampering by unqualified persons with installed system settings be made as difficult as possible. Thus, conventional input devices like keypads and other easily accessible switches are undesirable because they make tampering too easy. In our system we reduce the temptation to tamper by making access to the setting controls difficult. It is also possible to require special key codes to put the control system in its commissioning mode, but for this particular application we prefer to control access to the commissioning switches.
[0006] It is also helpful in understanding the invention, to know the basics of electromechanical actuator design. An actuator typically has a small, relatively high-speed reversible motor driving a rotating output shaft or hub of some kind through a high-ratio reduction gear train. Typically though not always, the output shaft rotates through a fraction of a revolution over a period of several tens of seconds. Maximum rotation in each direction is limited by mechanical stops. The motor drives the gear train through a magnetic slip clutch that allows the motor to rotate without harm if the output shaft is locked for any reason. Actuators are for the most part of two types, foot-mounted and direct coupled. Foot-mounted actuators are bolted to a frame of some type, and have a shaft that connects to the controlled device's input. Direct-coupled actuators have a rotating hub with a connection feature of some type such as a square or splined hole. The controlled device's shaft clamps to the actuator hub, and then the actuator housing is bolted at a single point to the controlled device itself. These two attachments cooperate to hold the actuator in its operating position.
[0007] Where modulation of the actuator position is required, it is usually necessary to sense the angular position of the actuator output. This can be done in a variety of ways. One common system uses a variable rheostat connected to the actuator output shaft. The rheostat provides a current signal varying from 4-20 ma. nominal as the shaft rotates from one mechanical stop to the other. This varying current can be converted to a quite accurate digital indication of the shaft position. The controller uses the position signal to determine the shaft position and to provide the appropriate control signal. Actuators often have manual controls that allow a human to set a desired position, overriding any controller setting of the actuator position.
BRIEF DESCRIPTION OF THE INVENTION
[0008] We have developed a system that permits easy commissioning of electrically or electronically controlled devices having status or position sensors and manual override of normal position control. Mechanical actuators having shaft position sensors and permitting manual positioning fall in this category. For purposes of commissioning, such a controlled device can be considered a manual input data source, by virtue of the position sensor output and the manual control. Then the system can be considered a data entry system for accepting manually generated data values.
[0009] In its broadest form, such a system comprises first and second data entry elements respectively providing first and second data entry signals responsive to a manual input applied to the respective data entry element. The first data entry signal typically encodes a single binary digit provided by a momentary contact switch, although this need not be. The second data entry element provides a signal encoding a plurality of data values such as those provided by a position sensor for a manually positionable device.
[0010] The system also includes a phase index memory element providing a phase signal sequentially encoding at least first and second distinct phase index values. The phase index memory element sequences the phase index values in the phase signal from the first and following phase index values to the next in order responsive to each first data entry signal. Most conveniently, a phase index can be a sequence of integers, say from one to five or any other desirable range.
[0011] An indicator element also forms a part of the system. The indicator element receives the phase signal and providing a different, humanly discernable indicator pattern for each phase index value. Finally, the system in its broadest form also includes a data recorder receiving the first and second data entry signals and the phase signal. The data recorder has at least first and second memory locations each for storing one data value. Each memory location is associated with one of the phase index values. The data recorder records the data value encoded in the second data entry signal in the memory location associated with the current value of the phase index and responsive to an occurrence of the first data entry signal.
[0012] One of the most useful embodiments uses as the second data entry element, a control element having an output element having a plurality of positions and a position sensor providing a position signal encoding the output element position. The manual input comprises an element or feature of the control element for manually positioning the output element. The preferred embodiment of the control element comprises a mechanical actuator having an output shaft forming the output element and changing position responsive to positioning power. A shaft position sensor comprises the position sensor. A manually operated switching element provides positioning power to change output shaft position responsive to operation of the switching element. Thus the element controlled by the controller also serves as its second data entry element. The installer can see or measure the shaft position, and can manually rotate the shaft to the position required.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] [0013]FIG. 1 is a block diagram of a system employing the invention.
[0014] [0014]FIG. 2 is a block diagram showing details of hardware elements used in implementing the invention.
[0015] [0015]FIGS. 3, 4, 5 , and 6 together form a flowchart of software instructions which when executed by the microprocessor shown in FIGS. 1 and 2 convert the microprocessor and its accessories into the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0016] Hardware
[0017] [0017]FIG. 1 diagrammatically shows one possible application for the invention. The reader should realize that many other applications for employing the invention surely exist. No purpose would be served by attempting to itemize these alternatives because those familiar with control systems can easily transform the teachings below into these alternative applications. Further, such itemizing would properly subject this description to criticism for prolixity.
[0018] System 10 of FIG. 1 includes a rotary actuator 17 that drives a controlled device 12 through a rotating shaft 15 . The curved double arrow around shaft 15 indicates that the shaft can rotate in both clockwise and counterclockwise directions. As previously mentioned, device 12 may be a valve for controlling flow of a fluid such as a fuel, or a damper for controlling air flow. In the particular embodiment for which the invention was developed, it is desirable to have full open and closed device positions, and between them a modulating position range. Actuator 17 receives 24 v. AC operating power on conductors 45 at power terminals 17 a and 17 b . Switches controlled by manually operable pushbuttons 17 d and 17 e allow shaft 15 to be driven by the AC power in the indicated counterclockwise and clockwise directions respectively when these are manually operated. Actuator 17 can also be controlled to drive shaft 15 in either the clockwise or counterclockwise direction depending on a control signal applied to control terminals 17 c and 17 d through paths 26 and 27 . This is well known in the industry, and no further notice need be taken of it.
[0019] A position sensor 21 senses the angular position of shaft 15 . In a typical arrangement, sensor 21 is incorporated into actuator 17 directly, and may be of the type providing a current signal varying from 4-20 ma. as shaft 15 moves from a minimum to a maximum angular position. One should note that actuator 17 is usually designed or selected to have the capability to operate shaft 15 through a greater range of motion than is necessary to properly control the operation of device 12 . Further, the desired or needed range of actuator 17 motion differs from installation to installation.
[0020] Actuator 17 and its pushbuttons 17 d and 17 e , shaft 15 , and sensor 21 together may be considered to comprise a data entry element. The signal provided by sensor 21 can have a plurality of data values dependent on position of shaft 15 , as controlled by the manual operation of the buttons 17 d and 17 e (and of course also on the control signals provided by a controller 30 ). Thus buttons 17 d and 17 e can control the data provided by sensor 21 on path 23 .
[0021] Controlled device 12 can be any of a number of flow control or heat-generating elements such as a valve, damper, furnace, fan etc. A condition sensor 46 provides a condition signal at a terminal 46 a encoding or indicating the level or value of a condition controlled by device 12 . Path 44 carries the condition signal provided by sensor 46 . Sensor 46 may measure temperature if device 12 is an HVAC device of some kind, or pressure if device 12 is a valve. The condition signal thus provides a direct indication of the effects resulting from the position of shaft 15 , as well as external effects produced by such things as air infiltration into a room, outside temperature changes, supply pressure variation, etc. The condition signal can then form a basis for controlling the position of shaft 15 .
[0022] A set point error generator 43 receives the condition signal on a path 44 from sensor 46 . Error generator 43 can for example have a manually adjustable dial or knob 47 for selecting a set point level or value indicated on a scale 47 a . A thermostat is a common example of one type of error generator 43 using either the dial 47 and scale 47 a shown or a keypad as done on electronic thermostats, to allow user control of the set point value. In the case of a thermostat, sensor 46 will be a temperature sensor of some kind. Error generator 43 provides a digital error signal on path 41 indicating existence of a difference and perhaps the magnitude of the difference as well between the sensed condition value encoded in the condition signal and the set point value selected by the user. Error generator 43 provides proportional control, with the error signal on path 41 encoding a value that can vary in magnitude between preselected minimum and maximum end point values. Each value that the error signal assumes corresponds to a particular position of shaft 15 . One feature of this invention allows the user to correlate the two end point values of the error signal with minimum and maximum positions of shaft 15 defining the proportional band within which actuator 17 can control device 12 . These proportional band minimum and maximum shaft 15 positions are usually within the minimum and maximum excursions allowed by controller 30 for shaft 15 .
[0023] Error generator 43 also can serve as a data input device that can be correlated with data provided by positioning of actuator 17 . We accomplish this by turning the dial 47 to indicate either the minimum or maximum setting, which specifies the minimum or maximum end point value for the error signal. Once these values have been loaded into memory 70 b , interpolation between these values and the corresponding minimum and maximum shaft 15 settings allows microprocessor 40 to precisely adjust the position of shaft 15 .
[0024] An AC to DC converter 22 provides DC operating power between a power terminal 30 f of controller 30 and a ground terminal GND. Controller 30 will be described in more detail below, but typically includes a small microprocessor 40 , and in this example, a few simple external components. Controller 30 has a number of communication terminals, typically I/O terminals of microprocessor 40 , of which terminals 30 a and 30 b provide output signals and terminals 30 c and 30 d receive input signals. Terminals 30 a and 30 b provide control signals to actuator 17 on paths 26 and 27 . Terminal 30 c receives the sensor signal on path 23 , and terminal 30 d receives a signal on path 41 from the set point error generator 43 . Of course, a controller 30 may have many more input and output terminals than that shown. Again, this is well within the level of skill that those familiar with this technology have. These communication terminals may be a part of microprocessor 40 , or may be separate, perhaps relay-controlled switches.
[0025] Controller 30 has rudimentary features allowing communication with humans. Save (S) and erase (E) pushbutton switches 36 and 37 allow a human to provide data to controller 30 . Mode (M) indicator element 33 and error (E) indicator element 34 allow controller 30 to communicate to a human. Indicator elements 33 and 34 typically are simple LEDs driven by microprocessor 40 through output terminals, not shown in FIG. 1. These switches 36 and 37 and indicator elements 33 and 34 have specific purposes in implementing the invention, and typically have other purposes once the invention has been operated the one time intended during system setup. The commercial embodiment of the invention includes sensing of switch 36 and 37 closings using so-called “debounce” logic, but this is not a specific feature of the invention. Where a switch 36 or 37 is stated to be closed, this means nothing more than the state of the switch has been sampled a number of times over a period of a few seconds and has been found to be closed for a large percentage of those sampling events. The system may provide a unique indication such as a rapid flash from one of the elements 33 and 34 when a switch 36 or 37 is first sensed as closed, and then a solid indication once the sampling period is over. This procedure is not specific to the invention either.
[0026] [0026]FIG. 2 shows a part of controller 30 in greater detail. As mentioned, controller 30 typically includes a microprocessor 40 of some type. These microprocessors invariably include a CPU 60 , an I/O (input/output) section 50 , and a memory 70 . CPU 60 communicates with memory 70 through a data bus 53 connected between CPU terminal 60 b and memory terminal 70 d . CPU 60 communicates with I/O section 50 through a bus 52 connected between internal CPU terminal 60 a and I/O section terminal 50 a . In addition, I/O section 50 is shown with input terminals 30 s and 30 e respectively connected to the switches 36 and 37 . Switches 36 and 37 are connected so that when closed, they ground their respective I/O section terminals 30 s and 30 e . Alternatively, switches 36 and 37 may connect the respective I/O terminal to a positive or negative logic voltage rather than ground. Switches 36 and 37 comprise data entry elements for entering data into controller 30 . Of course, the ground or non-zero logic voltage source must include any required pull-up or pull-down resistor.
[0027] I/O section 50 also has output terminals 30 m and 30 h for operating LEDs 33 and 34 . A typical LED 33 or 34 can be driven to emit visible light with only a few ma. of current, which is well within the current available from most microprocessor output terminals. The other input and output terminals shown in FIG. 1 are shown in FIG. 2 as well, and serve the previously indicated functions.
[0028] Memory 70 represents the ROM or PROM storing the instructions executed by CPU 60 as well as the EEPROM 70 b (electrically erasable PROM) and RAM 70 a in which CPU 60 stores operands and data used or generated by instruction execution. EEPROM 70 b can be read as quickly as conventional RAM 70 a or PROM, but is written orders of magnitude more slowly. Accordingly, it is customary to use RAM 70 a for storing values being calculated for EEPROM 70 b and after calculations have been completed, write the data to EEPROM 70 b . To assure that this data transfers accurately, it is customary to uses cyclic redundancy check (CRC) testing of transferred data. Some of this CRC activity will be shown in the software flow charts, but does not really form a part of the invention.
[0029] The various parameters whose loading forms the commissioning process are stored in EEPROM 70 b when the commissioning process is complete. It is convenient to consider RAM 70 a and EEPROM 70 b to provide signals representing particular parameters. For example the signal from EEPROM 70 b encoding the phase index value can be considered to be a phase index signal.
[0030] The chip carrying a typical microprocessor 40 includes some on-board RAM and EEPROM. If this memory is inadequate, additional EEPROM may be located in a separate memory module. Since this is well understood by those familiar with this technology, it is easiest to simply show a separate memory module 70 representing both the memory on-board microprocessor 40 as well as any external memory needed. Memory 70 is shown as including particular RAM locations 70 a and EEPROM locations 70 b that serve as memory storage for implementing the invention. These memory locations specifically involved with the invention will be identified while explaining the flowcharts of FIGS. 3 - 6 . An internal memory bus 70 e carries data between a bus terminal 70 d and the internal memory locations. Addressing hardware, not shown, routes the data between terminal 70 d and the individual memory locations.
[0031] Software Introduction
[0032] The flowcharts of FIGS. 3 - 6 represent software instructions whose execution by CPU 60 transform controller 30 into apparatus that implements the invention. Those familiar with software design realize that first, software does in fact have a specific physical existence within the memory holding it and within the data processor or CPU 60 that executes the software, and second, that the CPU itself becomes a functional hardware element performing the programmed function while executing the software intended for that purpose. As to the first point, the instructions held in memory 70 have a physical structure that incorporates the unique combination of software instructions loaded into and readable from memory 70 and thereby uniquely defines its own structure by the physical characteristics of a memory holding the instructions. As to the second point, while the CPU 60 is executing the instructions for any particular function, the CPU becomes for that short period of time a physical functional element performing that function. As instruction execution continues, CPU 60 successively becomes the physical embodiment of each of the functional elements intended by the programmer and defined by the flow charts. As a set of instructions for a particular function is re-executed, the processor can become that functional element as many times as is required. From this standpoint one can easily realize that a properly programmed data processor is a physical device in which an invention is physically implemented. A microprocessor type of data processor implementation is often preferred to discrete or special purpose hardware because of cost savings to produce, relatively easy development, and easy modification and upgrade.
[0033] It is useful to generally discuss the flowcharts of FIGS. 3 - 6 and the three types of symbol boxes in them. These flowcharts describe the functions of software stored in memory 70 of FIG. 2 and which implements various functions of controller 30 including those of the invention. Each symbol box represents one or more CPU 60 instructions. The lines with arrowheads connecting the boxes signify the order in which the instructions symbolized by the boxes are to be executed, with the flow of instruction execution following the direction of the arrowheads. Each box has a short verbal description of the function performed by the instructions represented.
[0034] Rectangular boxes such as element 82 of FIG. 3 are activity (as opposed to decision) elements. Activity elements define some type of computational operation or data manipulation, such as an arithmetic operation or data transfer. Hexagonal boxes as at 81 of FIG. 3 are decision elements and have two paths labeled “YES” and “NO” from them to two further symbol boxes. Decision element instructions test or detect some mathematical or logical characteristic or condition. Depending on the test result, instruction execution can either continue in sequence or take a path to another symbol box specified by the results of that test. A decision element also symbolizes execution by CPU 60 of one or more instructions testing the specified condition or arithmetic or logical value indicated and causing instruction execution to branch depending on the result of that test.
[0035] Lastly, circles comprising connector elements as at 80 of FIG. 3 imply continuity of instruction execution between the same connector elements located at different points in the instruction sequence without direct connection between them by lines with arrowheads. That is, instruction execution continues from a connector element having a particular alphabetic definer into which an arrow enters (of which there may be several), to the identical connector element from which an arrow exits (of which there will be only one), as for connector element A 88 . The letter in the circle designates the connector elements at which instruction execution ends and at which execution continues.
[0036] As explained above, the instructions that an activity or decision element symbolizes cause the data processor to become during execution of those instructions, the functional equivalent of a physical device that performs the stated function. Of course each functional element exists for only a short time, and during this time none of the other elements exist. However, nothing in the patent law requires all of the components of an embodiment described in a patent to simultaneously exist. Accordingly, one can describe and claim the invention using terms of art or functional terms describing these physical devices with reference to their implementing software.
[0037] Note there may be many different specific embodiments for these physical devices within CPU 60 that all provide identical functionality. We wish to include all of these possible different embodiments in the definition of our invention, and by no means limit ourselves to that shown in the flowcharts of FIGS. 3 - 6 .
[0038] Software Description
[0039] When power is first applied to the microprocessor 40 , internal circuitry directs instruction execution to connector element 80 and the immediately following activity element 82 in FIG. 3. Typical microprocessors are designed to start instruction execution at a prearranged instruction address after DC power is applied across terminals GND and 30 f , and connector element H 80 symbolizes the power-on execution address.
[0040] As a general rule, to assure accurate operation of memory 70 a CRC (cyclic redundancy code) value is computed for all of the data recorded in EEPROM 70 b each time values in EEPROM 70 b are changed. This newly calculated value is then stored in EEPROM 70 b . The CRC value is then immediately recomputed and the result of the second computation compared with the value stored for the first computation. If the two computational results are identical it is very likely that the data in EEPROM 70 b can be read accurately. If values in RAM 70 a are block transferred to EEPROM 70 b , then the CRC can be computed and compared for each of the RAM and EEPROM blocks of data, or the RAM and EEPROM values can be compared on a byte-by-byte basis. Further, on each power-up, the CRC value is recomputed and tested against the stored CRC value to assure proper operation of EEPROM 70 b . Activity element 82 and decision element 81 test EEPROM 70 b by recomputing a CRC value for the contents of EEPROM 70 b and then testing the recomputed value against the CRC value stored in EEPROM 70 b . If the recomputed and stored values of the CRC are not equal, then execution transfers to the instructions of activity element 84 which set a lockout flag to indicate some type of system failure. The activity element 84 instructions also set an error type flag the indicates the type of failure detected, and instruction execution then branches through connector element G 102 to activity element 129 (FIG. 6) which sets a lockout flag and then continues to other activity elements that return the controlled device 12 to a safe configuration (fuel valves closed, etc.) and indicate the type of error. The set lockout is tested at appropriate points in the execution of the software by the controller 10 to prevent further operation pending human intervention. In general any type of detected error that raises the question of proper operation of microprocessor 40 will cause the lockout flag to be set by transferring execution to element 129 .
[0041] If the EEPROM CRC value has tested to be correct, then decision element 86 tests whether the lockout flag has been set. Detecting a set lockout flag at this point implies that the lockout flag was set earlier and then the power to controller 30 was lost. When power is then reapplied, an already set lockout flag if present is detected by element 86 . The error type flag is set to an appropriate value by activity element 91 and instruction execution transfers to activity element 129 through connector element G 102 .
[0042] If the lockout flag is not set, then the instructions of decision element 87 are executed next. These instructions test whether a value called the phase index, about which more will soon be said, is equal to 1. If so, then no programming or commissioning of controller 30 is required, and instruction execution transfers to activity element 141 through connector element B 85 (FIG. 6). The set of instructions starting with activity element 141 is the normal operating functions loop.
[0043] If the phase index is not equal to 1, then programming or commissioning of controller 30 is required, and the execution sequence transfers through connector element A 88 to activity element 89 in FIG. 3. The main software loop for commissioning controller 30 starts with activity element 89 . When the save switch 36 or the erase switch 37 is closed, software stores a value indicating that switch closure in a RAM 70 a location dedicated to that switch. To be sure that these RAM 70 a locations have been set to indicate at the start of this instruction sequence that the associated switches have not been closed, activity element 89 clears these save and erase switch RAM locations.
[0044] The instructions of activity element 90 are executed next, and these are the first that directly involve the phase index value. The phase index must equal some number between 5 and 1 inclusive because the software allows only these values. Values different from 1 direct instruction execution to commissioning functions, per the decision by element 87 . The commercial embodiment for which this invention was developed provides for loading six different parameters provided by manually setting the shaft 15 position and the value encoded in the error signal on path 41 . These parameters are related to the phase index values in Table I as follows:
TABLE I Phase Index Parameter(s) 5 Maximum CW shaft 15 position 4 Maximum CCW shaft 15 position 3 Maximum CW position of shaft 15 for proportional control range, and Corresponding error signal end point value 2 Maximum CCW position of shaft 15 for proportional control range, and Corresponding error signal end point value
[0045] Memory space 70 b represents six EEPROM storage locations for semi-permanently rcording the four different actuator shaft 15 positions and the two error signal values. The assignment of parameters to phase index values is of course completely arbitrary.
[0046] Executing the instruction sequence for activity element 90 causes microprocessor 40 to provide electrical current to terminal 30 g creating a visual indication of the current setup phase by blinking mode LED 33 a number of times equal to the phase index value, followed by a short pause. In one suitable embodiment, each blink comprises an ON time for mode LED 33 of 500 ms followed by a 500 ms OFF time. After a number of blinks equal to the phase index have been completed, the instruction of activity element 90 cause controller 30 to provide a further OFF time of 2 sec. This visual indication is sufficient to inform the operator precisely where (s)he is in the setup process. Other visual indication formats may be equally suitable.
[0047] After providing the visual indication of the current setup phase index value, microprocessor 40 continues by executing the instructions represented by activity element 92 . These instructions convert the signal provided on path 23 by sensor 21 to a digital value, and store this digital value in a temporary location in RAM 70 a . The number of blinks by the mode LED 33 prompt the installer to adjust shaft 15 to the position for the parameter specified in Table I for the current phase index value. Activity element 94 instructions then write the value encoded in the error signal on path 41 into another location of RAM 70 a.
[0048] The instructions of activity element 110 sample the save switch 36 and erase switch 37 levels and store these values in preselected RAM 70 a locations. If save switch 36 or erase switch 37 has been closed, a 0 v. logic level will be present at the corresponding terminal 30 s or 30 e . Element 110 instructions sample the save switch 36 and erase switch 37 status by sensing the voltage level at terminals 30 s and 30 e . To correct for the possibility of inaccurate reading, it is customary to take several samples of the status of a switch 36 or 37 , and instructions that implement that practice are in fact symbolized by activity element 110 .
[0049] Next, instruction execution moves through connector element E 97 to the instructions of decision element 98 in FIG. 4, which tests the status of save switch 36 by testing the value of the RAM location loaded with the value indicating the voltage at terminal 30 s . If switch 36 has not been operated, instruction execution moves to decision element 111 . Decision element 111 tests in a similar manner if switch 37 has been operated. If not, instruction execution moves as indicated by connector element A 88 to reexecute the instructions of activity element 89 (FIG. 3). This sequence of instructions continues until either save switch 36 or erase switch 37 is operated. During this time, the operator will change the position of shaft 15 using the switches 17 d and 17 e to the position needed for the particular installation.
[0050] If decision element 111 senses that the erase switch 37 has been closed, the instructions of decision element 101 (FIG. 5) are executed as indicated by connector element F 100 . The functions performed by the instruction sequence accessed by connector element F 100 will be discussed below. Generally, this functionality allows the installer to reenter a previously entered parameter value corresponding to a larger phase index value.
[0051] If the instructions of decision element 109 sense that save switch 36 was operated during this pass through the main loop, then instructions for activity element 107 are executed. EEPROM 70 b is loaded during manufacture with a position data limit value for each of the phase index values. The activity element 107 instructions test the position data recorded in RAM 70 a by the instructions of activity element 92 against the preloaded limit value assigned to the current phase index value. If the position data value recorded for the current phase index value is not within the preset limit recorded in EEPROM 70 b for that phase index value, the instructions of decision element 107 continue with instruction execution at activity element 113 . Element 113 instructions flash error LED 34 in a preset pattern indicating the error, pauses, and then repeats the preset pattern, to indicate visually the type of error detected. Instruction execution then returns to activity element 89 in FIG. 3 through connector element A 88 .
[0052] If decision element 107 determines that the position data is acceptable, then the instructions of activity element 108 are executed next, transferring the position data from RAM 70 a to the location in EEPROM 70 b corresponding to the current value of the phase index. The CRC value is THEN recalculated and stored back into EEPROM 70 b by the instructions of activity element 119 .
[0053] Then the instructions of decision element 114 test whether the phase index value is 2 or 3. If not, then the instruction sequencing proceeds to activity element 122 (FIG. 5) through connector element C 118 . If the phase index is 2 or 3, then the error data loaded into RAM 70 a by activity element 94 is tested by the instructions of decision element 115 against an error data limit value preloaded into EEPROM 70 b and assigned to the current phase index value. If the value is not within the preset limit, the instructions of activity element 119 are executed, which flash error LED 37 is a preset pattern to indicate this type of error. Then execution returns through connector element A 88 to the start of the main loop thereby giving the operator another chance to reenter the error data, perhaps by resetting dial 47 .
[0054] As mentioned earlier, the operator should turn dial 47 to one of its extreme positions on scale 47 a for each of the phase index values of 2 and 3. These settings of dial 47 will generate either a minimum or maximum error signal value, which will allow the operating program to interpolate to precisely position shaft 15 as a function of the error signal value.
[0055] If decision element 115 determined that the stored error data is within the preset limit, the instructions of activity element 116 copy the current error data from RAM 70 a to the EEPROM 70 b error data location corresponding to the current phase index value. The new value of the EEPROM CRC value is then calculated and stored in EEPROM 70 b by the instructions of activity element 121 . Then execution proceeds through connector element C 118 to the instructions of activity element 122 in FIG. 5 which subtract 1 from the phase index value.
[0056] Decision element 130 instructions then test whether the EEPROM 70 b CRC is correct. If not, the instructions of activity element 132 are executed and the execution proceeds to the instructions of activity element 129 through connector element G 102 . If the CRC value is found to be correct by decision element 130 , then the phase index value is tested by decision element 117 . If the phase index is unequal to 1, then instruction execution continues through connector element A 88 to execute the instructions of activity element 89 . If the phase index equals 1, then setup is complete, and the instructions of activity element 120 are executed. The instructions of element 120 cause the mode LED 33 to slowly flash or blink to indicate completion of the setup. The instructions of activity element 141 (FIG. 6) are executed next through connector element B 85 .
[0057] In FIG. 5, the sequence of instructions starting at connector element F 100 are used to increment the value of the phase index if the operator closes the erase switch 37 . When the instructions of either decision element 111 (FIG. 4) or decision element 143 in the normal operating loop shown in FIG. 6 detect the erase switch 37 to have been closed, the decision element 101 instructions are executed. These instructions test whether the phase index is equal to 5. If not, the instructions of activity element 105 increment the phase index by one. Then in either case, the execution of instructions transfers back to the start of the main commissioning loop in FIG. 3 through connector element A 88 .
[0058] Turning next to the instructions for activity element 141 in FIG. 6, these read the erase switch 37 status. The instructions of decision element 143 are executed next to determine whether erase switch 37 has been operated. If the erase switch 37 has been operated, this means that the operator has decided to change one or more of the controller 30 commissioning parameters. By repeatedly operating the erase switch 37 while in the main loop starting at connector element A 88 it is possible to continuously increment the phase index value to any of the allowable values desired. If a parameter for a phase index value different from 2 is to be changed, then each of the other values for smaller phase indexes must also be changed in the normal sequence. Since these commissioning values will be changed very rarely, this is not considered to be a significant problem.
[0059] If the erase switch has not been operated, then the instruction sequence represented by activity element 146 is executed. These are the operating control instructions for positioning the shaft 15 based on the position signal provided by sensor 21 , the Table I parameters loaded into EEPROM 70 b , and the error signal provided on path 41 . The instructions of element 146 convert controller 30 into an operating control element.
[0060] In FIG. 6, connector element G 102 starts the series of software elements that process various types of errors detected by controller 30 and requiring controlled device 12 to be returned to a safe condition. Activity element 129 represents instructions that set the lockout flag and that also return controlled device 12 to a safe state. If device 12 is a fuel valve for example, this would mean closing the valve. Then the instructions of activity element 125 are executed to cause mode LED 33 to turn on solidly and the error LED 34 to flash in a pattern dictated by the error type flag.
[0061] After that, the save and erase switch 36 / 37 inputs are sensed and stored in the RAM 70 a locations assigned to them. Then the instructions of decision element 131 are executed, which test whether both the save switch 36 and the erase switch 37 have been closed. If not, instruction execution returns through connector element G 102 to reexecute the instruction sequence starting with activity element 129 . If both the save switch 36 and the erase switch 37 have been closed the instructions of activity element 140 are executed. These instructions restore the commissioning parameters to their default values, and recalculate and store the CRC value. This new CRC value is tested to be correct by decision element 148 . If it is correct, instruction execution continues through connector element A 88 to activity element 89 . If not correct, executing the instructions of activity element 150 sets the error type flag, and execution then continues through connector element G 102 to activity element 129 . Accordingly, one can see that any serious error requires operator intervention to push both the save and erase switches 36 / 37 . If errors keep occurring, the operator will soon realize that the controller 30 itself is defective and install a new one.
[0062] Thus, it is possible to use a device such as an actuator 17 with a manual control mode or a manually adjustable set point error generator 43 (or both) as an input source for setting or commissioning a controller 30 for properly operating a controlled device 12 in a specific installation. This allows a controller 30 having only a very few simple elements for communicating with a human operator or installer to be manually commissioned with a substantial amount of flexibility. | A system for commissioning a controller accepts a different manual input during each of several different phases of the installation and provides the installer with a different detectable cue during each phase. The installer provides the manual input and then operates a switch indicating the input is present. The system stores the manual input present and advances the system to the next phase, and in a preferred embodiment provides a visible cue identifying each phase. The preferred embodiment uses devices controlled by the controller during normal operation and which also have manual position adjustment or set point selection to provide the manual inputs. | 6 |
This application is based on Application No. 2001-153056, filed in Japan on May 22, 2001, the contents of which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an O 2 -sensor fault diagnosis apparatus and method for diagnosing whether a fault occurs in an O 2 -sensor used to perform feedback control of a fuel supply to an internal combustion engine.
2. Related Background Art
O 2 -sensors are used to perform air/fuel ratio feedback control for internal combustion engines, as described in Japanese Patent Application Laid-open No. Sho 57-137633. Also, various O 2 -sensor fault diagnosis apparatuses have been conventionally proposed which detect faults of O 2 -sensors and breaking of signal wires on the basis of output voltages of the sensors.
Such O 2 -sensors, however, have a problem in that irrespective of air/fuel ratios, their output voltages remain low until they become active and thus it is difficult to distinguish this situation from a state where there is breaking of signal wires. A conventional fault diagnosis apparatus is disclosed in Japanese Patent Application Laid-open No. Hei 5-203611, according to which if an inactive state of an O 2 -sensor is detected, air/fuel ratio is forcibly enriched. If the O 2 -sensor remains in the inactive state even after the air/fuel ratio is enriched, the sensor is diagnosed as having a fault. With this technique, however, the enriched air/fuel ratio causes the increase of pollutants in an exhaust gas and misdiagnosis is made depending on the amount of injected fuel.
Also, proposed is another conventional diagnosis apparatus that precisely detects a state where there is wire breaking by changing the input resistance of an input circuit to an ECU that is connected to an O 2 -sensor. With this technique, however, feedback control needs to be temporarily suspended when the input resistance is changed. This portion that frequent input resistance change increases pollutant emissions, so that once the detection of wire breaking is carried out, it is difficult to conduct fault diagnosis again. As a result, even if wire breaking occurs during driving after the detection of wire breaking is performed, it is impossible to inform a driver of the necessity of repair at an early stage.
As described above, with the conventional O 2 -sensor fault diagnosis apparatuses, it is difficult to precisely distinguish an inactive state from a state where wire breaking occurs and at the same time, to successively perform the detection of wire breaking. As can be seen from this, there is still room for improvement in the O 2 -sensor fault diagnosis apparatuses.
SUMMARY OF THE INVENTION
The present invention has been made to solve the stated problems and an object of the present invention is to achieve an O 2 -sensor fault diagnosis apparatus and method therefor, which enable successive detection of wire breaking without increasing pollutant emissions.
An O 2 -sensor fault diagnosis apparatus according to this invention comprises: an O 2 -sensor for detecting concentration of oxygen contained in an exhaust gas of an internal combustion engine; a feedback control portion for controlling a quantity of fuel supplied to the internal combustion engine through feedback control according to an output signal of the O 2 -sensor; a state judging portion for judging whether the O 2 -sensor is in an active state or in an inactive state on the basis of an voltage of the output signal of the O 2 -sensor; and a fault diagnosis portion for diagnosing whether the O 2 -sensor has any fault on the basis of the voltage of the output signal of the O 2 -sensor under a condition where it is judged that the O 2 -sensor is in the inactive state.
Also, the fault diagnosis portion includes an input resistance changing portion for changing an input resistance so as to cause a change in a level of the output signal of the O 2 -sensor, and identifies a fault of the O 2 -sensor on the basis of the change in the level of the output signal caused by changing the input resistance.
Further, the fault diagnosis portion diagnoses whether the O 2 -sensor has any fault each time the state judging portion judges that the O 2 -sensor is in the inactive state.
Furthermore, the O 2 -sensor fault diagnosis apparatus according to this invention further comprises an informing portion for sending a notice if the fault diagnosis portion diagnoses that the O 2 -sensor has a fault.
Also, an O 2 -sensor fault diagnosis method according to this invention comprises: a state judging step for judging whether an O 2 -sensor, which detects concentration of oxygen contained in an exhaust gas of an internal combustion engine, is in an active state or in an inactive state on the basis of an voltage of an output signal of the O 2 -sensor; and a fault diagnosis step for diagnosing whether the O 2 -sensor has any fault on the basis of the voltage of the output signal of the O 2 -sensor under a condition where it is judged that the O 2 -sensor is in the inactive state.
Further, in the fault diagnosis step, a fault of the O 2 -sensor is identified on the basis of a change in a level of the output signal of the O 2 -sensor caused by changing an input resistance.
Furthermore, in the fault diagnosis step, it is diagnosed whether the O 2 -sensor has any fault each time it is judged in the state judging step that the O 2 -sensor is in the inactive state.
Finally, the O 2 -sensor fault diagnosis method according to this invention further comprises an informing step for sending a notice if the O 2 -sensor is diagnosed to have a fault in the fault diagnosis step.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings:
FIG. 1 shows the overall construction of a fuel supply control apparatus including an O 2 -sensor fault diagnosis apparatus according to an embodiment of the present invention;
FIG. 2 is a block diagram showing the construction of the O 2 -sensor fault diagnosis apparatus according to the embodiment of the present invention;
FIG. 3 shows how an input resistance of an input circuit for receiving an output signal of the O 2 -sensor is changed according to the embodiment of the present invention; and
FIG. 4 is a flowchart showing an O 2 -sensor fault diagnosis operation according to the embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows the overall construction of a fuel supply control apparatus including an O 2 -sensor fault diagnosis apparatus according to an embodiment of the present invention. Referring to the figure, an air-flow sensor 13 (hereinafter referred to as the AFS) which is disposed within an intake pipe 15 on the downstream side of an air cleaner 10 is designed to generate a pulse signal having a duty ratio which depends on the amount of air fed to an engine 1 , where the pulse signal is supplied to an electronically controlled fuel injection unit (hereinafter referred to as the ECU) 20 . A crank angle sensor 17 provided on a crank shaft of the engine 1 generates a pulse signal whose number of pulses corresponds to the rotation speed (rpm) of the engine 1 . This pulse signal is also supplied to the ECU 20 .
Further, the ECU 20 receives output signals of the AFS 13 , a water temperature sensor 18 , an O 2 -sensor 19 for detecting oxygen concentration of an exhaust gas, and the crank angle sensor 17 , to thereby control the fuel injectors 14 provided for the individual cylinders of the engine 1 . The ECU 20 also serves to detect a fault of the O 2 -sensor 19 and generates a signal indicative of the result of the detection, where an alarm lamp 21 is activated according to the generated signal to inform a driver of the fault of the O 2 -sensor. Note that a throttle valve 12 and a surge tank 11 are disposed in the intake pipe 15 on the downstream side of the AFS 13 . Also, reference numeral 16 denotes an exhaust pipe and numerals 22 and 23 represent an input circuit and an output circuit of the ECU 20 , respectively.
FIG. 2 is a block diagram showing the construction of the O 2 -sensor fault diagnosis apparatus according to this embodiment. The ECU 20 constituting the O 2 -sensor fault diagnosis apparatus is composed of a microcomputer 24 , the output circuit 23 , and the input circuit 22 . The microcomputer 24 calculates an optimal amount of fuel to be supplied to the engine on the basis of the output signals of the AFS 13 , the crank angle sensor 17 , the water temperature sensor 18 , and the O 2 -sensor 19 . The microcomputer 24 then converts the calculated fuel amount into an injector driving time period to supply a desired amount of fuel to the engine. The microcomputer 24 also detects a fault of the O 2 sensor 19 on the basis of the output signal of the O 2 sensor 19 and outputs a detection signal indicating the detected fault to the alarm lamp 21 . The output circuit 23 outputs a pulse signal having a duty ratio proportional to the injector driving time period to the injector 14 . The input circuit 22 changes the level of the output signal of the O 2 -sensor 19 and inputs the output signal having the changed level to the microcomputer 24 .
Furthermore, the microcomputer 24 includes a storage portion 25 , an input resistance changing portion 26 , and an active state judging portion 27 . The storage portion 25 stores output signals of the AFS 13 , the crank angle sensor 17 , the water temperature sensor 18 , and the O 2 -sensor 19 . The input resistance changing portion 26 serves as a fault diagnosis portion for changing input resistance of the input circuit 22 and detecting a fault of the O 2 -sensor 19 on the basis of levels of output signals obtained from the O 2 -sensor 19 during a period in which the input resistance of the input circuit 22 is changed. The active state judging portion 27 judges whether the O 2 -sensor 19 is in an active state.
Further, the O 2 -sensor 19 outputs a voltage corresponding to the ratio between the oxygen concentration of the air and that of an exhaust gas. The output voltage of the O 2 -sensor is related to an air/fuel ratio and changes quickly at a theoretical air/fuel ratio. Accordingly, the output voltage of the O 2 -sensor is an exhaust gas air/fuel ratio signal indicating an air/fuel ratio of an exhaust gas. A slice level (0.45V) is set for the output signal of the O 2 -sensor 19 . The microcomputer 24 determines that the air/fuel ratio is rich if the output voltage of the O 2 -sensor 19 is equal to or higher than the slice level. On the other hand, if the output voltage of the O 2 -sensor 19 is below the slice level, the microcomputer 24 determines that the air/fuel ratio is lean.
In this manner, the microcomputer 24 activates and controls the injectors 14 according to the exhaust gas air/fuel ratio signal detected by the O 2 -sensor 19 , and performs feedback control such that the air/fuel ratio of the mixture supplied to the internal combustion engine is at the theoretical air/fuel ratio.
The microcomputer 24 is equipped with the active state judging portion 27 for judging whether the O 2 -sensor 19 is in an active state. If a predetermined time has passed after a judgement condition is satisfied, the active state judging portion 27 judges whether the O 2 -sensor 19 is in an active state. If it is judged that the sensor is in an inactive state, the fault diagnosis portion 26 performs fault diagnosis to judge whether the O 2 -sensor 19 has any fault.
The fault diagnosis portion 26 also calculates the timing at which the input resistance of the input circuit 22 should be changed, and changes the input resistance for a predetermined period of time when the timing is achieved. The fault diagnosis portion 26 performs the fault diagnosis on the basis of the level of an output signal of the O 2 -sensor 19 obtained during the time period in which the input resistance is changed.
If it is judged that the O 2 -sensor 19 is in an inactive state and the fault diagnosis portion 26 detects any fault of the O 2 -sensor 19 as a result of these operations, the alarm lamp 21 is turned on.
It should be noted here that the input circuit 22 can be implemented merely by adding simple parts to a conventional input circuit of the O 2 -sensor 19 and/or merely by altering the configuration of the conventional input circuit.
FIG. 3 shows the construction of the input circuit 22 . As shown in this drawing, the input circuit 22 has a construction where one end of a resistor 61 is connected to an input terminal that connects the O 2 -sensor 19 to an A/D converter 60 , a transistor 64 serving as a switching element is connected between the other end of the resistor 61 and the ground potential, and a junction between the resistor 61 and the transistor 64 is connected to the ground potential via a resistor 62 and a voltage source 63 . An ON/OFF control signal is supplied to the input circuit 22 from the microcomputer 24 having the fault diagnosis portion 26 (see FIG. 4) connected to the base of the transistor 64 having the stated connection construction, which serves as the input resistance changing portion. With this construction, the input resistance of the O 2 -sensor 19 with respect to the A/D converter 60 is changed.
Ordinarily, when the output signal of the O 2 -sensor 19 is inputted to the microcomputer 24 via the input circuit 22 , the transistor 64 is turned on and the signal from the O 2 -sensor 19 is connected to the ground via the resistor 61 . Since the value of the resistor 61 is set to be sufficiently large for the input impedance of the O 2 -sensor 19 , the output voltage of the O 2 -sensor 19 is inputted to the A/D converter 60 as it is.
At the timing when the input resistance is changed in order to diagnose whether the O 2 -sensor 19 has any fault, the transistor 64 is turned off and therefore one end of the resistor 61 is connected to the voltage source 63 via the resistor 62 . In that case, if a wire fault takes place in the output line of the O 2 -sensor 19 , the input voltage Vi of the A/D converter 60 assumes the level of the voltage Vo of the voltage source 63 . On the other hand, if a ground-fault occurs in the output line of the O 2 -sensor 19 , the input voltage Vi of the A/C converter 60 assumes the ground potential level. By detecting the changes in the level of the input voltage Vi described above, it is possible to identify a fault of the O 2 -sensor 19 .
As described above, if any abnormality occurs in the O 2 -sensor during the period in which the input resistance is changed, the output signal of the O 2 -sensor 19 assumes a level impossible in usual cases. As a result, a fault of the O 2 -sensor 19 is detected with reliability. The fault diagnosis portion 26 makes it possible to detect wire breaking with reliability, thus achieving an advantage that misdiagnosis is prevented.
Next, the operation of the O 2 -sensor diagnosis according to this embodiment will be described by referring to the flowchart shown in FIG. 4 . FIG. 4 is a flowchart for illustrating the general outline of the O 2 -sensor fault diagnosis operation according to this embodiment. In step S 41 , the output voltage of the O 2 -sensor 19 is compared with a judgement reference value (=0.5V) used to judge whether an air/fuel ratio A/F is on the rich side or on the lean side. Each time the output voltage of the O 2 -sensor 19 crosses 0.5V, it is determined that the O 2 -sensor 19 is in an active state and an inactive judgement time period is reset in step S 42 .
In step S 43 , it is judged whether a time period between the moment when the output voltage of the O 2 -sensor 19 crosses 0.5V and the moment when the output voltage crosses 0.5 again exceeds a set time period. If the judgement result is affirmative, the processing proceeds to step S 44 in which it is determined that the O 2 -sensor is in an inactive state.
To decide whether wire breaking occurs in the O 2 -sensor 19 , the processing further proceeds to step S 45 in which it is checked whether a condition for changing the input resistance is satisfied. If the condition is satisfied, the processing proceeds to step S 46 in which the input resistance is changed.
In step S 47 , it is judged whether the output voltage of the O 2 -sensor exceeds 4.5V under a condition where the input resistance is changed. If the judgement result in step S 47 is affirmative, the processing proceeds to step S 48 in which it is determined that wire breaking occurs. The processing then proceeds to step S 49 in which a diagnosis lamp of the alarm lamp 21 is activated.
As described above, according to the present invention, it is judged whether an O 2 -sensor is in an active state or in an inactive state on the basis of the voltage of the output signal of the O 2 -sensor that detects the oxygen concentration of an exhaust gas emitted from an internal combustion engine. If the O 2 -sensor is judged to be in the inactive state, it is judged whether there is any fault in the O 2 -sensor on the basis of the output signal voltage of the O 2 -sensor. As a result, whether the O 2 -sensor itself and the output line of the O 2 -sensor have any faults that make feedback control impossible is judged with reliability. Also, fault diagnosis can be successively performed each time an inactive state is detected after the start of an engine.
Also, a fault of the O 2 -sensor is identified according to a change in a voltage level caused by changing an input resistance for changing the level of the output signal of the O 2 -sensor. As a result, a fault of the O 2 -sensor, such as ground-fault or wire breaking of an output line of the O 2 -sensor, is identified by detecting the voltage level appearing while the input resistance is changed.
Further, fault diagnosis is conducted on the O 2 -sensor each time an inactive state is detected, so that it is possible to detect any fault occurring in the O 2 -sensor at an early stage.
Also, if a fault is detected in the O 2 -sensor, an informing portion informs an operator or a driver of the fault, so that it is possible to detect the fault at an early stage. | An O 2 -sensor fault diagnosis apparatus and method therefor, which are capable of detecting wire breaking of an O 2 -sensor with reliability and successively performing fault diagnosis with minimal effect on an exhaust gas. An O 2 -sensor 19 detects concentration of oxygen contained in an exhaust gas of an engine 1. An ECU 20 controls a quantity of fuel supplied to the engine 1 through feedback control according to an output signal of the O 2 -sensor. A fault diagnosis portion changes an input resistance value of an input circuit that is connected to the O 2 -sensor 19 and constitutes the ECU 20 each time a control condition for determining that the O 2 -sensor 19 is in an inactive state is satisfied, determines that wire breaking occurs in the O 2 -sensor 19 only if the output voltage of the O 2 -sensor 19 exceeds a predetermined voltage, and activates an informing portion to send a notice showing that there is a fault in the O 2 -sensor 19. | 5 |
CROSS-REFERENCES TO RELATED APPLICATIONS
This application claims the priority of German Patent Application, Serial No. 197 56 099.7, filed Dec. 17, 1997, the subject matter of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
The present invention relates to a method of and apparatus for screening bulk material.
It is known to use pneumatic sifters for screening granulate bulk material. These pneumatic sifter are available in a wide variety of different designs, such as counterflow sifters, deflection sifters etc., and can be configured also as zigzag sifters. While in counterflow sifters, the sifting gas is conducted in opposition to the bulk material being screened, in deflection sifters the gas flow is typically conducted transversely to the flow direction of bulk material. Regardless of the type of pneumatic sifter being used, all designs require a very precise setting of the energy of gas, e.g. air, to be supplied. If the air energy is too weak, the separation of the fraction of fine particles will not be satisfactory. On the other hand, if the gas energy is excessive, the amount of coarse particles being entrained together with the fraction of fine particles is too high. This causes a problems, in particular, when different mixtures of bulk material are repeatedly screened, so that a correct adjustment of the air energy can normally be carried out only on the basis of empirical observation and only approximated.
SUMMARY OF THE INVENTION
It is thus an object of the present invention to provide an improved method and apparatus for screening bulk material, obviating the afore-stated drawbacks.
In particular, it is an object of the present invention to provide an improved method and apparatus for screening bulk material by which the gas energy (quantity, velocity) is precisely adjusted in a simple and rapid manner, even when screening varying mixtures of bulk material.
These objects, and others which will become apparent hereinafter, are attained in accordance with the present invention by conducting a gas in counterflow to a direction of movement of incoming granulate bulk material for separating a fraction of fine particles from a fraction of coarse particles, determining the amount of coarse particles carried with the fraction of fine particles, comparing the determined amount with a desired value, and changing the energy of gas in dependence on the comparison between the determined amount and the desired value so as to match the determined amount with the desired value.
The determination of the amount of coarse particles contained in the fraction of fine particles can be carried out at any point after separation of the fraction of fine particles, and depends on the demands at hand, e.g. speed of control system. Preferred is a location, for example, immediately after the sifter, or a location in or after a separator positioned downstream of the sifter.
In principle, any process that is suitable to determine the amount of coarse particles in the outgoing fraction of fine particles may be applicable within the scope of the present invention. An example includes screening of cleaned granulate bulk material and subsequent weighing (or determination of volume) of the individual fractions. This process is, however, time consuming, which may be of secondary considerations when fairly even mixtures of bulk material are involved. However, when less homogenous mixtures are used, such as plastic granulates, and quantities of fine particles are encountered in the sifter, the gas energy must be correctly adjusted in a relatively rapid manner.
Therefore, according to a preferred embodiment of the present invention, the determination of the amount of coarse particles entrained together with the exiting fraction of fine particles is realized by having the outgoing granulate bulk material stream, which is carried by the gas stream, impact on a sound 3 emanating surface, and analyzing the structure-borne noise. Sound analysis has been applied, for example, for observing the operation of ball mills or of die casting machines. Examples of sound analysis processes are described in German Pat. Nos. DE-C-10 70 478, or DE-C-24 14 819, or DE-A-39 40 560, or DE-A-33 00 327, or European Pat. Nos. EP-A-0 000 827, or EP-A-0 112 619.
Preferably, the sound-emanating surface is formed by at least one impact plate which projects into the flow path of the outgoing gas stream.
In accordance with the present invention, an apparatus for screening granulate bulk material includes a pneumatic sifter having a gas inlet and a gas outlet, a sound-emanating area incorporated in the gas outlet and generating noise upon impact of granule-laden gas stream, a microphone actuated by sound waves radiating from the sound-emanating area upon impact of the granule-laden gas stream, and delivering an output signal, a sound analyzer having a comparator for comparing the output signal with a desired value and delivering an output signal, and an actuator operated by the sound analyzer for adjusting a gas energy of the gas stream in dependence of the output signal of the sound analyzer.
BRIEF DESCRIPTION OF THE DRAWING
The above and other objects, features and advantages of the present invention will now be described in more detail with reference to the accompanying drawing in which the sole FIG. 1 shows a schematic illustration of an apparatus for screening bulk material, embodying the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Turning now to FIG. 1, there is shown a schematic illustration of an apparatus for screening bulk material, embodying the present invention and generally designated by reference character S. By way of example, the apparatus is designed in the form of a counterflow sifter. A specific construction and manner in which a pneumatic sifter of this type is typically operated is fully described in U.S. Pat. No. 5,458,245, the entire specification and drawings of which are expressly incorporated herein by reference. Persons skilled in the art will appreciate, however, that the principles described in the following description are equally applicable to other types of sifters such as e.g. cross-flow sifters, deflection sifter, or other pneumatic sifters.
The counterflow sifter S has a housing 5 formed with an upper inlet 1 for introduction of granulate bulk material containing coarse particles and fine particles, and an outlet 2 for discharge of bulk material granules on its lower side. Accommodated in the housing 5 is a retention unit 20 for realizing a pre-separation of fine particles. The retention unit 20 includes a feed hopper 21 and a guiding cone 22 disposed above the feed hopper 21 and interacting with a conical metering valve 23 . The feed hopper 21 is positioned above a distributing plate 6 for directing bulk material into the path of a gas stream which flows in counterflow to remove a fraction of fine (or unwanted) particles from the bulk material flow, while coarse particles exit through the outlet 2 . It will be appreciated by persons skilled in the art that the specific construction and manner in which the counterflow sifter S operates is described in more detail in afore-mentioned U.S. Pat. No. 5,458,245 so that further discussion thereof is omitted for the sake of simplicity.
Sifting gas, typically air, is supplied by a suitable source, e.g. by a fan 3 , and enters the housing 5 via a conduit 4 through a lateral inlet port 13 . Suitably, a sound absorber 25 is disposed in the conduit 4 downstream of the fan 3 . The air flow generated by the fan 3 and forced through the conduit 4 is conducted across a filter 7 before being introduced through inlet port 13 into the housing 5 . Disposed in the conduit 4 downstream of the filter 7 before the inlet port 13 is an air flow controller 8 , e.g. a proportional valve. After entering the inlet port 13 , the air flow is deflected by a baffle plate 10 and flows upwardly in direction of arrow 36 in opposition to the downward flow of bulk material to separate fine particles. The air flow laden with fine particles leaves the housing 5 through an outlet port 9 .
Located inside the outlet port 9 is an impact area labeled A and formed by an impact plate 11 which is impacted by the bulk material fraction entrained by the air flow when leaving the housing 5 through the outlet port 9 . By striking the impact plate 11 , the granules entrained by the gas stream generate a sound which is defined by frequencies that are substantially dependent on the size of the particles and registered by a sound analyzer 14 . Thus, the frequencies can be used as measure for the fraction of coarse particles which is contained in the bulk material stream entrained by the gas flow and substantially comprised of the fraction of fine particles. As the fraction of coarse particles is intended to flow downwards toward the outlet 2 , while the fraction of fine particles exits through outlet 9 , an excessive amount of coarse particles in the exiting gas stream translates in an increased sound generation, indicating an inefficient operation of the pneumatic sifter S.
Persons skilled in the art will appreciate that the incorporation of the impact plate 11 is a preferred embodiment because sound frequencies can be kept within predetermined limits; However, it is certainly within the scope of the present invention to make the outlet 9 of such material that enables generation of structure-borne noise upon impact of granules. Also, the particular location of the impact plate 11 should be selected in such a way that coarse particles contained in the outflowing gas stream definitely strike the impact plate 11 . When using pipelines as areas to radiate sound, it should be taken into account that these areas, as a consequence of increased dimensions of the pipelines, are subject to a greater extent to changes due to moisture and temperature so that the sound analyzer 14 should periodically be re-adjusted.
Sound generated by impacting granules is suitably received by a microphone, e.g. a structure-borne sound microphone, which is accommodated in a line 12 (shown in dashed representation) and forms an output signal commensurate with the detected sound level. The output signal is transmitted to a conventional sound analyzer 14 (“FQIC + ”) for processing the output signal of the microphone. Persons skilled in the art will appreciate that the structure and operation of the sound analyzer 14 are generally known and not described in more detail for sake of simplicity.
Integrated in the sound analyzer 14 is a comparator which compares the output signal received by the microphone with a desired value inputted at 30 and commensurate to a predetermined, admissible fraction of coarse particles contained in the fraction of fine particles carried away by the air flow. Based on the comparison, the sound analyzer 14 generates an output signal for operating an adjustment device 24 , e.g. an electromotor, for actuating the control valve 8 .
In principle, it is not necessarily required to control the amount of gas by means of the control valve 8 because in conjunction with sifters, it is the relative energy of the gas stream in relationship to the supplied amount of bulk material that is crucial for carrying out an effective screening operation. Thus, although control of the amount of gas being used in the system is a preferred embodiment, it is certainly within the scope of the present invention to incorporate in the system controllers that modify the gas velocity or the amount of bulk material.
The outlet port 9 is fluidly connected to a conduit 15 for directing the outgoing air flow, laden primarily with the fraction of fine particles, to a separator 16 , e.g. a filter. Instead of using a filter, it is certainly within the scope of the present invention to utilize a cyclone or any other suitable separator, such as a zigzag sifter. Optionally, as indicated symbolically by reference character B, the conduit 15 may have incorporated therein a further impact plate which interacts with a microphone (not shown) to receive sound emanating from particles that strike the impact plate at B, with the microphone transmitting a commensurate output signal to the sound analyzer 14 via line 17 . Certainly, instead of being utilized as a separate sound-emanating area in addition to the impact plate 11 , the impact plate at B may also be used as an alternative to the impact plate 11 .
The separator 16 offers two more options to provide sound-emanating surfaces such as impact plates, i.e. as indicated by reference character C, the provision of an impact area in proximity of the inlet into the separator 16 , and, as indicated by reference character D, the provision of an impact plate in proximity of the outlet from the separator 16 , with the impact area C being operatively connected via a suitable microphone (not shown) to the sound analyzer 14 by line 18 , and with the impact area D being operatively connected via a suitable microphone (not shown) to the sound analyzer 14 by line 19 .
It will be appreciated by persons skilled in the art that the sound-emanating impact areas A, B, C, D may be commonly operated, or it is certainly possible to only operate some of the impact areas A, B, C, D. A multiple measurement of the sound level at different impact areas produces additional information about size and composition of the entrained fraction of bulk material. The selection of which of the sound-borne areas A, B, C, D should be used depends largely on the dimensions of the apparatus, on the type of bulk material, and on the required speed of control. Clearly, the control system as employed by the present invention runs slower and more sluggish (PI part) the farther the impacts areas A, B, C, D are located from the sifter S (or purifier) being controlled.
While the invention has been illustrated and described as embodied in a method of and apparatus for screening bulk material, it is not intended to be limited to the details shown since various modifications and structural changes may be made without departing in any way from the spirit of the present invention. | In a method of screening bulk material, a gas is conducted in counterflow to a direction of movement of bulk material for separating the bulk material into a fraction of coarse particles and a fraction of fine particles. In order to limit the amount of coarse particles in the outgoing fraction of fine particles, the amount of coarse particles contained in the fraction of fine particles is measured and compared with a desired value. When encountering a deviation of the measured the amount of coarse particles contained in the fraction of fine particles form the desired value, the energy of gas is so controlled as to match the amount of coarse particles contained in the fraction of fine particles with the desired value. | 1 |
BACKGROUND AND SUMMARY OF THE INVENTION
[0001] This application claims the priority of German Application No. 102 29 400.3, filed Jun. 29, 2002, the disclosure of which is expressly incorporated by reference herein.
[0002] A commonly owned co-pending application Ser. No. ______, filed Jun. 29, 2003 (Attorney Docket No.: 028987.52313US), based on German application of German Application No. 102 29 401.1 filed on Jun. 29, 2002, describes related subject matter and the same is incorporated herein by reference thereto to the extent that the disclosure aids in understanding the present invention.
[0003] The present invention concerns the structure for a vehicle, specifically a passenger vehicle containing a passenger cell with a windshield frame, which is attached to a panel structure of the passenger cell.
[0004] A prior structure described in U.S. Pat. No. 5,076,632 has been designed for a passenger vehicle with an open body without fixed members between a windshield frame and rear structure. The windshield frame consists of a surrounding tubular metal member covered with foam material and an enveloping surface.
[0005] European Patent Document No. EP 0 286 058 A2 deals with a self-supporting structural element of composite material for a vehicle structure, that is formed by a panel piece. This panel piece has a transition piece bordered by surface layers. This structural element produces a good strength-to-weight ratio.
[0006] U.S. Pat. No. 3,145,000 discloses a high-strength, glass-fiber reinforced component for an aircraft wing, where the wing is provided with a panel section that contains a core e.g. honeycomb structure embedded in deck panels.
[0007] It is a purpose of the invention to design a structure for a vehicle, specifically a passenger vehicle, including a passenger cell with a high-strength windshield frame that can easily be integrated in the structure.
[0008] The present invention meets said purpose by providing a structure for a passenger vehicle, containing a passenger cell with a windshield frame, which is attached to a panel structure of the passenger cell. Additional advantageous invention feature details are described herein and in the claims.
[0009] The invention offers major advantages in that the panel structure and the windshield frame consist of basically the same high-strength non-metallic material—fiber reinforced plastic, carbon fiber reinforced plastic (CFRP). Besides resulting in an identical-material design of different structural components, it also facilitates a particularly stable windshield frame. Furthermore, the choice of this material allows optimization of manufacturing processes. On the side of the panel structure, the windshield frame is provided with flanges held in position by adhesive bonding to a first and a second panel section of the panel structure, which contributes to a functional connection of said structural components.
[0010] Support columns are provided inside the hollow spaces of the upright columns of the windshield frame, which, combined with the columns of the windshield frame, increase passenger safety during multiple rollovers of the passenger vehicle, in that the support columns will be effective in addition to the windshield frame columns. The metal support columns are connected with retainer plates attached thereto and supported by the panel structure. The retainer plates are bolted to said panel structure.
[0011] Other objects, advantages and novel features of the present invention will become apparent from the following detailed description of the invention when considered in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] [0012]FIG. 1 is a schematic view from above, of a passenger vehicle with a structure according to the invention;
[0013] [0013]FIG. 2 is a large-scale cross sectional view along line II-II of FIG. 1;
[0014] [0014]FIG. 3 is a perspective angular view of a windshield frame column of the structure of FIGS. 1 and 2; and
[0015] [0015]FIG. 4 is a large-scale cross section approximately along line IV-IV of FIG. 3.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0016] In the drawing FIG. 1, unnumbered structure shown to the right to the right of the reference character 12 is depicted only to show an exemplary environment of the present invention and is therefore not further described herein.
[0017] Of a passenger vehicle 1 with an open body, essentially only one vehicle body structure 2 is shown, which comprises structure 3 . Structure 3 includes a passenger cell 4 with a passenger compartment 5 , housings 6 and 7 , and two diagrammatically indicated vehicle seats 8 and 9 . The passenger cell 4 consists of high-strength non-metallic material such as carbon fiber-reinforced plastic composite (CFRP) and has a panel body 10 with a front panel structure 11 and a rear panel structure 12 , joined to a floor structure 13 . The floor structure 13 is bordered on the longitudinal sides 14 , 15 by cross-sectional box-shaped frame side members 16 , 17 that extend between the panel structures 11 and 12 , and contains a center tunnel 18 that runs between the front panel structure 11 and the rear panel structure 12 ; the frame side members 16 , 17 and the center tunnel 18 extend in longitudinal vehicle direction A-A.
[0018] According to FIG. 2, the front panel structure 11 and a non-metallic windshield frame 19 are structurally joined; the windshield frame 19 also consisting of high-strength fiber-reinforced plastic (CFRP) just like the remaining structure 3 or passenger cell 4 . The windshield frame 19 is designed as a hollow girder 19 (FIG. 2), which, on a side B facing the passenger cell 4 encloses a bearing panel 20 in a defined width Bdef for a windshield 21 . This bearing panel 20 is provided with support panels 21 , 22 , its free ends 23 , 24 being provided with flanges 25 , 26 . Between bearing panel 20 and windshield 21 one or more adhesive seals are provided. The support panel 21 forms an obtuse or a right angle with the bearing panel 20 ; there is a similar angle between flange 25 and support panel 21 , and the flange 25 forms an obtuse angle with a horizontal line 27 . With its relatively short, horizontal piece 28 , the second support panel 22 leads away from the bearing panel 20 and joins a piece 29 that extends to the bearing wall 20 in a right or obtuse angle and becomes a horizontal piece 30 . This piece continues as a perpendicular piece 31 , and transitions into the horizontal flange 26 . The flanges 25 , 26 lead to a first panel section 32 and a second panel section 33 of the panel structure 11 and are there held in position by means of bonding 34 , 35 . For alignment of the flange 25 , the first panel section 32 is provided with an opening 36 . Furthermore, the hollow space 37 of the hollow girder 19 may be filled with suitable material, preferably foam material, which, among other things, serves to reinforce the hollow girder 19 .
[0019] The windshield frame 19 shows upright columns 39 , 40 , so-called A-pillars, (FIG. 1), that are provided with hollow spaces 41 , 42 containing support columns 43 (FIG. 3). Each support column 43 consists of metal—high-strength steel or aluminum alloy—and is attached to the front panel structure 11 . The support column 43 is held in position on said panel structure by means of a retaining plate 44 , which retaining plate 44 has legs 45 , 46 that extend toward each other at an angle (FIG. 4). The legs 45 , 46 abut the corresponding panel areas 47 , 48 of the front panel structure 11 . The retaining plate 44 is attached with bolts 49 , which align with the tap holes 50 of a metallic insert 51 . The insert 51 with angular legs 52 , 53 is integrated in the front panel structure 11 in such manner that this insert is surrounded by border panels 54 , 55 of the panel structure 11 which enclose a core 54 outside the insert 51 . A corresponding design can be found in EP 0 286 058 A2. Between the support column 43 and the column 39 , foamed material 56 will limit possible relative motion (FIG. 3). This foamed material extends across a relatively small section Tb of the entire length of the support column 43 and adjacent on one free end 57 of said column. Also, the support column 41 consists of three sleeved tubes 58 , 59 , 60 , which in this design show a circular cross section and are retained by a press fit.
[0020] The foregoing disclosure has been set forth merely to illustrate the invention and is not intended to be limiting. Since modifications of the disclosed embodiments incorporating the spirit and substance of the invention may occur to persons skilled in the art, the invention should be construed to include everything within the scope of the appended claims and equivalents thereof. | A structure is provided which is suitable for a passenger vehicle, containing a passenger cell with a windshield frame. For optimization of this structure with regard to advantageous manufacture and purposeful stability, panel structure and windshield frame consist of high-strength non-metallic material, e.g. fiber reinforced plastic, and are structurally joined. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the invention
The field of invention relates to fire alarm apparatus, and more particularly pertains to a new and improved alarm kit apparatus for use in cooperation with fire alarm circuitry of an associated dwelling.
2. Description of the Prior Art
Various fire alarm devices are utilized in the prior art in accommodating various situations dealing with a fire situations. An example is set forth in U.S. Pat. No. 4,805,701 to Mountford wherein a fire extinguisher mounts a fire alarm thereon.
U.S. Pat. No. 4,592,301 to Monte sets forth a fire extinguisher support mechanism that includes an audible alarm.
U.S. Pat. No. 4,418,336 to Taylor sets forth an alarm organization when a fire extinguisher is removed from an associated mount structure.
U.S. Pat. No. 4,532,996 to Wilson, et al. sets forth an alarm system utilizing an acoustic alarm arrangement.
As such, it may be appreciated that there continues to be a need for a new and improved alarm kit apparatus as set forth by the instant invention addresses both the problems of ease of use as well as effectiveness in construction in providing a kit construction for accommodating a fire situation by an individual and in this respect, the present invention substantially fulfills this need.
SUMMARY OF THE INVENTION
The present invention provides an alarm kit apparatus wherein the same sets forth an organization utilizing an audible alarm and illumination unit to direct an individual to an associated fire extinguisher and associated portable flashlight mounted thereon. As such, the general purpose of the present invention, which will be described subsequently in greater detail, is to provide a new and improved alarm kit apparatus which has all the advantages of the prior art fire alarm apparatus and none of the disadvantages.
To attain this, the present invention provides a mounting plate securing a fire extinguisher canister within a releasable securement strap, wherein the securement strap further includes a flashlight member released upon releasing of the fire extinguisher canister. An audible alarm is cooperative with a flashing light to direct a visual and audible signal in association with a smoke detector circuitry of a dwelling.
My invention resides not in any one of these features per se, but rather in the particular combination of all of them herein disclosed and claimed and it is distinguished from the prior art in this particular combination of all its structures for the functions specified.
There has thus 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. There are, of course, additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto. 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 alarm kit apparatus which has all the advantages of the prior art fire alarm apparatus and none of the disadvantages.
It is another object of the present invention to provide a new and improved alarm kit apparatus which may be easily and efficiently manufactured and marketed.
It is a further object of the present invention to provide a new and improved alarm kit apparatus which is of a durable and reliable construction.
An even further object of the present invention is to provide a new and improved alarm kit apparatus which is susceptible of 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 alarm kit apparatus economically available to the buying public.
Still yet another object of the present invention is to provide a new and improved alarm kit apparatus which 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 which characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and 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 an isometric illustration of the instant invention.
FIG. 2 is an orthographic view, taken along the lines 2--2 of FIG. 1 in the direction indicated by the arrows.
FIG. 3 is an isometric illustration of the audible alarm utilized by the instant invention.
FIG. 4 is a diagrammatic illustration of the alarm structure in association with a fire alarm circuitry of a dwelling.
FIG. 5 is an isometric illustration of a modified strap construction utilized by the instant invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference now to the drawings, a new and improved alarm kit apparatus embodying the principles and concepts of the present invention and generally designated by the reference numeral 10 will be described.
More specifically, the alarm kit apparatus 10 of the instant invention essentially comprises a mounting plate 11, including a planar forward surface formed with a top edge, wherein the top edge includes a translucent canopy 13 projecting orthogonally and beyond the planar forward surface, including a flasher light 14 positioned within the canopy 13. The translucent canopy 13 is typically of a red configuration to indicate alarm. A clear transparent lens 16 is positioned below the flashing light 14 communicating the translucent canopy 13 with the planar forward surface to provide illumination of the components of the alarm kit apparatus 10. A support shelf 15 is positioned in a spaced relationship relative to the top edge 12 adjacent a lower edge of the mounting plate, wherein the support shelf 15 supports a fire extinguisher canister 17 thereon. The fire extinguisher canister 17 includes a neck projection 18 extending coaxially and above the canister 17 for manual grasping of the neck projection in removal of the canister from the support shelf 15. A serpentine securement strap 19 includes an arcuate strap portion 25 circumferentially extending about a portion of the canister 17, wherein the arcuate strap portion includes a first strap hinge 22. A second strap hinge 23 is mounted adjacent a flashlight member 24, for use in a manner to be discussed in more detail below. An audible alarm 20 is in electrical communication with the fire alarm electrical circuitry 28, as depicted in FIG. 4, to effect electrical energy to the associated audible alarm 20 mounted to the planar forward surface 12 adjacent the canister 17. It should be noted that the electrical energy may be from a battery power pack or may be from an electrical communication with circuitry of an associated dwelling, as required or deemed convenient. The flashlight member 24 utilizes rechargeable batteries to maintain its continuous use. A flashlight strap 24a fixedly and securedly mounts a flashlight to the canister 17 and aligns the illumination from the flashlight towards the upper end or nozzle structure of the canister 17. A frangible connection 24b permits breakage of the strap 24a permitting removal of the flashlight 24 as required by use of an individual. In a like manner, the alarm 20 may optionally be mounted to the canister 17 or to the mounting plate 11, wherein mounting the the carrier 17 permits transport of the alarm to provide audible indication and orientation of an individual transporting the canister in use. Further it should be noted that a flasher unit 27 is in electrical association with the flashing light 14 to effect integral flashing of the light member 14. A first frangible strap connection 30 is positioned adjacent the first strap hinge 22, with a second frangible strap connection 31 positioned substantially diametrically opposed to the first frangible strap connection about the arcuate strap member 25 (FIG. 5). In this manner, grasping of the neck projection 18 ensures removal of the arcuate strap member 25 between the first and second frangible connections 30 and 31 respectively to ensure removal of the canister relative to the planar forward surface of the mounting plate 11. A third frangible strap connection 32 is provided adjacent the second strap hinge 23 to ensure release of the "L" shaped strap member 26 for access to the flashlight member 24.
As to the manner of usage and operation of the instant invention, the same should be apparent from the above disclosure, and accordingly no further discussion relative to the manner of usage and operation of the instant invention shall be provided.
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.
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. | A mounting plate secures a fire extinguisher canister within a releasable securement strap, wherein the securement strap further includes a flashlight member released upon releasing of the fire extinguisher canister. An audible alarm is cooperative with a flashing light to direct a visual and audible signal in association with a smoke detector circuitry of a dwelling. | 6 |
RELATED APPLICATION
This application is a continuation of our application Ser. No. 527,997, filed Aug. 31, 1983, abandoned, entitled CELL CULTURE SYSTEM, the disclosure of which is incorporated by reference herein.
BACKGROUND OF THE INVENTION
This invention relates to a method and apparatus for the culture of cells. The cells to be cultured in this invention are prokaryotic and eukaryotic cells such as bacteria, yeast, plant, animal and human cells. These cells may be derived in any manner, that is, isolated from nature, mutated, in the naturally-occurring form, genetically engineered or modified, transformed or non-transformed, hybrids formed by fusion between portions of cells or whole cells of the same or different species. These cells may be attached to the substrate, grown in suspension, or in suspension attached to another substrate, such as microcarrier bead. The cultures may consist of a single cell line or a plurality of cell lines of the same or different species.
Conventionally, cells have been attached to and grown on the interior surface of glass or plastic roller bottles or tubes or on culture plates. This approach does not permit high-density growth of cells and requires large amounts of nutrient medium, in most cases. Use of these systems is also labor intensive.
U.S. Pat. Nos. 4,189,534 and 4,266,032 describe the growth of cells on tiny beads referred to in the art as microcarrier. Microcarrier systems have several disadvantages, such as cell damage from collision of beads, mingling of the desired cell product with the nutrient medium, cell fragments and other contaminants, and the difficulty of achieving continuous production of the desired product.
It is also known that cells may be grown on or near hollow or solid fibers. See U.S. Pat. Nos. 3,883,393; 3,997,396; and 4,087,327; 4,220,725; 4,391,912 also J. Feder and W. R. Tolbert, "The Large-Scale Cultivation of Mammalian Cells", Scientific American, Vol. 248, No. 1 and Amicon Technical Data Publication Number 442C, "Vitafiber™ Artificial Capillary Systems for Tissue Culture". Typically the nutrient medium is passed through the hollow fibers and diffuses through the lumen thereof into the cell growth space and extracapillary space bounded by an envelope. These capillaries are susceptible to mechanical vibration and shock. The location of the cells is not closely constrained and the cells most distal from the fibers may not be well nourished. Large volumes of nutrient are typically utilized.
U.S. Pat. No. 4,225,671 describes a cell culture apparatus in which a stack of parallel flat membranes defines separate, typically alternating, cell culture medium, and cell growth spaces. These membranes are spaced widely apart (2 mm), so excessive quantities of nutrient must be provided to ensure the nourishment of the cells most distal from the membrane. Since the membranes are supported only at their edges, the maximum surface area of each membrane is limited by the tensile strength of the membrane. Thus, production capacity is limited. In addition the membrane is not designed to restrict the flow of the cell product into the nutrient medium and the product is collected in that medium. Because the cell product is mingled with the culture medium, product, recovery and purification is complex and results in a low yield of product.
U.S. Pat. No. 3,948,732 shows a spacer structure which is convoluted to offer internal support to the substrate surfaces. It does not, however, recognize the importance of a fluid path separate from that of the nutrient medium.
One object of the invention is to provide a closed sterile system for cell culture in order to prevent both exposure of personnel to the cells and the contamination or infection of the cell culture by wild strains entering from the outside environment.
Another object of the invention is to provide a system for cell culture which more closely approximates a continuous system than those known previously, thus increasing the average or steady-state output of product and minimizing opportunities for contamination.
Another object of the invention is to simulate the supply of nutrient to and exchange of gases by cells in vivo, wherein cells are typically less than 200 microns from the capillaries, the sources of nutrients and respiratory gases.
Another object of the invention is to provide a cell culture assembly in which the maximum distance between a cell and the nearest source of nutrients and dissolved gases approximates that typical of the cells in vivo.
Another object of the invention is to provide a cell culture assembly which can be economically manufactured.
Another object of the invention is to provide a cell culture assembly and cell culture system which lends itself to the growth of cells at high densities.
Another object of the invention is to provide a cell culture assembly and cell culture system in which fluctuations in cell growth and production of the desired product are reduced.
Another object of the invention is to provide a cell culture system in which nutrient supply, heat transfer, gas transfer, cell growth and product collection functions are integrated.
Another object of the invention is to provide a cell culture system in which those functions are performed by separate modules of similar construction, and thus more economical to fabricate.
Another object of the invention is to provide multi-layered modules for cell culture and related purposes which can be assembled by lamination into an essentially rigid block structure.
Another object of the invention is to provide a cell culture assembly and cell culture system in which the nutrient medium circulation path is independent from the path carrying the cell product, metabolic products from the component of the culture medium and the cells themselves.
Another object of the invention is to provide a cell culture system in which the cells' environmental conditions are continuously monitored and any departures from the desired range of value in any environmental parameter are automatically indicated and corrected.
Another object of this invention is to provide a laminated structure for the fluid paths such that high strength and reliability are attained.
Another object of this invention is to provide a laminated structure that may be increased in size to accommodate large scale cell culture.
Another object of this invention is to provide a cell culture assembly which does not require large volumes of medium.
The aforesaid objects as well as other objects of the present invention will be made more apparent by the following description, claims and drawings.
SUMMARY OF INVENTION
In accordance with these objects, the cell culture system comprises a series of connected modules which provide a favorable location for cell growth and maintain the environment of the cells so as to promote continued production of the desired product. Typically, the modules will be heat transfer, gas transfer, cell culture and cell-product separation modules. Multiple separate and independent circulation loops exist within the cell culture system. In a given module only two of these circulation loops are operational. Means are provided for continuous circulation of nutrient culture medium through all of these modules (except for the cell-product separation module). In the second circulation path separate and independent means (secondary or auxiliary loops) exist for (a) the passage of gases through the gas transfer module, (b) the passage of heat through the heat transfer module, (c) the introduction of cells into the cell culture module, and (d) the withdrawal of product from the cell growth module into the cell-product separation module. In addition, a separate and independent means exists for the transfer of the separated cell product(s) into a collection vessel to be held for further processing.
The modules are preferably fabricated in a similar manner to achieve similar structures. The common structure of the preferred modules is described below as the basic module. The various modules differ from the basic module in the nature of the separator sheets 11 of FIG. 4 or sheets 43 of FIG. 15, and in the nature of the fluids circulated in the auxiliary circulation system. All of the modules except the cell-product separation module are connected and serviced by the nutrient medium circulatory system.
The modules of the present invention provide a large surface area, relative to the volume occupied by the modules, for cell growth and or attachment. The modules of the present invention are sterile, disposable, and replaceable. In accordance with one of the features of the system there is provided a sterile, disposable temperature control module. This feature allows a constant temperature fluid to circulate on one side of the non-porous membrane to control the temperature of the growth medium on the opposite side of the membrane without contact or contamination. In accordance with another feature of this invention, there is provided another sterile, disposable module for the exchange of gases with the growth medium by diffusion of the gases across either a hydrophobic or hydrophilic membrane. In accordance with another feature of this system, there is provided another sterile, disposable module to provide an environment and source of suitable growth medium. The cells are then cultivated on the opposite side of the membrane free from many of the contaminates in the growth medium. In accordance with another feature of this invention, there is provided another sterile, disposable module that incorporates a microporous filter to retain any free cells in the case of substrate attached cells or in the case of suspension cells to retain the free mobile cell culture and provide a closed loop thus allowing circulation back through the growth module. The soluble products are then eluted off the opposite side. In accordance with another feature of the system the available contact surface area of the modules may be varied from 200 sq cm to 80,000 sq cm. In accordance with another object of this system there is provided a means for growing cells in a totally enclosed environment to decrease the probability of contamination of the external environment by cells or cell products, and to decrease the probability of contamination of the cellular environment by foreign particulate matter or biological organisms. This system which is comprised of individual disposable modules also provides a means for disposing of individual contaminated units in an efficient manner which minimizes the threat to the environment. Further, since the system allows the culture of high densities of cells in a small volume of necessity for handling large numbers of culture vessels and the medium required to feed them is reduced resulting in a lowered risk of compromising the laboratory and surrounding environment. In accordance with another object of this invention there is provided a selective semi-permeable membrane to separate the cell nutrient flow path from the cell growth and cellular production path and thus permits the collection of cell product in a more highly concentrated form free of certain nutrient medium components which would dilute the cell product were the two pathways common. In accordance with another object of this invention there is provided a means for the collection of the concentrated cell product that permits less complicated and less costly methods to be used in the recovery and purification of the product because smaller volumes must be processed. In addition the use of a highly concentrated starting material for recovery and purification generally promotes more efficient recovery of final product in terms of purity and recovery.
In accordance with another object of this invention there is provided a means for periodic reversal of the nutrient medium flow and cell production collection flow to provide more efficient exchange of nutrient medium and cell waste products and thereby permit growth of greater cell numbers and thus increase the amount of product produced per unit of cell growth area.
In accordance with another object of this invention there are provided assemblies wherein the boundaries of the channels constrain the cells and fluids in such a manner that the cells are never more than 200 microns from the nearest source of nutrients.
Other features and benefits of the invention will be seen as the description of each module progresses, in conjunction with the following drawings.
FIG. 1--Cover plates top view
FIG. 2--Auxiliary primary sheet top view
FIG. 3--Auxiliary secondary sheet top view
FIG. 4--Separator sheet top view
FIG. 5--Media secondary sheet top view
FIG. 6--Media primary sheet top view
FIG. 7--Pictorial view basic module construction
FIG. 8--Schematic view of total system
FIG. 9--Cross-Section Part of FIG. 7
FIG. 10--Schematic of microprocessor
FIG. 11--Pictorial view basic module with perpendicular circulation
FIG. 12--Top cover plate top view
FIG. 13--Media and Auxiliary spacer sheet
FIG. 14--Auxiliary capillary sheet
FIG. 15--Separator sheet
FIG. 16--Media capillary sheet
FIG. 17--Bottom cover sheet top view
FIG. 18--Exploded view basic module with perpendicular circulation
DETAILED DESCRIPTION OF INVENTION
Basic Module
The basic module preferably has a large number of narrow parallel channels which are preferably formed by the superposition of the various sheets (FIGS. 1-6) of the assembly, as more fully set forth below.
In one embodiment of the invention, a secondary sheet 9, as shown in FIG. 3, has a plurality of narrow, parallel slots 10. This sheet is disposed between a separator sheet 11 (FIG. 4) and a primary sheet 6 (FIG. 2). As can be seen in FIG. 9, these three sheets cooperate to bound a plurality of channels 10 in sheet 9 whose depth is that of sheet 9. These channels 10 will be referred to by reason of their function, as auxiliary capillaries. The number, spacing, width and depth of these auxiliary capillaries is preferably chosen in view of the function of the module in which they appear. The result is that numerous parallel channels are formed on each side of the separator sheets. The flow through the capillaries is sealed from and independent from the flow on opposite side of each separator sheet 11; although, the nature of the separator sheet 11 may allow exchange of appropriate and desired substances between the chambers. Similarly, a secondary sheet 12 (FIG. 5) is disposed between a separator sheet 11 and a primary sheet 14 (FIG. 6) to create channels 13, the media capillaries. As can be seen in FIG. 9 these three sheets cooperate to bound a plurality of channels 13 in sheet 12, whose depth is that of sheet 12; and that said channels are separate and independent and communicate across said membrane.
The disposition of the auxiliary primary sheet 6 (FIG. 2) between the secondary sheet 9 and either a cover plate 5 or another secondary sheet 11 creates two larger channels 7 and 8, referred to as the auxiliary vein 7 and the auxiliary artery 8.
Similarly, the disposition of the media primary sheet 14 between the secondary sheet 12 and either a cover plate or another secondary sheet 11 creates a media vein 15 and a media artery 16.
Cover plate 5, as shown in FIGS. 1 and 7, has as auxiliary inlet 1, an auxiliary outlet 2, a medium inlet 3, and a medium outlet 4. In FIG. 7, only the ports on the top cover plate are in use, while the ports on the bottom cover plate are capped. It is possible to use some top plate ports and some bottom plate ports as shown in FIG. 8, moreover the precise location of these outlets and inlets may be varied as deemed appropriate. Note that the terms "top" and "bottom" are for convenience and do not refer to the orientation of the module. The modules are preferably constructed by lamination of the sheets. It is not necessary that all of the sheets comprising the module be made from the same material.
Although in the configuration shown FIGS. (7-9) the media and auxiliary capillaries are substantially parallel to each other it can be seen in FIGS. (11, 18) that in a second embodiment these channels may run substantially perpendicularly. In the second embodiment only one separator sheet 41 FIG. (13) may be required due to the perpendicular construction. It can be seen in FIG. 13 that spacer sheet 41 contains the arteries 16, 8 and veins 15,7 requiring two sheets, sheets (6,14 FIGS. 2, 6) in the first embodiment.
It is preferable, but not necessary, that the media and auxiliary capillary channels have the same dimensions. The channels in the appropriate sheets may be aligned with each other, or they may be offset in the direction perpendicular to their longest dimension. This offset may increase mechanical strength. The perpendicular construction has a similar advantage.
Although in the configuration shown in FIG. 18 there is only one set of media and auxiliary capillaries; it can be seen in FIG. 18 that a large number of narrow parallel channels are formed by the superposition of various sheets 41-44 FIGS. (13-16) as set forth below and previously described in the basic module. The superposition of an additional separator sheet 43 and media capillary sheet 44 between the spacer sheet 41 FIG. (18) and the auxiliary capillary sheet 42 FIG. (18) provides additional media capillaries and a complete set of veins and arteries.
Similarly the superposition of an additional separator sheet 43 and auxiliary capillary sheet 42 between the media capillary sheet 44 and the spacer sheet 41 FIG. (18) provides additional auxiliary capillaries and another complete set of veins and arteries.
As in the basic module description the flow through the capillaries is independent from and sealed from the flow on the opposite side of separator sheet 43; although, the nature of separator sheet 43 may allow the exchange of appropriate and desired substances between the chambers as shown in FIG. (8).
In the media circulatory system, media enters fluid inlet 3 sheet 40 FIG. (12) and flows into the media artery 16 of FIGS. (13, 14, 15). It then is distributed through media capillaries 13 sheet 44 FIG. (16). If the separator sheet 43 FIG. (15) is a permeable membrane, then certain substances will permeate separator sheet 43 which separates media capillaries 13 of FIG. 16 and the auxiliary capillaries 10 sheet 42 of FIG. 14. Media leaves the media capillaries 13 through media vein 15 of FIGS. (13, 14, 15) and then leaves through media outlet 4 sheet 45 FIG. (17). Fluids permeating separator sheet 43 FIG. (15) are collected first in the auxiliary capillaries 10 FIG. (14) and are thence extracted from auxiliary inlet and auxiliary outlet 1,2 FIGS. (12, 17) through the arteries and veins 8,7 FIGS. (13, 15, 16).
Suitable culture media for the cultivation of various types of cells are known and may be used in the method and apparatus of this invention. Culture media typically are composed of assimilable sources of elements such as carbon, nitrogen, and phosphorus, and may include amino acids and blood serum, by way of example. The composition of the culture medium may be varied from time to time to control cell metabolism and reproduction. In addition, the pH of the medium may be controlled or monitored.
The function of the auxiliary circulatory system varies from one type of module to another. Fluid enters at auxiliary inlet 1 and flows into the auxiliary arteries 8 of FIG. 2. It is then distributed by auxiliary capillaries 10 of FIG. 3. The fluid is collected by the auxiliary veins 7 and withdrawn through auxiliary outlet 2.
The number of veins, arteries and capillaries in the module is proportional to the number of separator sheets 11 FIG. (4) or sheets 43 FIG. (15) in the module. Typically, a single module will contain 2 to 400 separator sheets.
Preferably each secondary sheet defines a minimum of 20 capillaries 10 or 13 (FIGS. 3, 14 and 5, 16 respectively), and these capillaries are, 7 thousandths of an inch (178 Microns) deep and no more than 25 centimeters in length. The width and spacing are less important, but we have sucessfully used a width of 760 to 1650 microns, and a spacing of 1270 to 2540 microns. The width, depth and spacing may be varied, in response to the growth needs of the cells. The minimum dimensions are defined by the typical dimensions of a single cell of the type of cells to be cultivated. The maximum dimension can not be so great as to unduly limit the nourishment of cells at the distal wall of the cell growth spaces from the membrane. In addition, as the width is increased, the strength of the structure is weakened. The depth should be substantially similar to the maximum distance separating cells from capillaries in vivo, and it is thought that 500 microns is the upper limit if the advantages of this structure are to be achieved. Preferably, it should be less than 200 microns, however the depth may be increased to 1000 microns to accomodate "micro-carriers", or other large hybrid cells.
The cell culture spaces should be so dimensioned and oriented that the distance between a cell in a distal region of said spaces from the vascular network defined by the culture medium spaces and connecting passages is less than or substantially similar to that typical of the tissues or organs in which a cell of the type grown is found in vivo.
The terms vein, arteries and capillaries are utilized hereto suggest the relative dimensions of these channels and the veins, whether they carry fluid into or out of the module, and to emphasize that the system and its component modules are meant to simulate certain of the characteristics of the supply of nutrients to and exchange of gases by cells in vivo.
The term fluid is here used to refer to both liquids and gases, whether pure or mixed, and to include liquids or gases carrying substances in solution or in suspension.
The following will be a description of the heat transfer module, gas transfer module, cell growth module and the cell-product separation module. It should be assumed that all modules will have the structure of the basic module, except as set forth below.
Heat Exchange Module
In the heat exchange module 18, the separator sheet 11 FIG. (4) or separator sheet 43 FIG. (15) is nonporous, and preferably of polysulfone, or other suitable film with good heat transfer characteristics (greater than 2.8 cal/sec per square centimeter). The auxiliary arteries, veins and capillaries conduct a heat transfer fluid, which mediates the temperature of the nutrient medium 27 in the nutrient medium capillaries 13 of module 18 as a result of heat transfer across separator sheet 11 or sheet 43.
The temperature at which the culture medium is maintained may be varied in accordance with the growth characteristics of the cells, and hence the heat transfer fluid may have either a heating effect of a cooling function. The fluid temperature is maintained in a conventional manner.
Gas Exchange Module
In the gas exchange module 19 the separator sheet 11 FIG. (4) or separator sheet 43 FIG. (15), is a porous film which may be either hydrophobic or hydrophilic in nature; and which has the ability to flow at least 7*10E-6 ml/min-sq-cm-mm Hg. The auxiliary arteries conduct life-sustaining gas into the auxiliary capillaries 10. These gases then pass across the separator sheet 11 or 43 into media capillaries 13 to be carried eventually to the cells in module 20. Waste gases carried by the medium 27 from module 20 are carried eventually to module 19 where they pass across sheet 11 or 43, into the auxiliary capillaries 10 and thence are removed from the system via auxiliary veins of the gas module 19.
The gas mixture circulated by the gas transport module may be air, or an artificial mixture of various elemental and compound gases.
The term "cell culture" encompasses both conditions for cell conservation and metabolic production and conditions providing for cell growth.
Cell Growth Module
In the cell culture module 20, the separator sheet 11 FIG. 4 or separator sheet 43 FIG. 15 is a porous film which is hydrophilic in nature; but which has a known and selected porosity. The porosity is such as to restrict the flow of substances of known molecular weights and/or charge, whose passage across the separator sheet 11 or sheet 43 from the media capillaries into the auxiliary capillaries is not desired. For example, a membrane having a 10,000 dalton nominal cutoff may be used to restrict the entrance of serum components including proteins having nominal molecular weights more than 10,000 daltons into the cell growth spaces, defined by the auxiliary capillaries. Likewise products which have a molecular weight greater than 10,000 daltons produced by the cells and secreted into the extra-cellular medium are restricted from entering the nutrient medium flow path. Membranes having higher or lower molecular weight cutoffs (range 1000→1×10E7) can be used to restrict the transfer of desired molecular weight materials from adjacent chambers. Similarly different charge densities may be applied to the membranes to restrict the transfer of charged materials across adjacent membranes. Thus standard culture media containing unnecessary components may be utilized without mingling these components with the desired product.
By providing a separator sheet having a desired molecular permselectivity, passage of chemical species across the sheet is controlled.
The auxiliary artery conducts new cells suspended in extra-cellular fluid, into the auxiliary capillaries of module 20, the cell growth or culture spaces, where they may adhere to the walls of the capillaries or may remain in suspension or attached to microcarriers.
These cells are nourished by nutrients passing across sheet 11 or sheet 43 from the the nutrient media capillaries. Product is removed through the auxiliary veins and does not mix with nutrient media 27. Once the cells are aseptically introduced into the cell culture assembly, other undesired cells cannot enter the cell culture spaces across the membrane from the nutrient medium spaces. Consequently, contamination of the cell culture spaces is prevented. (Of course, since the nutrient medium is continuously circulated within a closed system, it is unlikely that the medium would be contaminated in the first place.)
Cell-Product Separation Module
In the cell-separation module 21 the separator sheet 11 FIG. (4) or separator sheet 43 FIG. (15) is a porous membrane which is hydrophilic in nature, and has the ability to retain particles of a known size. For example, a membrane having a pore size of 5 microns could be used to restrict cells having a mean size of greater than 5 microns to the cell growth module. This pore size would permit transfer of the cell products across the membrane into a collection means, which may be a holding vessel or additional processing apparatus. The conduit 16 of module 21 distributes fluid received from inlet 3 (sometimes referred to as media inlet 3) to the capillary channels 13 (sometimes referred to as media capillaries). The fluid 32 then moves along separator sheet 11 or 43, which retains particles greater than the rated size. Part of this fluid 32 passes through the membrane and is collected in the auxiliary channels 10 and collected in the auxiliary conduits 7 and 8 thence passed to collection means 31 from auxiliary connections 1 and 2.
The Cell Culture System
Referring to FIG. 8 there is shown an incubator 22 containing heat transfer fluid 23, maintained at a suitable temperature. The heat transfer fluid in conduit 23 is pumped to inlet 1 of the temperature control module 18 by pump 25 and returned to the incubator through sensor blocks 33, 34 from outlet 2. Controlled gases from reservoir 29 are introduced to auxiliary inlet 1 of module 19 by pressure and exit through sensor 30, 34 from outlet 2 module 19. Located in the incubator 22 is a media reservoir 26 containing medium 27. Medium 27 is pumped using a diaphraghm pump 24 to inlet 3 of the temperature control module 18 then from outlet 4 of module 18 to inlet 3 of the gas exchange module 19. Collected at outlet 4 of module 19; and fed to inlet 3 thought 30, 34 of the cell growth module 20, and finally it is collected at outlet 4 of module 20 and returned to reservoir 26, through sensor block 30, 34. The cells are introduced to inlet 1 of the cell growth module 20. The extracellular fluid which includes both product and loose cells, is pumped to inlet 3 of the cell/product separation module 21, by pump 28 from outlet 2 module 20. The loose cells and product are separated by separator (11 or 43) and the product is conducted from inlet 1 and outlet 2 of module 21 to collection means 31. The remaining extracellular fluid is returned to inlet 1 module 20 from outlet 4, module 21. Alternatively the cells themselves may be removed through a valve 36 after outlet 4 of module 21. This allows the harvest of cells to be ruptured to release product(s) not normally secreted by the cells.
Despite the use of the term "continuous process", it should be understood that, on occasion the culture medium and other fluids may be replaced.
Preferably, an automatic control subsystem is provided. A microprocessor 37 of FIG. 10 is connected to sensor blocks 30 and 34 via an A/D, D/A converter 38 so as to monitor the pressures, gases, Ph, temperature, and dissolved gas content and to pumps 24, 25 and 28 such that it will monitor, alarm, and react if any of the state variables enter an unacceptable range. This is especially important for preserving the safe atmosphere for the personnel using the equipment. Alarm means are connected to the microprocessor and triggered when an unacceptable state is reached. By control means connected to said pumps, it causes corrective measures to be taken. This automated system enhances the safety of the closed system by virtue of the controls, alarms and ability to shut down the system on detection of failure. This feature thus provides an additional safety factor for the personnel in the production environment.
While in FIG. 7 only a single module of each type is shown in the cell culture system, it should be understood that additional modules of any type may be added to the system. In addition, it should be understood that the system may be simplified (though at a cost to its ability to function automatically for long periods of time) by omitting certain of the modules.
While a cell culture system preferably employs modules of the modular construction described herein, any of the individual modules may be used in a cell culture system which is not characterized by modularity.
While the particular system description of this invention has been shown and described, various modifications will be apparent to the user's skill in this area and the art of tissue culture and it is therefore not intended that this invention be limited to the disclosure herein contained, and that departures may be made therefrom within the scope and spirit of this invention. | A device is described which provides a totally enclosed and secure environment for the culture of cells and for the production of biologicals, pharmaceuticals, and other cell-derived products of commercial value. The device comprises several modules of differing functions: regulating the cellular growth environment, providing a suitable cell growth substrate or environment, or separating of desired product form interfering substances. Each module comprises a series of membranes separated by a solid support material which is channeled to provide a series of parallel capillaries for the flow of nutrients, environmental regulating fluids, or gas exchange. The structure and composition of the separating membranes limits the nature, rate, and size of the particular material exchanged across an individual membrane into or from an adjacent compartment. The capillaries are so dimensioned that the nutrients and gases are diffused over distances typical of human tissue. | 2 |
The present invention relates to a system for holding cutting tool teeth used on earth moving machines such as mechanical loaders, excavating machines, and mechanical shovels. Similar systems of teeth are often referred to as wear parts. In these systems the foremost parts such as teeth tips, and to a certain extent even the shovel front cutting edges are subjected to very extensive wear. It is therefore advantageous if these parts are relatively easily replaceable. With smaller cutting tools, normally the complete set of teeth is replaced, whilst in very large cutting tools the teeth are divided up into several parts which can be replaced individually.
The system of teeth according to the invention includes a tooth tip, an adapter, an inward folded distance piece welded to the shovel front, and a locking wedge which when placed locks the various parts relative to each other. The interconnection of the various parts is carried out by interacting complementary specially formed male and female parts.
The invention includes a specially formed locking wedge. The various parts are provided with locking grooves adapted to this type of locking wedge.
The invention as defined by the patent claims is described with reference to the enclosed figures of a preferred embodiment which show a complete system of teeth and all its parts.
DESCRIPTION OF THE FIGURES
FIG. 1 shows in angled projection a cutting edge for a mechanical loader shovel equipped with the system of teeth as described by the invention.
FIGS. 2-9 shows on a larger scale the parts in the system, where:
FIG. 2 shows a tooth tip.
FIG. 3 shows a normal tooth adapter.
FIG. 4 shows a shovel corner adapter.
FIG. 5 shows a normal distance piece.
FIG. 6 shows a corner distance piece.
FIG. 7 shows a locking wedge with locking device.
FIG. 8 shows a cutting edge protector.
FIG. 9 shows a tooth adapter, and
FIG. 10 shows in lateral cross-section an assembled system of teeth.
FIGS. 11 and 12 show a detailed cross-section along the length of the locking wedge with several variations of the locking grooves into which the locking wedges fit.
FIG. 13 shows an alternative embodiment of the locking groove which avoid transmission of locking forces on the wedge 7.
FIG. 14 shows the locking device engaging a respective locking wedge.
DESCRIPTION OF THE PREFERRED EMBODIMENT
According to the preferred embodiment of the invention the system of teeth normally includes a tooth tip (1), an adapter (2), an inward folded distance piece (4) welded to the shovel front (3), a cover (6) welded to the upper side (5) of the shovel front, and a locking wedge (7) with associated locking device (8). When a particular tooth is to be fit to a shovel, special corner distance pieces (9) which are folded inwards and welded to the corner of the shovel are used together with suited corner adapters (10). Between the various teeth can be fitted loose replaceable cutting edges (11). These are kept in place by suitable grooves (12) in the adjacent adapters (see FIG. 9).
The joints between tooth and adapter, and between adapter and the inward folded distance piece in the shovel front, include the same basic functions. Both tooth tip (1) and adapter (2) or (10), grip by means of a recess or female part (13) or (14), over a projection from the parts (2 or 10, alternatively 4 or 9), immediately behind, male part (15) or (16), and extend via a rear overhang (17), or (18), along the rearwardly located part, which can be either the adapter (2) or (10), or alternatively the inward folded distance piece (4) or (9) in the shovel front. The rear end of the overhang is provided with a rearward projecting male part (19) or (20). This male part functions together with a forward opening female part (21), or (22), located in the part behind it. The female part (22) can either be formed as an integral part of the distance piece or the corner fitted distance piece (9), or as a loose, welded cover (6) on the upper side (5) of the shovel front.
The jointly functioning male and female parts are meshed with each other when a part in front is pushed over a rear part. In order to lock the various parts relative to each other, a locking wedge is required which prevents a forward located part from being drawn out of a rear located part. This locking function is achieved in the system of teeth according to the invention, by a locking wedge which is pushed in between crosswise, and overhanging locking surfaces. The forward located part is provided with a forward facing locking surface (23), irrespective of whether it is a tooth (1), or an adapter (2) or (10), while the rear located part is provided with a rearward facing locking surface (24), irrespective of whether it is an adapter (2) or (10), or a distance piece (4) or (9). These locking surfaces can be formed as one edge of a right-angled groove in a tooth and the adapter overhangs (17) and (18) and the overhanging gripping parts of the distance pieces (4). Two such connected grooves form a tunnel for the rectangular cross-sectioned locking wedge. These grooves, as is shown in FIGS. 4 and 5, can be wholly, or partly, be a part of through-going openings (25) and (26), arranged in the distance pieces and adapters. This solution has therefore been chosen for the corner adapter (10) and the corner fitted distance piece (9). In the case of the latter, even the forward opening female part has been replaced by two lugs (27) and (28) which project to the side (lug (28) is hidden in the figure). These lugs are formed as a single unit with an upwards pointing ridge (29) intended to fit into and be welded to the side of the shovel. This ridge is provided with a lock opening (25). The corner adapter (10) has also two rearward projecting arms (30) and (31) so designed that when fitted they extend along both sides of the ridge (29). The outer ends of these arms each form a male part (32) which are designed to function with the lugs (27) and (28). In the arms (30) and (31) there are also the lock openings (26). The rear edge of the lock openings consequently replace the forward facing locking surface (23) which is normally located in the adapter.
In order to lock the various parts after they have been fitted a specially formed locking system is used. This locking system consists of a solid steel wedge (7) and a locking device (8). The locking device consists of an elastic compressible part (35) and a metal toothed catch (36). The wedge (7) is provided with grooves (37) which receive the teeth of the catch (36). A particular characteristic of the wedge is the fact that it has a rectangular cross-section and that it is bent in an arc along its length. Consequently the wedge has a convex broad side (33) and a concave broad side (34).
In order to use the wedge, the tunnel receiving the locking wedge and the associated locking surfaces, must be formed in such a way that at least the tunnel broad side which faces the same way as the concave side (34) of the wedge (7) has a profile which fits inside or is equal with the concave form of the wedge. In the same way, the relevant locking surfaces follow this form. In this connection reference should be made to FIGS. 11-13 which show a cross-section along the length of a locking wedge at A--A, alternatively B--B, with the adapters in place and equipped with a tooth tip.
The figures show that the form of the overhang must fit within the arc r which is equivalent to the radius of the concave broad side (34) of the locking wedge. Further, the distance d from the lowest point (39) of the locking wedge broad side, to the highest point (40) of the neighbouring parts broad side in equivalent to the space required for the wedge (7).
FIG. 11 shows a variation where the broad side of the overhand (39) describes an arc having a radius which is equal to the locking wedge broad side while the broad side of the opposing part is completely flat and only touches the longest point of the locking wedge. The locking surfaces provided in the locking wedge are raised so that they provide the side of the locking wedge with complete support. The foremost locking groove in the adapter, which is shown in the figures, is of this type.
FIG. 12 shows a variation where the opposing broad side (41) of the neighbouring part follows the convex broad side (33) of the locking wedge (7). This variation is illustrated in those figures which show the distance piece (4). This form can be specially suitable when the groove with locking surfaces (24) must begin and end with a level surface, as is the case with the distance piece (4).
FIG. 13 shows a variation where the overhang broad side facing the wedge is obviously not perfectly convex, but where its form (42) is within a convex profile whose radius is suited to the concave surface (34) of the locking wedge. With this design, the risk that a limited surface wear on the bearing surfaces of the jointly functioning male and female parts would transfer the bearing points for the reacting forces from the male and female surfaces to the wedge (7) is avoided. The wedge shall have a purely locking function and shall not transmitt the reacting forces between the parts.
One of the great advantages with the above described design is that the arc-shaped locking wedge is much easier to fit than flat wedges, especially when the relevant teeth are relatively close together. The risk that the locking wedge shall work itself out of its locked position is also practically eliminated. Even well locked, flat wedges can under certain circumstances work themselves loose from a theoretically well locked position. The bellied wedge is easily fitted in position by means of a few blows from a heavy hammer or similar.
Consequently the latter is entered at a downward angle to the front of the shovel, and not parallel with and immediately connected to the same, as is necessary in the case of horizontally fitted flat wedges.
The same advantage applies when the locking wedge in the equivalent way is disassembled with the aid of an arc formed drift.
The locking wedge (7) is further held in place by the locking device (8) (see FIG. 14). The locking device is fitted into a fishtail shaped groove connected to the rearward facing locking surface in the adapter, or alternatively the distance piece. When the locking wedge has been forced into position, its elastic part (35) is compressed, and under a certain amount of tension the teeth of the locking part (36) are forced into the toothed grooves (37) of the locking wedge (7). In order that the wedge (7) will have the best possible landing surface against the locking surface (23) of the overhang, it can be provided with a centrally located recess (43). A certain amount of play is necessary to get the wedge in position. Due to the tension in the elastic part (35), the play present in the assembled parts will be distributed between the locking surface (24) and the wedge (7). If the assembled parts are subjected to tensile forces, this play is eliminated and the solid locking wedge (7) is pressed between the locking surfaces (23) and (24).
The figures also illustrate a cutting edge protector (11) which is provided with two lugs (44) and (45) intended to lock in the locking groove (12), which is provided in the adapters between which the cutting edge protector is fitted. Consequently the said cutting edge protector is fitted at the same time as the adapters located on its both sides. | This invention relates to a wear-parts system of teeth for earth-moving machine shovels, mounted at the front of the shovel and comprising several loosely interconnected parts such as tooth points (1), adapters or holders (2, 9), cutting edge protectors (11) etc. The interconnection of these parts is carried out by means of interacting male and female formed parts (15, 16, 19, 20 and 13, 14, 21, 22). The parts are locked in the assembled position by means of specially formed locking wedges (7) fitted at right angles to the assembly direction. Openings are provided in the various parts for the locking devices. | 4 |
BACKGROUND OF THE INVENTION
This invention relates generally to a mower mounted to the three-point hitch of a tractor and carrying a disc cutterbar that severs standing crop material by impact action and, more particularly, to a sealing apparatus for the pivot assembly about which the disc cutterbar pivots to move between the raised transport position and the lowered operative position.
Disc cutterbars have been utilized in agricultural harvesting implements for many years. Each disc cutterbar includes a plurality of transversely spaced disc cutters driven for rotation about a generally vertical axis. Each disc cutter has two or three knives pivotally mounted on the periphery thereof to sever standing crop from the ground through an impact action. For background information on the structure and operation of disc cutterbars, reference is made to U.S. Pat. No. 4,815,262, issued to E. E. Koch and F. F. Voler, the descriptive portions thereof being incorporated herein by reference.
The construction of disc cutterbars has evolved over the years to the configuration of having a modular construction with cutter modules and spacer modules, such as shown in U.S. Pat. No. 4,840,019, issued to L. J. Pingry, the descriptive portions of which are incorporated herein by reference. In some instances, the cutter modules and the spacer modules were integrally formed into one unit such as shown and described in U.S. Pat. No. 4,947,629, issued to R. Ermacora and H. Neuerburg.
A disc mower is typically mounted to the three-point hitch of the tractor providing the source of operative power thereto. The driven components of the disc cutterbar are operatively connected through a conventional drive mechanism to the power-takeoff shaft of the tractor or, possibly to a hydraulic drive mechanism powered from the tractor. The disc mower is provided with a base frame that may be supported from the tractor three-point hitch. The disc cutterbar is pivotally supported from the base frame to be movable between a raised transport position, in which the cutterbar may be generally vertically oriented, and a lowered operative position in which the cutterbar is riding on the ground to sever standing crop material through operation of the rotating disc members and affixed cutting knives.
The mower structure carries a pivot mechanism defining a longitudinally extending pivot axis to enable the cutterbar to move between a generally vertical, raised transport position and a generally horizontal, lowered operative position adjacent the ground so that the cutterbar can be operated substantially parallel thereto. The operation of the cutterbar close to the ground typically result in the rotating knives occasionally impacting the surface of the ground to throw soil around the mower structure, including the pivot mechanism. With time, the accumulation of dirt enters the bushing working surfaces causing extraordinary wear due to the abrasive nature of the soil and resulting in a premature failure of the bushings and the pivot mechanism. Worn bushings allow excessive fore-and-aft movement of the cutterbar, resulting in misalignment of the drive mechanism.
SUMMARY OF THE INVENTION
It is an object of this invention to provide a sealing apparatus for a disc mower pivot mechanism to overcome the aforementioned disadvantages of the prior art.
It is another object of this invention to provide a seal for the thrust washer working surfaces that conforms to the configuration of a groove between the pivot support arm and the gearbox housing.
It is a feature of this invention that the seal is formed with a T-shaped cross-section to conform to the groove between the pivot support arm and the gearbox housing.
It is an advantage of this invention that dirt is prevented from working into the groove between the pivot support arm and the gearbox housing to reach the thrust washer working surfaces.
It is another feature of this invention that the seal is formed in a circular shape to fit around the pivot mechanism.
It is another advantage of this invention that the pivot mechanism has an extended operative life.
It is still another object of this invention to provide a sleeve bushing seal to prevent dirt from entering the radial bearing surface between the bevel gearbox front and rear hubs and the front and rear pivot support arms.
It is still another feature of this invention that the sleeve bushing seal is formed with a deformed inner diameter to make contact with the face of the gearbox hubs.
It is still another advantage of this invention that the deformed inner diameter lip creates an inner cavity underneath the seal.
It is yet another feature of this invention that the inner cavity can be filled with grease to further form a barrier to the entrance of dirt into the bushing.
It is yet another object of this invention to provide grease fittings to permit a replenishment of the supply of grease to the sealing mechanism.
It is a further object of this invention to provide a sealing mechanism for the pivot assembly of a disc mower which is durable in construction, inexpensive of manufacture, carefree of maintenance, facile in assemblage, and simple and effective in use.
These and other objects, features and advantages are accomplished according to the instant invention by providing a sealing apparatus for a pivot assembly on a disc mower incorporating a disc cutterbar to sever standing crop material by impact action. A first circular labyrinth seal has a T-shaped cross-section and fills a correspondingly-shaped groove between the pivot support arm and the gearbox housing. The combination of the T-shaped groove and corresponding labyrinth seal creates a labyrinth path for the entrance of dirt into the pivot assembly. A second circular face seal is constructed with a deformed inner diameter to create a lip that engages the face of the gearbox hubs. The deformed inner diameter lip of the face seal creates an inner cavity underneath the seal that can be filled with grease to provide a further deterrent to the entry of dirt into the pivot mechanism.
BRIEF DESCRIPTION OF THE DRAWINGS
The advantages of this invention will be apparent upon consideration of the following detailed disclosure of the invention, especially when taken in conjunction with the accompanying drawings wherein:
FIG. 1 is a top plan view of a disc mower incorporating the principles of the instant invention, the mower is mounted to the three-point hitch of a representative tractor, the mower canopy being broken away for purposes of clarity;
FIG. 2 is an enlarged partial top plan view of the mower shown in FIG. 1 to depict the drive mechanism;
FIG. 3 is a partial elevational view of the disc mower as seen in FIG. 2, the support position of the jack stand being shown in phantom;
FIG. 4 is a left end view of the disc mower as shown in FIG. 3, the shielding surrounding the V-belt drive apparatus being shown in phantom;
FIG. 5 is a partial cross-sectional view of the disc mower corresponding to lines 5--5 of FIG. 3 to depict a top plan view of the spring tensioning mechanism for the V-belt drive apparatus;
FIG. 6 is a rear elevational view of the spring tensioning mechanism shown in FIG. 5;
FIG. 7 is an exploded view of the spring tensioning mechanism;
FIG. 8 is a top plan view of the disc mower similar to that of FIG. 1 but with the front part of the mower canopy folded back to permit access to the disc cutterbar;
FIG. 9 is an enlarged rear elevational view of the disc mower corresponding to lines 9--9 of FIG. 1 to depict the disc cutterbar and canopy;
FIG. 10 is an enlarged top plan view of the distal end of the mower to depict the mounting of the cutterbar guard on the canopy support;
FIG. 11 is an enlarged top plan view of one half of the cutterbar guard;
FIG. 12 is an elevational view of the cutterbar guard shown in FIG. 11;
FIG. 13 is a rear elevational view of the disc mower shown in FIG. 1 with the disc cutterbar raised to the maximum upward flotational movement;
FIG. 14 is a rear elevational view similar to that of FIG. 13, but with the disc cutterbar lowered to the ground, which is the maximum downward flotational movement of the cutterbar;
FIG. 15 is a rear elevational view of the disc mower shown in FIG. 14, the rotational movement of the mounting frame encountered by a failure to release the flotation spring force being shown in phantom;
FIG. 16 is an enlarged partial top plan view of the mounting frame area of the disc mower to better show the anchor point for the flotation spring;
FIG. 17 is a top plan view similar to that of FIG. 16, but with the flotation spring released by the removal of the mounting pin to depict the subsequent mounting of the support jack in order to dis-mount the disc mower from the tractor three-point hitch;
FIG. 18 is a partial cross-sectional view of the pivot mechanism taken along lines 18--18 of FIG. 4;
FIG. 19 is a detail plan view of the labyrinth seal corresponding to the pivot axis of the pivot mechanism;
FIG. 20 is a radial elevation of the labyrinth seal shown in FIG. 19;
FIG. 21 is an enlarged partial cross-sectional view of the labyrinth seal taken along lines 21--21 of FIG. 19;
FIG. 22 is a detail plan view of the face seal corresponding to the pivot axis of the pivot mechanism; and
FIG. 23 is a cross-sectional view of the face seal taken along lines 23--23 of FIG. 22.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings and, particularly, to FIGS. 1 and 2, the disc mower 10 utilizing a modular disc cutterbar and incorporating the principles of the instant invention can best be seen. Left and right references are used as a matter of convenience and are determined by standing at the rear of the machine facing forwardly into the normal direction of travel.
The disc mower 10 is mounted in a conventional manner to the three-point hitch 3 of a tractor T to be operable outboard to the right of the tractor T. The mower 10 includes a triangular mounting frame member 12 adapted to connect to the three-point hitch mechanism 3 and an integral base frame 13 to support the cutterbar 19 and the drive mechanism 20. The mower also includes a support frame 15 pivotally connected to the base frame 13, as will be described in greater detail below, for supporting the disc cutterbar 19 for pivotal movement between a raised transport position and a lowered, ground-engaging, operative position. The support frame 15 also supports a protective canopy 45 encircling the disc cutterbar 19.
The V-belt drive mechanism 20 is operably powered from a power-takeoff (PTO) shaft 17 transferring rotational power from the tractor T in a conventional manner. A drive pulley 21 is supported in a cantilevered fashion from a main bearing 22 and is powered directly from the PTO shaft 17. A driven pulley 24 transfers rotational power into a gearbox 26, which in turn provides operative driving power for the disc cutterbar 19, as is described in co-pending U.S. patent application Ser. No. 08/673,604, entitled "Disc Cutterbar for Agricultural Implements" and filed concurrently herewith, the descriptive portions of which are incorporated herein by reference. An endless V-belt 25 entrains the drive pulley 21 and the driven pulley 24 to transfer rotational power therebetween.
The V-belt 25 must be properly tensioned to maximize life of the belt 25 and the associated supporting structure, such as the bearing 22 and gearbox 26. To provide proper tension, a spring tensioning mechanism 30 is operably connected to the drive pulley 21 to vary the distance relative to the driven pulley 24. The tensioning mechanism 30 includes a pivot member 31 pivotally connected to the base frame 13 for support of the drive pulley 21 at one end thereof. The opposing end of the pivot member 31 is connected to a tensioning rod 33 to effect pivotal movement of the pivot member 31 and a corresponding movement of the drive pulley 21.
The tensioning rod 33 is spring-loaded by a spring 35, properly positioned on the tensioning rod 33 by a spacer 32, to urge the drive pulley 21 away from the driven pulley 24 and, thereby, apply tension in the V-belt 25. The spring 35 pushes against a support bracket 36 affixed to the base frame 13. An adjustment nut 34 threaded onto the tensioning rod 33 is effective to compress the spring 35 against the support bracket 36 and, thereby, draw the tensioning rod 33 to apply greater tension to the belt 25. An L-shaped bracket 39 is affixed to the support bracket 36 and extends along the spring 35 to terminate at a location corresponding to the correct spring length for applying the proper tension on the belt 35.
In operation, the tension is varied in the V-belt 25 by manipulating the adjustment nut 34 on the tensioning rod 33 and, thereby, effect a pivotal movement of the pivot member 31. The operator can determine the proper tension to be applied to the belt 25 by compressing the spring 35 until the length of the spring 35 equals the length of the indicator bracket 39 positioned adjacent the spring 35. The spring 35 is designed to maintain the adequate tension in the V-belt 25 during the initial stretch of the V-belt 25 so that the operator will not be inconvenienced by having to tighten the V-belt 25 during the initial use period. Tension can be adjusted at normal service intervals.
Referring now to FIGS. 1 and 8-12, the details of the cutterbar guard 40 can best be seen. The guard 40 is mounted on the distal end of the canopy support 46, 47 from which the canopy 45 is hung to prevent objects from coming laterally into the remote end of the disc cutterbar 19. This guard 40 consists of a pair of sheet metal stampings 41, 43. One of the stampings 41 is bolted to the outboard end of the front canopy support 46, which is mounted to swing rearwardly to expose the cutterbar 19 for access thereto, while the other identical stamping 43 is bolted to the outboard end of the rear stationary rear canopy support 47.
The two guard pieces 41, 43 are formed with an "L-shape" and are installed such that the legs 42 of the L-shape overlap at the middle of the support frame 15 to form a continuous guard 40. The continuous configuration does not present a gap to catch viney crops, saplings, fence wire, etc. that can result in a deformation of or damage to the canopy support.
As best seen in FIGS. 8 and 10, the leg 42 of the front guard stamping 41 is positioned below the leg 42 of the rear guard stamping 43 so that when the front canopy support 46 is raised, the leg 42 of the front guard 41 pivots down and toward the front of the rear guard member 43. The front guard member 41 extends toward the front of the front canopy support 46 and beyond the front edge thereof where the canopy 45 is beveled inwardly. The leading edge 44 of the guard members 41, 43 act as a guide to deflect tall crops, saplings and fence wire, etc. away from the canopy support 46, 47 and the canopy 45 so that the canopy 45 and canopy support 46, 47 are not subjected to wear from the contact therewith. The front of the guard 40 is secured directly to the canopy support 46, 47 by fasteners 49 so that no gaps exist that could catch vines, etc. and pull the canopy 45 and support frame 15 rearwardly, with possible failure thereof.
As an alternative, the guards 41, 43 could be constructed from a pliable material which will allow some deformation upon impact by a substantial object, such as a sapling, and a subsequent return to its normal shape after engagement with the object has been eliminated.
Referring now to FIGS. 1-4 and 13-17, the details of the flotation mechanism can best bee seen. The flotation mechanism 50 suspends the support frame 15 from the base frame 13 and assists the pivotal movement thereof relative to the base frame 13. In the event the cutterbar 19 strikes an object on the ground G or follows ground undulations, the cutterbar 19 can move upwardly through a range of flotational movement, as shown in a comparison between the positions of FIGS. 13 and 14. The flotation mechanism 50 includes a flotation spring 55 interconnecting the gearbox 26, or some other remote part of the support frame 15, and the base frame 13. Preferably, the spring 55 is coupled to a rod 56 that passes through a collar 52 affixed to the base frame 13.
An engagement pin 59 is engageable through a hole in the rod 56 to restrain the movement of the rod 56 through the collar 52 toward the cutterbar 19, although the rod 56 is free to pass through the collar 52 in the opposite direction. When engaged with the rod 56, the pin 59 forces an extension of the spring 55 to floatingly support the cutterbar 19 relative to the ground G. The cutterbar 19 is pivotally movable through operation of the hydraulic lift cylinder 16 interconnecting the base frame 13 and the support frame 15 to raise the cutterbar 19 into a substantially vertical orientation (not shown) for transport by pivoting the cutterbar 19 primarily about the axis corresponding to the shaft of the driven pulley 24 and partly about the pivotal connection between the base frame 13 and the support frame 15.
The disc mower 10 is stored with the cutterbar 19 lying against the ground in the operative position, as shown in FIG. 15, with the base frame 13 support on a support jack 60. As depicted in FIG. 15, the weight of the cutterbar 19 is such that the disconnection of the mounting frame 12 from the tractor three-point hitch 3 will result in a sudden rotation of the mounting frame 12, as depicted in phantom in FIG. 15, due to the force exerted by the flotation spring 55. To prevent this sudden movement of the mounting frame 12, the flotation spring 55 must be released prior to the disconnection of the mounting frame 12 from the three-point hitch 3.
To assure that the flotation spring 55 is released prior to disconnecting the mounting frame 12, the jack 60 is tethered to the engagement pin 59 by a cable 62 that is too short to allow the jack 60 to be connected to the base frame 13 in the operative position unless the engagement pin 59 is first removed from the rod 56. Once the pin 59 is removed, the jack 60 can be dismounted from the transport position on the mounting frame 12 and mounted on the mounting bracket 65 on the base frame 13 in the operative position to support the mower 10 above the ground G. The engagement pin 59 then serves its double duty by securing the jack 60 to the base frame 13. Since the engagement pin 59 has been removed from the rod 56, the rod 56 is free to slide through the collar 52 in either direction without engaging the force of the flotation spring 55.
To dismount the mower 10 from the tractor T, the operator must first raise the cutterbar 19 toward the vertical transport position to release the pressure on the flotation spring 55 and, thereby, preferably move the rod 56 upwardly through the collar 52, whereupon the pin 59 can be easily removed. Preferably, the rod 56 is provided with a detent mechanism (not shown) that will keep the pin 59 properly located in the rod 56 unless sufficient force is exerted to overcome the detent force. The detent mechanism will keep the pin 59 engaged with the rod 56 even when the cutterbar is raised to the substantially vertical transport position. The pin 59 is then removed from the rod 56 to release the flotation mechanism 50. The support jack 60 is then removed from its storage location on the mounting frame 12 and installed on the mounting bracket 65 on the base frame 13. The pin 59 is then installed to fasten the jack 60 to the mounting bracket 65.
Since the flotation spring force is released, the cutterbar 19 is then lowered to the ground G with no flotation support from the spring 55, the rod 56 sliding through the collar 52. The mower 10 is then resting on the jack 60 and the lowered cutterbar 19. The mounting frame 12 can then be released from the three-point hitch 3 and the mower 10 removed from the tractor T. Re-mounting the mower 10 to the tractor T is accomplished by reversing the above procedure.
The sealing apparatus 70 for the pivot mechanism 28 pivotally supporting the disc cutterbar 19 from the support frame 15 is best seen in FIGS. 18-23. The pivot mechanism 28 includes a thrust washer 29 providing a bearing surface between the gearbox housing 27 on the pivot support arms 15a forming part of the support frame 15. The thrust washer 29 withstands the fore-and-aft loads imposed on the cutterbar 19. Beyond the thrust washer 29 is a bushing 29a, or alternatively a bearing, that provides rotatable support for the gearbox hub 27a on the pivot support arm 15a.
A groove 71 is formed between the pivot support arm 15a, the gearbox housing 27 and the thrust washer 29 to provide clearance for the relative movement to be accommodated therebetween. To enhance the operation and effectiveness of the sealing apparatus 70, the groove 71 is formed in a T-shaped configuration. The sealing apparatus 70 includes a circular labyrinth seal 72 formed to correspond to the T-shaped groove 71. The labyrinth seal 72, as best seen in FIG. 21, is formed with a T-shaped cross-section with opposing, axially extending legs 73 projecting perpendicularly from the body 74 of the labyrinth seal 72 to fit within the groove 71 and retain the seal 72 radially within the groove 71, as well as form a labyrinth through which dirt must pass in order to reach the bushing 29. Preferably, the thrust washer 29 is bonded to the labyrinth seal 72.
The exterior face of the pivot mechanism 28 must also be sealed to prevent dirt from reaching the bushing 29a, the edge of which is exposed. As shown in FIGS. 22 and 23, the sealing apparatus 70 further includes a circular face seal 75 detachably fastened to the pivot support arm 15a. As best seen in FIG. 23, the face seal 75 has an inner diameter that is permanently deformed inwardly to form a lip 77 that engages the gearbox hub 27a. The deformed lip 77 creates an inner cavity 79 underneath the face seal 75. The cavity 79 can be filled with grease to provide a further deterrent to the entrance of dirt to the bushing 29a.
Appropriate grease fittings (not shown) can be provided to enable the supply of grease within the inner cavity 79 to be replenished without requiring the removal of the face seal 75. Preferably, the lip 77 will be somewhat pliable to accommodate the tolerances between the gearbox hub 27a and the pivot support arm 15a and to facilitate the sealing therebetween. One skilled in the art will recognize that the exterior face of the pivot mechanism 28 is duplicated front and back so as to provide proper pivotal support between the gearbox housing 27 and the pivot support arms 15a.
It will be understood that changes in the details, materials, steps and arrangements of parts which have been described and illustrated to explain the nature of the invention will occur to and may be made by those skilled in the art upon a reading of this disclosure within the principles and scope of the invention. The foregoing description illustrates the preferred embodiment of the invention; however, concepts, as based upon the description, may be employed in other embodiments without departing from the scope of the invention. Accordingly, the following claims are intended to protect the invention broadly as well as in the specific form shown. | A sealing apparatus is provided for a pivot assembly on a disc mower incorporating a disc cutterbar to sever standing crop material by impact action. A first circular labyrinth seal has a T-shaped cross-section and fills a correspondingly-shaped groove between the pivot support arm and the gearbox housing. The combination of the T-shaped groove and corresponding labyrinth seal creates a labyrinth path for the entrance of dirt into the pivot assembly. A second circular face seal is constructed with a deformed inner diameter to create a lip that engages the face of the gearbox hubs. The deformed inner diameter lip of the face seal creates an inner cavity underneath the seal that can be filled with grease to provide a further deterrent to the entry of dirt into the pivot mechanism. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to connection pin assemblies for attaching replaceable implements to earthworking buckets of excavating equipment and the like. The invention also relates to a method of attachment, and to earthworking buckets with replaceable implements attached by means of the connection pin assemblies.
2. State of the Art
Earth working bucket used for heavy earthworks applications such as mining are fitted with teeth for engaging the ground surface. Due to the highly abrasive nature of the materials encountered by the teeth, they wear more quickly than the bucket. For this reason, they are detachably connected to the bucket to allow replacement.
On smaller buckets, the teeth are generally attached directly to an adapt or on the bucket by means of a connection pin. On larger buckets, intermediate adaptors are attached to the bucket nose and the teeth are attached to respective of the intermediate adaptors. Both connections are by means of connection pins, so that the teeth and intermediate adaptors can be replaced as required.
Connection pin assemblies of the type generally employed, and with which this invention is concerned, are known in the art as spool and wedge assemblies.
Prior art spool and sedge assemblies include a spool, often C-shaped with tapered engagement surfaces, which can be inserted into aligned apertures in the parts to be connected. A wedge is then inserted to contact the rear surface of the C and is driven home by sledgehammer to cause lateral expansion of the spool and wedge until it bears firmly against appropriate parts of the inner wills of the apertures to provide lateral loading and optionally a clamping action of the adaptor in the case of `Whisler` style attachments. Any part of the spool and wedge protruding above or below the aligned apertures is then cut off by oxy acetylene equipment.
The tightness of the connections must be regularly monitored, and when a tooth or intermediate adaptor works loose the spool and wedge must be tightened by hammering the wedge in further. This can be difficult as the protruding part of the wedge may already have been removed and thus the end of the wedge is not readily accessible. When the tooth or intermediate adaptor requires replacement, the spool and wedge often has to be cut out.
It will be appreciated that the fitting, monitoring, adjustment and removal of the prior art spool and wedge assemblies is time consuming and labour intensive, particularly as each bucket will have a number of teeth and an equal number of adaptors, each attached by respective spool and wedge assemblies.
Patent Application No. PCT/AU94/00035 describes a spool and wedge assembly in which a pair of spools are forced apart by a pair of wedges which are drawn together by a bolt. While that disclosure is in some respects an improvement over the prior art, there is much scope for improvement. For example, the arrangement is relatively complicated, still requires regular monitoring and adjustment and, in practice, may need to be cut out for removal.
SUMMARY OF THE INVENTION
The present invention aims to provide alternative spool and wedge assemblies.
In a first form, the invention provides a spool and wedge assembly for attaching a replaceable implement to the nose of an earthworking bucket, the spool and wedge assembly including;
at least one spool having a first surface, at
least one wedge having a second surface, the first and second surfaces co-operating to form a ramp arrangement which causes lateral expansion of the spool and wedge assembly upon relative axial movement in a first direction in which said surfaces are drawn towards each others,
bolting means for forcing said relative movement in said first direction, and
disengagement means adapted to act between said spool and/or wedge and the bolting means to cause relative movement of the spool and wedge in a second direction opposite the first direction.
Preferably, the disengagement means engages with the spool or wedge and, desirably, includes screw means bearing against the bolting means to force relative movement of the spool or wedge and the bolting means.
In a further form, the invention provides a spool and wedge assembly for attaching a replaceable implement to the nose of an earthworking bucket, the spool and wedge assembly including:
at least one spool having a first surface,
at least one wedge having a second surface, the first and second surfaces co-operating to form a ramp arrangement which causes lateral expansion of the spool and wedge assembly upon relative axial movement in a first direction in which said surfaces are drawn towards each other,
bolting means for causing said relative movement in said first direction, and
resilient means which deforms under load from said bolting means, so that when the bolting means is actuated to cause said lateral expansion the resilient means applies a resilient force urging the relative movement of the spool and wedge in said first direction.
Preferably, the resilient means comprises a resilient washer means, such as a spring washer arrangement or similar device, acting between the bolting means and the wedge.
As used herein, the expression "nose of an earthworking bucket" is to be understood as also including any intermediate adaptor fitted on the nose.
In a further form, the assembly is adapted to be inserted within aligned apertures in the replaceable implement and the bucket nose and contains a spool and a wedge with co-operating ramp surfaces as hereinbefore described, the bolting means forcing said relative movement rich that the lateral expansion causes the wedge to push forwardly against the nose and spool to push rearwardly against the implement.
Preferably, the bolting means includes a bolt with its bolt head captured by a slot in the spool, the bolt extending gene ally axially to enter an axial passage through the wedge.
Further preferred embodiments of the invention will now be described with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a preferred spool and wedge assembly;
FIG. 2 is an exploded side elevation of the spool and wedge assembly of FIG. 1;
FIG. 3 is the same view as FIG. 2, after the wedge has been connected to the spool;
FIG. 4A is a cross-sectional elevation of an intermediate adaptor positioned on a bucket nose;
FIG. 4B shows the arrangement of FIG. 4A, with the spool and wedge inserted and tightened;
FIG. 5 is a side elevation of the spool and wedge assembly, in which the nut and washer are removed and replaced by a disengagement device;
FIG. 6 is an exploded perspective view of FIG. 5;
FIG. 7 is a side elevation showing a modified disengagement device; and
FIG. 8 is an exploded view of the arrangement of FIG. 7, showing also the modified nut for use with that embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to FIGS. 1-3, the spool and wedge assembly consists generally of a spool 10, a wedge 12, and a bolt 14 and nut 16 arrangement.
The spool 10 is elongated in the axial direction and is shaped to allow insertion in aligned apertures in the intermediate adaptor and the nose of a ground engaging implement, so as to engage with the back portion of the intermediate adaptor without engaging the back of the nose aperture. The illustrated spool has on one side thereof a pair of projections 18a, 18b separated by a recessed portion 20, so that that side of the spool 10 is approximately C-shaped.
The other side of the spool has ramp surfaces 22a, 22b and a block 24 for retaining the head of the bolt 14. The block 24 has an open slot 26 shaped to receive the head 28 of the bolt 14 which connects the wedge 12 to the spool 10.
The slot opens to the side of the spool opposite the projection 18a. The slot has a broader portion 32 for receiving the bolt bead and preventing its rotation, and a more narrow portion between shoulders 36 of the block to receive the part of the bolt shaft 38 adjacent the head. As can be seen from FIGS. 2 and 3, the bolt head is inserted into the slot so that the head is captured behind the shoulders 36. There is sufficient clearance behind the bolt head to allow the angular or lateral movement of the bolt to accommodate lateral expansion of the assembly as it is tightened.
The wedge 12 has ramp surfaces 40a, 40b complementary to the ramp surfaces 22a and 22b of the spool. The wedge also has an axial through-hole 42 through which the shaft of the bolt passes. The distal end of the bolt shaft has a threaded portion for attachment of the nut 16. A belleville spring washer 46 separates the nut 16 and the end of the wedge.
As the nut 16 is threaded onto the bolt shaft, the wedge is moved axially relative to the spool and the ramp surfaces 40a,40b of the wedge slide along those of the spool. This causes the spool and wedge assembly to expand laterally until it tightens against the inner walls of the apertures in which it has been inserted. Further tightening of the nut causes resilient compression of the spring washer 46.
By undergoing resilient compression, the spring washer provides self tightening of the spool and wedge assembly. If, in use, the nose to intermediate adaptor assembly works slightly loose, the spring washer will decompress, forcing the wedge further towards the bolt heed and therefore causing further lateral expansion o the assembly until the spool and wedge is again tight against the inner walls of the aligned apertures.
FIG. 4A illustrates the positioning of an excavator intermediate adaptor 48 on the nose 50.
The bucket nose has a tapering front portion 52 which is received in a corresponding tapered cavity 54 of the intermediate adaptor. When positioned properly on the bucket nose, an aperture 56 of the intermediate adaptor aligns with an aperture 58 of the bucket nose to allow insertion of the spool and wedge assembly shown in FIGS. 1-3.
FIG. 4B shows the spool and wedge assembly inserted in the aligned apertures. The spool is dimensioned to pass between the rear 60 and front 62 walls of the aperture in the bucket nose and then be positioned so that the projection 18a, 18b, come into contact with the rear walls 64 of the aperture in the intermediate adaptor without contact between the recessed portion 20 and the rear wall 60 of the aperture.
The bolt is connected to the spool before insertion of the spool in the apertures, by capturing the bolt head in the block 24 of the spool as described above with reference to FIGS. 1-3. The wedge 12 and resilient device 46 are slid along the bolt shaft, and the nut is then threaded on to the bolt shaft to cause lateral expansion of the spool and wedge so that the wedge bears against the front wall 62 of the bucket nose 58 and the spool pushes against the rear walls 64 of the aperture in the intermediate adaptor 48. This forces the intermediate adaptor rearwards relative to the nose, tightening the engagement of the tapered surfaces 52 and 54 and thereby securing the intermediate adaptor to the bucket nose.
In a modification to the arrangement shown in FIGS. 1-4B, the nut 16 may be elongated and/or capped to cover the end threads of the bolt shaft. This ensures that the end threads of the bolt remain clean so that the nut can be removed.
In further modifications, the nut may be replaced with a hydraulic nut which is initially threaded onto the bolt. Final tightening is then effected by pumping grease or other fluid into the nut to cause it to expand. Alternatively, the bolt can have a round head which allows it to rotate in the slot 26 and has a drive block at its distal end. The wedge is threaded directly onto the bolt, so that rotation of the bolt via the drive block will cause tightening and disengagement of the spool and wedge.
FIGS. 5 and 6 illustrate a first arrangement for disengaging the ramp surfaces of the spool and wedge so that the assembly can be removed. The hole 42 through the wedge is broadened at its distal end, and this portion 66 of greater diameter is provided with an internal thread. There is provided a disengagement device 68 formed generally as a short bolt with a hollowed-out shaft. The external thread of this device mates with the internal thread of hole 66 so that the device screws into the end of the wedge.
The distal end of the bolt shaft 38 is received with clearance in the axial bore 70 in the shaft until the end of the bolt contacts the end of the bore. Screwing the device 68 into the wedge pushes the bolt backwards until the bolt head 28 contacts the end of slot 26. Further screwing of device 68 then drives the spool and wedge in opposite directions, so that the spool and wedge assembly is released from its tight engagement in the aligned apertures of the adaptor and tooth and can be removed.
In the modification shown in FIG. 7 and 8, the bolt shaft 38 is shortened to end inside the wedge and the nut 16 (shown in FIG. 8) and the enlarged diameter portion 42a of the passage 42 through the wedge are lengthened correspondingly.
At the distal end of the wedge, the entrance of the hole 42 has L-shape keyways 72 along the inner surface of the passage to receive lugs 74 on an internally threaded member 76 of a removal device 78 which further comprises a bolt 80. In use, lugs 74 of the removal device are pushed into keyways 72 and twisted to form a bayonet connection, and bolt 80 is then screwed in to bear against the end of bolt shaft 38 within the wedge. Further tightening of bolt 80 drives disengagement of the spool and wedge. The removal device 78 may include an extra set of lugs 74a for use if set 74 become damaged.
While particular embodiments of this invention have been described, it sill be evident to those skilled in the art that the present invention may be embodied in other specific forms without departing from the essential characteristics thereof. The present embodiments and examples are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than the foregoing description, and all changes which come within the meaning find range of equivalency of the claims are therefore intended to be embraced therein. | A spool and wedge assembly for attaching a replaceable implement to the nose of an earthworking bucket has a spool 12 and wedge 10 with ramp surfaces 22, 40 causing lateral expansion of the unit upon relative axial movement, and bolting mechanism 14, 16 for drawing the spool and wedge together so that the wedge pushes forwardly against the bucket nose and the spool pushes forward against the implement. A disengagement tool 78 acts between the wedge and the bolt 14 to force disengagement of the ramp surfaces for removal. | 4 |
FIELD OF INVENTION
This invention concerns the making of new stretchable batts, and more particularly to a new process for making such new batts whereby the amount of stretch can be varied and controlled in the machine and cross directions, to the resulting batts, to the processing of such batts into articles of various kinds, and to the resulting articles themselves.
BACKGROUND
Fibrous batts (sometimes referred to as battings) have been made from synthetic staple fibers, particularly from polyester fiberfill, and have been disclosed, for example, in Moler, U.S. Pat. No. 3,007,227, Willis, U.S. Pat. No. 3,290,704, Tolliver, U.S. Pat. No. 3,772,137, Scott U.S. Pat. No. 4,129,675, Street, U.S. Pat. Nos 4,668,562 and 4,753,693, and Burnett WO 88/00258 and other art referred to herein. A preferred synthetic polymer for many purposes has been polyester homopolymer, i.e. poly(ethylene terephthalate), sometimes referred to as 2G-T, and various batts of such polymer fiber have been made and used for many years as filling materials. As indicated in some of the references, for many purposes it has been found desirable to make such batts from blends of filling fiber with lower melting binder fibers that soften at temperatures appropriate for making a bonded batt, preferably sheath/core binder fibers that have a higher melting core, such as 2G-T, surrounded by a sheath of binder material, so that, upon activation of the binder material, which has usually been achieved by heating to a temperature below the melting or softening point of the core and of the filling fiber, but above the binding temperature of the binder material, the latter bonds the filling fiber and provides tie points, connected by the remaining cores of the original binder fibers.
For some uses, especially in some apparel, it has been desired to provide batts with "stretchable" characteristics, by which is meant the ability to recover from extensions such as are encountered in normal usage, and to be able to control the amount of stretch in different directions (as mentioned more hereafter). Some batts have been produced with limited extensions that have been approximately equal directionally, i.e. are not controlled as to direction of stretch; I believe such batts have been made by air-laying, e.g. on a RANDO/DOA system, or some such system of randomly laying the fibers to form the batt. Other batts with limited stretch capability have been produced from carded webs with essentially unidirectional stretch in the machine direction (MD), i.e. with no significant stretch in the cross direction (XD). Such prior batts have not fulfilled the need that has existed for such uses in apparel, such as gloves, and stretch pants, for example.
SUMMARY OF THE INVENTION
According to my invention, I provide batts with superior stretch characteristics, and more particularly the ability to control the stretch in certain directions, as determined in the method of manufacture when forming the batt, by cross-lapping webs of filling fibers that are deferentially shrinkable bicomponent fibers and have been oriented (as by carding, i.e. to impart a degree of parallelization to such fibers), and by using the differential shrinkage of the bicomponent fibers to impart stretch-recovery to such filling fibers.
So, there is provided, according to one aspect of the invention, a process for preparing stretchable fibrous battings, comprising the steps of (1) forming a carded web of bicomponent fibers, the components of which exhibit differential shrinkage, (2) cross-lapping at an angle of about 30° to about 60° to build up a batt of the desired thickness and weight, (3) stabilizing the batt with the fibers in the batt thus cross-lapped, and (4) heat-setting the batt so as to effect differential shrinkage of the bicomponent fibers and thereby impart recoverable stretch to the batt.
According to another aspect, there is provided a multilayered, cross-lapped, stretchable batt having recoverable extensions in the plane of the layers that are balanced to the extent such that the maximum recoverable extension is no more than about 1.5 times the recoverable extension in the direction at right angles to the direction of maximum recoverable extension, and comprising bicomponent fibers that have a helical curl on account of bicomponent differential shrinkage.
A preferred process for preparing stretchable fibrous battings, comprising the steps of (1) forming a blend of bicomponent fibers, the components of which exhibit differential shrinkage, with binder fibers that soften under conditions that do not soften the bicomponent fibers, (2) cross-lapping at an angle of about 30° to about 60° to build up a batt of the desired thickness and weight, (3) activating the binder fibers so as to provide a bonded batt, and (4) heat-setting the bonded batt so as to effect differential shrinkage of the bicomponent fibers and thereby impart recoverable stretch to the batt.
DETAILED DESCRIPTION OF THE INVENTION
Bicomponent filaments of differential shrinkage of various types have already been disclosed, e.g., by Reese in U.S. Pat. No. 3,998,042, and Mirhej, U.S. Pat. No. 4,157,419, and the art referred to therein, and some such bicomponent combinations have been used as filling fibers in the prior batts with limited stretch capability referred to above. According to the present invention, the different components are preferably in a side-by side relationship, so as to maximize the effect of differential shrinkage in providing a desired helical configuration or curl with stretch properties, and compatible components should be selected with the same end in view. Preferred components for some purposes are polyesters, particularly combinations that have been used and disclosed for their differential shrinkage, but other components, such as nylon may be used, e.g. a nylon 66 bicomponent with 2G-T/SSI. The copolyester often referred to as 2G-T/SSI being poly(ethylene terephthalate/5-sodium-sulfo-isophthalate) containing about 2 mole % of the ethylene 5-sodium-sulfo-isophthalate repeat units, and disclosed, e.g., by Griffing & Remington in U.S. Pat. No. 3,018,272. Other bicomponents, such as polyolefins, for instance polypropylene/polyethylene-type bicomponents with melting point differences of the order of 50° C., may be used depending on the end-use. The ways to get differential shrinkage have been disclosed in the art, and include using entirely different polymers, or similar polymers with differences, such as differing melting points and/or differing relative viscosities to provide different shrinkages under the conditions desired (which have usually been heat-setting, e.g. in a hot oven).
As indicated, for many purposes, bonded batts are preferred. Bonding may be effected by using a resin binder, as described in the art, but, especially if through-bonding is desired, this is achieved preferably by use of binder fibers that are blended with the polyester fiberfill. Typical binder fibers are described in the art referred to, and, for example, in copending Ahn et al, USSN 07/260,540, filed Oct. 24, 1988, and Ahn USSN 07/281,825 filed Dec. 9, 1988 and the binder fibers and references cited therein. Preferably, the difference in melting point is of the order of 100° C., especially for olefin binders. Binder fibers may be blended with the bicomponent fiberfill by methods known per se in the art, and, if desired, other components may be blended in, e.g. as disclosed, e.g., by Pamm in U.S. Pat. No. 4,281,042 and Frankosky in U.S. Pat. No. 4,304,817.
An essential element of my invention is in using cross-lapping, whereby I provide the possibility of varying and controlling the stretch characteristics of the resulting batts very simply, by altering the angle of cross-lapping the webs, and then stabilizing the angle at which the fibers are oriented relative to the batt by the cross-lapping. This contrasts with the random orientation of some prior batts referred to above; I have found the amount of (recoverable) stretch has been greater in my batts, quite apart from my ability to control and vary (in a directional sense) the amounts of stretch, which can be a very important advantage, in practice, to the user of the batts, e.g. for designing apparel and other articles, such as furniture. The angle of cross-lapping is measured herein in the cross-direction (XD), in contrast to MD for the machine-direction, and may vary, e.g. from 10° to 80°. However, in practice, angles of 30° to 60° will generally be preferred. An angle of 45° will give approximately equal stretch in both directions (MD and XD), but these stretch characteristics are found to be superior to those of the prior random batts referred to above. An angle of more than 45° will increase the MD stretch and lower the XD stretch, whereas angles of less than 45° will increase the XD stretch and correspondingly lower the MD stretch. Webs from homopolymer fibers have generally had predominantly XD stretch (rather than MD) and increasing the cross-lapping angle for such webs has had the opposite effect to what occurs according to the present invention (using bicomponent fibers to provide stretch) in relation to the MD:XD stretch ratio.
The batts are formed prior to applying heat sufficient to induce the desired differential shrinkage, and such differential shrinkage is induced later, by appropriate means, conventionally simply heating the batt, e.g. in an appropriate oven, or using hot air, by way of example. The differential shrinkage may be induced in the batt in its original lofted state. Desirably, however, in practice, the differential shrinkage is induced after stabilization of the batt, e.g. with a low level of heat (enough to provide only some slight degree of curl in the fibers sufficient to provide cohesion and stability, and possibly to activate any binder material, for instance in the form of binder fibers) and/or pressure to densify the batt or by needle-punching. Needle-punching is preferred for many end-uses, as it forms an integral batt and can minimize further change during subsequent heating.
Stabilizing is important for control, i.e., to preserve the angle of orientation of the fibers after cross-lapping, and so the eventual directional stretch characteristics. It should be understood that cross-lapping has generally been carried out merely to build up a desired weight of fiber in the batt, and precise control of any angle has not been of much concern, especially as the orientation of the fibers will likely change during later handling and processing unless and until fixed by bonding or other means.
Suitable bicomponent fibers may have a cut length of about 38 to 100 mm, and denier of 2 to 15, which is suitable for webs having a weight of 10 to 100 g/sq. meter, when processed by carding or garnetting. The webs are cross-layed (cross-lapped) onto a moving apron (floor apron). The web speed on the cross-lapper and the relative speed of the moving floor apron are controlled in a way that will allow control of the angle of the webs as they are cross-layed onto the moving apron (floor apron). The weight of the web and number of the cross-layed webs are controlled in a way that will allow control of the batting weights. All these controls are generally by variable drives which will give necessary weight and speed flexibility.
Carding or garnetting the fiber is the preferred process in order to align fibers in the machine direction (MD) of the web as produced. After cross-laying these carded, aligned fibers to a predetermined angle, subjecting the cross-lapped batting to needle punching at about 80-100 penetrations per sq. inch using a low aggression needle is the preferred method for stabilizing the batting; however, this does not preclude the option of using lofted or compressed batting.
Tests have been carried out using 2.5 denier side-by side homopolymer//copolymer bicomponent polyester fibers of 50//50 (by weight) 2G-T//2G-T/SSI. The batts have also contained about 10% by weight of MELTY 4080 as binder fiber, and TR-934 resin. The apron speed was 10 meters/minute (but may be varied conventionally, e.g. between 5 and 20 meters/minute) and the cross-lapping speed is generally 4 times as fast, and was 40 meters/minute in this test. The heating means in the first stage may conveniently be a hot roll or hot air oven, and a hot air oven has been preferred for the second stage.
Tests conducted to demonstrate the development and control of stretch using such side-by-side polyester bicomponent fibers showed the transverse web (XD) stretch was 17-21% and the machine direction (MD) was only 8% when a low cross-lap angle of 15° from XD was used. Changing the angle to 30° for the cross-lap, however, resulted in an increase in stretch to 25% MD while maintaining 17% transverse (XD). This was an unexpected result and showed the stretch responded to the angle of the fibers in the web (obtained by cross-lapping and stabilizing).
Battings produced as described above may, as indicated, if desired, contain a suitable percentage (e.g. 10 to 20% by weight) of low melt binder fibers. These may be a sheath core or a side-by-side type wherein the sheath or one side melts at a suitable temperature, preferably between 100° and 130° C. Whether the batting contains binder fiber or not, the batting is preferably initially subjected to about 110-120° C. to initiate a low level of shrinkage in the copolymer and generate slight curl or spiral in the fibers for stabilization and cohesion purposes. The low heat will also activate the binder fibers, if present, adding strength to the batting. This can be particularly important for battings produced by methods other than needle punching, as mentioned above.
After any such initial heat setting, the batting is subjected to heat (at a higher temperature than any such initial heating) to generate maximum curl, spiral, or crimp in the fibers, without melting or otherwise degrading them. This heat-setting is to create a more permanent, highly crystalline state, and to minimize removal of such curl, spiral, or crimp when force is applied to stretch the batting. The preferred temperature for this step is 160-180° C., or 50-60° C. higher than the original heating cycle.
The addition of a soft latex resin, such as E-32, E-358, or TR-934 produced by Rohm & Haas or a similar performing resin product, is suggested for control of fiber migration or percolation through coverings. These may be added at levels of 12-18% of the gross batting weight and may be applied by spray using normal techniques for resin bonding settings during the second heating cycle for the batting. The use of resin may restrict stretch character but is used to add force to recovery and minimize elongation or permanent stretch. | Improved stretchable battings of differentially-shrinkable bicomponent staple fibers are obtained by cross-lapping webs, e.g. from cards, garnets or the like machines, at an angle that determines and controls the degrees of stretch in the machine direction (MD) and cross direction (XD), and then inducing helical crimp in the bicomponent fibers on account of their differential shrinkage. Such batts are especially useful in apparel. | 8 |
[0001] The present invention relates to the field of instruments that can be used in surgery and in interventional radiology, and more particularly to a perforating trocar that can be used especially in the field of bone biopsy, cementoplasty of the skeletal areas, and treatment of bone damage by photocoagulation or thermocoagulation.
BACKGROUND OF THE INVENTION
[0002] Various types of trocars are known that are surgical instruments used to gain access to natural or pathological cavities, to carry out biopsies or to introduce substances, for example to perform intestinal or gynecological celioscopy, or to perform endoscopic operations, in particular arthroscopic operations, by which it is possible to greatly reduce the patient's post-operative recovery period by comparison with procedures involving open surgery. A trocar is generally composed of a hollow tube, also called a cannula or sheath, in which a rod or obturator is able to slide, the distal end of which rod or obturator emerges at the distal end of the tube and is in the form of a tip in order to facilitate penetration into the tissues.
[0003] Thus, the patent FR 2,697,150 describes a trocar intended for celioscopy and comprising a tube in which a hollow rod engages which is provided with a tip having recessed facets and capable of containing a device for protecting the tip. The patent application WO 03020140 describes a trocar designed to require only minimal force for insertion into the tissues, so as to reduce as far as possible the damage caused by the penetration, said trocar comprising a tip at the distal end of the obturator, fitting perfectly in the continuation of the distal opening of the cannula, which has a certain degree of flexibility. Such a trocar is intended essentially to be introduced into the soft tissues. Another type of trocar is described in the patent application WO 03045260, according to which a perforating obturator is able to slide in the cannula of the trocar in order to pierce the abdominal wall of a patient during a laparoscopy operation involving introduction of a gas into the abdominal cavity in order to distend it and make the operation easier. However, the trocar according to said document is not designed to perforate a hard wall, such as that of a bone.
[0004] Some types of perforating trocars are also known, and are available on the surgical instruments market, which comprise a tip associated with a tube with a cutting distal edge in order to permit penetration into a relatively hard bone, but the effectiveness of trocars of this type is not always satisfactory, particularly in the case of very hard bone resisting conventional cutting tools. Thus, the patent U.S. Pat. No. 5,810,826 describes a perforating trocar comprising a rod with an end in the form of a drill-bit with eccentric tip, guided by a tube. When the rod comes into contact with the bone, its rotation causes the formation of a hole with a diameter wider than that of the rod, by virtue of the off-centered position of the tip, while the tube is held immobile. The use of this trocar is difficult because the operator has to hold the tube with one hand and turn the rod with the other hand.
SUMMARY OF THE INVENTION
[0005] The subject matter of the present invention is a perforating trocar that permits a very effective perforation and that is very easy to use and safe to handle.
[0006] The invention also relates to a perforating trocar with which it is possible, under good conditions of efficacy and reliability, to perform operations such as bone biopsies, vertebroplasty procedures, and treatment of lesions.
[0007] The trocar according to the present invention is of the type comprising a rigid tube in which a rod with a perforating distal tip is able to slide, and it is characterized in that the zone of the distal tip of the rod has the form of a perforating drill-bit that is able to turn on its axis, while the distal end of the tube is divided into at least two segments with a helical cutting edge. According to the invention, each helical segment corresponds to an angle of less than or equal to 180° about the axis of the tube.
[0008] The segments with a helical cutting edge are preferably identical or have like or similar profiles. Segments with like profiles means segments that are substantially identical or that differ only in minor details. Segments with similar profiles means segments that are the same shape but have different dimensions.
BRIEF DESCRIPTON OF THE DRAWINGS
[0009] FIG. 1 shows an overall view of a trocar according to the present invention.
[0010] FIG. 2 shows a perspective view of the tip of the trocar from FIG. 1 , illustrating the distal ends of the tube and of the inner rod.
[0011] FIG. 3 shows a plan view of the tip of the trocar, illustrating the respective positions of the tube and of the rod.
[0012] FIG. 4 shows a view of the distal end of the tube alone, without the rod.
[0013] FIG. 5 shows a view of the distal end of the rod alone, without the tube.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0014] According to an advantageous embodiment of the invention, the distal end of the tube is divided into two symmetrical segments along the axis of the tube, and the cutting edge of each part forms a helical ramp inclined by 1 to 45°, preferably by 10 to 30°, with respect to the plane perpendicular to the axis. The edges of these parts, depending on the thickness of the tube, can be sharpened to improve the efficacy of the cut, for example by providing a beveled section.
[0015] According to a preferred embodiment, the helical edge parts of the distal end of the tube are separated by a recess cut out in the wall of the tube, the depth of the recess, from the lower edge of the helical ramp to the bottom of the recess, being between 0.5 and 5 times, preferably between 1 and 2 times, the internal diameter of the tube.
[0016] According to another feature of the invention, the zone of the distal tip of the rod comprises at least two cutting ridges that extend from a point situated preferably on the axis to the periphery of the tip. According to a preferred embodiment, these cutting ridges are arranged symmetrically with respect to the axis of the rod, and their profiles can be identical to or different than one another. For example, two cutting ridges can be arranged on either side of the axis of the rod and off-centered relative to the latter. In a variant according to the invention, the cutting ridges extend from a point that is slightly off-centered relative to the axis.
[0017] According to an advantageous embodiment of the invention, at least part of the body of the rod has the form of a perforating drill-bit with two helical flutes. The attacking surfaces of the distal tip are delimited by the cutting ridges and have a concave shape joining each flute, thus facilitating the perforation of a hard surface, for example that of a bone, when the rod is applied against such a surface and a movement of rotation is applied to it.
[0018] The above-described rod with a tip in the form of a drill-bit can be withdrawn from the tube after perforation of the bone, in order to be replaced, for example, by a biopsy needle or cannula or by an ultrasound probe or fiber optics.
[0019] The trocar of the invention can thus be used not only in bone biopsy, but also in cementoplasty for the skeletal areas, in particular in vertebroplasty for injection of a bone-filling cement, or for treatment of damaged bone by photocoagulation with the aid of a fiber-optic laser, or by thermocoagulation with the aid of a radio-frequency or ultrasound apparatus.
[0020] By way of example, in the case where a biopsy of damaged bone behind a hard bone is to be carried out, the practitioner, having induced local anesthesia by conventional techniques, introduces the trocar, comprising the tube and a rod with a pointed distal end, through the skin and the soft tissues of the patient until it contacts the bone. A control abutment, which is movable on the tube of the trocar, ensures that the depth of insertion is controlled as a function of the distance by which the bone is to be perforated. The rod is then withdrawn, leaving the tube in place, its distal end being against the wall of the bone. The perforating rod is then inserted into the sheath until its handle is locked, its tip then being in contact with the bone, and the assembly made up of the tube and of the perforating rod is then subjected to a rotation movement in order to drill the bone. The biopsy is then performed by replacing the perforating rod by a suitable instrument, for example a biopsy needle.
[0021] The structure of the trocar according to the invention has the advantage of making it very easy to use, since it can be put in place and maneuvered with just one hand by virtue of the cooperation between the sheath with cutting edges and the rod with perforating tip, which are integral during the movement of perforation by rotation.
[0022] The simplicity of the structure of the trocar according to the invention makes it possible to provide the user with an assembly or kit composed of several trocars, tubes, solid rods or hollow rods, and perforating or extracting needles, this assembly being adapted to use in surgery, and more particularly to the conduct of bone biopsies, for example for fairly deep lesions.
[0023] Other features and advantages of the present invention will become clear from the following description of a preferred embodiment, with reference being made to the attached drawings, in which:
[0024] FIG. 1 shows an overall view of a trocar according to the present invention.
[0025] FIG. 2 shows a perspective view of the tip of the trocar from FIG. 1 , illustrating the distal ends of the tube and of the inner rod.
[0026] FIG. 3 shows a plan view of the tip of the trocar, illustrating the respective positions of the tube and of the rod.
[0027] FIG. 4 shows a view of the distal end of the tube alone, without the rod.
[0028] FIG. 5 shows a view of the distal end of the rod alone, without the tube.
[0029] The trocar ( 1 ) shown in FIG. 1 comprises a hollow cylindrical tube ( 2 ) in which a rod ( 3 ) is able to slide and pivot. The trocar ( 1 ) also comprises a handle ( 4 ), which allows it to be maneuvered by the user and which comprises two parts, namely an inner part ( 5 ) integral with the tube ( 2 ), and an outer part ( 6 ) integral with the rod ( 3 ). The two parts ( 5 and 6 ) of the handle ( 4 ) can be displaced relative to each other in order to move the rod ( 3 ) in the tube ( 2 ) of the trocar, either in a sliding movement by pulling the part ( 6 ) of the handle away from the part ( 5 ), or in a pivoting movement by turning the part ( 6 ) with respect to the part ( 5 ) of the handle.
[0030] The trocar ( 1 ) also comprises an abutment ( 7 ) whose position on the tube ( 2 ), can be adjusted by way of a screw ( 8 ).
[0031] As is shown in FIG. 2 , which depicts the tip of the trocar in detail, the tube ( 2 ) has two recesses of rectangular cross section, of which only one ( 9 ) is visible in FIG. 2 . These two recesses ( 9 ) and ( 9 ′) divide the end of the tube ( 2 ) into two lips ( 10 ) and ( 11 ), which have a helical cutting ridge and which are arranged symmetrically with respect to the axis of the tube, as is shown more clearly in FIG. 4 .
[0032] The distal end of the rod ( 3 ) has the form of a perforating drill-bit, which is shown better in FIG. 5 and which emerges beyond the end of the tube when it is inserted fully in the tube ( 2 ), in such a way that the two parts ( 5 ) and ( 6 ) of the handle ( 4 ) are then joined, in the position shown in FIG. 1 .
[0033] The elevation view in FIG. 3 shows the tip of the trocar ( 1 ), the respective positions of the two lips ( 10 ) and ( 11 ) that are symmetrical with respect to the axis, and the two cutting ridges ( 12 ) and ( 13 ) whose profiles differ from one another. The inclination of the cutting ridge of the lips with respect to the plane perpendicular to the axis of the rod is approximately 15°.
[0034] The two recesses ( 9 ) and ( 9 ′) appearing in FIG. 4 facilitate the evacuation of the bone debris during perforation by means of the cutting lips ( 10 ) and ( 11 ), the action of which combines with that of the tip of the rod ( 3 ) when the user pivots it on its axis in the tube ( 2 ).
[0035] As is shown in FIG. 5 , the tip of the rod ( 3 ) has the form of a perforating drill-bit with two helical flutes ( 14 ) and ( 14 ′) and a terminal end forming a cutting ridge ( 15 ) substantially on the axis of the rod ( 3 ), in such a way that the rotation of the rod in the reverse direction (direction of the hands of a clock), when the tip of the rod ( 3 ) is against a bone wall, promotes the perforation of said bone wall. The attacking surfaces of the cutting ridges ( 12 ) and ( 13 ) have a concave shape delimited on one side by the cutting ridges ( 12 ) and ( 13 ) and on the other sides by the end of the helical flutes ( 14 ) and ( 14 ′). | The invention concerns the field of surgical instruments. The inventive trocar ( 1 ) is of the type comprising a rigid tube ( 2 ) wherein may slide a rod ( 3 ) with a perforating distal tip, and it is characterized in the distal tip zone of the rod forms a perforating drill capable of rotating on its axis while the distal end of the tube is divided into at least two segments ( 10, 11 ), with helical cutting edge. The invention is applicable in particular to bone biopsy. | 0 |
TECHNICAL FIELD
The invention relates generally to the field of XML payload generation. More particularly, the invention relates to generating a XML payload from an XML list without using the schema.
BACKGROUND OF THE INVENTION
An XML list of multi-dimensional data is usually associated with a schema to assist in defining the data. However processing a schema and an XML data file to create a XML payload for export to a software application or a web page is very computational intensive. A large amount of computer processing power is consumed in applying the schema to the XML data file. It is very desirable to be able to receive imported XML data or enter XML data, then optionally modify XML data and finally export the data without use a schema during import, modification and export.
It is with respect to these considerations and others that the present invention has been made.
SUMMARY OF THE INVENTION
In accordance with the present invention, a method is provided for generating an XML payload from an XML list irrespective of a schema associated with the XML list. This is accomplished by collecting the paths from the field entries in the XML list and creating an XML payload node tree reflective of the relationship of data in the paths of the XML list. The XML payload can then be generated from the XML payload node tree and exported as needed to target applications or web pages.
In another aspect of the invention, the creation of the XML payload node tree is accomplished by first grouping the paths indicative of parent/child relationships of data according to path length. An XML payload node tree is created reflective of the parent/child relationship of data in the paths of the XML list. Then for each record in the XML list, the shortest parent path is traversed starting with a primary parent or root node. The traversal determines if nodes for the shortest parent path have been created in the payload node tree. If nodes are missing along this shortest parent path in the node tree, nodes are created for the missing node along this path, and a pointer is set to identify the end node in the node tree, i.e. the end of a branch, from which longer paths for the record might extend. If there is a longer path for the same record in the XML list, the above node creating operation and pointer setting operation are repeated starting with the end node, extending the branch with new nodes to a new end node until the longest path for the same record has been processed and a branch in the XML payload node tree for the record has been completed. Then the above operations are repeated for the next record in the XML list until a complete node tree has been built for all the records in the XML list.
The invention may be implemented as a computer process, a computing system or as an article of manufacture such as a computer program product or computer readable media. The computer readable media may be a computer storage media readable by a computer system and encoding a computer program of instructions for executing a computer process. The computer program readable media may also be a propagated signal on a carrier readable by a computing system and encoding a computer program of instructions for executing a computer process.
These and various other features as well as advantages, which characterize the present invention, will be apparent from a reading of the following detailed description and a review of the associated drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates one embodiment of the invention in which XML list is received, an XML payload node tree is created and an XML payload is built from the node tree and exported.
FIG. 2 illustrates an example of a suitable computing system environment on which embodiments of the invention may be implemented.
FIG. 3 illustrates the operational flow of the operations performed in creating an XML payload node tree.
FIG. 4 shows some exemplary input data for a spreadsheet that may be received as an XML list and processed by the operations of FIG. 1 to generate an XML payload for export.
FIG. 5 shows an exemplary XML payload node tree created from the input data of FIG. 4 .
FIG. 6 shows an exemplary XML payload built from the node tree of FIG. 5 and ready for export to a software application.
DETAILED DESCRIPTION OF THE INVENTION
The logical operations of the various embodiments of the present invention are implemented (1) as a sequence of computer implemented acts or program modules running on a computing system and/or (2) as interconnected machine logic circuits or circuit modules within the computing system. The implementation is a matter of choice dependent on the performance requirements of the computing system implementing the invention. Accordingly, the logical operations making up the embodiments of the present invention described herein are referred to variously as operations, structural devices, acts or modules. It will be recognized by one skilled in the art that these operations, structural devices, acts and modules may be implemented in software, in firmware, in special purpose digital logic, and any combination thereof without deviating from the spirit and scope of the present invention as recited within the claims attached hereto.
FIG. 1 illustrates one embodiment of the invention for processing an XML list to create an XML payload. Receive operation 102 , receives the XML list for processing. An XML list might be input by the user or it might be imported from a software application or as a part of a web page component. Although XML lists can be extended to represent data in multi-dimensional format, currently they are being used in a two dimensional form in the form of rectangular regions, or tables, typically in a spreadsheet application. Each definition of XML list describes how the table should look like and how cells inside relate to the payload data.
A collection of these XML lists can be found inside an XMLSS file. An exemplary format for a XML list definition in an XMLSS file is shown immediately below in Table 1.
<Entry x2:ID=“List1”>
<Range>‘Employee Lookup’!R5C1</Range> <XPath>/Corp/Department</XPath> <Field>
<XSDType>string</XSDType> <XPath>©name</XPath>
</Field> <Field>
<XSDType>string</XSDType> <XPath>DepartmentID</XPath>
</Field> <Field>
<XSDType>string</XSDType> <XPath>Managers/Person@name</XPath>
</Field> <Field>
<XSDType>string</XSDType> <XPath>Managers/Person/PersonID</XPath>
</Field>
</Entry>
Table 1
Each XML list begins with an <Entry . . . > XML tag and ends with the an </Entry> XML tag. Cells inside the XML list (or table) are arranged in the form of records. A record corresponds to a row in the table. Columns inside the table are called fields, they are defined in the XML list by each <Field> and </Field> tags. Thus, the exemplary XML list in Table 1 defines four columnar fields in each row of the table. Further, the XML list has XPaths on a line in each field that begin with the <XPath> tag and end with the </XPath> tag. The XPaths indicate the parent/child relationship of each field in a record and will be used in the present embodiment of the invention to create an XML payload node tree.
The preferred embodiment of the invention generates an XML payload from a XML List. It does so using only the paths, i.e. XPATHs, specified in the XML list and without processing the schema of the payload. The operations may be summarized as follows:
1. When the XML list is loaded, all the Field XPATHs are examined and their corresponding Parent XPATHs are generated. A Parent XPATH is the XPATH to the parent of a particular Field XPATH assuming that it represents a property in both element and attribute centric cases. For example, for an attribute Field XPATH,/a/b/@c, it's Parent XPATH is /a/b. For an element Field XPATH, /a/b/c, it's Parent XPATH /a/b. 2. The Parent XPATH with the most number of “steps” is then chosen to be the Bottom XPATH. If there is more than one, the first one is chosen. 3. All the other Parent XPATH should either be a subset or equal to the Bottom XPATH. For example, /a, /a/b are subset of /a/b/c. If this is not the case, we have a nested table case and the load will be aborted. Those Fields with Parent XPATHs with a fewer number of steps than the Bottom XPATH are called “fill-downs”. 4. All the Parent XPATHs are grouped together according to the number of steps that they have. 5. The algorithm starts with the Parent XPATH that has the least number of steps. Note that in the case where there are no fill-downs, this is also the Bottom XPATH. 6. Starting with the first row in the XML List 7. Initialize an empty result node set 8. Starting from the Parent XPATH with the least number of steps, the XPATH is traversed from the node contained in the result set, if any. If the node is missing while traversing the XPATH, a new node is created along the path. At the end node, the values of all the Fields using this Parent XPATH are used to locate the node. If there is no node with all those values at the attribute/element properties, a new node is created and the values from the Fields are put into their appropriate attribute/element properties. If there are more than one end nodes with all the matching properties, the first one is chosen. 9. The result node set is cleared and that particular end node is then inserted into it. 10. If there are more Parent XPATHs, go back to step 8 to process the next Parent XPATH. 11. If there are more rows in the XML List, go back to step 7 to process the next row.
In FIG. 1 , load module 104 collects all the XPaths in an XML list per the first three steps above so that they may be processed by create module 106 . Node tree create module 106 takes the parent/child relationship information from the XPaths and starting with the shortest XPath in a record and working through to the longest XPath in the same record builds a branch of the XML payload node tree. Once all records in an XML list have been processed by node tree create module 106 , a complete payload node tree for the XML list will have been created. The node tree create module will be described in more detail hereinafter with reference to FIG. 3 .
Once an XML payload node tree has been created and stored, it may be retrieved or read by the build module 108 . Build module 108 will convert the XML payload node tree into an XML payload list (one example is shown in FIG. 6 ) for export to a software application or as a web component in a web page. Export module 110 performs the acts to export the XML payload list.
FIG. 2 illustrates an example of a suitable computing system environment on which embodiments of the invention may be implemented. In its most basic configuration, system 200 includes at least one processing unit 202 and memory 204 . Depending on the exact configuration and type of computing device, memory 204 may be volatile (such as RAM), non-volatile (such as ROM, flash memory, etc.) or some combination of the two. This most basic configuration is illustrated in FIG. 2 by dashed line 206 .
In addition to the memory 204 , the system may include at least one other form of computer-readable media. Computer readable media can be any available media that can be accessed by the system 200 . By way of example, and not limitation, computer-readable media might comprise computer storage media and communication media.
Computer storage media includes volatile and nonvolatile, removable and non-removable media implemented in any method or technology for storage of information such as computer readable instructions, data structures, program modules or other data. Memory 204 , removable storage 208 and non-removable storage 210 are all examples of computer storage media. Computer storage media includes, but is not limited to, RAM, ROM, EPROM, flash memory or other memory technology, CD-ROM, digital versatile disks (DVD) or other optical storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other medium which can be used to store the desired information and which can accessed by system 200 . Any such computer storage media may be part of system 200 .
System 200 may also contain a communications connection(s) 212 that allow the system to communicate with other devices. The communications connection(s) 212 is an example of communication media. Communication media typically embodies computer readable instructions, data structures, program modules or other data in a modulated data signal such as a carrier wave or other transport mechanism and includes any information delivery media. The term “modulated data signal” means a signal that has one or more of its characteristics set or changed in such a manner as to encode information in the signal. By way of example, and not limitation, communication media includes wired media such as a wired network or direct-wired connection, and wireless media such as acoustic, RF, infrared and other wireless media. The term computer readable media as used herein includes both storage media and communication media.
In accordance with an embodiment, the system 200 includes peripheral devices, such as input device(s) 214 and/or output device(s) 216 . Exemplary input devices 214 include, without limitation, keyboards, computer mice, pens, or styluses, voice input devices, tactile input devices and the like. Exemplary output device(s) 216 include, without limitation, displays, speakers, and printers. Each of these “peripheral devices” are well know in the art and, therefore, not described in detail herein.
In FIG. 3 the operational flow for creating an XML payload node tree begins when group operation 302 groups the parent XPaths in the XML list. This operational flow is best understood by describing the operations of FIG. 3 with reference to exemplary input data shown in FIG. 4 and with reference to a resulting XML payload node tree as shown in FIG. 5 . In FIG. 4 , the input data 402 contains four rows, or records, 404 , 406 , 408 , 410 and four columns, or fields, 412 , 414 , 416 , 418 . The XML list will appear in format shown and discussed above with reference to TABLE 1.
Group operation 302 examines each Field XPaths and groups them according to the path length, which is the number of steps it contains, not number of characters in the path. Steps in an XPath are separated by the ‘/’ character. For the XML list, XPaths by Field would be grouped as follows.
/Corp/Department
/Corp/Department/Managers/Person.
In this example, “Corp” is the primary or root node, and the shortest XPath for the record is /Corp/Department.
In FIG. 3 payload initialize operation 304 assigns and empties or clears a storage space for the XML payload node tree. Likewise result node set initialize operation 306 assigns and empties or clears a storage space to store an end node pointer for the current end node in each branch of the node tree as a branch for each record is being created in the node tree. With the storage space for the node tree initialized and cleared, and with the end node pointer initialized and cleared, retrieve operation 308 starts the creation of the node tree by retrieving the shortest parent XPath. In the example, the shortest parent XPath is /Corp/Department.
Traverse operation 310 using the Parent XPath as a guide traverses nodes in the XML node tree from the end point node. Thus, the traverse operation determines if the nodes in the XPath are in the XML node tree in node tree storage. Since this is the first parent XPath traversed, the end point node is the root node, Corp. The traverse operation finds that the nodes, Corp and Department, have not been created and stored in node tree storage space. Empty test operation 312 detects that these nodes are not in XML payload node tree storage, and the operation flow branches YES to node create operation 314 .
Node create operation 314 creates and stores a node for each node, Corp and Department in the shortest parent XPath. Further, node create operation stores for each node its parent/child link or relationship. The property values of “Engineering” and “1001” for the Department are also missing from the node tree. Therefore, create operation 314 stores in the Department node all of its attribute properties, i.e. name=Engineering, and creates all of its element property nodes, i.e. DepartmentID, storing their values, i.e. 1001, with a value node linked back to the Department node. Value nodes only contain values and are not an end node from which longer branches of the same record might extend. Thus, in the example XML payload node tree in FIG. 5 , node create operation 314 ( FIG. 3 ) has created the Corp node 500 , the Department element node 502 with the name “Engineering” and the Department ID value node 504 with value 1001. Node 502 is an element node from which further children may relate and is in fact the new end node. Node 504 is a value node and stores the value for the Department ID.
After the nodes for the shortest XPath have been created and stored as a portion of the XML payload node tree, pointer reset operation 316 empties or clears the current pointer for the record, i.e. default pointer pointing to root node Corp, and stores a new end node pointer pointing to the Department node 502 . More parent XPaths test operation 318 then detects whether there are more parent XPaths to be traversed and added to the branch of the node tree for this record. In the present example, there are more and longer parent XPaths, and the operation flow branches YES to retrieve operation 320 to retrieve next shortest parent XPath. The next shortest parent XPath is /Corp/Department/Managers/Person, and this XPath is provided to traverse operation 310 .
Traverse operation 310 determines that the nodes, Corp and Department, are in the payload node tree and further that Department node is pointed to by the pointer in the result node set as the end node from the previous path. Traverse operation also determines that the nodes, Managers and Person, are not in the node tree, and further finds that the values “John” and 20001 are the properties for the Person node. Since Managers node is not in the XML payload node tree, empty test operation 312 branches the operation flow YES to node create operation 314 .
Node create operation 314 now creates a node for Managers and a node for Person. Further, the create operation stores the parent/child relationship or link for the Mangers node and the Person node. The Managers node 506 links up to the Department node 502 , and the Person node 508 links up to the Managers node 506 . Also the attribute, John, is stored with the Person node by node create operation 314 , and a value node 510 for Person ID is created that links to the Person node and stores the value 20001. Reset operation 316 now empties the result node set and stores a pointer to point to a new end node which is the Person node 508 . There are no more parent XPaths in the XML list. Accordingly, operation flow branches NO from more parent XPaths test 318 to XML row test operation 324 . This completes the branch of the XML payload node tree for record 404 . Since there are more rows or records in the XML list, the operation flow branches YES to initialize a result node set for the next record to empty. The next record to be processed is row 406 . Some properties are different as the Person name is Peter and the PersonID is 20002. Note that another row or record could be processed next rather than row 406 as the sequence of processing the rows is not important. The same XML payload node tree as shown in FIG. 5 will result irrespective of the sequence of processing the XML list for the rows 404 , 406 , 408 , 410 in FIG. 4 .
Retrieve operation 308 now starts with the shortest parent XPath which is /Corp/Department. Traverse operation 310 traverses this path from the root node Corp and determines that the nodes Corp and Department are already in the XML payload node tree. Accordingly, the operation flow branches NO from the empty test operation 312 to properties test operation 322 . Properties test operation 322 detects whether the properties in the existing end node, which is Department node 502 ( FIG. 5 ), match the properties at the end node, which is also a department node, of the XPath being traversed. In this example the properties at the existing end node, which is Department node 502 , are Engineering and 1001, and the properties for Department at the end of the shortest Parent XPath for the new record are also Engineering and 1001. Accordingly, there is a match, and the operation flow branches YES to reset operation 316 . Reset operation 316 empties the node result set for record 406 and sets a new pointer pointing to Department node 502 .
More parent XPaths test operation 318 detects that there is another parent XPath to be processed for record 406 and the operation flow branches YES to retrieve operation 320 . Retrieve operation 320 retrieves the next shortest parent XPath which is /Corp/Department/Managers/Person. Traverse operation traverses s this path and finds that there are already nodes for Corp, Department with Name=Engineering, Managers and Person in the XML payload node tree. The empty test operation 312 therefore branches the operation flow to properties test operation 322 . Properties test operation 322 detects whether the properties in the existing end node, which is Person node 508 ( FIG. 5 ), match the properties at the Person end node of the XPath being traversed. Since the XPath being traversed has an end node Person with the properties, name=Peter and a Person ID of 20002, the properties do not match. The operation flow branches NO from properties test 322 to node create operation 314 .
Node create operation 314 now creates another Person node 512 linked to Managers node 506 and having as an attribute, name=Peter. Further, node create operation creates a PersonID node 514 linked to Person node 512 . PersonID node 514 is a value node containing the value 20002 as the PersonID for Peter, who is named in Person node 512 . After the Person node and the PersonID node are created, reset operation 316 resets the pointer in the result node set to point to the Person node 512 . More parent XPaths test operation 318 tests for more XPaths for the record 406 . Since there are no more XPaths for record 406 , the processing of record 406 is complete. The operation flow branches NO from test operation 318 and YES from row test operation 324 to begin the generation of a branch in the XML payload node tree for the next record such as row 408 ( FIG. 4 ).
The next record is row 408 . Some properties are different in the shortest path as the Department name is Human Resources and the DepartmentID is 1002. Retrieve operation 308 now retrieves the shortest parent XPath. Traverse operation 310 traverses this path from the root node Corp and determines that the nodes Corp and Department are already in the XML payload node tree. Accordingly, the operation flow branches NO from the empty test operation 312 to properties test operation 322 . Properties test operation 322 detects that the properties in the existing end node, which is Department node 502 ( FIG. 5 ), do not match the properties at the end node, which is also a department node, of the XPath being traversed. In this example the properties at the existing end node, which is Department node 502 , are Engineering and 1001, and the properties for Department at the end of the shortest Parent XPath for the new record are Human Resource and 1002. Accordingly, the operation flow branches NO to node create operation 314 .
Node create operation 314 creates new Department node 516 ( FIG. 5 ) with a parent/child relationship linked to the Corp node 500 . Further, the attribute Name=Human Resource is stored with the Department node 516 . In addition node create operation creates a Department ID node 518 linked to the Department node 516 and storing the value 1002. Reset operation 316 empties the node result set for record 408 and sets a new pointer pointing to Department node 516 .
More parent XPaths test operation 318 detects that there is another parent XPath to be processed for record 408 , and the operation flow branches YES to retrieve operation 320 . Retrieve operation 320 retrieves the next shortest parent XPath which is /Corp/Department/Managers/Person. Traverse operation starts with Department node 516 pointed to by pointer in the end node result set and traverses this path to find that there are no nodes for Managers and Person linked to Department node 516 in the XML payload node tree. The empty test operation 312 detects the absence of the Managers and Person node and branches the flow YES to node create operation 314 .
Node create operation 314 now creates a new node for Managers and a new node for Person. Further, the create operation stores the parent/child relationships or links for the Mangers node and the Person node. The Managers node 520 links up to the Department node 516 , and the Person node 522 links up to the Managers node 520 . Also the attribute, Corey, is stored with the Person node by node create operation 314 , and a value node 524 for Person ID is created that links to the Person node and stores the value 20003. Reset operation 316 now empties the result node set and stores a pointer to point to a new end node which is the Person node 522 . There are no more parent paths in the record or row 404 ( FIG. 4 ). Accordingly, operation flow branches NO from more parent XPaths test 318 to XML row test operation 324 . This completes the branch of the XML payload node tree for record 408 . Since there is one more row or record in the example in FIG. 4 , the operation flow branches YES to initialize a result node set for the last record which is row 410 .
Retrieve operation 308 now retrieves the shortest parent XPath for record 410 which is /Corp/Department. Traverse operation 310 traverses this path from the root node Corp and determines that the nodes Corp and Department with Name=Human Resource are already in the XML payload node tree. Accordingly, the operation flow branches NO from the empty test operation 312 to properties test operation 322 . Properties test operation 322 detects whether the properties in the existing end node, which is Department node 516 ( FIG. 5 ), match the properties at the end node, which is also a department node, of the XPath being traversed. In this example the properties at the existing end node, which is Department node 516 , are Human Resource and 1002, and the properties for Department at the end of the shortest Parent XPath for the new record are also Human Resource and 1002. Accordingly, there is a match, and the operation flow branches YES to reset operation 316 . Reset operation 316 empties the node result set for record 406 and sets a new pointer pointing to Department node 516 .
More parent XPaths test operation 318 detects that there is another parent XPath to be processed for record 410 , and the operation flow branches YES to retrieve operation 320 . Retrieve operation 320 retrieves the next shortest parent XPath which is /Corp/Department/Managers/Person. Traverse operation traverses this path from the end node 516 pointed to by the pointer in the result node set and finds that there are already nodes for Managers and Person in the XML payload node tree linked from Department node 516 . Further, the traverse operation finds that the Person end node in the path being traversed has the properties, Name=Pat and PersonID 20004. The empty test operation 312 therefore branches the operation flow to properties test operation 322 . Properties test operation 322 detects whether the properties in the existing end node, which is Person node 522 ( FIG. 5 ), match the properties at the Person end node of the XPath being traversed. Since the existing Person node 522 has the properties, name=Corey and a Person ID of 20003, the properties do not match. The operation flow branches NO from properties test 322 to node create operation 314 .
Node create operation 314 now creates another Person node 526 linked to Managers node 520 and having as an attribute, name=Pat. Further, node create operation creates a PersonID node 528 linked to Person node 526 . PersonID node 528 is a value node containing the value 20004 as the PersonID for Pat, who is named in Person node 526 . After the Person node and the PersonID node are created, reset operation 316 resets the pointer in the result node set to point to the Person node 526 . More parent XPaths test operation 318 tests for more XPaths for the record 410 . Since there are no more XPaths, the processing of record 410 is complete, and the operation flow branches NO from test operation 318 to row test operation 324 . Since row or record 410 is the last record of the present example of an XML list, the generation of the XML payload node tree is complete, and the operation flow returns to the main program flow.
When the system is called upon to export the XML payload, the build operation 108 ( FIG. 1 ) will build the XML payload as shown in FIG. 6 from the XML payload node tree shown in FIG. 5 . Export operation 110 will then export the XML payload to a software application or to a web page as a web component.
The various embodiments described above are provided by way of illustration only and should not be construed to limit the invention. Those skilled in the art will readily recognize various modifications and changes that may be made to the present invention without following the example embodiments and applications illustrated and described herein, and without departing from the true spirit and scope of the present invention, which is set forth in the following claims. | An XML payload is generated from an XML list irrespective of a schema associated with the XML list. The parent/child relationship pats are collected from the field entries in the XML list. An XML payload node tree is created reflective of the parent/child relationship of data in the paths of the XML list. The XML payload can then be generated from the XML payload node tree and exported as needed to target software applications or web pages. | 8 |
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0001] This invention was made with Government support under Contract DE-AC0576RLO1830 awarded by the U.S. Department of Energy. The Government has certain rights in the invention.
BACKGROUND
[0002] A low cost, long lifetime and highly efficient energy storage system can enable large-scale implementation of renewable energy products and electric vehicles. Sodium-based energy storage systems have been considered as an attractive alternative to lithium-based systems since sodium is an earth abundant element and its production cost is very low. Traditional Na ion battery electrode materials (especially cathodes) are based on intercalation reactions. The capacity of Na + intercalation cathode materials is usually limited to ˜120 mAh/g. For higher capacity cathode materials, the capacity fading during cycling is fast. This is mainly because Na + is a large ion (about 50% larger than Li + ) and Na + insertion/desertion in host materials can be difficult and/or problematic. For example, during Na + insertion/desertion, large structure changes can occur in the intercalation material of the cathode, thereby leading to instability. Therefore, a need exists for improved sodium ion batteries that avoid the problems associated with sodium intercalation in cathodes.
SUMMARY
[0003] This document describes methods and apparatuses for storing energy based upon surface-driven reactions between sodium ions and functional groups attached to surfaces of a cathode in a sodium-based energy storage device. The cathode substrate, which comprises a conductive material, provides high electron conductivity while the surface functional groups provide reaction sites to store sodium ions. The embodiments described herein can exhibit significantly enhanced energy storage capacity, rate capability and especially cycling stability since long-range diffusion (insertion/desertion) of sodium ions need not occur. Accordingly, reaction kinetics are increased and the structure of the electrode is preserved.
[0004] One embodiment encompasses a method for operating a sodium-based energy storage cell comprising sodium ions, an anode, and a cathode comprising a substrate. The method comprises binding sodium ions to surface functional groups attached to the surfaces of the substrate during discharge cycles and releasing sodium ions from the surface functional groups during charge cycles. In preferred embodiments, the sodium ions preferentially bind to the surface functional groups relative to intercalating in the substrate. In some embodiments, sodium ions can be adsorbed directly on the substrate surface (i.e., in contrast to sodium ions bound to functional groups attached to the surface) and up to 50% of the storage cell capacity can be attributed to the direct-surface bound sodium ions.
[0005] In some instances, the substrate of the cathode can comprise an electrically conductive material that is not a sodium intercalation material. For example, the substrate can comprise carbon, such as hard carbon. Examples of surface functional groups can include, but are not limited to those having oxygen and/or sulfur. Preferably, the functional groups comprise oxygen.
[0006] The method can further comprise transferring sodium ions to and/or from an anode that comprises sodium. Examples of anode materials can include, but are not limited to, sodium metal, sodium alloys, sodium intercalation compounds, carbon, and combinations thereof.
[0007] Embodiments of the present invention can also encompass sodium-based energy storage cells comprising sodium ions, an anode, and a cathode comprising a substrate. The energy storage cell comprises surface functional groups attached to surfaces of the cathode substrate and by the sodium ions bound to the surface functional groups during discharge cycles.
[0008] In some embodiments, the surface functional groups comprise oxygen. The functional groups can alternatively, or in addition, comprise sulfur. The substrate of the cathode can comprise an electrically conductive material. One example includes, but is not limited to carbon. The sodium-based energy storage cell can further comprise an anode. The anode can comprise sodium. Examples of anode materials can include, but are not limited to sodium metal, sodium alloys, sodium intercalation compounds, carbon, and combinations thereof.
[0009] In some instances, the energy storage cell can operate as a super capacitor.
[0010] In another embodiment, the sodium-based storage cell has a storage cell capacity, wherein 50% of the storage cell capacity is stored in sodium ions adsorbed directly on the substrate surface.
[0011] In yet another embodiment, the sodium ions are charge carriers between the cathode and the anode.
[0012] The purpose of the foregoing summary is to enable the United States Patent and Trademark Office and the public generally, especially the scientists, engineers, and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The summary is neither intended to define the invention of the application, which is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way.
[0013] Various advantages and novel features of the present invention are described herein and will become further readily apparent to those skilled in this art from the following detailed description. In the preceding and following descriptions, the various embodiments, including the preferred embodiments, have been shown and described. Included herein is a description of the best mode contemplated for carrying out the invention. As will be realized, the invention is capable of modification in various respects without departing from the invention. Accordingly, the drawings and description of the preferred embodiments set forth hereafter are to be regarded as illustrative in nature, and not as restrictive.
DESCRIPTION OF DRAWINGS
[0014] Embodiments of the invention are described below with reference to the following accompanying drawings.
[0015] FIG. 1 is a schematic diagram depicting the mechanisms for sodium ion energy storage at the cathode of a sodium-based energy storage cell.
[0016] FIG. 2 includes Cyclic voltammograms on functionalized carbon paper (CP-Acid) cathode in a CP-Acid/Na coin cell, a) 1.0 mV/s, b) 0.2-5 mV/s (Inset: linear relationship between redox peak current and scanrates).
[0017] FIG. 3 includes a) Discharge-charge curves of CP-Acid/Na cells at the rates from 0.1 A/g to 5 A/g; b) Comparison of discharge-charge curves of CP-Acid/Na, CP-KOH/Na, and CP/Na cells at the rate of 0.1 A/g; c) Ragone plot of various Na cathodes (including embodiments of the present invention as well as cathodes of the prior art for comparison); d) Cycling stability of CP-Acid, CP-KOH and CP electrodes (cycling protocol: repeating cycling of 0.1 A/g-6 cycles/1 A/g-100 cycles; only the 0.1 A/g cycling data are shown here).
[0018] FIG. 4 includes SEM images of carbon papers before and after acid functionalization. a) and b) show CP, while c) and d) show CP-Acid.
[0019] FIG. 5 includes XPS spectra of CP-Acid electrodes before and after discharge/charge in CP-Acid/Na cells. a) C1s, b) wide scan XPS, which shows the presence of Na after discharge and its disappearance after charge.
DETAILED DESCRIPTION
[0020] The following description includes the preferred best mode of one embodiment of the present invention. It will be clear from this description of the invention that the invention is not limited to these illustrated embodiments but that the invention also includes a variety of modifications and embodiments thereto. Therefore the present description should be seen as illustrative and not limiting. While the invention is susceptible of various modifications and alternative constructions, it should be understood, that there is no intention to limit the invention to the specific form disclosed, but, on the contrary, the invention is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the invention as defined in the claims.
[0021] Embodiments described below utilize a surface-driven sodium ion energy storage mechanism based on redox reactions between sodium ions and a cathode comprising functional groups on the surface of a substrate. Referring to FIG. 1 , a schematic diagram depicts the interactions between sodium ions and the cathode. Functional groups 102 are attached to the surface 106 of the cathode substrate 100 . According to embodiments of the present invention, sodium ions 101 are bound to the surface functional groups 103 . Sodium ions can also be bound directly to the surface of the substrate 104 . Traditional cathode materials comprise intercalation materials in which sodium ions intercalate 105 . However, intercalation is not a significant mechanism for energy storage according to embodiments described herein.
[0022] In the examples below, the functional groups comprise oxygen and the substrate comprises carbon. The surface reaction, instead of Na + bulk intercalation reaction, leads to high rate performance and cycling stability due to the enhanced reaction kinetics and the absence of electrode structure change. For instance, some embodiments can deliver at least 150 mAh/g capacity at a rate of 0.1 A/g and a capacity retention of 82% within 10000 cycles (in comparison with tens to hundreds of cycles for the state-of-art sodium ion battery cathode materials).
[0023] In one example, sodium coin cells were assembled to operate according to the surface-driven sodium ion storage mechanism described herein. The cells were assembled in an Ar-filled glovebox with moisture and oxygen content less than 1 ppm. Sodium foil and functionalized free-standing carbon paper were used as anode and cathode, respectively. The separator comprised Celgard K1640®, a polyethylene membrane. The electrolyte was 1.0M NaPF 6 in EC/DMC (3:7). The discharge/charge was carried out in the potential range of 1.5-4.2V (vs. Na/Na′) on a battery test station. The cyclic voltammograms (CVs) were recorded on a CHI660® electrochemical workstation.
[0024] Battery-grade ethylene carbonate (EC) and dimethyl carbonate (DMC) were utilized in the coin cells. NaPF 6 (98%) was dried under vacuum at 100° C. in glovebox antechamber for 72 hrs before use. In order to simplify the surface analysis and reaction mechanism study, free-standing carbon paper (without binder) was used as cathodes. These high surface area carbon papers (CP) were functionalized using concentrated H 2 SO 4 /HNO 3 mixed acid. In brief, the carbon papers were put into H 2 SO 4 /HNO 3 (Vol 3:1) at 80° C. under mild mechanical stirring for 2 hrs; the functionalized carbon papers were washed with DI water and dried in vacuum (80° C., 24 hrs) before use (hereinafter, “CP-Acid”). The KOH activation of carbon paper was carried out under N 2 at 700° C. for two hrs (hereinafter, “CP-KOH”). In brief, carbon paper was soaked in concentrated KOH for 20 min, and then dried in vacuum. The dried KOH-soaked carbon paper was heated to 700° C. under N 2 for 2 hr. Carbon paper was cooled down to room temperature under N 2 and washed with DI water, followed by drying in vacuum for at least overnight.
[0025] The working potential range of functionalized carbon paper (CP-Acid) electrodes was first determined using CV data. FIG. 2A shows the CV in a CP-Acid/Na cell. Oxidation (electrolyte) occurs above 4.2V and reduction (electrolyte) occurs below 1.5V. Therefore, the potential range of 1.5-4.2V (shadow region) was chosen for subsequent electrochemical tests. Broad redox peaks occur in the CV and are attributed to redox reactions of carbon-oxygen functional groups and Na + (—C═O+Na + +e —C—O—Na).
[0026] FIG. 2B includes CV graphs at various scanrates. The linear relationship between peak currents and scanrates indicates that the redox reaction is confined at the surface of the cathode substrate.
[0027] FIG. 3A includes the discharge/charge curves of a CP-Acid/Na cell at various discharge/charge rates. The discharge/charge curves of CP/Na cell and CP-KOH/Na cell are presented together with a CP-Acid/Na cell in FIG. 3B for comparison. A CP-Acid electrode delivers a high capacity of 152 mAh/g with an average discharge cell voltage of 2.58V and an average charge voltage of 2.85V (0.1 A/g, 0.625 C). The rate performance is excellent; the specific capacity is ˜100 mAh/g at the discharge rate of 1.0 A/g (6.25 C) and ˜50 mAh/g at 5.0 A/g (31.25 C). In comparison, CP and CP-KOH deliver a specific capacity of only 46 mAh/g and 70 mAh/g respectively (0.1 A/g). This is consistent with CV results, which show the highest current response for a CP-Acid electrode while CP-KOH and CP shows rectangle-shaped CVs that are characteristic for electrochemical double layer capacitors.
[0028] The CP-Acid electrode exhibits improved power/energy capability. The Ragone plot of CP-Acid/Na cathode is presented in FIG. 3C together with two traditional Na-ion battery cathodes, Na 4 Mn 9 O 18 (see Cao, Y. L., et al., Reversible Sodium Ion Insertion in Single Crystalline Manganese Oxide Nanowires with Long Cycle Life . Advanced Materials, 2011. 23(28): p. 3155-3160) and P2-Na 2/3 [Fe 1/2 Mn 1/2 ]O 2 (see Yabuuchi, N., et al., P 2- type Na - x Fe ½ Mn ½ O -2 made from earth - abundant elements for rechargeable Na batteries . Nature Materials, 2012. 11(6): p. 512-517). P2-Na 2/3 [Fe 1/2 Mn 1/2 ]O 2 presents one of the highest known energy storage capacities and Na 4 Mn 9 O 18 shows one of the best known cycling stabilities in the literature. The CP-Acid cathode encompassed by embodiments of the present invention shows superior energy storage/delivery performance than Na 2/3 [Fe 1/2 Mn 1/2 ]O 2 , especially at high power. Since LiFePO 4 is widely proposed as a Li-ion battery cathode material for stationary energy storage, the Ragone plots of LiFePO 4 /Li cell and a more practical LiFePO 4 /TiO 2 cell are presented for comparison (see Choi, D. W., et al., Li - ion batteries from LiFePO 4 cathode and anatase/graphene composite anode for stationary energy storage . Electrochemistry Communications, 2010. 12(3): p. 378-381). CP-Acid/Na is much better than LiFePO 4 /TiO 2 in terms of the rate and energy.
[0029] The cycling stability (at changing discharge/charge rates) of CP-Acid, CP-KOH and CP is presented in FIG. 3D . The capacity of CP-Acid electrode drops at the beginning cycles and then becomes flat; the capacity retention for CP-Acid is 82% within 10000 cycles and the capacity is still stable after that. At fixed discharge/charge rate (0.1 A/g), the cycling stability of CP-Acid is even better with 90% capacity retention within 1650 cycles. In comparison, the capacity of a cell having a cathode of Na 2/3 [Fe 1/2 Mn 1/2 ]O 2 drops by over 20% within 30 cycles. Cells having Na 4 Mn 9 O 18 cathodes drop by over 20% within 500 cycles.
[0030] FIG. 4 presents SEM images of CP and CP-Acid. Both CP and CP-Acid electrodes show highly porous structure. But there is no change in the morphology of carbon paper before and after acid functionalization. BET test results show similar pore size/distribution among CP, CP-KOH and CP-Acid. BET surface area is the almost the same for CP and CP-Acid, with an enhanced specific surface area for CP-KOH (Table 1). Comparing CP and CP-KOH, the enhanced capacity of CP-KOH comes from the increased surface area; the two are electrochemical double-layer capacitors. However, the improved surface area does not increase the capacity so high as to be similar to the capacity from CP-Acid cathodes, as CP-KOH only delivers half the capacity of CP-Acid. The 330% improved capacity of CP-Acid in comparison with CP appears to come from other faradic reaction processes instead of double-layer capacitor charge since they have almost the same surface area.
[0000]
TABLE 1
BET test results of CP-Acid, CP-KOH and CP.
CP-Acid
CP-KOH
CP
Surface area (m 2 /g)
513.4
1082
537.4
Pore size (nm)
17.9
17.7
17.7
Pore volume (cc/g)
0.75
1.11
0.79
[0031] In the instant example, surface reactions between Na ions and oxygen functional groups (—CO═O+Na + +e —C—O—Na) appear to be the mechanism contributing primarily to the capacity of CP-Acid. Alternative mechanisms can include 1) the adsorption/desorption of negatively charged PF 6 − ion, and/or 2) the bulk insertion/desertion of PF 6 − . Bulk insertion/desertion is not likely because the working potential of CP-Acid electrode (1.8-4.5V vs Li/Li + ) during operation is not within the expected range for the insertion/desertion of PF 6 − from NaPF 6 . XRD analysis also confirms that there is no detectable bulk insertion of PF 6 − in CP-Acid electrode because the diffraction peak does not change before and after discharge/charge. The absence of changes in the diffraction peaks means that the d-value between graphene layers does not change as a result of PF 6 − insertion/desertion into the substrate.
[0032] XPS element analysis indicates that the mechanism is not based on surface adsorption of PF 6 − either. The ratio of P/F is 1/52 and 1/29 for a discharged and charged CP-Acid cathode respectively (Table 2), significantly different from the stoichiometry of 1/6 for PF 6 − . The P/F surface chemistry of discharge/charged electrodes are quite different from PF 6 − .
[0000]
TABLE 2
Atomic percentages of Na/P/F/C/O on carbon paper electrodes
(calculated from the high-resolution XPS).
%
Na
P
F
C
O
CP
0
0
0
97.2
2.8
CP-KOH
0
0
0
91.1
4.6
CP-Acid (Original)
0
0
0
77.4
22.6
CP-Acid (After
6.5
0.3
15.7
51.3
23.2
discharge)
CP-Acid (After charge)
0.2
0.5
14.5
56.6
26.5
[0033] The surface chemistry analysis provides direct evidence of the reaction between oxygen functional groups and Na ions. After acid functionalization, C1s XPS shows a peak on CP-Acid in the binding energy (BE) range of 287-290 eV which can attribute to carbon-oxygen double bond groups (O—C═O/C═O). FIG. 5A shows the C1s XPS of CP-Acid electrode before and after discharge/charge. After discharge, the carbon-oxygen double bond peak (O—C═O/C═O) decreases and a new bump peak appears in the BE range of 285.5-287.5 eV which is attributed to carbon-oxygen single bond (C—O). This correlates perfectly with the discharge reaction —C═O+Na + +e→—C—O—Na which involves the breaking of double bond and the formation of single bond. After charge, the C1s XPS resembles again that for original CP-Acid. This again correlates very well with the charge reaction —C—O—Na→—C═O+Na + +e. This also indicates that the breaking/formation of carbon-oxygen double bond is in fact reversible.
[0034] The analysis result of Na content on CP-Acid is also consistent with carbon-oxygen bond change during discharge/charge. In FIG. 5B , which includes a wide scan XPS spectrum, the Na signal increases significantly on CP-Acid electrode after discharge, and then disappears after charge. The results from high-resolution XPS provide quantitative information: after discharge, Na content increases from 0 for original CP-Acid to 6.5%; after charge, Na content decreases back to ˜0 (0.2%). Therefore, the charge storage mechanism of CP-Acid electrode is mainly the redox reaction between carbon oxygen surface functional groups and Na ions. In some embodiments, the double-layer capacitor mechanism seen in CP can also be present in CP-Acid (they both have the same surface area). For example, up to 50% of the capacity can be stored in sodium ions adsorbed to the surface of the substrate rather than being bound to surface functional groups.
[0035] While a number of embodiments of the present invention have been shown and described, it will be apparent to those skilled in the art that many changes and modifications may be made without departing from the invention in its broader aspects. The appended claims, therefore, are intended to cover all such changes and modifications as they fall within the true spirit and scope of the invention. | The performance of sodium-based energy storage devices can be improved according to methods and devices based on surface-driven reactions between sodium ions and functional groups attached to surfaces of the cathode. The cathode substrate, which includes a conductive material, can provide high electron conductivity while the surface functional groups can provide reaction sites to store sodium ions. During discharge cycles, sodium ions will bind to the surface functional groups. During charge cycles, the sodium ions will be released from the surface functional groups. The surface-driven reactions are preferred compared to intercalation reactions. | 8 |
[0001] This application claims priority to U.S. Provisional Patent Application Ser. No. 60/431,532 filed Dec. 6, 2002, the disclosure of which is incorporated by reference herein in its entirety.
FIELD OF THE INVENTION
[0002] The present invention pertains to concrete construction, and more particularly to an apparatus for creating a void in a concrete slab.
BACKGROUND OF THE INVENTION
[0003] The construction of various concrete surfaces is typically accomplished by forming a plurality of adjacent concrete slabs separated by expansion joints. When the concrete surfaces are used to support heavy loads, such as those surfaces used as aircraft runways, taxiways, and parking aprons, the heavy loads supported by the concrete surface may cause vertical movement of adjacent slabs.
[0004] To control relative movement between adjacent slabs and more evenly distribute loads among the slabs, it is common to provide load bearing dowels which extend between adjacent slabs and across the expansion joints. Various methods of installing the dowels between joints have been used.
[0005] According to a first, more or less conventional method, wet concrete is poured into a slab form and allowed to cure. The form is then removed and holes are drilled into the sides of the slab, generally parallel to an upper surface of the slab. After the holes have been drilled, first ends of the dowels are coated with an epoxy and inserted into the drilled holes. The opposite ends of the dowels extend outwardly from the slab into an area adjacent the slab, where additional concrete is poured to cover the outwardly extending ends of the dowels and thereby create an adjacent slab.
[0006] U.S. Pat. No. 5,674,028 discloses a second, improved method of installing dowels between adjacent slabs. As seen in this patent, plastic sleeves are inserted into the edges of concrete slabs after the forms are removed, but while the concrete is still relatively plastic. After the concrete hardens, dowels are inserted into the sleeves with an end of each of the dowels projecting outwardly. Thereafter, an adjacent slab is poured, embedding the outwardly projecting ends of the dowels and completing the joint.
[0007] Dowel placement sleeves are also described in U.S. Pat. Nos. 5,005,331; 5,216,862, and 5,487,249. In constructions of this type the sleeves are removed after the concrete is hardened. In the '862 patent, for example, it is disclosed that a sleeve may be tapered to facilitate extraction. While this type of sleeve may be relatively easily removed from the void it creates after an initial longitudinal displacement of the sleeve has been effected, a significant amount of force may still be required to break the sleeve free from the cured concrete and obtain that initial displacement.
[0008] The prior methods described above have various drawbacks. For example, drilling holes for receiving the dowels after the concrete has cured is a labor-intensive and time consuming process. Furthermore, without adequate controls, the holes drilled into the concrete may not be properly aligned with the top surface of the concrete slab or the edge into which the holes are drilled. Such misalignment may restrict relative movement between the slabs to a point which hinders performance of the expansion joint. While forming voids in the concrete by means of removable sleeves has advantages, it is often difficult, as noted above, to remove the sleeves from the concrete after the concrete slab has cured.
[0009] There is thus a need for a device which may be used to form voids in concrete slabs while the concrete is in a plastic state and which overcomes various drawbacks of the prior art, such as those described above.
SUMMARY OF THE INVENTION
[0010] The present invention provides a void former or dowel sleeve that may be completely and easily removed from a concrete slab or the like after the concrete has hardened to provide an opening or void to receive a load-transmitting dowel. The void former or sleeve may either be inserted into an edge of a concrete slab or other structure after the form has been removed but while the concrete is in a plastic state, or attached to an inner surface of a form and the concrete poured over and around it. In either case, once the concrete has hardened, the void former or sleeve can be easily removed from the hardened concrete by simply imparting a tensile force to its outer end. This will cause the void former or sleeve to collapse inwardly upon itself, thereby reducing its diameter to a dimension substantially less than that of the void it has formed, and allowing it to be completely and easily removed from the hardened concrete slab or other structure. In accordance with the present invention this is accomplished by injection molding the void former or sleeve with a closed inner end and a flanged outer end, with the body of the void former or sleeve provided on its inner surface with a groove extending spirally about the inner wall of the void former or sleeve. The groove does not extend completely through the wall of the void former or sleeve, but stops just short of the outer surface. This provides a smooth outer surface and a thin bridge of material over the spiral groove. As a consequence, the void former or sleeve possesses sufficient rigidity for handling and placement, while at the same time, furnishing a readily rupturable section when exposed to the proper forces. More specifically, when it is desired to remove the void former or sleeve from a hardened concrete slab or the like, a tensile force, acting substantially longitudinally of the void former or sleeve, is applied to its flanged end. This tensile force is transmitted as a shear force normal to the thin web bridging the spiral groove and thereby permitting the void former or sleeve to be collapsed inwardly.
[0011] In other words, the longitudinal tensile force applied to the outer end of the void former or sleeve, tends to elongate it. As a result, the void former or sleeve, tends to contract in diameter. This brings a shear force to bear transversely of the wall of the void former, rupturing the wall at its weakest point, and resulting in further contraction to a size permitting ready withdrawal from the slab.
[0012] The features and objectives of the present invention will become more readily apparent from the following Detailed Description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with a general description of the invention given above, and the detailed description given below, serve to explain the invention.
[0014] FIG. 1 is a perspective view of an exemplary concrete dowel void former, according to the present invention;
[0015] FIG. 2 is a partial cross-sectional view of the void former of FIG. 1 , taken along line 2 - 2 ;
[0016] FIG. 2A is a partial cross-sectional view similar to FIG. 2 , depicting another embodiment of the void former; and
[0017] FIGS. 3A-3B are cross-sectional views depicting operation of the void former.
DETAILED DESCRIPTION
[0018] Referring to FIG. 1 , there is shown an exemplary concrete dowel void former 10 of the present invention. The void former 10 has an elongate tubular body 12 with a first, open end 14 and a second, closed end 16 . The second end 16 of the body 12 may be tapered to facilitate insertion of the void former 10 into a slab of plastic concrete. The body 12 comprises a body wall 18 having an inner surface 20 and an outer surface 22 . An interior cavity 24 extends along the body 12 between the first and second ends 14 , 16 . A spiral groove 32 is formed in the inner surface 20 of body wall 18 and extends from the first end 14 toward the second end 16 . In the exemplary embodiment shown, groove 32 extends around the circumference of the body 12 in a helical fashion, defining adjacent spiral-wound portions 12 a , 12 b , 12 c of the body 12 , between successive turns of the groove 32 .
[0019] Referring to FIG. 2 , there is shown a partial section of the void former 10 illustrating the groove 32 formed in the inner wall 20 of body wall 18 . In the exemplary embodiment shown, groove 32 is defined as a v-shaped cross section formed into the inner surface 20 of the body wall 18 , but it will be understood that groove 32 may have other shapes and configurations. In an exemplary embodiment, groove 32 is formed from the inner surface 20 toward the outer surface 22 , but does not completely extend through the thickness of body wall 18 . Advantageously, a thin web of material 34 is retained between the groove 32 and the outer surface 22 to provide rigidity to the body 12 . In another embodiment, shown in FIG. 2A , the groove 32 is formed from the outer surface 22 toward the inner surface 20 .
[0020] Advantageously, groove 32 permits the void former 10 to collapse inward when a tensile or torsional force is applied to the first end 14 of the body 12 . This collapsing action of void former 10 may be best understood with reference to FIGS. 3A-3B . Specifically, when a tensile force is applied to first end 14 of void former 10 while void former 10 is otherwise gripped within a void in a concrete slab 36 , adjacent spiral-wound portions 12 a , 12 b , 12 c of the body 12 defined by groove 32 become separated as body 12 assumes an increasingly elongated shape under the tensile force. As body 12 increases in length, it also undergoes a reduction in outer diameter whereby outer surface 22 is urged in a direction away from the concrete wall defining the void formed in the concrete slab 36 .
[0021] When groove 32 does not extend fully through body wall 18 and a tensile force is applied to the first end 14 , the configuration of the spiral groove 32 creates shearing forces in a direction transverse to the thin web of material 34 . Advantageously, the thickness of the web 34 between the groove 32 and outer surface 22 may be configured such that the shear forces rupture the web 34 when a desired tensile force is applied to the first end 14 of the body 12 . After the web 34 has ruptured, the unrestrained groove 32 facilitates collapsing of the body 12 inward to make removal of the void former 10 easier. Because void former 10 can collapse inwardly to facilitate removal from cured concrete, the outer surface 22 of the body 12 can be formed without a taper along its length so that substantially cylindrical voids may be formed in the slab.
[0022] Void former 10 further includes a flange 26 disposed at the first end 14 . Flange 26 extends in a generally radially outward direction from the body 12 and circumscribes a portion of the first end 14 . In the exemplary embodiment shown, a notch 28 in the flange 26 is located proximate outer terminus of groove 32 , with side edges 29 a , 29 b lying on opposite sides of the terminus of the groove 32 . Flange 26 may be provided with additional notches or apertures 30 configured to receive fasteners (not shown) for securing void former 10 to a concrete form, or to facilitate grasping flange 26 to thereby apply a tensile force and/or torque to first end 14 .
[0023] In use, void former 10 may be used to create voids in concrete slabs for receiving dowels. In this regard, a series of void formers 10 may be secured to an inner surface of a concrete form to face inward of an area for receiving poured, wet concrete. The poured concrete surrounds the void former 10 . Once the concrete has cured, the forms may be removed and the void formers, still attached to the form, will be withdrawn from the slab as described above, to expose the voids.
[0024] In another exemplary embodiment, void former 10 may be inserted into a concrete preformed concrete slab, while the concrete is still in a plastic state. After the concrete has cured, void former 10 may be removed as described above to expose the void. A dowel may then be inserted into the void and concrete poured into an adjacent area to create an adjacent slab.
[0025] While the present invention has been illustrated by the description of the various embodiments thereof, and while the embodiments have been described in considerable detail, it is not intended to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art. The invention in its broader aspects is therefore not limited to the specific details, representative apparatus and methods and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the scope or spirit of Applicant's general inventive concept. | A void former or dowel sleeve adapted to be encapsulated in a hardened mass of concrete, which is collapsible upon the application of a tensile force longitudinally thereof to remove the void former from the concrete and provide a void for a load transferring dowel. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a laser irradiation device used for various medical treatments such as transpiration (cutting out) and coagulation (stopping bleeding) of tissues by irradiating intensive laser light to tissues of living bodies, in particular, human bodies.
2. Prior Art
Before describing the prior art of the laser irradiation device for medical treatment, the basic transpiration and coagulation principles by irradiating laser light are described below referring to FIG. 21.
Transpiration and coagulation by laser light irradiation are performed by converting laser light into thermal energy and by applying the energy to tissues. The transpiration and coagulation capabilities greatly depend on the irradiation conditions of the laser light, such as the irradiation angle and diffusion conditions of the laser light.
More specifically, in the case of sharp transpiration which does not require coagulation on the sides of a transpiration section, the laser light 101 should be irradiated in a concentrated beam within a small angle range from the end of a contact probe 100 as shown in FIG. 21 (a).
In the case of fairly deep transpiration which requires coagulation on the sides of a transpiration section, laser light 101 should be irradiated at a large irradiation angle of θ° from the end of the contact probe 100 as shown in FIG. 21 (b). By setting the large irradiation angle θ°, the coagulation capability during transpiration, that is, the capability of stopping bleeding on the sides of the transpiration section is enhanced. In particular, by setting the irradiation angle of the laser light 101 at a uniform value in the range of the irradiation angle θ°, the transpiration on the sides is smoothened and the coagulation capability is enhanced. In addition, the transpiration and coagulation capabilities on the sides are also enhanced. By restricting an excessive output in the axial direction of the probe and distributing the output to the sides, the output of the laser light can be reduced. This can reduce the effect of the laser light to the operator, the patient and the peripheral tissues of the transpiration section. The affected area of the patient can thus less damaged. When a greater transpiration depth is required in the case of transpiration and coagulation at tissues with numerous blood vessels, the laser light 101 should be irradiated from the probe's side having a length from the end to the base section of the contact probe 100 as shown in FIG. 21 (c). The above explanations regarding the relationship between the transpiration and coagulation capabilities and the laser light irradiation angle applies to a contact probe including a cylindrical base section and a tapered cone section being symmetrical around the axis of the probe (hereafter referred to as "a cone probe"). In addition, a hemispheric probe with a hemispheric end which offers a converging convex lens effect and can be pressed against affected areas is primarily used for transpiration. A flat probe with a flat end is primarily used for coagulation at affected areas. Moreover, a point chisel-shaped probe with symmetrical chisel surfaces is primarily used to slantly cut off affected areas. There is no doubt that the transpiration and coagulation capabilities are also greatly dependent on the irradiation and diffusion conditions of the laser light from the end sections of these kinds of various probes in the same way as the above-mentioned cone probe.
A means for changing the incidence energy of the laser light to the incidence end surface at the base section of the probe of a conventional laser irradiation device is generally used to change the transpiration and coagulation capabilities. Other means for changing the capabilities, such as a means for changing the overall length (L1) of the probe 100 with taper angle θ2 to change the irradiation angle θ° of the laser light 101 as shown in FIG. 22 and a means for changing the outside diameter (D2) of the base section of the probe 100 with taper angle θ2 to change the irradiation angle θ° of the laser light 101 as shown in FIG. 23 have been known when cone probes are taken as examples. Among the above-mentioned conventional capability changing means, in the case of the means for changing the incidence energy of the laser light to the incidence end surface at the base section of the probe, the transpiration and coagulation capabilities can be changed by proportionally adjusting the irradiation energy of the laser light depending on the adjustment of the incidence energy of the laser light. However, in that case the transpiration and coagulation capabilities depending on the laser light irradiation angle and diffusion conditions cannot be changed. Accordingly, the increase in rate of the transpiration and coagulation capabilities is low even when the output of the laser generation unit is increased significantly. The increase of the output energy causes danger to the operator and the patient, damage to the tissues of the affected area and early worn-out of the probe. As shown in FIGS. 22 and 23, in the case of the means for changing the overall length of the probe or the diameter of the base section of the probe, the increase rate of the transpiration and coagulation capabilities is restricted depending on clinical purposes, the structural limitations of the holding members used to coaxially secure the probe and the optical fiber, and the operation limitations by the operator.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a laser irradiation device capable of varying the irradiation angle, which can increase the transpiration and coagulation capabilities using a low output laser generation unit without impairing the operability of the device and can commonly incorporate holding and other members.
Another object of the present invention is to change the irradiation angle at low cost by simply machining a contact probe.
Still another object of the present invention is to improve the transpiration and coagulation capabilities while maintaining the inherent form of the contact probe and securely achieving the intended clinical purposes.
To accomplish the above-mentioned objects, the laser irradiation device capable of varying irradiation angle of the present invention comprises an optical fiber connected to a laser generation unit, a contact probe which irradiates, from the end section of the probe, laser light being incident from the incidence end surface thereof provided facing the irradiation end surface of the end section of the optical fiber, and a holding member which coaxially secures the base section of the contact probe including the incidence end surface thereof and the end section of the optical fiber including the irradiation end surface thereof. The irradiation device is characterized in that the device further comprises a means for changing the irradiation angle of the laser light being irradiated from the end section of the contact probe of the device under the condition that the diameter of the base section of the contact probe is standardized.
The present invention has the following numerous embodiments. With the first embodiment, the irradiation angle changing means comprises a plurality of laser light reflection surfaces which are successively formed on the circumferential surface of the contact probe along the axis thereof and differ in angle to the axis thereof from one another.
With the second embodiment, the irradiation angle changing means comprises a partially tapered step section in which the taper angle of at least one reflection surface is larger than those of the rest of the reflection surfaces.
With the third embodiment, the irradiation angle changing means comprises a combination of a plurality of cylindrical surfaces provided in parallel along the axis of the probe and a plurality of cone surfaces, each diameter of which becomes smaller toward the end of the surface.
With the fourth embodiment, the irradiation angle changing means comprises a plurality of the reflection surfaces formed by the circumferential surfaces with different taper angles on a plurality of contact probes formed coaxially.
With the fifth embodiment, the contact probe is a tapered cone symmetrical around the axis thereof and the irradiation angle changing means comprises partial step sections formed on the circumferential surface of the probe wherein the reflection angle of the incident laser light exceeds the critical angle for reflection of the light and a part of the laser light leaks from the circumferential surface of the probe.
With the sixth embodiment, the irradiation angle changing means comprises a lens-shaped curved surface at the incidence end surface of the contact probe to change the incidence angle.
With the seventh embodiment, the lens-shaped curved surface is concave to increase the incidence angle of the laser light.
With the eighth embodiment, the lens-shaped curve is convex to decrease the incidence angle of the laser light.
With the ninth embodiment, the irradiation angle changing means comprises a combination of a plurality of the reflection surfaces formed on the circumferential surface of the contact probe and having different reflection angles of the laser light and a lens-shaped curved surface on the incidence end surface of the contact probe.
With the tenth embodiment, the irradiation angle changing means incorporates an optical means which can change the irradiation angle of the laser light from the optical fiber and is provided between the irradiation end surface of the end section of the optical fiber and the incidence end surface of the base section of the contact probe, while maintaining the distance between said two surfaces.
With the eleventh embodiment, the irradiation angle changing means incorporates an optical means which can change the irradiation angle of the laser light from the laser generation unit and is provided on the incidence end surface of the base section of the optical fiber, while maintaining the position of the incidence end surface of the base section.
With the twelfth embodiment, the irradiation angle changing means is structured such that the distance between the irradiation end surface of the end section of the optical fiber and the incidence end surface of the base section of the contact probe can be changed.
Other embodiments and their contents will be apparent from the later description of the embodiments wherein the assigned embodiment numbers do not coincide with the above-mentioned manner numbers. Using the present invention having the above-mentioned structures, the laser beam irradiation and diffusion conditions which greatly affect the transpiration and coagulation capabilities can be set and changed as desired by changing the irradiation angle of the laser light irradiated from the end section of the contact probe. Therefore, the transpiration and coagulation capabilities can be increased using a low output laser generation unit, while maintaining the length and diameter of the probe at values suited for easy operation. It is not necessary to extend or expand the length or diameter of the probe to a value larger than that required. In addition, the transpiration and coagulation capabilities can be improved as described above by using the probe, the base section diameter of which is standardized in a certain value. When coaxially securing the end section of the optical fiber and the base section of the probe, the same holding member can be commonly used for any probes having different capabilities. In other words, a single holding member can be interchangeably used with a plurality of probes of different capabilities. Accordingly, by using the present invention, the output of the laser generation unit can be lowered. Because the output of the laser generation unit is proportional to its price, the entire system can be structured at lower cost.
The improvement of the transpiration and coagulation capabilities can be attained at low cost by simple additional machining of the probes of the same specifications while maintaining the probe structure in a shape suited for clinical purposes so that the probes can be used for the various types of the laser light irradiation angle changing means. The means has partially stepped sections with different taper angles along the axis of the circumferential surface of the contact probe, a combination of a cylindrical surface and a tapered surface, a consecutive forming of a plurality of probes along the axis of the contact probe with circumferential surfaces having different taper angles to form a plurality of reflection surfaces with different reflection angles of the laser light, or a lens-shaped (concave or convex) curve at the incidence end surface of the contact probe capable of changing the incidence angle of the laser light.
Furthermore, it is not necessary to machine the probe when an optical means is incorporated as a laser light irradiation angle changing means to change the irradiation angle from the optical fiber, when an optical means is incorporated to change the irradiation angle of the laser light from the laser generation unit or when the distance between the irradiation end surface of the end section of the optical fiber and the incidence end surface of the base section of the probe is changed. Therefore the improvement of the transpiration and coagulation capabilities can be attained while the inherent form of the probe is maintained to achieve the intended clinical purposes.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partially cutaway side view illustrating the structure (prior art) of the laser irradiation device related to first, second and third embodiments of the present invention,
FIGS. 2 (a), (b) and (c) are side views of the probes of the first embodiment,
FIGS. 3 (a) and (b) are side views of the probes of the second embodiment,
FIG. 4 is a side view of the probe of the third embodiment,
FIG. 5 is a partially cutaway side view illustrating a prior art structure of a laser irradiation device upon which to a fourth embodiment of the present invention is based, FIG. 6 (a) and (b) are side views of the probes of the fourth embodiment,
FIG. 7 is a partially cutaway side view illustrating the structure of the laser irradiation device related to a fifth embodiment of the present invention,
FIGS. 8 (a) and (b) are side views of the probes of the fifth embodiment,
FIG. 9 is a partially cutaway side view illustrating a prior art structure of a laser irradiation device upon which a sixth embodiment of the present invention is based,
FIGS. 10 (a) and (b) are side views of the probes of the sixth embodiment,
FIG. 11 is a partially cutaway side view illustrating a prior art structure of a laser irradiation device upon which to a seventh embodiment of the present invention is based, FIG. 12 (a) and (b) are side views of the probe of the seventh embodiment,
FIGS. 13 (a) to (i) are side views of the probes of an eighth embodiment,
FIG. 13 (j) is a sectional view taken on line X--X of
FIG. 13 (i),
FIG. 14 (a) to (d) are side views of the probes of a ninth embodiment,
FIGS. 15 (a) and (b) are vertical sectional side views of major sections of a tenth embodiment,
FIG. 16 (a) and (b) are enlarged vertical sectional side views of the laser irradiation device related to an eleventh embodiment,
FIGS. 17 (a) and (b) are enlarged vertical sectional side views of major sections of the laser irradiation device related to a twelfth embodiment,
FIGS. 18 to 20 are enlarged side views illustrating modification examples of partially tapered step sections,
FIGS. 21 (a) to (c) are side views illustrating the relationship between the transpiration and coagulation capabilities and laser light irradiation angles, and
FIGS. 22 and 23 are side views of the probes incorporating the examples of the conventional capability changing means.
DETAILED DESCRIPTION OF THE INVENTION
First Embodiment
This embodiment applies to a laser irradiation device equipped with a cone probe. As shown in FIG. 1, the embodiment comprises an optical fiber 1 which is connected to a laser generation unit (not shown) and optically converges parallel laser light generated from the laser generation unit at a certain angle then conducts the laser light, a cone contact probe 2 which reflects laser light 10A being incident at the maximum diverging angle from the incidence end surface 2C provided facing the irradiation end surface 1C of the optical fiber 1, and a holding member 3 composed of a pair of cylindrical male and female screw members 3A and 3B screw-connectable to each other so that the cylindrical base section 2A including the incidence end surface 2C of the probe 2 is coaxially secured with the end section 1B including the irradiation end surface 1C of the optical fiber 1.
With this embodiment, a laser light irradiation angle changing means shown in FIG. 2 has been added to the laser irradiation device having the above-mentioned structure (prior art). Referring to FIG. 2, the overall length (L1) of the probe 2, the length (L2) of the cylindrical base section 2A, the incidence angle (θ1) to the incidence end surface 2C, the taper angle (θ2) of the probe 2 and the outside diameter (D1) of the cylindrical base section 2A are standardized. On the circumferential surface of the probe 2 between the base section 2A and the end section 2B, a partially tapered step section 4 with a length (L4) and a taper angle (θ5) being larger than the taper angle (θ2) of the probe 2 is formed to function as the above-mentioned irradiation angle changing means. The taper angle (θ5), the length (L4) and the number of the partially tapered step sections 4 have been determined by considering the relationship to the values of the lengths (L1 and L2), the angles (θ1 and θ2) and the diameter (D2) so that the laser light 10A can be irradiated from the end section 2B in the desired pattern. FIG. 2 (a) shows a device with one tapered step section 4, FIG. 2 (b) shows a device with two tapered step sections 4 and FIG. 2 (c) shows a device with three tapered step sections 4. In the case of the device shown in FIG. 2 (a), the laser light 10B has a large irradiation angle (θ3) to improve the transpiration and coagulation capabilities. In the cases of the devices shown in FIGS. 2 (b) and (c), the laser light 10B is irradiated from the side surface with a certain length (1) on the end section 2B to improve the transpiration and coagulation capabilities at tissues including many veins.
In the first embodiment, the irradiation angle (θ3) of the laser light 10B and the irradiation range length (1) on the side can be set as desired by changing the number of steps, the length (L4), the taper angle (θ5) of the partially tapered step section 4 and the positions and space of a plurality of the partially tapered step sections 4.
Instead of the cylindrical base section, a single cone shape along the entire length of the probe can be used in the case of the first embodiment.
Second embodiment
This embodiment applies to the laser irradiation device equipped with a cone probe, which is basically identical to the first embodiment. The overall length (L1) of the probe 2, the length (L2) of the cylindrical base section 2A, the incidence angle (θ1) to the incidence end surface 2C, the taper angle (θ2) of the probe 2 and the outside diameter (D1) of the cylindrical base section 2A are standardized. The incidence end surface 2C of the probe 2 has a curved surface of a concave lens as shown in FIG. 3 (a) or has a curved surface of a convex lens as shown in FIG. 3 (b).
In the case of the device shown in FIG. 3 (a), the incidence angle (θ6) is larger than the incidence angle (θ1) at the incidence end surface 2C. The coagulation capability can be improved by irradiating the laser light 10B from the side of the end section 2B. In the case of the device shown in FIG. 3 (b), the incidence angle (θ7) is smaller than the incidence angle (θ1). The irradiation angle (θ8) of the laser light 10B at the end section 2B is small and thus sharp transpiration is possible. With the second embodiment, the laser light irradiation length and angle from the side surface of the probe can be set as desired by changing the curvature radius (R1) of the concave lens-shaped curvature surface, 2C and the curvature radius (R2) of the convex lens-shaped curvature surface 2C.
Third Embodiment
This embodiment applies to the laser irradiation device equipped with a cone probe. The structure and the specifications (L1, L2, θ1, θ2 and D1) are the same as those of the first and second embodiments. The partially tapered step section 4 with a taper angle (θ5) is formed at the circumferential surface close to the end section 2B of the probe 2. The incidence end surface 2C of the probe 2 has a curved surface of a concave lens as shown in FIG. 4 (a) or has a curved surface of a convex lens as shown in FIG. 4 (b). With the combination, the irradiation angle and diffusion conditions for the laser light 10B irradiated from the end section 2B of the probe 2 can be changed so that the transpiration and coagulation capabilities can be changed as desired. The number of the tapered step sections 4 of the third embodiment can be two as shown in FIGS. 4 (a) and (b) or one or three or more.
Fourth Embodiment
This embodiment applies to the laser irradiation device equipped with a hemispherical probe mainly used for transpiration. The mechanical details of the coupling between the fiber optic and the probe of the fourth embodiment are as shown in FIG. 5. In particular, the embodiment has a structure comprising an optical fiber 1 which is connected to a laser generation unit (not shown) and conducts laser light from the laser generation unit, a hemispherical probe 2 which converges the laser light 10A being incident from the incidence end surface 2C provided facing the irradiation end surface 1C of the optical fiber 1 using the convex lens's converging effect and irradiates the laser light 10B from the hemispherical end section 2B which can be pressed against the affected area of the patient, and a pair of cylindrical male and female screw members 3A and 3B screw-connectable to each other so that a cylindrical base section 2A including the incidence end surface 2C of the probe 2 is coaxially secured with the end section 1B including the irradiation end surface 1C of the optical fiber 1.
With the laser irradiation device having the above-mentioned structure, the outside diameter (D1) of the cylindrical base section 2A of the probe 2 and the incidence angle (θ1) to the incidence end surface 2C are standardized. On the circumferential surface of the probe 2, the partially tapered step section 4 with a length (L4) and a taper angle (θ5) is formed as shown in FIG. 6 (a). The incidence end surface 2C of the probe 2 is formed on the concave (or convex) lens-shaped curved surface with a curvature radius (R) as shown in FIG. 6 (b). The irradiation diameter (D4) of the laser light 10B from the end section 2B can be set as desired using the tapered step section or curvature section.
Fifth embodiment
This embodiment applies to the laser irradiation device equipped with a flat probe mainly used for coagulation. As shown in FIG. 7, the embodiment comprises an optical fiber 1, a flat probe 2 comprises a flat end section 2B and a holding member including a pair of cylindrical male and female screw members 3A and 3B screw-connectable to each other in the same way as the fourth embodiment. With the laser irradiation device having the above-mentioned structure, the outside diameter (D1) of the cylindrical base section 2A of the probe 2 and the incidence angle (θ1) to the incidence end surface 2C are standardized. On the circumferential surface of the probe 2, the partially tapered step section 4 with a length (L4) and a taper angle (θ5) are formed as shown in FIG. 8 (a). The incidence end surface 2C of the probe 2 is formed on the concave (or convex) lens-shaped curved surface with a curvature radius (R) as shown in FIG. 8 (b). The irradiation diameter (D4) of the laser light 10B can be set as desired using the tapered step section or curvature section in the same way as the fourth embodiment.
Sixth Embodiment
This embodiment applies to the laser irradiation device equipped with a point chisel-shaped probe mainly used for slantly cutting off affected areas. The mechanical details of the coupling between the fiber optic and the probe of the sixth embodiment are as shown in FIG. 9. In particular, the embodiment comprises an optical fiber 1, a point chisel-shaped probe 2 including an end section 2B with symmetrical chisel surfaces and an edge right-angled to the axis of the probe, and a holding member 3 composed of a pair of cylindrical male and female screw members 3A and 3B in the same way as the fourth and fifth embodiments. The irradiation length (X) of the end section 2B of this type should be as short as possible. The taper angle (θ4) of the end section 2B, the outside diameter (D1) of the cylindrical base section 2A and the incidence angle (θ1) to the incidence end surface 2C are standardized. On the circumferential surface of the probe 2, the partially tapered step section 4 with a length (L4) and a taper angle (θ5) are formed as shown in FIG. 10 (a). The incidence end surface 2C of the probe 2 is formed on the convex lens-shaped or cylindrical curvature surface. With this type, the irradiation length (X) of the end section 2B can be set as desired.
Seventh Embodiment
This embodiment applies to a laser irradiation device equipped with a short probe used for high-speed transpiration and uniform heating of affected areas. The mechanical details of the coupling between the fiber optic and the probe of the seventh embodiment are as shown in FIG. 11. In particular, the embodiment comprises an optical fiber 1, a short cone probe 2 having a cone end section 2B and irradiates the laser light 10B from the entire surface of the taper section, and a holding member 3 composed of a pair of cylindrical male and female screw members 3A and 3B in the same way as the above-mentioned embodiments. With this type, the laser light 10B should be irradiated from the entire surface of the end section 2B. The taper angle (θ4) of the end section 2B, the outside diameter (D1) of the cylindrical base section 2A and the incidence angle (θ1) to the incidence end surface 2C are standardized. On the circumferential surface of the probe 2, a partially tapered step section 4 with a length (L4) and a taper angle (θ5) is formed and the incidence end surface 2C of the probe 2 is formed on the concave lens-shaped curved surface with a curvature radius (R) as shown in FIG. 12 (a). Or two partially tapered step sections 4 with a length (L4) and a taper angle (θ5) are formed as shown in FIG. 12 (b). With these types, the irradiation length (X) of the tapered end section 2B can be changed as desired.
Eighth Embodiment
In a laser irradiation device equipped with a cone probe used in the above-mentioned first, second and third embodiments, the device of this embodiment is another example of the means for forming a plurality of reflection surfaces with different reflection angles of the laser light. The devices shown in FIGS. 13 (a) to (f) have two probe members 20 and 21 with circumferential surfaces 20A and 21A having different taper angles (θ2A) and (θ2B). The two probe sections are consecutively formed along the same axis to form a single probe 2. Around the tapered surfaces 20A and 21A of the probe sections 20 and 21, a plurality of reflection surfaces with different reflection angles (α) and (β) of the laser light 10A are formed. In addition, a circular step section 22 is projected outward perpendicular to the axis of the probe at the border section of the probe sections 20 and 21. The device shown in FIG. 13 (g) is a formation of a probe section 20 with a cylindrical surface 20B which extends to its entire length along the axis of the probe 2 and a probe section 21 with a circumferential surface 21A with a constant taper angle (θ2B) to form a single probe 2. A circular step section 22 similar to the one described above is formed at the border section of the probe sections 20 and 21. The device shown in FIGS. 13 (h) and (i) comprises three probe sections 20, 21 and 21' with circumferential surfaces 20A, 20B and 20C having different taper angles (θ2A),(θ2B) and (θ2C) along the same axis to form a single probe 2. In particular, the device shown in FIG. 13 (h) comprises a plurality of micro-step sections 23 composed of V-shaped circular grooves around the end section of the probe section 21' located closest to the end section. The device shown in FIG. 13 (i) has a plurality of grooves 24 shown in FIG. 13 (j) along the axis around the end section of the probe section 21' located closest to the end section to change the laser light irradiation condition at the end section. In the case of the embodiments shown in FIGS. 13 (a) to (i), by forming a plurality of probe sections, a laser irradiation device with a desired irradiation angle (θ3) and a desired side irradiation range (1) can be made. This type can be produced by either of cutting a single spindle or joining separate probe
Ninth Embodiment
In a laser irradiation device equipped with a cone probe used in the above-mentioned first, second and third embodiments, the device of this embodiment is still another example of the means for forming a plurality of reflection surfaces with different reflection angles of the laser light. As shown in FIGS. 14 (a) to (d), on the circumferential surface of the probe 2, one or a plurality of cylindrical surfaces 2P along the axis of the probe 2 are formed with one or a plurality of tapered surfaces 2T, the diameter of which is smaller at a point closer to the end section, by setting the irradiation angle (θ3) of the laser light from the end section of the probe and the irradiation range (1) at the side surface as desired.
This type can be produced in the same way as that of the eighth embodiment.
Tenth Embodiment
As shown in FIGS. 15 (a) and (b), an optical lens capable of changing the irradiation angle (θ1) of the laser light from the optical fiber 1 is incorporated between the irradiation end surface 1C at the end section of the optical fiber 1 and the incidence end surface 2C of the base section 2A of the contact probe 2 to change the irradiation angle of the laser light from the end section of the contact probe 2. More specifically, a pair of male and female screw members 3A and 3B are used to coaxially secure the end section 1B including the irradiation end surface 1C of the optical fiber 1 with the base section 2A of the probe 2, and a convex lens 25 is secured via a holding member 26 on the cylindrical screw member 3A. By relatively moving the screw members 3A and 3B along the optical axis, the distance between the irradiation end surface 1C of the fiber 1 and the convex lens 25 is changed. This changes the incidence angle (θ9) at the probe 2.
Eleventh Embodiment
As shown in FIGS. 16 (a) and (b), with the incidence end surface 1A of the base section of the optical fiber 1 set at a constant position, an optical means capable of changing the converging angle (θ7) of the parallel laser light 11 from a laser generation unit (not shown) is incorporated to change the irradiation angle of the laser light irradiated from the end section of the contact probe 2. More specifically, a cylindrical member 6 equipped with a fixed lens 5 on which the laser light 11 is incident is provided on the side of the incidence end surface 1A of the optical fiber 1. A movable cylindrical member 8 equipped with a convex lens 7 which is coaxial to the fixed lens 5 is coaxially fit in the cylindrical member 6 so that the movable member 8 can be moved along the optical axis and fixed via a screw section 9.
Twelfth Embodiment
As shown in FIGS. 17 (a) and (b), the distance (L5) between the irradiation end surface 1C of the optical fiber 1 and the incidence end surface 2C of the contact probe 2 is changed to change the diameter of the laser light in the probe 2. By changing the diameter, the irradiation angle of the laser light from the end section 2B of the contact probe 2 can be changed. More specifically, a pair of male and female cylindrical screw members 3A and 3B of the holding member 3 for coaxially securing the optical fiber 1 and the probe 2 are movable along the optical axis and can be fixed via a lock nut 3C at the desired distance (L5).
Various types are obtained without changing the specifications of the probe 2. In addition, the irradiation angle and diffusion conditions can be changed without replacing the probe 2.
Other Embodiments
The partially tapered step sections 4 shown in the above-mentioned embodiments can have a V-shaped form shown in FIG. 18. Alternately, the partial step section can also be formed by a concaved circular arc surface as a reflection surface shown in FIG. 19 and a concaved complex curve surface shown in FIG. 20. The holding member 3 can have various structures other than those shown in the above-mentioned embodiments. | A laser irradiation device comprising an optical fiber, a contact probe which irradiates laser light from the irradiation end section thereof, and a holding member which coaxially secures the contact probe and the optical fiber. The device is further characterized in that the irradiation angle of the laser light irradiated from the irradiation end section of the contact probe can be changed while the diameter of the contact probe is standardized, whereby the irradiation angle and diffusion conditions of the laser light can be set and changed as desired to improve the transpiration and coagulation capabilities using a low output laser generation unit, thus reducing the coast of the entire laser irradiation system. | 6 |
TECHNICAL FIELD OF THE INVENTION
[0001] Present invention discloses biocompatible metal-organic frameworks (MOFs) of formula I that combine a metal and a derivative of an amino acid. Particularly, the invention discloses MOFs of a metal and a derivative of an amino acid which are water soluble.
BACKGROUND AND PRIOR ART OF THE INVENTION
[0002] Metal-organic frameworks (MOFs) are a class of new materials well known for their high surface area and pore size. They can be tuned by dictating the various derivatives of amino acids. Most of the reported MOFs in the literature, numbering nearly 25000 till date, are insoluble in water. The brittle nature of these crystalline materials put many challenges for their industrial processing. Further, it is also a challenge to synthesize them in combination with other functional materials without pore blocking and/or decrease of the inner surface area.
[0003] Research on Metal-Organic Frameworks (MOFs) has picked up researchers attention because of their diverse topological architectures and applications like gas sorption, catalysis, magnetism and electrical conductivity. Proton (ion) conductivity in solid-state materials are important due to their application in transport dynamics; electrochemical devices, fuel cells and most importantly to understand the complex biological ion channels. For such diverse applications there is a need for the MOFs to have adequate stability in environments that vary in temperature, pressure, water content and such like. A very limited attempt on the proton conductivity on MOFs has been reported where either lattice backbone, added guest molecules like imidazole and 1,2,4-triazole in an anhydrous medium, or water chains and clusters already present inside the framework facilitate proton conduction.
[0004] References may be made to Journal J. Am. Chem. Soc. 2009, 131, 13516 by Kitagawa et al. have extensively studied proton conductivity in various MOFs where coordinated water or guest molecules play a vital role in proton conduction. However, the role of halogens (especially halogens coordinated to metals) in controlling proton conduction in MOFs has not been explored at all. Moreover, most of the MOFs, due to their insoluble nature in water can't be fabricated easily as a thin film and usable for proton conduction and various separation applications.
[0005] References may be made to Journal entitled “Helical Water Chain Mediated Proton Conductivity in Homochiral Metal_Organic Frameworks with Unprecedented Zeolitic unh-Topology” (JACS) by Sahoo et al which discloses Four new homochiral metal_organic framework (MOF) isomers, [Zn(l-LCl)/(Cl)](H2O)2 (1), [Zn(l-LBr)(Br)]—(H2O)2 (2), [Zn(d-LCl)(Cl)](H2O)2 (3), and [Zn(d-LBr)—(Br)](H2O)2 (4) [L=3-methyl-2-(pyridin-4-ylmethylamino)-butanoic acid], have been synthesized by using a derivative of LID-valine and Zn(CH3COO)2 3 2H2O. A three-periodic lattice with a parallel 1D helical channel was formed along the crystallographic c-axis.
[0006] Present invention disclose amino acid based MOFs as a water soluble MOF for industrial application like thin film fabrication etc. which are non-obvious from the point of view that although more than 25000 MOFs have been reported in the literature in the last decade, still most of them are water unstable and thus inappropriate for application in day to day purpose, which narrow down the picture many fold to a few class of MOFs which are water stable. Furthermore, the MOF backbone disintegrates as ligand and corresponding metal oxide/hydroxide by means of which the process become irreversible to reconstruct the MOF. Hence, it will be utmost difficult for a researcher to envisage a homochiral MOF material to be water soluble, which is the most non-obviousness disclosed in the patent. Synthesis of four valine based MOFs in the JACS paper, along with the proton conducting data has been reported. However, the process of water solubility has not been at all discussed anywhere in the paper, which is the most striking feature, as well as the most non-obvious, too. Moreover, in the present patent control over the anion to tune the solubility along with the proton conductivity has achieved. Also, change of the ligand backbone (from valine to alanine) has been achieved to prove the extension of the concept described in the disclosure, which has not been ever discussed in the ma paper. The synthesis of Alanine based MOFs were achieved entirely different procedure described in the JACS paper, as general/straightforward synthetic pathway didn't yield the same. The synthesis of the MOFs with suitable variation of eight synthetic parameters i.e. the ligand backbone, the synthesis temperature, the solvents and their ratio for synthesis, the choice of anion, the reactant ratio and the metal salt as well as the pH of the medium has been reported in the present patent proposal. Hence, under this circumstance we, enable us to claim that any researcher, established and expertise in the synthesis of MOF arena won't be able to synthesize the aforementioned MOFs as now the difficulty level of synthesis has increased eight fold as compared to procedure reported in our JACS paper. Also, the water solubility in non-obvious from the point of view that most of the well known MOFs reported in the literature are water unstable and also they decompose in contact of water. The water solubility information is not reported in JACS paper and also non-obvious for any reader or researcher to envisage the water solubility from the data reported therein. Hence, we have pinpointed the non-obviousness of the process in an elaborated manner along with the new Alanine based MOF structures prepared by suitably adjusting synthesis parameters resulted from the point to point description given in the patent disclosure.
[0007] Thus it will highly desirable to have MOFs that have properties that are enlisted herein, but till date, there is no patent or publication available that disclose a MOF with solubility in water. MOFs known in the art, due to their 3-D orientation are known to be water insoluble.
[0008] There is therefore a need in the art to provide stable and water soluble MOFs that can be easily fabricated for proton conduction and for various thin film applications.
OBJECTS OF THE INVENTION
[0009] The main objective of the present invention is to provide water soluble Metal-Organic Frameworks (MOFs) for synthesizing various functionalized materials for proton conduction as well as for selective separation applications including various thin film applications.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 represents ( a ) schematic representation of the links with mirror isomers (l-L X ) and (d-L X ) in the form of different salts, where X═Cl, Br are shown in green. ( b ) Ball and stick model of an asymmetric unit of MOFs with mirror isomers, showing a five-coordinated zinc center (pink ball): ( c ) Space-filling model of two enantiomers of MOF 1 and 3. Opposite helicity is shown as a blue curved arrow. Colour code: gray, Cl; green, Cl; red, 0; blue, N; pink, Zn; white, H.
[0011] FIG. 2 represents ( a ) Polyhedral representation of the MOF 1 lattice viewed down the c-axis. Pink polyhedra represent zinc centers, and lattice water molecules are shown as red balls. ( b ) Tiling figure of MOF 1, showing zeolitic unh-topology (unh is a three letter code representing the topology (structural arrangement) of a zeolite) along the c-axis. The tiling shows one kind of vertices, two kinds of edges, two kinds of faces, and one kind of tiles. ( c ) Mirror isomers of helical water chains surrounded by a molecular helix (outer helix). The molecular helix (outer helix) is shown as pink balls connected via gray bonds, and the helical water chain (inner helix) is shown as red balls connected via blue rods.
[0012] FIG. 3 represents ( a ) In situ variable-temperature powder X-ray diffraction (VT-PXRD) of MOF 3 upon both heating (25-200° C.) and cooling (200-25° C.). This VT-PXRD experiment shows that the framework is stable and remains crystalline over a wide range of temperatures and after solvent removal. ( b ) Water adsorption isotherm of MOF 1 and MOF 2 showing 12 and 6 wt % of adsorption, respectively, at relative pressure P/Po=0.9. wherein P actual pressure exerted by gas and Po=pressure exerted by gas at standard condition.
[0013] FIG. 4 represents ( a ) Photographs of MOF 1 before and after evacuation at 150° C., followed by rehydration showing reappearance of single crystallinity. ( b ) Appearance and disappearance of water peaks in IR spectra of as-synthesized, evacuated, and rehydrated MOF 1 confirms the reversible transformation. The Solid State Nuclear Magnetic Resonance (SSNMR) spectrum of MOF 1-D 2 O (D 2 O exchanged sample of MOF1) is shown in the inset. ( c ) Reversible crystal transformation of MOF 1 confirmed by in situ single-crystal XRD showing the MOF framework with/without solvent (water) as a balland- stick model along the c-axis. Crystallinity of MOF 1 remains intact and suitable for data collection over the temperature, as shown by crystal pictures taken during data collection. ( d ) Thermal desolvation and in situ VT (variable-temperature) single-crystal experiment of evacuated MOFs 1 and 2 achieved at 80 and 40° C., respectively, confirms that MOF 2 has lower water holding capacity than MOF 1.
[0014] FIG. 5 represents ( a ) Proton conductivity data comparison of MOF 1 and 1-D 2 O (inset) at 98% relative humidity (RH) showing decreasing proton conductivity value after D 2 0 substitution. ( b ) Temperature-dependent proton conductivity values of MOF 1 at different temperatures. ( c ) Proton conductivity of MOF 2 at 98% RH, showing zero proton conduction as compared to MOF 1 under similar conditions. ( d ) Arrhenius plots of proton conductivity of MOF 1.
[0015] FIG. 6 represents 3D representation of the water soluble MOF of the invention. MOF crystallizes in the P6 1 space group, which comprises of one Zn(II), one derivative of amino acids and one lattice water molecule in the asymmetric unit. The Zn(II) center adopts a distorted square pyramidal geometry (τ=0.88) chelated by monodentate carboxylate [(Zn1-O2 2.170(3) Å)], and one amino functionality [(Zn1-N1 2.092(4) Å)] of first derivative of amino acids. One pyridyl functionality and one carboxyl oxygen atom of the second derivative of amino acids coordinates in the equatorial positions, and one free chlorine atom occupies the axial site. Noticeably, the amine group is induced by the neighboring chiral carbon center into a homochiral unit to coordinate the zinc atom. As a result, the zinc atom acquires a third homochiral center associated with two homochiral centers. All adjacent zinc nodes are bridged, by pyridyl group to form a 6 1 helical chain with a pitch of 12 Å along the crystallographic c axis. The two coordinated carboxylate oxygen stay opposite to each other along c axis through which additional molecules derivative of amino acids to form the wall of the helical chain. Among the pyridyl rings along the helical chain, one set of pridyl rings run in clockwise direction while other (linking two molecular chains) run anti clockwise to extend the lattice along the ab-plane. This result in a 3D supramolecular network containing close-packed 1D open channel along the c-axis filled with free water molecules weekly hydrogen bonded to halogen atoms coordinated to metal ions. All pyridyl rings and isopropyl groups constitute the wall of the helical channel and provide a hydrophobic environment to it. This molecular arrangement results in a rare zeolitic unh-topology which has not been perceived so far in any synthetic means even though it is theoretically proposed in ZIFs (Zeolitic Imidazolate Framework).
[0016] FIG. 7 represents the schematic process of water solubility exhibited by the water soluble MOF. When a specific amount of water soluble MOF (50 mg) was taken along with specific amount of solvent (2 ml) the MOF shows water solubility, yielding first turbid solution which turns clear upon heating. Both the solution represents the MOF solution in water. To get back or regenerate the original MOF material, only one step is necessary is that to heat the solution at 90° C. to take out the water.
SUMMARY OF THE INVENTION
[0017] Accordingly, present invention provides stable, water soluble and biocompatible metal organic frameworks (MOFs) of formula I
[0000] [M( l/d -L X )(X)](H 2 O) 2 Formula I
wherein M is a metal selected from the group consisting of Sc, Ti, V, Cr, Mn, Fe, Co, Ni, Cu, Zn, Y, Zr, Nb, Mo, Tc, Ru, Rh, Pd, Cd, La, W, Os, Ir, Pt, Au, Hg, Sm, Eu, Gd, Tb, Dy, Ho, Al, Ga, In, Ge, Sn, Pb), Li, Na, K, Rb, Cs, Mg, Ca, Sr or Ba: L is derivatives of an amino acid ligand of formula II
[0000]
wherein R 1 =methyl or isopropyl; R 2 =pyridyl, bipyridyl, imidazoleyl, piparizineyl, napthayl, tetrazoleyl and nitrogen containing heterocycles;
X═CH3COO or HCOO when R1=isopropyl in Ligand L of formula II;
X═Cl, Br, CH 3 COO or HCOO; when R1=methyl in Ligand L of formula II.
[0024] In an embodiment of the present invention, representative compounds of said MOF comprising:
[Zn(l-L1 CH3COO )(CH 3 COO)](H 2 O) 2 (5); wherein R1=isopropyl, R2=pyridyl in ligand L; [Zn(l-L1 HCOO )(HCOO)](H 2 O) 2 (6); wherein R1=isopropyl, R2=pyridyl in ligand L; [Zn(l-L2 Cl )(Cl)](H 2 O) 2 (7); wherein R1=methyl, R2=pyridyl in ligand L; [Zn(l-L2 Br )(Br)](H 2 O) 2 (8); wherein R1=methyl, R2=pyridyl in ligand L; [Zn(l-L2 CH3COO )(CH 3 COO)](H 2 O) 2 (9); wherein R1=methyl, R2=pyridyl in ligand L; [Zn(l-L2 HCOO )(HCOO)](H 2 O) 2 (10); wherein R1=methyl, R2=pyridyl in ligand L
[0031] In yet another embodiment of the present invention, the derivative of an amino acid ligands of formula II is selected from the group consisting of:
[0000]
[0032] in yet another embodiment of the present invention, water solubility of compound of formula 1
[0000]
[0000] wherein R 1 =methyl or isopropyl; R 2 =pyridyl, bipyridyl, imidazoleyl, piparizineyl, napthayl, tetrazoleyl and nitrogen containing heterocycles; X═Cl, Br, CH 3 COO or HCOO; when R1=methyl or isopropyl in Ligand L of formula II are in the range of 20-28 mg/ml.
[0033] In yet another embodiment of the present invention, the biocompatible metal organic frameworks are useful for proton conduction.
[0034] In yet another embodiment of the present invention, proton conductivity of the said MOFs is in the range of 3.6×10 −5 S cm −1 to 3.5×10 S cm −1 .
[0035] In an embodiment, present invention also provides a process for preparation of biocompatible water soluble metal organic frameworks (MOF) prepared under hydrothermal conditions and the said process comprising the steps of:
a) adding metal salt to an aqueous solution of derivative of an amino acid in the ratio ranging between 1:1 to 1:2 followed by sonicating to obtain clear solution; b) keeping the tightly capped solution as obtained in step (a) undisturbed, at temperature in the range of 50 to 90° C. to obtain transparent crystals of water soluble metal organic framework (MOF) of formula I.
[0038] In yet another embodiment of the present invention, metal salt is zinc acetate.
DETAILED DESCRIPTION OF INVENTION
[0039] Present invention provides stable, water soluble biocompatible Metal organic frameworks (MOFs) of formula I comprises a metal and derivatives of an amino acid ligand L of formula II
[0000] [M( l/d -L X )(X)](H 2 O) 2 , Formula I
[0000] wherein M is metal;
X is a anion selected from Cl, Br, CH 3 COO or HCOO.
[0040] L is derivatives of an amino acid ligand of formula II and
[0000] The metal of the water soluble MOF of the invention is selected from d-block metals (M +n ═Sc, Ti, V, Cr, Mn, Fe, Co, Ni, Cu, Zn, Y, Zr, Nb, Mo, Tc, Ru, Rh, Pd, Cd, La, W, Os, Ir, Pt, Au, Hg), f-block metals (M +n ═Sm, Eu, Gd, Tb, Dy, Ho), p-block metals (M +n ═Al, Ga, In, Ge, Sn, Pb), alkali metals (M +n ═Na, K, Rb, Cs), alkaline earth metals (M +n ═Mg, Ca, Sr, Ba) and such like.
[0041] The derivative of an amino acid (L) is selected from
[0000]
[0000] wherein R 1 is side chain residue of amino acids;
R1 is methyl for Alanine and isopropyl for valine.
R 2 =pyridyl, bipyridyl, imidazoleyl, piparizineyl, napthayl, tetrazoleyl and nitrogen containing heterocycles,
[0042] Some preferred derivative of an amino acid ligand of the water soluble MOF of the invention are selected from the group consisting of
[0000]
[0043] The MOFs of the invention is prepared by a process under hydrothermal conditions comprising:
a) adding metal salt to an aqueous solution of derivative of an amino acid followed by sonicating the solution to obtain clear solution and b) keeping the tightly capped solution undisturbed at 90° C. to obtain transparent crystals of water soluble MOF.
[0046] Accordingly, to an aqueous solution (2 ml) of derivative of an amino acid (0.2 mmol), suitable metal salt (0.1 mmol) was added and sonicated for 10 min. The clear solution was kept in a tightly capped 5 ml vial for 24 h at 90° C. to produce rod shaped transparent crystals of water soluble MOF (Solubility is 20 mg/ml of water). One preferred metal salt according to the invention is Zn salt, preferably Zn acetate.
[0047] The MOF is characterized by its 3D coordinates as exemplified herein. The MOF is tested for solubility in water by boiling it in water for few minutes. The MOF dissolves in boiling water and on evaporation of the solvent water, the crystallized MOF has been characterized.
[0048] Saturated solutions of the MOF can be made by adding excess MOF into the solution and filtering out the undissolved portion. Such water soluble MOFs are proton conducting and can be fabricated for various thin film applications. The present MOF, due to its easy solubility and stability in water has major advantage over the known MOFs and thus can easily be fabricated for various thin film applications. Due to its solubility in water, a rarely observed phenomenon, as compared to reported′ MOFs, it can provide a new pathway for synthesizing various functionalized materials for selective separation applications.
[0049] Present invention provides six novel biocompatible homochiral metal organic framework (MOF) isomers have been synthesized by using a derivative of L-/D-valine and Zn(CH 3 COO) 2 .2H 2 O and studied for their proton conductivity.
[0000] [Zn( l -L1 CH3COO )(CH 3 COO)](H 2 O) 2 (5)
[0000] [Zn( l -L1 HCOO )(HCOO)](H 2 O) 2 (6)
[0000] [Zn( l -L2 Br )(Br)](H 2 O)2 (7)
[0000] [Zn( l -L2 Br )(Br)](H 2 O) 2 (8)
[0000] [Zn( l -L2 CH3COO )(CH 3 COO)](H 2 O) 2 (9)
[0000] [Zn( l -L2 HCOO )(HCOO)](H 2 O) 2 (10).
[0050] These MOFs are characterized by single crystal X-ray diffraction (SCXRD), thermogravimetric analysis (TGA), powder X-ray diffraction (PXRD), circular dichroism (CD), and hot-stage microscopy. The mobility of the water molecule with respect to temperature has been monitored by in situ variable-temperature powder X-ray diffraction (VT-PXRD) and single-crystal to single-crystal (SC-SC) transformation experiments. The ordered water molecules anchored by weak metalhalogen groups facilitate proton conduction, as confirmed by proton conductivity measurements coupled with deuterium exchange and solid-state (SS) NMR experiments. MOFs such as [Zn(l-L1Cl)(Cl)](H2O)2 (1) and [Zn(d-L1Cl)(Cl)](H2O)2 (3), due to this helical water chain, exhibit a high proton conductivity of ˜4.45×10-5 S cm-1 at ambient temperature, while MOFs [Zn(l-L1Br)(Br)](H2O)2 (2) and [Zn(d-L1Br)(Br)](H2O)2 (4) show almost zero proton conductivity, even though all four MOFs adopt similar architectures [L=3-methyl-2-(pyridin-4-ylmethylamino)butanoic acid].
[0051] MOFs 1-6 reported here were synthesized by mixing Zn(CH 3 COO) 2 .2H 2 O and 3-methyl-2-(pyridin-4: ylmethylamino) butanoic acid (a valine-derived link) ( FIG. 1 a ) under hydrothermal conditions in water medium. Phase-pure rod shaped crystals were grown in a capped vial at 90° C. within 5-6 h. MOFs 1-6 are structural isomers with different anions (Cl or Br or CH 3 COO or HCOO) coordinated to the metal atoms or enantiomers with respect to ligand backbone (d or I). MOF 1 crystallizes in the P61 space group, comprising one Zn(II), one l-L Cl ligand, and two lattice water molecules in the asymmetric unit. The Zn(II) center adopts a distorted square pyramidal geometry (r=0.38), chelated by monodentate carboxylate [(Zn1O2 2.170(3) Å)] and one amino functionality [(Zn1N1 2.092(4) Å)] of the first l-L Cl link. One pyridyl functionality and one carboxyl oxygen atom of the second l-L Cl ligand coordinate in the equatorial positions, and one free chlorine atom occupies the axial site ( FIG. 1 b ). Noticeably, the amine group is induced by the neighboring chiral carbon center into a homochiral unit to coordinate the zinc atom. As a result, the zinc atom acquires a third homochiral center associated with two homochiral centers. All adjacent zinc nodes are bridged by pyridyl groups to form a 6 1 helical chain with a pitch of 12 Å along the crystallographic c-axis ( FIG. 1 c ). The two coordinated carboxylate oxygens stay opposite to each other along the c-axis, through which additional molecules link to form the wall of the helical chain.
[0052] Among the pyridyl rings along the helical chain, one set of pridyl rings run in a clockwise direction while the others (linking two molecular chains) run anti-clockwise to extend the lattice along the ab-plane. This results in a 3D supramolecular network containing a close-packed 1D open channel along the c-axis filled with water molecules ( FIG. 2 a ). Pyridyl rings and isopropyl groups constitute the wall of the helical channel, providing a hydrophobic environment. This molecular arrangement results in a rare zeolitic unh-topology which has not been perceived so far in any synthetic means, even though it is theoretically proposed in ZIFs.
[0053] Lattice water molecules weakly H-bonded to the M-Cl atom (0 . . . . Cl-M, 3.175(1) Å) run along the helical channel ( FIG. 2 c ). The second water molecule resides within H-bonding distance of the first water molecule (DO . . . O=3.234(3)Å) to make a continuous water channel along the c-axis. This H-bonding distance is well within the range of DO . . . O of O—H . . . O hydrogen-bonding reported in the literature. As a result, a secondary helical water chain surrounded by the molecular helix is formed. Weak (O—H . . . Cl-M) H-bonding may allow the water protons to become more acidic. It was found that the helical orientation of
[0000] water molecules is the structural basis by which K+ ion and proton transport occurs inside a KcsA K+ channel and in protein aquaporin-1, respectively. 1D water chains also play vital roles for stabilizing the native conformation of biopolymers, but such helical water chains are less reported in synthetic homochiral crystal hosts, especially in MOFs, because in most cases high boiling solvents like DMF, DMA, DMSO, and DEF are used for MOF synthesis instead of water.
[0054] Single-crystal XRD analysis revealed that MOFs 2, 3, 4, 5 and 6 are isomorphous to MOF 1, where ½ and ¾ are isomers with respect to substituted halogen atoms, like 1 [L 2 M-Cl] and 2 [L 2 M-Br], but ⅓ and 2/4 are enantiomers. In further experiments, it has been confirmed that all six isomers possess similar lattice arrangement (unh-topology) and the helical water chain persists irrespective of the different anion substitution or change in chirality of the ligand backbone.
[0055] The phase purity of the bulk materials was confirmed by PXRD experiments, which are in good agreement with the simulated PXRD patterns. TGA performed on as-synthesized 1-4 MOFs revealed that these compounds have thermal stability up to ˜270° C. The TGA trace for as synthesized 1, 2, 3 and 4 showed gradual weight-loss steps of ˜7% (2H2O in 1 and 3, calcd 10.5%) and ˜6% (2H2O in 2 and 4, calcd 9.3%) over a temperature range of 40-100° C., corresponding to escape of guest water molecules from the pores. We note that the water molecules of 1 and 2 were released without damaging the frameworks, as evidenced by the coincidence of the PXRD patterns of 1 and 2 samples heated to and held at 150° C. in a N2 atmosphere with the PXRD patterns simulated from single-crystal structures. The above fact is also verified by in situ VT-PXRD of MOF 1 and MOF 2. All major peaks of experimental and simulated PXRDs are well matched, indicating the sample's phase purity ( FIG. 3 a ). A combined heating and cooling in situ VT-PXRD experiment reveals that the framework is stable, remains crystalline over a wide temperature range (heating from 25 to 200° C. and then cooling from 200 to 25° C.), and remains stable after solvent removal (solvent escape ˜100° C., confirmed by TGA). Escape of water molecules from the crystals was also monitored by hot-stage microscopy at different temperature intervals (25-270° C.). Pictures taken on a hot-stage microscope reveal that the trapped water molecules escape the lattice between 60 and 120° C. as heating gees on and cracking appears on the crystal surface, but crystallinity remains intact up to 250° C. This observation indicates that it is possible to monitor the arrangement of water molecules with respect to temperature, and we can achieve a solvent-free framework after successful removal of solvent at higher temperatures.
[0056] It is noteworthy that the water molecules adopt similar arrangements in all MOFs 1-6 reported in this paper, except the handedness. The guest-free frameworks of MOFs 1-6 reported in this paper show high affinity for water, irrespective of different structural variation.
[0057] To provide further evidence of water affinity apart from crystallographic information, MOF 1 was extensively studied by various experiments. MOF 1 shows a reversible transformation in the presence of water vapor. After evacuation at 150° C. for 2 days, the dehydrated polycrystalline sample of 1 (confirmed by PXRD, IR, and TGA) was exposed in a closed chamber saturated with water vapor. The single-crystalline nature of MOF 1 comes back within 6-12 h ( FIG. 4 a ), which is confirmed by IR, TGA, and crystallography. FT-IR spectra of the evacuated MOF 1 sample collected at time intervals of 1 h showed a gradual increase in the intensity of the water peaks after exposure of 1 to moisture ( FIG. 4 b ), which further confirms the high affinity of 1 for water. The water affinity of 1 and 2 was also examined by water adsorption isotherms. Surprisingly, it was found that MOF 1 shows 12 wt % water vapor uptake (150 cm3/g at STP), whereas MOF2 shows 6 wt % (75 cm3/g at STP), about half at a relative pressure (P/Po) of 0.9 ( FIG. 3 b ). It is quite clear that MOF 2 has less water affinity compared to MOF 1, though the framework arrangements in 1 and 2 are similar. The CO2 adsorption isotherm indicates much less uptake (25 cm3/g for 1 and 20 cm3/g for 2) than predicted on the basis of X-ray crystallography and indicates a low degree of interaction points inside the pore.
[0058] From TGA experiments, it was found that the MOFs lose lattice water molecules in the temperature range of 40-80° C. After careful observation of the collected data, it was found that 80° C. is the ideal temperature at which one could achieve a stable and solvent-free framework of 1 with reasonably good data [R1=6.4%, wR2=14.7%, GOF=1.005]; below that temperature, water stays in the lattice as solvent and the framework remains intact, but high thermal vibration observed in some of the atom sites results in high refinement parameters ( FIG. 4 d ). A similar experiment performed on MOF 2 (Br analogue′ of MOF 1) reveals that one can achieve an evacuated framework at a much lower temperature of 40° C. [R1=5.7%, wR2=15.12%. GOF=1.071]. So far, the amount of water uptake of MOF1 with respect to MOF 2 and the achievement of an evacuated framework of MOF 2 at only 40° C. clearly indicate that MOF 2 has a lower water affinity than MOF 1. It has been mentioned already that the structural arrangements of MOFs 1-6 are all similar, except for the handedness and halogen atoms in the framework [M-X, X═—Cl, —Br, —CH3COO, —HCOO)]. The X-ray crystal structures of 1-6 established that these materials are amenable to proton-conduction owing to the continuous (O . . . O) helical 1D water chain (D O . . . O =3.234(3)Å) in a confined hydrophobic and acidic environment (D O . . . Cl-M =3.164 Å, D O . . . Br-M =3.175 Å).
[0059] The invention provides the proton conductivity of the MOFs 1 to 4, The proton conductivities of two halogen isomers, 1 and 3, were measured by a quasi-two-probe method, with a Solartron 1287 electrochemical interface with frequency response analyzer. The conductivities were determined from the semicircles in the Nyquist plots ( FIG. 5 . The proton conductivities of 1 and 3 were 4.45×10 −5 and 4.42×10 −5 S cm −1 , respectively, at 304 K and 98% relative humidity (RH). This value, was highly humidity dependent and dropped to 1.49×10 −5 and 1.22×10 −5 S cm4 at 75% and 60% RH, respectively, at 304 K.
[0060] Surprisingly, 2 and 4 show almost zero proton conductivity after testing the proton conduction′ 4-5 times on different batches of samples. The above anomalous behavior is attributed to a few reasons: (1) the water holding capacity of MOF 2 is less than that of MOF 1, confirmed by water adsorption; (2) at room temperature (˜35° C.), MOF 1 has a continuous water chain, while MOF 2 has a discrete water assembly, confirmed by VT-SCXRD experiments; (3) the interior cavities with halogen atoms with different electro-negativities are hydrogen bonded to water molecules. The present results also supported the lower water adsorption property shown by MOF 2 (6 wt %) compared to MOF 1 (12 wt %), as discussed previously.
[0061] To prove the role of water molecules, we synthesized 1-D 2 O [Zn(l-L Cl )(Cl)(D 2 O)], taking D 2 O as solvent of synthesis. 1-D 2 O was studied further by IR and 2H SSNMR, which confirmed the D 2 O incorporation in 1-D 2 O and its structural similarity to MOF 1.
[0062] Impedance studies on the deuterated sample in a H2 atmosphere humidified (98%) with D 2 O gave a conductivity value of 1.33×10 −5 S cm-1. The lower value is expected due to the heavier isotopic substitution. Proton conductivity measurements performed at different temperatures show a gradual increase in proton conductivity from 3.13×10 −5 to 4.45×10 −5 S cm −1 as the temperature is increased from 299 to 304 K, respectively ( FIG. 5 b ). At higher temperatures, above. 40° C., the proton conductivity of 1 decrease due to partial dehydration, as indicated by a TGA plot, and the 2H SSNMR data had indicated mobile protons/deuterons even at 25° C. The above result concludes the fact that MOFs having higher water holding capacity has the better proton conductivity over the MOFs having lower water holding capacity.
[0063] The ordered water molecules anchored by weak metal halogen groups facilitate proton conduction, as confirmed by proton conductivity measurements coupled with deuterium exchange and solid-state (SS) NMR experiments.
[0064] The activation energies (Ea) for the proton transfer derived from the bulk conductivity of 1 and 3 were 0.34 and 0.36 eV, respectively, as determined from least-squares fits of the slopes. MOF 1 show a higher Ea value than Nafion (0.22 eV), 25b but comparable with those of Zr(HPO4)2 (0.33)25c and HUO2PO4 3 4H2O (0.32 eV).25d This low Ea observed in 1 indicates that the ordered helical water chain (observed crystallographically) functions to transport protons via a Grotthuss hopping mechanism, as opposed to the higher Ea value, observed for a vehicular transfer mechanism. The proton conductivity value of MOF 1 is higher than those of MIL-53-based MOFs (˜10 −6 10 −9 S cm reported by Kitagawa et al. at 25° C., 95% RH) and comparable to that of a zinc-phosphonate MOF (1.33×10 −5 S cm −1 reported by Shimizu et al. at 25° C., 98% RH) but lower than those of ferrous oxalate dihydrate (1.3×10 −3 S cm −1 at 25° C., 98% RH) and cucurbit [6]uril (1.1×10 −3 S cm −1 at 25° C., 98% RH) under similar conditions.
[0065] By judicial choice of different metal ions stated above and various derivative of amino acids shown above (where variation in the derivative of amino acids back bone can be easily made by changing both amino acid residue and aromatic groups), it will become obvious to one skilled in the art to synthesize a wide verity of different MOFs. Such synthesized MOFs and examples given are merely an illustration of the instant invention and should not be construed as limiting the scope of the present invention in any manner means that innumerous MOFs can be prepared using varying the R1, R2 and metal ion and only limited MOFs are presented here for examples.
EXAMPLES
[0066] Following examples are given by way of illustration therefore should not be construed to limit the scope of the invention.
Materials and General Methods
[0067] All reagents were commercially available and used as received. Powder X-ray diffraction patterns were recorded on a Phillips PANalytical diffractometer with Cu Kα irradiation (A=1.5406 Å), a scan speed of 2° min −1 , and a step size of 0.02° in 2θ. Fourier transform (FT)IR spectra (KBr pellet) were obtained on a Perkin Elmer FT-IR spectrometer (Nicolet). Thermogravimetric analysis was carried out in the temperature range of 25-800° C. on an SDT Q600 TG-DTA analyzer under aN2 atmosphere at a heating rate of 10° C. min-1. All low-pressure CO2 adsorption experiments (up to 1 bar) were performed on a Quantachrome Quadrasorb automatic volumetric instrument. All low-pressure water adsorption experiments (up to 1 bar) were performed on a BELSORPmax volumetric instrument. A Leica M-80 optical, microscope with hot stage and camera attachment was used for collecting photographs. Proton conductivity data were measured by a quasi-two-probe method, with a Solartron 1287 electrochemical interface and a frequency response analyzer; circular dichroism data were measured with a JASCO J-851-150 L CD spectropolarimeter. Solid-state NMR spectra were recorded with a Bruker 300 MHz NMR spectrometer, and ligand NMR spectra were recorded with a Bruker 200 MHz NMR spectrometer.
Comparative Examples 1 to 7
Example 1
N-(4-Pyridylmethyl)-L-valine.HCl [l-L Cl ]
[0068] The ligand N-(4-pyridylmethyl)-L-valine.HCl (l-L Cl ) was prepared using a modified literature procedure. To an aqueous solution (10 mL) of L-valine (2 g, 17 mmol) and Na 2 CO 3 (0.91 g, 8.5 mmol), 4-pyridinecarboxaldehyde (1.82 g, 17 mmol) in MeOH (10 mL) was added slowly. The solution was stirred for 1 h and cooled in an ice bath. NaBH 4 (0.76 g, 20.4 mmol) in 10 ml of water was added. The mixture was stirred for 1 h, and 3 N HCl, was used to adjust the pH to 6. The solution was stirred further for 2 h and then evaporated to dryness. The solid was extracted in hot and dry MeOH (150 mL×3), and the filtrate was evaporated to get a white powder. Yield: 2.9 g, 70% yield. IR (KBr, cm −1 ): vOH, 3421; vas(CO 2 ), 1562; vs(CO 2 ), 1409.
[0069] 1H NMR (D 2 O, ppm): —CH 3 (1.21, d, 3H), —CH 3 (1.35, d, 3H), —CH (3.20, m, 1H), —HN—CH (3.65, m, 1H), —CH2 (3.82, dd, 2H), py-H (7.34, d, 2H), py-H (8.38, d, 2H).
Example 2
N-(4-Pyridylmethyl)-L-valine.HBr [l-L Br ]
[0070] The ligand N-(4-pyridylmethyl)-L-valine.HBr (l-L Br ) was prepared exactly as l-LCl, except HBr was used instead of HCl for off adjustment (i.e. 5.5). Yield: 3.4 g, 70%. IR (KBr, cm −1 ): vOH, 3420; vas(CO 2 ), 1560; vs(CO 2 ), 1411.
[0071] 1H NMR (D 2 O, ppm): —CH 3 (1.20, d, 31-1), —CH 3 (1.33, d, 3H), —CH (3.24, m, 1H), —HN—CH (3.63, m, 1H), —CH 2 (3.79, dd, 2H), py-H (7.34, d, 2H), py-H (8.37, d, 2H).
Example 3
N-(4-Pyridylmethyl)-D-valine.HCl [d-L Cl ]
[0072] The ligand N-(4-pyridylmethyl)-D-valine. HCl (d-L Cl ) was prepared exactly as (l-L Cl ), except D-valine was used instead of L-valine. Yield: 3.1 g, 72%.
[0073] IR (KBr, cm −1 ): vOH, 3417; vas(CO 2 ), 1564; vs(CO 2 ), 1415.
[0074] 1H NMR (D 2 O, ppm): —CH 3 (1.21, d, 3H), —CH 3 (1.34, d, 3H), —CH (3.22, m, 1H), —HN—CH (3.65, m, 1H), —CH 2 (3.78, dd, 2H), py-H (7.30, d, 2H), py-H (8.36, d, 2H).
Example 4
N-(4-Pyridylmethyl)-D-valine.HBr [d-L Br ]
[0075] The ligand N-(4-pyridylmethyl)-D-valine.HBr (d-L Br ) was prepared exactly as l-L Br , except D-valine was used instead of L-valine. Yield, 3.6 g, 72%.
[0076] IR (KBr, cm −1 ): vOH, 3419; vas(CO 2 ), 1570; vs(CO 2 ), 1421.
[0077] 1H NMR (D 2 O, ppm): —CH 3 (1.20, d, 3H), —CH 3 (1.34, d, 3H), —CH (3.24, m, 1H), —HN—CH (3.63, m, 1H), —CH 2 (3.80, dd, 2H), py-H (7.35, d, 2H), py-H (8.37, d, 2H).
Example 5
[Zn(l-L1 Cl )(Cl)](H 2 O) 2 (1)
[0078] To an aqueous solution (2 mL) of l-L Cl (0.044 g, 0.2 mmol), Zn(CH3COO)2 0.2H2O (0.022 g, 0.1 mmol) was added and sonicated for 10 min. The clear solution was kept in a tightly capped 5 mL vial for 24 h at 90° C. to produce rod-shaped transparent crystals. Yield: 0.025 g, 71%.
[0079] IR (KBr, cm1): vOH, 3421; vNH, 2977; vas(CO2), 1589; vs(CO2), 1395; vCN, 1626.
[0080] Elemental analysis: calcd C (38.8%), H (4.44%), N (8.23%). Found C (38.78%), H (4.41%), N (8.25%).
[0000]
Empirical formula
C 11 H 15 ClN 2 O 3 Zn
Formula weight
324.09
CCDC No.
831054
Wavelength
0.71073 Å
Temperature
296(2) K
Volume
2862.76(6) Å 3
Crystal system
Hexagonal
Z
6
Space group
P6 1
Density (calculated)
1.128
Unit cell dimensions
a = 17.691(2) Å
Absorption coefficient
1.427
b = 17.691(2) Å
c = 10.5617(12) Å
γ = 120
F(000)
996
Reflections collected
4581
Independent
4302
Goodness-of-fit on F2
1.065
reflections
Final R indices
R1 = 0.0408, wR2 = 0.1423
R indices (all data)
R1 = 0.0456, wR2 =
[I > 2sigma(I)]
0.1467
Atoms
Bond lengths (Å)
Bond Angles (°)
Zn1N1
2.090(2)
Zn1Cl/Br
2.2389(14)
Zn1N2
2.057(3)
N2Zn1N1
116.48(13)
Zn1O1
2.167(3)
N2Zn1O2
89.83(12)
Zn1O2
2.093(3)
N1Zn1O2
91.61(11)
N2Zn1O1
91.71(11)
N1Zn1O1
78.60(9)
O2Zn1O1
169.71(11)
N2Zn1Cl/Br
115.45(10)
N1Zn1Cl/Br
127.87(9)
O2Zn1Cl/Br
92.77(10)
O1Zn1Cl/Br
95.75(8)
Example 5
[Zn(l-L1 Br )(Br)](H2O)2 (2)
[0081] To an aqueous solution (2 mL) of l-L Br (0.044 g, 0.2 mmol), Zn(CH3COO)2.2H2O (0.022 g, 0.1 mmol) was added and sonicated for 10 min. The clear solution was kept in a tightly capped 5 mL vial for 24 h at 90° C. to produce rod-shaped transparent crystals. Yield: 0.026 g, 67%.
[0082] IR (KBr, cm1): vOH, 3427; vNH, 2974; vas(CO2), 1590; vs(CO2), 1394; vCN, 1623.
[0083] Elemental analysis: calcd C (34.37%), H (3.90%), N (7.29%). Found C (34.35%), H (3.92%), N (7.25% Y.
Example 6
[Zn(d-L1 Cl )(Cl)](H 2 O) 2 (3)
[0084] To an aqueous solution (2 mL) of d-L a (0.044 g, 0.2 mmol), Zn(CH3COO)2. 2H2O (0.022 g, 0.1 mmol) was added and sonicated for 10 min. The clear solution was kept in a tightly capped 5 mL vial for 24 h at 90° C. to produce rod-shaped transparent crystals. Yield: 0.023 g, 71%.
[0085] IR (KBr, cm1): vOH, 3420; vNH, 2975; vas(CO2), 1589; vs(CO2), 1397; vCN, 1627.
[0086] Elemental analysis: calcd C (38.82%), H (4.44%), N (8.23%). Found C (38.79%), H (4.42%), N (8.24%).
Example 7
[Zn(d-L1Br)(Br)](H2O)2 (4)
[0087] To an aqueous solution (2 mL) of d-L B , (0.044 g, 0.2 mmol), Zn(CH3COO)2. 2H2O (0322 g, 0.1 mmol) was added and sonicated for 10 min. The clear solution was kept in a tightly capped 5 mL vial for h at 90° C. to produce rod-shaped transparent crystals. Yield. 0.026 g, 69%.
[0088] IR (KBr, cm1): vOH; 3425; vNH, 2970; vas(CO2), 1592: vs(CO2), 1395; vCN, 1622.
[0089] Elemental analysis: calcd C (34.37%), H (3.90%), N (7.29%). Found C (34.36%), H (3.91%), N (7.27%).
Examples 8 to 20
Example 8
(4-Pyridylmethyl)-L-valine.CH 3 COOH [l-L CH3COO ]
[0090] The ligand N-(4-pyridylmethyl)-L-valine.CH 3 COOH (l-L CH3COO ) was prepared exactly as l-L Cl , except CH 3 COOH was used instead of HCl for pH adjustment. Yield: 3.6 g, 70%.
[0091] IR (KBr, cm1): vOH, 3420; vas(CO2), 1560; vs(CO2), 1411.
[0092] 1H. NMR (D 2 O, ppm): —CH 3 (1.20, d, 3H), —CH 3 (1.33, d, 3H), —CH (3.24, m, 1H), —HN—CH (3.63, m, 1H), —CH 2 (3.79, dd, 2H), py-H (7.34, d, 2H), py-H (8.37, d, 2H).
Example 9
N-(4-Pyridylmethyl)-L-valine.HCOOH [l-L HCOO ]
[0093] The ligand N-(4-pyridylmethyl)-L-valine.HCOOH (l-L HCOO ) was prepared exactly as l-L Cl , except HCOOH was used instead of HCl for pH adjustment. Yield: 3.5 g, 70%. IR (KBr, cm1): vOH, 3420; vas(CO2), 1560; vs(CO2), 1411.
[0094] 1H NMR (D 2 O, ppm): —CH 3 (1.20, d, 3H), —CH 3 (1.33, d, 3H), —CH (3.24, m, 1H), —HN—CH (3.63, m, 1H), —CH2 (3.79, dd, 2H), py-H (7.34, d, 2H), py-H (8.37, d, 2H).
Example 10
N-(4-pyridylmethyl)-L-alanine.HCl (l-L1 Cl )
[0095] The ligand N-(4-pyridylmethyl)-L-alanine. HCl (l-L1 Cl ) was prepared using a modified literature procedure. To an aqueous solution (10 mL) of L-alanine (1.78 g, 17 mmol) and Na 2 CO 3 (0.91 g, 8.5 mmol), 4-pyridinecarboxaldehyde (1.82 g, 17 mmol) in MeOH (10 mL) was added slowly. The solution was stirred for 1 h and cooled in an ice bath. NaBH 4 (0.76 g, 20.4 mmol′)′ in 10 mL of water was added. The mixture was stirred for 1 h, and 1 N Ha was used to adjust the pH to 6-7. The solution was stirred further for 2 h and then evaporated to dryness. The solid was extracted in hot and dry MeOH (150 mL×3), and the filtrate was evaporated to get a white powder. Yield: 2.7 g, 75% yield.
Example 11
N-(4-Pyridylmethyl)-L-alanine.HBr [l-L1 Br ]
[0096] The ligand N-(4-pyridylmethyl)-L-alanine. HBr (l-L1 Br ) was prepared using same procedure as described for Example 11, only HBr was used instead of HCl for pH adjustment of 5.5-6. Yield: 2.9 g, 72% yield.
Example 12
N-(4-Pyridylmethyl)-L-alanine.CH 3 COOH [l-L1 CH3COO ]
[0097] The ligand N-(4-pyridylmethyl)-L-alanine. CH 3 COOH (l-L1 CH3COO ) was prepared using same procedure as described for Example 11, only CH 3 COOH was used instead of HCl for pH adjustment of 6.2-6.5: Yield: 2.9 g, 70% yield.
Example 13
N-(4-Pyridylmethyl)-L-alanine. HCOOH [l-L1 HCOO ]
[0098] The ligand N-(4-pyridylmethyl)-L-alanine.HCOOH(l-L1 HCOO ) was prepared using same procedure as described for Example 11, only HCOOH was used instead of HCl for pH adjustment of 5.7-6. Yield: 2.7 g, 72% yield.
Example 14
[Zn(l-L1 CH3COO )(CH3COO)](H2O)2 (5)
[0099] To an aqueous solution (0.5 ml) of l-L CH3COO (0.046 g, 0.2 mmol) Zn(CH 3 COO) 2 .2H 2 O (0.022 g, 0.1 mmol) in 5 ml MeOH was added and sonicated for 10 min. The clear solution was kept in a 15 mL vial for 24 h to produce rod-shaped transparent crystals. Yield: 0,028 g, 71%.
Example 15
[Zn(l-L1 HCOO )(HCOO)](H2O)2 (6)
[0100] To an aqueous solution (0.5 mL) of l-L HCOO (0.046 g, 0.19 mmol), Zn(CH 3 COO) 2 .2H 2 O (0.022 g, mmol) in 5 ml MeOH was added and sonicated for 10 min. The clear solution was kept in a 15 mL vial for 24 h to produce rod-shaped transparent crystals. Yield: 0.027 g, 71%.
Example 16
[Zn(l-L2 Cl )(Cl)](H2O)2 (7)
[0101] To an aqueous solution (0.25 mL) of l-L1 Cl (0.045 g, 0.19 mmol), Zn(CH 3 COO) 2 .2H 2 O (0.020 g, 0.09 mmol) in 5 ml MeOH was added and sonicated for 10 min. The clear solution was kept in a 15 mL vial for 24 h to produce rod-shaped transparent crystals. Yield: 0.026 g, 70%.
[0000]
Empirical formula
C9H11ClN2O4Zn
Formula weight
312.04
Radiation type
Mo/K α
Wavelength
0.71073 Å
Temperature
293(2) K what is 2 in this
Volume
2777.4(5) Å 3
value.
Crystal system
Hexagonal
Z
6
Space group
P6 1
Density (calculated)
1.119
Unit cell dimensions
a = 17.6588(13) Å
Absorption coefficient
1.473
b = 17.6588(13) Å
c = 10.2847(6) Å
γ = 120
F(000)
948
Reflections collected
3431
Independent
2889
Goodness-of-fit on F2
1.119
reflections
Final R indices
R1 = 0.0665, wR2 = 0.1946
R indices (all data)
R1 = 0.0818, wR2 =
[I > 2sigma(I)]
0.2301
Atoms
Bond lengths (Å)
Bond Angles (°)
Zn1N1
2.081(6)
Zn1Cl/Br
2.220(4)
Zn1N2
2.044(7)
N2Zn1N1
122.5(3)
Zn1O1
2.190(6)
N2Zn1O2
88.0(3)
Zn1O2
2.124(7)
N1Zn1O2
88.9(3)
N2Zn1O1
90.7 (3)
N1Zn1O1
76.4(2)
O2Zn1O1
161.6(3)
N2Zn1Cl/Br
113.0(3)
N1Zn1Cl/Br
124.2(3)
O2Zn1Cl/Br
98.8(3)
O1Zn1Cl/Br
98.6(2)
Example 17
[Zn(l-L2 Br )(Br)](H2O)2 (8)
[0102] To an aqueous solution (0.4 mL) of l-L1 Br (0.048 g, 0.19 mmol), Zn(CH 3 COO) 2 .2H 2 O (0.021 g, 0.95 mmol) in 5 ml MeOH was added and sonicated for 10 min. The clear solution was kept in a 15 mL vial for 12 h, to produce rod-shaped transparent crystals. Yield: 0.029 g, 70%.
Example 18
[Zn(l-L2 CH3COO )(CH3COO)](H2O)2 (9)
[0103] To an aqueous solution (0.2 mL) of l-L1 CH3COO (0.046 g, 0.2 mmol), Zn(CH 3 COO) 2 .2H 2 O (0.020 g, 0.9 mmol) in 8 ml MeOH was added and sonicated for 10 min. The clear solution was kept in a 15 mL vial for 36 h to produce rod-shaped transparent crystals. Yield: 0.025 g, 65%.
Example 19
[Zn(l-L2 HCOO )(HCOO)](H2O)2 (10)
[0104] To an aqueous solution (0.1 mL) of l-L1 HCOO (0.045 g, 0.2 mmol), Zn(HCOO) 2 .2H 2 O (0.022 g, 0.1 mmol) in 10 ml MeOH was added and sonicated for 10 min. The clear solution was kept in a 15 mL vial for 24 h to produce rod-shaped transparent crystals. Yield: 0.025 g, 75%.
Example 20
Water Solubility of MOF
[0105] 50 mg of MOF as prepared in example 2 was dissolved in 10 ml of water by boiling it for 5 minutes to get a clear solution. After allowing, water to evaporate overnight, the crystallized MOF was tested again and found to match the coordinates of the MOF of examples 1 and 2.
[0000]
MOF
Solubility
MOF 1
22 mg/ml
MOF 2
20 mg/ml
MOF 3
22 mg/ml
MOF 4
20 mg/ml
MOF 5
25 mg/ml
MOF 6
26 mg/ml
MOF 7
25 mg/ml
MOF 8
21 mg/ml
MOF 9
27 mg/ml
MOF 10
28 mg/ml
Example 21
Proton Conductivity of MOFs
[0106]
[0000]
MOFs
PROTON CONDUCTIVITY
MOF 1
4.45 × 10 −5 S cm −1
MOF 2
NO PROTON CONDUCTIVITY
MOF 3
4.42 × 10 −5 S cm −1
MOF 4
NO PROTON CONDUCTIVITY
MOF 5
NO PROTON CONDUCTIVITY
MOF 6
3.6 × 10 −5 S cm −1
MOF 7
3.5 × 10 −3 S cm −1
MOF 8
NO PROTON CONDUCTIVITY
MOF 9
NO PROTON CONDUCTIVITY
MOF 10
2.2 × 10 −4 S cm −1
Advantages of the Invention
[0107] This easy one step solution-state processing of proton conducting homochiral MOF will provide us an environment friendly low cost pathway for casting MOF films and many other things for industrial applications. Further control over MOF solubility and proton conductivity has been demonstrated by suitable choice of ligand and anion, which will be another advantageous effort for tailor made materials for different applications. | An efficient, one step solution state processing of Proton Conducting Homochiral Metal Organic Framework has been achieved by using derivate of amino acid and Zn(II) salt as a MOF constructor. Control over MOF solubility as well as proton conductivity has also been achieved by judicious of the ligand architecture. This invention will lead the way for ease preparation of MOF films for industrial application. | 2 |
FIELD OF THE INVENTION
The present invention is directed generally the field of child safety devices, and more particularly to an apparatus for setting a boundary across a pathway, such as a driveway, so as to discourage children from venturing across the boundary and/or to discourage vehicles from entering.
BACKGROUND OF THE INVENTION
It is well known that children are not always observant of safety risks. As such, an entire industry has developed that is dedicated to producing products that help protect children from injury. For example, Kidkusion, Inc. of Washington, N.C. produces a number of products that help shield children from the various sharp edges that exist indoors.
With respect to outdoor activities, one common problem is that children tend to wander away from play areas, even when specifically instructed not to. For instance, a parent may allow children to play on the portion of a driveway close to the house, but tell the children not to venture beyond a certain point on the driveway so as to keep them out of the street. However, once the children are playing, their attention to the relevant boundary markers is typically somewhat haphazard. One method of addressing this is to physically block the driveway with a large immovable object, such as a car. However, such objects themselves offer dangers, as they are typically fairly hard and unforgiving when fallen against. In addition, it may be inconvenient or otherwise undesirable to have to move a car just to establish a play zone. Likewise, it may be inconvenient or otherwise undesirable to have to move the car in order to allow unimpeded use of the pathway.
As such, there remains a need for child safety devices that allow for readily viewable boundaries across pathways to be established and removed.
SUMMARY OF THE INVENTION
The present invention provides a retractable barrier that is particularly adapted to providing a readily viewable boundary across a pathway, such as a driveway, so that a child may be discouraged from wandering outside, and/or to discourage vehicles from entering, the safe zone established thereby. The retractable barrier includes a main post assembly that rotatably supports a net carrier assembly for rotation about an axis. The main post assembly also includes an upper flange, a lower post mount, and a non-rotating cap. A net is secured on one end to the net carrier and has a secondary post is secured to the other end. A spring is disposed between the cap and the upper flange. A first end of the spring is secured to the cap and a second end of the spring engages the net carrier assembly. The spring supplies a retraction bias to the net carrier assembly. A first ground sleeve is inserted in the ground and adapted to releasably engage the lower post mount. A second ground sleeve is inserted in the ground and adapted to releasably engage the second post. The barrier is moveable between a retracted configuration and a deployed configuration. In the retracted configuration, the net is substantially wound onto the net carrier assembly. In the deployed configuration the lower post mount is inserted in the first ground sleeve, the axis is generally vertical, the second post is remote from the first post assembly and inserted in the second ground sleeve, and the net extends therebetween.
With the net of the barrier device stretched across the pathway, a child playing in the protected portion of the pathway, such as riding a tricycle on a portion of the driveway close to the house, will be confronted with the visual barrier if they try to venture farther down the driveway and out onto the street. However, when it is desired to remove the device so that the pathway may be used unimpeded, the secondary post is simply lifted up out of the ground sleeve and walked slowly back towards the post assembly. The retraction biasing force of the spring will cause the net carrier assembly to rotate and thereby rewind the net onto the net carrier assembly. The post assembly may then be removed from the ground, leaving only the grounding sleeves in place.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of one embodiment of the retractable barrier deployed across a driveway in accordance with the present invention.
FIG. 2 is a partially exploded view of the retractable barrier of FIG. 1 with the net retracted.
FIG. 3 is a partially exploded view of the retractable barrier of FIG. 1 with the net deployed.
FIG. 4 is a sectional view of a portion of the retractable barrier of FIG. 3 along line IV—IV with the net removed for clarity.
FIG. 5 is a top view of a portion the retractable barrier of FIG. 4 along line V—V with upper portion of the cap removed to shown the spring mounting thereof.
DETAILED DESCRIPTION OF THE INVENTION
The following description of a preferred embodiment of the present invention will be in the context of a conventional paved driveway 10 as an illustrative example of a relevant pathway to be blocked. However, it should be noted that the present invention may be used with a wide variety of pathways, and is not limited to use solely with conventional driveways. Indeed, the present invention may also be used to delineate boundaries of outdoor play areas such as wooded areas, severely sloped area of yards, and the like.
As illustrated in FIG. 1, the barrier device of the present invention, generally indicated at 20 , can be used to create a boundary across the driveway 10 so as to deter a child 16 from venturing out of the protected area. With the net 90 of the barrier device 20 stretched across the driveway 10 , a child 16 playing in the protected portion of the driveway will be confronted with the visual barrier if they try to venture farther down the driveway 10 and out onto the street.
In a preferred embodiment, the barrier device 20 generally includes a main post assembly 25 , a retractable net 90 of substantial height, and a pair of ground sleeves 98 . The main post assembly 25 includes a center post assembly 30 , a net carrier assembly 60 , a cap 70 , and a spring 80 , as generally shown in FIGS. 2-5. The center post assembly 30 typically includes a center post 32 , a lower flange 40 , an upper flange 42 , and a shroud 50 . The center post 32 includes a main body 36 , an upper end 34 , and a lower end 38 . The portions 34 , 36 , 38 of the center post 32 may be formed of separate elements that are joined together, or may be integrally formed; the latter arrangement is shown in the figures for simplicity. The main body 36 of the center post 32 extends between the upper and lower flanges 40 , 42 and provides the main support of the main post assembly 25 . The upper end 34 of the center post 30 extends through a bore 44 in the upper flange 42 and advantageously includes a threaded end portion. The lower end of the center post 32 extends below the area associated with the net 90 , through the lower flange 40 , and forms the lower post mount 38 . In addition, a generally curved shroud 50 extends partially around the center post assembly 30 (e.g., 90°-180°) and is mounted to the upper and lower flanges 40 , 42 so as to extend therebetween.
The net carrier assembly 60 is rotatably mounted on the center post assembly 30 for rotation about a central axis 28 that runs generally along center post 32 . The net carrier assembly 60 typically takes the form of an elongate hollow tube. The lower portion of the net carrier assembly 60 is supported by the lower flange 40 . The upper portion of the net carrier assembly 60 includes a shoulder 64 that rests against a corresponding shoulder 44 on the upper flange 42 . In this manner, the net carrier assembly 60 is rotatably supported about the center post 32 between the upper and lower flanges 40 , 42 . The upper portion of the net carrier assembly 60 , referred to herein as the spindle 62 , extends upward through the upper flange 42 and terminates short of the inside surface of cap 70 . See FIG. 4 . The spindle portion 62 of the net carrier assembly 60 is mounted to the main body of the net carrier assembly 60 such that rotational forces applied to the spindle 62 cause the main body of the net carrier assembly 60 to rotate. If desired, the spindle portion 62 of the net carrier assembly 60 may be integrally formed with the main body of the net carrier assembly 60 . The spindle 62 advantageously includes a slit 66 for engaging the spring 80 , as described further below. One end of the net 90 is attached to the outer surface of the net carrier assembly 60 so as to rotate therewith, as described further below.
A cap 70 is disposed above the upper flange 42 and provides a cavity for holding the spring 80 . The spring 80 includes one end 82 anchored to the cap 70 , such as by riveting, and a second end 84 that engages the slit 66 in the spindle 62 . See FIG. 5 . The spring 80 is preferably of a type commonly referred to as a flat coil spring, and more preferably of a type commonly referred to as a constant tension flat coil spring. Thus, as shown in FIG. 5, the spring 80 is disposed about the spindle 62 of the net carrier assembly 60 , with one end 82 fixed to the non-rotating cap 70 , and the other end 84 engaging the rotating not carrier assembly 60 . The threaded upper end 34 of the center post 32 extends up through the spindle 62 and through a corresponding hole (not labeled) in the cap 70 . A nut with associated spring and flat washers (collectively 39 ) is secured to this threaded upper end 34 of a center post 32 and helps retain the center post 32 in the proper position. If desired, a washer 74 or other retainer may also be disposed about the center post 32 above the spring 80 so as to provide a bearing surface for the upper end of the net carrier assembly 60 , and to help retain the spring 80 in proper position with respect to the spindle 62 . The cap 70 is secured to the center post assembly 30 via the upper nut 39 , and to the upper flange 42 via additional screws 52 that engage the upper flange 42 , as may be desired.
As discussed above, the net 90 has a tethered end 92 secured to the net carrier assembly 60 and a free end 94 that is movable away from the main post assembly 25 . The tethered end 92 of the net 90 may be attached to the net carrier assembly 60 via any known method. For instance, the net 90 may be secured to the net carrier assembly 60 by sewing the net 90 to a vinyl strip that is in turn adhesively secured to the outer surface of the main body of the net carrier assembly 60 . The free end 94 of the net 90 has a secondary post 96 coupled thereto. The secondary post 96 may be permanently attached to the free end 94 of the net 90 in a manner similar to the affixation of the tethered end 92 to the net carrier assembly 60 , or the secondary post 96 may simply slide through a loop formed in the free end 94 of the net 90 , or other coupling approaches known in the art may be used. The net 90 is preferably of a somewhat open weave plastic net, and preferably of a readily visible color such as optic orange. Of course, other fabrics may be used, such as coated non-plastic nets, and/or other colors may be used, such as yellow, blue, green, etc. The weave of the net 90 should be relatively small, but need not be very fine; for instance, a knitted polyethylene net 90 with ⅛ inch by ⅛ inch mesh may be used. The net 90 should be long enough to stretch across the intended pathway, and be tall enough to provide a suitable visual barrier for a child. Thus, the lower edge of the net 90 should be very close to the ground forming the pathway 10 , and the upper edge of the net should be substantially above this level, preferably to a height taller than that of a typical young child. The net 90 may advantageously be a length of at least fifteen feet and a height of at least two feet, and more advantageously three feet or more.
The ground sleeves 98 may take the form of simple elongate tubes that are open on their upper end and are flattened or otherwise sharpened at their lower end. It is intended that the lower end of these ground sleeves 98 be inserted into the ground on opposing sides of the driveway. The upper ends of the ground sleeves are open and sized to accept the corresponding lower post mount 38 of the main post assembly 25 or the secondary post 96 . Preferably the lower post mount 38 and the secondary post 96 are of the same outer diameter and length, so that the ground sleeves 98 may be interchangeable.
The barrier device 20 may be assembled by coupling the tethered end 92 of the net 90 to the net carrier assembly 60 and winding the net 90 thereon. The lower flange 40 is secured to the center post 32 , for instance by inserting a pin (not shown) through the lower flange 40 and the center post 32 . With the lower flange 40 secured to the center post 32 , the net carrier assembly 60 is slid over the center post 32 and down onto the lower flange 40 . The upper flange 42 is then added by feeding the spindle 62 through the hole in the upper flange 42 such that the respective shoulder portions 64 , 44 engage each other. The shroud 50 is joined to the lower and upper flanges 40 , 42 via screws 52 . The cap 70 , with the spring 80 anchored on one end 82 thereof is fitted over the upper end 34 of the center post 32 and slid downward such that the spindle end 84 of the spring 80 engages the slit 66 in the spindle 62 and the center post 32 extends through the retaining washer 74 . The cap 70 is then turned a number of turns to pre-load the spring 80 , and secured to the upper flange 42 by additional screws and cap nut 39 . The secondary post 96 is then added to the free end of the net 90 . The main post assembly 25 and the ground sleeves 98 are then packaged with suitable instructions. At this point the barrier device 20 ready for deployment in the field.
In the field, the device 20 may be used to establish a boundary of a safe zone of a pathway, for instance a driveway, as follows. The ground sleeves 98 are driven vertically into the ground 14 on either side of the driveway 10 . The main post assembly 25 is then inserted into the ground sleeve 98 on one side of the driveway 10 such that axis 28 is generally vertical. At this point, the device 20 is still in its retracted position. That is, the net 90 is wound about the net carrier assembly 60 due to the retraction bias force of the spring 80 , such that the secondary post 96 is located proximate the main post assembly 25 . The secondary post 96 is then pulled across the driveway 10 and inserted into the ground sleeve 98 on that side. At this point, the barrier device 20 is in its deployed position with the secondary post 96 located remote from the main post assembly 25 , and the net 90 extending therebetween (FIG. 3 ). The lower edge of the net 90 is in close proximity to the driveway 10 , and the net extend generally vertically upward at least a couple of feet to a height taller than that of a typical young child. With the net 90 of the barrier device 20 stretched across the driveway 10 , from the grass 14 on one side to the grass 14 on the other side, a child 16 playing in the protected portion of the driveway, such as riding a tricycle 18 therein, will be confronted with the visual barrier of the net 90 if they try to venture farther down the driveway 10 and out onto the street. Thus, the barrier device 20 of the present invention provides a visual barrier across a pathway 10 in the deployed position.
When it is desired to remove the barrier device 20 so that the driveway 10 may be used unimpeded, the secondary post 96 is simply lifted up out of its ground sleeve 98 and walked slowly back towards the main post assembly 25 . The retraction biasing force of the spring 80 will cause the net carrier assembly 60 to rotate and thereby rewind the net 90 onto the net carrier assembly 60 between the flanges 40 , 42 and inside the shroud 50 . The main post assembly 25 may then be removed from the ground, leaving only the grounding sleeves 98 in place.
While not pointed out above, it may be advantageous for the upper flange 42 to include a peripheral recess (not shown) corresponding to the shroud 50 so that the upper end of the shroud 50 and upper flange 42 may fit inside the cap 70 for a more aesthetic appearance. In addition the various portions of the barrier device 20 may be integrally formed or assembled together as may be efficient from a cost perspective, provided that the net carrier assembly 60 is rotationally supported and biased toward retraction, and the main post assembly 25 and the secondary post 96 are releasably engaged by the ground sleeves 98 .
The present invention may, of course, be carried out in other specific ways than those herein set forth without departing from the essential characteristics of the invention. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive, and all changes coming within the meaning and equivalency range of the appended claims are intended to be embraced therein. | A retractable barrier particularly adapted to providing a readily viewable boundary across a pathway so that a child may be discouraged from wandering outside the safe zone established thereby. A main post assembly rotatably supports a net carrier for rotation about an axis. A net of substantial height is secured on one end to the net carrier and has a secondary post secured to the other end. A spring is disposed between a cap and an upper flange. The spring secures to the cap and engages the net carrier assembly to supply a retraction bias to the net carrier. A first ground sleeve is inserted in the ground and adapted to releasably engage the lower post mount. A second ground sleeve is inserted in the ground and adapted to releasably engage the second post. The barrier is moveable between a retracted configuration and a deployed configuration. | 4 |
FIELD OF THE INVENTION
This invention relates to door latches, and more specifically to a rotary latch for standard doors in houses and other buildings.
RELATED CASE
This application is a continuation-in-part of application Ser. No. 577,180, filed May 14, 1975 now abandoned.
BACKGROUND OF THE INVENTION
The design of latches for doors has taken a variety of forms, the most common being the horizontal spring bolt which is depressed by the striker plate and then pops into an opening in the striker plate when the door is fully closed. This type of spring latch has a number of disadvantages in that it is difficult to adjust except by repositioning the stop or the striker plate on the jamb, giving rise to the problem of a door which rattles. Unless some positive latching control is used, the spring bolts can be easily wedged or deflected by a wire, plastic card, or other metal devices to permit the door to be opened even though the mechanism controlling the latch is locked. This has given rise to the use of "dead bolt" type latches particularly for outside doors to provide a positive locking action.
Various types of rotary latches have heretofore been proposed, particularly for use with automobile doors where alignment problems and other safety considerations impose special requirements. However, such rotary latch arrangements have generally been too complicated or expensive, or difficult to install to be useful with common household doors. A rotary door latch mechanism, for example, as is described in U.S. Pat. No. 1,711,213 requires the door to close against a stop. It does not provide a flush, smooth external appearance either with the door open or closed, since the keeper requires a striking lip which must project toward the door and requires an exposed opening in the jamb adjacent the door.
SUMMARY OF THE INVENTION
The present invention provides a rotary type latch for use with household doors which provides a number of advantages over conventional spring bolt or dead bolt latches commonly found in use, yet is simple and therefore less costly to manufacture and also is easy to install. The rotary latch is designed to interface with existing door knob controls and standard locking systems. It provides a positive latching device which cannot be forced open by plastic cards or other metal devices inserted between the door and the jamb. The latch is relatively silent in operation and requires a minimum of physical effort to operate the latch. The latch is capable of accommodating a relatively large tolerance range in the spacing between the edge of the door and the jamb and yet provides a smooth external edge with a flush face plate on the jamb.
These and other advantages are achieved by providing a door closure in which a striker plate mounted on the jamb has a pair of openings forming a vertically extending post between the openings. A latch assembly mounted in the opposing edge of the door has a rotary latch member pivotally supported on a vertical axis. The latch member is rotated between open and closed positions, first by a portion projecting beyond the edge of the door which engages the edge of the striker plate as the door is moved towards the closed position, and then by a notch in the latch member which is rotated into engagement with the post. When the door is in the fully closed position, a releasable detent locks the rotary latch member against further rotation in either direction. The engagement of the latch member with the post secures the door in the closed position. On release of the detent and opening of the door, the rotary latch member returns to its initial open position by the action of a spring. The latch assembly can be inserted in a round bore drilled in the edge of the door, making the assembly easy to install. The rotary latch uses a face plate that is mounted flush with the opposing jamb, giving a smooth, attractive appearance when the door is either in the closed or open positions.
DESCRIPTION OF THE DRAWINGS
For a better understanding of the invention reference should be made to the accompanying drawings, wherein:
FIGS. 1, 2, and 3 are top views in section showing the latch in the open, partially closed, and fully closed positions;
FIG. 4 is a sectional view taken substantially on the line 4--4 of FIG. 3;
FIG. 5 is an elevational view of the striker plate;
FIG. 6 is a side elevational view partly in section of an alternative embodiment of the invention;
FIG. 7 is an edge view of a door with the latch installed;
FIGS. 8A and 8B are top views in sections showing the latch in the open or unlatched position and the latched position, respectively;
FIG. 9 is a sectional view taken substantially on the line 9--9 of FIG. 6; and
FIG. 10 is a perspective view of the rotary latch member.
DETAILED DESCRIPTION
Referring to the drawings in detail, the numeral 10 indicates generally a door, such as a conventional panel or hollow core door commonly used in building construction. The door is hinged along one edge by suitable hinges 12 to the door frame 14. The opposite side of the door frame includes a jamb 16. The edge of the jamb, at the desired height above the floor at which the latch is located on the door, is recessed at 18, and a striker plate 20 is secured to the jamb so as to bridge the recess 18. As shown in FIG. 5, the striker plate is provided with a pair of rectangular openings 21 and 22, a post 24 being formed between the two openings which extend vertically. The striker plate 20 has a curved lip or edge 26 which is turned in toward the jamb for engaging the latch when the door is moved toward the closed position.
The door directly opposite the striker plate 20 is also provided with a recess 30 which is semi-cylindrical in shape and having an inwardly directed passage 32 which intersects a large circular bore 34 passing through the face of the door. A latch assembly, indicated generally at 36, is mounted in the recess 30, the latch assembly having a facing plate 38 which is mounted flush with the edge surface of the door.
The assembly 36 includes a housing formed from an upper wall 40 and lower wall 42 which are secured in parallel relation to the face plate 38. The housing extends through the bore 34 and terminates in an end wall 44 which is substantially tangent to the surface of the bore 34 in the door. The top and bottom walls 40 and 42 are joined by sidewalls 48 and 50 which include arcuate portions 52 and 54 that terminate at the face plate 38.
The arcuate portions 52 and 54, together with the top and bottom walls 40 and 42, form a semi-cylindrical chamber in which is mounted a rotary latch member 56. The latch member 56 rotates about a vertical axis on a shaft 58, the ends of which are journaled in the top and bottom walls 40 and 42. A return spring 62 has turns extending around the shaft 58 with one end anchored to the rotary latch member 56 and the other end anchored to the frame. The spring 62 urges the rotary latch member 56 to rotate in a counterclockwise direction as viewed in FIGS. 1-3. This brings the rotary latch member 56 against a stop 64 when the door is in the open position, as shown in FIG. 1. In this position, the rotary latch member has a flat surface 66 which is flush with the face plate 38 and radially extending surface 68, forming a large obtuse angle to the surface 66. The surface 68 is defined by a portion 70 which projects outwardly of the face plate 38 in position to engage the lip 26 of the striker plate 20 when the door is moved toward a closed position.
The latch member has a radial notch 72, the centerline of the notch passing through the axis of rotation of the latch member. The notch 72 is immediately adjacent to surface 66, which is parallel to the sides of the notch. Where the side of the notch joins the outer periphery adjacent the surface 66, it is rounded off, as indicated at 74.
When the door 10 is moved to the closed position and the surface 68 comes in contact with the lip 26, the latch member 56 is caused to rotate in a clockwise direction against the action of the spring 62. This causes the rounded edge 74 at the outer end of the notch 72 to be rotated into the opening 22 in the striker plate. As the door continues to close, the post 24 engages the notch 72, as shown in FIG. 2. When the door is fully closed, the latch 56 has been rotated through substantially 90° to the position shown in FIG. 3. In this position, a detent mechanism, indicated generally at 76, engages a notch 78 on the edge of the rotary latch member 56, locking the rotaty latch member against rotation in either direction. Thus the door is secured in position by the engagement between the notch 72 and the post 24. A stop 79 limits rotation of the latch member in the clockwise direction.
The detent mechanism 76 includes a plunger 80 which is joined at one end to a transverse shaft 82 on which are journaled a pair of rollers 84 that are in rolling engagement with the peripheral surface of the latch member 56. The plunger 80 extends through an opening in the end member 44 of the frame, and a coil spring 86 urges the plunger toward the rotary latch member 56. The cross-sectional shape of the plunger and shape of the opening are preferably rectangular to prevent rotation of the plunger. The outer ends of the shaft 82 engage slots 88 in the top and bottom walls 40 and 42 for guiding the plunger. The rollers 84 engage a peripheral cam surface 85 extending around the back portion of the latch member 56. The radial distance of the surface 85 from the axis of rotation increases toward the notch 78, which acts to compress the spring 86 and gradually increase the resistance to rotation of the latch member as the door approaches the fully closed position.
The plunger 80 has a T-shaped end 90 extending into the bore 34. This enables the latch to be used with a conventional door knob assembly 92 inserted in the bore 34 after the latch assembly 36 is mounted in position. The door knob assembly includes a slide member 94 having a pair of fingers 95 which extend around the back side of the T-shaped end 90 of the plunger 80 when the door knob assembly 92 is inserted in the bore 34. The door knobs rotate an arcuate member 96, the ends of which engage a cross portion 98 of the slide member 94. Thus rotation of the arcuate member 96 in either direction urges the slide member against a spring 100 and, by means of the fingers 95, thereby moves the plunger 80 to release the detent and unlatch the door.
An alternative embodiment of the present invention is shown in FIGS. 6 through 9. The latch assembly, indicated generally at 110, is arranged to fit into a cylindrical bore 112 drilled into the edge of the door, the diameter of the bore 112 being somewhat smaller than the thickness of the door. The bore 112 intercepts a second bore 114 of larger diameter drilled in the face of the door for receiving a conventional door knob assembly (not shown). The rotary latch assembly has a housing including a face plate 116, flat top and bottom walls 118 and 120 and cylindrically contoured side walls 122 and 124 of slightly smaller radius than the bore 112. Thus the housing can be readily inserted in the bore. The face plate 116 is recessed in the edge of the door and secured in place by suitable wood screws at the four corners of the face plate, as indicated at 126.
The housing has a back plate 128 which is held in place against the back edges of the side walls 122 and 124 of the housing by providing tabs 130 extending from the edges of the flat top and bottom walls. The tabs 130 are crimped over after assembly to lock the back plate in place. A plunger 132 extends through an opening in the back plate 128 and forms a T-connection with a latch pin 134. The ends of the latch pin 134 are guided in slots 136 and 137 in the top and bottom walls 118 and 120. The outer end of the plunger 132 has a T-shaped end 140 adapted to engage a conventional door knob assembly (not shown). A concentric coil compression spring 142 urges the latch pin toward a rotary latch member 144.
The rotary latch member 144 projects through an elongated opening 146 in the face plate conforming to the interior cross sectional shape of the housing. A hinge pin 148 extends through the rotary latch 144, the pin being journaled in aligned holes in the top and bottom walls 118 and 120 of the housing. The rotary latch 144 has the axis of rotation offset from the vertical centerline of the housing, as viewed in FIG. 7. The rotary latch rotates against the urging of a spring 145 about the offset hinge pin 148 through substantially 90° when going from the unlatched to the latched position, as shown respectively in FIGS. 8A and 8B. This causes the inner end 150 of a notch 152 in the rotary latch to move through an arc. Thus the inner edge 150 moves outwardly beyond the face plate 116 toward a post 154 on the striker plate 156 mounted in the opposing jamb 157. The notch 152 itself is elongated with a pair of parallel flat surfaces 158 and 160, the surface 160 being curved outwardly, as indicated at 162, to an intersection with a flat surface 164 that normally is flush with the face plate when the rotary latch is in the unlatched position, as shown in FIG. 8A. The surface 158 extends radially outwardly from the pivot axis a greater distance than the surface 160 to insure that the post can easily move into the notch 152 as the latch member 144 rotates, as hereinafter described.
The rotary latch is rotated about the hinge pin 148 by engagement between a retractable nose member 166 coming in contact with a lip 168 of the striker plate 156 which projects beyond the front edge of the jamb. The nose portion 166 is substantially wedge-shaped and fits in a slot 169 in a projecting portion 171 of the rotary latch member 144. The retractable nose member 166 is pivotally supported on the hinge pin 148. The nose member 166 is normally urged outwardly by a compression spring 170. In its outermost position it provides a wedging surface 172 which projects at a substantial angle outwardly from the flat surface 164 of the latch member. When retracted it is flush with a surface 174 extending outwardly at a substantially smaller angle to the surface 164. The retractable nose permits a much greater tolerance in the gap between the edge of the door and the adjacent jamb and striker plate. If the gap is very small, as the latch begins to rotate on contact between the surface 172 and the lip 168, the surface 164 will rotate toward and come in contact with the inner guide 176 of the striker plate. This prevents the latch from rotating too far, but causes notch 152 to be guided toward and into engagement with the post 154. With rotation the outer end of surface 158 engages the posts and guides the post on into the slot. The retractable nose member 166 will be moved into the slot 169 against the spring 170 by the lip 168 even though the rotation of the latch is restricted by the surface 176, preventing any binding. If the gap is very wide, the retractable nose member 166 insures that the rotary latch 144 will still be rotated sufficiently by engagement with the lip 168 to rotate the point formed by the radius surface 162 past the post 154 so that the notch 152 still receives the post 154. When the door is fully closed, the latch 144 is rotated to the position shown in FIG. 8B in which the latch pin 134 drops into a notch 173 in the latch 144. This secures the door in the closed position until the latch pin 134 is retracted to release the latch.
From the above description it will be seen that a rotary latch is provided which can be easily installed by merely drilling or boring holes in the door. The latch provides positive latching action over a wide variation in spacing between the edge of the door jamb. The slot and post form a snug fit to eliminate any rattle even though the door stop is not properly fitted. The rotary latch can be used with any standard door knob assembly presently available on the market. | A latch carried by a door is rotatable about a vertical axis. The rotary latch member has a portion which engages a stationery striker plate on the door jamb which rotates the latch as the door moves to the closed position. Rotation of the latch causes a notch in the latch to engage either side of a post in the striker plate. The latch member continues to rotate until the door is fully closed by the interaction of the post with the notch. A releasable detent member locks the rotary latch against further rotation in either direction when the door reaches the fully closed position. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional application that claims priority from copending non-provisional application Ser. No. 09/950,986 filed Sep. 12, 2001, the contents of which are incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to mining. More specifically, the present invention relates to a self-inflating borehole plug for use in sealing an explosive column.
[0003] Typically, boreholes are dug and used as explosive columns. Detonation of a typical, full column confined charge produces a single high amplitude stress wave that crushes the borehole wall and moves out into the surrounding rock producing a crack mechanism. In conjunction with the stress wave, high temperature gases assist in extending the crack formation and moving the rock mass of the ground and sublayers.
[0004] By incorporating an air gap (air deck) above, below, or within the explosive column, shock wave reflections within the borehole produce a secondary stress wave. This wave extends the crack formation before gas pressurization. The reduced borehole pressure caused by the air column reduces excessive crushing of the rock adjacent to the borehole wall but still is capable of extending the crack formation and moving the rock out away from the opening of the hole. Air deck volumes of up to about 50% can be used before there is any reduction in fragmentation. By using an air deck, smaller amounts of explosives may be used without much change in fragmentation.
[0005] Self-inflating plugs, such as gas bags, are used to seal boreholes at various depths. One disadvantage with gas bags currently available is that they leak over time and thus have a limited shelf life. Another problem with bags currently available is that precise amounts of acid are not used, thus causing variations in performance. In some cases, vinegar is used as the acid, and the concentration of acid in the vinegar is not always consistent. Still another disadvantage with currently available gas bags is that they are folded such that the folds sometimes prevent them from fully inflating and expanding.
[0006] In order to overcome these disadvantages, an improved gas bag is provided. This gas bag is able to fully expand to tightly fit within a borehole. It may further be used to create air decks of various volumes.
SUMMARY OF THE INVENTION
[0007] It is an object of the present invention to provide a gas bag that is folded in a way that can easily inflate completely and seal the borehole.
[0008] It is another object of the present invention to provide an inflatable gas bag that is durable so that it has a longer shelf life than conventional bags.
[0009] It is a further object of the present invention to provide a method of making the inflatable gas bag of the present invention.
[0010] According to the present invention, the foregoing and other objects are achieved by a chemically inflated gas bag that includes a high density polyethylene (HDPE) bag that contains acetic acid, a polyvinyl alcohol (PVA) water soluble bag that contains sodium bicarbonate, and a nylon/polyethylene (PE) bag wherein the HDPE bag and the PVA bag are contained within the nylon/PE bag. Another aspect of the present invention is a method of making this gas bag. This method includes pouring diluted acetic acid into an HDPE bag and sealing said HDPE bag, putting sodium bicarbonate in a PVA bag, sealing the PVA bag, and placing the PVA bag and the HDPE bag within a nylon/PE bag. The gas bag is folded in such a manner as to easily inflate. Still another aspect of the present invention involves using this gas bag by lowering it into a borehole before or as it inflates.
[0011] Additional objects, advantages, and novel features of the invention will be set forth in the description that follows and in part will become apparent to those skilled in the art upon examination of the following, or may be learned by practice of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] In the accompanying drawings, which form a part of the specification and are to be read in conjunction therewith, and in which like reference numerals are used to indicate like parts in the various views:
[0013] [0013]FIG. 1 is a perspective view of the gas bag of a preferred embodiment of the present invention;
[0014] [0014]FIG. 2 is a cross-sectional view of the gas bag of FIG. 1 taken along line 2 - 2 ;
[0015] [0015]FIG. 3 is a cross-sectional view of the gas bag of FIG. 1 taken along line 3 - 3 ;
[0016] [0016]FIG. 4 is an elevational view of the gas bag shown in FIG. 1 with the nylon/PE bag unfolded and the folds indicated by dotted lines; and
[0017] [0017]FIG. 5 is a schematic illustration of use of the gas bag in a borehole in a preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0018] A device embodying the principles of this invention is shown in FIG. 1 and is broadly designated by the reference numeral 10 . Gas bag 10 typically comprises sodium bicarbonate 12 contained within a PVA bag 14 , as shown in FIG. 3, and acetic acid 16 contained within an HDPE bag 18 , as shown in FIG. 2. Both the PVA bag 14 and the HDPE bag 18 are contained within a nylon/PE bag 20 which is folded and bundled together by bands 22 . Tab 24 is coupled with nylon/PE bag 20 .
[0019] Gas bag 10 is constructed by securing the HDPE bag 18 to one end of nylon/PE bag 20 and placing the PVA bag 14 at the other end. As shown in FIGS. 1, 4, and 5 , a tab 24 is secured to gas bag 10 for lowering the bag into a borehole. Referring to FIG. 4, a fold in nylon/PE bag 20 is made inwardly along a dotted line 26 , and a fold is made outwardly along a dotted line 28 . Next, a fold is made inwardly along a dotted line 30 , and a fold is made outwardly along a dotted line 32 . Following this, a fold is made inwardly along a dotted line 34 , and a fold is made outwardly along a dotted line 36 . The folded gas bag 10 is then secured with bands 22 . Bands 22 may be, but are not limited to, rubber bands, strings, or tape. The gas bag has a shelf life of over about one year. In the preferred embodiment of the present invention, the gas bag has a shelf life of about 2-3 years.
[0020] The gas bag 10 is used by securing a line 38 to tab 24 and lowering the bag into a borehole 40 below the ground 42 , as shown in FIG. 5. The gas bag can be placed at various depths in borehole 40 , as discussed infra.
[0021] The acetic acid 16 is less corrosive than many other acids. Preferably, technical grade acetic acid is used. By using technical grade acetic acid, the reaction with the sodium bicarbonate has increased reliability and control. The acetic acid should be diluted with water to between about 8-30% by volume acetic acid. Preferably, the acetic acid is diluted to about 10-20% by volume acetic acid. Most preferably, the acetic acid is diluted to about 12-20% by volume acetic acid. If a 20 inch by 24 inch nylon/PE bag or smaller is used, then most preferably, the solution is about 12% volume per solution volume (v/v) acetic acid. If a 20 inch by 26 inch bag or similar sized bag is used, then most preferably, the solution is about 16% v/v acetic acid. If a 26 inch by 32 inch nylon/PE bag or larger is used, then most preferably, the solution is about 20% v/v acetic acid.
[0022] A high density polyethylene (HDPE) bag is used to hold the acetic acid. This bag should be substantially impervious to acetic acid vapors and water. It may be comprised of any material that can act as a barrier to the acid. Preferably, it is comprised of fluorinated polyethylene. Preferably, the bottom side of the HDPE bag has a weak heat seal so that when the bag is broken the acetic acid exits through the bottom side and is directed to flow onto the sodium bicarbonate. Most preferably, the HDPE bag is contained within a second bag that is not shown. This bag may be made of a water/acetic acid substantially impervious material such as PE or HDPE. The bag has small holes in its bottom side so that when the weak heat seal of the HDPE bag breaks, the small holes of the second bag control the flow of acetic acid onto the sodium bicarbonate creating a delay mechanism while the gas bag is lowered into a borehole. The acid slowly drips onto the sodium bicarbonate controlling the generation of carbon dioxide.
[0023] The sodium bicarbonate usually is in powder or tablet form. It reacts with the acetic acid to generate carbon dioxide gas and inflate nylon/PE bag 20 . The amount of inflation is controlled by the amount of acetic acid released because acetic acid is the limiting reagent.
[0024] Polyvinyl alcohol (PVA) bag 14 may be used to hold the sodium bicarbonate. It should be water soluble. It is an optional component of gas bag 10 . Alternatively, the sodium bicarbonate can merely be contained loose in nylon/PE bag 20 . Preferably, the PVA bag is modified PVA such that it does not hydrolyze under alkaline conditions and thus has an improved shelf life. Most preferably, the acetate groups of the PVA are replaced so as to make the bag stay soluble under alkaline conditions and so as to prevent hydrolysis of the bag as quickly. The PVA bag begins to dissolve when acetic acid contacts it. It provides a delay means by creating a barrier that slows the contact of the acetic acid and the sodium bicarbonate.
[0025] Nylon/PE bag 20 includes one or more layers of nylon and one or more layers of PE. Each layer of the bag can be a PE/nylon/PE layer or a nylon/PE layer. The nylon acts as a vapor barrier and prevents the bag 20 from stretching when it inflates. The PE allows the bag to be sealed and therefore must be the most inner layer of bag 20 . Other materials that are CO 2 barriers may also be used as bag 20 .
[0026] Preferably, bag 20 is contained within a woven polypropylene outer container (not shown), and tab 24 is attached to this outer container. The woven polypropylene layer acts as an abrasion and puncture barrier. It is folded with bag 20 , so that both are folded together in the S-fold configuration that is discussed in further detail infra. Preferably, the woven polypropylene layer and bag 20 are substantially clear so that the acetic acid and sodium bicarbonate can be viewed to determine if the HDPE bag has broken and the reaction has started. Also, preferably, the woven polypropylene has 10-12 strands per inch.
[0027] The nylon/PE bag 20 is substantially gas-tight and is of a shape such that it can be dropped or lowered into a borehole. The nylon bag will not develop weak spots when folded for long periods of time or when inflated. Weak spots do not develop in the nylon bag from inflation because the bag does not stretch. It is preferred that the gas bag is able to withstand at least about 20 psi internal pressure and is able to maintain that pressure for up to about four weeks.
[0028] The fold lines need not be in the particular places that are shown in FIG. 4. More generally, the folds may be as follows: The bottom corner of the first side of bag 20 is folded diagonally inward and the bottom corner of the second side of bag 20 is folded diagonally outward. A first side edge of bag 20 is folded inwardly along a first line substantially parallel to the first side edge of gas bag 20 , and a second side edge of bag 20 is folded outwardly along a second line substantially parallel to the first line. The first side is folded inwardly along a third line substantially parallel to the first line and between the first line and the second line, and the second side is folded outwardly along a fourth line substantially parallel to the second line and between the second line and the third line. Preferably, none of the lines intersects the HDPE bag. This S-type folding configuration allows the bag to unfold easily as it is inflated. This configuration also provides better borehole sealing because the gas bag fully expands and inflates. Still further, this configuration funnels all of the sodium bicarbonate to the bottom center of the bag by having diagonally folded corners that prevent it from spreading throughout the bottom of the bag. In addition, in this configuration, the acetic acid is channeled toward the sodium bicarbonate. The S-type folding configuration also is an effective configuration for storing the gas bag because it provides extra layers of nylon/PE and woven polypropylene around the reagents so as to prevent them from reacting prematurely.
[0029] The inflation of the gas bag is achieved by a chemical reaction of the acetic acid and the sodium bicarbonate which results in the evolution of carbon dioxide gas. More specifically, the acetic acid is contained in an HDPE bag so that it does not inadvertently mix with the sodium bicarbonate but is capable of being mixed when so required. The acetic acid is contained within an HDPE bag so as to keep it separated from the sodium bicarbonate until the bag is activated by breaking, popping, or puncturing the HDPE bag. Upon activation, all of the acid in the HDPE bag is released onto the sodium bicarbonate. Delay means in the gas bag provide a sufficient time interval between release of the acetic acid and the generation of carbon dioxide gas so as to permit the gas bag to be dropped or lowered down a borehole to a preselected position. This delay may be accomplished by a system which allows the acid to drip slowly onto sodium bicarbonate, as discussed above.
[0030] Boreholes are drilled so that an explosive charge may be delivered to an underground earth structure. Gas bags may be placed at selected depths in a borehole so as to form air decks. The gas bag or borehole plug can be dropped or lowered down a borehole to a preselected position since the extent of the gas-producing chemical reaction is able to be delayed following initiation of mixing of co-reagents.
[0031] In use, the acetic acid is caused to commence diffusion towards the sodium bicarbonate. The gas bag is placed in a borehole and lowered down into the borehole to a preselected position. The acetic acid is allowed to mix with the sodium bicarbonate so as to generate carbon dioxide gas, gas generation continues within the gas bag of the present invention to form an inflated borehole plug firmly associated with and in contact with the borehole wall. Preferably, following this, an explosive is lowered down the borehole and placed on the inflated borehole plug.
[0032] Alternatively, the gas bag may be lowered down into the borehole to a preselected position before the acetic acid and sodium bicarbonate are brought together for reaction to form a gas to inflate the gas bag.
[0033] In still another alternative, after bringing the reagents together, the gas bag may be dropped down a borehole so that the device falls under the force of gravity. The gas inflates the device during falling whereby the diameter of the device reaches a size comparable to the diameter of the borehole at a preselected position. This causes the device to locate at the preselected position and form a decking plug at this position.
[0034] The gas bag of the present invention also can be used to cap a borehole at the time of drilling or to protect it from rain. Such capping avoids use of waterproof explosives and prevents water damage or backfilling of the borehole. The cap can be burst to load a borehole with explosives. In addition, the bottom of a borehole can be sealed by placing a gas bag at the bottom of the hole at the time of drilling so as to prevent water from flowing into the borehole. Still further, an inflated gas bag may be positioned on top of water in the bottom of the borehole. Then, an explosive may be placed on the gas bag. Also, an inflated gas bag may be positioned above an explosive column in a borehole so as to provide an air column.
[0035] The following are examples of various gas bags and methods of making these gas bags that are within the scope of this invention. These examples are not meant in any way to limit the scope of this invention.
EXAMPLE 1
[0036] A gas bag of the present invention was made as follows: Sodium bicarbonate powder was placed in a PVA bag, and then the bag was sealed. Technical grade acetic acid was diluted with water to 16% v/v and was poured into an HDPE bag. The HDPE bag was sealed and secured within a 20 inch by 26 inch nylon/PE bag. The PVA bag was secured at the opposite end of the nylon/PE bag from the HDPE bag. The bag was folded as described above. The folded bag was secured with rubber bands.
EXAMPLE 2
[0037] A gas bag of the present invention was made as follows: Sodium bicarbonate tablets were placed in a modified PVA bag, and then the bag was sealed. Technical grade acetic acid was diluted with water to 20% v/v and was poured into an HDPE bag. The HDPE bag was sealed and secured within a 26 inch by 32 inch nylon/PE bag. The modified PVA bag was secured at the opposite end of the nylon/PE bag from the HDPE bag. The bag was folded as described above. The folded bag was secured with strings.
EXAMPLE 3
[0038] A gas bag of the present invention was made as follows: Sodium bicarbonate powder was placed in a modified PVA bag, and then the bag was sealed. Acetic acid was diluted with water to 12% v/v and was poured into an HDPE bag. The HDPE bag was sealed and secured within a 20 inch by 24 inch nylon/PE bag. The PVA bag was secured at the opposite end of the nylon/PE bag from the HDPE bag. The bag was folded as described above. The folded bag was secured with tape.
EXAMPLE 4
[0039] A gas bag of the present invention was made as follows: Acetic acid was diluted with water to 18% v/v and was poured into an HDPE bag. The HDPE bag was sealed and secured within a 20 inch by 26 inch nylon/PE bag. Sodium bicarbonate tablets were also placed in the nylon/PE bag away from the HDPE bag. The bag was folded as described above, and the tablets were at the end where the diagonal folds were located. The folded bag was secured with rubber bands.
[0040] From the foregoing, it will be seen that this invention is one well adapted to attain all the ends and objects herein above set forth together with other advantages which are obvious and inherent to the structure. It will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations. This is contemplated by and is within the scope of the claims. Since many possible embodiments may be made of the invention without departing from the scope thereof, it is to be understood that all matter herein set forth or shown in the accompanying drawings is to be interpreted as illustrative and not in a limiting sense. | A chemically inflated gas bag for mining is provided. This gas bag includes a modified PVA bag that contains sodium bicarbonate and an HDPE bag that contains acetic acid. The PVA bag and the HDPE bag are contained within a nylon/PE bag. Preferably, when the HDPE bag is broken, the flow of acetic acid onto the PVA bag is controlled by a second bag having small holes therein surrounding the HDPE bag, allowing the gas bag to be lowered into a borehole before it inflates. Another aspect of the present invention is a method of making this gas bag. This method includes pouring diluted acetic acid into an HDPE bag, putting sodium bicarbonate into a PVA bag, sealing these bags, and placing these bags within a nylon/PE bag. The gas bag is folded in such a manner as to easily inflate and completely seal the borehole. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention:
This invention relates to a process for preparation of valuable antimicrobial agents. More particularly, it relates to the process for the preparation of quinoline carboxylic acid derivatives.
2. Description of the Prior Art:
Previously, the present inventors made clear that 1-ethyl-6-fluoro-7-(1-piperazinyl)-4-oxo-1,4-dihydroquinoline-3-carboxylic acid has more potent antimicrobial activities than the known antimicrobial agents, and reported the process for the preparation of the above compound, simultaneously (Japanese Laid-Open Patent Application No. Sho 53-141286). Also, the preparations of 1-ethyl-6-fluoro-7-(4-methyl-1-piperazinyl)-4-oxo-1,4-dihydroquinoline-3-carboxylic acid and the related compounds were reported by the present inventors (Japanese Laid-Open Patent Application No. Sho 54-138582, No. Sho 55-40656 and No. Sho 55-47658). Further, many substituted quinoline carboxylic acids and their preparation have been also stated by Pesson (France) in Japanese Laid-Open Patent Application No. Sho 54-66686.
In the above prior arts, the antimicrobial agents [IV] are prepared by the reaction of the corresponding carboxylic acid [V], ##STR3## wherein R 1 is defined as above, with the compound [II]. In this method, the purity of the starting material [V] and the reaction condition exert an awful influence upon the yield of the purified product [IV].
Namely, the purification of the material [V] is difficult because of its slight solubility in various kinds of solvents, so it is hard to obtain pure material [V] in industrial scale. Furthermore, even if the purified material [V] is used in the reaction with the compound [II], a following compound [VI], ##STR4## wherein R 1 and R 4 are defined as above, is produced as a by-product. The formation of the by-product causes lowering of the yield of the purified product [IV].
SUMMARY OF THE INVENTION
This invention relates to the process for the preparation of useful antimicrobial agents, 1-substituted-6-fluoro-7-(1-piperazinyl or 4-substituted-1-piperazinyl)-4-oxo-1,4-dihydroquinoline-3-carboxylic acids having the chemical structure [IV], ##STR5## wherein
R 1 is ethyl or vinyl group, and
R 4 is ##STR6## (R 3 is hydrogen atom or lower alkyl group), and more particularly, relates to the process of industrial manufacture of antimicrobial agents represented by the formula [IV] having high purity. The intermediate substances, 1-substituted-6-fluoro-7-(1-piperazinyl or 4-substituted-1-piperazinyl)-4-oxo-1,4-dihydroquinoline-3-carboxylic acid esters [III] are prepared by the reaction of the corresponding 7-halo-4-oxo-1,4-dihydroquinoline-3-carboxylic acid esters [I], ##STR7## wherein R 1 is defined as above, and R 2 is lower alkyl group, with piperazine derivative [II] ##STR8## wherein R 3 is defined as above. And then, desired antimicrobial agents [IV] are prepared by hydrolysis of the intermediate compounds represented by the formula [III], ##STR9## wherein R 1 , R 2 and R 4 are defined as above.
The present invention was accomplished as a result of studies for industrial preparation of the antimicrobial agent having a high purity. The application of 6-fluoro-4-oxo-1,4-dihydroquinoline-3-carboxylic acid esters as a starting material is the main point of the present invention.
In the present invention, we found, surprisingly, the above-mentioned by-product was not produced as a result of confirmation by high-speed liquid chromatography. Therefore, the product [IV] is obtained in a high yield and can be easily purified. Moreover, the intermediate substance [III] is soluble in many solvent and so easily purified. The present invention has marked characteristics on these points when compared with the prior arts.
DETAILED DESCRIPTION OF THE INVENTION
In the present invention, a mixture of the starting material [I] (1 mol), organic base, and piperazine derivative [II] (2-4 mol) is heated in a range of 90°-150° C., preferably 110°-120° C., in the presence or absence of non-polar solvent. The heating time is varied depending on the reaction temperature and, for example, the reaction at 110° C. is completed within 5 hrs. Organic bases such as, for example, pyridine, picoline, triethylamine or the like, may be used in the reaction. These organic bases may serve as the reaction solvent, and volume of the base may be decreased when a non-polar solvent such as, for example, benzene, toluene or the like, is used.
In the hydrolysis reaction using an acid, it is desirable that the intermediate substance [III] is refluxed in a mixture of mineral acid such as hydrochloric acid, and organic acid such as acetic acid. In the hydrolysis reaction using an alkali, the intermediate substance [III] is heated in a diluted sodium hydroxide solution in a range of 50°-100° C., preferably at 90°-95° C. The hydrolysis reaction by the acid needs several hours, but the reaction using the alkali is accomplished in a few minutes.
EXPERIMENT 1
Antibacterial Activity
The antibacterial activities of the compounds of this invention were assayed by the standard agar dilution streak method against Gram-positive and Gram-negative bacteria [Chemothrapy, 22, 1126 (1974)]. The result was shown in Table 1 together with a known agent, nalidixic acid. The compounds of Examples 1, 6, 8 and 9 in the present invention were more active than nalidixic acid against Gram-positive and Gram-negative bacteria.
TABLE 1__________________________________________________________________________Antibacterial Activity(Minimum inhibitory concentration)(μg/ml) The compound ofOrganisms Gram Ex. 1 Ex. 6 Ex. 8 Ex. 9 NA__________________________________________________________________________Bacillus subtilis PCI219 + 0.39 0.10 0.39 0.39 6.25Staphyloccocus aureus 209P + 0.78 0.39 3.13 1.56 50S. aureus ATCC14775 + 3.13 0.39 6.25 3.13 >100Streptococcus pyogenes IID692 + 1.56 6.25 12.5 12.5 >100Diplococcus pneumoniae IID552 + 3.13 3.13 -- -- >100Escherichia coli NIHJ JC-2 - 0.10 0.10 0.10 <0.10 3.13Proteus vulgaris IF03167 - 0.10 0.10 0.20 0.20 3.13Klebsiella pneumoniae IF03512 - 0.05 0.05 0.10 <0.10 1.56Pseudomonas aeruginosa VI - 0.39 1.56 0.39 3.13 100Pseudo. aeruginosa IF012689 - 1.56 3.13 1.56 3.13 >100Salmonella enteritidis IID604 - 0.20 0.78 0.39 0.78 12.5Shigella sonnei IID969 - 0.10 0.10 0.20 0.20 1.56__________________________________________________________________________ NA: Nalidixic acid
DESCRIPTION OF PREFERRED EMBODIMENTS
The following examples serve to illustrate and explain the present invention, but the present invention should not be limited thereto.
EXAMPLE 1
Anhydrous piperazine (19.5 g) and 1-ethyl-6-fluoro-7-chloro-4-oxo-1,4-dihydroquinoline-3-carboxylic acid ethyl ester (16.8 g) were added to 34 ml of pyridine, and the mixture was refluxed with stirring for 5 hrs. The reaction mixture was concentrated under reduced pressure and the residue was dissolved in 100 ml of chloroform. The chloroform layer was washed with water for three times.
After the chloroform layer was dried over anhydrous magnesium sulfate, the chloroform was evaporated under reduced pressure and the residue was dissolved with heating in benzene. After filtered, the benzene layer was cooled. The precipitated crystals were recrystallized from a mixture of methylene chloride (50 ml) and benzene (100 ml) to give 17.3 g (88% yield) of 1-ethyl-6-fluoro-7-(1-piperazinyl)-4-oxo-1,4-dihydroquinoline-3-carboxylic acid ethyl ester. mp: 178.5°-180° C.
______________________________________ C H N______________________________________Anal. Calcd. for C.sub.18 H.sub.22 FN.sub.3 O.sub.3 : 62.31 6.22 12.03Found: 62.23 6.38 12.10______________________________________
MS (m/e): M + 347 (Calcd. 347).
IR (KBr): 3320 cm -1 (ω, piperazine nuclear N--H), 1729 cm -1 (s, C═O of ester), 1623 cm -1 (s, C═O in ring).
NMR (δ): 1.30-1.62 ppm (m, CH 3 .CH 2 --), 2.95-3.28 ppm (m, --CH 2 CH 2 --), 4.00-4.48 ppm (m, CH 3 .CH 2 --), 6.60-6.74, 7.83-8.03, and 8.29 ppm (m and s, ##STR10##
To a hot (90° C.) solution of 6% aqueous sodium hydroxide (40 ml) was added the above ester (5 g). After kept at the same temperature for 5 minutes, the reaction mixture was cooled in the water. The reaction mixture was adjusted to pH 7.5 with diluted hydrochloric acid to obtain crystals. The crystals in 20 ml of methanol were stirred for a while, filtered off, dried, and recrystallized from a mixture of methylene chloride (25 ml) and ethanol (15 ml) to give 4.1 g (89% yield) of 1-ethyl-6-fluoro-7-(1-piperazinyl)-4-oxo-1,4-dihydroquinoline-3-carboxylic acid. mp: 221°-222° C.
EXAMPLE 2
A mixture of 18 ml of picoline, 10.3 g of anhydrous piperazine, and 8.9 g of 1-ethyl-6-fluoro-7-chloro-4-oxo-1,4-dihydroquinoline-3-carboxylic acid ethyl ester was refluxed with stirring for 5 hrs. The reaction mixture was concentrated under reduced pressure, and the residue was treated by the same manner described in Example 1 to give 8.2 g (79% yield) of 1-ethyl-6-fluoro-7-(1-piperazinyl)-4-oxo-1,4-dihydroquinoline-3-carboxylic acid ethyl ester. mp: 178°-180° C.
To a mixture of glacial acetic acid (170 ml) and concentrated hydrochloric acid (170 ml) was added 4.3 g of 1-ethyl-6-fluoro-7-(1-piperazinyl)-4-oxo-1,4-dihydroquinoline-3-carboxylic acid ethyl ester and the reaction mixture was concentrated under reduced pressure. The residue was dissolved in 10 ml of water and adjusted to pH 7.5 with diluted sodium hydroxide solution. The precipitated crystals were carried out by the same way in the Example 1 to give 3.3 g (84% yield) of 1-ethyl-6-fluoro-7-(1-piperazinyl)-4-oxo-1,4-dihydroquinoline-3-carboxylic acid. mp: 220.5°-222° C.
EXAMPLE 3
A mixture of 18 ml of triethylamine, 10.3 g of anhydrous piperazine, and 8.9 g of 1-ethyl-6-fluoro-7-chloro-4-oxo-1,4-dihydroquinoline-3-carboxylic acid ethyl ester was refluxed with stirring for 20 hrs. The reaction mixture was concentrated under reduced pressure, 30 ml of chloroform was added to the residue, and cooled at 0° C. to give crystals. The crystals were filtered to recover 2 g of 1-ethyl-6-fluoro-7-chloro-4-oxo-1,4-dihydroquinoline-3-carboxylic acid ethyl ester. The above filtrated solution was extracted with diluted hydrochloric acid, the hydrochloric acid layer was neutralized with diluted sodium hydroxide solution, and the neutralized solution was extracted with chloroform. The chloroform layer was washed with water and dried over anhydrous magnesium sulfate, the chloroform was evaporated under reduced pressure. The residue was treated by the same procedure in Example 1 to give 7.4 g (71% yield) of 1-ethyl-6-fluoro-7-(1-piperazinyl)-4-oxo-1,4-dihydroquinoline-3-carboxylic acid ethyl ester. mp: 178°- 180° C.
The above product was hydrolyzed by operating as in Examples 1 and 2 to give the corresponding acid.
EXAMPLE 4
Anhydrous piperazine (10.3 g) and 1-ethyl-6-fluoro-7-chloro-4-oxo-1,4-dihydroquinoline-3-carboxylic acid ethyl ester were added to a mixture of pyridine (9 ml) and toluene (18 ml), and the mixture was refluxed with stirring for 5 hrs. The same procedure as described in Example 1 was followed to give 8.4 g (81% yield) of 1-ethyl-6-fluoro-7-(1-piperazinyl)-4-oxo-1,4-dihydroquinoline-3-carboxylic acid ethyl ester. mp: 178.5°-180° C.
The above ethyl ester was hydrolyzed by the same manner described in Examples 1 and 2 to give the corresponding acid.
EXAMPLE 5
A mixture of 1.7 g of anhydrous piperazine and 1.4 g of 1-ethyl-6-fluoro-7-chloro-4-oxo-1,4-dihydroquinoline-3-carboxylic acid methyl ester in 3 ml of pyridine was refluxed with stirring for 5 hrs. The reaction mixture was cooled to give crude crystals. The crude crystals were recrystallized from a mixture of methylene chloride and methanol to give 1.55 g (77.5% yield) of 1-ethyl-6-fluoro-7-(1-piperazinyl)-4-oxo-1,4-dihydroquinoline-3-carboxylic acid methyl ester. mp: 179°-181° C.
______________________________________ C H N______________________________________Anal. Calcd. for C.sub.17 H.sub.20 FN.sub.3 O.sub.3 : 60.87 6.19 12.22Found: 61.25 6.05 12.60______________________________________
MS (m/e): M + 333 (Calcd. 333).
IR (KBr): 1712 cm -1 (C═O in ester), 1631 cm -1 (C═O in ring).
NMR (δ): 1.50 (t,--CH 2 CH 3 ), 2.08 (s, NH), 2.90-3.35 (m,--CH 2 CH 2 --), 3.89 (s,--OCH 3 ), 4.18 (q,--CH 2 CH 3 ), 6.67 (d, 8-H), 7.94 (d, 5H), 8.33 (s, 2-H).
The above methyl ester was hydrolyzed by the same way in the Example 1 to give 1.1 g (85.2% yield) of 1-ethyl-6-fluoro-7-(1-piperazinyl), 1,4-dihydroquinoline-3-carboxylic acid. mp: 220.5°-221.5° C.
EXAMPLE 6
To an 8 ml of pyridine were added 3.6 g of 1-methylpiperazine and 3.6 g of 1-ethyl-6-fluoro-7-chloro-4-oxo-1,4-dihydroquinoline-3-carboxylic acid ethyl ester, and the mixture was refluxed for 5 hrs.
The reaction mixture was concentrated under reduced pressure, 10 ml of water was added to the residue, and extracted with 10 ml of chloroform. The chloroform layer was dried, evaporated in vacuo, and the residue was recrystallized from a mixture of benzene and ethyl ether to give 3.1 g (72.1% yield) of 1-ethyl-6-fluoro-7-(4-methyl-1-piperazinyl)-4-oxo-1,4-dihydroquinoline-3-carboxylic acid ethyl ester. mp: 176°-179° C.
______________________________________ C H N______________________________________Anal. Calcd. for C.sub.19 H.sub.24 FN.sub.3 O.sub.3 : 63.28 6.73 11.40Found: 63.14 6.69 11.63______________________________________
MS (m/e): M + 361 (Calcd. 361).
IR (KBr): 1723 cm -1 (C═O in ester), 1620 cm -1 (C═O in ring).
NMR (δ): 1.37, 1.48 (t,--CH 2 CH 3 ×2), 2.34 (s, N--CH 3 ), 2.48-2.70 ##STR11## 3.12-3.32 ##STR12## 4.15, 4.32 (q, CH 2 CH 3 ×2), 6.63 (d, 8-H), 7.87 (d, 5-H), 8.24 (s, 2-H).
The above ethyl ester was hydrolyzed by the same manner described in Example 1 to give 0.97 g (89.8% yield) of 1-ethyl-6-fluoro-7-(4-methyl-1-piperazinyl)-4-oxo-1,4-dihydroquinoline-3-carboxylic acid. mp: 271.0°-271.4° C.
EXAMPLE 7
A mixture of 8 ml of α-picoline, 4.8 g of 1-methylpiperazine, and 3.6 g of 1-ethyl-6-fluoro-7-chloro-4-oxo-1,4-dihydroquinoline-3-carboxylic acid ethyl ester was refluxed for 5 hrs. The reaction mixture was treated by operating as in Example 6 to give 2.8 g (64.8% yield) of 1-ethyl-6-fluoro-7-(4-methyl-1-piperazinyl)-4-oxo-1,4-dihydroquinoline-3-carboxylic acid ethyl ester. mp: 176°-177° C. The above ethyl ester was hydrolyzed by the same way in Example 1 to obtain the corresponding acid.
EXAMPLE 8
To a 120 ml of anhydrous dimethyl sulfoxide (DMSO), 6.32 g of 1-(2-chloroethyl)-6-fluoro-7-chloro-4-oxo-1,4-dihydroquinoline-3-carboxylic acid ethyl ester and 2.89 g of 1,8-diazabicyclo[5,4,0]-7-undecene were added and the mixture was heated at 84°-89° C. for 2 hrs. The reaction mixture was concentrated in vacuo and the residue was dissolved in chloroform. The chloroform layer was washed with water and dried. The residue obtained through evaporation of chloroform was recrystallized from ethyl ether to give 3.66 g (65.1% yield) of 1-vinyl-6-fluoro-7-chloro-4-oxo-1,4-dihydroquinoline-3-carboxylic acid ethyl ester. mp: 146°-149° C.
______________________________________ C H N______________________________________Anal. Calcd. for C.sub.14 H.sub.11 ClFNO.sub.3 : 56.72 3.66 4.85Found: 56.87 3.75 4.74______________________________________
MS (m/e): M + 295 (Calcd. 295).
IR (KBr): 1723 cm -1 (CO in ester), 1635 cm -1 (C═C in vinyl), 1612 cm -1 (C═O in ring).
NMR (δ): 1.40 (t,--CH 2 CH 3 ), 4.36 (q,--CH 2 CH 3 ), 5.61, 5.74 (dd,--CH═CH), 7.12 (dd,--CH═CH 2 ), 7.52 (d, 8-H), 8.05 (d, 5-H), 8.48 (s, 2-H)
Anhydrous piperazine (1.4 g) and 1.2 g of the above ethyl ester were added to a 3 ml of pyridine and the mixture was refluxed for 5 hrs. After cooled, the appeared crystals were filtered off, washed with ethanol, and recrystallized from a mixture of methylene chloride and benzene to give 1.0 g (71.4% yield) of 1-vinyl-6-fluoro-7-(1-piperazinyl)-4-oxo-1,4-dihydroquinoline-3-carboxylic acid ethyl ester. mp: 208°-210° C.
______________________________________ C H N______________________________________Anal. Calcd. for C.sub.18 H.sub.20 FN.sub.3 O.sub.3 : 62.25 5.78 12.02Found: 62.60 5.84 12.17______________________________________
IR (KBr) 3195 (NH), 1723 (C═O in ester), 1639 (C═C vinyl).
NMR (δ) 1.53 (t,--CH 2 CH 3 ), 3.40-3.86 ##STR13## 3.86-4.30 ##STR14## 4.69 (q,--CH 2 CH 3 ), 5.98-6.24 (m,--CH═CH 2 ), 7.37 (d, 8-H), 7.37-7.60 (m,--CH═CH 2 ), 8.28 (d, 5-H), 9.14 (s, 2-H).
The above ethyl ester was treated by the same manner described in Example 1 to give 1.8 g (92.4% yield) of 1-vinyl-6-fluoro-7-(1-piperazinyl)-4-oxo-1,4-dihydroquinoline-3-carboxylic acid. mp: 248.5°-251° C.
EXAMPLE 9
1-Methylpiperazine (1.6 g) and 1-vinyl-6-fluoro-7-chloro-4-oxo-1,4-dihydroquinoline-3-carboxylic acid ethyl ester (1.2 g) were added to a 3 ml of pyridine, and the mixture was refluxed for 5 hrs. The reaction mixture was concentrated in vacuo, water was added to the residue, and the mixture was adjusted to pH 4 with acetic acid. After filtering, the filtrate made alkali with sodium hydroxide solution. The crude crystals were recrystallized from a mixture of chloroform and benzene to give 1.0 g (68.5% yield) of 1-vinyl-6-fluoro-7-(4-methyl-1-piperazinyl)-4-oxo-1,4-dihydroquinoline-3-carboxylic acid ethyl ester. mp: 186.5°-187.5° C.
______________________________________ C H N______________________________________Anal. Calcd. for C.sub.19 H.sub.22 FN.sub.3 O.sub.3 : 63.27 6.25 11.59Found: 63.50 6.17 11.69______________________________________
IR (KBr): 1726 cm -1 (C═O in ester), 1615 cm -1 (C═O in ring).
NMR (δ): 1.39 (t,--CH 2 CH 3 ), 2.38 (s, N--CH 3 ), 2.52-2.72 ##STR15## 3.15-3.38 ##STR16## 4.36 (q,--CH 2 CH 3 ), 5.56 and 5.68 (dd, --Ch═CH 2 ) 6.64 (d, 8-H), 7.11 (dd, --Ch═CH 2 ), 7.84 (d, 5-H), 8.38 (s, 2-H).
The above ethyl ester (1.1 g) was treated as described in Example 1 to yield 0.9 g (90% ethyl) of 1-vinyl-6-fluoro-7-(4-methyl-1-piperazinyl)-4-oxo-1,4-dihydroquinoline-3-carboxylic acid. 242°-243° C.
EXAMPLE 10
A mixture of 1-ethyl-6-fluoro-7-chloro-4-oxo-1,4-dihydroquinoline-3-carboxylic acid ethyl ester (10 g), anhydrous piperazine (11.6 g) and 10 ml of 3-methoxybutanol was refluxed with stirring at 125° C. for 5 hrs. After cooling, 22 ml of 20% sodium hydroxide solution was added to the reaction mixture, and heated at 90° C. for 30 min. After cooling, 35 ml of water was added to the reaction mixture, the reaction mixture was adjusted to pH 7.5 with diluted acetic acid solution, appeared crystals were filtered. The crystals were dissolved in a solution of 42 ml of acetic acid in 52 ml of water, after treating with active carbon the solution was filtered, 4.5 ml of sulfuric acid was added to the filtrate. The appeared sulfuric acid salt was recrystallized from water. The obtained crystals were dissolved in a solution of 20% sodium hydroxide solution (9 ml) in 110 ml of water, and filtered. The filtrate was adjusted to pH 7.5, appeared crystals were washed with water.
These crystals were added to 100 ml of ethanol, and stirred for 1 hr, dried to give 9.2 g (85.8% yield, calculated from starting material) of 1-ethyl-6-fluoro-7-(1-piperazinyl)-4-oxo-1,4-dihydroquinoline-3-carboxylic acid. mp: 221°-222° C. | Process for the preparation of useful antimicorbial agents, 1-substituted-6-fluoro-7-(1-piperazinyl or 4-substituted-1-piperazinyl)-4-oxo-1,4-dihydroquinoline-3-carboxylic acids having the chemical structure [IV], ##STR1## wherein R 1 is ethyl or vinyl group, and
R 4 is ##STR2## (R 3 is hydrogen atom or lower alkyl group). | 2 |
BACKGROUND
[0001] Pool drains with enlarged or elongated channel sumps are popular in view of their compliance with the Virginia Graham Baker Pool & Spa Safety Act (“VGB Act”), requiring swimming pool and spa drains to prevent body parts from covering the entire drain intake and becoming entrapped. Anti-entrapment channel drains generally comply with the VGB Act by providing multiple intake ports or being of a sufficient length that they cannot be simultaneously blocked. For example, if one drain port or a portion of a drain port is blocked, the other drain intake ports allow water to continue flowing into the drain, ensuring a low pressure differential at the intake. One example of such a drain is embodied in Applicant's U.S. Pub. No. 2014/0157510, which discloses a channel drain having a water stop for embedding in the surface of a pool.
[0002] Pool drains having drain intakes separated from a central hub are also known in the art. These drains are typically installed in the plaster surface of a pool with the water transit between the drain intake and the central hub embedded in the plaster surface. While more aesthetically pleasing than a drain having an intake and filter connection at the same location, these drains are typically limited to a circular design. One example of such a drain is embodied in Applicant's U.S. Pub. No. 2014/0250581, which discloses a circular drain intake separate from and encircling a central drain hub. In addition to the limited design appearance of these drains, a problem persists in that if the drain intake is not equidistant from the central hub, a pressure differential is created at portions of the intake closer to the hub. For this reason, these drains remain limited to their circular shape.
[0003] Thus there is a need for a pool drain that provides a large or lengthy intake, and wherein the drain intake is separated from a central hub. There is also a need for such a drain that can be produced in an aesthetic shape other than circular, but which maintains an even pressure differential across all drain intakes regardless of distance from the central hub. A drain accomplishing these and other objects is disclosed in the following summary, description and claims.
SUMMARY
[0004] A pool drain for flush mounting in a surface material of a swimming pool or spa having a pump-driven filtering system, the pool drain includes a central hub having an access port. The central hub is in fluid communication with the pump-driven filtering system. A plurality of elongated drain ports are in fluid communication with the central hub, and the plurality of elongated drain ports extend radially away from the central hub. The surface material individually surrounds the access port and each of the plurality of elongated drain ports, separating the elongated drain ports from the access port when the pool drain is installed in the surface material.
[0005] The pool drain also includes a removable lid covering the access port and a plurality of internal dividers, Each of the internal dividers is disposed between the central hub and one of the plurality of elongated drain ports. The plurality of internal dividers are positioned to direct fluid away from the central hub, around the plurality of internal dividers and back toward the central hub.
[0006] A water stop surrounds the central hub to anchor the central hub within the surface material and prevent leakage. The pool drain may include a plurality of water stops surrounding each of the plurality of elongated drain ports to anchor the plurality of elongated drain ports within the surface material and prevent leakage.
[0007] In some embodiments, the plurality of elongated drain ports comprises four elongated drain ports. The plurality of drain ports may also comprise two longitudinal drain ports oriented along a longitudinal axis and two lateral drain ports oriented along a lateral axis. In such a configuration, the longitudinal drain ports and the lateral drain ports are substantially narrower than the access port.
[0008] The pool drain may also be configured as having a central hub in fluid communication with the pump-driven filtering system, with an arm extending from the central hub, the arm coupling an elongated drain port to the central hub. The arm has an internal divider partially occluding the arm and the internal divider is positioned in the arm to direct fluid entering the elongated drain port away from the central hub, around the internal divider, and back toward the central hub.
[0009] In this configuration, the pool drain preferably includes a removable lid covering the central hub, and a water stop surrounding the central hub to anchor the central hub within the surface material and prevent leakage. The pool drain also includes a water stop surrounding the elongated drain port to anchor the elongated drain port within the surface material and prevent leakage. This configuration may also include a plurality of arms, each having an elongated drain port. Typically the plurality of arms consists of two opposing longitudinal arms arranged substantially perpendicular to two opposing lateral arms.
[0010] In another configuration, the pool drain includes a central hub having an access port, the central hub in fluid communication with the pump-driven filtering system. Two longitudinal elongated drain ports extend away from the central hub in opposing directions along a first axis and two lateral elongated drain ports extend away from the central hub in opposing directions along a second axis, with the first axis substantially perpendicular to the second axis.
[0011] In this configuration the pool drain includes a removable lid covering the access port and a plurality of internal dividers disposed between the central hub and each of the longitudinal elongated drain ports and the lateral elongated drain ports. The internal dividers are positioned to direct fluid away from the central hub, around the plurality of internal dividers and back toward the central hub, and the pool drain may include a water stop surrounding the central hub, the longitudinal elongated drain ports and the lateral elongated drain ports for anchoring the pool drain in the surface material to prevent leakage.
BRIEF DESCRIPTION OF THE FIGURES
[0012] FIG. 1 illustrates a perspective view showing the top side of a pool drain having water diversion features;
[0013] FIG. 2 illustrates a perspective view showing the bottom side of the pool drain;
[0014] FIG. 3 illustrates a top view of the of the pool drain;
[0015] FIG. 4 illustrates an exploded view of the pool drain; and
[0016] FIG. 5 illustrates a plaster surface of a pool showing the pool drain installed therein.
DESCRIPTION
[0017] Referring to FIGS. 1-4 , a pool drain with water diversion features (“pool drain”) 10 includes a central hub 12 the central hub 12 forming a sump 14 for installation in the plaster surface 100 of a swimming pool or spa having a pump-driven filtering system 102 . The central hub 12 includes a first tube 16 , second tube 18 and third tube 20 for drainage and connecting to the pump-driven filtering system 102 . The central hub 12 also includes a lid 22 for cleaning out the central hub 12 in the unlikely event the central hub 12 becomes clogged with debris. The lid 22 seats in an access port 24 and may be fastened to the access port 24 with tools necessary for removal to prevent unauthorized access.
[0018] A first longitudinal arm 26 and second longitudinal arm 28 extend from the central hub 12 . Preferably the first longitudinal arm 26 and second longitudinal arm 28 are oriented in opposing directions away from the central hub 12 . A first lateral arm 30 and second lateral arm 32 also extend from the central hub 12 . Preferably the first lateral arm 30 and second lateral arm 32 are also oriented in opposing directions away from the central hub 12 , perpendicular to the first longitudinal arm 26 and second longitudinal arm 28 . Water enters the pool drain 10 through the first longitudinal arm 26 , second longitudinal arm 28 , first lateral arm 30 and second lateral arm 32 and travels to the central hub 12 . Additionally, the first longitudinal arm 26 , second longitudinal arm 28 , first lateral arm 30 and second lateral arm 32 impart a distinctive cross shape to the pool drain 10 on the pool's plaster surface 100 .
[0019] To provide for economical manufacturing and transport, the pool drain 10 may comprise several component parts assembled on site during pool installation. A longitudinal basin 34 forms lower portions of the central hub 12 , and lower portions of the first longitudinal arm 26 and second longitudinal arm 28 . A first lateral basin 36 and a second lateral basin 38 , molded separately, form lower portions of the first lateral arm 30 and second lateral arm 32 , respectively. The first lateral basin 36 and second lateral basin 38 may be packaged parallel to the longitudinal basin 34 , including being nested in the longitudinal basin 34 to fit in a smaller package for transport.
[0020] Since the longitudinal basin 34 , first lateral basin 36 and second lateral basin 38 are open-topped, a complimentary longitudinal basin cover 40 is preferably included, forming upper portions of the central hub 12 , first longitudinal arm 26 and second longitudinal arm 28 . Likewise, a first lateral basin cover 42 and a second lateral basin cover 44 , form upper portions of the first lateral arm 30 and second lateral arm 32 . The longitudinal basin cover 40 , first lateral basin cover 42 and second lateral basin cover 44 may also be stored in a parallel or nested configuration with other components of the pool drain 10 for ease of packaging and transport.
[0021] To ensure efficiently assembly of the pool drain 10 , connectors 46 are provided. In one embodiment the connectors 46 are formed as part of the longitudinal basin 34 , and affix the first lateral basin 36 and second lateral basin 38 to it. In the illustrated embodiment, a sliding channel-and-rail connector 46 is shown, although any preferred substantially water tight connection is contemplated. In another contemplated embodiment, the longitudinal basin cover 40 seats over the first lateral basin cover 42 and the second lateral basin cover 44 , thereby locking them over the first lateral basin 36 and second lateral basin 38 when the longitudinal basin cover 40 seats over the longitudinal basin 34 .
[0022] The longitudinal basin cover 40 , in addition to the access port 24 , includes a first elongated drain port 48 located over the first longitudinal arm 26 and a second elongated drain port 50 located over the second longitudinal arm 28 . A third elongated drain port 52 is located over the first lateral arm 30 and a fourth elongated drain port 54 is located over the second lateral arm 32 . The elongated drain ports 48 - 54 are all preferably substantially the same size and elongated shape, and are separated from the access port 24 , thereby providing an interesting and aesthetic appearance to the pool drain 10 by providing a cross shape when installed.
[0023] To secure the pool drain 10 in pool plaster or similar surfacing material (not shown) a hub water stop 56 is formed around the access port 24 . Similarly, a first drain port water stop 58 is formed around the first elongated drain port 48 , a second drain port water stop 60 is formed around the second elongated drain port 50 , a third drain port water stop 62 is formed around the third elongated drain port 52 , and a fourth drain port water stop 64 is formed around the fourth elongated drain port 54 .
[0024] Since the elongated drain ports 48 - 54 are oriented along the first longitudinal arm 26 , second longitudinal arm 28 , first lateral arm 30 and second lateral arm 32 , respectively, greater suction forces are created in the elongated drain ports 48 - 54 as they near the central hub 12 . Correspondingly, lesser suction forces are created in the elongated drain ports 48 - 54 at a greater distance from the central hub 12 . Thus a disfavored uneven pressure differential is created in each of the elongated drain ports 48 - 54 . To solve this problem, a first internal divider 66 is placed in the first elongated drain port 48 , a second internal divider 68 is placed in the second elongated drain port 50 , a third internal divider 70 is placed in the third elongated drain port 52 and a fourth internal divider 72 is placed in the fourth elongated drain port 54 .
[0025] The internal dividers 66 - 72 , like the elongated drain ports 48 - 54 , are preferably of substantially equal size and shape. The internal dividers 66 - 72 are each seated below in the elongated drain ports 48 - 54 , and located closer to the central hub 12 to shift the direction of water entering the elongated drain ports 48 - 54 away from the central hub 12 . The internal dividers 66 - 72 don't completely occlude the elongated drain ports 48 - 54 . Instead, the first internal divider 66 creates a first water passage 74 in the first elongated drain port 48 , the second internal divider 68 creates a second water passage 76 in the second elongated drain port 50 , the third internal divider 70 creates a third water passage 78 in the third elongated drain port 52 and the fourth internal divider 72 creates a fourth water passage 80 in the fourth elongated drain port 54 .
[0026] The water passages 74 - 80 cause water entering the pool drain 10 to travel initially away from the central hub 12 before traveling back toward the central hub 12 through the first longitudinal arm 26 , second longitudinal arm 28 , first lateral arm 30 and second lateral arm 32 , thereby equalizing suction pressure at the elongated drain ports 48 - 54 .
[0027] The pool drain's 10 structure having been shown and described, its method of manufacture, assembly and operation will now be discussed.
[0028] To form the components of the pool drain 10 , a open-topped longitudinal basin 34 is formed, having lower portions of a first longitudinal arm 26 and a second longitudinal arm 28 oriented in opposition away from a central hub 12 . Also formed in the longitudinal basin 34 are a first tube 16 , second tube 18 and third tube 20 serving as outflows for connecting to a pump driven pool filter. An open-topped first lateral basin 36 and second lateral basin 38 , forming lower portions of the first lateral arm 30 and second lateral arm 32 are also formed.
[0029] A longitudinal basin cover 40 is formed for covering the longitudinal basin 34 . A first lateral basin cover 42 and a second lateral basin cover 44 are also formed for covering the first lateral basin 36 and second lateral basin 38 , respectively. The longitudinal basin cover 40 has an access port 24 , a first elongated drain port 48 and a second elongated drain port 50 formed therein. A third elongated drain port 52 is incorporated into the first lateral basin cover 42 , and a fourth elongated drain port 54 is incorporated into the second lateral basin cover 44 . Internal dividers 66 - 72 sized to partially occlude the elongated drain ports 48 - 54 are also created.
[0030] These components (including a lid 22 for covering the access port 24 ) may be aligned and preferably nested to fit in a relatively small and elongated package for transport. Also preferably included is a hub water stop 56 for installation around the access port 24 , and drain port water stops 58 - 64 for installation around the elongated drain ports 48 - 54 . In one preferred embodiment, the hub water stop 56 and drain port water stops 58 - 64 may be formed as part of the longitudinal basin cover 40 , first lateral basin cover 42 and second lateral basin cover 44 through injection molding or similar technology.
[0031] To construct the pool drain 10 , the first lateral basin 36 and the second lateral basin 38 are joined to the longitudinal basin 34 at the central hub 12 with connectors 46 , preferably in a sliding arrangement. Thereafter, the internal dividers 66 - 72 are installed above the longitudinal basin 34 adjacent the central hub 12 , and above the first lateral basin 36 and the second lateral basin 38 . The first lateral basin cover 42 and second lateral basin cover 44 are then installed over the first lateral basin 36 and second lateral basin 38 , and the longitudinal basin cover 40 is installed over the longitudinal basin 34 , locking the first lateral basin cover 42 and second lateral basin cover 44 in place. If not integrally formed, the hub water stop 56 and drain port water stops 58 - 64 are installed over the central hub 12 and elongated drain ports 48 - 54 , respectively. The lid 22 is placed in the access port 24 to close the central hub 12 .
[0032] To install the pool drain 10 , the first tube 16 , second tube 18 and third tube 20 are installed on pipes leading to the pump-driven filtering system 102 during initial construction of the pool. When the pool is plastered or surfaced with a similar material, the plaster surface 100 surrounds the pool drain 10 up to the entrances of the access port 24 , first elongated drain port 48 , second elongated drain port 50 , third elongated drain port 52 and fourth elongated drain port 54 . In the process, plaster completely surrounds the hub water stop 56 , first drain port water stop 58 , second drain port water stop 60 , third drain port water stop 62 and fourth drain port water stop 64 , thereby securing the pool drain 10 in the plaster and preventing cracking an leakage.
[0033] In operation, when the pump-driven filtering system 102 is activated, water is drawn toward the pool drain 10 from suction pressure. The water must travel around the internal dividers 66 - 72 before passing through the water passages 74 - 80 , which equalizes suction pressure along the elongated drain ports 48 - 54 . Once the water clears the internal dividers 66 - 72 , it travels through the first longitudinal arm 26 , second longitudinal arm 28 , first lateral arm 30 and second lateral arm 32 and into the central hub 12 before leaving the pool drain 10 through the first tube 16 , second tube 18 and third tube 20 . If one or more of the tubes 16 - 20 becomes blocked, a user may simply deactivate the pump-driven filtering system, remove the lid 22 and clear the debris from the central hub 12 . With the debris removed, the lid 22 may be replaced and the pump-driven filtering system 102 reactivated.
[0034] The pool drain 10 provides for an attractive and aesthetic cross pattern on the surface 100 of the pool which also avoids entrapment hazards by creating even suction pressure at multiple elongated drain ports 48 - 54 . | A pool drain for flush mounting in the surface of a swimming pool includes a central hub and elongated drain ports in fluid communication with the central hub. The elongated drain ports extend radially away from the central hub. The surface material individually surrounds the central hub and elongated drain ports when the pool drain is installed in the surface material. Internal dividers are located between the central hub and the elongated drain ports. The internal dividers are positioned so that they direct fluid away from the central hub, around each of the internal dividers and back toward the central hub. A water stop surrounding the central hub and elongated drain ports anchors the pool drain in the surface and prevents leakage. | 4 |
[0001] This application is a Divisional Application of co-pending application Ser. No. 12/445,170 filed on Jun. 12, 2009 and for which priority is claimed under 35 U.S.C. §120, which is the national phase of PCT International Application No. PCT/EP2007/060797 filed on Oct. 10, 2007, which claims priority under 35 U.S.C. 119(e) to U.S. Provisional Application No. 60/850,743 filed on Oct. 11, 2006 and under 35 U.S.C. 119(a) to Patent Application No. EP 06122138.8 filed in Europe on Oct. 11, 2006, all of which are hereby expressly incorporated by reference into the present application.
[0002] The present invention relates to a novel polymorph of N-{2-Fluoro-5-[3-(thiophene-2-carbonyl)-pyrazolo[1,5-a]pyrimidin-7-yl]-phenyl}-N-methyl-acetamide, methods for its preparation, its use as a therapeutically active agent and pharmaceutical compositions comprising the novel polymorph.
BACKGROUND OF THE INVENTION
[0003] N-{2-Fluoro-5-[3-(thiophene-2-carbonyl)-pyrazolo[1,5-a]pyrimidin-7-yl]-phenyl}-N-methyl-acetamide is a potent ligand of γ-Aminobutyric acid A (GABA A ) receptors useful in the treatment or prevention of anxiety, epilepsy, sleep disorders, and insomnia, for inducing sedation-hypnosis, anesthesia, and muscle relaxation, and for modulating the necessary time to induce sleep and its duration, such as described in PCT/EP2006/063243 and U.S. 60/692,866.
[0004] Throughout the present application the term “compound (I)” refers to N-{2-Fluoro-5-[3-(thiophene-2-carbonyl)-pyrazolo[1,5-a]pyrimidin-7-yl]-phenyl}-N-methyl-acetamide.
[0005] Compound (I) is structurally related to N-{3-[3-(thiophene-2-carbonyl)-pyrazolo[1,5-a]pyrimidin-7-yl]-phenyl}-N-methyl-acetamide, also known as indiplon. The compound and its use as sedative or hypnotic agent is described in U.S. Pat. No. 6,399,621. Unlike compound (I) this compound is only mono-substituted in the phenyl ring.
[0006] The only crystalline form of compound (I) is reported to date from the above specifications and shows a melting point of 165-167° C. In the present research this form showed a DSC with a sharp melting peak between 166.2° C. and 167.4° C. The slight difference with the previously reported melting point is acceptable and is within the range of experimental error. This form is coded here Polymorph A.
[0007] It is important for a drug substance to be in a form in which it can be conveniently handled and processed. This is of importance, not only from the point of view of obtaining a commercially viable manufacturing process, but also from the point of subsequent manufacture of pharmaceutical formulations comprising the active compound. The drug substance, and compositions containing it, should be capable of being effectively stored over appreciable periods of time, without exhibiting a significant change in the active component's physico-chemical characteristics. Moreover, it is also important to be able to provide drug in a form which is as pure as possible. The skilled person will appreciate that, if a drug can be readily obtained in a stable crystalline form, the above problems may be solved. Therefore, in the manufacture of commercially viable and pharmaceutically acceptable drug compositions, it is desirable, wherever possible, to provide drug in a substantially crystalline, and stable form. Thus, there is a need for a stable crystalline form of compound (I) that can be conveniently handled and processed.
SUMMARY OF THE INVENTION
[0008] Inventors have found a new crystalline form of compound (I) This novel form is referred to as Polymorph B.
[0009] Polymorph B of compound (I) shows a powder X-Ray diffraction pattern containing the most intense peaks at 2θ=7.1° (±0.1°) and 21.4° (±0.1°); a Fourier-Transform Raman Spectrum (FT-Raman Spectrum) with characteristic signals at 3107 cm −1 , 1605 cm −1 , 1593 cm −1 , 1538 cm −1 , 1336 cm −1 , and 102 cm −1 ; and a Differential Scanning calorimetry (DSC) with a melting peak at approximately 158° C.
[0010] Like Polymorph A, Polymorph B is a potent ligand of GABA A and is useful in the treatment or prevention of anxiety, epilepsy, sleep disorders, and insomnia, for inducing sedation-hypnosis, anesthesia, and muscle relaxation, and for modulating the necessary time to induce sleep and its duration.
[0011] Polymorph B of compound (I) differs from indiplon in that the para position of the phenyl ring is substituted by a fluorine atom. Polimorph B displays an unexpected higher efficacy and surprisingly improved safety margin compared to the prior art compound indiplon, as supported by the data provided in the detailed description, therefore making the compound of the present invention a surprisingly improved therapeutic drug for sedative/hypnotic response.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The invention is described in connection with the appended drawings in which:
[0013] FIG. 1 is the Powder X-Ray Diffraction curve of Polymorph A. The Intensity, on the ordinate, is expressed in cps.
[0014] FIG. 2 is the Powder X-Ray Diffraction curve of Polymorph B. The Intensity, on the ordinate, is expressed in cps.
[0015] FIG. 3 is the FT-Raman Spectrum of Polymorph A.
[0016] FIG. 4 is the FT-Raman Spectrum of Polymorph B.
[0017] FIG. 5 is the DSC curve of Polymorph A.
[0018] FIG. 6 is the DSC curve of Polymorph B.
[0019] FIG. 7 shows the results of the evaluation of the following parameters: time of wake, slow wave sleep and paradoxical sleep, for both the compound of the present invention and indiplon (U.S. Pat. No. 6,399,621)
DETAILED DESCRIPTION OF THE INVENTION
[0020] The first aspect of the present invention consists in the novel Polymorph B of compound (I).
[0021] Polymorph B of compound (I) shows a powder X-Ray diffraction pattern containing the most intense peaks at 2θ=7.1° (±0.1°) and 21.4° (±0.1°); said polymorph is characterized by a powder X-Ray diffraction pattern containing specific peaks at 2θ=7.1° (±0.1°), 11.8° (±0.1°), 12.3° (±0.1°), 12.6° (±0.1°), 13.7° (±0.1°), 14.7° (±0.1°), 15.5° (±0.1°), 19.0° (±0.1°), 20.8° (±0.1°), 21.4° (±0.1°), 22.0° (±0.1°), 22.3° (±0.1°), 22.6° (±0.1°), 23.4° (±0.1°), 23.9° (±0.1°), 25.6° (±0.1°), 26.3° (±0.1°), 27.1° (±0.1°), 27.8° (±0.1°), 31.8° (±0.1°) and 36.5° (±0.1°). Polymorph B of compound (I) also shows a FT-Raman Spectrum with characteristic signals at 3107 cm −1 , 1605 cm −1 , 1593 cm −1 , 1538 cm −1 , 1336 cm −1 , and 102 cm −1 ; and a Differential Scanning calorimetry with a melting peak at approximately 158° C.
[0022] The second aspect of the present invention is to provide a process for the preparation of Polymorph B of compound (I) by suspending Polymorph A of compound (I) at room temperature (r.t., 20-25° C.) in a solvent selected from the group consisting of C 1 -C 6 aliphatic alcohols, C 1 -C 6 aliphatic ketones, C 1 -C 4 alkyl esters of C 1 -C 4 aliphatic acids, C 4 -C 5 saturated cyclic ethers, C 1 -C 6 aliphatic nitriles, aromatic hydrocarbons and water, and mixtures selected from the group consisting of a C 1 -C 6 aliphatic alcohol and a C 1 -C 6 aliphatic organic acid, water and a C 1 -C 6 aliphatic alcohol, and water and a C 4 -C 5 saturated cyclic ether; and recovering the resultant crystals.
[0023] Preferably the solvent is selected from the group consisting of methanol, ethanol, 1-methoxy-2-propanol, methyl ethyl ketone, ethyl acetate, dioxane, acetonitrile, toluene, water, a mixture of ethanol and acetic acid, a mixture of water and ethanol, and a mixture of water and tetrahydrofuran. The volume ratio of ethanol to acetic acid preferably ranges from 90:10 to 98:2 respectively when a mixture of ethanol and acetic acid is employed. More preferably the ratio is 95:5. Alternatively the volume ratio of water to ethanol preferably ranges from 5:95 to 95:5 respectively when a mixture of water and ethanol is employed. More preferably the range is from 10:90 to 90:10. If the mixture of water and tetrahydrofuran is used, then the volume ratio of water to tetrahydrofuran goes from 85:15 to 95:5 respectively. More preferably the ratio is 90:10. The crystals obtained may be recovered by common procedures, for example by ordinary filtration, by filtration under reduced pressure or by centrifugal filtration, followed by washing, if necessary, and drying, to obtain the Polymorph B of compound (I) of the present invention.
[0024] Within the second aspect of the present invention there is a variation of the previous process, in which a mixture of Polymorph A of compound (I) and Polymorph B of compound (I) is suspended in an aromatic solvent at a temperature between 80° C. and the boiling temperature, followed by recovering the resultant crystals. The mixture of Polymorph A and Polymorph B is in the weight range of 25:75 to 75:25, preferably 50:50. The selected aromatic solvent is toluene and the temperature ranges from 95° C. to 105° C. preferably.
[0025] Another aspect of the present invention is to provide a process for the preparation of Polymorph B of compound (I) by dissolving Polymorph A of compound (I) in a suitable solvent; filtering; and allowing for complete evaporation of solvent. Suitable solvents are acetone and tetrahydrofuran.
[0026] Another aspect of the present invention is to provide a process for the preparation of Polymorph B of compound (I) by dissolving Polymorph A of compound (I) in a mixture of water and tetrahydrofuran at room temperature; and recovering the resultant crystalline precipitate. The volume ratio of water to tetrahydrofuran preferably ranges from 5:95 to 15:85 respectively. More preferably the ratio is 10:90. The resultant crystalline precipitate can be collected as before.
[0027] Another aspect of the present invention is to provide a process for the preparation of Polymorph B of compound (I) by dissolving Polymorph A of compound (I) in a solvent selected from the group consisting of C 1 -C 6 aliphatic sulfoxides, aromatic amines, C 1 -C 6 aliphatic organic acids and mixtures of a C 1 -C 2 halogenated aliphatic hydrocarbon and a C 1 -C 6 aliphatic alcohol; filtering the solution; adding the solution to an anti-solvent selected from the group consisting of C 1 -C 6 aliphatic alcohols and C 1 -C 4 alkyl esters of C 1 -C 4 aliphatic acids; and recovering the resultant crystals.
[0028] Preferably the solvent is selected from the group consisting of dimethyl sulfoxide, pyridine, acetic acid and a mixture of dichloromethane and 2-propanol. The volume ratio of dichloromethane to 2-propanol preferably ranges from 0.5:10 to 2:10 respectively when a mixture of dichloromethane and 2-propanol is employed. More preferably the ratio is 1:10. The anti-solvent is selected from the group consisting of ethanol, 2-propanol and ethyl acetate.
[0029] To ensure a controlled production of Polymorph B, a seeded process is clearly advisable. This could be a seeded suspension equilibration, precipitation or crystallization from hot solution. Accordingly, the Polymorph B of compound (I) can be conveniently obtained by adding seeding crystals of said polymorph to a solution of compound (I) in a suitable solvent to induce crystallization and recovering the resultant crystals, by using known procedures in Chemistry.
[0030] Another aspect of the present invention is to provide Polymorph B of compound (I) for use as a medicament.
[0031] Another aspect of the present invention is to provide a pharmaceutical composition comprising the Polymorph B of compound (I) in admixture with one or more pharmaceutically acceptable carriers, excipients, diluents or adjuvants.
[0032] Another aspect of the present invention is to provide a pharmaceutical composition comprising the Polymorph B of compound (I) for use in the treatment or prevention of anxiety, epilepsy, sleep disorders, and insomnia, for inducing sedation-hypnosis, anesthesia, and muscle relaxation, and for modulating the necessary time to induce sleep and its duration.
[0033] The invention also relates to a method of treatment and/or prophylaxis of a mammal, including a human, suffering from or being susceptible to anxiety, epilepsy, sleep disorders, and insomnia, for inducing sedation-hypnosis, anesthesia, and muscle relaxation, and for modulating the necessary time to induce sleep and its duration, said method comprising the administration to said patient of a therapeutically effective amount of the polymorph B of compound of formula (I), together with pharmaceutically acceptable diluents or carriers.
[0034] Pharmaceutical compositions include those suitable for oral, rectal and parenteral (including subcutaneous, intramuscular, and intravenous) administration, although the most suitable route will depend on the nature and severity of the condition being treated. The most preferred route of the present invention is the oral route. The compositions may be conveniently presented in unit dosage form, and prepared by any of the methods well known in the art of pharmacy.
[0035] The active compound can be combined with a pharmaceutical carrier according to conventional pharmaceutical compounding techniques. The carrier may take a wide variety of forms depending on the form of the preparation desired for administration, e.g. oral or parenteral (including intravenous injections or infusions). In preparing the compositions for oral dosage form any of the usual pharmaceutical media may be employed. Usual pharmaceutical media include, for example, water, glycols, oils, alcohols, flavoring agents, preservatives, coloring agents, and the like in the case of oral liquid preparations (such as for example, suspensions, solutions, emulsions and elixirs); aerosols; or carriers such as starches, sugars, microcrystalline cellulose, diluents, granulating agents, lubricants, binder's, disintegrating agents and the like, in the case of oral solid preparations (such as for example, powders, capsules, and tablets) with the oral solid preparations being preferred over the oral liquid preparations.
[0036] Because of their ease of administration, tablets and capsules represent the most advantageous oral dosage unit form, in which case solid pharmaceutical carriers are employed. If desired, tablets may be coated by standard aqueous or no aqueous techniques.
[0037] A suitable dosage range for use is from about 0.01 mg to about 100.00 mg total daily dose, given as a once daily administration or in divided doses if required.
[0038] Another aspect of the present invention is to provide the use of Polymorph B of compound (I) in the manufacture of a medicament for use in the treatment or prevention of anxiety, epilepsy, sleep disorders, and insomnia, for inducing sedation-hypnosis, anesthesia, and muscle relaxation, and for modulating the necessary time to induce sleep and its duration.
[0039] The predictive sedative-hypnotic action of the polymorph B of compound (I) has been determined as shown below and has been compared with the effect produced by indiplon (closest prior art compound described in U.S. Pat. No. 6,399,621).
[0040] The effect of oral administration of both indiplon and the compound of the present invention on the spontaneous motor activity in mice is an accepted model to evaluate the induction of the sedation, an experiment considered predictive of hypnotic efficacy. In this experiment, the ED50—the dose that induces sedation in 50% of animals—was calculated. The prior art compound (indiplon) described in U.S. Pat. No. 6,399,621 showed an ED50=0.2 mg/Kg, whereas the compound of the present invention showed an ED50=0.13 mg/Kg, 35% more potent.
[0041] This increased sedative/hypnotic efficacy was confirmed by electroencephalographyc (EEG) experiments, when the recording of the sleep-wake cycle in mice was evaluated. Based on the previous experiment, doses were chosen and both compounds were tested at equipotent pharmacological doses (the ED50, 3-fold and 6-fold for both cases). The compound of the present invention demonstrated a statistically significant improvement on all three of the parameters evaluated (time of wake, slow wave sleep and paradoxical sleep), as depicted in the graphs of FIG. 7 , whereas the prior art compound indiplon was effective only in one parameter (slow wave sleep).
[0042] In FIG. 7 , results are expressed as the mean time (min±SEM) spent in each behavioral state during a recording period of 6 h in the same animals (n=9). The largest dose of the compound of the present invention (GF-015535-00) gave rise to an increase in slow wave sleep (SWS, up to 140 min) and paradoxical sleep (PS) and a decrease in waking (W), whereas the prior art compound (indiplon) only increased SWS for a shorter period of time than our compound (less than 140 min), clearly indicating an improved efficacy on sleep for the compound of the present invention.
[0043] Finally, a third experiment to evaluate adverse effects was performed. The model was the two-way active avoidance paradigm, which represents a behavioural test useful for evaluating learning and memory processes in mice. In this case, the amnesia liability index was obtained. Since it was reported that benzodiazepine-like drugs induce amnesia, this index allows to determine the margin between the preclinical effective doses that induce sedation compared to the minimal effective dose that induce statistically significant impairment of memory in mice (MED amnesia/ED50 sedation). Therefore, the amnesic liability index was calculated for both compounds. The results obtained are included in Table 1
[0000]
TABLE 1
Amnesic Liability Index (MED amnesia/ED50 sedation)
in mice after oral administration of the compounds.
MED
Amnesic liability
Compound
amnesia
ED50 sedation
Index
Indiplon
10 mg/Kg
0.20 mg/Kg
50 fold margin
Compound (I)
10 mg/Kg
0.13 mg/Kg
75 fold margin
[0044] As a result, the compound of the present invention demonstrated 25 fold greater margin between sedation induction and amnesia than the prior art compound indiplon.
[0045] In conclusion, the compound of the present invention clearly displays unexpected higher efficacy and surprisingly improved safety margin compared to the prior art compound indiplon.
[0046] The polymorph of the present invention is prepared in accordance with the following examples which are illustrative.
Preparative Example 1
[0047] The starting material polymorph A was made in accordance with Examples 2 of PCT/EP2006/063243 and U.S. 60/692,866 specifications.
Preparative Example 2
Preparation of Polymorph B from Polymorph A in Methanol
[0048] Polymorph A (151.8 mg) was suspended in methanol (2 mL) and stirred at r.t. for 3 days. The solid was filtered off by centrifugation (0.22 μm filter) and dried under vacuum at r.t. for 15 min. Polymorph B (95 mg) was obtained.
Preparative Example 3
Preparation of Polymorph B from Polymorph A in Acetonitrile
[0049] Polymorph A (151.8 mg) was suspended in acetonitrile (2 mL) and stirred at r.t. for 3 days. The solid was filtered off by centrifugation (0.22 μm filter) and dried under vacuum at r.t. for 15 min. Polymorph B (90 mg) was obtained.
Preparative Example 4
Preparation of Polymorph B from Polymorph A in Ethanol
[0050] Polymorph A (153.3 mg) was suspended in ethanol (2 mL) and stirred at r.t. for 3 days. The solid was filtered off by centrifugation (0.22 μm filter) and dried under vacuum at r.t. for 15 min. Polymorph B (110 mg) was obtained.
Preparative Example 5
Preparation of Polymorph B from Polymorph A in 1-methoxy-2-propanol
[0051] Polymorph A (152.4 mg) was suspended in 1-methoxy-2-propanol (2 mL) and stirred at r.t. for 3 days. The solid was filtered off by centrifugation (0.22 μm filter) and dried under vacuum at r.t. for 15 min. Polymorph B (90 mg) was obtained.
Preparative Example 6
Preparation of Polymorph B from Polymorph A in Methyl Ethyl Ketone
[0052] Polymorph A (150.6 mg) was suspended in methyl ethyl ketone (2 mL) and stirred at r.t. for 3 days. The solid was filtered off by centrifugation (0.22 μm filter) and dried under vacuum at r.t. for 15 min. Polymorph B (100 mg) was obtained.
Preparative Example 7
Preparation of Polymorph B from Polymorph A in Ethyl Acetate
[0053] Polymorph A (150.0 mg) was suspended in ethyl acetate (2 mL) and stirred at r.t. for 3 days. The solid was filtered off by centrifugation (0.22 μm filter) and dried under vacuum at r.t. for 15 min. Polymorph B (105 mg) was obtained.
Preparative Example 8
Preparation of Polymorph B from Polymorph A in Toluene
[0054] Polymorph A (150.0 mg) was suspended in toluene (2 mL) and stirred at r.t. for 3 days. The solid was filtered off by centrifugation (0.22 μm filter) and dried under vacuum at r.t. for 15 min. Polymorph B (90 mg) was obtained.
Preparative Example 9
Preparation of Polymorph B from Polymorph A in Ethanol/Acetic Acid 95:5
[0055] Polymorph A (156.0 mg) was stirred with ethanol/acetic acid 95:5 (2 mL) for 8 days at r.t. The sample was filtered off and dried under vacuum for 10 min. Polymorph B (100 mg) was obtained.
Preparative Example 10
Preparation of Polymorph B from Polymorph A in Acetone
[0056] Polymorph A (157.9 mg) was dissolved in acetone (8 mL). The solution was filtered and allowed to evaporate at r.t. Yellow crystals corresponding to polymorph B formed after complete evaporation of the solvent after several days.
Preparative Example 11
Preparation of Polymorph B from Polymorph A in Tetrahydrofuran
[0057] Polymorph A (157.8 mg) was dissolved in tetrahydrofuran (5 mL). The solution was filtered and allowed to evaporate at r.t. Yellow crystals corresponding to polymorph B formed after complete evaporation of the solvent after several days.
Preparative Example 12
Preparation of Polymorph B from Polymorph A in Water/Ethanol 10:90
[0058] Polymorph A (148 mg) was suspended in H 2 O (0.2 mL) and ethanol (1.8 mL) and stirred at r.t. for 3 days. The solid was filtered off and dried under vacuum for 10 min. Polymorph B (110 mg) was obtained.
Preparative Example 13
Preparation of Polymorph B from Polymorph A in Water/Ethanol 90:10
[0059] Polymorph A (146 mg) was suspended in H 2 O (1.8 mL) and ethanol (0.2 mL) and stirred at r.t. for 3 days. The solid was filtered off and dried under vacuum for 10 min. Polymorph B (160 mg, wet) was obtained.
Preparative Example 14
Preparation of Polymorph B from Polymorph A in Water/Tetrahydrofuran 10:90
[0060] Polymorph A (154 mg) was dissolved in H 2 O (0.2 mL) and tetrahydrofuran (1.8 mL) and stirred at r.t. for 3 days. A precipitate had formed after that time that was filtered off and dried under vacuum for 10 min. Polymorph B (40 mg) was obtained.
Preparative Example 15
Preparation of Polymorph B from Polymorph A in Water/Tetrahydrofuran 90:10
[0061] Polymorph A (151 mg) was suspended in H 2 O (1.8 mL) and tetrahydrofuran (0.2 mL) and stirred at r.t. for 3 days. The solid was filtered off and dried under vacuum for 10 min. Polymorph B (165 mg, wet) was obtained.
Preparative Example 16
Preparation of Polymorph B from Polymorph A in Dioxane
[0062] Polymorph A (151 mg) was suspended in dioxane (1 mL). The suspension was stirred at r.t. for 6 days. The solid was then filtered off and dried under vacuum for a few minutes having been identified as polymorph B.
Preparative Example 17
Preparation of Polymorph B from a Mixture of Polymorph A/Polymorph B 50:50 in Toluene
[0063] A mixture of polymorph A (75.7 mg) and polymorph B (75.3 mg) were suspended in toluene (1 mL) and agitated at 99° C. for 1 day. A sample was taken from the hot solution and immediately identified as polymorph B.
Preparative Example 18
Preparation of Polymorph B from Polymorph A in Dimethyl Sulfoxide/2-Propanol 1:10
[0064] Polymorph A (180.0 mg) was dissolved in dimethyl sulfoxide (1.5 mL). The filtered solution was added dropwise to 2-propanol (15 mL). The formation of a precipitate started several minutes after complete addition of the solution. After stirring for 10 min., the solid was filtered off, washed with 2-propanol and dried under vacuum for 15 min. to give 75 mg of polymorph B.
Preparative Example 19
Preparation of Polymorph B from Polymorph A in Pyridine/2-Propanol 1:10
[0065] Polymorph A (182.8 mg) was dissolved in pyridine (1 mL). The solution was filtered and added dropwise to 2-propanol (10 mL). The formation of a precipitate started toward the end of the addition of the solution. The suspension was stirred for 5 min., the solid was filtered off, washed with 2-propanol and dried under vacuum for 15 min. to give 90 mg of polymorph B.
Preparative Example 20
Preparation of Polymorph B from Polymorph A in Acetic Acid/2-Propanol 1:10
[0066] Polymorph A (180.9 mg) was dissolved in acetic acid (1 mL). The solution was filtered and added dropwise to 2-propanol (10 mL). The formation of a precipitate started 1-2 min. after the end of the addition of the solution. The suspension was stirred for 5 min., the solid was filtered off, washed with 2-propanol and dried under vacuum for 15 min. to give 95 mg of polymorph B.
Preparative Example 21
Preparation of Polymorph B from Polymorph A in Acetic Acid/Ethanol 1:10
[0067] Polymorph A (155 mg) was dissolved in acetic acid (1 mL). The filtered solution was added dropwise to ethanol (10 mL). Crystallization started 5 min after complete addition of the solution. The suspension was stirred for 1 h, the crystals were filtered off and dried under vacuum to give 75 mg of polymorph B.
Preparative Example 22
Preparation of Polymorph B from Polymorph A in Acetic Acid/Ethyl Acetate 1:10
[0068] Polymorph A (158 mg) was dissolved in acetic acid (1 mL). The filtered solution was added dropwise to ethyl acetate (10 mL). Crystallization started 2 h after complete addition of the solution. The suspension was stirred for additional 2 h, the crystals were filtered off and dried under vacuum to give 45 mg of polymorph B.
Preparative Example 23
Preparation of Polymorph B from Polymorph A in Dichloromethane/2-Propanol 1:10
[0069] Polymorph A (177.4 mg) was dissolved in dichloromethane (1.5 mL). The solution was filtered and added dropwise to 2-propanol (15 mL). The formation of a precipitate started ca. 3 min. after the end of the addition of the solution and increased slowly over time. The suspension was stirred for additional 30 min., the solid was filtered off and dried under vacuum for 15 min to give 80 mg of polymorph B.
Preparative Example 24
Preparation of Polymorph B from Polymorph A in Water
[0070] Polymorph A (149 mg) was suspended in water and stirred at r.t. for 5 days. The resulting crystals were identified as polymorph B.
Composition Example 1
5 mg Tablets
[0071]
[0000]
Polymorph B of compound (I)
5.0
mg
Colloidal silicon dioxide
0.6
mg
Croscarmellose sodium
12.0
mg
Talc
4.0
mg
Magnesium stearate
1.5
mg
Polysorbate 80
1.0
mg
Lactose
75.0
mg
Hydroxypropyl methylcellulose
3.0
mg
Polyethylene glycol 4000
0.5
mg
Titanium dioxide E171
1.5
mg
Microcrystalline cellulose q.s. to
125.0
mg
Composition Example 2
10 mg Capsules
[0072]
[0000]
Polymorph B of compound (I)
10.0
mg
Colloidal silicon dioxide
0.6
mg
Crospovidone
12.0
mg
Talc
4.0
mg
Magnesium stearate
1.5
mg
Lauryl sulfate sodium
1.5
mg
Lactose
77.0
mg
Gelatin
28.5
mg
Titanium dioxide E171
1.5
mg
Indigotin E132
0.02
mg
Microcrystalline cellulose q.s. to
155.0
mg
Composition Example 3
Oral Drops
[0073]
[0000]
Polymorph B of compound (I)
0.5
g
Propylene glycol
10.0
g
Glycerin
5.0
g
Saccharin sodium
0.1
g
Polysorbate 80
1.0
g
Lemon flavor
0.2
g
Ethanol
25.0
mL
Purified water q.s. to
100.0
mL
Composition Example 4
2.5 mg Tablets
[0074]
[0000]
Polymorph B of compound (I)
2.5
mg
Colloidal silicon dioxide
0.6
mg
Croscaramellose sodium
12.0
mg
Talc
4.0
mg
Magnesium stearate
1.5
mg
Polysorbate 80
1.0
mg
Lactose
75.0
mg
Hydroxypropyl methylcellulose
3.0
mg
Polyethylene glycol 4000
0.5
mg
Titanium dioxide E171
1.5
mg
Microcrystalline cellulose q.s. to
125.0
mg
Composition Example 5
5 mg Capsules
[0075]
[0000]
Polymorph B of compound (I)
5.0
mg
Colloidal silicon dioxide
0.6
mg
Crospovidone
12.0
mg
Talc
4.0
mg
Magnesium stearate
1.5
mg
Lauryl sulfate sodium
1.5
mg
Lactose
77.0
mg
Gelatin
28.5
mg
Titanium dioxide E171
1.5
mg
Indigotin E132
0.02
mg
Microcrystalline q.s. to
155.0
mg
Composition Example 6
Oral Drops
[0076]
[0000]
Polymorph B of compound (I)
0.25
g
Propylene glycol
10.0
g
Glycerin
5.0
g
Saccharin sodium
0.1
g
Polysorbate 80
1.0
g
Lemon flavor
0.2
g
Ethanol
25.0
mL
Purified q.s. to
100.0
mL
Characterization of Polymorphs
[0077] The polymorphs of compound (I) were characterized using the following procedures.
Instrumental and Experimental Conditions
[0078] Powder X-Ray Diffraction: Bruker D8 Advance. Cu Kα radiation; tube power 35 kV/45 mA; detector VANTEC1; 0.017° 2θ step size, 105±5 s per step, 2°-50° 2θ scanning range (printed range may be different). Silicon single crystal sample holders were used, sample diameter 12 mm, depth 0.1 mm.
[0079] FT-Raman Spectroscopy: Bruker RFS100. Nd:YAG 1064 nm excitation, 100 mW laser power, Ge-detector, 64 scans, range 50-3500 cm-1, 2 cm-1 resolution, Aluminum sample holder.
[0080] Differential Scanning calorimetry: Perkin Elmer DSC 7. Gold crucibles, heating rates of 2° C. min −1 or 10° C. min −1 , varying start and end temperatures.
[0081] Single-Crystal X-Ray Diffraction: The crystal was measured on a Nonius Kappa CCD diffractometer at 173° K using graphite-monochromated Mo Kα radiation with λ=0.71073 Å. The COLLECT suite was used for data collection and integration. The structure was solved by direct methods using the program SIR92. Least-squares refinement against F was carried out on all non-hydrogen atoms using the program CRYSTALS. Sheldrick weights were used to complete the refinement. Plots were produced using ORTEP III for Windows.
Characteristics of Polymorph A
[0082] Powder X-Ray Diffraction: The X-Ray diffractogram is characterized by an extremely intense peak at 2θ=5.7°. Considering the highly anisotropic shape of the crystals, it has to be expected that this high intensity is due to a preferential orientation of the crystals. The X-Ray diffractogram is shown in FIG. 1 .
[0083] FT-Raman Spectroscopy: Characteristic Raman signals are the most intense peak of the C—H region at 3073 cm −1 , peaks at 1616 cm −1 , 1590 cm −1 , 1544 cm −1 , 1326 cm −1 , and a double peak at 117 cm −1 /79 cm −1 . The FT-Raman spectrum is shown in FIG. 3 .
[0084] Differential Scanning calorimetry: DSC showed a sharp melting peak between 166.2° C. and 167.4° C. (slight variations depending on scan rate) with Δ fus H=85 J/g. The substance did not re-crystallize upon cooling even at a cooling rate of only 2° C./min and exhibited a glass transition at 61.3° C. instead. The DSC curve is shown in FIG. 5 .
Characteristics of Polymorph B
[0085] Powder X-Ray Diffraction: The most intense peaks in the X-ray diffractogram are located at 2θ=7.1° and 21.4°. The X-Ray diffractogram is shown in FIG. 2 .
[0086] FT-Raman Spectroscopy: Characteristic signals in the Raman spectrum of polymorph B are found at 3107 cm −1 (most intense peak in the C—H region), 1605 cm −1 , 1593 cm −1 , 1538 cm −1 , 1336 cm −1 , and 102 cm −1 . The FT-Raman spectrum is shown in FIG. 4 .
[0087] Differential Scanning calorimetry: The DSC measurement showed a sharp melting peak at approximately 158° C. with a melting enthalpy Δ fus H=104 J/g. The DSC curve is shown in FIG. 6 .
[0088] Single crystal structure: The compound crystallizes in the centro-symmetric space group P-1. The structure shows two molecules in the asymmetric unit which are not related by space group symmetry. These two molecules can be superimposed almost perfectly by rotation around the ‘a’ axis, but the unit cell cannot be transformed in order to gain higher lattice symmetry.
[0089] The structure can be interpreted as being based on dimers of the compound. The driving force for the formation of these dimers is most likely π-π interaction between the phenyl ring and the thiophene ring on the one hand and the N-heterocycles on the other hand. The two different types of molecules in the unit cell form two different types of dimers with slightly different short distances between the condensed N-heterocycles (3.348 Å and 3.308 Å for the shortest distance, respectively). The dimers are arranged in layers with a fishbone structure. Bands of the two types of dimers always alternate in the fishbone structure, as well as they alternate from one layer to the next. The crystal data are reported in Table 2.
[0000]
TABLE 2
Crystal data for Polymorph B
Molecular formula
C 20 H 15 FN 4 O 2 S
Molecular weight
394.43
g/mol
Molecules per unit cell Z
4
Calculated density
1.478
g/cm 3
Number of electrons per unit cell F(000)
816
Size of crystal
0.14 × 0.18 × 0.24
mm 3
Absorption coefficient
0.218
mm −1
Min./max. transmission
0.96/0.97
Temperature
173°
K
Radiation (wavelength)
Mo Kα (α = 0.71073 Å)
Crystal system
triclinic
Space group
P-1
a
8.9236(2)
Å
b
14.0292(3)
Å
c
15.6218(3)
Å
α
65.3449(14)°
β
87.0440(14)°
γ
86.0799(14)°
Volume of the unit cell
1772.69(7)
Å 3
Min./max. θ
1.435°/27.883°
Number of collected reflections
16548
Number of independent reflections
8448 (merging r = 0.034)
Number of observed reflections
5430
(I > 2.00σ(I))
Number of refined parameters
506
r (observed data)
0.0455
rW (all data)
0.0734
goodness of fit
0.9980
residual electron density
−0.37/0.39
e Å −3 | The present invention relates to a method of treating anxiety, epilepsy, sleep disorders, and insomnia, for inducing sedation-hypnosis, anesthesia, and muscle relaxation, and for modulating the necessary time to induce sleep and its duration, which comprises administering a therapeutically effective amount of Polymorph B of N-{2-Fluoro-5-[3-(thiophene-2-carbonyl)-pyrazolo[1,5-a]pyrimidin-7-yl]-phenyl}-N-methyl-acetamide characterized by a powder X-Ray diffraction pattern containing specific peaks at 2θ=7.1° (±0.1°) and 21.4° (±0.1°) to a patient in need thereof. | 2 |
[0001] This application claims priority of Ser. No. 61/438,699 filed Feb. 2, 2011, which is incorporated herein in its entirety.
[0002] The present invention relates to methods and tools for reducing appetite, and reducing weight.
[0003] To reduce appetite, Jackson, US 2005/0037031 has suggested blocking the sense of smell. One document found on the internet, by Swanner, suggests using an altoid to avoid eating. (The extent to which this document is or was indexed sufficiently to be a publication is unclear.) Among the things that Swanner does not describe are (a) a method of partial meal avoidance and (b) a sufficiently long-lasting, strongly flavored agent.
[0004] We eat for many reasons, including to sustain life, to be social, to feel full, to feel satisfied, to relieve depression, but mostly because we like the way food tastes. The taste stimulus is one of nature's primary motivators of human behavior. Nature created taste as a very strong inducement for people to put things in their mouths and swallow them, in order to supply the energy and nutrition necessary for life. However, in the modern context, the abundance of food and drink in developed nations and the additives in many foods and drinks, transforms the taste stimulus from a healthy survival motivator for individuals into a significant national health threat.
[0005] The medical cost and burden to society of obesity is enormous. The risks of obesity include heart disease, diabetes, peripheral vascular disease, cancer, strokes, arthritis, joint disease, depression, increased surgical risks, hip fractures, knee replacements, sleep apnea, high cholesterol, premature death, and much more. Obesity is bad for our health, bad for our society, and is as much a disease as are high blood pressure and pneumonia.
[0006] A number of diets focus on the symptom of obesity; excessive caloric intake. The methods and tools of the invention address the cause of excessive caloric intake; which is taste. Thus, the invention provides methods and tools that addresses the real problem—the taste of the foods we love to eat.
[0007] The flavor masking product and avoidance diet method described herein provides critical willpower support by reducing the motivational influence of taste on the decision making process for when, what, and how much to eat. This results in an increase in self-control and reasonable eating decisions based on rational health concepts; versus subconscious drives, emotional needs, or impulsive-indulgent eating behavior that turns nutrients into toxins due to their consumption in excessive quantity.
[0008] In one embodiment of the invention, the taste-masking effect is created by or supplemented with an analgesic agent. Analgesic has been found to deaden taste.
SUMMARY OF THE INVENTION
[0009] Provided is a method of reducing dietary intake comprising: eating a portion of food; and immediately thereafter applying to the mouth a long-lasting, taste-blocking agent in an appetite reducing effective amount. the taste-blocking agent can be applied in a form adapted to release the appetite reducing effective amount in the mouth for ten minutes or more. An adhesive portion of a tab can be, or in the mouth can transition to, a waxy or gel-like form. The tab can be a mouth-adherent film or tablet.
[0010] Further provided is an oral delivery form that is mucoadhesive and (a) the taste-blocking agent is packaged so that a diffusion-limiting membrane allows but limits the rate of diffusion of taste-blocking agent therethrough into the mouth, wherein for a period of time the diffusing amount is an effective amount, or (b) wherein an effective amount of the taste-blocking agent is comprised within the adhesive layer of a patch, and wherein the patch has a backing layer adapted to allow diffusion of the taste-blocking agent therethrough.
[0011] Also provided as one option is a delivery form comprising at least (i) a delivery formulation that, if unchewed, delivers an effective amount of the taste-blocking agent to the mouth for an appropriate amount of time and (ii), intimately associated with but distinct from the delivery formulation, a chew retarding formulation that, chewed, delivers a strongly unpleasant flavor but that, unchewed, sufficiently retains the unpleasant flavor.
[0012] Further provided is an oral delivery form comprising effective amount of an analgesic and an effective amount of a strongly-flavored agent, wherein the amount of strongly-flavored agent is a super-flavoring amount.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 shows an embodiment in which there are modules of bad flavor.
DETAILED DESCRIPTION OF THE INVENTION
[0014] The taste-blocking tools of the invention allow a person to control their eating by removing a primary inducement to eat: flavor. The user can elect to avoid consuming food or drink altogether, or to eat and/or drink a portion and then take the flavor agent to help limit further eating overeating or drinking. For example, in a restaurant or at a communal meal there is often a greater selection or portion of food than would be compatible with the portion control one seeks—yet the natural impulse is to continue to eat while flavorful food is available. Using the taste-blocking tools of the invention reduces the impulse, and psychologically further imprints the idea that one will not eat beyond the prescribed portion.
[0015] One specific tactic is portion control, which is limiting the quantity of any food or drink. Even healthful food and drink choices may nevertheless become unhealthy and add weight if overeaten. At times it may be necessary, as a part of a weight loss program, to limit even healthful food and drink which would normally be eaten in response to legitimate hunger.
[0016] A second tactic is control of binge eating and snacking, which is eating food that is not healthful or necessary and is for example motivated by recreational, emotional or “situational” stimuli rather than hunger.
[0017] In any situation, including portion control and binge/snack control situations, the invention helps the user to achieve diet goals by supporting the decision and willpower to stop eating when appropriate. The product does this by the process of removing, altering or minimizing flavor, which is a strong inducement to eat; and especially to eat the wrong things, or to over-eat. As an example, one can apply an appropriate strongly flavored agent to the mouth, and then smell or taste a food material that is usually highly enticing to the user. In the typical situation, the subject will then find the smell and/or taste no longer enticing. Though a primary effect is believed to be on gustatory taste receptors, it is believed that the brain compiles the taste information with olfactory inputs, which can alter perception of otherwise enticing odors.
[0018] In one embodiment, the methods and tools of the invention can be used to avoid an entire meal. When a user wants to skip a meal completely use the strongly flavored agent before your meal begins. If necessary given the form of the strongly flavored agent, the user may reapply the taste-masking agent as needed until the urge to eat has dissipated or until the user leaves the environment where food is available. If the urge returns or the environment is unfavorable to dieting reapply the strongly flavored agent.
[0019] In an important embodiment, the methods and tools of the invention can be used to limit the portion of food and/or drink taken at a meal setting. This process allows one to eat whatever he or she wants, thereby enjoying the taste, smells and pleasures associated with any particular food—but to limit total caloric consumption by using the taste agent when the user has had a diet-appropriate amount or at a predetermined time, e.g., half a meal. This allows one to enjoy the benefits of an unstructured, social meal, while limiting the inducements inherent in such a setting to overeat.
[0020] In another embodiment of the invention, the methods and tools of the invention can be used to avoid or minimize certain types of situations where historically one has overeaten. One can use either full or partial strategies for such situational avoidance. For example, one can choose to avoid the whole cocktail hour, or, one could use the taste agent to partially avoid the situation, namely to eat some food and then use the strongly flavored agent. Examples of such situations that can be avoided or minimized are cocktail hours, super bowl parties, bar food, the desert course of a meal, late night snacking, munchies, eating for emotional reasons, celebrations, junk food hangouts, and the like.
[0021] In still another embodiment, the methods and tools of the invention can be used to avoid or minimize alcohol consumption. Avoiding overdrinking is not only good for losing weight but also helps avoiding driving while intoxicated which can pose serious health and legal risks. Alcohol is fattening and it can harm the liver, and further it decreases inhibitions making it more likely for one to overeat or further over drink. The invention can be used either for complete avoidance, e.g., before one begins to drink, or to limit consumption, for example, after 1 or 2 drinks.
[0022] The taste-blocking tools typically use delivery form (“tab”) that is adapted to reside in the mouth for a sustained period. A tab will generally have enough strongly flavored agent and, if present, analgesic for maintaining food avoidance for the sustained period, or the appropriate integer fraction thereof if more than one tab (such as two or three) is to be used with each administration. The tab contains a strongly flavored agent and/or an analgesic agent, i.e, a “taste-blocking agent.”
Strongly Flavored Agents
[0023] One exemplary strongly flavored agent is the extract/oil of peppermint, from Mentha×piperita. The agent is typically applied in a form that is stronger than found in many breath mints, and in a form that is adapted, if used per instruction, to last longer than a breath mint. Another exemplary strongly flavored agent is the extract/oil of spearmint, from Mentha spicata . Another exemplary strongly flavored agent is wintergreen oil, e.g., methy salicylate or extract/oil of Gaultheria procumbens . A number of plants of the genus Mentha are believed to provide useful oils/extracts. Capsaicin and zinc (such as without limitation zinc gluconate, zinc sulfate or zinc acetate) provide further strongly flavored agents. In one embodiment, the metallic flavor of zinc is deemed less than sufficiently strongly flavored—in which case zinc can be used as supplementary agent for blocking taste perception.
[0024] The flavor is generally adapted to be pleasant, or at least not unpleasant. In one embodiment, the idea is to not detract from the pleasant taste sensations of a meal, while nonetheless altering flavor appreciation sufficiently that the desire to take more food is reduced. However, in some embodiments, the flavor is unpleasant.
[0025] Strongly flavored agents are preferably already established as GRAS (generally recognized as safe) by the US Food and Drug Administration, and, if relevant, in amounts deemed safe pursuant to the Cumulative Estimated Daily Intake/Acceptable Daily Intake Database maintained by the US Food and Drug Administration.
[0026] Some of the strongly flavored agents are believed to contain agents having known, mild therapeutic effects. For example, peppermint oil contains menthol (2-isopropyl-5-methylcyclohexanol, especially its 1R,2S,5R form), that is known to trigger a cooling sensation (believed to be via the transient receptor potential cation channel, subfamily M, member 8, also known as TRPM8), and to be an analgesic (believed to be mediated through activation of κ-opioid receptors). Without being bound by theory, effects via TRPM8 or opioid receptors may contribute to appropriate taste altering effects.
[0027] The amount of strongly flavored agent present in a typical tab will depend on the particular strongly flavored agent. Where peppermint is the strongly flavored agent, the amount can be, for example, about the amount in an Altoid mint or more. Amounts may be adjusted dependent on a given segment of the population for which the tab is formulated. For example, certain populations may be more sensitive to strongly flavored agents, and the amount can be adjusted downwards for tabs intended for usage with these populations. Or, certain populations may be less sensitive to strongly flavored agents, and the amount can be adjusted upwards for tabs intended for usage with these populations. Populations that can be targeted include for example children (optionally of various age groups), adults of various age groups, those with various medical conditions, and the like.
Analgesic Agents
[0028] Analgesics can be, for example, procaine benzocaine, chloroprocaine, cocaine, cyclomethycaine, dimethocaine/larocaine, piperocaine, propoxycaine, procaine/novocaine, proparacaine, tetracaine/amethocaine, lidocaine, articaine, bupivacaine, cinchocaine/dibucaine, etidocaine, levobupivacaine, lidocaine/lignocaine, mepivacaine, prilocaine, ropivacaine, trimecaine, or the like, and naturally derived local anesthetics, such as saxitoxin, tetrodotoxin, menthol, eugenol, kava, or the like. Combinations may be used. The formulation may contain a portion or all free base form, or be in salt form (e.g., acid addition salt). Counter ions will be pharmaceutically acceptable such ions. Where the strongly flavored agent is an analgesic, in this embodiment there is a second analgesic in the tab.
[0029] The amount of analgesic agent present in a typical tab will depend on the particular analgesic agent. Where benzocaine is the analgesic agent, the amount can be, for example, comparable to that in a pea-size dollop of 20% wt gel, or more. Amounts can be adjusted based on particular populations.
[0030] Without being bound by theory, it is believed that analgesics work by blocking the action of taste receptors. Without being bound by theory, it is believed that analgesics that act on the tongue are particularly useful. Without being bound by theory, it is believed that transmucosally deliverable analgesics are particularly useful. Without being bound by theory, it is believed that an amount of analgesic that deadens pin-prick sensation in the mouth will be an appetite reducing effective amount (for the period of such reduced mouth feel).
Additional Agents
[0031] Other diet promoting agents can be added to the tabs, such as gymnema, a herbal agent that is believed to block sugar taste receptors and ease sugar craving.
Compositions/Formulations
[0032] In certain embodiments, the taste-blocking agents are applied to the mouth in particular formulations. For example, in a tab that is a mouth-adherent film or tablet. Mouth-adherent compositions are known in the art and include, for example, the denture liners described in US 20070196787, 20080293015, 20050228066 and 20040028930, or the denture liner found in Polygrip™ Comfort Seal™ Strips, or the mouth deodorizing films described in U.S. Pat. No. 7,407,669. The films of the '669 patent are believed to generally dissolve too fast to be preferred in the present invention, but can be modified with more hydrophobic polymers and with waxes such as used in the denture liners to provide a more preferred residence time in the mouth. Though not a required feature of the invention, these films can be non-adhesive in dry form, but become adhesive as they wet in the mouth. This feature makes them relatively easy to handle. The commercial denture liner, Polygrip™ Comfort Seal™ Strips, is believed to comprise PEG-90M (high molecular weight polyol), microcrystalline wax, polybutene and cellulose gum in the adhesive, with the adhesive slab sandwiched between a thin, highly porous fabric that is infused or intimately associated with the adhesive.
[0033] In certain embodiments, the taste-blocking agents are applied in an adhesive form that is difficult to dislodge, so that the user is trained not to cheat on the regime by dislodging and swallowing. In certain embodiments, a waxy film form is used that cannot be easily dislodged, and which can be uncomfortable to dislodge. For example, films composed similar to Polygrip™ Comfort Seal™ Strips (with or without fabric) are believed to be difficult to dislodge in this fashion.
[0034] Tablets containing the taste-blocking agents can be coated with or compressed against an adhesive composition. If needed, the mouth adherent surface can include the thin, highly porous fabric mentioned above, or be packaged with a release liner (as is known in the art).
[0035] Any number of taste-blocking agents are believed to be compatible with film-forming adhesive compositions. To the extent that the polymer/plasticizer components of a film need to be modified in view of the taste-blocking agents, many of which it is believed will act as plasticizers, such modification is within the skill of the art.
[0036] The taste-blocking agents can be formulated in a chewing gum as is know in the art. The taste-blocking agents can be compounded with time-release components such as polymers (including hydrophobic polymers or a mixture of hydrophobic and hydrophilic polymers), for example such that time release nodules are dispersed through the gum. In some embodiments, mastication of nodules speeds release from those nodules. In certain embodiments, the nodules have individual time release coatings, such as formed by a fluidized bed coating process, or by another process known in the art.
[0037] Patch designs are well known in the art, as illustrated in http://www.uspharmacist.com/index.asp?show=article&page=8 — 1061.htm; and http://www.pharmainfo.net/reviews/transdermal-drug-delivery-systems-review (both as downloaded from the internet Dec. 16, 2008). Patches tend to fall in two categories. Most prevalent are those in which the adhesive (“matrix”) serves as the primary reservoir for the agent to be released. The other category is for patches that contain a separate layer or housing that provides the primary reservoir. Contrary to many traditional transdermal patches, but well within the skill in the art, the backing layer used in the patch will generally be selected to allow diffusion of the taste-blocking agent from the reservoir and through the backing layer. The extent of transmission through the backing layer can be selected to provide an appropriate rate of release of the taste-blocking agent. In certain embodiments, transmission through the backing layer is a minor source of distributing taste-blocking agent into the mouth, with the boundaries of the patch or the tissue adherent side providing all or the bulk of transmission.
[0038] Traditional patches, that are intended to deliver bioactive into the underlying strata, give rise to problematic issues that do not pertain in the present context. Here, in certain embodiments, one needs not be concerned with the extensive experimentation needed to find compositions and delivery enhancers that deliver to the underlying strata, as delivery is instead aimed at a medium that allows relatively free diffusion.
[0039] The taste-blocking agent can be encapsulated in a membrane that allows diffusion of the taste-blocking agent therethrough, but limits the rate of diffusion. For example, the membrane can be a microporous dialysis membrane, such as a cellulose-based dialysis membrane, or any other polymeric membrane that provides a useful, but rate limiting rate of diffusion of the taste-blocking agent therethrough. Such a membrane can be the backing layer of a patch.
[0040] In certain embodiments, the formulation of the taste-blocking agent is effective, if unchewed, to deliver an effective amount of the taste-blocking agent for a desired period of time. For example, the form could be a slowly dissolving tablet. Therefore, in certain embodiments it can be useful to train the user not to chew on the delivery form. One way to do so is to physically associate the taste-blocking agent formulation with another formulation including an agent whose taste is undesirable. For example, the bad flavor can be sandwiched between to non-dissolving or slowly dissolving layers, with the edges also blocked by the non-dissolving or slowly dissolving material. This sandwich can be adhered to, for example, a tablet containing the taste-blocking agent. Thus, if the user bits on the combined form, he or she releases the bad taste, and therefore a lesson to not chew again—while in many cases also receiving an effective, if less desirable, taste-blocking agent.
[0041] The bad flavor can also be encapsulated or otherwise formulated in nodules to provide for very slow to negligible release. Such nodules can be dispersed in the delivery form, such that chewing/biting release a sufficient bolus of bad flavor to remind the user not to chew, while preserving the bulk of the delivery form for continued use (with the more desired strong flavor thereafter reasserting itself). For example, tablet 10 in FIG. 1 has two layers, agent layer 2 contains the desired taste-blocking agent, while avoidance layer 4 contains modules 6 that contain bad flavor.
[0042] The tabs can be patches, gums, tablets, lozenges, hard candies, films, sprays, gel, and the like.
[0043] For most any of the above-described formulations, or for more simple formulations, the time of delivery of an effective amount of taste-blocking agent can be extended by instructing the user to apply the taste-blocking composition where there is delivery to the mouth, but less chance of chewing or other manipulation that might speed agent release. For example, the taste-blocking agent can be applied to the cleft between the lips and gums.
[0044] The form of the taste-blocking agent can be designed to, if used according to instruction, to release an appetite reducing effective amount of taste-blocking agent for 15 minutes or more, or 20 minutes or more, or 25 minutes or more, or 30 minutes or more, or 40 minutes or more. There may be a delay from application until an appetite reducing effective amount begins to be released, but this time is generally adapted not be so long as to impinge on the psychological commitment to avoid eating. For example, in preferred embodiments the delay is less than 2 minutes, more preferably less than one minute. Delivery forms with time release components can be combined with forms that provide more immediate release to assure this balance.
[0045] Appetite Reducing Effective Amount
[0046] An appetite reducing effective amount of a taste-blocking agent will be an amount that (a) reduces (e.g., inhibits alters, mitigates or masks) one or more gustatory perceptions of the food (e.g., of the five known, salty, sweet, sour, bitter and umamai (savory)) and (b) reduces appetite for the food. This effect may not hold for all foods, and may not hold in certain circumstances, such as notably elevated hunger, but shall be generally applicable. Optionally, the appetite reducing effective amount of a taste-blocking agent alters the perception of the odor of a food to generally reduce the savoriness of such food.
[0047] Mouth
[0048] Without limitation, the mouth includes the (i) the narrow cleft between the lips and gums and (ii) the oral cavity proper.
[0049] Oil-Based Flavor Extract
[0050] An oil-based flavor extract is a natural product flavor extract (or engineered mimic) in which a substantial portion of the flavoring agents are hydrophobic, i.e., favor partitioning in the organic phase of a octanol-water phase separation (molar basis). In certain embodiments, a substantial portion of the flavoring agents are favor partitioning in organic phase of a octanol-water phase separation by 5:1 or more, or 10:1 or more.
[0051] Oral Cavity Proper
[0052] The oral cavity proper is the space between the dental arches, limited posteriorly by the isthmus of the fauces (palatoglossal arch).
[0053] Super-Flavoring Amount
[0054] A super-flavoring amount of a strongly flavored agent is an amount that, as released by a tab, provides in the mouth for an operative period (e.g., 10 min. or more) a sustained amount of taste-masking effect as provided by a peppermint Altoid one minute after insertion into the mouth (and without chewing). The amount can be established by questionnaires using volunteer test subjects. In the various embodiments of the invention that use a strongly-flavored agent, the amount can be a super-flavoring amount.
[0055] Publications and references, including but not limited to patents and patent applications, cited in this specification are herein incorporated by reference in their entirety in the entire portion cited as if each individual publication or reference were specifically and individually indicated to be incorporated by reference herein as being fully set forth. Any patent application to which this application claims priority is also incorporated by reference herein in the manner described above for publications and references.
[0056] While this invention has been described with an emphasis upon preferred embodiments, it will be obvious to those of ordinary skill in the art that variations in the preferred devices and methods may be used and that it is intended that the invention may be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications encompassed within the spirit and scope of the invention as defined by the claims that follow. | Provided, among other things, is a method of reducing dietary intake comprising:
eating a portion of food; and immediately thereafter applying to the mouth a long-lasting, taste-blocking agent (strongly flavored agent and/or analgesic) in an appetite reducing effective amount. | 0 |
BACKGROUND OF THE INVENTION
This invention relates to a bed for practising the body slant exercise to maintain and promote good health by the use of one's body weight.
It has for long been recommended that the "Yoga Slant Position", that is, the body slant position with the head being retained lower than the feet, is effective in fighting and recovering from fatigue of the spune and internal organs. The Yoga Slant Position is also believed to be effective in promoting good blood circulation. To practise the Yoga Slant Position, however, various inconveniences must be overcome such as specific apparatuses, skill and labor in manipulation of the apparatuses, floor space requirement therefor, and so forth. Because of these and other inconveniences, the Yoga Slant Position has not been widely practised conventionally despite its reputed effectiveness.
As a remedial practice for a spinal or sciatic disorders, attaching weights to the body of a patient lying prone on a bed in order to stretch his body has been conventionally practices. This method, however, entails inevitable risks involved in attaching weight to a patient's body, and preparing various weights to match with the condition of patients illnesses is a problem.
SUMMARY OF THE INVENTION
It is therefor an object of the present invention to provide a bed which allows one to take the "Yoga Slant Position" with the head lower than the feet in an extremely easy manner through tilting operation of the bed which resumes its normal horizontal position after a predetermined period of time, e.g., after 30 minutes.
It is another object of the invention to provides a bed which employs only an individuals own weight but no other driving sources at all for tilting operation thereof.
It is still another object of the invention to provide a bed which, after having once tilted subsequently resumed its normal horizontal position.
It is a further object of the invention to provide a bed which when tilted, naturally imparts a stretching force to the body of the individual lying prone thereon, said stretching force being exclusively generated by the weight of the body but by no other means such as weights of an artificial nature.
It is still a further object if the invention to provide a bed which can also be used as an ordinary bed, that is, which allows one to sleep thereon as in an ordinary bed after having tilted and resumed the normal horizontal position once or twice as mentioned above.
Similarly, it is still a further object of the present invention to provide a bed which, when one leaves it in the morning, automatically resumes its horizontal position and which allows one to practise exercises for promotion of health or for the remedy of disorders without specific skills, endeavours, time, or a floor space requirement.
BRIEF DESCRIPTION OF THE DRAWING
These and other objects, features and advantages of the present invention will become more apparent from the detailed description of preferred embodiments thereof taken in connection with the accompanying drawings, in which
FIG. 1 is a partially vertical cross-sectional view of the bed in accordance with a first embodiment of the invention;
FIG. 2 is a side view of the bed shown in FIG. 1 as viewed from the right side thereof;
FIG. 3 is an enlarged schematic view of an air feed device;
FIG. 4 is a partially vertical cross-sectional view of a bed in accordance with a second embodiment of the invention;
FIG. 5 is a plan view of the bed frame in accordance with a third embodiment of the invention;
FIGS. 6 and 7 are sectional view of the portions taken respectively along the lines VI--VI and VII--VII of FIG. 5;
FIGS. 8-13 are schematic views showing the mode of the tilting operation of the bed frame;
FIG. 14 is a partially vertical cross-sectional view of the bed in accordance with a fourth embodiment of the invention; and
FIG. 15 is a schematic electric and hydraulic circuit in accordance with a fourth embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIGS. 1 and 2, a bed frame is indicated by the reference numeral 10. For the ease of explanation, the bed end of the bed frame is shown situated on the right side, and the foot end on the left, as also indicated by imaginary lines. A pillow support 28 is supported at the front end of the bed frame 10 considerably spaced apart from the upper surface of the bed frame by support plates 27, 27, and is tiltable back and forth to a certain extent. The pillow support 28 is, for the most part, horizontally retained by a spring 29.
The reference numeral 40 denotes a base onto which a pair of hydraulic support means 41 and 41a are adapted to support the bed frame 10 at both the front and rear sections. Since the hydraulic support means 41 and 41a have the same construction, explanation will hereinafter be given only on one of said means 41. A cylinder 42 is vertically erected on the base 40, and incorporates a piston 43 as well as an oil chamber 44 defined below the piston 43. The upper end of a piston rod 45 is fixed by a pin to a metal member 30 which is secured to the lower surface of the bed frame 10.
A balance mechanism 46 functions to prevent the bed frame 10 from tilting in the transverse direction relative to the head and foot ends of the frame. In other words, it prevents an individual from falling off from the sides of the bed.
The balance mechanism 46 is of a parallel motion mechanism known per se in the art. As shown in FIG. 2, for example, four links 47 of an equal length are assembled in a pantagraphic linking mechanism by pin-joints at the central position as well as both ends of each link 47. Longer holes 471 are bored respectively in the upper and lower ends of each link 47 so that horizontal pins 481 of metal members 48 are fitted into these holes 471 slidely, said metal members 48 being adapted so as to project into the lower surface of the frame 10 and to the upper surface of the bace 40.
The reference numeral 51 represents an oil tank 51 which is formed, for example, by dividing an air-tight vessel 52 (e.g. the cylindre erected on the base 40) into an oil chamber 54 at the lower section and a compressed air chamber 55 at the upper section by means of a separator 53. The separator 53 is capable of displacement while maintaining airtightness (such as, for example, a piston).
The internal volume of the compressed air chamber 55 is rendered variable in order to also vary the air pressure therein. Another piston 56 is disposed inside the compressed air chamber 55 in order to supply air as will herein be described in more detail. A screw rod 57 is secured to the upper portion of the piston 56, and projects outside from the vessel 52 in an upward direction. A handle 571 is fitted to the upper end of the screw rod 57 so that the piston 56 is caused to move vertically along with rotation of the handle 571.
A cylinder 58 for feeding compressed air (shown in FIG. 3) incorporates a piston 59 which is allowed to move vertically by rotation of a handle 601 of a screw rod 60 secured thereto. A lower chamber 61 of the cylinder 58 is communicated by a pipe 63 to an inlet port 62 positioned at the upper section of the airtight vessel 52 of the abovementioned oil tank 51. An air feed port 64 is disposed at the upper section of the cylinder 58.
Air is fed through the air feed port 64 while the piston 59 is maintained at a position indicated by dot-and-dash lines, and the piston 56 at a position of the full line (in FIG. 3). When the piston 59 is pushed down below the air feed port 64, the air inside the chamber 61 is compressed whereby the air pressure is also elevated in the air chamber 55. Next, when the piston 56 is pushed down below the air inlet port 62, the air is further compressed inside the air chamber 55.
Subsequently, a pipe 71 is connected to the oil chamber 54 of the oil tank 51 as shown in FIG. 1. The pipe 71 is branched at its top, one 72 being connected to the lower end of the cylinder 42 and the ither 72a tp the lower end of the cylinder 42a. These pipes 72 and 72a are provided respectively with variable throttle valves 73 and 73a.
The pipe 71 is also equipped with a manual switch valve 74 which is of a normally-closed type, and is opened when pulled by, for example, a piano wire 75. The piano wire 75 is incorporated in a helical tube (not shown), and the other end of the same is secured to the pillow support 27 passed through the bed frame 10 slidably. When the head of an individual is placed on the pillow of the pillow support 27, the support 27 rotates in the direction indicated by an arrow in FIG. 1, whereby the piano wire 75 is pulled, thereby opening the switch valve 74.
A pipe 76 connected the oil chamber 44 of the support-means 41 to the oil chamber 54, and a pipe 76 likewise connects the air chamber 44a to the oil chamber 54. These pipes 76 and 76a are provided with check valves 77 and 77a so as to allow the oil from the oil tank 51 to flow only in the direction of oil chamber 44 and 44a.
Next, the mode of operation of the bed frame in accordance with the above-described embodiment will be explained in the paragraphs which follow.
1. When an individual does not lie down on the bed, the pistons 43 and 43a of the hydraulic means 41 and 41a are kept at the uppermost position whereby the bed frame 10 is kept horizontal.
2. Next, when an individual lies down on the bed frame 10 (on which a mattress or a cushion is placed) and places his head on the pillow support 27 (on which a pillow also is placed) as shown in FIG. 8, the valve 74 is caused to open. In consequence, the piston 43 and 43a are forced to move downward by the weight of the body, thereby feeding the oil from the oil chambers 44 and 44a to the oil tank 51. In this instance, the throttle valves 73 and 73a are regulated such that the descending speed of the piston 43 (on the foot-end side of the bed frame) is much slower than the ascending speed of the piston 43a (on the head-end side).
For example, when the throttle valves are so regulated as to allow the piston 43 and the piston 43a to reach the lowermost position in 10-30 seconds for the former and in about 30 minutes for the latter, the body of an individual on the bed frame 10 is brought into a slanted state ("Yoga Slant Position") as shown in FIG. 9. Subsequently, the foot end of the bed frame is lowered gradually, and within about 30 minutes, the bed frame 10 is placed again in a normal horizontal state as shown in FIG. 10.
3. Simultaneously with the abovementioned operation (2) the following action takes place in the hydraulic mechanism.
Namely, when the oil is transfered from the oil chambers 44 and 44a to the oil tank 51, the separator 53 (the lower piston) elevates to diminish the compressed air chamber 55, thus increasing the air pressure.
4. When an individual leaves the bed frame, the pillow support 27 resumes a normal horizontal position whereby the valve 74 is closed. On the other hand, the separator 53 is pushed downward by the air pressure of the air chamber 55. Accordingly, the oil of the oil chamber 54 flows back to the oil chamber 44 and 44a via the check valves 77 and 77a, and pushes the pistons 43 and 43a upward to restore the bed frame to the starting horizontal position as shown in FIG. 11.
5. When the opening direction of the throttle valve 73 is reversed with respect to the throttle valve 73a, the bed frame is tilted in the direction opposite to the above-mentioned operation (that is, with the head end being higher than the foot end).
In the above-described embodiment, the balance mechanism 46 may, if desired, be replaced by the four hydraulic support means 41.
Another embodiment of the present invention will next be explained with reference to FIG. 4.
As shown in FIG. 4, another pipe 78 is disposed at the bottom of the oil tank 51, and branched to pipes 79 and 79a. These pipes 79 and 79a are connected respectively to the intermediate positions 80 and 80a of the same height of the oil chamber 44 (of the hydraulic means 41) and the oil chamber 44a. These pipes 79 and 79a are provided, respectively, with throttle valves 81 and 81a, while a switch valve 82 is fitted to the pipe 78 so that it is opened when pulled by a piano wire 75 (interlocked with the pillow support 27) in the like manner as is in the aforementioned embodiment.
Another switch valve 74 may be operated either manually or automatically by use of automatic means to be described later.
Namely, a cylinder 83 is adapted to an optional position of the base 40 (on the left side in FIG. 4), and two pistons 84 and 85 are incorporated therein to define an oil chamber 85 below the piston 84, and a compressed air chamber 87 between the piston 84 and 86. A screw rod secured to the upper piston 86 which has a handle 881 at the top thereof. hence, manipulation of the handle 881 causes the vertical motion of the piston 86 to optionally vary air pressure inside the air chamber 87.
On the other hand, a rod 89, secured to the lower piston 84, passes through the upper piston 86 and the screw rod 88 slidably as well as air-tightly. The upper end of this rod 89 is interlocked with the switch valve 74 by a piano wire, for example, in such a fashion that when the lower piston 84 elevates to a predetermined position against the air pressure inside the air chamber 87, the switch valve 74 is pulled by the piano wire, and caused to open.
A pipe connecting the oil chamber 85 to the oil chamber 54 of the oil tank 51 is provided with check valve 91 and a variable throttle valve 92 disposed in parallel. Thus, oil flow is free from the oil chamber 85 to the oil tank 51, but the reverse oil flow is limited to only a small amount by the throttle valve 92.
The mode of operation of the bed in this embodiment is as follows.
1. When an individual lies down on the bed frame and places his head on the pillow, the piano wire 75 is pulled to open the valve 82 in a manner similar to that in the first embodiment. When the throttle valves 81 and 81a are opened to substantially the same degree as in the first embodiment, the bed frame is tilted from the state shown in FIG. 8 to the state shown in FIG. 12, and thereafter maintains the state shown in FIG. 13. Note that in FIG. 13, the piston 41 and 41a' are stopped midway. In other words, the bed frame stops descending at a position where these pistons 41 and 41a close the outlet ports 80 and 80a of the oil.
2. Simultaneously with the abovementioned operation of the bed frame mentioned in the paragraph (1), the separator 53 of the oil tank 51 causes elevation. Simultaneously a portion of the oil inside the oil tank 51 passes through the pipe 90, and fed to the oil chamber 85 in extremely small amounts that are controlled by the throttle valve 92. In consequence, the piston 84 is forced to move upward, thereby opening the valve 74 at a predetermined position as mentioned in the foregoing paragraph.
3. Accordingly, the bed frame is finally placed horizontally as shown in FIG. 10 via the state shown in FIG. 9 in the same way as in the first embodiment.
4. When an individual leaves the bed, the bed frame resumes its normal horizontal position as shown in FIG. 11. In this instance, the piston 80 also descends to the starting position by the force of the compressed air inside the air chamber 87, and the oil of the oil chamber 85 flows back to the oil tank 51.
The third embodiment of the present invention contemplates to impart a pulling force to the body of an individual ehen he lies down on the bed frame tilted in a manner as in the aforementioned two embodiments. The construction of the bed frame in this embodiment is substantially similar to the aforementioned two embodiments except that the structure of the frame 10 per se is somewhat different.
In FIGS. 5 through 7, the bed frame 10 consists principally of a main body 11 and a moving frame 15 which is movable back and forth above the main body11. The main body 11 is of a flat square, and a leg 111 thereof is higher than the other parts (FIG. 6). Guide gutters 12, 12 are bored in both the front and rear sections of the main body 11 as shown in FIG. 7. Stoppers 13 and 14 also are disposed projectively at the central positions of the main body 11.
The moving frame 15 has a flat square shape, and is provided with four castors 16 the detail of which is illustrated in FIG. 7. That is to say, a small cylinder 161 is secured to the lower surface of the frame 15. The upper section of a metal fitting 162 of a wheel 163 is fitted into the small cylinder 161 in such a fashion as to be vertically slidable therein but not subject to falling. A compression spring 164 is interposed between the cylinder 161 and the fitting metal 162. The wheels 163 travel on the guide gutters 12, 12. When an individual lies down on the bed frame 15, the moving frame 15 is lowered to thwewby press the spring 164. The moving frame is connected to the main body 11 by a tension spring 17.
On both sides of the lower surfaces of the moving frame 15, there are disposed guide frames 18 and 18 in the longitudinal direction in parallel with each other. These guide frames 18 slidably support there between an engaging member 19. A hole 192 is bored down wardly in a main body 191 of the engaging member 19 as shown in FIG. 6, and a pin 193 is fitted into this hole in such a manner as to be vertically slidable therein but not subject to falling, and interposes a compression spring 194 therebetween. Also, the rear end of the lever 20 is secured to this engaging member 19, while links 21 and 22 are sequentially pin-jointed to the front end of the lever 20. A bolt 23 is inserted into the lower surface at the front end of the moving frame 15. A cylindrical member 24 is rotatably fitted to this bolt 23, and the front end of the link 22 is secured to the member 24. Further, a handle 25 and a dial plate 26 are secured to the cylindrical member 24.
The apparatus of this embodiment operates in the following manner.
1. When the handle 25 is turned, the engaging member 19 is caused to move via the links 22 and 21 as well as the lever 20. The piston of the engaging member 19 is indexed by the dial plate 26.
2. When the bed frame 10 as a whole is tilted (as shown in FIGS. 9 and 12), the moving frame 15 transfers the main body 11 forward against the force of the spring 17. If the legs of an individual are secured to the foot end section 111 of the main body 11, therefore, a stretching force is imparted to his body. The stretching force is expressed by the product of the weight of the person and the sine of the inclined angle. No additional weight is required in this instance.
3. When the moving frame 15 moves forwards, the pin 193 of the engaging member 19 engages with the stopper 13 whereby the moving frame 15 stops at this position. Accordingly, the distance of movement of the moving frame 15 is regulated by the position of the engaging member 19 (in accordance with instructions of a medical practitioner).
4. When an individual leaves the bed, the moving frame floats upwards to a certain extent by the action of the spring 164 incorporated in the leg 16 whereby the pin 193 detaches from the stopper 14, and resumes the normal horizontal position by the action of the spring 17.
Fourth embodiment of the invention
There will be a difficulty in the downward movement of the bed frame 10 with a child or very light weight individual if the pressure is lowered excessively inside the compressed air chamber 55 of the oil tank 51. With a lowered pressure in the compressed air chamber 55, however, there will be another difficulty in restoring the original position of the bed frame 10 after the individual leaves the bed frame 10.
These difficulties may be solved by using an oil tank 51 of very large capacity. As an alternative solution, however, the pump 94 may be operated only for restoring the position of the bed frame 10 as illustrated in FIG. 14 and 15.
The pump 94 is connected between the oil chamber 54 of the oil tank 51 and the branching point leading to the pipes 76 and 76a as shown in FIG. 14. In addition, the pressure switch 95 is mounted at the most favorable location over the bed frame 10. This switch 95 is of normally-closed type and turned off when an individual lies down on the bed frame 10. Another normally-closed type limit switch 96 is mounted on the upper portion of the cylinder 42 via a suitable support member. The reference numeral 99 in FIG. 15 represents a relief valve.
The operational mechanism is described below.
If an individual lies down on the bed frame 10, the pressure switch 95 is turned off and the bed frame 10 is lowered in level while tilting as aforementioned.
When the individual leaves the bed frame 10, the pressure switch 95 is turned on and the electeic motor 98 in FIG. 15 then starts to rotate to operate the pump 94 so that the oil in the oil chamber 54 is fed to both the oil chambers 44 and 44a. The bed frame 10 is thereby elevated to reach its uppermost level, when the dog 97 that is secured to the piston rod 45 touches the limit switch 96. the limit switch 96 is then turned off to stop the electric motor 98.
Since numerous changes may be made in the abovedescribed apparatus and different embodiments of the invention may likewise be made without departing from the spirit and scope thereof, it is intended that all the matters contained in the foregoing description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. | The invention provides a bed which, when an individual lies down upon it, allows him to take the "Yoga Slant Position" -- with the head lower than the feet -- through its automatic tilting operation, which gently returns the bed to its normal horizontal position after a short time. The bed is supported by a pair of hydraulic support means disposed respectively at the front and rear section, each oil chamber of the hydraulic support means being connected to an oil chamber of an oil tank which is provided separately, via a variable throttle valve. | 0 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Application No. 61/638,861 filed Apr. 26, 2012. The aforementioned priority application is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] The present disclosure relates to an eyewash and integral faucet combination utilizing a common support structure but with separate water supplies to insure appropriate water flow, and water temperature, through the eyewash and faucet.
[0003] Emergency eyewash stations are mandated by governmental authorities to ensure worker safety, particularly in laboratories, factories, and warehouses where workers may have improper or accidental exposure to harmful chemicals. Conventionally, eyewash stations are positioned separately from sink faucets and require significant floor or deck space.
[0004] There are, however, several benefits to having a system which integrates an eyewash with a faucet. Various solutions have been proposed for integral eyewash and sink faucets. Each, however, has limitations. Some proposed solutions couple eyewash attachments to existing sink faucets. Such approaches create a potential risk of slow flow or minimal to zero flow to the eyewash if the water supply to the faucet is reduced or shut off. Also, such devices typically require a user to apply multiple hand movements to actuate the eyewash, which, in an emergency, may not be properly coordinated because of panic associated with the emergency. As such, these types of attachments are not suitable for industrial use. Other proposed solutions require cumbersome installation procedures and significant modification to surrounding areas and supporting structures.
[0005] Other prior art approaches to providing eyewash and faucet functions separate faucet handles from the structure supporting the eyewash. One example of such an approach is U.S. Pat. No. 6,385,794, assigned to the owner of this application. However, installation costs associated with the faucet of this patent can be substantial. For example, installation will often require extra penetrations in the deck on which handles for the faucet are mounted and extra piping connecting the faucet to the water supply. These problems are more pronounced in a typical application for the type of faucet-eyewash combination of this invention, i.e., in laboratory settings where the deck is often stone or other difficult to penetrate material. The present invention satisfies the need for an integral eyewash and faucet, utilizing a single deck penetration.
BRIEF SUMMARY OF THE INVENTION
[0006] An integral eyewash and faucet with direct connection to sources of hot and cold water provides considerable savings in time and expense of installation. Internal porting within the faucet provides independent water supply to the faucet and the eyewash. The eyewash is directly, and separately, supplied with water from the cold, or tempered, water supply utilizing an internal water passageway separate from those supplying the faucet. The latter is supplied by water whose temperature is controlled by hot and cold water faucets mounted on columnar posts of the integral eyewash and faucet. The functions of this integral eyewash and faucet can be further expanded by adding a water fountain (e.g. a bubbler) to the cold water line otherwise used to supply the eyewash.
DESCRIPTION OF THE DRAWINGS
[0007] The drawings described herein are for illustrative purposes only and are not intended to limit the scope of the present disclosure. In the drawings:
[0008] FIG. 1A is a left perspective view of an eyewash-faucet system;
[0009] FIG. 1B is another left perspective view of the eyewash-faucet system shown in FIG. 1A ;
[0010] FIG. 1C is a right perspective view of the eyewash-faucet system shown in FIG. 1A ;
[0011] FIG. 2A is a top perspective view of the eyewash-faucet system shown in FIG. 1A with eyewash dust covers in an open position;
[0012] FIG. 2B is a top perspective view of the eyewash-faucet system shown in FIG. 1B with eyewash covers in a closed position;
[0013] FIG. 3 is a partial sectional view of the eyewash-faucet system shown in FIG. 1B illustrating internal passageways;
[0014] FIG. 4A is a partially exploded perspective view of the eyewash-faucet system shown in FIG. 1B ;
[0015] FIG. 4B is another exploded perspective view of the eyewash-faucet system shown in FIG. 1B ;
[0016] FIG. 5 is a front view of the eyewash-faucet system;
[0017] FIG. 6A is a cross-sectional right side view of the eyewash-faucet system shown in FIG. 5 taken along line A-A of FIG. 5 , illustrating internal water passageways;
[0018] FIG. 6B is a left side view of the eyewash-faucet system shown in FIG. 5 , illustrating internal water passageways;
[0019] FIG. 6C is a right cross-sectional side view of an eyewash-faucet system, illustrating internal water passageways;
[0020] FIG. 7 is a top view of the eyewash-faucet system shown in FIG. 5 ;
[0021] FIG. 8 is a cross-sectional view of the eyewash-faucet system shown in FIG. 7 taken along line B-B of FIG. 7 ;
[0022] FIG. 9 is a cross-sectional view of a portion of the eyewash-faucet system shown in FIG. 7 taken along line C-C of FIG. 7 ; and
[0023] FIG. 10 is a perspective view of an eyewash-faucet system having an optional cold water dispenser/bubbler.
DETAILED DESCRIPTION OF THE INVENTION
[0024] FIGS. 1-10 show various views of an integral eyewash-faucet system 10 , having a modular mount assembly 12 , an above-deck valve assembly 14 , and a combination spout and valve assembly 16 . These assemblies are stacked on one another to form a columnar structure. The system components are mostly positioned above deck 17 , where a deck is broadly defined as a support surface, such as a countertop or sink body. Because all operational components are in a single columnar structure, only one deck penetration is needed to mount system 10 to deck 17 .
[0025] As previously explained, the single deck penetration used to install the instant eyewash-faucet combination has economic advantages over other combinations that require multiple deck penetrations. Included within the overall system 10 are passageways, as further described below, which facilitate fluid communication from hot and cold water sources (not shown) to multiple water outlets. The outlets may be configured in various ways such that they are suitable for use as a faucet, eyewash, drinking spout, and/or other types of water dispensing means. Where an eyewash is included, the system is configured with passageways which preclude hot water from reaching the eyewash. This arrangement prevents damage to the eyes of a user that would otherwise result if hot water reached the eyewash.
[0026] FIGS. 4A and 4B are exploded views of the eyewash-faucet system 10 . The system generally includes three separate sections: (1) a modular mount assembly 12 , (2) an above-deck valve assembly 14 , and (3) an eyewash spray head and valve assembly 16 . These assemblies are stacked one upon another to form the single columnar-like structure with a single-hole mount to facilitate passage of hot and cold water feeds to the system 10 by utilizing a single penetration in the deck or, at most, multiple small penetrations that are cumulatively no larger than the diameter of the modular mount assembly 12 .
[0027] In one configuration, as shown particularly in FIG. 4B , the modular mount assembly 12 includes a mount body 18 , a flange base 20 , and a flange washer 22 . When mounted to a deck 17 ( FIG. 6B ), the flange washer 22 is positioned under the flange base 20 . The mount body 18 and the flange base 20 are configured for threadable engagement. Alternatively, the mount body and the flange base may be unitary.
[0028] Alternatively, the assemblies may be coupled to a deck using mount washers 24 , mounting rods 26 , and mounting nuts 28 . The mount washers 24 are provided with thru-holes for the mounting rods 26 . The washers 24 and rods 26 are positioned within the coupled mount body and flange base such that the mount assembly 12 is substantially secured to a deck. Within the mount assembly 12 is a chamber 30 ( FIGS. 3 , 6 A, 6 C, and 8 ) through which water supply conduits 102 , 104 , 106 pass for ultimate threaded attachment to hot and cold water passageways 96 , 98 and 99 in valve assembly 14 (see FIG. 3 , 6 A and 6 C).
[0029] The above-deck valve assembly 14 includes a valve body 32 , a hot water valve cartridge 34 , a cold water valve cartridge 36 , a hot water handle 38 , a cold water handle 40 , handle fasteners 42 , a hot water index 44 , a cold water index 46 , and handle collars 48 . In combination, the assembled collars and valve body form chambers to house valve cartridges 34 , 36 . Each valve cartridge may be specified as a conventional ¼ turn cartridge or any other suitable cartridge that controls and selectively blocks liquid from an inlet point to an outlet point. In preferred configurations, each valve cartridge 34 , 36 threadably mates respectively with handles 38 , 40 . An upper section 41 of the valve body 32 also mates with the eyewash spray head and valve assembly 16 .
[0030] The spray head and valve assembly 16 includes a spout 50 ( FIG. 4A ), having a lower spout section 52 , an upper spout section 54 , and a handle chamber 56 that houses the spout valve cartridge 72 and handle assembly 58 . The spray head and valve assembly 16 also includes a spout collar 53 . Referring to FIG. 4B , the spout collar 53 includes an upper collar section 57 that mates with an index button 59 , a lower collar section 60 that threadably mates with the upper section 41 of valve body 32 , and a front collar section 62 that threadably mates with the rear spout section 64 of spout 50 . The lower spout section 52 is configured to mate with aerator 66 , while the upper spout section 54 is configured to mate with eyewash spray head assembly 68 or a water dispenser/bubbler 70 , the latter being described below with reference to FIG. 10 .
[0031] The handle assembly 58 includes a spout valve cartridge 72 , a retainer collar 74 , a retainer nut 76 , and an eyewash handle 78 . The cartridge 72 is configured to initiate flow of water from an internal passageway, upon application of a single force eyewash handle, such as an applied force causing lifting motion, by a user. The eyewash handle 78 preferably has a bright color, such as white, red, or yellow, and includes one or more indicia 82 , 84 (See, e.g. FIGS. 2A and 2B ) to indicate the purpose of the handle and the lift direction. Preferably, the cartridge 72 is configured to route cold water from a cold water source (not shown). After water flow is initiated, water will travel through the system and out of either the eyewash spray head assembly 68 or the water dispenser/bubbler 70 , as further described below.
[0032] Referring to FIGS. 4A and 4B , the eyewash spray head assembly 68 includes a bottom housing 83 , a top housing 85 , aerators 86 , caps 88 , fastening elements 90 , and various flow control elements. The flow control elements include a flow control conduit 92 , a flow control washer 94 , and a flow control adapter 95 , which upon assembly facilitate travel of water flow from the upper spout section 54 to aerators 86 . The fastening elements 90 are preferably mounting screws or other suitable elements that securely couple the eyewash spray head assembly 68 to spout 50 . In the configurations shown, caps 88 are hingedly coupled to the top housing 85 such that dust and other contaminants do not build up on aerators 86 over time. The caps may also include cap indicia which indicate the purpose of the eyewash spray head assembly and/or other features of the system.
[0033] Integration of valving controlling flow of water through the eyewash-faucet system 10 is, as discussed above, an important feature of this invention. Such integrated valving must remain as readily accessible to the user after the integration as it was with prior art devices where the valving was deck mounted. Integration of this valving, however, presents unique design and placement problems which were resolved as described in more detail below.
[0034] One problem with integration of valving is routing separate water passageways for the eyewash (or bubbler 70 ) and the water spout 52 within the close confines of the above-deck valve assembly 14 and spout and valve assembly 16 . For safety reasons, i.e., potential scalding of eyes bathed by eyewash spray head assembly 68 , hot water passageways cannot, under any circumstance connect with the eyewash.
[0035] Another challenge in the design of the subject eyewash-faucet system 10 is the physical placement of hot and cold water valving within the columnar structure of the integral eyewash-faucet system 10 . To facilitate placement of valving and fluid passageways in valve body 32 ( FIG. 3 ), the axes 31 , 33 of valves 34 and 36 are oriented at an acute angle to the central vertical axis β of the valve assembly 14 , preferably of about 65°. These valves advantageously intersect vertical hot and cold water inlets at about a 65° angle (see FIG. 3 ). Preferably ¼ turn ceramic cartridges are used in valves 34 and 36 . These features minimize the volume within valve body 32 taken up by valving. Internal area within the valve body consumed by water passageways is minimized as described below.
[0036] As particularly shown in FIGS. 3 and 6A , upon assembly, the eyewash-faucet system 10 includes a cold water passageway 96 , a hot water passageway 98 , and mixing passageway 100 which allow water travel to the lower spout section 52 . These passageways are coupled to conduits 102 , 104 , which are positioned in chamber 30 such that installation of the system is relatively simple. Upon turning hot and cold water handles 38 , 40 , a user can therefore initiate flow of cold water through cold water passageway 96 and hot water through hot water passageway 98 . Where both hot and cold water flow is initiated, flowing water is mixed in mixing passageway 100 such that warm water exits from lower spout section 52 . Thus, a user may manipulate the release of hot and cold water in a conventional manner to provide water flow (cold, hot, or cold/hot mixture).
[0037] Alternatively, the passageways for cold and hot water and mixing passageways can be formed from tubing within a relatively hollow version of the columnar structure of the eyewash-faucet system 10 (not shown). Like the embodiment illustrated in the drawings separate tubing would connect the source of cold water with the eyewash to prevent scalding the eyes of an eyewash user.
[0038] With respect to the eyewash spray head assembly, upon lifting the eyewash handle 78 an eyewash valve 110 is opened which initiates cold water flow from a separate conduit 108 connected to cold water passageway 99 . As shown in FIG. 6A , cold water passageway 99 extends to couple with a conduit 108 , having two sections 108 a and 108 b. Water then flows through eyewash valve 110 such that water is released from the eyewash spray head assembly 68 .
[0039] Sealing elements 112 such as o-rings, quad rings, and various other types of gaskets may be disposed within the system to prevent exiting of water during use. Also, various types of fastening elements 113 may be disposed within the system to secure respective components to each other and to the deck.
[0040] FIG. 10 shows an optional configuration of the system, where a water dispenser/bubbler 70 or other type of water dispensing system may be coupled to the upper spout section 54 instead of an eyewash assembly. Such an arrangement provides flexibility. The water dispenser/bubbler 70 may include a cover 114 or other device that controls the flow of water from a water source to the water dispenser outlet 116 . The water dispenser/bubbler may have any configuration such that its positioning over the upper spout section is substantially aligned with the contour of the spout 50 .
[0041] As used herein cold water is meant to include water from a cold water source that is tempered with auxiliary devices attached to the cold water supply which are operated in accordance with AS SE Standard 1071, promulgated by the American National Standards Institute. Adherence to this Standard is required in some applications where very cold water flowing from an eyewash might hinder the effectiveness of the eyewash in an emergency.
[0042] Any and all materials used for any components of the system, as used herein, have sufficient resistance to corrosion from water over time. Such materials include, but are not limited to, plastic materials, brass, stainless steel, copper, etc.
[0043] While embodiments of this invention have been shown and described, it will be apparent to those skilled in the art that many more modifications are possible without departing from the inventive concepts herein. The invention, therefore, is not to be restricted, except in the spirit of the following claims. | An integrated columar structure is connected to hot and cold water supplies. On the structure is separately mounted on eyewash and faucet. In an alternative embodiment a water bubbler can be substituted for the eyewash. Water passageways within the columnar structure separately supply the appropriate temperature water to the faucet and eyewash/bubbler. Valving mounted on the columnar structure, preferably with an angle oriented at an acute angle to the axis of the column, controls the temperature of water supplied to the fauce. Cold, or slightly tempered, water is supplied to the eyewash. | 4 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention is in the field of structures designed to house sailplanes and small aircraft. More particularly, the present invention pertains to a structure which is specifically suited for protecting sailplanes and other small aircraft from exposure to the elements.
[0003] 2. Brief Description of Background Art
[0004] It is well known that small aircraft is best stored in hangars or like buildings where the aircraft is protected from exposure to the elements. This is particularly true for sailplanes (also known as gliders) which in modern times are usually made from fiber glass, carbon fiber or like synthetic material. It is known that these synthetic materials are severely damaged by prolonged exposure to the sun. However, storage space in hangars or like structures is usually limited in the airports and airfields where sailplanes are normally operated, and when storage space is available it is usually expensive. Sailplanes are often moved from one airfield to another or are retrieved from off-airfield landings in covered trailers in which the sailplane can be stored and transported but only if the wings are first disassembled from the fuselage. For this reason many sailplane owners or operators have specifically dimensioned trailers for each sailplane.
[0005] In order to avoid exposing sailplanes, especially sailplanes made from fiberglass, carbon fiber or like synthetic material to the elements the owners or pilots usually remove the wings from the sailplane and store the sailplane in its covered trailer even when there is no intention or need to move the disassembled sailplane from one location to another. However, as it is known by those familiar with sailplane operations, sailplane wings are heavy, and removing them can be burdensome and time-consuming, especially when this operation is performed by one person. Reassembling the wings to the sailplane to make it airworthy again is equally burdensome and time consuming. Moreover, the reassembly of the wings and reconnection of the control surfaces must be performed with absolute precision with no room for error, since failure of properly attaching the wings to the fuselage, and/or failure of properly connecting the control surfaces is likely to cause serious and possibly fatal crashes.
[0006] The present invention provides a solution to the problem of disassembling sailplanes for storage just to protect them from the elements, and provides convenient and relatively inexpensive storage space for sailplanes and other small aircraft.
SUMMARY OF THE INVENTION
[0007] It is an object of the present invention to provide storage space for housing a sailplane or like small aircraft whereby the sailplane or aircraft is protected from the elements.
[0008] It is another object of the present invention to provide storage space for a sailplane or like small aircraft that is relatively inexpensive to manufacture.
[0009] It is still another object of the present invention to provide storage space for a sailplane or like small aircraft that can be assembled at the site of usage from pre-fabricated parts.
[0010] It is yet another object of the present invention to provide storage space for a sailplane or like small aircraft which is easy to operate.
[0011] It is a further object of the present invention to provide storage space for a sailplane or like small aircraft that is operated by electric power without being dependent on a power grid.
[0012] These and other advantages are attained by a storage structure or hangar which has a substantially T-shaped pre-fabricated truss or upper frame support anchored to the ground at a plurality of locations, first set of frame members mounted immovably to the truss or upper frame support in areas where the fuselage and tail and the two wings are located when the sailplane or small aircraft is in the storage structure, and a second set of frame members hingedly mounted in part to the truss or upper frame support and partly to first set of frame members. The second set of frame members are located substantially where the front or cockpit of the plane is located and in front of the wings. Panels covering the first and second frame members and enclosing the structure are mounted to the first and second frame members. A cable, chain or like mechanism operated by a winch raises the second set of hinged frame members together with the cover panels mounted thereon to allow the plane to be placed into the storage structure. The winch also lowers the second set of frame members to close the structure and enclose the plane therein.
[0013] The foregoing and other objects and advantages attained by the present invention will become readily apparent from the following description taken together with the appended drawings where like numerals indicate like parts.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] [0014]FIG. 1 is a top plan view of the storage structure or hangar of the present invention.
[0015] [0015]FIG. 2 is a front plan view of the storage structure or hangar of the present invention.
[0016] [0016]FIG. 3 is a side view of the storage structure or hangar of the present invention, the view showing a second hinged set of frame members in a down position whereby the storage structure is closed.
[0017] [0017]FIG. 4 is a side view of the storage structure or hangar of the present invention, the view showing a second hinged set of frame members in a raised position whereby the storage structure is open.
[0018] [0018]FIG. 5 is a diagramatic top plan view of the storage structure or hangar of the present invention, the view showing a second hinged set of frame members in a raised position whereby the storage structure is open, and a sailplane is being maneuvered into placement within the structure.
[0019] [0019]FIG. 6 is an enlarged view of an area shown in FIG. 5.
[0020] [0020]FIG. 7 is a perspective view of the substantially T-shaped truss or upper frame support of the storage structure or hangar of the present invention.
[0021] [0021]FIG. 7A is a schematic, simplified perspective view of the substantially T-shaped truss or upper frame support of the storage structure or hangar and of the first and second sets of frame members attached to the truss, without showing any cross-bracing members or panels covering the frame members.
[0022] [0022]FIG. 8 is a diagrammatic top plan view showing the location of the first and second frame members which form the walls of the storage structure or hangar of the present invention.
[0023] [0023]FIG. 9 is a cross-sectional view, taken on lines 9 , 9 of FIG. 8.
[0024] [0024]FIG. 10 is a cross-sectional view taken on lines 10 , 10 of FIG. 9, the view showing the juncture of two members of rectangular cross-section which are part of the truss.
[0025] [0025]FIG. 11 is a plan view taken on lines 11 , 11 of FIG. 9, the view showing attachment of the truss or upper frame support to the first set of frame members.
[0026] [0026]FIG. 12 is a cross-sectional view taken on lines 12 , 12 of FIG. 11.
[0027] [0027]FIG. 13 is a cross-sectional view taken on lines 13 , 13 of FIG. 9, the view showing the attachment of two adjoining frame members.
[0028] [0028]FIG. 14 is an enlarged view taken of the area indicated by 14 on FIG. 9, the view showing connection of two members which are part of the truss or upper frame support.
[0029] [0029]FIG. 15 is a cross-sectional view taken on lines 15 , 15 of FIG. 9, the view showing connection of the truss to an anchor post.
[0030] [0030]FIG. 16 is a cross-sectional view, taken on lines 16 , 16 of FIG. 9.
[0031] [0031]FIG. 17 is a view taken on lines 17 , 17 of FIG. 16, the view showing connection of the truss to an anchor post.
[0032] [0032]FIG. 18 is a view taken on lines 18 , 18 of FIG. 17.
[0033] [0033]FIG. 19 is a front plan view of the right half of the hangar of the present invention, the view showing the second set of the hinged frame members attached to the truss.
[0034] [0034]FIG. 20 is a view taken on lines 20 , 20 of FIG. 19, the view showing a hinge in detail.
[0035] [0035]FIG. 21 is a front plan view of the front of the hangar of the present invention, the view showing the second set of frame members which enclose the cockpit, attached to the truss or upper frame support.
[0036] [0036]FIG. 22 is an enlarged view of the area indicated 22 in FIG. 21.
[0037] [0037]FIG. 23 is a cross-sectional view taken on lines 23 , 23 of FIG. 22.
[0038] [0038]FIG. 24 is a diagrammatic side view of the truss and of the second set of hinged frame members capable of enclosing the cockpit part of a plane, the view showing the cable and winch mechanism that raises and lowers the hinged frame members.
[0039] [0039]FIG. 25 is a cross-sectional view taken on lines 25 , 25 of FIG. 24.
[0040] [0040]FIG. 26 is a view taken on lines 26 , 26 of FIG. 24.
[0041] [0041]FIG. 27 is a diagrammatic side view showing the raised position of the second set of hinged frame members capable of enclosing the cockpit part of a plane.
[0042] [0042]FIG. 28 is a diagrammatic perspective view showing mechanical connection between the hinged frame members normally covering the cockpit and hinged frame members normally covering the wing of a plane in the storage unit of the invention.
[0043] [0043]FIG. 29 is an enlarged view of the are indicated at 29 on FIG. 24, the view showing a locking mechanism for the storage unit of the present invention.
[0044] [0044]FIG. 30 is a diagrammatic top view of a channel or trough and a ramp utilized for moving a plane in and out of the storage structure or hangar of the present invention.
[0045] [0045]FIG. 31 is a diagrammatic cross-sectional view of a channel or trough and a ramp utilized for moving a plane in and out of the storage structure or hangar of the present invention, the view also showing a plane as it is being moved.
[0046] [0046]FIG. 32 is a diagrammatic cross-sectional view of a channel or trough and a ramp utilized for moving a plane in and out of the storage structure or hangar of the present invention, the view also showing a plane positioned for storage in the storage structure.
[0047] [0047]FIG. 33 is a cross-sectional view taken on lines 33 , 33 of FIG. 1, the view showing attachment of corrugated metal siding to the first set of frame members.
[0048] [0048]FIG. 34 is a cross-sectional view taken on lines 34 , 34 of FIG. 33.
[0049] [0049]FIG. 35 is a diagrammatic view showing a cable, electric and hand winches utilized for raising the hinged frame members of the storage structure or hangar of the present invention.
[0050] [0050]FIG. 36 is a circuit diagram of the electric components of the storage unit of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0051] The following specification taken in conjunction with the drawings sets forth the preferred embodiment of the present invention in such a manner that any person skilled in the art can use the invention. The embodiment of the invention disclosed herein is the best mode presently contemplated by the inventor, although it should be understood that various modifications can be accomplished within the parameters of the present invention.
[0052] Referring now to the appended drawing figures, a preferred embodiment of the storage structure, storage unit or hangar 50 of the present invention is disclosed. It should be noted at the outset that the storage structure or hangar 50 of the present invention is designed primarily for storage of sailplanes which are also known as gliders. Sailplanes or gliders typically have small cockpits for one or two persons and the cockpits tend to be relatively low to the ground. Sailplanes or gliders also typically have long wings and a relatively narrow fuselage. All of the foregoing is especially true for the sailplanes that are made from fiberglass, carbon fiber or like synthetic material. Thus, the storage structure or hangar 50 of the present invention is primarily dimensioned for the housing of sailplanes, and in this specification the preferred embodiment of the storage structure or hangar 50 is shown and described in connection with the housing of a single sailplane. However, the invention is not so limited and the storage structure 50 of the invention can also be readily adapted for the housing and storage of other small aircraft, for example a small power plane.
[0053] It is an important feature of the storage structure or hangar 50 of the present invention that it can be readily assembled from pre-fabricated parts at a desired site, such as an airfield, where sailplanes operate. Principal components or parts of the storage structure or hangar 50 include a substantially T-shaped truss or upper frame support 52 that is best shown by itself in FIG. 7. Conceptually, the T-shaped truss or upper frame support 52 has a frontal part 54 to which structures housing the wings and cockpit of a sailplane are mounted, and a rear part 56 to which structures housing the fuselage are mounted. The T-shaped truss or upper frame support 52 is advantageously pre-fabricated from steel in several sections and is assembled at the desired site from the several pre-fabricated sections. In the presently preferred embodiment the frontal part 54 is assembled from five pre-fabricated sections 58 , and the rear part 56 is assembled from two pre-fabricated sections 58 . Preferably, as in the herein described preferred embodiment each pre-fabricated section 58 is made of steel bars of substantially rectangular cross-section which are welded together to form the respective pre-fabricated section 58 . As is shown in FIGS. 9 and 14, the pre-fabricated sections 58 are attached to one another by bolts 60 and nuts 62 . Moreover, adjoining linearly lined up bars of the sections 58 are linked with a reinforcing internal steel tube or bar 64 , shown in FIG. 10. FIGS. 7, 9, 17 and 18 illustrate that the T-shaped truss 52 is attached to and is supported in its elevated position by three vertical posts 66 which are embedded in the ground 68 , preferably in concrete 70 . The cross-sectional view of FIG. 15 illustrates in detail the mounting of the T-shaped truss 52 into the vertical post 66 by bolt 72 and nut 74 .
[0054] The simplified diagrammatic view of FIG. 7A illustrates conceptually the mounting and location of first and second set of frame members to the substantially T-shaped truss 52 . FIG. 7A is simplified for illustration, because it does not show vertical and diagonal reinforcing bars that form part of these structures. However, the vertical and diagonal reinforcing bars are amply illustrated in other drawing figures. The first set of frame members 76 rests on the ground and is also attached to the truss 52 . FIGS. 11 and 12 show that the truss 52 includes tabs 78 that are mounted with bolts 80 and nuts 82 to the first set of frame members 76 . The first set of frame members 76 is also preferably pre-fabricated in multiple sections 84 and in the preferred embodiment these sections are attached to one another by the hose clamps 85 , as shown in detail by FIG. 13. The first set of frame members 76 has no moving parts in the assembled storage structure or hangar 50 of the invention, and serve to support cover members or panels 86 which actually enclose a sailplane 88 in the storage structure or hangar 50 of the invention and protect it from rain, solar rays and other exposure to the elements. The second set of frame members 90 , also shown conceptually in FIG. 7A, is attached in part to the truss 52 and in part to the first set of frame members 76 . More specifically, the second set of frame members 90 include parts 92 which are hingedly attached to a frontal horizontal member 94 of the truss 52 and parts 96 which are hingedly attached to frontal horizontal members 98 of the first set of frames 76 . This attachment is by hinges 100 and is perhaps best shown in FIGS. 19 and 21 while FIG. 20 shows the hinge 100 in detail. The second set of frame members 90 is also preferably pre-fabricated from several sections 102 , as shown in FIG. 19 for the part that is included in the right side of the hangar 50 and which provides the front cover for one wing of the sailplane 88 to be stored in the hangar 50 . The sections 102 shown in FIG. 19 are attached to one another by nuts 104 and bolts 106 , although other types of attachment may also be used.
[0055] Generally speaking, connections or mounting between mechanical parts such as welding, bolting, using hose clamps or other types of clamps, U-bolts or types of mechanical fasteners are well known in the art. In many instances, which will be readily apparent to those skilled in the art in light of the present disclosure, the herein described and other types of known mechanical fastening devices and means are interchangeable or equivalent. For this reason, a person of ordinary skill in the art may be able to build on the basis of the present disclosure the hangar or storage structure 50 of the present invention utilizing different types of mechanical fasteners than the ones specifically described in connection with the preferred embodiment. For example, hose clamps may be substituted with bolts and nuts or welding. Bolts, nuts and other type of mechanical fasteners can, in many instances, be replaced by welding the respective parts together and such apparent variations or modifications of attaching parts together are within the scope of the present invention.
[0056] [0056]FIG. 8 also shows the location of first and second sets of frame members 76 and 90 in the storage structure or hangar 50 of the present invention relative to the truss 52 and a sailplane 88 which may be stored in the structure 50 . FIGS. 1 through 4 shows the structure or hangar 50 with the cover members or panels 86 mounted on the first and second sets of frame members 76 and 90 . A door 108 is located in one of the sections 84 of the first set of frame members 76 to allow access to the interior of the storage structure or hangar 50 .
[0057] The cross-sectional views of FIGS. 33 and 34 show in detail the mounting of the cover member or panel 86 to the frame members 76 and 90 . The cover members or panels 86 of the presently preferred embodiment comprise corrugated metal plates 86 , which are attached to the frames 76 and 90 with self-tapping sheet metal screws 110 . Foam 112 is located between the corrugated metal panels 86 and the frame members 76 and/or 90 to provide insulation. Instead of corrugated metal plates 86 , wood or plastic panels could also be attached to the members 76 and/or 90 to enclose the sailplane 88 and protect it from the elements.
[0058] Referring now primarily to FIGS. 3, 4 and 21 through 28 , opening and closing the storage unit or hangar 50 of the present invention is disclosed. A winch 114 is mounted to a vertical member 116 of the second set of frame 90 that serves as cover for the cockpit of the sailplane 88 . A cable or wire 118 is attached to the winch 114 and is lead through pulleys 120 to a second winch 122 in the rear of the structure 50 . The second winch 122 is shown in FIG. 16. In the preferred embodiment the winch 114 is powered by a 12 volt battery 124 . The battery 124 is charged by a solar panel 126 that is placed on one of the cover plates 86 . The battery 124 and solar panel 126 are shown in FIG. 36. Rotation of the winch 114 , powered by the battery 124 winds-up or releases the cable 118 depending on the polarity of the current which is supplied to it through a switch 128 shown in FIG. 36. The second winch 122 of the preferred embodiment is hand operated and is intended for use only when for some reason or another the first winch 114 is inoperative. In alternative embodiments both winches may be electrically powered and/or may be powered by 110 AC current rather than by a D.C. battery.
[0059] When the winch 114 is powered through the switch 128 to take up the cable 118 , the hinged second set of frame members 90 are lifted so as to allow the movement of a sailplane 88 into or out of the hangar 50 . More specifically, first that part of the frame members 90 is lifted together with the corresponding cover panels 86 which encloses the cockpit of the sailplane 88 . The winch 114 rides up on the cable 118 together with the frame member 116 to which it is mounted. Sides of the frame members 90 are connected with a link 130 to the respective the frame members 90 that are hingedly mounted to the frontal horizontal members 98 and enclose the wings of the sailplane 88 . Details of the operation of the link 130 that in essence links the cockpit cover door with the wing cover door, are shown in FIGS. 22, 23, 27 , and 28 . As these figures disclose, the link 130 is mounted to the respective frames members 90 in such a manner that the frame members 90 can pivot relative to the link 130 . Thus, as the frame members 90 forming the cockpit cover are lifted, the link 130 also lifts the frame members 90 forming the front cover for the wings of the sailplane 88 . When the polarity of current is reversed by the switch 128 , the winch 114 unrolls cable 118 and the frame members 90 forming the cockpit and wing covers are lowered, thereby closing the structure 50 and enclosing the sailplane 88 that may be present in the storage structure or hangar 50 . Limit switches 132 shown in FIG. 36 prevent lifting the hinged frame members 90 too high or lowering them too low and therefore prevent damage to the structure.
[0060] [0060]FIGS. 5, 6 and 30 through 32 disclose other features of the storage unit or hangar 50 of the present invention which further facilitate the movement of a sailplane 88 into and out of the storage structure 50 . Specifically FIGS. 5 and 6 disclose a substantially circular indentation 136 or shallow dent in concrete 70 embedded in the ground 68 at a distance from the front of the structure 50 which substantially corresponds to the length of the wing of the sailplane 88 that is to be stored in the structure 50 . This makes it easy for a person (not shown) to push a sailplane 88 with its fuselage parallel with the front of the storage structure or hangar 50 at the proper distance from the structure 50 until the front wheel 138 of the sailplane 88 rests in the indentation 136 . Then the sailplane 88 is pivoted 90 degrees on its front wheel 138 , as shown in FIG. 5, before its is pushed into the structure 50 for storage.
[0061] [0061]FIGS. 30 through 32 disclose a trough 140 formed inside the structure 50 and in alignment with the rear part 56 of the T shaped frame support 52 . In the presently preferred embodiment the trough 140 is comprised of a 4″ by 6″ wooden board 142 that is disposed flat on the ground 68 and of two 4″ by 4″ or 4″ by 6″ wooden boards 144 positioned on their respective edges and attached to the 4″ by 6″ board 142 by wood screws (not shown). In alternative embodiments the trough 140 may be made of metal or plastic or of any combination of wood, metal and plastic materials.
[0062] As is known by those who are familiar with sailplane operations, sailplanes are frequently moved around by attaching a tail dolly 146 to the rear part of the fuselage 147 , as is shown in FIGS. 31 and 32. The tail dolly 146 causes the tail wheel 148 of the sailplane 88 to be lifted off the ground 68 , however the tail dolly 146 must not be attached to the sailplane 88 during flight because it significantly changes the weight and balance and is likely to cause a serious accident. Nevertheless use of the tail dolly 146 greatly facilitates transportation of the sailplane 88 on the ground, as for example when the sailplane 88 is moved from the hangar 50 to a take-off line, or when it is returned to the hangar 50 after flight. It is also customary to remove the tail dolly 146 from the fuselage 147 when the sailplane 88 is stored or hangared, principally because during prolonged storage the pressure by the straps and buckles attaching the tail dolly 146 to the fuselage 147 may discolor or damage the delicate synthetic material of the sailplane 88 .
[0063] To facilitate the movement of a sailplane 88 with a tail dolly 146 into and out of the storage structure or hangar 50 of the present invention and to avoid the need for lifting the relatively heavy tail of the sailplane 88 when the tail dolly 146 is removed, a ramp 150 is placed at the end of the trough 140 in a location where the tail wheel 148 of the sailplane 88 is to be located. The sloping part 152 of the ramp 150 begins high enough so that the tail of the sailplane 88 clears it as the sailplane 88 is pushed into the hangar 50 with the wheel 154 of the tail dolly 146 and the sailplane's front wheel 138 rolling in the trough 140 . To store the sailplane 88 and to render it easy to remove the tail dolly 146 the sailplane 88 is moved until its rear wheel 148 rests in an oval depression 156 provided in the ramp 150 , as is shown in FIG. 32. In this position the wheel 156 of the tail dolly 146 is lifted off the trough 140 and the tail dolly 146 can be readily removed, and also reassembled when it is desired to move the sailplane 88 out of the storage unit 50 .
[0064] [0064]FIG. 29 illustrates an optional lock 158 which may be attached to one of the 4″ by 4″ or 4″ by 6″ boards forming the trough 140 and to a panel 86 to prevent unauthorized opening of the structure or hangar 50 . Another lock (not shown) is usually provided in the door 108 .
[0065] As noted above the storage structure or hangar 50 is preferably made from pre-fabricated parts. Although the steps of building the structure 50 should be apparent to those skilled in the art from the foregoing description, the preferred method of construction is briefly described below.
[0066] First and preferably a location on the ground 68 is prepared by selecting a suitable flat area, the trough 140 is built from wooden boards and the ground 68 is preferably covered with light gravel (not shown) to cover the base of the structure 50 . The vertical posts 66 are embedded in concrete 70 in the ground 68 , and the substantially T-shaped truss 52 is mounted to the vertical posts 66 . Sections 84 of the first set of frame members 76 are then placed on the ground and mounted to the truss 52 , and to each other, as applicable, followed by sections 102 of the second set of frame members 90 mounted with hinges 100 to the truss 52 , to each other, and to the first set of frames 76 , as applicable. The truss 52 and the frame members 76 and 90 can then be painted if so desired, and if they have not been painted before. Subsequently, the battery 124 , the switches, the door 108 , winches 114 and 122 and the cover plates or panels 86 and insulating foam 112 are mounted to the structure. | A storage structure or hangar designed primarily for housing a sailplane or other small aircraft has a substantially T-shaped pre-fabricated upper frame support anchored to the ground at several locations, a first set of frame members mounted immovably to the upper frame support in areas where the fuselage and tail and the two wings are located when the sailplane or small aircraft is in the storage structure, and a second set of frame members hingedly mounted in part to the upper frame support and partly to first set of frame members. The second set of frame members are located substantially where the front or cockpit of the plane is located and in front of the wings. Panels covering the first and second frame members and enclosing the structure are mounted to the first and second frame members. A cable, chain or like mechanism operated by a winch raises the second set of hinged frame members together with the cover panels mounted thereon to allow the sailplane to be placed into the storage structure. The winch also lowers the second set of frame members to close the structure and enclose the plane therein. The winch is powered by a battery that is charged by a solar panel associated with the structure. | 8 |
FIELD OF THE INVENTION
[0001] The present invention relates to improving the continuity of a phosphinimine ligand containing catalyst on an alumina support in a dispersed phase (i.e. gas phase, fluidized bed or stirred bed or slurry phase) olefin polymerization. There are a number of factors which impact on reactor continuity in a dispersed phase polymerization. A decrease in catalyst productivity or activity is reflected by a decrease in ethylene uptake over time but may also result in a lower kinetic profile and potentially a lower potential for fouling.
BACKGROUND OF THE INVENTION
[0002] Single site catalysts for the polymerization of alpha olefins were introduced in the mid 1980's. These catalysts are more active than the prior Ziegler Natta catalysts, which may lead to issues of polymer agglomeration. Additionally, static may contribute to the problem. As a result reactor continuity (e.g. fouling and also catalyst life time) may be a problem.
[0003] The kinetic profile of many single site catalysts starts off with a very high activity over a relatively short period of time, typically about the first five minutes of the reaction, the profile then goes through an inflection point and decreases rapidly for about the next five minutes and thereafter there is period of relative slower decline in the kinetic profile. This may be measured by the ethylene uptake, typically in standard liters of ethylene per minute in the reactor.
[0004] Canadian Patent Application 2,716,772 filed Oct. 6, 2010 discloses a process to improve the dispersed phase reactor continuity of catalyst having a phosphinimine ligand by supporting the catalyst on a silica support treated with Zr(SO 4 ) 2 .4H 2 O. The support is also treated with MAO. This patent application fails to disclose or suggest an alumina support.
[0005] U.S. Pat. No. 6,734,266 issued May 11, 2004 to Gao et al., assigned to NOVA Chemicals (International) S.A. teaches sulfating the surface of porous inorganic support with an acid, amide or simple salt such as an alkali or alkaline earth metal sulphate. The resulting treated support may be calcined. Aluminoxane and a single site catalyst are subsequently deposited on the support. The resulting catalyst shows improved activity. However, the patent fails to teach or suggest depositing zirconium sulphate on an alumina support.
[0006] U.S. Pat. No. 7,001,962 issued Feb. 21, 2006 to Gao et al., assigned to NOVA Chemicals (International) S.A. teaches treating a porous inorganic support with a zirconium compound including zirconium sulphate and an acid such as a fluorophosphoric acid, sulphonic acid, phosphoric acid and sulphuric acid. The support is dried and may be heated under air at 200° C. and under nitrogen up to 600° C. Subsequently a trialkyl aluminum compound (e.g. triethyl aluminum) or an alkoxy aluminum alkyl compound (e.g. diethyl aluminum ethoxide) and a single site catalyst are deposited on the support. The specification teaches away from using aluminoxane compounds. The activity of these supports is typically lower than the activity of the catalyst of U.S. Pat. No. 6,734,266 (compare Table 5 of U.S. Pat. No. 7,001,962 with Table 2 of U.S. Pat. No. 6,734,266). The present invention eliminates the required acid reagent that reacts with the zirconium compound.
[0007] U.S. Pat. No. 7,273,912 issued Sep. 25, 2007 to Jacobsen et al., assigned to Innovene Europe Limited, teaches a catalyst which is supported on a porous inorganic support which has been treated with a sulphate such as ammonium sulphate or an iron, copper, zinc, nickel or cobalt sulphate. The support may be calcined in an inert atmosphere at 200 to 850° C. The support is then activated with an ionic activator and then contacted with a single site catalyst. The patent fails to teach aluminoxane compounds and zirconium sulphate.
[0008] U.S. Pat. No. 7,005,400 issued Feb. 28, 2006 to Takahashi, assigned to Polychem Corporation teaches a combined activator support comprising a metal oxide support and a surface coating of a group 2, 3, 4, 13 and 14 oxide or hydroxide different from the carrier. The support is intended to activate the carrier without the conventional “activators”. However, in the examples the supported catalyst is used in combination with triethyl aluminum. The triethyl aluminum does not appear to be deposited on the support. Additionally the patent does not teach phosphinimine catalysts.
[0009] U.S. Pat. No. 7,442,750 issued Oct. 28, 2008 to Jacobsen et al., assigned to Innovene Europe Limited teaches treating an inorganic metal oxide support typically with a transition metal salt, preferably a sulphate, of iron, copper, cobalt, nickel, and zinc. Then a single site catalyst, preferably a constrained geometry single site catalyst and an activator are deposited on the support. The activator is preferably a borate but may be an aluminoxane compound. The disclosure appears to be directed at reducing static in the reactor bed and product in the absence of a conventional antistatic agent such as STADIS®.
[0010] U.S. Pat. No. 6,653,416 issued Nov. 25, 2003 to McDaniel at al., assigned to Phillips Petroleum Company, discloses a fluoride silica -zirconia or titania porous support for a metallocene catalyst activated with an aluminum compound selected from the group consisting of alkyl aluminums, alkyl aluminum halides and alkyl aluminum alkoxides. The patent does not suggest an alumina support. Comparative examples 10 and 11 show the penetration of zirconium into silica to form a silica-zirconia support. However, the examples (Table 1) show the resulting catalyst has a lower activity than those when the supports were treated with fluoride.
[0011] None of the above art suggests treating the support with an antistatic agent.
[0012] The use of a salt of a carboxylic acids, especially aluminum stearate, as an antifouling additive to olefin polymerization catalyst compositions is disclosed in U.S. Pat. No. 6,271,325 (McConville et al., to Univation) and U.S. Pat. No. 6,281,306 (Oskam et al., to Univation).
[0013] The preparation of supported catalysts using an amine antistatic agent, such as the fatty amine sold under the trademark KEMANINE® AS-990, is disclosed in U.S. Pat. No. 6,140,432 (Agapiou et al.; to Exxon) and U.S. Pat. No. 6,117,955 (Agapiou et al.; to Exxon).
[0014] Antistatic agents are commonly added to aviation fuels to prevent the buildup of static charges when the fuels are pumped at high flow rates. The use of these antistatic agents in olefin polymerizations is also known. For example, an aviation fuel antistatic agent sold under the trademark STADIS composition (which contains a “polysulfone” copolymer, a polymeric polyamine and an oil soluble sulfonic acid) was originally disclosed for use as an antistatic agent in olefin polymerizations in U.S. Pat. No. 4,182,810 (Wilcox, to Phillips Petroleum). The examples of the Wilcox '810 patent illustrate the addition of the “polysulfone” antistatic agent to the isobutane diluent in a commercial slurry polymerization process. This is somewhat different from the teachings of the earlier referenced patents—in the sense that the carboxylic acid salts or amine antistatics of the other patents were added to the catalyst, instead of being added to a process stream.
[0015] The use of “polysulfone” antistatic composition in olefin polymerizations is also subsequently disclosed in:
[0016] 1) chromium catalyzed gas phase olefin polymerizations, in U.S. Pat. No. 6,639,028 (Heslop et al.; assigned to BP Chemicals Ltd.);
[0017] 2) Ziegler Natta catalyzed gas phase olefin polymerizations, in U.S. Pat. No. 6,646,074 (Herzog et al.; assigned to BP Chemicals Ltd.); and
[0018] 3) metallocene catalyzed olefin polymerizations, in U.S. Pat. No. 6,562,924 (Benazouzz et al.; assigned to BP Chemicals Ltd.).
[0019] The Benazouzz et al. patent does teach the addition of STADIS antistatic agent to the polymerization catalyst in small amounts (about 150 ppm by weight). However, in each of the Heslop et al. '028, Herzog et al. '074 and Benazouzz et al. '924 patents listed above, it is expressly taught that it is preferred to add the STADIS antistatic directly to the polymerization zone (i.e. as opposed to being an admixture with the catalyst).
[0020] None of the above art discusses the kinetic profile of the catalyst system. One of the difficulties with high activity (“hot”) catalyst is that they tend to have a very high initial reactivity (ethylene consumption) that goes through an inflection point and rapidly decreases over about the first 10 minutes of reaction and then decreases at a much lower rate over the next 50 minutes together with fluctuations in reactor temperature. It is desirable to have a high activity catalyst (e.g. more than about 1,500 grams of polymer per gram of supported catalyst normalized to 200 psig (1,379 kPa) ethylene partial pressure and 90° C.) having a kinetic profile for a plot of ethylene consumption in standard liters of ethylene per minute against time in minutes, corrected for the volume of ethylene in the reactor prior to the commencement of the reaction, in a 2 liter reactor over a period of time from 0 to 60 minutes is such that the ratio of the maximum peak height over the first 10 minutes to the average ethylene consumption from 10 to 60 minutes taken at not less than 40, preferably greater than 60 most preferably from 120 to 300 data points, is less than 3.0, preferably less than 2.5, most preferably less than 2.
[0021] The present invention seeks to provide a catalyst having a kinetic profile as described above, optionally having reduced static and its use in the dispersed phase polymerization of olefins.
SUMMARY OF THE INVENTION
[0022] In one embodiment the present invention provides a catalyst system having an activity greater than 1,500 g of polymer per gram of supported catalyst per hour normalized to 1,379 kPag (200 psig) of ethylene partial pressure and a temperature of 90° C. in the presence of 1-hexene comonomer and a kinetic profile for a plot of ethylene consumption in standard liters of ethylene per minute against time in minutes, at a reaction pressure of 1,379 kPag (200 psig) and 90° C., corrected for the volume of ethylene in the reactor prior to the commencement of the reaction, in a 2 liter reactor over a period of time from 0 to 60 minutes is such that the ratio of the maximum peak height over the first 10 minutes to the average ethylene consumption from 10 to 60 minutes taken at not less than 40 data points, is less than 2.5, comprising:
[0023] (i) an alumina support having an average particle size from 10 to 150 microns, a surface area greater than 100 m 2 /g, and a pore volume greater than 0.3 ml/g impregnated with
[0024] (ii) at least a 1 weight % based on the weight of alumina of Zr(SO 4 ) 2-4 H 2 O, based on the weight of the support of said salt;
[0025] (iii) from 10 to 60 weight % of an aluminum activator based on the weight of said alumina support said activator having the formula:
[0000] R 12 2 AlO(R 12 AlO) q AlR 12 2
[0026] wherein each R 12 is independently selected from the group consisting of C 1-20 hydrocarbyl radicals and q is from 3 to 50; and
[0027] (iv) from 0.1 to 30 weight % of a phosphinimine catalyst of the formula:
[0000]
[0000] wherein M is a group 4 metal having an atomic weight less than 179; PI is a phosphinimine ligand of the formula
[0000]
[0000] wherein each R 21 is independently selected from the group consisting of a hydrogen atom; a halogen atom; C 1-10 hydrocarbyl radicals which are unsubstituted by or further substituted by a halogen atom; L is a monoanionic ligand selected from the group consisting of a cyclopentadienyl radical which is unsubstituted or substituted by a substituent selected from the group consisting of a C 1-6 alkyl radical which is substituted by 2n+1 fluorine atoms where n is the number of carbon atoms in the alkyl radical, and a C 6 F 5 radical which cyclopentadienyl ligand is optionally further substituted with up to two C 3-6 alkyl radicals [in the 2 or 3 position relative to the fluorine containing substituent]; Y is an activatable ligand; m is 1 or 2; q is 1; and p is an integer and the sum of m+q+p equals the valence state of M.
[0028] In a further embodiment the present invention provides the above catalyst further comprising from 15,000 to 120,000 ppm based on the weight of the supported catalyst of an antistatic comprising:
[0029] (i) from 3 to 48 parts by weight of one or more polysulfones comprising:
(a) 50 mole % of sulphur dioxide; (b) 40 to 50 mole % of a C 6-20 an alpha olefin; and (c) from 0 to 10 mole % of a compound of the formula ACH═CHB where A is selected from the group consisting of a carboxyl radical and a C 1-15 carboxy alkyl radical and B is a hydrogen atom or a carboxyl radical provided if A and B are carboxyl radicals A and B may form an anhydride;
[0033] (ii) from 3 to 48 parts by weight of one or more polymeric polyamides of the formula:
[0000] R 20 N[(CH 2 CHOHCH 2 NR 21 ) a —(CH 2 CHOHCH 2 NR 21 —R 22 —NH) b —(CH 2 CHOHCH 2 NR 23 ) c H x ]H 2-x
[0000] wherein R 21 is an aliphatic hydrocarbyl group of 8 to 24 carbon atoms; R 22 is an alkylene group of 2 to 6 carbon atoms; R 23 is the group R 22 —HNR 21 ; R 20 is R 21 or an N-aliphatic hydrocarbyl alkylene group having the formula R 21 NHR 22 ; a, b and c are integers from 0 to 20 and x is 1 or 2; with the proviso that when R 20 is R 21 then a is greater than 2 and b=c=0, and when R 20 is R 21 NHR 22 then a is 0 and the sum of b+c is an integer from 2 to 20; and
[0034] (iii) from 3 to 48 parts by weight of C 10-20 alkyl or arylalkyl sulphonic acid.
[0035] In a further embodiment the present invention provides a process of making a catalyst system having an activity greater than 1,500 g of polymer per gram of supported catalyst per hour normalized to 1,379 kPag (200 psig) of ethylene partial pressure and a temperature of 90° C. in the presence of 1-hexene comonomer and a kinetic profile for a plot of ethylene consumption in standard liters of ethylene per minute against time in minutes, at a reaction pressure of 1,379 kPag (200 psig) and 90° C., corrected for the volume of ethylene in the reactor prior to the commencement of the reaction, in a 2 liter reactor over a period of time from 0 to 60 minutes is such that the ratio of the maximum peak height over the first 10 minutes to the average ethylene consumption from 10 to 60 minutes taken at not less than 40 data points, is less than 2.5, comprising:
[0036] (i) impregnating an alumina support having an average particle size from 10 to 150 microns, a surface area greater than 100 m 2 /g, and a pore volume greater than 0.3 ml/g with
[0037] (ii) at least a 1 weight % aqueous solution of Zr(SO 4 ) 2 .4H 2 O, to provide not less than 1 weight % based on the weight of the support of said salt;
[0038] (iii) recovering the impregnated support;
[0039] (iv) calcining said impregnated support in one or more steps at a temperature from 300° C. to 600° C. for a time from 2 to 20 hours in an inert atmosphere;
[0040] (v) and either
(a) contacting said calcined support with a hydrocarbyl solution containing an aluminum activator compound of the formula:
[0000] R 12 2 AlO(R 12 AlO) q AlR 12 2 wherein each R 12 is independently selected from the group consisting of C 1-20 hydrocarbyl radicals and q is from 3 to 50 to provide from 10 to 60 weight % of said aluminum compound based on the weight of said calcined support; optionally, separating said activated support from said hydrocarbyl solution and contacting said activated support with a hydrocarbyl solution containing a single site catalyst as set out below to provide from 0.1 to 30 weight % of said catalyst; Or (b) contacting said support with a hydrocarbyl solution of an aluminum activator compound of the formula:
[0000] R 12 2 AlO(R 12 AlO) q AlR 12 2 wherein each R 12 is independently selected from the group consisting of C 1-20 hydrocarbyl radicals and q is from 3 to 50 to provide from 10 to 60 weight % of said activator and at of a single site catalyst of the formula:
[0000]
wherein M is selected from the group consisting of Ti, Zr and Hf; PI is a phosphinimine ligand of the formula:
[0000]
wherein each R 21 is independently selected from the group consisting of a hydrogen atom; a halogen atom; C 1-10 hydrocarbyl radicals which are unsubstituted by or further substituted by a halogen atom;
L is a monoanionic ligand selected from the group consisting of a cyclopentadienyl radical which is unsubstituted or substituted by a substituent selected from the group consisting of a C 1-6 alkyl radical which is substituted by 2n+1 fluorine atoms where n is the number of carbon atoms in the alkyl radical, and a C 6 F 5 radical which cyclopentadienyl ligand is optionally further substituted with up to two C 3-6 alkyl radicals [in the 2 or 3 position relative to the fluorine containing substituent]; Y is an activatable ligand; m is 1 or 2; q is 1; and p is an integer and the sum of m+q+p equals the valence state of M to provide from 0.1 to 30 weight % of said catalyst
[0048] and
[0049] (vi) recovering and drying the catalyst.
[0050] In a further embodiment the present invention provides the above process further comprising contacting said catalyst with from 15,000 to 120,000 ppm based on the weight of the supported catalyst of an antistatic comprising:
[0051] (i) from 3 to 48 parts by weight of one or more polysulfones comprising:
(a) 50 mole % of sulphur dioxide; (b) 40 to 50 mole % of a C 6-20 an alpha olefin; and (c) from 0 to 10 mole % of a compound of the formula ACH═CHB where A is selected from the group consisting of a carboxyl radical and a C 1-15 carboxy alkyl radical; and B is a hydrogen atom or a carboxyl radical provided if A and B are carboxyl radicals A and B may form an anhydride;
[0055] (ii) from 3 to 48 parts by weight of one or more polymeric polyamides of the formula:
[0000] RN[(CH 2 CHOHCH 2 NR 1 ) a —(CH 2 CHOHCH 2 NR 1 —R 2 —NH) b —(CH 2 CHOHCH 2 NR 3 ) c H x ]H 2-x
[0000] wherein R 1 is an aliphatic hydrocarbyl group of 8 to 24 carbon atoms; R 2 is an alkylene group of 2 to 6 carbon atoms; R 3 is the group-R 2 —HNR 1 ; R is R 1 or an N-aliphatic hydrocarbyl alkylene group having the formula R 1 NHR 2 , a, b and c are integers from 0 to 20 and x is 1 or 2; with the proviso that when R is R 1 then a is greater than 2 and b=c=0, and when R is R 1 NHR 2 then a is 0 and the sum of b+c is an integer from 2 to 20; and
[0056] (iii) from 3 to 48 parts by weight of C 10-20 alkyl or arylalkyl sulphonic acid and optionally from 0 to 150 parts by weight of a solvent or diluent.
[0057] In a further embodiment the present invention provides a dispersed phase olefin polymerization process having improved reactor continuity conducted in the presence of the above catalyst further comprising an antistatic agent.
[0058] In a further embodiment the present invention provides a disperse phase polymerization process comprising contacting one or more C 2-8 alpha olefins with a catalyst system which does not contain an antistatic agent, and feeding to the reactor from 10 to 80 ppm based on the weight of the polymer produced of an antistatic comprising:
[0059] (i) from 3 to 48 parts by weight of one or more polysulfones comprising:
(a) 50 mole % of sulphur dioxide; (b) 40 to 50 mole % of a C 6-20 an alpha olefin; and (c) from 0 to 10 mole % of a compound of the formula ACH═CHB where A is selected from the group consisting of a carboxyl radical and a C 1-15 carboxy alkyl radical and B is a hydrogen atom or a carboxyl radical provided if A and B are carboxyl radicals A and B may form an anhydride;
[0063] (ii) from 3 to 48 parts by weight of one or more polymeric polyamides of the formula:
[0000] R 20 N[(CH 2 CHOHCH 2 NR 21 ) a —(CH 2 CHOHCH 2 NR 21 —R 22 —NH) b —(CH 2 CHOHCH 2 NR 23 ) c H x ]H 2-x
[0000] wherein R 21 is an aliphatic hydrocarbyl group of 8 to 24 carbon atoms; R 22 is an alkylene group of 2 to 6 carbon atoms; R 23 is the group R 22 —HNR 21 ; R 20 is R 21 or an N-aliphatic hydrocarbyl alkylene group having the formula R 21 NHR 22 ; a, b and c are integers from 0 to 20 and x is 1 or 2; with the proviso that when R 20 is R 21 then a is greater than 2 and b=c=0, and when R 20 is R 21 NHR 22 then a is 0 and the sum of b+c is an integer from 2 to 20; and
[0064] (iii) from 3 to 48 parts by weight of C 10-20 alkyl or arylalkyl sulphonic acid.
BRIEF DESCRIPTION OF THE DRAWING
[0065] FIG. 1 is the kinetic profile of the catalysts run in example 1.
DETAILED DESCRIPTION
[0066] As used in this specification dispersed phase polymerization means a polymerization in which the polymer is dispersed in a fluid polymerization medium. The fluid may be liquid in which case the polymerization would be a slurry phase polymerization or the fluid could be gaseous in which case the polymerization would be a gas phase polymerization, either fluidized bed or stirred bed.
[0067] As used in this specification kinetic profile means a plot of ethylene consumption in standard liters of ethylene per minute against time in minutes, corrected for the volume of ethylene in the reactor prior to the commencement of the reaction, in a 2 liter reactor over a period of time from 0 to 60 minutes.
[0068] As used in this specification gram of supported catalyst means a gram of the catalyst system and activator on the support treated with Zr(SO 4 ) 2 .4H 2 O.
The Support
[0069] The support for the catalysts of the present invention comprises activated alumina. Typically the alumina is heated to temperatures in the range from about 600° C. to about 800° C.
[0070] The support should have an average particle size from about 10 to 150 microns, preferably from about 20 to 100 microns. The support should have a large surface area typically greater than about 100 m 2 /g, preferably greater than about 200 m 2 /g, most preferably from 250 m 2 /g to 500 m 2 /g. The support will be porous and will have a pore volume from about 0.25 to 3.0 ml/g, typically from 0.3 to 0.5 ml/g.
[0071] One suitable support for the present invention is sold by Alcoa Industrial Chemicals under the trade name HiQ-20 Alumina.
Treatment of the Support
[0072] The support is treated with an aqueous solution of Zr(SO 4 ) 2 .4H 2 O. The support need not be dried or calcined as it is contacted with an aqueous solution.
[0073] Generally a 2 to 50, typically a 5 to 15, preferably an 8 to 12, most preferably a 9 to 11 weight % aqueous solution of Zr(SO 4 ) 2 .4H 2 O is used to treat the support. The support is contacted with the solution of Zr(SO 4 ) 2 .4H 2 O at a temperature from 10° C. to 50° C., preferably from 20 to 30° C., for a time of not less than 30 minutes, typically from 1 to 10 hours, preferably from 1 to 4 hours, until the support is thoroughly impregnated with the solution.
[0074] The impregnated support is then recovered typically by drying at an elevated temperature from 100° C. to 150° C., preferably from 120° C. to 140° C., most preferably from 130° C. to 140° C., for about 8 to 12 hours (e.g. overnight). Other recovery methods would be apparent to those skilled in the art.
[0075] The dried impregnated support is then calcined. It is important that the support be calcined prior to the initial reaction with an aluminum activator, catalyst or both. Generally, the support may be heated at a temperature of at least 200° C. for up to 24 hours, typically at a temperature from 500° C. to 675° C., preferably from 550° C. to 600° C. for about 2 to 20, preferably 4 to 10 hours. The resulting support will be free of adsorbed water and should have a surface hydroxyl content from about 0.1 to 5 mmol/g of support, preferably from 0.5 to 3 mmol/g of support.
[0076] The amount of the hydroxyl groups in a support may be determined according to the method disclosed by J. B. Peri and A. L. Hensley, Jr., in J. Phys. Chem., 72 (8), 2926, 1968, the entire contents of which are incorporated herein by reference.
[0077] The Zr(SO 4 ) 2 is substantially unchanged by calcining under the conditions noted above. At higher temperatures the Zr(SO 4 ) 2 starts to be converted to ZrO.
[0078] The resulting dried and calcined support is then contacted sequentially with the activator and the catalyst in an inert hydrocarbon diluent.
The Activator
[0079] The activator is an aluminoxane compound of the formula R 12 2 AlO(R 12 AlO) q AlR 12 2 wherein each R 12 is independently selected from the group consisting of C 1-20 hydrocarbyl radicals and q is from 3 to 50. In the aluminum activator preferably R 12 is a C 1-4 alkyl radical, preferably a methyl radical and q is from 10 to 40. Optionally, a hindered phenol may be used in conjunction with the aluminoxane to provide a molar ratio of Al:hindered phenol from 2:1 to 5:1 if the hindered phenol is present. Generally the molar ratio of Al:hindered phenol, if it is present, is from 3.25:1 to 4.50:1. Preferably the phenol is substituted in the 2, 4 and 6 position by a C 2-6 alkyl radical. Desirably the hindered phenol is 2,6-di-tert-butyl-4-ethyl-phenol.
[0080] The aluminum compounds (aluminoxanes and optionally hindered phenol) are typically used as activators in substantial molar excess compared to the total amount of metal in the catalysts (e.g. group 3 to 11, preferably 4 to 6 transition metal in the phenoxide catalyst and group 4 transition metal in the phosphinimine catalyst). Aluminum: total metal (in the catalyst) molar ratios may range from 10:1 to 10,000:1, preferably 10:1 to 500:1, most preferably from 50:1 to 150:1, especially from 90:1 to 120:1.
[0081] Typically the loading of the aluminoxane compound may range from 10 up to 60 weight % preferably from 15 to 50 weight %, most preferably from 20 to 40 weight % based on the weight of the calcined support impregnated with metal salt.
[0082] The aluminoxane is added to the support in the form of a hydrocarbyl solution, typically at a 5 to 30 weight % solution, preferably an 8 to 12 weight % solution, most preferably a 9 to 10 weight % solution. Suitable hydrocarbon solvents include C 5-12 hydrocarbons which may be unsubstituted or substituted by C 1-4 alkyl group such as pentane, hexane, heptane, octane, cyclohexane, methylcyclohexane, toluene, or hydrogenated naphtha. An additional solvent is Isopar™ E (C 8-12 aliphatic solvent, Exxon Chemical Co.).
[0083] The treated support may optionally be filtered and/or dried under an inert atmosphere (e.g. N 2 ) and optionally at reduced pressure, preferably at temperatures from room temperature up to about 80° C.
[0084] The optionally dried support with activator is then contacted with the catalysts again in a hydrocarbyl solution.
[0085] In an alternate embodiment the support could be treated with a combined solution of activator and catalyst(s). However care needs to be taken with this approach as prolonged contact (e.g. more than about 15 minutes) of the activator with the catalyst may result in degradation of one or both components.
The Catalysts
Phosphinimine Catalyst
[0086] The catalytic component the catalyst system is a phosphinimine catalyst of the formula:
[0000]
[0000] wherein M is a group 4 metal having an atomic weight less than 179; PI is a phosphinimine ligand; L is a monoanionic ligand selected from the group consisting of a cyclopentadienyl radical which is unsubstituted or substituted by a substituent selected from the group consisting of a C 1-6 alkyl radical which is substituted by 2n+1 fluorine atoms where n is the number of carbon atoms in the alkyl radical, and a C 6 F 5 radical which cyclopentadienyl ligand is optionally further substituted with up to two C 3-6 alkyl radicals in the 2 or 3 position relative to the fluorine containing substituent; Y is an activatable ligand; m is 1 or 2; q is 1; and p is an integer and the sum of m+q+p equals the valence state of M.
[0087] The preferred metals (M) are from Group 4 (especially titanium, hafnium or zirconium) with titanium being most preferred (e.g. with an atomic weight less than 179).
[0088] The phosphinimine ligand is defined by the formula:
[0000]
[0000] wherein each R 15 is independently selected from the group consisting of a C 1-8 , preferably C 1-6 hydrocarbyl radicals which are unsubstituted or further substituted by a halogen atom. Most preferably the phosphinimine ligand is tris t-butyl phosphinimine.
[0089] In the phosphinimine catalyst preferably Y is selected from the group consisting of a hydrogen atom; a halogen atom, a C 1-10 hydrocarbyl radical. Most preferably Y is selected from the group consisting of a hydrogen atom, a chlorine atom and a C 1-4 alkyl radical.
[0090] The loading of the catalysts on the support should be such to provide from about 0.010 to 0.50, preferably from 0.015 to 0.40, most preferably from 0.015 to 0.036 mmol of metal M, preferably group 4 metal (e.g. Ti) from the catalysts per gram of support (support treated with Zr(SO 4 ) 2 . 4H 2 O and calcined and treated with an activator).
[0091] The phosphinimine ligand containing catalyst may be added to the support in a hydrocarbyl solvent such as those noted above. The concentration of phosphinimine ligand containing catalyst in the solvent is not critical. Typically, it may be present in the solution in an amount from about 5 to 15 weight %.
[0092] The supported catalyst (e.g. support, Zr(SO 4 ) 2 , activator and catalyst) typically has a reactivity in a dispersed phase reaction (e.g. gas or slurry phase) greater than 1,500 g of polymer per gram of support preferably greater than 2,000, most preferably greater than 2,200 g of polyethylene per gram of supported catalyst per hour normalized to an ethylene partial pressure of 200 psig (1379 kPa) and a temperature of 90° C. in the presence of 1-hexene comonomer.
[0093] The supported catalyst of the present invention may be used in dispersed phase polymerizations in conjunction with a scavenger such as an aluminum alkyl of the formula Al(R 30 ) 3 wherein R 30 is selected from the group consisting of C 1-10 alkyl radicals, preferably C 2-4 alkyl radicals. The scavenger may be used in an amount to provide a molar ratio of Al:Ti from 20 to 2,000, preferably from 50 to 1,000, most preferably 100 to 500. Generally the scavenger is added to the reactor prior to the catalyst and in the absence of additional poisons, over time declines to 0.
[0094] The supported catalyst will have a kinetic profile for a plot of ethylene consumption in standard liters of ethylene per minute against time in minutes, corrected for the volume of ethylene in the reactor prior to the commencement of the reaction, in a 2 liter reactor over a period of time from 0 to 60 minutes is such that the ratio of the maximum peak height over the first 10 minutes to the average ethylene consumption from 10 to 60 minutes taken at not less than 40, preferably greater than 60, most preferably from 120 to 300 data points, is less than 2.50, preferably less than 2.25.
[0095] The supported catalyst may be used in conjunction with an antistatic agent. In one embodiment the antistatic is added directly to the supported catalyst. The antistatic may be added in an amount from 0 (e.g. optionally) up to 150,000 parts per million (ppm), preferably from 15,000 up to 120,000 ppm based on the weight of the supported catalyst.
[0096] In a further embodiment the antistatic may be added to the reactor in an amount from 0 to 100, preferably from 10 to 80 ppm based on the weight of the polymer produced (i.e. the weight of polymer in the fluidized bed or the weight of polymer dispersed in the slurry phase reactor). If present the antistatic agent may be present in an amount from about 0 to 100, preferably from about 10 to 80 most preferably from 20 to 50 ppm based in the weight of polymer. From the productivity of the catalyst it is fairly routine to determine the feed rate of the antistatic to the reactor based on the catalyst feed rate.
Antistatic “Polysulfone” Additive
[0097] The antistatic polysulfone additive comprises at least one of the components selected from:
[0098] (1) a polysulfone copolymer;
[0099] (2) a polymeric polyamine; and
[0100] (3) an oil-soluble sulfonic acid, and, in addition, a solvent for the polysulfone copolymer.
[0101] Preferably, the antistatic additive comprises at least two components selected from above components (1), (2) and (3). More preferably, the antistatic additive comprises a mixture of (1), (2) and (3).
[0102] According to the present invention, the polysulfone copolymer component of the antistatic additive (often designated as olefin-sulfur dioxide copolymer, olefin polysulfones, or poly(olefin sulfone)) is a polymer, preferably a linear polymer, wherein the structure is considered to be that of alternating copolymers of the olefins and sulfur dioxide, having a one-to-one molar ratio of the comonomers with the olefins in head to tail arrangement. Preferably, the polysulfone copolymer consists essentially of about 50 mole percent of units of sulfur dioxide, about 40 to 50 mole percent of units derived from one or more 1-alkenes each having from about 6 to 24 carbon atoms, and from about 0 to 10 mole percent of units derived from an olefinic compound having the formula ACH═CHB where A is a group having the formula—(C r H ex )—COOH wherein x is from 0 to about 17, and B is hydrogen or carboxyl, with the provision that when B is carboxyl, x is 0, and wherein A and B together can be a dicarboxylic anhydride group.
[0103] Preferably, the polysulfone copolymer employed in the present invention has a weight average molecular weight in the range 10,000 to 1,500,000, preferably in the range 50,000 to 900,000. The units derived from the one or more 1-alkenes are preferably derived from straight chain alkenes having 6-18 carbon atoms, for example 1-hexene, 1-heptene, 1-octene, 1-decene, 1-dodecene, 1-hexadecene and 1-octadecene. Examples of units derived from the one or more compounds having the formula ACH═CHB are units derived from maleic acid, acrylic acid, 5-hexenoic acid.
[0104] A preferred polysulfone copolymer is 1-decene polysulfone having an inherent viscosity (measured as a 0.5 weight percent solution in toluene at 30° C.) ranging from about 0.04 dl/g to 1.6 dl/g.
[0105] The polymeric polyamines that can be suitably employed in the antistatic of the present invention are described in U.S. Pat. No. 3,917,466, in particular at column 6 line 42 to column 9 line 29.
[0106] The polyamine component in accordance with the present invention has the general formula:
[0000] R 20 N[(CH 2 CHOHCH 2 NR 21 ) a —(CH 2 CHOHCH 2 NR 21 —R 22 —NH) b —(CH 2 CHOHCH 2 NR 23 ) c H x ]H 2-x
[0000] wherein R 21 is an aliphatic hydrocarbyl group of 8 to 24 carbon atoms; R 22 is an alkylene group of 2 to 6 carbon atoms; R 23 is the group R 22 —HNR 21 ; R 20 is R 21 or an N-aliphatic hydrocarbyl alkylene group having the formula R 21 NHR 22 ; a, b and c are integers from 0 to 20 and x is 1 or 2; with the proviso that when R 20 is R 21 then a is greater than 2 and b=c=0, and when R 20 is R 21 NHR 22 then a is 0 and the sum of b+c is an integer from 2 to 20.
[0107] The polymeric polyamine may be prepared for example by heating an aliphatic primary monoamine or N-aliphatic hydrocarbyl alkylene diamine with epichlorohydrin in the molar proportion of from 1:1 to 1:1.5 at a temperature of 50° C. to 100° C. in the presence of a solvent, (e.g. a mixture of xylene and isopropanol) adding a strong base, (e.g. sodium hydroxide) and continuing the heating at 50 to 100° C. for about 2 hours. The product containing the polymeric polyamine may then be separated by decanting and then flashing off the solvent.
[0108] The polymeric polyamine is preferably the product of reacting an N-aliphatic hydrocarbyl alkylene diamine or an aliphatic primary amine containing at least 8 carbon atoms and preferably at least 12 carbon atoms with epichlorohydrin. Examples of such aliphatic primary amines are those derived from tall oil, tallow, soy bean oil, coconut oil and cotton seed oil. The polymeric polyamine derived from the reaction of tallowamine with epichlorohydrin is preferred. A method of preparing such a polyamine is disclosed in U.S. Pat. No. 3,917,466, column 12, preparation B.1.0
[0109] The above-described reactions of epichlorohydrin with amines to form polymeric products are well known and find extensive use in epoxide resin technology.
[0110] A preferred polymeric polyamine is a 1:1.5 mole ratio reaction product of N-tallow-1,3-diaminopropane with epichlorohydrin. One such reaction product is “Polyflo™130” sold by Universal Oil Company.
[0111] According to the present invention, the oil-soluble sulfonic acid component of the antistatic is preferably any oil-soluble sulfonic acid such as an alkanesulfonic acid or an alkylarylsulfonic acid. A useful sulfonic acid is petroleum sulfonic acid resulting from treating oils with sulfuric acid.
[0112] Preferred oil-soluble sulfonic acids are dodecylbenzenesulfonic acid and dinonylnaphthylsulfonic acid.
[0113] The antistatic additive preferably comprises 1 to 25 weight % of the polysulfone copolymer, 1 to 25 weight % of the polymeric polyamine, 1 to 25 weight % of the oil-soluble sulfonic acid and 25 to 95 weight % of a solvent. Neglecting the solvent, the antistatic additive preferably comprises about 5 to 70 weight % polysulfone copolymer, 5 to 70 weight % polymeric polyamine and 5 to 70 weight % oil-soluble sulfonic acid and the total of these three components is preferably 100%.
[0114] Suitable solvents include aromatic, paraffin and cycloparaffin compounds. The solvents are preferably selected from among benzene, toluene, xylene, cyclohexane, fuel oil, isobutane, kerosene and mixtures thereof.
[0115] According to a preferred embodiment of the present invention, the total weight of components (1), (2), (3) and the solvent represents essentially 100% of the weight of the antistatic additive.
[0116] One useful composition, for example, consists of 13.3 weight % 1:1 copolymer of 1-decene and sulfur dioxide having an inherent viscosity of 0.05 determined as above, 13.3 weight % of “Polyflo™ 130” (1:1.5 mole ratio reaction product of N-tallow-1,3-diaminopropane with epichlorohydrin), 7.4 weight % of either dodecylbenzylsulfonic acid or dinonylnaphthylsulfonic acid, and 66 weight % of an aromatic solvent which is preferably toluene or kerosene.
[0117] Another useful composition, for example, consists of 2 to 7 weight % 1:1 copolymer of 1-decene and sulfur dioxide having an inherent viscosity of 0.05 determined as above, 2 to 7 weight % of “Polyflo™ 130” (1:1.5 mole ratio reaction product of N-tallow-1,3-diaminopropane with epichlorohydrin), 2 to 8 weight % of either dodecylbenzylsulfonic acid or dinonylnaphthylsulfonic acid, and 78 to 94 weight % of an aromatic solvent which is preferably a mixture of 10 to 20 weight % toluene and 62 to 77 weight % kerosene.
[0118] According to a preferred embodiment of the present invention, the antistatic is a material sold by Octel under the trade name STADIS, preferably STADIS 450, more preferably STADIS 425.
Gas Phase Polymerization
[0119] Fluidized bed gas phase reactors to make polyethylene are generally operated at low temperatures from about 50° C. up to about 120° C. (provided the sticking temperature of the polymer is not exceeded) preferably from about 75° C. to about 110° C. and at pressures typically not exceeding 3,447 kPa (about 500 psi) preferably not greater than about 2,414 kPa (about 350 psi).
[0120] Gas phase polymerization of olefins is well known. Typically, in the gas phase polymerization of olefins (such as ethylene) a gaseous feed stream comprising of at least about 80 weight % ethylene and the balance one or more C 3-6 copolymerizable monomers typically, 1-butene, or 1-hexene or both, together with a ballast gas such as nitrogen, optionally a small amount of C 1-2 alkanes (i.e. methane and ethane) and further optionally a molecular weight control agent (typically hydrogen) is fed to a reactor and in some cases a condensable hydrocarbon (e.g. a C 4-6 alkane such as pentane). Typically, the feed stream passes through a distributor plate at the bottom of the reactor and vertically traverses a bed of polymer particles with active catalyst, typically a fluidized bed but the present invention also contemplates a stirred bed reactor. A small proportion of the olefin monomers in the feed stream react with the catalyst. The unreacted monomer and the other non-polymerizable components in the feed stream exit the bed and typically enter a disengagement zone where the velocity of the feed stream is reduced so that entrained polymer falls back into the fluidized bed. Typically the gaseous stream leaving the top of the reactor is then passed through a compressor. The compressed gas is then cooled by passage through a heat exchanger to remove the heat of reaction. The heat exchanger may be operated at temperatures below about 65° C., preferably at temperatures from 20° C. to 50° C. If there is a condensable gas it is usually condensed and entrained in the recycle stream to remove heat of reaction by vaporization as it recycles through the fluidized bed.
[0121] Polymer is removed from the reactor through a series of vessels in which monomer is separated from the off gases. The polymer is recovered and further processed. The off gases are fed to a monomer recovery unit. The monomer recovery unit may be selected from those known in the art including a distillation tower (i.e. a C 2 splitter), a pressure swing adsorption unit and a membrane separation device. Ethylene and hydrogen gas recovered from the monomer recovery unit are fed back to the reactor. Finally, make up feed stream is added to the reactor below the distributor plate.
Slurry Polymerization
[0122] Slurry processes are conducted in the presence of a hydrocarbon diluent such as an alkane (including isoalkanes), an aromatic or a cycloalkane. The diluent may also be the alpha olefin comonomer used in copolymerizations. Preferred alkane diluents include propane, butanes, (i.e. normal butane and/or isobutane), pentanes, hexanes, heptanes and octanes. The monomers may be soluble in (or miscible with) the diluent, but the polymer is not (under polymerization conditions). The polymerization temperature is preferably from about 5° C. to about 200° C., most preferably less than about 110° C. typically from about 10° C. to 80° C. The reaction temperature is selected so that the ethylene copolymer is produced in the form of solid particles. The reaction pressure is influenced by the choice of diluent and reaction temperature. For example, pressures may range from 15 to 45 atmospheres (about 220 to 660 psi or about 1,500 to about 4,600 kPa) when isobutane is used as diluent (see, for example, U.S. Pat. No. 4,325,849) to approximately twice that (i.e. from 30 to 90 atmospheres—about 440 to 1,300 psi or about 3,000−9,100 kPa) when propane is used (see U.S. Pat. No. 5,684,097). The pressure in a slurry process must be kept sufficiently high to keep at least part of the ethylene monomer in the liquid phase.
[0123] The reaction typically takes place in a jacketed closed loop reactor having an internal stirrer (e.g. an impeller) and at least one settling leg. Catalyst, monomers and diluents are fed to the reactor as liquids or suspensions. The slurry circulates through the reactor and the jacket is used to control the temperature of the reactor. Through a series of let down valves the slurry enters a settling leg and then is let down in pressure to flash the diluent and unreacted monomers and recover the polymer generally in a cyclone. The diluent and unreacted monomers are recovered and recycled back to the reactor.
[0124] The slurry polymerization may also take place in a continuous stirred tank reactor.
The Polymer
[0125] The resulting polymer may have a density from about 0.910 g/cc to about 0.960 g/cc. The resulting polymers may be used in a number of applications such as blown and cast film, extrusion and both injection and rotomolding applications. Typically the polymer may be compounded with the usual additives including heat and light stabilizers such as hindered phenols; ultra violet light stabilizers such as hindered amine stabilizers (HALS); process aids such as fatty acids or their derivatives and fluoropolymers optionally in conjunction with low molecular weight esters of polyethylene glycol.
Phosphinimine Catalyst
[0126] Phosphinimine Ligand
[0127] To solid tBu 3 P (24.8 g, 123.0 mmol) at 25° C. was added trimethylsilylazide (2.0 mL, 15.0 mmol,). The reaction was warmed to 90° C. After 15 minutes further azide (3.0 mL) was added over the next 2 hours further azide (22.5 mL) was added in 3-9 mL aliquots (total azide added=27.5 mL, 208.0 mmol). The reaction was stirred at 95° C. for a further 4 hours then allowed to cool overnight before the excess azide was removed in vacuo. (34.4 g, 97%)
[0128] Metal Precursor.
[0129] A solution of hexafluorobenzene (59.5 g, 320.0 mmol) in 50 mL of THF was added dropwise over 10 to 15 minutes to two molar equivalents of sodium cyclopentadienide in THF (320.0 mL, 2.0 M, 640.0 mmol). The reaction was mildly exothermic and the reaction was maintained at about room temperature by cooling the reaction flask in an oil bath. On completing C6F6 addition, the purple reaction mixture was heated and kept at 60° C. for 3 hours. The reaction was allowed to cool slightly and was then added to neat chlorotrimethylsilane (60.0 mL, 450.0 mmol) at 0° C. over 15-30 minutes. After an additional 30 minutes, the reaction was warmed to 30° C. and the THF, excess chlorotrimethylsilane and other volatiles were removed in vacuo. The resulting wet solid was washed with heptane and filtered to remove inorganic solids. Concentration of the heptane filtrate in vacuo yielded an oily product, (76.6 g, 79%). Butyllithium (1.6 M in hexane, 157.0 mL, 252.0 mmol) was added to this oil in THF (50 mL) at 0° C. and the mixture allowed to warm to room temperature and stirred for an additional 45 minutes. The reaction mixture was added to TiCl4 (47.8 g, 252.0 mmol) and the reaction mixture heated to 60° C. for 3 hours. Volatiles were removed in vacuo to yielding the metal precursor (74.8 g, 77%).
[0130] Final Complex.
[0131] The metal precursor (9.6 g, 25.0 mmol) and the phosphinimine ligand (7.2 g, 25.0 mmol) were weighed together into a Schlenk flask and toluene (150 mL) added. The reaction was heated at 90° C. for 5 hours. The volume of the reaction mixture was reduced to 15 mL and heptane (100 mL) added. The mixture was stirred overnight and then filtered and washed with heptane. The solids collected were dried in vacuo (12.6 g, 86%).
[0132] The aluminoxane was a 10% MAO solution in toluene supplied by Albemarle.
[0133] The support was HIQ-20 alumina obtained from Alcoa Industrial Chemicals. The support had a particle size of 50 μm, a surface area of 280 m 2 /g and a pore volume of 0.48 cc/g.
[0000] Preparation of the Support (Apart from the Control)
[0134] A 10% aqueous solution of the Zr(SO 4 ).4H 2 O was prepared and impregnated into the support by incipient wetness impregnation procedure. The solid support was dried in air at about 135° C. to produce a free flowing powder. The resulting powder was subsequently dried in air at 200° C. for about 2 hours under air and then under nitrogen at 600° C. for 6 hours.
[0135] To a slurry of calcined support in toluene was added a toluene solution of 10 weight % MAO (4.5 weight % Al, purchased from Albemarle) plus rinsings (3×5 mL). The resultant slurry was mixed using a shaker for 1 hour at ambient temperature. To this slurry of MAO-on-support was added a toluene solution of catalyst to give a molar ratio of Al:Ti of 120:1. After two hours of mixing at room temperature using a shaker, the slurry was filtered, yielding a colorless filtrate. The solid component was washed with toluene and pentane (2×), then ˜400 mTorr and sealed under nitrogen until use.
[0136] For the comparative example the same procedure was used except that the support was not treated with Zr(SO 4 ).4H 2 O.
Polymerization
[0137] A 2 L reactor fitted with a stirrer (˜675 rpm) containing a NaCl seed bed (160 g) (stored for at least 3 days at 130° C.) was conditioned for 30 minutes at 105° C. An injection tube loaded in the glovebox containing the catalyst formulation was inserted into the reactor system, which was then purged 3 times with nitrogen and once with ethylene at 200 psi. Pressure and temperature were reduced in the reactor (below 2 psi and between 60 and 85° C.) and TIBAL (500:1 Al:Ti) was injected via gastight syringe followed by a 2 mL precharge of 1-hexene. After the reactor reached 85° C. the catalyst was injected via ethylene pressure and the reactor was pressurized to 200 psi total pressure with 1-hexene fed with a syringe pump at a mole ratio of 6.5% C 6 /C 2 started 1 minute after catalyst injection. The temperature of reaction was controlled at 90° C. for a total runtime of 60 minutes. Reaction was halted by stopping the ethylene flow and turning on reactor cooling water. The reactor was vented slowly to minimize loss of contents and the polymer/salt mixture was removed and allowed to air dry before being weighed.
[0138] Fouling was measured by collecting the polymer from the reactor (including lumps and sheeted material) and sieving through a number 14 sieve (1.4 mm openings) the product (lightly brushing but not “pushing” product through) to determine what percent of the polymer did not pass through the sieve as a percentage of the total polymer produced. The results of the experiments are set forth in Table 1 below. Unfortunately the catalyst and modified catalyst are both extremely reactive resulting in fouling behavior which was poor.
[0000]
TABLE 1
Time
AL:Ti
Productivity
Max
to
Rate of
Max height 1-10/
Molar
gPE/g
C 2
Max
Rise
Average C 2
Support
ratio
catalyst
Flow
Flow
scLM/min
concentration
Fouling %
Phosphinimine:
120:1
2399
1.33
2.60
0.51
2.01
100
Zr(SO 4 ) 2 /HiQ
alumina
Phosphinimine
120:1
2743
1.92
2.83
0.86
2.68
100
HiQ alumina
[0139] FIG. 1 is a kinetic profile of the catalyst on alumina and modified alumina. As noted above the catalyst is extremely “hot” and both catalysts have a very significant initial rate of reaction. However, after about a minute it is clear the modified catalyst has a lower and more consistent rate of reaction. | A supported catalyst system comprising a phosphinimine ligand containing catalyst on an alumina support treated with a metal salt has improved reactor continuity in a dispersed phase reaction in terms of initial activation and subsequent deactivation. The resulting catalyst has a lower consumption of ethylene during initiation and a lower rate of deactivation. Preferably the catalyst is used with an antistatic agent. | 2 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This present invention is directed to fastening gratings to members below a grating and to systems for such fastening.
[0003] 2. Description of Related Art
[0004] The prior art discloses a wide variety of grating fasteners and methods for fastening gratings to a floor or beam; including, but not limited to, the disclosures in U.S. Pat. Nos. 1,707,533; 2,403,842; 2,467,877; 2,572,432; 3,367,078; 3,456,412; 3,466,829; and 4,180,343, all incorporated fully herein for all purposes.
[0005] U.S. Pat. No. 4,362,422, incorporated fully herein for all purposes, discloses a grating fastener having a base member, a saddle clamp and a swivel clamp rotatably mounted on the base member and spring biased perpendicular to the base member for ease of installation. The fastener is installed by rotating the swivel clamp parallel to the base member and inserting the assembly between two adjacent bearing bars and allowing the swivel clamp to spring to its engaged position automatically engaging the bottoms of two adjacent bearing bars. The saddle clamp engages the tops of the same two bearing bars engaged by the swivel clamp. In one aspect, there is disclosed a fastening device for fastening a parallel bar grating to a support member having: a base member having a width less than the spacing between adjacent grating bars, an aperture disposed centrally in the base member and an engagement portion disposed on a first end of the base member; an upper clamp adapted to engage the top of a bearing bar; a threaded fastening means passing through the upper clamp and engaging the base member; and a swivel clamp having a length greater than the spacing of adjacent bars and adapted to engage the bottoms of two adjacent bars and being rotatably mounted on the base member on an end opposite to the engagement portion, including: spring means biasing the swivel clamp against a first rotation stop in the engaged position and the swivel clamp being rotatable against the spring bias to a second position parallel to the base member such that the base member and the swivel clamp may be passed through adjacent bearing bars.
[0006] U.S. Pat. No. 4,759,654, incorporated fully herein for all purposes, discloses a clamping device for holding-down a grid-like support member on an underlying flanged support beam, the device being taken in use from the side of the member which is remote from the beam and partly through a space defined between two generally parallel elongate elements of the member, and being manipulatable so as to bring the device into gripping engagement with a flange of the support beam. The device has a saddle portion which is shaped so as to be capable of being non-rotatably seated on said elements at the one side of the member, a clamping portion which is engageable with one side of the flange of the support beam which is remote from the grid-like member, and a threaded fastener which interconnects the saddle portion and the clamping portion and which is operable relatively to draw the portions towards each other in order to clamp the grid-like member to the support beam when the saddle portion is seated on the elements and when the clamping portion is in engagement with the flange of the support beam. The clamping portion has a first part which is engageable with the one side of the flange of the support beam and a second part which is generally diametrically opposed to the first part with respect to the axis of the fastener and which has at least two steps each shaped so as to be capable of seating-engagement with one of the elements on a side thereof remote from the one side of the grip-like member. Upon initial installation of the clamping device, the second part of the clamping portion is rotatable by the fastener, as the latter is tightened, until the second part comes into engagement with the one element and one of the steps comes into seating engagement therewith, whereby further tightening of the fastener causes clamping together of the grid-like member and the support beam.
[0007] U.S. Pat. No. 4,798,029, incorporated fully herein for all purposes, discloses hold-down clamp for fastening a non-metallic grate, e.g. formed of fiberglass, to a structural member. The clamp includes a restraining clip which prevents spreading of adjacent beams of the grate, and a hold-down clamp which bears on the inner portion of the base of each beam. A threaded fastener urges the hold-down clamp toward the structural member, thereby forcing the bases of the beams into engagement with the structural member to clamp the grate to the structural member. In one aspect the clamp for clamping a grate to a structural member is used with a grate having parallel beams with a I-beam cross section, the clamp including: a restraining clip extending between a pair of adjacent beams and about the outer portion of the base of each beam; a hold-down clamp extending between the pair of adjacent beams proximate the restraining clip and contacting the inner portion of the base of each beam; fastening means for fastening the grate to the structural member by urging the hold-down clamp toward the structural member, and thereby urging the bases of the pair of beams against the structural member, the restraining clip preventing separation of the pair of beams.
[0008] U.S. Pat. No. 4,904,105, incorporated fully herein for all purposes, discloses a tensioned grating fastener that includes a deep draft saddle clip of U-shaped configuration that is engagable with a pair of load-support bars of a criss-cross configured grating, an elongated foot that is provided with a vertical upstanding headed stud which projects through a hole of the saddle clip and a coil spring that is concentrically mounted under slight compression about the stud between the head of the stud and the base of the saddle clip. The depression of the headed stud compresses the coil spring and permits the foot to be rotated from a position in alignment with the saddle clip to a position at an oblique angle thereto, such that one end of the foot is beneath and in engagement with a flange of an underlying grating support member, and the opposite end, beneath and in engagement with one parallel load-supporting bars of the grating. Release of the depressed headed stud partially relaxes the compressed coil spring while ensuring tensioning of the clip engaged grating against the support flange to overcome vibration of the assembly of the grating to the flanged support. In one aspect the tensioned grating fastener for fastening a grating formed of laterally spaced parallel bars interconnected by longitudinally spaced cross bars to an underlying support having a flange at one side perpendicular to said laterally spaced parallel bars said fastener includes: an elongated foot having a first end positionable in contact with the flange on a face of the flange opposite that in contact with the grating parallel bars: a second end positionable in contact with one of the parallel bars proximate to the support; a headed rod mounted at one end to the foot and projecting outwardly of the face of the foot, contacting the grating, the rod positionable between adjacent parallel bars; a hook element having a base portion with a hole therein, at least one hook element side wall unitary with the base and projecting at right angles thereto to the side of the hole, the hook element side wall terminating at an end remote from the base in a reversely bent hook, sized to fit over and about one of the parallel bars, the headed rod projecting through the hole within the base and coupled to the foot; and a coil spring concentrically mounted about the rod having one end in contact with the headed end of the rod and another end in contact with the base; and wherein the height of the grating parallel bars, the height of the rod and the hook element the wall and the axial length of the coil spring are such that with the hook fitted over one of the parallel bars, axial displacement of the rod through the hook element base hole in the direction of the foot, causes the coil spring to be placed under compression, permitting rotation of the foot from a position in line with hook element, to a position at an angle therewith and engagement of respective ends of the foot with the support flange and the one grating parallel bar with the coil spring maintained under compression, thereby tensioning the hook engaged grating against the flange support to resist disengagement as a result of vibration or the like.
[0009] U.S. Pat. No. 5,118,147, incorporated fully herein for all purposes, discloses a grating fastener which can be used to connect grating to structural members, grating sheets to other grating sheets, or to mount a projection means above the grating for connection of other structural or mechanical devices. The grating fastener in one embodiment includes a jaw assembly which has teeth that provide extra strength and holding power for the grating fastener. The top cover or recess clip mounts on top of the grating and includes a square recess area which provides additional strength and durability. The grating fastener can be installed from above the grating by one person with no power tools required and without any holes required to be formed into the structure. The grating fastener is retrievable and can be reused as many times as desired. In one aspect the grating fastener is for fastening a grating sheet to another member in contact with the grating sheet, the grating sheet having a plurality of parallel grating bars wherein each grating bar has an upper and lower surface and a first and second side, the grating fastener having: a recess clip for mounting on the upper surface of adjacent grating bars and having a hole disposed therein, the recess clip having a length and a width greater than the distance between adjacent grating bars such that either the length or the width of the recess clip spans across the adjacent grating bars; an assembly for engaging the member or lower surface of adjacent grating bars; and a fastening means for passing through the hole in the recess clip and for engaging the assembly. In one aspect, the fastener is a composite grating fastener for fastening a first grating sheet to an adjacent second grating sheet wherein each grating sheet has a plurality of parallel grating bars, the composite grating fastener having: a first grating fastener attaching to the first grating sheet; a second grating fastener attaching to the second grating sheet; a connecting means for connecting the first grating sheet to the second grating sheet; wherein the first and second grating fasteners engage the connecting means.
BRIEF SUMMARY OF THE INVENTION
[0010] The present invention discloses, in certain aspects, a grating fastener with a first bolt that is secured with a nut to a plate, floor, substructure, bar or structural member. The first bolt has an interior threaded channel that receives a second bolt inserted through a grating that is placed on top of the plate, etc. A washer surrounds the second bolt and abuts the top of the grating.
[0011] The second bolt is installed from above through the grating into the first bolt. Thus, when securing a grating to a plate, etc., it is not necessary to access the area beneath the plate, etc. when installing the second bolt since the nut has already been tightened below the plate, etc. If the second bolt begins to unthread from the first bolt and/or is loosened, gravity holds the second bolt and/or washer in place and the projection of the second bolt into the interior channel of the first bolt holds the second bolt in position with respect to the grating. This holding in position of the second bolt also inhibits separation of the washer from the second bolt. Neither the second bolt nor the first bolt (secured to the floor, etc.), nor the washer will fall down into or through the grating.
[0012] The nut used to secure the first bolt to the plate, etc. may be any suitable nut, including, but not limited to, a lock nut. Optionally, a washer may be used with the nut.
[0013] The first bolt has a bolt head which can be any suitable shape, e.g., but not limited to, square, rectangular, or hex-head the bolt head size and/or shape may be selected to accommodate any grating and any spacing between grating parts between which the bolt head is located. In one particular aspect, to enhance maintenance of the grating in position, the bolt head fits snugly between two parts of the grating when the grating is placed on top of the plate, etc.
[0014] The present invention discloses methods for securing a grating to a lower member (e.g. a plate, beam, subfloor, etc.), the methods including: inserting a primary bolt of a securement apparatus through a hole in a member; the securement apparatus including the primary bolt, a nut to secure the primary bolt to the member, the primary bolt having an interiorly threaded interior channel, a secondary bolt exteriorly threaded and insertable into the interior channel of the primary bolt to threadedly engage the threaded interior channel of the primary bolt, and a washer positionable around the secondary bolt; securing the primary bolt to the member with the nut; placing a grating on the member above the primary bolt, the grating having a plurality of spaced-apart grating members; inserting the secondary bolt through the washer and between two of the plurality of spaced-apart grating members and into the interior channel of the primary bolt so that the exterior threading of the secondary bolt threadedly engages the interiorly threaded interior channel of the primary bolt; and tightening the secondary bolt to the primary bolt with the washer abutting a top of the grating to secure the grating to the member. A plurality of such securement apparatuses may be used, spaced-apart, to secure the grating to a member below the grating.
[0015] The present invention discloses securement apparatus for securing a grating to lower member, the securement apparatus including: a primary bolt insertable through a hole in a member; a nut to secure the primary bolt to the member; the primary bolt having an interiorly threaded interior channel; a secondary bolt exteriorly threaded and insertable into the interior channel of the primary bolt to threadedly engage the threaded interior channel of the primary bolt; a washer positionable around the secondary bolt; the primary bolt securable to the member with the nut; the secondary bolt insertable through the washer and between two of a plurality of spaced-apart grating members of a grating placed above the lower member and into the interior channel of the primary bolt so that the exterior threading of the secondary bolt can threadedly engage the interiorly threaded interior channel of the primary bolt; and the secondary bolt tightenable to the primary bolt with the washer abutting a top of the grating to secure the grating to the member.
[0016] It is, therefore, an object of at least certain preferred embodiments of the present invention to provide new, useful, unique, efficient, nonobvious grating fastening systems and methods of their use; and
[0017] Such systems and methods in which parts of a fastener are inhibited from falling through a grating.
[0018] Accordingly, the present invention includes features and advantages which are believed to enable it to advance grating fastening technology. Characteristics and advantages of the present invention described above and additional features and benefits will be readily apparent to those skilled in the art upon consideration of the following detailed description of preferred embodiments and referring to the accompanying drawings.
[0019] Certain embodiments of this invention are not limited to any particular individual feature disclosed here, but include combinations of them distinguished from the prior art in their structures, functions, and/or results achieved. Features of the invention have been broadly described so that the detailed descriptions that follow may be better understood, and in order that the contributions of this invention to the arts may be better appreciated. There are, of course, additional aspects of the invention described below and which may be included in the subject matter of the claims to this invention. Those skilled in the art who have the benefit of this invention, its teachings, and suggestions will appreciate that the conceptions of this disclosure may be used as a creative basis for designing other structures, methods and systems for carrying out and practicing the present invention. The claims of this invention are to be read to include any legally equivalent devices or methods which do not depart from the spirit and scope of the present invention.
[0020] What follows are some of, but not all, the objects of this invention. In addition to the specific objects stated below for at least certain preferred embodiments of the invention, there are other objects and purposes which will be readily apparent to one of skill in this art who has the benefit of this invention's teachings and disclosures. It is, therefore, an object of at least certain preferred embodiments of the present invention to provide new, useful, unique, efficient, nonobvious systems and for securing a grating to a member below the grating; and, in certain aspects, to such systems and methods in which gravity can hold a loose secondary bolt in place.
[0021] The present invention recognizes and addresses the problems and needs in this area and provides a solution to those problems and a satisfactory meeting of those needs in its various possible embodiments and equivalents thereof. To one of skill in this art who has the benefits of this invention's realizations, teachings, disclosures, and suggestions, other purposes and advantages will be appreciated from the following description of certain preferred embodiments, given for the purpose of disclosure, when taken in conjunction with the accompanying drawings. The detail in these descriptions is not intended to thwart this patent's object to claim this invention no matter how others may later attempt to disguise it by variations in form, changes, or additions of further improvements.
[0022] The Abstract that is part hereof is to enable the U.S. Patent and Trademark Office and the public generally, and scientists, engineers, researchers, and practitioners in the art who are not familiar with patent terms or legal terms of phraseology to determine quickly from a cursory inspection or review the nature and general area of the disclosure of this invention. The Abstract is neither intended to define the invention, which is done by the claims, nor is it intended to be limiting of the scope of the invention or of the claims in any way.
[0023] It will be understood that the various embodiments of the present invention may include one, some, or all of the disclosed, described, and/or enumerated improvements and/or technical advantages and/or elements in claims to this invention.
[0024] Certain aspects, certain embodiments, and certain preferable features of the invention are set out herein. Any combination of aspects or features shown in any aspect or embodiment can be used except where such aspects or features are mutually exclusive.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0025] A more particular description of embodiments of the invention briefly summarized above may be had by references to the embodiments which are shown in the drawings which form a part of this specification. These drawings illustrate certain preferred embodiments and are not to be used to improperly limit the scope of the invention which may have other equally effective or legally equivalent embodiments.
[0026] FIG. 1 is a perspective view of a grating fastening apparatus according to the present invention.
[0027] FIG. 1A is a perspective view of a secondary bolt apparatus of FIG. 1 .
[0028] FIG. 1B is a perspective view of a washer of the apparatus of FIG. 1 .
[0029] FIG. 1C is a perspective view of a primary bolt of the apparatus of FIG. 1 .
[0030] FIG. 1D is a perspective view of a nut of the apparatus of FIG. 1 .
[0031] FIG. 1E is a cross-section view of the secondary bolt of FIG. 1A .
[0032] FIG. 1F is a cross-section view of the washer of FIG. 1B .
[0033] FIG. 1G is a cross-section view of the primary bolt of FIG. 1C .
[0034] FIG. 1H is a cross-section view of the nut of FIG. 1D .
[0035] FIG. 1I is a top view of the washer of FIG. 1B .
[0036] FIG. 1J is a bottom view of the washer of FIG. 1B .
[0037] FIG. 2A is a top view of a steel plate to which a primary bolt is to be attached.
[0038] FIG. 2B is a side view of the plate of FIG. 2A .
[0039] FIG. 2C is a perspective view of the plate of FIG. 2A .
[0040] FIG. 3A is a top view of the plate of FIG. 2A with a primary bolt installed.
[0041] FIG. 3B is a side view of the plate of FIG. 3A .
[0042] FIG. 3C is a bottom view of the plate of FIG. 3A .
[0043] FIG. 4A is a perspective view of the plate of FIG. 3A with a nut on the bolt.
[0044] FIG. 4B is a side view of the plate of FIG. 4A .
[0045] FIG. 4C is a cross-section view of the plate of FIG. 4 A.
[0046] FIG. 5A is a top view of the plate of FIG. 4A with a grating on the plate.
[0047] FIG. 5B is a side view of the plate and grating of FIG. 5A .
[0048] FIG. 5C is a perspective view of the plate and grating of FIG. 5A .
[0049] FIG. 6A is a top view of the plate and grating of FIG. 5A with a secondary bolt and washer installed.
[0050] FIG. 6B is a side view of the items of FIG. 6A .
[0051] FIG. 6C is a top view of the items of FIG. 6A .
[0052] FIG. 7A is a perspective view of the items of FIG. 6A .
[0053] FIG. 7B is a cross-section view of the items shown in FIG. 7A .
[0054] FIG. 8 is a top view of a grating fastened to a lower structure with apparatuses according to the present invention.
[0055] FIG. 9A is a perspective view of parts of an apparatus according to the present invention on a plate.
[0056] FIG. 9B is a side view of a system according to the present invention securing a grating to the plate of FIG. 9A .
[0057] Presently preferred embodiments of the invention are shown in the above-identified figures and described in detail below. Various aspects and features of embodiments of the invention are described below and some are set out in the dependent claims. Any combination of aspects and/or features described below or shown in the dependent claims can be used except where such aspects and/or features are mutually exclusive. It should be understood that the appended drawings and description herein are of preferred embodiments and are not intended to limit the invention or the appended claims. On the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the invention as defined by the appended claims. In showing and describing the preferred embodiments, like or identical reference numerals are used to identify common or similar elements. The figures are not necessarily to scale and certain features and certain views of the figures may be shown exaggerated in scale or in schematic in the interest of clarity and conciseness.
[0058] As used herein and throughout all the various portions (and headings) of this patent, the terms “invention”, “present invention” and variations thereof mean one or more embodiment, and are not intended to mean the claimed invention of any particular appended claim(s) or all of the appended claims. Accordingly, the subject or topic of each such reference is not automatically or necessarily part of, or required by, any particular claim(s) merely because of such reference. So long as they are not mutually exclusive or contradictory any aspect or feature or combination of aspects or features of any embodiment disclosed herein may be used in any other embodiment disclosed herein.
DETAILED DESCRIPTION OF THE INVENTION
[0059] FIG. 1 shows an apparatus 10 according to the present invention for securing a grating to a plate, member, substructure, floor, or other structure. FIGS. 1A-1J show parts of the apparatus 10 . The apparatus 10 includes a primary bolt 20 which has a body 22 , a bolt head 24 and an interior threaded channel 26 . The body 22 is exteriorly threaded. A threaded nut 28 is used to fasten the primary bolt 20 to a plate, etc.
[0060] A secondary bolt 30 has a body 32 which is exteriorly threaded for threaded engagement in the interior threaded channel 26 of the primary bolt 20 . The bolt 30 has a bolt head 34 .
[0061] A washer 40 has a body 42 with a hole 44 for the secondary bolt 30 and an optional inner indentation or “bucket” 46 . In one aspect a washer 40 is sized so that it covers two grating bars or members.
[0062] FIGS. 2A-7B illustrate steps in a method according to the present invention to use an apparatus 10 according to the present invention to secure a grating 100 to a plate 102 . As shown in FIGS. 2A-2C , a hole 104 is drilled in the plate 102 for receiving a primary bolt 20 (shown installed in FIGS. 3A-3C ). A nut 28 secures the primary bolt 20 to the plate 102 .
[0063] A secondary bolt 30 threaded into the interior channel 26 of the primary bolt 20 holds a washer 40 in place on the grating 100 and, when tightened, secures the grating 100 to the plate 102 ( FIGS. 5A-7B ).
[0064] As shown in FIGS. 6A , 6 B, and 7 A, the washer 40 is sufficiently wide to contact two spaced-apart parts 106 of the grating 100 . As shown in FIG. 7A , the primary bolt 20 has a head 24 sized to fit snugly between bases 101 of the parts 106 . Optionally, such a bolt head can be smaller so that there is no such snug fit.
[0065] FIG. 8 illustrates the amount of total area of a grating 110 with spaced-apart grating members 112 covered by washers 40 a (like the washer 40 , FIG. 1 ) around bolts 30 a of apparatuses according to the present invention. For example, with a grating 110 which has an area (as viewed from above as in FIG. 8 ) of about one square meter, six apparatuses are used according to the present invention. The grating 110 has connection members 114 connecting the grating members 112 .
[0066] FIGS. 9A and 9B show another embodiment of an apparatus according to the present invention. The apparatus 90 according to the present invention is like the apparatus 10 ( FIG. 1 ) and like numerals indicate like parts. A primary bolt 92 has a body 94 with a bolt head 96 which has generally rectangular shape (as viewed from above in FIG. 9A ). In one aspect the bolt head 96 has a width which fits snugly between bases 108 of bars 109 of a grating 120 when the bolt 92 is secured to a plate 107 . Sides of the bolt head 96 are straight to correspond to straight surfaces of the bars 109 .
[0067] Using fasteners according to the present invention with a first bolt secured to a lower plate or other member and a second bolt secured to the first bolt, the incidence of parts of a fastener falling through a grating is reduced. Even when the second bolt may be loosened with respect to the first bolt, gravity holds the second bolt and washer in place.
[0068] The present invention, therefore, provides in at least some embodiments, a method for securing a grating to a lower member, the method including: inserting a primary bolt of a securement apparatus through a hole in a member; the securement apparatus including the primary bolt, a nut to secure the primary bolt to the member, the primary bolt having an interiorly threaded interior channel, a secondary bolt exteriorly threaded and insertable into the interior channel of the primary bolt to threadedly engage the threaded interior channel of the primary bolt, and a washer positionable around the secondary bolt; securing the primary bolt to the member with the nut; placing a grating on the member above the primary bolt, the grating having a plurality of spaced-apart grating members; inserting the secondary bolt through the washer and between two of the plurality of spaced-apart grating members and into the interior channel of the primary bolt so that the exterior threading of the secondary bolt threadedly engages the interiorly threaded interior channel of the primary bolt; and tightening the secondary bolt to the primary bolt with the washer abutting a top of the grating to secure the grating to the member. Such a method according to the present invention may have one or some (in any possible combination) of the following: wherein the washer has a washer width sufficient for the washer to cover a portion of each of two adjacent grating members, the method further including: positioning the washer to contact two adjacent grating members; wherein the primary bolt has a bolt head with bolt faces, the spaced-apart grating members have exterior surfaces, the exterior surfaces parallel to each other, the method further including: positioning the primary bolt between a first grating member and a second grating member so that opposed bolt faces of the bolt head abut an exterior surface of each of the first grating member and the second grating member; wherein the bolt head is hexagonal with six bolt faces; wherein the bolt head is rectangular with four bolt faces; wherein the washer includes a central bucket area; loosening of the secondary bolt with respect to the primary bolt, and the secondary bolt held in position by gravity following said loosening; and/or wherein the lower member is a plate, beam bar substructure, or structural member.
[0069] The present invention, therefore, provides in at least some embodiments, a method for securing a grating to a lower member, the method including: inserting a primary bolt of a securement apparatus through a hole in a member; the securement apparatus including the primary bolt, a nut to secure the primary bolt to the member, the primary bolt having an interiorly threaded interior channel, a secondary bolt exteriorly threaded and insertable into the interior channel of the primary bolt to threadedly engage the threaded interior channel of the primary bolt, and a washer positionable around the secondary bolt; securing the primary bolt to the member with the nut; placing a grating on the member above the primary bolt, the grating having a plurality of spaced-apart grating members; inserting the secondary bolt through the washer and between two of the plurality of spaced-apart grating members and into the interior channel of the primary bolt so that the exterior threading of the secondary bolt threadedly engages the interiorly threaded interior channel of the primary bolt; tightening the secondary bolt to the primary bolt with the washer abutting a top of the grating to secure the grating to the member; wherein the washer has a washer width sufficient for the washer to cover a portion of each of two adjacent grating members, the method further including positioning the washer to contact two adjacent grating members; loosening of the secondary bolt with respect to the primary bolt; and the secondary bolt held in position by gravity following said loosening.
[0070] The present invention, therefore, provides in at least some embodiments, a method for securing a grating to lower member, the method including employing a plurality of securement apparatuses to connect the grating to the lower members, the plurality of securement apparatuses spaced-apart above the lower member, the method further including: inserting a primary bolt of each securement apparatus through a hole in the lower member; each securement apparatus including a primary bolt, a nut to secure the primary bolt to the lower member, the primary bolt having an interiorly threaded interior channel, a secondary bolt exteriorly threaded and insertable into the interior channel of the primary bolt to threadedly engage the threaded interior channel of the primary bolt, and a washer positionable around the secondary bolt; securing each primary bolt to the lower member with a nut; placing a grating on the lower member above the primary bolts, the grating having a plurality of spaced-apart grating members; inserting each secondary bolt through a washer and between two of the plurality of spaced-apart grating members and into an interior channel of a primary bolt so that the exterior threading of each secondary bolt threadedly engages the interiorly threaded interior channel of a primary bolt; and tightening each secondary bolt to a primary bolt with a washer abutting a top of the grating to secure the grating to the lower member. Such a method according to the present invention may have one or some (in any possible combination) of the following: wherein the grating has an area of about one square meter and six securement apparatuses are used to secure the grating to the lower member; wherein each primary bolt has a bolt head with bolt faces, the spaced-apart grating members having exterior surfaces, the exterior surfaces parallel to each other, the method further including positioning each primary bolt between two grating members so that opposed bolt faces of each bolt head abut an exterior surface a grating member; wherein the bolt heads are hexagonal with six bolt faces; wherein the bolt heads are rectangular with four bolt faces; wherein each washer includes a central bucket area; and/or loosening of the secondary bolts with respect to the primary bolts, and the secondary bolts held in position by gravity following said loosening.
[0071] The present invention, therefore, provides in at least some embodiments, a securement apparatus for securing a grating to lower member, the securement apparatus including: a primary bolt insertable through a hole in a member; a nut to secure the primary bolt to the member; the primary bolt having an interiorly threaded interior channel; a secondary bolt exteriorly threaded and insertable into the interior channel of the primary bolt to threadedly engage the threaded interior channel of the primary bolt; a washer positionable around the secondary bolt; the primary bolt securable to the member with the nut; the secondary bolt insertable through the washer and between two of a plurality of spaced-apart grating members of a grating placed above the lower member and into the interior channel of the primary bolt so that the exterior threading of the secondary bolt can threadedly engage the interiorly threaded interior channel of the primary bolt; and the secondary bolt tightenable to the primary bolt with the washer abutting a top of the grating to secure the grating to the member. Such a securement apparatus according to the present invention may have one or some (in any possible combination) of the following: wherein the washer has a washer width sufficient for the washer to cover a portion of each of two adjacent grating members; wherein the primary bolt has a bolt head with bolt faces, the spaced-apart grating members having exterior surfaces, the exterior surfaces parallel to each other, the primary bolt positionable between a first grating member and a second grating member so that opposed bolt faces of the bolt head abut an exterior surface of each of the first grating member and the second grating member; wherein the washer includes a central bucket area; and/or wherein the secondary bolt is loosenable with respect to the primary bolt, and the secondary bolt is holdable in position by gravity following said loosening.
[0072] In conclusion, therefore, it is seen that the present invention and the embodiments disclosed herein and those covered by the appended claims are well adapted to carry out the objectives and obtain the ends set forth. Certain changes can be made in the subject matter without departing from the spirit and the scope of this invention. It is realized that changes are possible within the scope of this invention and it is further intended that each element or step recited in any of the following claims is to be understood as referring to the step literally and/or to all equivalent elements or steps. The following claims are intended to cover the invention as broadly as legally possible in whatever form it may be utilized. The invention claimed herein is new and novel in accordance with 35 U.S.C. § 102 and satisfies the conditions for patentability in § 102. The invention claimed herein is not obvious in accordance with 35 U.S.C. § 103 and satisfies the conditions for patentability in § 103. This specification and the claims that follow are in accordance with all of the requirements of 35 U.S.C. § 112. The inventors may rely on the Doctrine of Equivalents to determine and assess the scope of their invention and of the claims that follow as they may pertain to apparatus not materially departing from, but outside of, the literal scope of the invention as set forth in the following claims. All patents and applications identified herein are incorporated fully herein for all purposes. It is the express intention of the applicant not to invoke 35 U.S.C. § 112, paragraph 6 for any limitations of any of the claims herein, except for those in which the claim expressly uses the words ‘means for’ together with an associated function. In this patent document, the word “comprising” is used in its non-limiting sense to mean that items following the word are included, but items not specifically mentioned are not excluded. A reference to an element by the indefinite article “a” does not exclude the possibility that more than one of the element is present, unless the context clearly requires that there be one and only one of the elements. | Methods and systems are disclosed for fastening a grating to a lower member such as a plate, floor, beam, or substructure below the grating. Such methods and systems can include securing a primary bolt with an interior threaded portion to the lower member and then securing a secondary bolt in the threaded portion of the primary bolt. This abstract is provided to comply with the rules requiring an abstract which will allow a searcher or other reader to quickly ascertain the subject matter of the technical disclosure and is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims, 37 C.F.R. 1.72(b). | 4 |
FIELD AND BACKGROUND OF THE INVENTION
The present invention relates to an electromagnetically actuatable directional valve.
Such valves are known from RD 29 060 of April 1993 of Mannesmann Rexroth. In order to obtain good automatic control of these valves, their valve chambers including the armature chambers of the actuating magnets which are in communication with each other via a channel extending within the valve housing must be vented. For this purpose, air-removal channels which can be closed by screws are present on the outer closure covers of the magnet housing. Upon the placing in operation, the closure screws are removed and working fluid introduced through the air-vent channel of the one actuating magnet until fluid emerges from the air-vent channel of the opposite actuating magnet. The air-vent channels are then closed by means of the closure screws.
SUMMARY OF THE INVENTION
The object of the invention is to create an electromagnetically actuated directional valve in connection with which the known cumbersome removal of air from the armature chambers of the actuating magnets can be dispensed with.
In accordance with the invention, the armature chambers are in communication via an inlet throttle (16, 17) with the connection (P) of the source of working fluid and, via an outlet throttle (7, 27, 8, 28), with the tank connection (T).
Due to the fact that the armature chambers are in communication with the source of working fluid via an inlet throttle and with the tank connection via an outlet throttle, the working fluid entering into the armature chambers is under a pressure the value of which is between the pump pressure and the tank pressure. The air present in the armature chambers is compressed by this pressure so that the armature chambers are substantially filled by the incoming working fluid so that dependable control of the valve is assured.
With the above and other objects and advantages in view, the present invention will become more clearly understood in connection with the detailed description of the preferred embodiment, when considered with the accompanying drawings of which:
In the drawing:
FIG. 1 is an axial section through a four-way proportional valve having two actuating magnets and integrated control electronics;
FIG. 2 is a longitudinal section through the valve housing in the plane of the housing channel with the threaded section with screw forming the throttle;
FIG. 3 is a section along the line III--III of FIG. 2; and
FIG. 4 is a partial longitudinal section through the proportional valve with throttle integrated in the control piston.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIG. 1, the valve housing is designated 1 and the control piston 2. The control piston 2 is displaced by the actuating magnets 3 and 4 fastened on both sides of the valve housing in one or the other direction, depending upon the signal given by the control electronics 6 placed on the actuating magnets 3. The control piston 2 has, on its ends, piston sections 7 and 8 which separate the housing recesses 9, 10 in communication with the armature chambers (not shown) of the actuating magnets from the control chambers 12, 13 of the valve housing 1 which are in communication with the tank from each other. From the control chamber 15 of the valve housing which is in communication with the working-fluid connection P, a housing-channel section provided with a female thread 16 and closed by a screw 17 leads to a housing-channel section 20 extending parallel to the actuating axis 19 of the control piston, from the ends of which housing channel sections 21, 22 extending from the ends of the housing channel section 20 close to the fastening walls 23, 24 for the actuating magnets 3 and 4 lead to the housing recesses 9, 10.
If, upon the placing in operation of a hydraulic system, the control chamber 15 which is in communication with the source of working fluid via the pressurized-fluid connection P is acted on by the working or pressurized fluid, then a small amount of working fluid flows via the flank clearance 26 (FIG. 2) between female and male threads of the housing channel section 16 closed by the screw 17 into the axially extending housing channel section 20 and from there further, via the lateral channel sections 21, 22, into the housing recesses 9, 10 and the armature chambers (not shown) of the actuating magnets 3, 4, not in liquid communication with said housing recesses 9, 10. From the housing recesses 9, 10 finally, the small amount of working fluid branched off from the main stream flows over the guidance clearance between the control-piston end sections 7, 8 and the guide holes 27, 28 in the housing flanges 30, 31 into the control chambers 12, 13 of the valve housing 1 which are in communication with the tank. The flank clearance between male and female threads of the channel section 16 and the screw 17 which forms the inlet throttle and the guidance clearance forming the outlet throttles in the end control piston sections 7, 8 in the guidance holes 27, 28 of the housing flanges 30, 31 for the housing recesses connected with the armature chambers are so adapted to each other that there is established within the armature chambers a pressure of the working fluid which compresses the air inclusions present in said chambers to such an extent that the incoming working fluid fills the armature chambers to such an extent that a dependable control of the valve is assured. By the control movement of the control piston, the working fluid present in the armature chamber is subjected to a backward and forward movement and in that way mixed with the small amount of working fluid flowing through the housing recesses so that, in the final analysis, also the air inclusions still present are washed into the tank. The inlet and outlet throttles are so adapted to each other that the working fluid present in the armature chambers is under a pressure which corresponds to 0.6 times the pump pressure. The sum of the cross sections of the two outlet throttles formed by the guidance clearance of the end control piston sections must therefore be kept slightly less than the cross section of the joint inlet throttle formed by the flank clearance between male and female threads in the channel section 16.
In accordance with FIG. 3, the axially extending channel section of the threaded channel section 16 is cut into only in a small edge region 20a. As a result, the working fluid which enters into this region of the edge can distribute itself uniformly to both sides of the axially extending channel section 20 and flow further into the corresponding housing recesses 9, 10 which are in liquid communication with the armature chambers. The axially extending channel section 20 is introduced, in accordance with FIG. 2, as a blind hole into the valve housing 1 and closed off from the outside by means of a screw 33. The threaded channel section 16 which forms the feed throttle together with the screw 17 is worked from the outside into the valve housing and widened in the housing inlet region in order to receive the screw head 17a. On the radial surface 35 which results therefrom, a packing ring 36 is provided which, via the corresponding radially extending surface 37 of the screw head 17a, assures a liquid-tight seal of the threaded channel section from the outside.
In accordance with FIG. 4, the control piston 2 has an axially extending blind hole 2a which is connected with a transverse hole 2b which discharges into the control chamber 15 connected with the working fluid connection P. On the control-piston end section 8, the blind hole is widened and provided with a grub screw 171. The flank clearance between female thread 161 and the thread of the grub screw 171 forms an inlet throttle over which, upon the placing in operation of the hydraulic system, a small amount of working fluid flows into the housing recess 10 and from there via a connecting channel 1b extending, as shown in dot-dash line, within the valve housing 1 also into the opposite housing recess 9. From the housing recesses 9, 10, the small amount of working fluid finally flows further, as in the embodiment of FIG. 1, over the guide clearance acting as outlet throttle between the control-piston end sections 7, 8 and the guidance holes 27, 28 in the housing flanges 30, 31 into the control chambers 12, 13 in communication with the tank, in which connection within the housing recesses 9, 10 and the armature chambers connected with the housing recesses, a pressure is built up which is determined by the size of the inlet throttle and the outlet throttles.
In order to obtain a constant pressure in the armature chambers, a pressure-limiting valve can be provided, independently of the guidance clearance of the control-piston end sections, between the one housing recess and the control chamber which is in communication with the tank. | An electromagnetically actuated directional valve wherein the armature chambers are in communication with the source of working fluid via an inlet throttle and with the tank connection via an outlet throttle. | 5 |
FIELD OF THE INVENTION
[0001] The present disclosure relates generally to systems and methods for boil detection. More particularly, the present disclosure is directed to systems and methods for boil detection in which a computer vision algorithm is applied to imagery of a cooktop captured by a camera to detect a boiling event.
BACKGROUND OF THE INVENTION
[0002] One primary use of a cooktop appliance is to boil water or other liquids. For example, when preparing rice, pasta, or other dishes, it may be desirable to bring a pot of water to boil using high heat and then reduce the level of supplied heat once the water begins to boil. As another example, some dishes may require bringing a sauce to boil and then reducing heat to let the sauce simmer.
[0003] However, in certain instances, the user may be distracted or performing another task and, therefore, fail to notice that the water or other liquid has reached a boiling state. Failure to reduce the heat once the liquid has achieved the boiling state can cause a number of problems including, for example, overcooking of the dish, splatter of liquid onto the cooktop surface, or even complete evaporation of the liquid, a condition referred to as “boil-dry,” which can potentially lead to ignition of a fire. Therefore, systems and methods for boil detection and alarming are desirable.
[0004] Certain existing systems have been proposed for performing boil detection. As an example, motion sensors can be used to detect motion at the cooktop. However, these systems suffer from significant problems with accuracy, as human motion (e.g. stirring) or rising steam trigger the sensor and leads to a false positive of a boiling event.
[0005] As another example, other existing systems may use temperature sensors to attempt to detect a boiling event. However, these systems can suffer from problems with accuracy and granularity, as well. For example, temperature sensors in a generally heated environment such as a cooktop may lead to significant numbers of errors.
[0006] Therefore, systems and methods for boil detection that provide improved accuracy are desirable.
BRIEF DESCRIPTION OF THE INVENTION
[0007] Additional aspects and advantages of the invention will be set forth in part in the following description, or may be apparent from the description, or may be learned through practice of the invention.
[0008] One aspect of the present disclosure is directed to a system for detecting a boiling event at a cooktop. The system includes a vision sensor positioned so as to collect imagery depicting the cooktop. The system includes one or more processors and one or more non-transitory computer-readable media storing instructions that, when executed by the one or more processors, cause the one or more processors to perform operations. The operations include obtaining a first frame of imagery and a second frame of imagery from the vision sensor. The first frame of imagery and the second frame of imagery respectively depict the cooktop. The operations include identifying a plurality of motion vectors based on the first and second frames of imagery. Each of the plurality of motion vectors describes a change in position of one or more pixels from the first frame of imagery to the second frame of imagery. The operations include generating a histogram describing a characteristic of the plurality of motion vectors. The operations include calculating a dissimilarity score. The dissimilarity score describes a difference between the histogram and a pre-learned histogram. The pre-learned histogram describes the characteristic for imagery depicting boiling liquid. The operations include determining whether a boiling event is occurring at the cooktop based at least in part on the dissimilarity score.
[0009] Another aspect of the present disclosure is directed to a method for detecting a boiling event at a cooktop. The method includes collecting, by a vision sensor, a plurality of frames comprising imagery depicting the cooktop. The method includes determining, by one or more computing devices, a plurality of motion vectors for each of the plurality of frames. Each motion vector for each frame describes a change in position of one or more pixels included in such frame with respect to a previous sequential frame of the plurality of frames. The method includes generating, by the one or more computing devices for each of the plurality of frames, one or more histograms describing the plurality of motion vectors determined for such frame. The method includes comparing, by the one or more computing devices for each of the plurality of frames, the one or more histograms generated for such frame with one or more pre-learned histograms. The method includes detecting, by the one or more computing devices, a boiling event at the cooktop based on the comparison of the one or more histograms generated for each frame with the one or more pre-learned histograms.
[0010] Another aspect of the present disclosure is directed to a non-transitory computer-readable medium storing instructions that, when executed by a processor, cause the processor to perform operations. The operations include obtaining a plurality of frames of imagery from a vision sensor. The plurality of frames of imagery respectively depict a cooktop. The plurality of frames of imagery form a plurality of pairs of consecutive frames. The operations include identifying a plurality of motion vectors for each pair of consecutive frames of imagery. The operations include generating, for each pair of consecutive frames of imagery, a histogram describing a characteristic of the plurality of motion vectors identified for such pair of consecutive frames. The operations include calculating, for each pair of consecutive frames of imagery, a dissimilarity score. The dissimilarity score describes a difference between the histogram generated for such pair of consecutive frames and a pre-learned histogram. The pre-learned histogram describes the characteristic for imagery depicting boiling liquid. The operations include determining whether a boiling event is occurring at the cooktop based at least in part on the dissimilarity scores respectively calculated for the plurality of pairs of consecutive frames.
[0011] These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which:
[0013] FIG. 1 depicts an example system according to an example embodiment of the present disclosure;
[0014] FIG. 2 depicts a flow chart of an example method according to an example embodiment of the present disclosure;
[0015] FIG. 3 depicts an example depiction of a vision sensor capturing imagery depicting a cooktop according to an example embodiment of the present disclosure;
[0016] FIG. 4 depicts an example frame of imagery depicting a cooktop according to an example embodiments of the present disclosure;
[0017] FIG. 5 depicts an example frame of imagery depicting a cooktop according to an example embodiments of the present disclosure;
[0018] FIG. 6 depicts an example histogram according to an example embodiment of the present disclosure;
[0019] FIG. 7 depicts an example histogram according to an example embodiment of the present disclosure;
[0020] FIG. 8 depicts an example histogram according to an example embodiment of the present disclosure; and
[0021] FIG. 9 depicts an example histogram according to an example embodiment of the present disclosure.
DETAILED DESCRIPTION OF THE INVENTION
[0022] Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.
[0023] With reference now to the FIGS., example embodiments of the present disclosure will be discussed in further detail. FIG. 1 depicts an example system 100 according to an example embodiment of the present disclosure.
[0024] System 100 can include a vision sensor 102 that can exchange data with a computing device 104 . As an example, the vision sensor 102 can be any suitable camera for capturing imagery. For example, in some embodiments, the vision sensor 102 can be a wide-angle VGA resolution camera.
[0025] vision sensor 102 can be positioned so as to collect imagery depicting a cooktop. For example, vision sensor 102 can be secured to the underside of an over the range microwave or hood and pointed downwards so that the view of the vision sensor generally corresponds to the dimensions of the cooktop.
[0026] Vision sensor 102 can collect a plurality of frames of imagery. For example, in some embodiments, computing device 104 can operate vision sensor 102 to collect between 0.3 to 1 frames per second of a VGA resolution video stream. The frame rate can be modifiable by the computing device 104 .
[0027] Computing device 104 can be any device that includes one or more processors 106 and a memory 108 . As an example, in some embodiments, computing device 104 can be a single board computer (SBC). For example, the computing device 104 can be a single System-On-Chip (SOC). Further, the vision sensor 102 can also be located on the same single circuit board. However, any form of computing device 104 can be used to perform the present disclosure.
[0028] The processor(s) 106 can be any suitable processing device, such as a microprocessor, microcontroller, integrated circuit, or other suitable processing devices or combinations thereof.
[0029] The memory 108 can include any suitable storage media, including, but not limited to, non-transitory computer-readable media, RAM, ROM, hard drives, flash drives, accessible databases, or other memory devices. The memory 108 can store information accessible by processor(s) 106 , including instructions 110 that can be executed by processor(s) 106 to perform aspects of the present disclosure.
[0030] Memory 108 can also include a counter 112 storing a counter value. In some embodiments, the counter 112 can be used to count a number of consecutive frames of imagery which the computing device 104 has determined depict a boiling event at the cooktop.
[0031] Computing device 104 can also include a number of modules to provide functionality or otherwise perform particular operations. It will be appreciated that the term “module” refers to computer logic utilized to provide desired functionality. Thus, a module can be implemented in hardware, application specific circuits, firmware and/or software controlling a general purpose processor. In one embodiment, modules are program code files stored on the storage device, loaded into memory and executed by a processor or can be provided from computer program products, for example computer executable instructions, that are stored in a tangible computer-readable storage medium such as RAM, hard disk or optical or magnetic media.
[0032] Computing device 104 can implement a motion vector determination module 114 to determine a plurality of motion vectors for each of a plurality of pairs of frames of imagery. For example, each of the plurality of motion vectors can describe a change in position of one or more pixels from a first frame of imagery to a second frame of imagery. In some embodiments, each motion vector can include a magnitude and an orientation. For example, the orientation can be expressed as an angle from 0 to 360.
[0033] In particular, in some embodiments, motion vector determination module 114 can be implemented to perform one or more motion estimation techniques to identify the plurality of motion vectors. As examples, motion vector determination module 114 can perform a block-matching technique, a phase correlation technique, a frequency domain technique, a pixel recursive technique, an optical flow technique (e.g. Lucas-Kanade or Horn-Schunck), corner detection, feature matching, patch matching, texture matching, or other techniques or statistical functions.
[0034] As another example, in some embodiments, processing performed by motion vector determination module 114 can be simplified by searching only along horizontal and/or vertical lines extending from each pixel in the earlier frame for matching pixels in the later frame. In such fashion, processing time and power requirements can be reduced to allow for an improved implementation speed or reduced product cost.
[0035] Computing device 104 can implement a histogram generation module 116 to generate one or more histograms for each of the plurality of pairs of frames of imagery. For example, each histogram can describe a characteristic of the plurality of motion vectors determined for each respective pair of frames. As examples, the histogram can describe a distribution of orientations associated with the plurality of motion vectors; a distribution of magnitudes associated with the plurality of motion vectors; a distribution of other variables; or distributions of various combinations of variables (e.g. both orientation and magnitude). The histograms may be embodied as stored data and are not necessarily represented or stored in a graphical or visual fashion. Further, the histograms can provide discrete intervals of data or may provide a continuous density function with kernel methods.
[0036] Computing device 104 can implement a histogram comparison module 118 to compare two or more histograms. For example, histogram comparison module 118 can be implemented to compare the one or more histograms generated by histogram generation module 116 with one or more pre-learned histograms stored in memory 108 .
[0037] In particular, the one or more pre-learned histograms stored in memory 108 can respectively describe one or more characteristics of a plurality of motion vectors exhibited by frames of imagery depicting a boiling event. For example, in some embodiments, the pre-learned histograms can be generated through testing or analyzing imagery depicting a boiling event. In other embodiments, the pre-learned histograms can be approximations, such as for example, a histogram having a uniform distribution of orientations.
[0038] Histogram comparison module 118 can be implemented to perform one or more histogram comparison techniques to compare two or more histograms. As examples, histogram comparison module 118 can perform an earth mover's distance (EMD) technique, a bin-to-bin comparison technique, an L-1 distance technique, an L-2 distance technique, a Wasserstein metric technique, a Kolmogorov-Smirnov test, an f-divergence technique (e.g. Kullback-Leiber divergence or Hellinger distance), a total variation distance technique, an absolute difference value, or other histogram comparison techniques.
[0039] Furthermore, histogram comparison module 118 can provide a dissimilarity score for two histograms being compared. As an example, the dissimilarity score can correspond to one or more distance values that respectively result from one or more histogram comparison techniques. For example, the dissimilarity score can be a weighted sum of a plurality of distance values respectively obtained using a plurality of histogram comparison techniques. In some embodiments, a smaller dissimilarity score will be provided for pairs of histograms that exhibit a similar distribution while larger dissimilarity score will be provided for pairs of histograms that exhibit divergent distributions.
[0040] Alarm means 120 can be any suitable component or grouping of components for providing an alarm to a user upon detection of a boiling event. As an example, alarm means 120 can include one or more light emitting devices (e.g. LEDs) that illuminate or flash upon detection of the boiling event or one or more speakers for providing an audible alarm upon detection of the boiling event.
[0041] As another example, in some embodiments, alarm means 120 can include circuitry for communicating with the cooktop appliance over a local network to inform the cooktop appliance of the boiling event. In such instance, the cooktop appliance may respond by lowering the temperature setting for the burner associated with the boiling event.
[0042] As yet another example, in some embodiments, alarm means 120 can include circuitry for sending an SMS text message or other form of electronic message (e.g. electronic mail) to a mobile computing device of a user to notify the user of the detected boiling event.
[0043] FIG. 2 depicts a flow chart of an example method ( 200 ) according to an example embodiment of the present disclosure. Although method ( 200 ) will be discussed with reference to system 100 of FIG. 1 , method ( 200 ) can be performed by any suitable system. In addition, FIG. 2 depicts steps performed in a particular order for purposes of illustration and discussion. Those of ordinary skill in the art, using the disclosures provided herein, will understand that the various steps of method ( 200 ) can be omitted, adapted, and/or rearranged in various ways without departing from the scope of the present disclosure.
[0044] At ( 202 ) a frame of imagery depicting a cooktop can be obtained. For example, computing device 104 can obtain a frame of imagery from vision sensor 102 . As an example, FIG. 3 depicts an example depiction of a vision sensor capturing imagery depicting a cooktop according to an example embodiment of the present disclosure.
[0045] Referring again to FIG. 2 , at ( 204 ) a plurality of motion vectors can be determined for the frame with respect to a previous sequential frame. For example, computing device 104 can implement motion vector determination module 114 to determine the plurality of motion vectors for the frame.
[0046] As an example, FIG. 4 depicts an example frame 400 of imagery depicting a cooktop according to an example embodiment of the present disclosure. In particular, frame 400 depicts a pot of water that is not boiling and a human that is moving.
[0047] Furthermore, a plurality of motion vectors are superimposed graphically upon frame 400 . For example, motion vector 402 shows motion of the human arm while motion vector 404 shows motion of the human leg. As can be seen from FIG. 4 , the motion vectors showing human motion in frame 400 are generally relatively large in magnitude and consistent in orientation.
[0048] As another example, FIG. 5 depicts an example frame 500 f imagery depicting a cooktop according to an example embodiment of the present disclosure. In particular, frame 500 depicts a pot of water that is boiling.
[0049] Furthermore, a plurality of motion vectors are superimposed graphically upon frame 500 . For example, motion vector 502 shows motion captured by frame 500 that corresponds to the boiling water. As can be seen from FIG. 5 , the motion vectors showing motion due to boiling water in frame 500 are generally relatively small in magnitude and randomized in orientation.
[0050] Referring again to FIG. 2 , at ( 206 ) one or more histograms can be generated that describe one or more characteristics of the plurality of motion vectors determined at ( 204 ). For example, computing device 106 can implement histogram generation module 116 to generate the one or more histograms.
[0051] As an example, FIG. 6 depicts an example histogram 600 according to an example embodiment of the present disclosure. Histogram 600 describes a distribution of motion vector orientations corresponding to the plurality of motion vectors shown on frame 400 of FIG. 4 , which depicts human motion. In particular, because the motion vectors for frame 400 are relatively consistent in orientation (e.g. showing the arm movement in a first direction and the leg movement in the second direction), the corresponding histogram 600 reflects a disproportionate number of motion vectors at two particular orientations.
[0052] As another example, FIG. 7 depicts an example histogram 700 according to an example embodiment of the present disclosure. Histogram 700 describes a distribution of motion vector orientations corresponding to the plurality of motion vectors shown on frame 500 of FIG. 5 , which depicts a boiling event. In particular, because the motion vectors for frame 500 are relatively randomized in orientation, the corresponding histogram 700 reflects a relatively uniform distribution of motion vector orientations.
[0053] Thus, if a histogram of motion vector orientations shows a significant number of motion vectors clustered about particular orientations, then it may indicate that the corresponding frames of imagery depict human motion. However, if the histogram of motion vector orientations shows a significant number of motion vectors distributed in a relatively uniform manner, then it may indicate that the corresponding frames of imagery depict a boiling event.
[0054] As another example, FIG. 8 depicts an example histogram 800 according to an example embodiment of the present disclosure. Histogram 800 describes a distribution of motion vector magnitudes corresponding to the plurality of motion vectors shown on frame 400 of FIG. 4 , which depicts human motion. In particular, because the motion vectors for frame 400 exhibit relatively large magnitudes, the corresponding histogram 800 reflects a disproportionate number of motion vectors at a particular magnitude having a relatively large value.
[0055] As another example, FIG. 9 depicts an example histogram 900 according to an example embodiment of the present disclosure. Histogram 900 describes a distribution of motion vector magnitudes corresponding to the plurality of motion vectors shown on frame 500 of FIG. 5 , which depicts a boiling event. In particular, because the motion vectors for frame 500 exhibit relatively small magnitudes, the corresponding histogram 900 reflects a disproportionate number of motion vectors at a particular magnitude having a relatively small value.
[0056] Thus, if an histogram of motion vector orientations shows a significant number of motion vectors clustered about a particular magnitude having a relatively large value, then it may indicate that the corresponding frames of imagery depict human motion. However, if the histogram of motion vector orientations shows a significant number of motion vectors clustered about a particular magnitude having a relatively small value, then it may indicate that the corresponding frames of imagery depict a boiling event.
[0057] Referring again to FIG. 2 , at ( 208 ) the one or more histograms generated at ( 206 ) can be respectively compared to one or more pre-learned histograms to determine a dissimilarity score. For example, computing device 104 can implement histogram comparison module 118 to compare the histograms.
[0058] In particular, the one or more pre-learned histograms stored in memory 108 can respectively describe one or more characteristics of a plurality of motion vectors exhibited by frames of imagery depicting a boiling event. For example, in some embodiments, the pre-learned histograms can be generated through testing or analyzing imagery depicting a boiling event. In other embodiments, the pre-learned histograms can be approximations, such as for example, a histogram having a uniform distribution of orientations.
[0059] The dissimilarity score can correspond to one or more distance values that respectively result from one or more histogram comparison techniques. For example, the dissimilarity score can be a weighted sum of a plurality of distance values respectively obtained using a plurality of histogram comparison techniques. In some embodiments, a smaller dissimilarity score will be provided for pairs of histograms that exhibit a similar distribution while a larger dissimilarity score will be provided for pairs of histograms that exhibit divergent distributions.
[0060] At ( 210 ) it can be determined whether the dissimilarity score determined at ( 208 ) is less than a threshold dissimilarity score.
[0061] If it is determined at ( 210 ) that the dissimilarity score is not less than the threshold dissimilarity score, then method ( 200 ) can proceed to ( 212 ) and clear a counter to zero. After ( 212 ), method ( 200 ) can return to ( 202 ) and obtain an additional frame of imagery depicting the cooktop. In such fashion, consecutive frames can be analyzed in an iterative fashion to identify a boiling event. However, the frames used to determine motion vectors at ( 204 ) are not necessarily consecutive in nature. As an example, one frame can be obtained for analysis each second event even though the vision sensor is collecting frames at a higher rate.
[0062] Returning to ( 210 ), if it is determined that the dissimilarity score is less than the threshold dissimilarity score, then method ( 200 ) can proceed to ( 214 ) and increment the counter. For example, computing device 104 can increment the counter 112 .
[0063] At ( 216 ) it can be determined whether the counter value is greater than a threshold counter value. If it is determined at ( 216 ) that the counter value is not greater than the threshold value, then method ( 200 ) can return to ( 202 ) and obtain an additional frame of imagery depicting the cooktop.
[0064] However, if it is determined at ( 216 ) that the counter value is greater than the threshold value, then method ( 200 ) can proceed to ( 218 ) and provide an alarm. In such fashion, a threshold number of consecutive frames of imagery must be classified as depicting a boiling event prior to providing the alarm. The threshold counter value can be adjustable to adjust for detection confidence.
[0065] Providing the alarm at ( 218 ) can include flashing a lighting device, sounding a sound with a speaker, or performing various communications methods or protocols to communicate with a mobile device of the user or the cooktop itself.
[0066] 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 include 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. | Systems and methods for boil detection are provided. One example system includes a vision sensor positioned to collect imagery depicting the cooktop and one or more processors implementing instructions to perform operations. The operations include obtaining a first frame of imagery and a second frame of imagery from the vision sensor. The first frame of imagery and the second frame of imagery respectively depict the cooktop. The operations include identifying a plurality of motion vectors based on the first and second frames of imagery. The operations include generating a histogram describing a characteristic of the plurality of motion vectors. The operations include calculating a dissimilarity score. The dissimilarity score describes a difference between the histogram and a pre-learned histogram. The pre-learned histogram describes the characteristic for imagery depicting boiling liquid. The operations include determining whether a boiling event is occurring at the cooktop based at least in part on the dissimilarity score. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
The present application is a continuation application of, and claims priority to, U.S. patent application Ser. No. 11/986,751, entitled “Biodegradable absorbents and methods of preparation,” filed Nov. 26, 2007 now U.S. Pat. No. 7,858,837, which is a continuation application of U.S. patent application, entitled “Biodegradable Absorbents and Methods of Preparation,” Ser. No. 10/267,823, filed on Oct. 9, 2002, now U.S. Pat. No. 7,309,498, which claims priority to U.S. provisional patent application Ser. No. 60/328,454, filed on Oct. 10, 2001. The disclosures of these copending applications are hereby incorporated by reference herein. The present application claims priority of U.S. provisional patent application No. 60/328,454 filed on Oct. 10, 2001, incorporated herein by reference.
BACKGROUND OF THE INVENTION
The present invention relates to the field of biodegradable hydrophilic nonwoven absorbents and more particularly to microfiber biodegradable absorbents prepared by the electrohydrodynamic method from blends of synthetic biodegradable polyesters and poly (N-vinyl) lactams which can be used for a variety of applications including wounds and burns dressings, drug carriers and for cosmetic applications.
It has been known to use poly (N-vinyl) pyrrolidone (PVP) complexes with polyurethanes to yield hydrophilic materials, which can be used as wound dressings or in cosmetic preparations. For example, U.S. Pat. No. 5,156,601 discloses a dressing, which includes a tacky gel of polyurethane and a poly (N-vinyl) lactam such as PVP. U.S. Pat. No. 5,420,197 describes hydrophilic gels formed by poly (N-vinyl) lactams, such as PVP, and chitosan. U.S. Pat. No. 6,121,375 disclose hydrophilic gel-like materials of PVP and polyaldehyde. Other references of general background interest include U.S. Pat. No. 5,206,322. All these materials are gel-like and non-biodegradable.
Although some of these hydrophilic materials can be used for wound dressings and other surgical and cosmetic applications, many hydrophilic materials known in the arts are hydrophilic gels that are non-biodegradable, and most of them are reversible.
It has also been known to make nonwoven fibrous-porous material on the base of a blend of poly (N-vinyl) pyrrolidone (PVP) and cellulose diacetate in component weight ratio of 1:(4-10) with high porosity and high moisture absorption prepared “in electrostatic field by continuous supply of an electrically charged polymeric solution through a nozzle” (Pat. RU No. 2111300). But this material is nonbiodegradable.
There is also known, Pat. RU No. 2031661, a microfibrous wound-healing remedy used for first and outdoors aid, prepared by the electrohydrodynamic method. The remedy comprises a composition of poly-d.l-lactide, poly (N-vinyl) pyrrolidone and a powdered sorptive material like polysaccharides networks, polyacrylates, cellulose esters or polyvinyl alcohol derivatives. The material could absorb 5-8 g/g water or blood; exhibited haemostatic abilities within 40 seconds and moderate wound healing effects. But introduction of nondegradable or slow degradable components such as polyvinyl alcohol derivatives into this material significantly decreased its biodegradation ability and limited its use for external application.
There is also known, Pat. RU No. 2120306, a totally biodegradable two layer dressing for wounds and burns consisting of a baking thin film layer (25-30 mkm) prepared from copoly (lactide-caprolactone) or copoly (lactide-glycolide) with a lactide/caprolactone or lactide/glycolide ratio of at most 50% w and a wound facing microfiber absorbent layer comprising a polylactide and poly (N-vinyl) pyrrolidone blend with a ratio of polylactide/poly (N-vinyl) pyrrolidone from 90/10 to 70/30 w/w. The microfiber absorbent layer is deposited on the film by the electrohydrodynamic method. The facing microfiber layer may also contain antiseptic, analgesic drugs and proteolysis ferments. The dressings described can absorb water and any biological liquids, including blood, at most 12 g/g and biodegrade within 12-36 days. However the vapor penetration of such dressings is at most 3.1 mg/cm 2 hour which precludes their use as dressings for wounds and burns that exhibit intensive “breathing”, for example, large external fresh burns, bleeding wounds or different kinds of external injuries. Furthermore these dressings have poorly controllable time of degradation, which limits their application in the treatment of wounds and/or burns, and especially in the treatment of internal wounds. Better control over the degradation time is desirable.
There is also known a microfiber biodegradable polylactide web prepared by the electrospinning method from a polymer solution. The polymer concentration is 4-6% w. The voltage is 33-60 kV; the average fiber diameter is about 1 μm (See the article in Proceeding of the ACS, PMSE, p. 115, Mar. 26-30, 2000). But there is no evidence of any hydrophilic or bioactive properties of such a web. According to the article a solution of polylactide in dichloromethane was placed in a syringe. The syringe was positioned with its needle pointing down, The piston of the syringe was moved down with a controlled velocity by a motor. The negative pole was set at the metal capillary of the syringe and the positive pole on the substrate bearing. Paper was used as a substrate.
SUMMARY OF THE INVENTION
Some embodiments of the invention provide dressings, implants, dermatological compatible compositions and drug carrier compositions which include totally biodegradable non-gel materials having water, blood and other biological liquids absorption ability and possessing biological active properties like haemostatic and wound healing acceleration abilities, which are irreversible, retain their contour and shape when wet, and do not exhibit any swelling.
Some embodiments provide totally biodegradable microfiber absorbents on the base of blends of synthetic biodegradable polyesters and poly (N-vinyl) lactams. These materials can be used in a variety of products such as cavity dressings, drug delivery patches, face masks, implants, drug carriers, wound and burn dressings with predictable biodegradation times and controlled absorption of biological liquids including blood, and with variable vapor penetration and controlled drug release for wounds and burns.
Some embodiments provide a method of the totally biodegradable microfiber absorbent preparation.
Some embodiments of the invention provide totally biodegradable microfiber absorbents which can be used for or incorporated into dressing compositions, dermatologicaly compatible compositions, wound packing, wound dressings, burn dressings, living cells like keratinocytes and/or fibroblasts transplants, drug delivery dressings, cosmetic masks, cosmetic wrap dressings, drug carrier compositions. The absorbents may incorporate (e.g. be soaked in) protein containing drug (e.g. insulin) and other drugs. The absorbents of the invention include a blend of synthetic biodegradable polyester and a polymer selected from a group of poly (N-vinyl)-lactams, preferably poly (N-vinyl)-pyrrolidone.
The synthetic biodegradable polyesters useful in preparing the absorbents of the invention include, but are not limited to, homopolymers of L (−), D (+), d, l-lactide, glycolide, caprolactone, p-dioxanon and/or mixtures thereof, copolymers of L (−), D (+), d, l-lactide and glycolide, or caprolactone, or p-dioxanon, or polyoxyethylene glycols, and/or mixtures thereof, or copolymers of glycolide and caprolactone, or p-dioxanon. and/or mixture thereof.
The poly (N-vinyl) lactams useful in preparing the absorbents of the invention include, but are not limited to, homopolymers, copolymers of N-vinyl lactams such as N-vinylpyrrolidone, N-vinylbutyrolactam, N-vinylcaprolactam, and the like, as well as the foregoing prepared with minor amounts, for example, up to about 20 weight percent, of one or more of other vinyl monomers that are capable to copolymerize with the N-vinyl lactams like acrylic monomers or others. Of the poly (N-vinyl) lactam homopolymers, the poly (N-vinyl) pyrrolidone (PVP) homopolymers are preferred. A variety of poly (N-vinyl) pyrrolidones are commercially available.
The absorbent is prepared by the electrohydrodynamic processing of a blend (a melt or a solution) of poly (N-vinyl) lactam and biodegradable polyester. In one embodiment, the blend is a solution at a polyester/poly (N-vinyl) lactam ratio from about 99/1 to about 1/99 w/w, preferably from about 98/2 to about 50/50 w/w.
The present invention provides totally biodegradable absorbents which are capable of absorbing at least 20 w/w in water or blood without swelling, are irreversible and mechanically strong, have predictable biodegradation times, are capable of controlled medication delivery to the body, have a variable water vapor penetration. The materials of the present invention have the unexpected properties such as proper haemostatic properties, enhancing the healing of wounds, especially chronic wounds (e.g., diabetic wounds), ulcers, and proper antiseptics abilities. The dressing compositions of the present invention have the advantage of self-adhesion to the wet skin with easy peelability.
Totally biodegradable absorbents may include at least one additional ingredient, which may be releasable from the absorbent. Preferably, the releasable ingredients are bioeffecting or body-treating substances including various low molecular weight or polymeric drugs for internal or external delivery to the body exactly where desired. Such absorbents may also be used as a transplantable solid support or scaffold for living cells, such as keratinocytes or fibroblasts, growing and applied as a living cell transplant for burns and wounds.
The totally biodegradable hydrophilic nonwoven microfiber absorbents can be prepared by the electrohydrodynamic spinning from a polymer blend solution using 20-120 kV at a gap distance 15-40 cm, preferably 20-40 kV. The initial solution contains a blend of a biodegradable polymer and a poly (N-vinyl) lactam and may also contain different medications for immobilization of the material. It was unexpectedly discovered that by this method the material of the invention could be prepared.
Other benefits will be identified in the following description. The description is not in any way intended to limit the scope of the present invention, but rather only to provide a working example of the preferred embodiments. The scope of the present invention will be pointed out in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic representation of a basic part of an electrohydrodynamic spinning apparatus, which was used to prepare a biodegradable absorbent in one embodiment. The device contains housing 1 , container 2 for a polymer blend solution, power source 3 having one pole connected to a metal capillary electrode 10 . The other pole is grounded. Compressor 4 provides compressed air into container 2 . The compressed air forces the solution out of container 2 and into connecting tube 11 , which conducts the solution into capillary electrode 10 . The solution emerges from the electrode 10 as a jet flying towards the rotating drum 5 . The electrostatic field generated by source 3 in the area between electrode 10 and drum 5 pulls out the solution stream into a thin thread. The solvent evaporates, and the thread becomes a solid fiber. These fibers are deposited on the surface of drum 5 . Drum 5 can be replace with a stationary (non-moving) substrate.
FIG. 2 is a schematic representation of a basic part of modified electrohydrodynamic spinning apparatus, which was used to immobilization for “dry” fine powder drugs including insoluble drugs into a biodegradable absorbent. The device as shown in FIG. 1 is modified by addition of a container 12 for a dry drug powder and of a microcompressor 13 . Compressor 13 provides compressed air into container 12 . The compressed air forces the powder out of container 12 and into connecting tube 14 , which conducts the powder into a ring channel 15 surrounding a capillary electrode 10 . The powder is sprayed towards the grounded surface of the rotating drum 5 and deposited simultaneously with the polymer microfibers or on the surface of a previously prepared microfiber mat.
DETAILED DESCRIPTION
Some embodiments of the invention provide a totally biodegradable hydrophilic nonwoven microfiber absorbents, impermeable to microbes, with variable degradation times and controlled vapor penetration for use in dressing, dressing compositions, drug carrier compositions, wound packing, wound dressings, burn dressings, including first aid dressings, drug delivery dressings, cosmetic mask dressings, cosmetic wrap dressings, cavity dressings for both internal and external applications. Cosmetic applications include skin rejuvenation and wrinkle removal. The absorbent of the invention includes a two-component blend. One component is a synthetic biodegradable polyester with different times of biodegradation selected from a group including, but not limited to, homopolymers or copolymers of L (−), D (+), d, l-lactide with glycolide, or caprolactone, or p-dioxanon, and/or mixtures thereof, or homopolymers or copolymers of caprolactone with L (−), or D (+), or d, l-lactide, or glycolide, or p-dioxanon and/or mixtures thereof, and copolymers of L (−), or D (+), or d, l-lactide, or caprolactone, or p-dioxanon with polyoxyethylene glycols (PEG) and/or mixtures thereof, or homopolymers or copolymers of p-dioxanon. The other component is a poly (N-vinyl) lactam selected from a group including, but not limited to, homopolymers, copolymers of N-vinyl lactams such as N-vinylpyrrolidone, N-vinylbutyrolactam, N-vinylcaprolactam, and the like, as well as the foregoing prepared with minor amounts, for example, up to about 15-20 weight percent, of one or more of other vinyl monomers copolymerizable with the N-vinyl lactams such as acrylic acid, acryl amides or hydroxyalkylacrylates. Of the poly (N-vinyl) lactam homopolymers, the poly (N-vinyl) pyrrolidone (PVP) homopolymers are preferred. A variety of poly (N-vinyl) pyrrolidones are commercially available.
To prepare a material with controlled biodegradation times, the ratio of polyester/poly (N-vinyl) lactam is used in the range from about 99/1 to about 1/99, preferably from about 98/2 to about 50/50 w/w for polylactide, or co (poly-lactide-glycolide) with a lactide/glycolide ratio from about 99/1 to about 50/50. Preferably, the poly (N-vinyl) pyrrolidone is used. Preferably, the molecular weights of the two components are in the range from 3×104 to 50×104 Dalton for polyester and from 0.5×104 to 4×104 Dalton for poly (N-vinyl) pyrrolidone. The biodegradable polyester component may contain caprolactone homopolymers and/or caprolactone copolymers with lactide (or glycolide) with a caprolactone/lactide (or glycolide) ratio from about 1/90 to about 99/1 w/w and with the molecular weights at least 15×10 4 Dalton for the polyester component and the polyester/poly (N-vinyl) pyrrolidone ratio from about 90/10 to about 50/50 w/w. The biodegradable polyester component may contain copolymers of glycolide (or lactide) and p-dioxanon with a glycolide (or lactide)/p-dioxanon ratio from about 50/50 to about 1/99 w/w.
For biodegradation time control, a low molecular weight polylactide or its copolymers with glycolide may be included into the blend in the amount of at least 5-10% w. The lactide/glycolide ratio is preferably 50/50 w/w. The molecular weights of these compounds are at least from 2×103 to 10×103 Dalton. Various low molecular weight or polymeric linear or branched alcohols such as mannitol, sorbitol, etc. or polyoxyethylene glycols (PEG) of different molecular weights, respectively, may be included into the blend in the amount of at least 5-10% w.
The totally biodegradable, hydrophilic unwoven absorbent consists of microfibers at most 0.1-5 μm is irreversible with non-leachable poly (N-vinyl) lactam. The material is capable of unswelling absorption at least 20 w/w in water or blood and/or other biological liquids with high absorption rates without changing the contour or shape of the device. The material is capable of delivering medicaments externally or internally to the body exactly where desired. The material of the present invention has by itself unexpected properties such as a haemostatic property and antiseptics property. The material enhances the healing of wounds, especially chronic wounds (e.g., diabetic wounds) and ulcers and may be applied without any additional medications. The material and its degradation products are biocompatible and don't induce any tissues immune response. The products based on the materials of the present invention have a good mechanical strength and preserve their shape under wet conditions. They can be sterilized by X-ray radiation. Other advantages obtained in some embodiments include softness and compliance with skin surfaces, and self-adhesion to the wet skin but with easy peelability and a variable “breathability”.
To obtain a totally biodegradable, hydrophilic unwoven absorbent, the electrohydrodynamic method for solution spinning can be applied. The method involves spraying the solution of a polymer blend through a capillary nozzle onto a substrate. More particularly, the method consists in providing a stream of compressed air or some other gas through a capillary nozzle, and continuously introducing into the air stream a solution of a blend of a biodegradable polyester and poly (N-vinyl) pyrrolidone or other poly (N-vinyl) lactams in a solvent (e.g. dichloromethane or mixture of ethyl acetate and a lower alcohol. An exemplary concentration of the polymer in the solution is 1-40% w. The voltage between the nozzle and the substrate can be 20-120 kV, preferably 20-40 kV. The negative pole is set at the metal capillary of the nozzle. The substrate is grounded. The gap between the nozzle and the substrate is 15-40 cm. Depending on the voltage, gap value and polymer in the solution concentration, materials of a controlled density and microfiber diameters from 0.1-5 μm can be prepared. After the completion of the process the microfiber unwoven material is removed from the substrate, cut into pieces (for example, squares) and vacuum dried. A finished product is packed and sterilized by γ-radiation by conventional techniques.
The substrate can be either a static surface or a rotating drum as described in Russian patent RU 2121036 (20 Oct. 1998).
FIG. 1 shows a schematic representation of a basic part of an apparatus of electrohydrodynamic spinning which was used for biodegradable absorbent of the invention preparation. The device contains housing 1 , container 2 for polymer blend solution used for spinning, power source 3 connected to metal capillary electrode by one pole with the second pole setting grounded, compressor 4 connected with the container 2 . The solution of a blend of a biodegradable polymer and poly (N-vinyl) lactam in a solvent is providing by a stream of compressed air from compressor 4 through a capillary nozzle with high voltage imposed from the source 3 . A polymer solution jet flowing out of the capillary nozzle in the stream of compressed air under the action of electrostatic field forces is drawing off into at least one ultra thin fiber that is deposited on a grounded substrate surface that can be a rotating drum 5 or non-moving substrate. For apparatus productivity increase the device can be supplied with an additional compressed air source 13 comprising a ring channel 15 surrounding a capillary electrode 10 ( FIG. 2 ).
Materials with a different degree of “breathability” can be obtained through: 1) selection of the microfiber thickness and packing density; 2) electrohydrodynamic microfiber deposition on at least 5-10 μm thick polymeric films of the appropriate breathability. These films can be prepared from biodegradable polymers and copolymers like polylactide, or poly (lactide-co-glycolide) with a lactide/glycolide ratio from about 1/99 to about 99/1, or poly (lactide-co-caprolactone) with a lactide/caprolactone ratio from about 1/99 to about 99/1, polycaprolactone, poly-p-dioxanon or its copolymers with glycolide or lactide with a p-dioxanon/lactide or glycolide ratio from about 1/99 to about 99/1. These biodegradable films, which serve as backing films in such dressings, may be prepared by any conventional methods of polymer processing from either a polymer melt or a polymer solution. A backing film with variable vapor permeability (i.e. breathability) can also be prepared from a mixture of biodegradable polyesters listed above and other biocompatible polymers of various molecular weights like polyoxyethylene glycols in the amount of at least 15% w. The backing film may also improve the mechanical properties of the dressings.
The “breathability” can also be increased by increasing the gap between the nozzle and the substrate if the electrohydrodynamic method is used. The “breathability” is believed to decrease if a higher voltage is used between the nozzle and the substrate. These techniques (gap size and voltage) can be used with or without the backing film. More particularly, in some embodiments, no backing film is present. The absorbent material is formed by the electrohydrodynamic method on a substrate as described above. The substrate can be a rotating drum. After this electrohydrodynamic deposition, the absorbent article is removed from the substrate. The article can be used without any backing film. Non-drum substrates including non-moving substrates, can be used.
The absorbent of the invention may also include at least one additional ingredient, which may be releasable from the absorbent. Preferably, the releasable ingredients are bioeffecting or body-treating substances including different low molecular weight or polymeric drugs for internal or external delivery to the body exactly where desired. Particularly preferred as biologically-active additives are also antimicrobials such as tetracycline, neomycin, oxytetracycline, triclosan, sodium cefazolin, silver sulfadiazine, and also salicylates such as methylsalicylate and salicylic acid, nicotinates such as methyl nicotinate; capsaicin, benzocaine, alpha-hydroxy acids, vitamins and biostats and others, or antioncology active drugs like doxorubicin, toxol and others or insulin, or interferon, or others.
When the material is used for wound and burn healing acceleration, it may contain living human cells like keratinocytes or fibroblasts previously grown on the material as on the solid porous scaffold.
To provide a prolonged and controlled drug release to the surface of internal and/or external wounds or burns, the material may contain two or more microfiber layers. Different layers may have different compositions. Each layer includes the biodegradable polymer with or without poly (N-vinyl) lactam. Different layers may also have different ratios of biodegradable polymer/poly (N-vinyl) lactam or different biodegradable polymers. Different types of polymers and/or copolymers may be used that may have different molecular weights, contain different biocompatible functional groups such as hydroxyl, carboxyl and/or amino groups or contain different additives such as low or high molecular weight alcohols like sorbitol, mannitol, starch, polyoxyethylene glycols, etc. Each layer may include at least one additional bioactive ingredient which may be releasable from the absorbent and which may be immobilized into polymeric matrix as by the electrohydrodynamic method as by conventional methods such as wetting of the material by drug solution.
When the electrohydrodynamic method is used for drug immobilization into an absorbent, the drug can be dissolved in a polymeric blend solution and immobilized using the device shown in FIG. 1 or can be immobilized as dry fine particles by compressed air steam using the modified device shown in FIG. 2 .
For drug delivery systems, the material of the present invention may contain drugs immobilized by the electrohydrodynamics or other methods and then ground into fine particles of a size less than 10 μm. These particles can be used for parenteral drug administration as a suspension in water, or for oral delivery after tableting the particles prepared by conventional compression methods. Tablets for oral drug delivery may also be prepared by conventional methods of tablet compression of the non-ground material with immobilized drugs. For drug carrier usage, the material may be prepared for example from the blend of polylactide and poly (N-vinyl) pyrrolidone, and polylactide molecular weights are at least 5×104 Dalton. The following examples are intended to illustrate but not limit the invention. The claim will serve to define the invention.
In the following examples the preparation of biodegradable absorbents is described, which absorbents can be used as wound and burn dressings, drug carriers and for cosmetic applications. These examples should not be viewed as limiting the scope of the invention. The claims will serve to define the invention.
Example 1
A Biodegradable Absorbent Utilizing Microfibres Containing Poly (Lactide-Co-Glycolide and/or Poly-N-Vinyl) Pyrrolidone with Variable “Breathing” Capabilities
Materials:
Poly (d.l-lactide-co-glycolide) with a lactide/glycolide ratio 70/30 w/w and with an average molecular weight of 150000 Dal and Poly-d.l-lactide with an average molecular weight of 230000 Dal was synthesized by conventional ring-opening polymerization from d.l-lactide and glycolide that were purchased from Russian National Institute of Monomers (Tula, Russia). Poly-(N-vinyl) pyrrolidone with an average molecular weight of 30000 Dal was purchased from a Russian enterprise.
Methods.
1. Solution Preparation.
Poly (d.l-lactide-co-glycolide) (PLGA) was dissolved in ethyl acetate to make a 20% (w/w) solution with solution viscosity 1-2 poise (Solution A) or a 10% (w/w) solution with solution viscosity 0.5 poise (Solution B). Poly-(N-vinyl) pyrrolidone (PVP) was dissolved in ethanol making a 20% (w/w) solution and mixed with the PLGA solution in ethyl acetate at PVP/PLGA ratio of 20/80 (w/w) that was used for the electrohydrodynamic spinning.
2. Microfiber Material Preparation.
The PLGA/PVP solution was filtered to remove mechanical and gel-like impurities and was placed into a container 2 ( FIG. 1 ) and spun into wound dressing materials in the form of microfiber mats, which were collected on the surface of a rotating drum 5 or on a film positioned on the surface of a rotating drum 5 that is used as a substrate. After the completion of the process, the microfiber unwoven material was cut into squares and vacuum dried to remove the solvent residue. The finished product was packed into a polyethylene laminated aluminum foil and sterilized by 2.5 Mrad γ-radiation using a conventional procedure.
3. Measurements of Microfiber Material Properties.
To measure the degree of absorbency, 2 cm 2 strips (0.5×4 cm) of the microfiber mat were cut and weighed (dry weight or DW), The end of the narrow side (0.5 cm side) of the strip was immersed in water or blood and soaked for 10-15 min. The liquid was drained and the strip was weighed (wet weight or WW). The content of water or blood absorbed by the material calculated using the equation:
Water/blood absorbed content=(WW−DW)/DW,g/g
Data on biodegradation times and haemostatic abilities of the material were obtained from in vivo experiments.
Sample 1.
Solution A: (PVP/PLGA in ethyl acetate, 20% PLGA) was spun by the electrohydrodynamic method with 30 kV at 25 cm gap distance L ( FIG. 1 ) for 1 hour. The microfiber thickness was around 1.5-2 μm with a surface density (a coating level) ˜5 mg/cm 2 .
Sample 2.
Solution B: (PVP/PLGA in ethyl acetate, 10% PLGA) was spun by the electrohydrodynamic method with 30 kV at 25 cm gap distance L ( FIG. 1 ) for 1 hour. The microfiber thickness was around 0.5-1 μm with a surface density (a coating level) ˜2.5 mg/cm 2 .
Sample 3.
Solution A: (PVP/PLGA in ethyl acetate, 20% PLGA) was spun by the electrohydrodynamic method with 40 kV at 25 cm gap distance L ( FIG. 1 ) for 1 hour. The microfiber thickness was around 1-1.5 μm with a surface density (a coating level) ˜5 mg/cm 2 .
Sample 4.
Solution A: (PVP/PLGA in ethyl acetate, 20% PLGA) was spun the electrohydrodynamic method with 30 kV at 40 cm gap distance L ( FIG. 1 ) for 1 hour. The microfiber thickness was around 1.5-2 μm with a microfiber surface density (a coating level) ˜3 mg/cm 2 .
Sample 5.
Solution A: (PVP/PLGA in ethyl acetate, 20% PLGA) was spun by the electrohydrodynamic method with 30 kV at 25 cm gap distance L ( FIG. 1 ). Drum 5 was covered by a poly (d.l-lactide) film (backing film) having a thickness of 8-10 μm. The film was formed from 10% w solution of Poly-d.l-lactide in methylene chloride. The microfibers were deposited on the film. The fiber size was around 1.5-2 μm with a microfiber surface density (a coating level) ˜5 mg/cm 2 .
Test results for the materials in Samples 1-5 are summarized in Table 1.
TABLE 1
Physical-chemical and biomedical properties of biodegradable absorbents.
Moisture vapor
Water/Blood
Times of
Sample
penetration,
absorbance,
biodegradation
Microbial
#
Mg/cm 2 hour
g/g
in vivo*, days
penetration
1
5-7
15-20/19-20
3-5
Non penetrable
2
2-3.5
10-15/14-18
3-5
Non penetrable
3
5-7
12-15/16-18
3-5
Non penetrable
4
7-8
12-15/16-18
3-5
Non penetrable
5
2-2.7
15-20/18-20
7-8
Non penetrable
*Visual observation of in vivo degradation of equal square pieces of the material on the surface of fresh clean wounds formed on rat skin.
Example 2
Preparation of Fiber and/or Biodegradable Absorbent with Additional Therapeutic Performance
Sample 1.
Silver sulfadiazine was dissolved under slight heating in ethanol to form a 5% solution and then added to the PLGA/PVP solution described above to yield a 1% silver sulfadiazine concentration in the final material. The solution was spun by the electrohydrodynamic method with 30 kV at 25 cm gap distance L ( FIG. 1 ) for 1 hour. The microfiber thickness was around 1.5-2 μm with a surface density (a coating level) ˜5 mg/cm 2 .
Sample 2.
Silver sulfadiazine in the form of fine particles was placed into container 12 ( FIG. 2 ) and immobilized using a compressed air stream (˜0.5 atm) onto the surface of a just prepared absorbent deposited on a surface of a rotating drum using 30 kV at a gap distance 25 cm.
The invention is not limited by the embodiments described above, For example, in the electrohydrodynamic method, an alternating electric field can be used. Also, solutions can be replaced by melts. Other embodiments are within the scope of the invention as defined by the appended claims. | A biodegradable microfiber absorbent comprises a substantially homogeneous mixture of at least one hydrophilic polymer and at least one biodegradable polymer. The absorbent can be prepared by an electro hydrodynamic spinning of a substantially homogeneous polymer mixture. Medical dressings for burns and wounds, cavity dressings, drug delivery patches, face masks, implants, drug carriers that comprises at least one microfiber electrospun from a polymer mixture are provided. The dressings can have variable water vapor penetration characteristics and variable biodegradation times. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. patent application Ser. No. 10/355,809, entitled “Devices and Methods for Treating Vaginal Delivery PPH”, filed Jan. 30, 2003 which is hereby incorporated by reference in its entirety and from which priority is hereby claimed under 35 U.S.C. § 120.
FIELD OF THE INVENTION
[0002] The invention is generally directed to the treatment of uterine disorders by detecting and regulating blood flow through one or both of the patient's uterine arteries.
BACKGROUND OF THE INVENTION
[0003] Hysterectomy (surgical removal of the uterus) is performed on approximately 600,000 women annually in the United States. Hysterectomy is often the therapeutic choice for the treatment of uterine cancer, adenomyosis, menorrhagia, prolapse, dysfunctional uterine bleeding (abnormal menstrual bleeding that has no discrete anatomic explanation such as a tumor or growth), and muscular tumors of the uterus, known as leimyoma or uterine fibroids.
[0004] However, hysterectomy is a drastic treatment, having many undesirable characteristics. Thus, any method which can approximate the therapeutic result of a hysterectomy without removing the uterus would be a significant improvement in this field. Newer treatment methods have been developed for some diseases which may spare these women a hysterectomy.
[0005] In 1995, it was demonstrated that uterine fibroids could be treated without hysterectomy using a non-surgical therapy, specifically comprising bilateral intraluminal occlusion of the uterine arteries (Ravina et al., “Arterial Embolization to Treat Uterine Myomata”, Lancet Sep. 9, 1995; Vol. 346; pp. 671-672, incorporated in its entirety herein). This technique is known as “uterine artery embolization”. In this technique, uterine arteries are accessed via a transvascular route from a common femoral artery into the left and right uterine arteries by means of an intravascular catheter and embolic material, such as small metallic coils, polyvinyl alchohol particulate and the like, is delivered through the catheter to the uterine arteries which quickly become occluded.
[0006] The uterus has a dual (or redundant) blood supply, the primary blood supply being from the bilateral uterine arteries, and the secondary blood supply from the bilateral ovarian arteries. Consequently, when both uterine arteries are occluded, i.e. bilateral vessel occlusion, the uterus and the fibroids contained within the uterus are both deprived of their blood supply. However, as demonstrated by Ravina et al., the ischemic effects on the fibroid is greater than the effect on the uterus. In most instances, the fibroid withers and ceases to cause clinical symptoms.
[0007] However, many physicians do not possess the training or equipment necessary to perform catheter-based uterine artery embolization under radiologic direction. Accordingly, there are substantially fewer uterine artery embolizations performed, worldwide, each year than hysterectomies for symptomatic uterine fibroids.
[0008] Recently, fibroid treatment procedures have been described wherein the uterine arteries are temporarily occluded by an intravaginal device which is non-invasively pressed against the patient's vaginal fornix and clamped or otherwise pressed against tissue bundle with the patient's uterine artery being within the bundle. Pressure on the tissue occludes the underlying uterine artery. While these procedures have shown much promise, in many situations the devices described to date do not always allow for accurate placement of the clamping surfaces.
[0009] What is needed, therefore, are devices and methods to detect blood vessels and blood flow in blood vessels, and devices and methods to occlude blood flow in blood vessels such as the uterine arteries that can be used by physicians with limited training and equipment.
SUMMARY OF THE INVENTION
[0010] The invention is directed to a relatively non-invasive uterine artery occlusion device and system and the procedure for using the device and system for occluding a female patient's uterine artery. The instruments and their use may be utilized in the treatment of uterine fibroids, dysfunctional uterine bleeding, post partum hemorrhage and other uterine disorders by reducing or terminating blood flow through a patient's uterine artery.
[0011] A device embodying features of the invention includes an intrauterine clamp which has a pressure applying or clamping member configured to apply pressure against the exterior of the patient's uterine cervix or against the patient's vaginal fornix. The intravaginal clamp also has a stabilizing or positioning member which is configured to be inserted into the patient's uterine cervix so as to stabilize at least a portion of the interior of the uterine cervix and facilitate the more effective application of pressure by the pressure applying member to the exterior of the cervix or the vaginal fornix to ensure effective occlusion of the patient's uterine artery. The uterine artery occlusion is temporary, and may be partial or complete.
[0012] One method of occluding a blood vessel comprises clamping the blood vessel effective to compress it so that blood flow through the vessel is reduced, or is abolished. Such clamping of a blood vessel may be direct or may be indirect. Preferably, clamping of a blood vessel effective to compress it is accomplished by applying a non-invasive blood vessel occlusion device to tissue near to a blood vessel (e.g., onto tissue surrounding the vessel). A blood vessel occlusion device may also be applied directly onto a blood vessel effective to compress the blood vessel.
[0013] In one embodiment of the invention, a non-invasive blood vessel occluding device (such as a clamp with a sensor) may be applied to a portion of a vaginal wall to detect and/or locate, and to occlude the uterine arteries. A vaginal clamp embodying features of the invention may used to sense the location of a uterine artery adjacent a vaginal wall, and may be used to compress and occlude a uterine artery adjacent a vaginal wall. The vaginal wall may be distended by an occlusion device so as to more closely approach a uterine artery; such an approach may aided by applying pressure or force to the uterus (e.g., by pulling on the uterine cervix). A uterine cervix may be grasped or pulled by any suitable device or implement, including forceps, suction devices, and other instruments, such as a tenaculum.
[0014] A non-invasive blood vessel occluding device embodying features of the invention may be a non-invasive intravaginal uterine artery occlusion device, comprising a pair of pressure-applying members having opposed tissue-contacting surfaces on distal portions thereof; at least one supporting shaft extending from a proximal extremity of at least one of the pressure-applying members which is configured to adjust the distance between the opposed tissue-contacting surfaces of the pressure-applying members; and at least one blood flow sensing sensor on one of the opposed tissue-contacting surfaces. An embodiment of a non-invasive blood vessel occlusion device embodying features of the invention may have, for example, a handle, a clamping member configured to apply pressure or force to body tissue, and a sensor for locating a blood vessel.
[0015] A pressure-applying member, such as a clamping member, may be, e.g., a jaw or jaws configured to engage a blood vessel or to engage tissue adjacent a blood vessel. A supporting shaft, such as a handle, is preferably configured for manipulating the jaw or jaws. In some embodiments of devices having features of the invention, a pressure-applying member may be attached to a connecting portion that is configured so that a jaw may be placed within a vagina while a handle remains outside a patient's body and available for use by an operator.
[0016] The clamping member is preferably provided with a blood flow sensor for locating the blood vessel to be occluded. The sensor may sense sound, pressure, strain, stress, chemical entity, electromagnetic radiation and the like, and may be a combination of such sensors. A sensor is preferably a Doppler ultrasound sensor. The sensor is mounted to the face of a tissue-contacting surface of the clamping member, such as the face of a jaw of a clamp, and is preferably oriented perpendicularly to the clamp face, although other orientations may be employed. Ultrasound energy useful for sensing a location of a blood vessel or of blood flow in a blood vessel has a frequency of less than about 20 MegaHertz (MHz), such as between about 5 MHz and about 19 MHz, and preferably between about 6 MHz and about 10 MHz. In commercially available Doppler sensors the frequency is typically about 8 MHz. For sensors based on electromagnetic energy useful for sensing a location of a blood vessel or of blood flow in a blood vessel, the EM energy should have a wavelength of about 500 nanometers (nm) to about 2000 nm, preferably about 700 nm to about 1000 nm.
[0017] A system embodying features of the invention includes an blood vessel occluding device as described above with a blood flow sensor on the clamping member for locating the target blood vessel, and a sensor controller which may include an energy source for the sensor. The sensor controller may be configured to aid in detecting a location of a blood vessel, by, e.g., providing a signal related to the output of a sensor that may be readily used by an operator. A sensor controller may include an energy source configured to provide energy for operating a blood flow sensor.
[0018] A method for occluding a uterine artery which embodies features of the invention include advancing the clamping device through the patient's vaginal canal, guiding the stabilizing member of the clamping device through the cervical os, into the cervical canal with the clamping member spaced from the stabilizing member so that the pressure applying surfaces of the clamping member is pressed into the patient's vaginal fornix. Adjustment of the clamping member allows the sensor on the distal end thereof to locate the uterine artery a short distance from the surface of the vaginal fornix. With the clamping member adjacent to the target blood vessel, the clamping device can be closed to compress underlying tissue and thereby occlude the uterine artery. The uterine artery is located with the blood flow sensor on the distal end of the clamping member. Tension may be applied to the uterine cervix with a grasping implement (e.g., by pulling on the uterine cervix) while applying force or pressure to a vaginal wall to occlude a uterine artery.
[0019] The invention allows for the non-surgical location and occlusion of blood vessels such as the uterine artery, providing effective therapeutic treatment. Importantly, the present invention allows for the occlusion of a female patient's uterine artery without the need for radiographic equipment or for extensive training in the use of radiographic techniques. The devices and methods are simple and readily used for treating uterine fibroids, dysfunctional uterine bleeding (DUB), adenomyosis, post-partum hemorrhage, and other uterine disorders. The devices, systems and methods embodying features of the invention allow for the separate occlusion of individual uterine arteries which provides effective therapy in those situations in which the uterine anatomy will not allow for the use of a single bilateral artery occlusion device.
[0020] These and other advantages will become more apparent from the following detailed description when taken in conjunction with the accompanying exemlary drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] [0021]FIG. 1 is an elevational view of a uterine artery clamping device embodying features of the invention in an open configuration.
[0022] [0022]FIG. 2 is a perspective view of the clamping device shown in FIG. 1.
[0023] [0023]FIG. 3 is an enlarged perspective view of the distal portion of an alternative clamping device having a serrated surface and a plurality of teeth to grasp tissue.
[0024] [0024]FIG. 4 is an enlarged perspective view of an alternative clamping device in which the clamping element and the stabilizer element are provided with teeth to grasp tissue.
[0025] [0025]FIG. 5 is a schematic illustration of the intrauterine clamp in position to occlude a female patient's uterine artery.
[0026] [0026]FIG. 6 is a perspective view of an alternative embodiment in which the clamping element and the stabilizing element are angled with respect to the handles of the clamp.
[0027] [0027]FIG. 7 is a perspective view of an alternative embodiment in which the spacing between the stabilizing member and the clamping member is adjusted by a spring coil.
[0028] [0028]FIG. 8 is perspective view of an alternative embodiment in which the spacing between the stabilizing member and the clamping member is adjusted by a rack and pinion arrangement.
DETAILED DESCRIPTION OF THE INVENTION
[0029] [0029]FIGS. 1 and 2 show a relatively non-invasive intra-uterine occluding clamp 10 embodying features of the invention. The clamp 10 includes a clamping member 11 having an elongated handle 12 with a finger grip 13 , and pressure-applying clamping element or jaw 14 on the distal end of the clamping element. The intra-uterine clamp also includes stabilizing member 15 which is configured to readily follow or track the patient's cervical os and cervical canal. The stabilizing member 15 has an elongated handle 16 with a finger grip 17 . The clamping member 11 and stabilizing member 15 are pivotally connected to each other at pivot point 18 and rotation of handles 12 and 16 , preferably by fingers of an operator's hand engaged through grips 13 and 17 respectively, adjust the spacing between the jaw 14 and the distal portion of stabilizing member 15 . Each of the handles 12 and 16 are provided with a ratchet member 19 and 20 respectively which interact to lock the relative positions of the clamping member 11 and the stabilizing member 15 .
[0030] A uterine artery clamp embodying features of the invention is preferably provided with a blood flow sensor 22 , preferably a Doppler ultrasonic sensing system, on the leading surface of the jaw 14 . This sensor location allows the operator to more easily guide the jaw 14 to the location of the patient's target uterine artery. Sensor 22 is provided with a signal transmission cable 23 which is operatively connected to sensor control device 24 . Cable 23 may be an insulated wire, plurality of wires, optical fiber, waveguide, or other connection effective to carry signals and/or energy or power between a sensor 22 and sensor controller 24 .
[0031] Sensor 22 may be a blood flow sensor for locating a blood vessel, and may be a passive sensor, configured to detect intrinsic signals indicating the presence of a blood vessel (i.e., a sound sensor, a motion sensor, a pH sensor, or other sensor configured to detect a physical, chemical, electrical, or physiological indication of the location of a blood vessel). In other embodiments, a blood flow sensor for locating a blood vessel may be an active sensor, configured to emit energy or a signal, and configured to detect signals in response to, or derived from, the emitted energy or signal indicating the presence of a blood vessel (i.e., a source of ultrasound having an ultrasound sensor configured to detect ultrasound reflections from a blood vessel, a source of infrared radiation configured to detect reflections from a blood vessel, or other source of energy and a sensor configured to detect a response indicating the location of a blood vessel). The operation of a sensor may be aided by an energy source such as the sensor controller 24 . For example, an energy source may provide electrical energy which aids an ultrasound sensor to produce and to detect ultrasound energy (as, e.g., in the MedaSonics® CardioBeat® Blood Flow Doppler with Integrated Speaker (Cooper Surgical, Inc., Trumbull Conn. 06611)). Other commercially available Doppler ultrasound sensors suitable for use in the present invention include the Koven model ES 100X MiniDop VRP-8 probe (St. Louis, Mo.) and the DWL/Neuro Scan Medical Systems' Multi-Dop B+ system (Sterling, Va.).
[0032] As shown in FIG. 3 jaw 14 may be provided with a serrated, tissue-grasping surface 25 configured to engage and hold onto tissue when jaw 14 is pressed into tissue of the patient's vaginal fornix. As shown in FIG. 4, one or both of the jaw 14 and/or stabilizer 15 may have retractable fingers or teeth 26 to better secure the contacting members to the target tissue.
[0033] [0033]FIG. 5 illustrates an alternative embodiment wherein the clamping member 11 and the stabilizing member 15 are oriented at an angle θ with respect to the handles 12 and 16 . The angulation provides a more direct attack angle to facilitate insertion of the stabilizing member 15 into the patient's cervix and direction of the jaw 14 toward a desired location at the patient's vaginal fornix to facilitate location and occlusion of the patient's uterine artery. Suitable angulation θ of the jaw 14 and stabilizer 15 is about 100° to about 175°, preferably about 130° to about 160°.
[0034] Closure of a blood vessel, which may be partial or total, is effected by pressure applied through the wall of the patient's vaginal fornix. Sufficient pressure or force applied to the tissue of the vaginal wall to compress and to at least partially occlude the underlying uterine artery. The blood flow sensor for detecting or locating the uterine artery should be disposed on the leading face off the clamping element and generally perpendicular to the tissue-contacting surface of a jaw 14 to be effective.
[0035] A non-invasive blood vessel occluding device embodying features of the invention may be configured to lock into a clamping position. Such a locked configuration may be temporary and releasable, or may be permanent. Non-invasive blood vessel occluding devices embodying features of the invention may have a locking mechanism, such as a ratchet, configured to hold at least one pressure-applying member in a pressure-applying position. Such locking mechanisms may include a release mechanism effective to allow the cessation of pressure or force application when desired. Thus, a non-invasive blood vessel occlusion device embodying features of the invention may be configured to release a locking mechanism effective to relieve the occlusion of a blood vessel by ending the application of pressure or force that had been previously applied to occlude a blood vessel.
[0036] The uterine arteries in human females are located adjacent the vaginal mucosa at a location within a few centimeters (cm) of the vaginal fornix. As a result, for accessing and occluding a uterine artery from within the patient's vaginal canala, the dimensions of a vagina determine what size clamping device is suitable, taking into consideration that the clamping device should readily reach the vaginal fornix and be operated from outside of a patient's body. For example, a clamping device may be between about 5 to about 16 inches in length, preferably between about 6 inch to about 12 inches in length for most applications.
[0037] [0037]FIG. 6 schematically illustrates in part a human female reproductive system, including a uterus 30 , uterine cervix 31 , uterine artery 32 , vaginal canal 33 and vaginal fornix 34 . A method of using the uterine artery clamp embodying features of the invention includes introducing the clamp 10 into the patient's vaginal canal 33 and advancing the clamp therein until the distal portions of the clamp are adjacent to the patient's uterine cervix 31 . The position of the handles 12 and 16 are adjusted to increase the spacing between the jaw 14 and the distal portion of the stabilizer 16 . The distal end of the stabilizer is guided through the cervical os 35 into the uterine cervix. The distal end of jaw 14 is urged against the vaginal fornix 34 and 14 . With the guidance of the Doppler sensor 22 , the pressure applying surface of the jaw is positioned as close as possible to the patient's uterine artery 32 . Sufficient pressure is applied to the uterine artery 32 or the tissue surrounding the uterine artery by jaw 14 to facilitate occlusion of the uterine artery. The handles 12 and 16 are locked by ratchet members 19 and 20 to press the jaw 14 against the tissue between the jaw 14 and the stabilizer 15 . The clamped position is maintained for about 0.5 to about 48 hours, preferably about 1 to about 24 hours for effective therapeutic treatment of a uterine disorder, e.g. for fibroids, PPH, DUB and the like. Blood flow sensor 22 is effective to locate uterine artery 48 by detecting blood flow and monitoring the treatment by detecting the lack of blood flow in the artery. Blood flow in the left uterine artery 50 may be similarly occluded, by a separate uterine artery clamp of the same design or the same clamp can be used on the other side after release of the occlusion of the right uterine artery 34 .
[0038] The ratchet members 19 and 20 are preferably releasable so that clamping member 11 of clamping device 10 can be released after the limited treatment time to re-establish blood flow to the uterine tissue.
[0039] [0039]FIGS. 7 and 8 illustrate alternate clamp design wherein the spacing between the jaw 14 and stabilizer 15 is controlled by a spring 40 as shown in FIG. 7 and a rack and pinion mechanism 50 as shown in FIG. 8. A variety of other means may be employed to open and close the jaw 14 and stabilizer 15 .
[0040] Uterine artery clamp 10 embodying features of the invention may be made from any suitable material or combination of materials, including metals such as stainless steel and superelastic shape memory alloys such as nickel titanium alloys having a stable austenite phase at body temperature, high strength plastics, ceramics, and other materials known in the art. Biocompatible polymers such as polycarbonate, polysulfone, polyester, polyacetal and a variety of fluoropolymers can be suitable for a variety of embodiments of the invention. The device or system may be designed for single use (disposable) or may be sterilizable and capable of multiple use.
[0041] While particular forms of the invention have been illustrated and described, it will be apparent that various modifications can be made to the invention and that individual features shown in one embodiment can be combined with any or all the features of another embodiment described herein. Accordingly, it is not intended that the invention be limited to the specific embodiments illustrated. It is therefore intended that this invention be defined by the scope of the appended claims as broadly as the prior art will permit. Terms such as “element”, “member”, “device”, “sections”, “portion”, “section”, “steps” and words of similar import when used herein shall not be construed as invoking the provisions of 35 U.S.C. § 112(6) unless the following claims expressly use the terms “means” or “step” followed by a particular function without specific structure or action. | The invention is directed to a uterine artery clamp and the relatively non-invasive treatment procedure utilizing this clamp. The uterine clamp includes a clamping member having a jaw with tissue-contacting surfaces for applying pressure to target tissue and a stabilizing member which is configured to be inserted into the patient's uterine cervical canal. The clamp may be provided with elongated handles to manually adjust the spacing between the jaw and stabilizer and thereby apply pressure to a uterine artery beneath a bundle of tissue held between the jaw and stabilizer. Uterine clamps embodying features of the invention by be used in procedures for treating uterine disorders such as fibroids, DUB, PPH and the like. | 0 |
This application claims priority to German Patent Application DE10309910.7 filed Mar. 7, 2003, the entirety of which is incorporated by reference herein.
BACKGROUND OF THE INVENTION
This invention relates to a shut-off system for the avoidance of an overspeed condition in the event of a shaft failure, in particular for the interruption of the fuel supply of an aircraft engine in the event of a failure of the low-pressure turbine shaft, with the energy-consuming end of the respective shaft being connected to a coaxial reference shaft.
In particular on aircraft engines, but also on turbomachines in general, a shaft failure, especially a failure of the low-pressure turbine shaft, constitutes a considerable hazard to persons and property. In the event of a failure of a turbine shaft, the energy-generating end of the shaft, i.e. the part of the shaft which is connected to the turbine rotor, will run up in an uncontrolled manner since it is now disconnected from the energy-consuming end of the shaft. Consequently, the engine and/or the aircraft may be damaged or destroyed.
Various devices for the mechanical and/or electronic detection of a shaft failure and for the subsequent interruption of the energy supply (fuel supply) to avoid an overspeed condition and its negative consequences are known. Here, it is crucial that a shaft failure is detected as early as possible and the engine is shut off instantly by interruption of the fuel supply.
In an electronic device for the detection or avoidance of an overspeed condition known from Patent Specification U.S. Pat. No. 4,712,372, two inductive sensors are arranged on the toothed turbine shaft, i.e. on the energy-consuming end and on the energy-generating end, which produce a speed-proportional signal corresponding to the number of pulses counted. If a speed difference resulting from an increase of the speed of that part of the shaft which is connected to the turbine rotor, and thus a shaft failure, is detected, a solenoid fuel valve will be actuated and the fuel supply interrupted, avoiding further acceleration of the turbine rotor. However, the electronic shut-off systems are critical in that their response times are relatively long. For safety reasons, relatively long shut-off times require a higher material input in the area of the turbine which, in turn, leads to an increase in weight.
Furthermore, mechanical devices are described in which a reference shaft is coaxially associated to the turbine shaft and connected to the forward, energy-consuming end of the turbine shaft. In the event of a shaft failure, the resultant rotation of the turbine shaft relative to the reference shaft is used to mechanically actuate the fuel shut-off valve. In a known mechanical device of this type for the control of overspeed conditions in the event of a failure of the low-pressure turbine shaft connecting the low-pressure turbine and the fan of an aircraft engine, recesses are provided on the rear ends of both shafts. In the event of a shaft failure, the low-pressure turbine shaft will rotate relative to the reference shaft and the—initially offset—recesses in both shafts will come into coincidence, as a result of which a pre-loaded driver provided on the low-pressure turbine shaft will swing out radially and engage a wire loop provided at the end of a wire rope. The pull exerted on the wire rope is transmitted to a fuel shut-off valve to close it, thus limiting the overspeed condition by interrupting the fuel supply. The known mechanical devices using a reference shaft are disadvantageous in that their response depends on a comparatively large angle of relative rotation between the turbine shaft and the reference shaft. Also, the purely mechanical design of the shut-off system, and, in particular, the wire rope connection between the turbine shaft and the fuel shut-off valve, incurs high design effort and is susceptible to wear.
BRIEF SUMMARY OF THE INVENTION
In a broad aspect, the present invention provides for a development of the known mechanical shut-off systems using a reference shaft to enable a shaft failure to be detected instantly and a resultant overspeed condition to be avoided or controlled rapidly.
It is a particular object of the present invention to provide solution to the above problems by a shut-off system designed in accordance with the features described herein. Further objects and advantages of the present invention become apparent from the description below.
The idea underlying the present invention is that, on the basis of a minor rotation of the main shaft relative to the reference shaft, a pre-loaded, axially movable signal trip element is released and moved with high acceleration and by a short route towards a sensor or electric switch mounted on the turbine casing, so that the distance change to an inductive, capacitive or similar sensor or the interruption of a light beam or a switch actuated by the signal trip element provides an electric signal by which the energy supply to the energy-generating end (driving end) of the respective shaft is interrupted via an electronic circuit. The signal trip element, which is held by means of an arrangement of radially protruding driver pins and latches, is released by drivers which are arranged immediately adjacent to the driver pins and extend from the main shaft.
In accordance with a further feature of the present invention, the signal trip element is a piston including a piston rod and a piston plate which is axially movable within a housing of the reference shaft and interacts with at least one pressure spring. The housing is located in a locating sleeve which extends from the main shaft and from which the drivers engaging the driver pins of the piston plate protrude radially inwards.
This form of a mechanical-electronic shut-off system combines simplicity of design and functional reliability. However, its major advantage lies in the fact that it enables a shaft failure to be detected instantly, if necessary as early as in the fracture initiation phase, and an electric signal for the electronically controlled interruption of the further energy supply to be generated immediately, thus avoiding, or at least limiting, a dangerous overspeed condition. In contrast to the known safety systems, significantly reduced signal trigger times and thus fuel supply shut-off times are obtainable which range, in the present case, between 1 and 3 milliseconds, this enabling the risk and extent of damage to be reduced, the safety-relevant dimensions of the engine rotors to be decreased and, thus, weight to be saved.
The functional reliability of the overall system results from the fact that all components for the release and movement of the signal trip element and for the production of the electric signal for the electronic control are, or can be, provided redundantly.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention is more fully described in the light of the accompanying drawings showing embodiments and favorable developments and advantageous objects thereof. In the drawings,
FIG. 1 is a partial view of a gas turbine engine in the area of the low-pressure turbine rotor, with a mechanical-inductive shut-off system for the fuel supply in the event of a shaft failure associated with the low-pressure turbine shaft,
FIG. 2 is a detailed representation of the mechanical-inductive shut-off device as per FIG. 1 ,
FIG. 3 is a developed partial view of the mechanical part of the shut-off device in the direction of arrowhead A in FIG. 2 ,
FIG. 4 is a section along line BB in FIG. 2 ,
FIG. 5 is a circuit arrangement associated with the mechanical-inductive shut-off device for the electronically controlled interruption of the fuel supply,
FIG. 6 is a sectional view of another embodiment of the shut-off device, here with mechanical-optical trigger of the electronically controlled shut-off process upon failure of the low-pressure turbine shaft, and
FIG. 7 is a sectional view of a further embodiment of the shut-off device, here with mechanical-electrical trigger of the electronically controlled shut-off process.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a partial view of a gas turbine engine in the area of the low-pressure turbine rotor 4 . As FIG. 1 shows, a reference shaft 2 is arranged coaxially with the low-pressure turbine shaft 1 and is positively connected to the forward end (energy-consuming end) of the low-pressure turbine shaft 1 (not shown). At the rear end of is the low-pressure turbine shaft 1 , a bearing support 3 and the low-pressure turbine rotor 4 are arranged. A locating sleeve 6 provided on a mounting flange 5 of the low-pressure turbine rotor 4 houses the mechanical part of the shut-off system, this mechanical part being firmly connected to the reference shaft 2 . Axially opposite of the locating sleeve 6 , a mounting plate 8 with a threaded-on sensor pad 20 is installed on the turbine exit casing 7 on which inductive sensors 21 are arranged which inductively detect a shaft failure registered by the mechanical part of the shut-off system and from which connecting lines 22 lead to an electronic control 24 which is electrically connected to a power supply 25 and the fuel shut-off valve 23 (cf. FIG. 5 ).
The mechanical part of the shut-off system, as becomes apparent from FIG. 2 , in particular, comprises a housing 9 which is attached to the reference shaft 2 on one side and located in the locating sleeve 6 connected to the low-pressure turbine shaft 1 on the other side, the housing 9 featuring a piston guide 10 and locating bushes 11 which each accommodate a mechanically pre-loaded pressure spring 12 as the force-exerting item in the event of a shaft failure. In the piston guide 10 , a piston rod 13 is axially and rotatably moveable which carries, at the end face which is downstream in the direction of flow 15 , a piston plate 14 (signal trip element) which is loaded by the pressure springs 12 and, at the end face which is upstream in the direction of flow 15 , a stop bolt 16 which limits the axial movement of the piston plate 14 in the direction of flow. The piston rod 13 and the piston plate 14 can be made of metal, plastic or a composite material, for example carbon fiber, or of a combination of light materials and metal. As becomes apparent from the developed view A in FIG. 3 , in particular, two, or another number of radial, cylindrical driver pins 17 are formed onto the circumference of the piston plate 14 which, together with the corresponding latches 18 provided on the housing 9 , retain the piston plate 14 in the spring-energized initial position. Rotary drivers 19 are formed onto the locating sleeve 6 which are spaced from the cylindrical driver pins 17 at a certain rotary angle. As already mentioned, inductive sensors 21 are arranged opposite of the piston plate 14 and connected to the fuel shut-off valve 23 via the electronic control and the power supply 25 for the inductive detection of a shaft failure and the subsequent interruption of the fuel supply.
The above-described device for the mechanical-inductive detection of a shaft failure and the electronic shut-off of the energy supply to the low-pressure turbine shaft functions as follows.
In the event of a failure of the low-pressure turbine shaft 1 , in which no torque is transmitted to the low-pressure compressor (energy-consuming side), but the low-pressure turbine rotor 4 is still subject to the energy of the core engine flow, a relative rotary movement (relative rotation) between the part of the low-pressure turbine shaft 1 (energy-generating end) which is connected to the low-pressure turbine rotor 4 and the reference shaft 2 will occur. At a certain rotary angle shift of the low-pressure turbine shaft 1 relative to the reference shaft 2 , the drivers 19 formed onto the locating sleeve 6 will, due to the rotation of the locating sleeve 6 in the direction of arrowhead 26 , engage the cylindrical driver pins 17 on the piston plate 14 . The piston plate 14 is now co-rotated by the drivers 19 in the direction of arrowhead 26 and disengaged from the latches 18 retaining the piston plate 14 in its axial position. The piston plate 14 , which is now freely moveable in the axial direction, is accelerated in the direction of the inductive sensors 21 by the action of the pressure springs 12 . The change in distance between the piston plate 14 and the inductive sensors 21 generates electric signals in the sensors 21 which are transmitted to the electronic control 24 to interrupt the fuel supply via the fuel shut-off valve 23 .
In contrast to the known electronic and mechanical systems for the shut-off of the fuel supply in the event of a shaft failure, significantly shorter signal trip times and shut-off times, which here lie in the range of 1 to 3 ms, can be achieved since the rotary angle required for the release of the piston plate 14 is reached rapidly and the travel of the quickly accelerated piston plate 14 for the tripping of the electric signals is very short. Consequently, the disks of the low-pressure turbine rotor 4 can be designed significantly smaller so that appreciable weight savings are achieved. Since the initiation of the shut-off process is independent of the angular position of the low-pressure turbine shaft 1 relative to the engine and, therefore, the supply of fuel is inhibited at the earliest possible time, the further fuel supply can, in the most favorable case, be interrupted already upon fracture initiation at the low-pressure turbine shaft 1 , thus minimizing engine damage. Furthermore, the shut-off system is of simple, space-saving and lightweight design and works nearly wear-free. The proposed shut-off system also lends itself for the retrofitting of gas turbines.
The mechanical part and the electric signal-producing part of the shut-off system are, however, not limited to the present embodiment. For example, the cylindrical driver pins 17 , the latches 18 and the drivers 19 , as well as the pressure springs 12 and the sensors 21 , can be provided redundantly. Similarly, the pressure spring 12 can be arranged centrally in the housing 9 . In lieu of the pressure springs 12 , other media acting upon the piston plate 14 , for example gas pressure, can be applied.
Further forms of signal production for the electronic control 24 are possible. For example, capacitive, optical or ultrasonic sensors can also be used or the electric signal for the electronic control 24 for shutting the fuel shut-off valve 23 can be provided by a switch which, actuated by the piston plate 14 , closes (or opens) an electric circuit.
FIG. 6 shows a further embodiment in which the inductive sensors are replaced by an optical transmitter 27 and an optical receiver 28 arranged such on the mounting plate 8 that the electric signal required for the electronic control 24 is produced when, upon shaft failure, the piston plate 14 is released and moved rearwards interrupting the optical path between the optical transmitter 27 and the optical receiver 28 . Here as well, several pairs of optical transmitters and receivers can be provided for redundancy.
In a further embodiment shown in FIG. 7 , the electric signal for the electronic control 24 is produced by means of an electric switching device, with the mechanical shut-off mechanism remaining unchanged. In this case, a switch housing 29 is integrated in the mounting plate 8 in which a switching cylinder 30 is axially moveable. The switching cylinder 30 , which features a flat tip 31 facing the piston plate 14 and locating pins 38 as anti-rotation elements, is provided on its circumference with a forward and a rearward locating groove 32 and 33 . A radial hole 34 is provided in the switch housing 29 in which a locking element consisting of a locating ball 36 loaded by a spring 35 is arranged. The spring 35 is retained by a screw 37 . In the rearward area of the switching cylinder 30 , a metallic or other type of conductive material conductor 40 is provided on an insulator 39 whose surface is flush with the surface of the switching cylinder 30 . A switch 41 of electrically non-conductive material associated with the switch housing 29 features two contact pins 42 which act upon the periphery of the switching cylinder 30 under the force of a spring 44 retained by a screw 43 . The enclosure of the switch 41 is sealed to the switching cylinder 30 by means of sealing rings 45 . In the initial position of the switching cylinder 30 illustrated in FIG. 7 (with the low-pressure turbine shaft 1 intact), the locating ball 36 is forced into the rear locating groove 33 under spring force and the forward contact pins 42 a touch the electrical conductor 40 . If the low-pressure turbine shaft 1 fails, the piston plate 14 will be accelerated rearwards in the manner described above, hitting the flat tip 31 of the switching cylinder 30 and forcing the switching cylinder 30 rearwards until the locating balls 36 engage the forward locating groove 32 . Both the forward contact pins and the rearward contact pins, 42 a and 42 b , now rest on the electrical conductor 40 . The electric signal produced by the electrical connection so created is fed via the connecting line 22 to the electronic control 24 for the actuation of the fuel shut-off valve 23 . According to the embodiment shown in FIG. 7 , two pairs of contact pins 42 a , 42 b , each with two insulators 39 , two electrical conductors 40 , two locating balls 36 and two locating pins 38 are provided. For reasons of functional reliability, these items can also be arranged redundantly, or several switches using other operating principles, if applicable, can be provided on the periphery of the switching cylinder 30 . | A mechanical-electronic shut-off system detects a shaft failure and initiates the shut-off of the fuel supply. It features, on the free end of a reference shaft ( 2 ) connected the to energy-consuming end of the respective shaft ( 1 ), an axially moveable signal trip element ( 13, 14 ) held under pre-load ( 12 ) whose locking arrangement ( 17,18 ) is released via a radial driver arrangement ( 17, 19 ) by rotary movement in the event of a shaft failure. The resultant relative rotation of the shaft ( 1 ) enables the signal trip element to move towards a sensor ( 21 ) or a switching element. An electric signal so produced instantly interrupts the further supply of fuel by means of an electronic control and avoids or controls a dangerous overspeed condition of the failed shaft. | 5 |
This is a division of application Ser. No. 11/345,175 filed Feb. 2, 2006.
FIELD OF THE INVENTION
This invention relates to a common use helicopter platform or parent vehicle designed to integrate with a variety of different modular cabins. The individual cabins, equipped and configured for different roles, all integrate with the parent vehicle for air transportation. This helicopter design improves safety, economics, versatility and operations.
BACKGROUND OF THE INVENTION
Helicopters are typically configured to perform specific roles such as troop transportation, cargo transportation, assault, medical evacuation, surveillance, AWAC, rescue, firefighting, construction, etc. Military helicopters are often designed with interior accessories to accommodate passengers and/or cargo. Various attachments are available to mount weapons, equipment, hoists, etc. It would be desirable for one common parent vehicle comprising the rotors, engines, fuel and aircraft systems to mate with a family of various aircraft cabins configured for specific roles and missions.
Denton Delong, in U.S. Pat. No. 5,190,250 depicts an Autonomous, Heliborne-Mobile, Construction/Emergency Pod System (AHP) which attaches to a helicopter's external stores support station. The AHP system includes a Dual Cable Winch and Rack (DCWR) assembly to secure, lower and raise the AHP. The AHP contains construction and/or rescue equipment and a self-contained power source. The DCWR can deploy the AHP on the ground from a hovering helicopter or retrieve the AHP in a similar fashion.
The Sikorsky S-64 Skycrane helicopter is designed to carry external payloads primarily for construction, logging and fire fighting operations. Lee Ramage depicts a fluid loading system in U.S. Pat. No. 6,874,734, which attaches externally and is used to load fluid from a ground source while in flight and subsequently dispenses the fluid on a fire.
The nature of helicopter mechanical mechanisms and operations creates considerable vibration. These vibrations cause fatigue in the aircraft structural components and systems. Furthermore, these vibrations are uncomfortable for the occupants and may contribute to pilot fatigue and performance. Much effort has been done to minimize these vibrations in modern helicopters; however, further improvements with current techniques may have reached their limits. It would be desirable to find another technique to further reduce and isolate helicopter vibrations.
Safety is a major concern in air transportation. Military planes have used ejection seats and escape capsules to improve safety. However, these safety features have not been incorporated into helicopters.
Recently, sport aviation has introduced a Ballistic Parachute System. This system can safely lower the entire plane in an emergency. This feature has been adopted in some small general aviation aircraft to dramatically improve flight safety. Unfortunately, this system is not available on helicopters.
Robert N. Talmage, Jr. depicts an Aircraft Escape Cabin (AEC) in U.S. Pat. No. 6,776,373 which uses a parachute to lower the Escape Cabin. This concept avoids dangers associated with ejection seats and permits safe emergency evacuation from aircraft. The AEC evacuates multiple individuals while still protected in their seats. The AEC protects ejected occupants from the environment and parachute landings. It would be advantageous if a similar concept could be applied to helicopters.
BRIEF SUMMARY OF THE INVENTION
This invention relates to a Modular Adaptive Configured Helicopter (MACH) designed to integrate with different modular cabins to offer a helicopter platform with a wide variety of configurations. In this manner, one common helicopter structure or parent vehicle with engines, fuel, aircraft systems and lift devices may integrate with different modular cabins to satisfy special mission requirements. This modular cabin may be designed for passengers, crew, weapons, cargo, surveillance, electronics, medical evacuation or any other specific purpose. These modular cabins are designed to attach and detach in field conditions with minimal support equipment and available personnel. Specific modular cabins can be attached with explosive bolts or mechanical devices which can be released in an emergency whereby the cabin will separate from the parent vehicle and safely parachute the cabin and occupants to the ground.
It is the primary objective of the present invention to provide a common use helicopter configuration or parent vehicle, which can integrate with a variety of different modular cabins to satisfy specific mission objectives and offer a failsafe feature for the occupants of the cabin.
It is another objective of the present invention to provide a MACH whereby the modular cabin integrates with the parent vehicle to form a streamlined aircraft with minimum drag.
Yet another object of the present invention is to provide a modular cabin which may include the cockpit.
Still another object of the present invention is to provide a modular cabin which may include landing gear.
It is another objective of the present invention to provide a modular cabin which can operate independently of the parent vehicle on land or water. These modular cabins would contain the necessary power, fuel, suspension, controls, systems and structure to function as a watercraft, land vehicle or an amphibious vehicle.
A further object of the present invention is to provide a MACH whereby the parent vehicle can operate without a modular cabin attached. One method involves the cockpit being incorporated into the parent vehicle and designed for the proper weight and balance of the parent vehicle while operating without the modular cabin attached. Another method is to design the parent vehicle to fly unmanned by remote control when unattached from the modular cabin.
Yet one more object of the present invention is to provide a modular cabin with emergency release means to separate from the parent vehicle. This release will sever all connecting electrical and mechanical lines. A static line attached to the parent vehicle will extract a parachute to deploy and safely parachute the modular cabin to the ground.
Another objective of the present invention is to provide the modular cabin with a parachute device and wheels or skids to decelerate the cabin upon contact with the ground.
Yet, another object of the present invention is to provide a door to provide ingress and egress from the modular cabin.
Still another objective of the present invention is to provide a door in the modular cabin to access areas in the parent vehicle.
Still another objective of the present invention is to provide a window in the modular cabin for visibility.
Yet, another object of the present invention is to provide a means to connect and disconnect electrical and mechanical lines, which connect components in the modular cabin with other components in the parent vehicle.
A further object of the present invention is to provide a means to reduce the destructive nature and discomfort of helicopter vibrations.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
In the drawings:
FIG. 1 is an elevational view of one embodiment of the invention with the modular cabin attached to the parent vehicle.
FIG. 2 is an elevational view of one embodiment of the invention with the modular cabin attached by a cable to the parent vehicle.
FIG. 3 is an elevational view of one embodiment of the invention illustrating the parent vehicle operating without a modular cabin attached.
FIG. 4 is an elevational view of one embodiment of the invention with a modular cabin containing the cockpit and attached to the parent vehicle for normal operations.
FIG. 5 is an elevational view of one embodiment of the invention illustrating the modular cabin of FIG. 4 separated from the parent vehicle after an emergency with the parachute deployed.
FIG. 6 is an elevational view of one embodiment of the invention illustrating the parent vehicle of FIG. 4 after the modular cabin has been released in an emergency.
FIG. 7 is an elevational view of one embodiment of the invention illustrating a modular cabin configured with external stores support stations.
FIG. 8 is an elevational view of one embodiment of the invention illustrating a modular cabin configured for oversized cargo and equipment.
FIG. 9 is an elevational view of one embodiment of the invention illustrating an unmanned parent vehicle hovering above a modular cabin configured with wheels and a jet engine.
FIG. 10 is an enlarged cross-sectional view of the mating devices.
FIG. 11 is an enlarged cross-sectional section view of the attachment/release device.
DETAILED DESCRIPTION OF THE INVENTION
Referring to the drawings wherein like referenced numerals indicate corresponding or similar elements throughout the several views, FIG. 1 illustrates a Modular Adaptive Configured Helicopter (MACH) comprising modular cabin 3 and parent vehicle 2 . This specific embodiment of the invention illustrates the parent vehicle 2 which is configured with the cockpit 4 designed as part of the parent vehicle and which enables the parent vehicle to operate with or without the modular cabin 3 attached. FIG. 3 illustrates the parent vehicle 2 operating without a modular cabin attached. In this manner, the parent vehicle can drop off various modular cabins and fly without a modular cabin to transport another modular cabin, carry a suspended load, transport a BOOT-V (reference patent application Ser. No. 10/683,710) or operate as an independent helicopter. Parent vehicle 2 of FIG. 1 has landing gear 5 and all necessary aircraft systems to conduct helicopter missions with or without a modular cabin attached. It contains a cable winch device 14 to raise and lower suspended loads. Furthermore, cable winch device 14 enables the parent vehicle 2 to deploy or retrieve modular cabin 3 without having to land the MACH. Using cable winch device 14 , the MACH can hover above an inaccessible or dangerous area and lower the modular cabin safely to the ground. After the modular cabin is on the ground, cable 15 in FIG. 2 can be detached from lifting tackle 26 . In a similar fashion, the parent vehicle can hover above a modular cabin, attach cable 15 to lifting tackle 26 , lift the modular cabin in the air, and fly it to another destination.
The MACH can connect or mate with various modular cabins by hovering down onto the modular cabin 3 , rolling above the modular cabin or sliding the modular cabin under the parent vehicle 2 . Cone shaped matting devices illustrated in FIG. 10 correctly position the parent vehicle and modular cabin to engage attachment/release device 13 .
Electrical connector 17 is plugged into the parent vehicle, which connects the electrical systems of the parent and the modular cabin. These electrical systems may include power, communications, data, avionics, weapons systems, controls, etc. The static line 24 from parachuting device 16 is connected to the parent vehicle. The parachute is connected to lifting tackle 26 . In case of an in-flight emergency, the modular cabin can separate from the parent vehicle and parachute to the ground. Emergency separation can be accomplished by using explosive bolts in the attachment device 13 or a mechanical system to release the attachment device 13 . Those skilled in the art of attachment devices and devices specifically designed for emergency separation can provide such attachment devices to satisfy the MACH criteria. Modular cabin wheel 6 can be designed into various modular cabins for mobility on the ground. These modular cabin wheels can be electrically powered and controlled by an operator to maneuver the modular cabin on land. A remote control device can be used to maneuver the modular cabin unmanned from a remote location. A similar remote control device may also be used by an operator outside the modular cabin to facilitate the mating of the modular cabin and parent vehicle.
Aircraft engine 1 powers the main rotor 8 . The parent vehicle incorporates fuel tank 18 to carry fuel for engine 1 . The modular cabin can receive electrical power from the parent vehicle electrical systems and/or utilizing its own generator 27 or fuel cell as a power source.
Modular cabin door 10 provides egress to the cabin. Corresponding doors in the parent vehicle and modular cabin can provide egress between the two MACH components. Large cargo door 9 is hinged with a ramp to open downward and easily load and unload cargo. Modular cabin view port 11 provides visibility and interior light.
FIG. 4 illustrates a MACH configured with the cockpit 4 as part of the modular cabin 3 and not part of the parent vehicle 2 . Those skilled in the art can provide the necessary connections between the cockpit and parent vehicle for all aircraft controls and systems. Built into these mechanical and electrical connections between the modular cabin and parent vehicle are the means to quickly separate these lines in an emergency to release modular cabin 3 .
One feature of the MACH embodied in FIG. 4 is the ability for the pilots in the cockpit to safely parachute with the modular cabin in an emergency. In this particular MACH configuration, the pilots can quickly and safely escape an inflight emergency while secured and protected in their seats.
As shown in FIG. 1 , the MACH pilots located in the parent vehicle, such have two emergency options. One option is to leave their seats in an emergency to enter the modular cabin prior to emergency separation. The other option is for the pilot to remain with the parent vehicle and attempt an emergency landing after releasing the modular cabin.
FIG. 4 illustrates a MACH configured with modular cabin skids 7 . These skids function as support for the modular cabin independently and for the complete MACH. Those skilled in the art will provide temporary support of the parent vehicle in FIG. 4 when it is not attached to a modular cabin. Access door 23 provides access to areas inside the parent vehicle.
FIG. 5 illustrates modular cabin 3 after emergency separation. The static line 24 in FIG. 6 has extracted the parachute device 16 . In FIG. 5 , the parachute device is fully deployed and attached to the modular cabin lifting tackle 26 . Attachment device 13 is detached and mechanical connectors 28 and electrical connectors 17 have been pulled apart by the emergency separation or severed by incendiary devices. Landing skids 7 are designed to absorb the landing impact.
FIG. 7 illustrates a MACH configured with the cockpit 4 as part of the modular cabin 3 . This specific modular cabin 3 is configured as an attack helicopter with external stores support wing 29 as an integral component of the modular cabin. Various external stores 25 may be attached to the external stores support wing 29 such as rocket launcher 20 , machine gun 21 , fuel tanks, etc.
FIG. 8 illustrates a MACH configured with an enlarged modular cabin 3 to accommodate large electronic weapons 22 , antennas, sensors, etc. Superconducting Magnetic Energy Storage (SMES) device 19 makes possible a large burst of power to fire electronic weapons. Fuel tank 18 supplements normal fuel reserve in the parent vehicle to increase range and endurance. This fuel may also be available for the cabin equipment. Rocket launcher 20 and machine gun 21 are easily incorporated into the modular cabin.
FIG. 9 illustrates an unmanned parent vehicle 2 hovering above a modular cabin. Remote control devices and positioning alignment devices enable the unmanned parent vehicle to lower downward onto the modular cabin and whereby the parent vehicle and cabin would then be engaged. Occupants can connect electrical connectors, mechanical connectors and static line for parachute recovery. Controls in the cockpit 4 of the modular cabin are available to operate the modular cabin 3 independently on the ground or water. Furthermore, other controls in the cockpit of the modular cabin are available to pilot the parent vehicle remotely or by direct link when the two components are mated.
The modular cabin may utilize aircraft engine 30 to provide propulsion on land, water and air. A modular cabin designed to be watertight and float upright can use engine 30 for propulsion on the water. On land, electric wheels 6 and engine 30 can provide maneuverability and high-speed road transportation. When in the air and operating as a MACH, engine 30 can provide additional forward thrust for increased speed.
Unmanned parent vehicle 2 illustrated in FIG. 9 contains recessed landing gear 5 to enable the parent vehicle to land without a modular cabin attached. This landing gear can be retracted for mating with a modular cabin. Electronic flight controls and position sensing equipment means located on the parent vehicle and modular cabin make it possible for the parent vehicle to mate with the modular cabin by remote control or autonomous means.
Robert Talmage, Jr. described a unique method of attachment/release for the Aircraft Escape Cabin, U.S. Pat. No. 6,776,373, issued Aug. 17, 2004. Talmage incorporates nonlocking, one directional release, linking and stabilizing devices (male & female) with an attachment/release device. This concept works well for the MACH and is embodied herein as one preferred method of attachment.
To minimize the discomfort and destructive properties of aircraft vibrations, the MACH can take advantage of its unique configuration of two separate components connected together. Flexible attachment device 13 absorbs oscillating vibrations of the main rotor and insulating pad 33 located between the matting devices absorbs and dampens vibrations from the parent vehicle. This same vibration dampening means has a synergistic effect on the parent vehicle by softening and absorbing vibrations.
To further identify specific components, the nonlocking, one direction, linking and stabilization device described by Talmage is shown in FIG. 10 illustrating the Female Mating Device (FMD) 32 as part of the parent vehicle 2 . Male Mating Device (MMD) 31 is shown as part of modular cabin 3 . Insulating pad 33 is shown between FMD 32 and MMD 31 . This insulating pad is an abrasive resistance foam-type material to absorb shock and vibrations. This insulating pad can be replaced when worn.
FIG. 11 illustrates the Attachment/Release Device (ARD) 13 . The ARD 13 is designed as a fail-safe flexible connection of the parent vehicle and the modular cabin. The flexibility is designed into explosive bolt 34 which can bend back and forth in lateral directions to allow for the slight movement permitted by the insulating pad 33 . The modular cabin is not allowed to drop downward and is instead stabilized by nut 35 and washer 36 .
The explosive charge in bolt 34 is located between strike 38 and nut 35 . In this manner, when spring loaded latch 37 is retracted back and off of bolt 34 , the ARD 13 will release modular cabin 3 when explosive bolt 34 is fired and separates the bolt.
A fail-safe feature is designed into ARD 13 to prevent separation of the modular cabin when the helicopter is operating below the minimum height above ground for safe deployment of parachute device 16 . Below the safe height above ground for separation, a ground proximity sensor triggers an electrical solenoid to push spring-loaded latch 37 against the spring and into contact with bolt 34 . This is the fail-safe position for latch 37 which will not allow the modular cabin to be released inadvertently.
The fail-safe mode is deactivated when the ground proximity sensor registers a safe height above ground for the parachute to deploy. At this time, the electrical solenoid is turned off which allows the spring to retract latch 37 . With latch 37 retracted back from bolt 34 , strike 38 is free and the modular cabin can separate in an emergency.
It will be understood by one skilled in the art that many variations, adaptations, or changes could be made to the disclosed preferred embodiment without departing from the spirit and scope of the present invention. For this reason, patent protection is not to be limited by or to what is illustrated herein and described above. Instead, patent protection is defined by the following claim or claims, properly interpreted according to accepted doctrines of claim interpretation, including the doctrine of equivalents and reversal of parts. | A method and apparatus for a composite helicopter comprising a rotary wing parent vehicle with various modular cabins detachable therefrom to facilitate various configuration aircraft platforms, dual operation and modular economy. | 1 |
FIELD OF THE INVENTION
The present invention relates generally to internal combustion engines and more particularly to a charge forming device for such engines.
BACKGROUND OF THE INVENTION
Small internal combustion engines may be used in various devices including recreational vehicles and garden implements such as chain saws, lawn mowers and string trimmers. Some of these devices have pull cord type starting systems that require a retractable cord to be pulled by a user of the device to start it. In a recoil starter mechanism, pulling the cord rotates a recoil pulley which, through a one way clutch, rotates a crank shaft of the engine to start the engine.
SUMMARY OF THE INVENTION
A charge forming device includes a body defining at least part of a fuel and air mixing passage and a bypass passage that communicates with the fuel and air mixing passage, and a throttle valve and a choke valve. The throttle valve is carried by the body for movement between idle and wide open positions and operable to control at least in part the fluid flow through the fuel and air mixing passage. The choke valve is operably associated with the fuel and air mixing passage, and movable between an open position permitting a substantially free flow of air into the fuel and air mixing passage and a closed position at least substantially restricting air flow into the fuel and air mixing passage. A bypass valve associated with the bypass passage is movable between an open position and a closed position to selectively permit fluid flow through the bypass passage. The bypass valve is movable toward its open position when the throttle valve is displaced at least a threshold amount away from its idle position.
In one implementation, the charge forming device includes a carburetor and at least one bypass valve is carried by the throttle valve and at least one bypass valve is carried by the choke valve. The bypass valves permit air flow therethrough when the choke valve is moved toward its closed position and the throttle valve is moved toward its wide open position, such as during a choke assisted start of an engine at wide open throttle. Of course, other arrangements of the bypass, throttle and choke valves may be utilized, as desired for different applications.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects, features and advantages of the present invention will be apparent from the following detailed description of preferred embodiments and best mode, appended claims and accompanying drawings in which:
FIG. 1 is a side view of one embodiment of a charge forming device with a throttle valve in its idle position;
FIG. 2 is a side view of the charge forming device of FIG. 1 illustrating a choke valve in its open position;
FIG. 3 is a plan view of the charge forming device;
FIG. 4 is a side view of the charge forming device illustrating the throttle valve in its wide open position;
FIG. 5 is a fragmentary side view illustrating the choke valve in its closed position;
FIG. 6 is a fragmentary sectional view illustrating an air bypass passage in the charge forming device with the choke valve in its closed position and the throttle valve in its idle position;
FIG. 7 . is a fragmentary sectional view like FIG. 6 illustrating the choke valve in its closed position and the throttle valve in its wide open position;
FIG. 8 . is a fragmentary sectional view like FIG. 6 illustrating the choke valve in its open position and the throttle valve in its idle position;
FIG. 9 is a fragmentary sectional view like FIG. 6 illustrating the choke valve in its open position and the throttle valve in its wide open position; and
FIG. 10 is a sectional view of a main body of the charge forming device illustrating a fuel and air mixing passage and the air bypass passage formed in the body.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring in more detail to the drawings, FIGS. 1-4 illustrate a charge forming device 10 , such as a carburetor, that has a main body 12 including a central block 14 and one or more plates 16 attached to the block 14 . The carburetor 10 may be a diaphragm-type carburetor that includes a flexible fuel pumping diagram and a flexible fuel metering diaphragm (not shown). In that regard, the carburetor may be constructed generally as disclosed in U.S. Pat. No. 4,752,420, the disclosure of which is incorporated herein by reference in its entirety.
The main block 14 includes a fuel and air mixing passage 18 formed therethrough and communicating with a fuel metering chamber (not shown). Fuel from the metering chamber is provided into an air flow through the fuel and air mixing passage 18 to provide a fuel and air mixture to an operating engine. At least one air bypass passage 20 is also provided, preferably in the main block 14 . In the implementation shown, two bypass passages 20 are formed in the carburetor 10 . The bypass passages 20 may be disposed on generally diametrically opposed sides of the fuel and air mixing passage 18 and are adapted to permit air to flow therethrough to, at least under certain engine conditions, permit additional air flow to the engine, as will be discussed in more detail herein.
The carburetor body 12 preferably also includes an outwardly extending stop 22 which as shown, is carried by a plate 16 attached to the block 14 of the carburetor body. A protrusion 24 may include a threaded bore in which a threaded idle adjustment screw 26 is received. A spring 28 may be disposed about the shank of the idle adjustment screw 26 between its head and the protrusion 24 . An end of the idle adjustment screw 26 , opposite its head, extends through the protrusion 24 and is adapted to engage a position limiting lever 30 of a throttle valve 32 to define the idle position of the throttle valve 32 . Accordingly, advancing or retracting the idle adjustment screw 26 relative to the protrusion 24 permits adjustment of the idle position of the throttle valve 32 . The protrusion 24 itself may provide a stop 34 ( FIG. 3 ) engageable by the throttle valve lever 30 to define the wide open position of the throttle valve 32 by limiting rotation of the throttle valve 32 away from its idle position.
In the implementation shown, the carburetor throttle valve 32 is a butterfly type valve that includes a valve shaft 36 rotatably carried in a bore 38 extending in the block 14 , through the fuel and air mixing passage 18 and through each bypass passage 20 . The throttle valve 32 also includes a valve head 40 which may be a flat disc fixed to the shaft 36 , such as by a fastener 41 , for corotation with the shaft. The throttle valve 32 may further include the position limiting lever 30 as previously recited, and at its opposite end, a start assist lever 42 extending generally radially outwardly from the shaft 36 and fixed to the shaft for rotation therewith. A spring 44 may be disposed about the throttle valve shaft 36 with one end of the spring engaged with the carburetor body 12 and its other end engaged with the position limiting lever 30 to yieldably bias the throttle valve 32 to its idle position wherein the valve head 40 substantially prevents fluid flow out of the fuel and air mixing passage 18 .
The carburetor 10 may also include a choke valve 46 , as is known in the art. The choke valve 46 is disposed upstream of the throttle valve 32 and preferably includes a shaft 48 rotatably carried by the carburetor such as in a bore 50 formed in the block 14 and extending through the fuel and air mixing passage 18 and the bypass passages 20 . The choke valve shaft 48 may extend parallel to the throttle valve shaft 36 . The choke valve 46 preferably also includes a start assist lever 52 disposed on the same side of the carburetor as the start assist lever 42 of the throttle valve 32 . A return spring 54 can be disposed about the choke valve shaft 48 and engaged at one end with the carburetor body 12 and at its other end with the start assist lever 52 to yieldably bias the choke valve 46 to its open position wherein a substantially unrestricted flow of air is permitted into the fuel and air mixing passage 18 . Opposite the start assist lever 52 , the choke valve shaft may extend out of the carburetor body 12 and be retained thereto by a suitable retainer, such as a clip or other fastener 58 . The choke valve 46 may also be of a butterfly type having a flat disc valve head 56 fixed to the choke valve shaft 48 and being complementary shaped to the adjacent portion of the fuel and air mixing passage 18 to substantially close the fuel and air mixing passage 18 when the choke valve 46 is rotated to its closed position, shown in FIG. 5 . The choke valve may not fully close the fuel and air mixing passage 18 to permit a limited, calibrated air flow therethrough when closed or in a “start” position. This may be done by providing a hole in the valve head 56 , or by providing a peripheral gap between the valve head 56 and carburetor body through which air may flow into the fuel and air mixing passage 18 .
As best shown in FIG. 10 , both the throttle valve 32 and the choke valve 46 preferably include at least one bypass valve 60 , 62 , respectively, that selectively permit or control the rate of air flow through the bypass passages 20 . In the implementation shown, two bypass valves 60 , 62 are carried by each of the throttle valve 32 and choke valve 46 . The bypass valves 60 , 62 may be defined or include one or more recesses 64 , 66 formed in the respective valve shafts 36 , 48 . The recesses 64 extend radially inwardly about one half of the thickness of the shafts 36 , 48 and axially a distance generally equal to the width of the bypass passages 20 , but of course other dimensions could be used. In one implementation, the recesses 66 are formed on either side of a land 67 of the choke valve shaft 48 . As also shown in FIG. 10 , the bypass passages 20 may extend completely through the block 14 from the choke valve side 68 through the throttle valve side 70 . However, the end of the bypass passages 20 at the throttle valve side 70 may be closed off by a gasket when the carburetor 10 is mounted to the engine. Accordingly, the air flow through the bypass passages 20 may follow the arrows in FIG. 10 which show the air flow entering the fuel and air mixing passage 18 through the bore 38 in which the throttle valve shaft 36 is carried. Of course, the bypass valves 60 , 62 may take other forms, such as relatively flat discs acting as valve heads fastened to the shafts 36 , 48 for rotation with the shafts or otherwise actuated by rotation of the shafts 36 , 48 , for example.
Accordingly, when the bypass valves 60 , 62 of both the throttle valve 32 and choke valve 46 are opened, or permit air flow therethrough, air flows through the bypass passages 20 from the choke valve side 68 of the carburetor 10 toward the throttle valve side 70 , with that air flow being provided into the fuel and air mixing passage 18 for delivery to the engine. In the implementation shown, the bypass valves 62 associated with the choke valve 46 are open only when the choke valve 46 is closed, or at least substantially closed. The bypass valves 60 of the throttle valve 32 are open when the throttle valve 32 is in its wide open position, or relatively near its wide open position. In one implementation, the air flow through the bypass passages 20 is permitted when the choke valve 46 is rotated at least ⅔ of the way from its open position toward its closed position, and the throttle valve 32 is rotated at least ⅔ of the way from its idle position toward its wide open position. The bypass passage valves 60 , 62 are preferably opened and closed, and moved between their opened and closed positions, as a function of the position of the throttle valve 32 and choke valve 46 , although they may be otherwise moved such as by an operator of the device with which the carburetor is used. In one form, the bypass valves 60 , 62 are coupled to the throttle valve 32 and choke valve 46 and are driven between their open and closed positions by movement of the throttle and choke valves. In the implementation shown, the bypass valves 60 , 62 are carried by the throttle valve 32 and choke valve 46 for corotation with these valves.
As best shown in FIG. 6 , when the choke valve 46 is closed or in a start position wherein the choke valve is substantially closed, the bypass valves 62 associated therewith are open, permitting air flow therethrough and toward the throttle valve side 70 of the carburetor 10 . However, when the throttle valve 32 is in its idle position, or a fast idle position such as may be employed during starting of an engine with which the carburetor is used, the bypass valves 60 associated with the throttle valve 32 are in their closed position, preventing air flow therethrough. This prevents or substantially restricts the flow of additional air to the fuel and air mixing passage 18 which would otherwise make the fuel and air mixture undesirably lean for starting and initial warming up of the engine. As shown in FIG. 8 , when the choke valve 46 is in its open position, the bypass valves 62 associated with the choke valve 46 are closed, or prevent the flow of air through the bypass passages 20 . In FIG. 8 , the throttle valve 32 is shown in its idle position and the bypass valves 60 associated therewith also prevent air flow through the bypass passages 20 . In FIG. 9 , the choke valve 46 is open so that its bypass valves 62 prevent air flow therethrough The throttle valve 32 is in its wide open position, but even though the bypass valves 60 associated therewith are open, no or substantially no air flows through the bypass passages 20 because the bypass valves 62 of the choke valve 46 are closed.
Accordingly, in this implementation, the bypass passages 20 provide air flow into the fuel and air mixing passage 18 only when, as shown in FIG. 7 , the choke valve 46 is in or near its closed position such that the bypass valves 62 associated therewith are open, and the throttle valve 32 is in or near its wide open position, such that the bypass valves 60 associated therewith are also open. The choke and throttle valves may be in this position, for example, when the engine becomes flooded during attempted starts with the throttle valve 32 in its idle position. After this occurs, the throttle valve 32 may be moved to its wide open position permitting increased air flow therethrough, in an attempt to start the engine with a leaner fuel and air mixture. However, with the choke valve 46 closed, there is not much air flow through the fuel and air mixing passage 18 . Accordingly, in this situation, the bypass air passages 20 are open and air flows therethrough and into the fuel and air mixing passage 18 to provide a relatively lean mixture and facilitate starting a flooded engine. In this manner, air flow is provided even though the choke valve 46 is closed or substantially closed.
This carburetor 10 may be used, for example, with an engine having an easy start system wherein the choke valve 46 is automatically applied upon pulling a pull cord to start the engine. Such systems couple the choke valve 46 to mechanisms that are moved upon pulling the pull cord. A representative example of such an easy start pull cord system is disclosed in U.S. patent application Ser. No. 11/285,554, now U.S. Pat. No. 7,275,508 which was filed on Nov. 21, 2005, the disclosure of which is incorporated herein by reference in its entirety.
In such systems, the choke valve 46 may be pulled closed as a function of the force resisting pulling of the pull cord such that the choke valve 46 becomes fully closed up to a top dead center position of a piston in the engine and after top dead center, the choke valve 46 may be moved towards its idle position by its return spring 54 . When the throttle valve 32 is in its idle position, the choke valve 46 will slip or move back to its start position which may be rotatably spaced or inclined from its fully closed position. The start assist levers 52 , 42 on both the choke valve 46 and throttle valve 32 , respectively, may become engaged with each other to define a start position of both the choke valve 46 and the throttle valve 32 . When the throttle valve 32 is in its wide open position upon attempted start of the engine, the start assist levers 42 , 52 of the throttle and choke valves 32 , 46 may or may not engage after the force closing the choke valve is reduced. If the levers, 42 , 52 do not engage in this situation, the choke valve 46 may return to its open position after the piston moves past top dead center if the force of the return spring 54 is greater than the force tending to close the choke valve 46 .
In any event, as the choke valve 46 is moved sufficiently towards its closed position when the engine pull cord is pulled to start the engine, the bypass valves 62 associated with the choke valve 46 are open. If the throttle valve 32 is in its wide open position, or sufficiently close thereto, its bypass valves 60 are also opened so that an air flow may occur through the bypass passages 20 and into the fuel and air mixing passage 18 . Of course, the flow rate of air through the bypass passages 20 during a wide open throttle engine start, combined with the flow of air through the choke valve 46 , can be calibrated for a particular engine or application to provide a desired fuel and air mixture to support starting and continued operation of the engine. | A charge forming device includes a body with a fuel and air mixing passage, a bypass passage that communicates with the fuel and air mixing passage, a throttle valve and a choke valve. The throttle valve is movable between idle and wide open positions and operable to control at least in part the fluid flow through the fuel and air mixing passage. The choke valve is movable between an open position permitting a substantially free flow of air into the fuel and air mixing passage and a closed position at least substantially restricting air flow into the fuel and air mixing passage. A bypass valve is movable between an open position and a closed position to selectively permit fluid flow through the bypass passage. The bypass valve is movable toward its open position when the throttle valve is displaced at least a threshold amount away from its idle position. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to connectors for windshield wiper arms and blades and, more particularly, to a transversely actuated latch for locking a hooked-end arm to a blade.
2. Description of the Prior Art
Windshield wiper arms have been provided with many different styles and types of connector ends for use in connecting the arm to a wiper blade. One such arm end has a hook shape and is generally designated a hook-ended wiper arm. Many different connectors have been developed for securing such arm ends to wiper blades. One such connector is a U-shaped spring encircling a pivot pin between the sides of the blade. One leg of the spring has a tang or dog sticking up from the plane of the spring to engage in a recess in the hooked end of the arm to secure the arm to the blade. This connector is subject to accidental disconnection due to twisting between the arm and blade or due to resistance between the blade and the windshield, i.e. freezing the rubber to the glass. In the two just enumerated situations, the tang unseats from the detent and the arm can separate from the blade.
Another form of connector for a hook-ended arm provides for a socket member pivoted between the side walls of a blade which socket member has two side-by-side rubber or plastic pins, such that the end of the hook passes between the pins when the socket member is at a right angle to the blade. Pivoting the socket member into the confines of the side walls of the blade locks the arm to the blade. During use, the socket member can unseat from the confines of the blade making it possible to release the blade from the arm.
Those and other prior art connectors are less than satisfactory and do lead to a certain number of cases where the blade is separated from the arm with the attendant problems.
SUMMARY OF THE INVENTION
An improved connector for attaching a hook-ended wiper arm to a blade is provided which overcomes the problems of the prior art and produces an improved connection that is substantially fail proof.
A connector is provided with a pin extending either between the side walls of the blade or between the side walls of a connector housing on the blade. The pin has a head on one end located exterior of one of the side walls and has a laterally projecting catch with an overhanging lug, which lug lies substantially parallel to the axis of the pin and projects into the open space between the side walls of said blade or housing. A spring urges the catch, lug and pin in a direction to maintain said lug in said open space between the side walls. The hook end of an arm is nested about the pin such that the lug on the catch is behind the hook end of the arm so as to trap the hook end between the lug and the pin to hold the arm to the blade. The arm is released from the blade by depressing the head so as to compress the spring and move the lug on the catch out from behind the hook end of the arm thereby releasing the arm for removal from the blade.
BRIEF DESCRIPTION OF THE DRAWINGS
The details of construction and operation of the invention are more fully described with reference to the accompanying drawings which form a part hereof and in which like reference numerals refer to like parts throughout.
In the drawings:
FIG. 1 is an elevational view of a wiper blade and a wiper arm incorporating the improved connector;
FIG. 2 is an enlarged partially broken away elevational view of the improved connector of FIG. 1;
FIG. 3 is a top plan view of the connector of FIG. 2;
FIG. 4 is an enlarged, partial cross-sectional view taken along the lines 4--4 of FIG. 2; and
FIG. 5 is a perspective view of the knob and pin assembly.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A preferred form of the invention is illustrated in the drawings wherein like reference numerals will refer to like parts throughout and, in particular, in FIG. 1 is illustrated a windshield wiper blade 10 carrying a connector 12 in which is connected a hook end 14 of a hook-ended windshield wiper arm 16. The blade 10, that is illustrated, is a triple yoke windshield wiper blade of the type invented by John W. Anderson and first broadly shown in U.S. Pat. No. 2,596,063. It is to be understood that the connector 12 of the present invention could be used on any windshield wiper blade, whether it is a stiff-backed blade, a single, double, triple or quadruple yoke blade, or any other appropriate blade.
The connector 12, as illustrated, is formed integrally with the secondary yoke 18 of the wiper blade 10 and has a pair of spaced apart, substantially parallel side walls 20,22. It should be recognized that the connector 12 could be a separate housing attached to the back of the yoke of the wiper blade without departing from the invention. The side walls 20 and 22 have aligned openings 24 and 26, respectively, with the opening 26 being circular and with the opening 24 being circular throughout a major portion thereof and having a rectangular-shaped open portion 25 extending sidewardly therefrom, the height of said rectangular portion 25 being substantially less than the diameter of the opening 24 so as to form a keyhole-shaped opening therein. A flat stamped metal latch or pin 30 bridges the space between the side walls 20 and 22 with the one end portion 32 projecting beyond the plane of the side wall 22 and having a knob portion 34 attached thereto. The knob 34 has a reduced diameter portion 36 that is small enough to clear the inside of the opening 26 and has an enlarged head portion 38 which overhangs the edges of the opening 26 so that the knob 34 cannot pass through the opening 26. The knob 34 is attached to the pin 30 by means of barbs or undercuts 40 on the pin 30 and ledges 42 on the knob 34, the knob 34 being formed of a plastic-type material and being adapted to forcibly receive the barbed end of the pin 30 and to be locked together by means of the interaction of said barbs and ledges. In the alternative, the pin 30 with the undercut 40 can be molded into the knob 34 to form a one piece structure. FIG. 5 shows the pin 30 and knob 34 assembly prior to insertion in the connector housing.
The opposite end of the pin 30 projects through the opening 24 and has a rectangularly-shaped, laterally extending catch or latch portion 46. The latch portion 46 has an overhanging ledge portion 47 which extends in overlapping relation with the edge of the wall 20 around the opening 24 so as to prevent the pin 30 from passing back through the opening 24. The latch portion 46 projects laterally from the axis of the pin 30 has an integrally formed inturned lug 48 doubling back on the pin 30 and has a planar face 50 which lies parallel to the axis of the pin 30 and is in overlapping relationship to the outer wall of the pin 30. The latch portion 46 projects through the opening 24 and through the rectangular portion 25 of the opening with the lug 48 extending back into the open space between the side walls 20 and 22. The remote wall 52 of the lug 48 has a tapered portion 54 with the junction of the taper 54 and the wall 52 being about the place of the inside of the wall 20.
A coil spring 60 encircles the body of the pin 30 and has one end bearing against the inner wall 20 with the other end bearing against the axially facing, laterally, outwardly extending wall 62 of the knob 34. The spring 60 is under compression so as to hold the ledge portion 47 of the latch 46 against the outer wall 20 with the lug 48 extending into the space between the side walls 20 and 22. At the same time, the overhang 38 of the knob 34 is urged away from the outside of the wall 22. Pressure on the knob 34 transverse to the plane of the side walls 20 and 22 and axially along the pin 30 will compress the spring 60 and move the overhanging portion 38 of the knob 34 against the outside wall 22 as the latch portion 46 is moved laterally outwardly with respect to the wall 20. At this point, the lug 48 is moved out of the open space between the side walls 20 and 22 so that the lug 48 does not extend into the area between the side walls 20 and 22. The space between the overchange 38 and the outside of wall 22 is substantially equal to the lateral distance the planar face 50 extends into the space between the walls 20 and 22.
The present connector 12 is intended for use with the hook end 14 of a hook-ended windshield wiper arm 16. As best shown in FIG. 2, the wiper arm 16 has a modified hook-shaped end 14 with the hooked end 14 wrapping around approximately 180° of the spring 60 and the pin 30. Also, as viewed in FIG. 4, the lug 48 of the latch 46 is in position behind the hooked end 14 of the hook-end arm 16 so as to trap the hooked end 14 between the lug 48 and the pin 30 of the connector 12. Also, as shown in FIG. 4, the hooked end 14 of the arm 16 is positioned between the side walls 20 and 22 and is trapped between the lug 48 of the latch 46 and the pin 30.
Transverse pressure on the knob 34 will move the pin 30 transverse to the plane of the side walls 20 and 22 so as to move the lug 48 out of the space between the side walls 20 and 22 and out of entrapping relationship with respect to the hook end 14 of the arm 16. With the knob 34 depressed, the arm end can be moved outwardly from the pin 30 and spring 60 until the end of the hook end 14 clears the spring 60 whereupon the arm 16 can be lifted upwardly, away from the connector 12 and blade 10. As shown in dashed lines in FIG. 2, the arm end may be extended as at 14' which will afford a more positive connection and further reduce the likelihood of the arm becoming accidentally displaced.
To assemble the arm 16 to the blade 10, one of two methods can be employed. In one case, the hook end 14 of the arm 16 is dropped down between the side walls 20,22 at a point removed from the lug 48. The arm 16 is then moved relative to the blade 10 until the hook end 14 engages the tapered wall 54 of the lug 48. Continued relative movement will cause the hook end 14 to force the lug 48 and pin 30 transverse to the walls 20,22 until the hook end 14 passes over the lug 48 whereupon the spring 60 forces the lug 48 into latching position by trapping the hook end 14 between the lug 48 and the pin 30. In the other case, it is necessary to depress the knob 34 to remove the lug 48 from the space between the side walls 20 and 22 whereupon the arm end is dropped into the space between the side walls 20 and 22 and is moved into nesting relation around the spring 60 and pin 30, whereupon release of the knob 34 will move the pin 30 axially thereof to align the lug 48 behind the hook end 14 and trap the hook end 14 between the lug 48 and the pin 30. In this position, the arm end is positively locked by means of the connector 12 to the blade 10. In either case, the hook end 14 cannot become separated from the connector 12 of the blade 10 until the lug 48 on the latch 46 is moved out of alignment with the hook end 14 of the arm 16 whereupon the arm 16 can be separated from the blade 10. The present construction provides a positive latching arrangement for an arm end to the blade which cannot be accidentally displaced from the locking position. In this way, the arm 16 is positively locked to the blade 10 for safe and efficient operation. | A connector is provided for connecting a hooked-end windshield wiper arm to a windshield wiper blade. The connector is mounted on the blade and has a transversely operative spring-urged latch which seats beyond the hook of the hooked-end arm so as to trap the hook between the latch and the pivot on the blade so as to retain the hook in position on the blade. Transverse movement of the latch releases the hook making it possible to remove the arm from the blade. | 1 |
This is a division of application Ser. No. 08/192,331 filed Feb. 4, 1994 U.S. Pat. No. 5,542,132, which is a division of Ser. No. 07/976,109, filed Nov. 13, 1992 now U.S. Pat. No. 5,305,475.
BACKGROUND OF THE INVENTION
This invention relates to water saving plumbing fixtures. More particularly, it relates to improved means for using a pump to assist in the operation of plumbing fixtures such as toilets and urinals.
DISCUSSION OF THE PRIOR ART
Gravity feed toilets of the type having a reservoir at least partially above the level of a toilet bowl have in the past typically had a water capacity of 3 or more gallons for flushing the toilet. In recent years the efficiency of these toilets have been improved such that in many cases 1.6 gallons of water is sufficient to clean the bowl. However, where especially large amounts of feces are present double flushing may still be needed to completely clean the bowl. Moreover, it was hoped that additional water savings could be effected if these toilets could be made even more efficient during normal flushes and if less water could be employed to flush when only urine and toilet tissue are in the bowl.
One known way to reduce the amount of water needed to effect flushing is to pressurize the flush water. See U.S. Pat. Nos. 2,979,731, 3,431,563 and 5,036,553. However, these prior systems were complex, costly and usually not suitable to completely fit in standard size toilets. They also suffered from other problems.
Thus a need exists for an improved pump operated plumbing fixture which alters the amount of water used based on the type of material to be flushed, more efficiently sequences the flush water with respect to the rim portion and the bowl portion, permits water distribution to multiple fixtures from a single reservoir, permits alternative placement of the reservoir, permits an aesthetically pleasing compact design, resolves potential water overflow problems, meets safety standards relating to electrical shorting, and has good bowl cleaning and waste evacuation characteristics
SUMMARY OF THE INVENTION
In one aspect, the invention provides a plumbing fixture for receiving flushable waste comprising at least one receptacle for receiving the waste, a reservoir tank for storing a volume of flush water, a pump motor and pump (both positioned in the reservoir tank), the inlet of the pump being in communication with the interior of the reservoir tank, a conduit connected between a pump outlet and the receptacle, and control means selectively and operatively connected to the motor to operate the pump for one period of time to deliver a quantity of flush water to the pump outlet.
In another preferred form, the pump means is positioned either inside or outside the reservoir tank and the control means is selectively and operatively connected to the motor to the pump means to operate the pump for at least one other period of time to deliver at least one other quantity of flush water to the receptacle.
In still another preferred form, there are at least two receptacles for receiving waste such as a toilet and an urinal.
In still another aspect, a refill valve is operatively connected to an intake conduit, and a tube is connected between the refill valve and the rim of a toilet bowl.
In still another preferred form, there are control means which include a time delay means to prevent activation of the pump and overflow of the toilet bowl.
In another aspect, there is a fluid passage means disposed through the tank wall and positioned below the motor and electrical connection to the motor.
In yet another aspect, there is a receptacle for storing a fluid such as a cleaning fluid and an additional pump means for pumping such a fluid into the toilet bowl to clean the toilet bowl.
In yet another aspect, there are overflow prevention means for both the reservoir tank and the toilet bowl. Concerning the reservoir tank, an electrically operated fail-safe valve is connected to the supply conduit to shut off the water supply in the instance where there is a leaky supply valve. There is also an overflow sensor connected to a pump motor to pump excess water from the tank. Concerning the toilet bowl, there is a time delay feature to prevent excessive operation of the pump and flooding of the toilet bowl.
In yet another preferred form, there are first and second conduits connected between the pump outlet and the basin and the rim. Control means connected to the motor and pump sequentially delivers a volume of flush water to the rim, a volume of flush water to the bowl either alternatively, or simultaneously, and in selective sequences.
The objects of the invention therefore include:
a. providing a plumbing fixture of the above kind wherein reduced quantities of water can be employed to remove flushable waste from a toilet bowl or a urinal.
b. providing a plumbing fixture of the above kind wherein a pump and motor can be electrically controlled to deliver different quantities of water and in different timing sequences to a toilet bowl and rim.
c. providing a plumbing fixture of the above kind wherein safeguards are provided to substantially reduce the possibility of overflow conditions.
d. providing a plumbing fixture of the above kind wherein the pump can be easily connected or disconnected to a plumbing fixture.
e. providing a plumbing fixture of the above kind wherein one pump can service a multiplicity of plumbing fixtures.
f. providing a plumbing fixture of the above kind wherein a constant, predetermined volume and flow of water is delivered to the jet channel regardless of supply line pressure or flow characteristics.
g. providing a plumbing fixture of the above kind wherein a cleaning fluid can be pumped from a separate tank to the toilet bowl for cleaning purposes.
h. providing a plumbing fixture of the above kind which can be fitted to standard water supply and waste lines.
i. providing a plumbing fixture of the above kind wherein the pump and the reservoir are positioned remote from a toilet bowl or urinal.
j. providing a plumbing fixture of the above kind wherein flush activation is effected by switches.
These and still other objects and advantages of the invention will be apparent from the description which follows. In the detailed description below, preferred embodiments of the invention will be described in reference to the accompanying drawings. These embodiments do not represent the full scope of the invention. Rather the invention may be employed in other embodiments. Reference should therefore be made to the claims herein for interpreting the breadth of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top plan, partially fragmentary view of a toilet (with tank lid removed) in which a preferred embodiment of the invention is mounted.
FIG. 2 is a partial sectional view taken along line 2--2 of FIG. 1.
FIG. 3 is a sectional view taken along line 3--3 of FIG. 1.
FIG. 4 is partial sectional view taken along line 4--4 of FIG. 1.
FIG. 5 is a partial sectional view taken along line 5--5 of FIG. 4.
FIG. 6 is a partial sectional view taken along line 6--6 of FIG. 3.
FIG. 7 is a rear elevational view of the toilet shown in FIG. 1.
FIG. 8 is a view in side elevation and partially in section illustrating an alternative embodiment.
FIG. 9 is a rear elevational view in partial section of the toilet shown in FIG. 8.
FIG. 10 is a sectional view taken on line 10--10 of FIG. 9.
FIG. 11 is a view similar to FIG. 8 showing still another alternative embodiment.
FIG. 12 is a diagrammatic view of yet another embodiment.
FIG. 13 is a view in vertical section illustrating in more detail a pump and motor for use in the toilets described herein.
FIG. 14 is a diagrammatic view of a control circuit for the motor and pump.
FIGS. 15A-17C are flow charts showing a signal flow block diagram for the control circuit shown in FIG. 14.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1 and 2, there is shown a toilet generally 10 having a basin or bowl portion 12 with a hollow rim 14. A "reservoir" 16 is in the form of tank 17. Positioned in the tank 17 is a pump 18 which is of the sump type. It is supported in the reservoir by vibration absorbing feet 19. Pump unit generally 43 includes a pump 18 driven by an electric motor 20 with electric power being supplied by electrical cord 21. The motor 20 drives the pump 18 by means of a sealed and enclosed magnetic drive which is explained below in more detail in conjunction with FIG. 13. It should be noted that one surprising aspect of the invention is positioning an electrical motor in the toilet water tank.
Water enters the pump 18 at inlet 23 and exits the pump 18 by the outlet manifold 25. An outlet conduit 27 delivers water to the lower portion of bowl 12, such as through jet channel 28 (See FIG. 4) attached via connector 68. A smaller conduit 30 delivers water to the rim 14 through the channel 32.
Referring to FIGS. 2 and 3, water enters the tank 17 by the inlet pipe 35 which is connected to a conventional water source. A float valve assembly 37 includes a float 39 which operates a valve (not shown) in pipe 40 by means of rod 42 and lever arm 44. Float 39 is guided by the guide member 45. Water that passes the inlet valve enters the reservoir through the inlet valve hush tube 47. There is also a bypass tube 50 connected to the float valve assembly to deliver a small amount of water to the rim 14 whenever the float valve is in an open condition.
As best seen in FIGS. 4 and 5, there is a return passage 33 between the upper bowl portion 12 and the reservoir 16. This allows for water to pass from the tank to the bowl in case there is an overflow condition in the tank. It also permits flow in the other direction if there is a stoppage in the bowl and a near over flow condition develops.
There is also a dam member 69 which is positioned adjacent the return passage 33 and inside the tank 17. This serves to raise the water level in the tank 17 or the bowl portion 12 before overflowing into the other occurs. A rim vent hole 73 is also provided to facilitate water flow, as best shown in FIGS. 3 and 6.
Referring now to FIG. 7, there are several openings 52 extending through the back wall 11 of the tank 17. The purpose of the openings 52 is that if return passage 33 is blocked to allow overflow water from tank 17 to spill out of the tank. The openings 52 provide a fluid spill passage and are positioned in the tank a distance above the bottom so that overflow water will escape prior to contact with the electrical connection from cord 21 with the motor 20 and are positioned below the point where water could enter the motor. The position of this connection is indicated in FIG. 2. The openings 52 also prevent contaminated water from rising high enough in the tank to contact intake water in pipe 40.
FIGS. 8-11 represent alternative embodiments generally 10A. The same or similar components are designated with the same reference numerals as for the first embodiment except followed by the letter "A". One of the differences between the two embodiments is the placement of the reservoir 16A below the bowl portion 12A and accordingly the water level in the reservoir 16A below that of the bowl portion 12A. A support post 15A for the bowl portion 12A is provided as well as a surrounding housing 22A extending along the sides and back of the bowl portion 12A.
In the FIG. 8 version, positioned on the reservoir 16A is a receptacle 24A which contains a cleaning fluid for cleansing the bowl portion 12A. The cleaning fluid is pumped from the receptacle 24A by means of the conduit 53A connected to the inlet side of the pump 54A driven by the motor 56A. A second conduit 57A extends from the outlet side of the pump 54A to the rim 14A of the bowl portion 12A where it is connected to inlet tube 55A.
FIG. 11 shows an alternative placement of the receptacle 24A outside of the surrounding housing 22A.
FIGS. 9 and 10 particularly illustrate the supply of water to the reservoir 16A, as well as to the rim 14A and bowl portion 12A. The pump 18A and motor 20A are located in the reservoir 16A. Water enters through the float valve assembly 37A and is delivered to the reservoir 16A by the outlet pipe 47A. However, in this instance, inlet water is supplied to the float valve assembly 37A by the supply line 59A. The inlet water is supplied through the back of housing 22A through line 59A and is controlled by a normally closed solenoid which opens, when electrically activated, the valve 60A. Pump 18A supplies water to the bowl portion 12A by means of the conduit 27A which is connected to conduits 27A' and 27A" as well as to manifold 25A. It also supplies water to the rim 14A by the conduit 30A connected to the manifold 25A.
As best seen in FIG. 10, there is a solenoid diaphragm valve 62A connected to conduit 27A'. It is operated by a pilot 63A and is maintained in a closed position until activated to supply water to the bowl portion 12A.
Referring specifically to FIG. 9, there is shown a water level sensor device generally 65A which includes a float 66A mounted on guide rod 64A having an electrical contact cap 67A on the end thereof. Contact by the float 66A with the cap 67A will send an electrical signal to motor 20A to operate pump 18A and thereby determine the maximum level of water 26A in reservoir 16A. Guide rod 64A is supported on bracket 61A which in turn is adjustably connected to support rod 51A. A trapway 49A communicating with the typical outlet drain 58A is also shown.
FIG. 12 illustrates yet another alternative embodiment (generally 70B). The same or similar components are designated with the same reference numerals as for the first embodiment, except followed by the letter "B". In this embodiment 70B, the pump 18B and the motor 20B are located outside of a plumbing fixture such as a wall hung toilet 10B. In this instance, flush water would be contained in reservoir 16B and is pumped from the reservoir 16B by means of the intake conduit 71B and the output conduit 72B. Water is diverted to the toilet 10B and/or the urinal 74B through the divertet valve 75B.
In a preferred manner, the volume of water pumped to the toilet 10B will be 1.6 gallons or less, whereas that normally delivered to the urinal 74B would be 1.0 gallon or less. The volume of water delivered to the toilet 10B and the urinal 74B can be controlled by a timing circuit as is explained later in conjunction with FIGS. 14 and 16A and B.
FIG. 13 shows in more detail a pump 18 which is driven by the motor 20. Both the motor 20 and the pump 18 are enclosed in sealed housings 29 and 31. An electric motor 13 drives rotor 34 having magnets 36 which attract magnets 38 carried by the pump rotor 41. This effects a pumping action causing water to enter at entrance 23 and to exit from manifold 25 (See FIG. 2). It should be noted that placement of the magnets 36 and 38 in their respective plastic housings effects a seal between the rotors 34 and 41, thus reducing the chance of an electrical short into the reservoir water. Foot members 46 provide for suitable spacing of entrance 23 from the bottom of reservoir 16 or 16A (See FIG. 2 or FIG. 3). A support member 48 positions the electric motor 13 at a predetermined distance above the floor of motor housing 29.
FIGS. 14-17C illustrate electrical controls for the previously described embodiments. A microprocessor 80 is programmed to effect the desired and described functions which in the instance of embodiment 10A include a short flush function, a long flush function (which can be activated by the seat cover being closed), as well as a special bowl cleaner flush. These functions can be initiated by the respective switch buttons 81, 82 and 83 which preferably are of the touch type. A switch of this kind would be a membrane switch which would have a long flush and a short flush function in the same switch housing. In the instance of the seat cover closed function, it has in addition to activating switch 84, a monostable multivibrator 85 which is commonly known as a "one-shot".
This particular seat cover closed function is described in more detail in commonly owned U.S. patent application Ser. No. 07/824,808 filed Jan. 22, 1992 which teachings are incorporated herein by reference. See also U.S. Pat. No. 3,590,397. Basically the idea is that the position of a magnet for the bowl lid is sensed by a sensor in the tank and the information leads to control of flushing (e.g. when the lid is first closed, a flush occurs). The level sensor 65A is also inputted to the microprocessor 80. The output side of the microprocessor 80 is connected to the main pump 18A, the pump 54A for the toilet bowl cleanser liquid, and the supply valve solenoid 62A by the lines 86, 87 and 88, respectively. As explained later, in conjunction with embodiment 70B, the short flush button 81 will represent the function of the urinal flush key being pressed as shown at 118 in FIG. 16B.
Referring to FIGS. 15A and B, these represent the flow diagram for embodiment shown in FIGS. 1-7. The first step in the operation of the pump toilet 10 after the start 89 is the decision step 90 as to whether a switch has been activated such as by a key or push button. If a key is not activated, a background timer is updated at 91 and at 92. It is checked to see if it has a designated number of units. If it does, it is reset at 93 and a flush timer is looked at at 94 to determine if it equals 0 seconds. If it does not, it is decremented at 95.
This background timer will operate in conjunction with the flush timer in a manner to be explained in conjunction with the actuation of the later described activation of the long and short keys at 97 and 105 and the timing of the main pump 18. At step 96, the flush timer is checked to see if it is at greater than 30 seconds. If it is not, this allows activation of either the long or short keys at 97 or 105.
If it is the long flush key at 97, such as activated by switch 82, then main pump 18 is turned on at step 99 after a valid input check at 98. This immediately delivers water to the rim portion 14 byway of conduit 30, as well as to the jet in the bowl portion 12 through conduit 27. After a delay of 3.17 seconds as indicated at step 100, the pump 18 is turned off at step 101. This will deliver 1.6 gallons of water and would normally be used to flush fecal matter. At step 102 there is added 60 seconds to the flush timer after which there is a determination made at 103 and 104 as to whether the long or short key has been pressed before another flush cycle is initiated. If instead of the long flush cycle, a shorter one is selected, the short flush key 105 is activated such as by switch 81. After an input check at 106, the pump 18 is activated at 107, and it is operated for 2.07 seconds as indicated at 108. It is turned off at 101 after delivering 1.0 gallon of water. This short flush would normally be used to flush urine and paper. Again 60 seconds would be added to the flush timer as indicated at 102.
The background and flush timers are programmed in conjunction with steps 96 and 102 so that there are two delay features. The first involves a situation where a second flush occurs more than 30 seconds but less than 60 seconds after the first flush. It will be recognized that there is always a 30 second delay between flushes in order to refill the tank 17. In this situation, the toilet may be flushed a second time after the initial 30 second delay, but if this is done, it may then not be flushed a third time until there has been a maximum of 90 seconds from the first flush and add 60 seconds to each flush thereafter. The second alternative involves a situation where the second flush does not occur within 60 seconds of the first flush or 90 seconds after any following flushes. In this case, the background timer automatically resets and the toilet can be flushed again with no limit other than the 30 seconds required to fill the tank. In essence, this means that the toilet may be flushed every 60 seconds without being limited, as in the first case.
Referring to FIGS. 16A and B, these represent the flow diagram for embodiment shown in FIG. 12. It will be seen that steps 89-96 are the same as previously described in conjunction with FIG. 15A. If the toilet flush key 110 is selected, which would be activated such as by switch 82, then the same steps 98-102 would be followed as previously explained in conjunction with FIG. 15B. Similarly, the same determinations of the status of the toilet and urinal flush keys are made at 116 and 117. In the event the seat flush feature is activated such as at 112 and by the lid closed switch 84, the same procedure will be followed as indicated at steps 98-102 for the long flush. In the instance where the urinal flush key is activated at 118, a short flush cycle is initiated which is similar to steps 106-108 and 101 and 102 as described in conjunction with FIG. 15B.
Referring to FIGS. 17A, B and C, these represent the flow diagrams for the embodiment shown in FIGS. 8-10. The steps 89-96 are the same as previously described in conjunction with FIGS. 15A and 16A except for step 122 where supply valve 60A is turned on. If the long flush key 97 is activated, then main pump 18A is turned on at step 99 after a valid input check at 98. This immediately delivers water to the rim portion 14A by way of conduit 30A. Water is prevented from flowing through conduit 27A to the jet in the bowl portion 12A as jet diaphragm valve 62A is closed. After a delay of 0.5 second as indicated at step 123, the solenoid pilot 63A is activated at step 124. This delivers water from pump 18A to flow to the jet in the bowl portion 12A as well as to the rim portion 14A through conduit 30A. After 3.5 seconds as seen at step 100, the valve 62A is closed at step 125. After a delay of 3.0 seconds as indicated at step 126, water continues to flow to the rim portion 14A. After the 3 second delay, the main pump 18A is turned off at step 101. The remaining steps 102-104 are the same as previously described in conjunction with FIG. 15B.
A seat activated function is also shown at step 136 in conjunction with long flush steps 98-101 as previously described.
In the event a shorter flush is desired, such as to flush urine or paper, the short flush button 81 is activated to initiate the short flush as indicated at step 105. The subsequent steps 106-130 are essentially the same as indicated for the respective steps 98-126 except for step 108 where the pump is operated for 2.5 seconds rather than 3.5 seconds.
In addition to the previous flushing functions, there is also an independent cleanser flush indicated at step 131 which delivers a cleaning fluid to the rim portion 14A. After a valid input check at 132, the main pump 18A and the sanitary pump 54A are turned on at step 133A. After a time period of 6.0 seconds at step 133B, the main pump 18A and the sanitary pump 54A are turned off at step 134 after which there is a delay period of 60 seconds as shown at 135.
Referring also to FIGS. 14 and 17B, it is seen that a signal is sent to the microprocessor 80 from the level sensor 65A. This signal is shown as activated at 137 with the main pump 18A being turned on at 138 as well as the jet solenoid to pump water from the reservoir 16A and to the toilet 10A in order to prevent an overflow condition in the reservoir 16A should float valve assembly 37A malfunction. After a delay of 4 seconds, the main pump 18A and jet solenoid are turned off at 140. If the overflow feature has been active 3 times in 60 minutes as shown at 141, the supply valve 60A is turned off at 142 and a waiting period initiated at 143. An additional safety feature in conjunction with the microprocessor 80 is the closing of supply valve 60A in the event of electrical failure to the control circuit and pump 18A and the failure of float valve assembly 37A to close.
Thus our invention provides an improved toilet flushing system which utilizes a minimum of water for each function. The need for double flushing is reduced. While preferred embodiments have been described above, it should be readily apparent to those skilled in the art from this disclosure that a number of modifications and changes may be made without departing from the spirit and scope of the invention. For example, while a delivery of flush water to the rim in a first sequence, to the rim and bowl in a second sequence, and to the rim only in a third sequence has been described in conjunction with the pump toilet, this system can be altered to deliver water only to the rim by eliminating the conduits 27, 27A, 27A' and 27A" to the bowl as well as the valve 62A. Alternatively, flush water delivery only to the bowl can be effected by the herein described system by elimination of the conduits 30 and 30A to the rim and valve 62A. Any combination of the delivery of flush water to the rim and/or bowl can be effected by suitable valving. For example, if it is desired to have water flow only to the bowl in one sequence with a rim-bowl-rim delivery, a valve such as 62A can be placed in conduit 30A. Alternatively, a 3-way valve could be used in conjunction with conduits 27, 27A, 27A', 27A" and 30A.
A long and short flush cycle have been described in conjunction with the previously disclosed embodiments. It should be understood that these two cycles can be employed independently of the bowl cleaner flush or the seat cover activation. In the same manner, a third longer flush cycle could be utilized with the long and short flush cycle as well as an intermediate one with varying quantities of flush water. Similarly, if desired, only a single flush cycle could be employed by eliminating one of the flush cycles and still operate the pump for a period of time to deliver a quantity of water from the reservoir tank to the toilet bowl. While the reservoir 16B and pump 18B have been described in conjunction with one toilet 10B and one urinal 74B, a multiplicity of these plumbing fixtures could be employed by interconnection with output conduits 73B and 74B. All of the flush cycles previously described in conjunction with embodiment 10A can be utilized with toilet 10B.
Further, the seat cover and sanitation functions could be eliminated and still accomplish the water saving feature. Similarly, the overflow features could be eliminated and still accomplish the described water saver functions. Also, the cleanser function could be automated such that the processor would count uses such that after a given number of uses of a toilet (e.g. thirty), the cleaning cycle would automatically occur. A long and short flush cycle have been effected by operating a pump motor for different time intervals. This could also be accomplished by running the pump motor at two different speeds as shown alternatively in dotted line in FIG. 15B. All such and other modifications within the spirit of the invention are meant to be within the scope of the invention. | A toilet has a pump to deliver selected quantities of water from a reservoir to a toilet bowl so as to effect a water savings. In one aspect, both the motor and pump are positioned in the reservoir to deliver water to both the rim and bowl portions. In another aspect, there are conduits connected between the basin, the rim and controls which are provided to deliver water to the rim and bowl either independently, simultaneously or in selective sequences. In alternative embodiments, a refill tube is connected to an intake conduit and the rim of the bowl to effect a water seal, a fail safe valve is connected to the supply conduit, a receptacle with a cleaning fluid and a pump is connected to the bowl and there are at least two receptacles for receiving waste. | 4 |
BACKGROUND
The present invention relates to an opening cylinder of an open-end spinning device having a base body containing at least parts of a face of the opening cylinder, over which the opening cylinder is installed on a shaft that is supported in a bearing for rotatable support of the opening cylinder, with a clothing holder containing at least part of a face of the opening cylinder, whereby the base body is located on the side of the shaft away from the bearing and whereby an axial distance exists between the base body and the clothing holder, producing a gap extending in a radial direction.
Opening cylinders are used with open-end spinning devices to prepare the fibers to be spun by detaching the fibers from a fiber sliver. To achieve this, the fiber sliver is fed into an opening cylinder housing in which it is opened into individual fibers by an opening cylinder provided with teeth or needles. In this process, the opening cylinder rotates at high speed. The individual fibers are then conveyed through a fiber channel from the housing of the opening cylinder to a spinning element, e.g. a spinning rotor.
To ensure the ability of the opening cylinder to rotate, it is installed on a shaft that is supported by a bearing. During the operation of the opening cylinder, the bearing is exposed to dust and fiber fly that is practically always present in a spinning installation. For this reason, the state of the art has already configured opening cylinders in such manner that their bearings are accessible, in particular for inspection and cleaning purposes.
DE 31 23 480 discloses an opening cylinder having a base body on which a combing clothing is pushed and fastened by means of a clamping mechanism. When the combing clothing support is removed from the base body, the area of the bearing can be inspected through radial bores going through the base body. In another embodiment, the opening cylinder has a separately installed face located on the outer ring of the bearing. The first embodiment of the opening cylinder shown here allows access to the interior of the base body, but the bearing itself is practically inaccessible because only a very narrow gap is left between the base body and the outer ring of the bearing, and besides, access is possible only through the bores.
The other embodiment has the disadvantage that the clothing support must be made at the same time so as to fit exactly with the base body as well as the face toward the bearing. The latter can be mounted by means of a fit to the outer ring of the bearing and is at a distance from the clothing ring, as the surface toward the bearing does not rotate together with the clothing ring. Furthermore, this embodiment has the disadvantage that the base body and the outer ring of the bearing are barely at a distance from each other, so that cleaning of the interior of the opening cylinder appears to be easy in principle, but not near the bearing. In particular, the not rotating face toward the bearing furthermore causes the production of this opening cylinder and the disassembly of the clothing ring to be expensive.
SUMMARY
It is a principal object of the present invention to design an opening cylinder in such manner that the disadvantages of the state of the art are avoided and good cleaning of the bearing and of an area across from it is possible, whereby the opening cylinder is at the same time made in several parts, so that the clothing can easily be replaced when it is worn out. Additional objects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.
The objects are attained by an opening roller designed according to the invention wherein, in order to bare the gap or an area of the base body across from it, the clothing holder is designed so as to be removable in the axial direction across the bearing and in that the clothing holder supports the face towards the bearing. Thanks to the opening cylinder designed according to the invention, a maintenance worker is able to easily clean fibers or grease deposited in the area of the bearing and, if the base body extends beyond the gap, in this extended area. Also, an opening cylinder designed according to the invention can be produced and mounted economically and easily. Here, the clothing holder can advantageously be pushed in the direction across the bearing, away from the base body of the opening cylinder, and the clothing holder together with the clothing support can be pushed toward the bearing in order to make the gap accessible, whether the clothing holder and the clothing support are made in one piece or in several pieces. Due to the fact that the clothing holder holds at the same time the face toward the bearing, it can be attached advantageously on the opening cylinder and rotates together with the clothing, so that it does not move in relation to the clothing.
In art especially advantageous further development of the invention, the opening cylinder is made with a stop for the clothing holder, whereby the stop acts in the axial direction and is located on the base body. On it, the clothing holder comes to lie against the base body in the axial direction. The clothing holder can also be stopped advantageously via the clothing support, whereby the clothing support contacts a stop of the base body in axial direction. The clothing holder can advantageously be disassembled from the base body so that it can be removed for the replacement of the clothing. It is especially advantageous if the clothing holder is attached for that purpose with fastening means to the base body of the opening cylinder.
In an advantageous further development of the invention, the fastening means for the clothing holder is itself located at least in part on the base body. For this purpose, the fastening means is advantageously made in the form of threads on the base body, whereby the clothing holder itself advantageously supports the corresponding part of the threads, so that the two can be attached together and so that the corresponding parts of the threads are the fastening means located on them.
In an advantageous further development of the invention, the fastening means is made in the form of a bore in the base body or the clothing holder, whereby the bore is advantageously provided with threads. In this manner, the clothing holder can easily be attached to the base body, e.g. by means of screws. A fastening means in the form of clip-on connection between the base body and clothing holder is especially advantageous. Especially easy assembly and disassembly of the clothing holder or clothing support can thus be effected on the base body. For this, the clip-on connection advantageously exerts a force in the direction of the base body. This ensures secure connection between the two components.
In an advantageous further development of the invention, the minimum width of the gap between the base body and the bearing is 1.5 mm. An embodiment in which the gap's smallest width is 2.5 mm is especially advantageous. The gap's maximum width is advantageously 19 mm, and a width of 9 mm is especially advantageous. The height of the gap is here advantageously less than 16 mm. Advantageous further developments of the invention are set forth in the claims and can be understood from the description and the drawings of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a section through an opening cylinder with bearing, where the clothing holder and the clothing support are separate components.
FIG. 2 shows the section of FIG. 1 , without clothing holder and support.
DETAILED DESCRIPTION
Reference is now made to particular embodiments of the invention, examples of which are shown in the drawings. Each embodiment is provided by way of explanation of the invention, and not as a limitation of the invention. The invention includes modifications and variations to the embodiments described herein.
The longitudinal section of the opening cylinder 1 of FIG. 1 according to the invention shows its structure and position for rotatable support on the bearing 21 . The opening cylinder 1 consists of a base body 12 that is attached by means of a force fit on the shaft 2 on the side away from the bearing 21 . The shaft 2 is supported by means of cylinder bearings that are not shown on the shaft 2 , whereby the bearing sleeve 210 on the right side of the base body 12 is the outer ring of a cylinder bearing and does not rotate together with the opening cylinder 1 .
In addition to the base body 12 , the opening cylinder 1 consists also of the clothing holder 3 which is attached by means of fastening means 5 , in this case in the form of screws, to the base body 12 . A ring-shaped clothing support 4 is located between the clothing holder 3 and the base body 12 . The clothing support 4 is impinged on one side by the base body 12 and on the other side by the clothing holder 3 .
The clothing support 4 in form of a ring 41 is stopped by the stop 8 of the base body 12 with its one edge 46 away from the bearing 21 . If the clothing holder 3 and the clothing support 4 are made in one piece, the opening cylinder can also be made that way, i.e. so that the edge 46 of the clothing support 4 contacts the stop 8 of the base body 12 . In case of a clothing holder 3 being in one piece with the clothing support 4 , there is also the possibility for the clothing holder to be stopped by the inside stop 81 of the base body 12 directly. The ring 41 is provided on its outer circumference 43 with clothing consisting of teeth or needles [not shown].
In another advantageous embodiment of the invention, the base body 12 and the ring 41 are interlocked in the direction of the circumference. For this purpose, the edge 46 has an opening 7 in the area of its cylindrical inner wall, into which a projection 6 of the base body 12 extends. The projection 6 and the opening 7 thus produce a positive connection as seen in the circumferential direction of the opening cylinder.
Thanks to this positive connection produced by the opening 7 and the projection 6 between the clothing support 4 in form of a ring 41 and the base body 12 , it becomes possible to absorb the forces produced by the opening of the fiber sliver and acting in the circumferential direction of the clothing support 4 . Pressing the clothing support 4 in the axial direction on the base body 12 in order to achieve a non-positive connection is therefore not necessary. The joint between the clothing support 4 and the clothing holder 3 are preferably closed as much as possible in this process, so that no fibers may enter.
In mounting the clothing holder 3 and the clothing support 4 , these are pushed in the axial direction across the bearing 21 on the base body 12 . Due to the design of the base body with stop 8 , a precise positioning of the clothing support 4 on the base body 12 is possible, also as seen in the axial direction. The clothing support 4 is held on the stop 8 through the fastening means 5 and the clothing holder 3 , without having to provide for this any pre-stress acting in axial direction, if a positive connection exists between the base body 12 and the clothing support 4 in the circumferential direction.
The base body 12 is attached on the shaft 2 via the seat 13 . The seat 13 and the shaft 2 constitute a compression joint so that a secure and strong connection is ensured between the base body 12 and the shaft 2 . The shaft 2 is supported rotatably via the bearing 21 in roller bearings. The roller bearings are sealed in a known manner by means of sealing disks, but care must nevertheless be taken that the support is shielded against the influence of dirt. This is achieved with the opening cylinder 1 of FIG. 1 by the clothing holder 3 which sits on the base body 12 and forms a tight seal, as well as through the fact that only a very narrow gap 22 is left between the clothing holder 3 and the bearing sleeve 210 . It may nevertheless be necessary to clean entering dirt from the area of the bearing, and for this purpose the gap 22 of the bearing 21 becomes easily accessible once the clothing holder 3 and the clothing support 4 have been removed. In removing the clothing holder 3 , it as well as the clothing support 4 are pushed in the axial direction across the bearing 21 once the fastening means 5 have been loosened. If necessary, the clothing support 4 can then also be replaced by removing it completely together with the clothing holder 3 and inserting a new one.
FIG. 2 shows a representation that is similar to FIG. 1 , but without clothing support and clothing holder. The base body 12 which is attached on the shaft by its seat 13 produces a gap 22 with the bearing sleeve 210 of bearing 21 . Base body 12 and bearing sleeve 210 are here at a distance 9 from each other. In order to prevent the entry of dirt into the area between the base body 12 and the bearing sleeve 210 , it could be attempted to reduce the distance 9 to a minimum. However, the utilization of the bearing in a spinning installation does not allow this. This is because fiber-containing dust is generated in yarn production that would not only overcome this narrow gap but would cause blockage of the moving parts at such narrow distance from each other. Nor does covering the gap 22 with the clothing holder 3 offer sufficient protection in order to prevent fibers from entering the gap 22 . Although the clothing holder 3 is connected to the base body 12 of the opening cylinder in such manner that no fibers can penetrate, a small gap does exist between the clothing holder 3 and the bearing sleeve 210 , since these two move in relation to each other.
By designing the base body 12 so that its face 11 is located on the side away from the bearing 21 , it is possible to make the gap accessible in a radial direction. Due to the fact that the second remaining face 11 of the opening cylinder (see FIG. 1 ) is not formed by the base body 12 but by the clothing holder 3 , the removal of the clothing holder 3 uncovers at the same time the gap 22 . For disassembly, after loosening the fastening means, the clothing holder 3 , whether made in one piece with the clothing support 4 or in two parts, is simply taken in the axial direction away from the base body 12 and over bearing 21 , so that the gap 22 is freely accessible in the radial direction. For the embodiment in two parts, the ring 41 must of course also be pulled off the base body.
During the disassembly of the clothing holder and the clothing support 4 , the opening cylinder 1 is in such position with its bearing 21 on face 11 of the base body 12 that the operator requires no other device in order to handle the opening cylinder 1 during the replacement of the clothing or the cleaning of gap 22 . With a design of the base body 12 and of the free end of the shaft 2 , certain dimensions must be kept so that the base body 12 can be securely attached to the shaft 2 via its seat 13 . This is achieved as already indicated previously, by means of a force fit. For a replacement of the clothing the base body must not be removed, so that once it is attached, it remains on the shaft 2 in spite of the replacement of the clothing.
For the dimensions of the gap width it has been shown that a value of approximately 4 mm provides sufficient access for cleaning. For the height of the gap it has been shown that for the above-mentioned width, a height of 13 mm still provides favorable conditions for the cleaning of the gap.
In addition to scrapers or brushes that make mechanical cleaning possible, compressed air can also be used and is then blown by a maintenance worker by means of a nozzle into the gap. As for the dimensions of the gap, for the width that is finally determined by the cleaning means, it is also necessary to provide a greater width for a greater height of the gap.
It should be apparent to those skilled in the art that modifications and variations can be made to the embodiments described herein without departing from the scope and spirit of the invention. It is intended that the invention include all such modifications and variations as come within the scope of the appended claims and their equivalents. | For the design of an opening cylinder ( 1 ) for an open-end spinning device where the opening cylinder ( 1 ) has a face ( 11 ), it is proposed that the base body ( 12 ) of the opening cylinder ( 1 ) be located on the end of a shaft ( 2 ) away from the bearing ( 21 ), whereby an axial distance ( 9 ) exists between the base body ( 12 ) and the bearing ( 21 ). To expose the gap ( 22 ) for maintenance purposes, the clothing holder ( 3 ) is designed so as to be removable in the axial direction across the bearing ( 21 ), whereby the face ( 11 ) towards the bearing ( 21 ) is formed on the clothing holder ( 3 ). | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to provisional application U.S. Serial No. 60/305,766 filed on Jul. 16, 2001.
BACKGROUND OF THE INVENTION
[0002] This invention relates to a method and apparatus for a household appliance such as, but not limited to a refrigerator. More specifically, this invention relates to such an appliance being able to monitor power outage duration.
[0003] Refrigerating appliances such as refrigerators, freezers, and related appliances require electrical power for refrigeration. For example, electrical power can be used for powering a compressor for compressing a refrigerant, an evaporator for generating cool air and/or a refrigerating fan for discharging cool air, or otherwise using external power to refrigerate. When this external power is interrupted such as during a power outage, refrigeration ceases. If the power outage is sufficiently long in duration, the contents of the refrigerator, typically food, can spoil.
[0004] Thus, if an individual is aware that a power outage has occurred, an individual is suspect of the food in the refrigerator and its fitness for consumption. If only a very short power outage has occurred, then there is no real cause for concern. However, if a power outage of sufficient duration has occurred, an individual may find it desirable to discard food from the refrigerator and/or otherwise avoid consuming it. Problems relating to power outages can occur in other types of household appliances as well.
[0005] Unfortunately, an individual may not be able to tell that a power outage has occurred or the duration of that power outage.
[0006] Thus, it is a primary object of the present invention to provide a method and apparatus for a household appliance that improves over the state of the art.
[0007] It is a further object of the present invention to provide a household appliance capable of automatically determining that a power outage has occurred.
[0008] Yet another object of the present invention is to provide a method and apparatus for a household appliance that determines the duration of a power outage.
[0009] Still another object of the present invention is to provide a method and apparatus for a household appliance that is capable of discerning that multiple power outages have occurred.
[0010] Yet another object of the present invention is to provide a method and apparatus for a household appliance that alerts a user that a power outage has occurred.
[0011] Another object of the present invention is to provide a method and apparatus for a household appliance that requires an acknowledgement from the user that the user acknowledges that a power outage has occurred.
[0012] These and other objects, features, or advantages of the present invention will become apparent from the specification and claims that follow.
SUMMARY OF THE INVENTION
[0013] The present invention is a method and apparatus for monitoring of power outages in a household appliance such as a refrigerator. The household appliance determines that a power outage has previously occurred. The household appliance then determines the duration of the power outage. The household appliance then alerts a user of the duration of the power outage.
[0014] One methodology of the present invention includes periodically storing a time. A current time is compared to a previously stored time. Based on this comparison, the duration of a power outage can be determined, as the current time is maintained but the times are not stored during power outages. Thus, upon reset after a power outage, the current time can be compared to the last stored time in order to determine the occurrence and duration of a power outage.
[0015] A refrigerating appliance according to one aspect of the present invention includes a refrigeration system, an external power source operatively connected to the refrigeration system and an intelligent control operatively connected to the external power source. A clock is operatively connected to the intelligent control and a second power source is electrically connected to the clock such that the clock is operable during a power outage of the external power source. The intelligent control is adapted for determining the duration of the power outage.
[0016] According to another aspect, the present invention provides for determining if more than one power outage has occurred, as well as determining the time and duration of each power outage or a total duration for multiple power outages.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] [0017]FIG. 1 illustrates an exemplary refrigerator having a display portion for displaying the duration of a power outage effecting the refrigerator.
[0018] [0018]FIG. 2 is a pictorial representation of a user interface according to the present invention.
[0019] [0019]FIG. 3 is a block diagram of a refrigerating appliance according to one embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0020] [0020]FIG. 1 illustrates a refrigerator 10 having a side-by-side configuration. In a side-by-side configuration, the refrigerator 10 includes two refrigerating compartments, one being a refrigerator compartment, the second being a freezer compartment. There is a door 12 to the refrigeration compartment and a door 14 provides access to the freezer compartment. The freezer compartment door 14 may contain a water and ice dispenser, generally shown at 16 . In addition, the water and ice dispenser 16 includes a lower receptacle 18 for receiving cups and dispensing water and ice therein. Above the receptacle 18 is a user interface 20 that is used to communicate power outage information.
[0021] [0021]FIG. 2 illustrates the user interface 20 in greater detail to include a central panel display 22 that is preferably a graphic liquid crystal display. Three selection buttons 24 , 26 , 28 are located along the lower edge of the display 22 . A menu button 30 is located to the left of the display 22 , and a message button 32 is located to the right of the display 22 . An LED 34 is positioned directly above the message button 32 .
[0022] In a normal or standard mode (not shown) wherein there has been no power outage, the display 22 may indicate which of the buttons 24 , 26 , 28 may be pressed to obtain water, cubed ice or crushed ice in the receptacle 18 of the water and ice dispenser 16 . However, where there has been an interruption of external power and then external power has been restored to the refrigerator 10 , the display 22 displays messages indicating the time and date of the last power outage, the time and date when the power was restored, the duration of the power outage, and the current time and date. Where multiple power outages have occurred, the time and duration of each power outage can be displayed and/or the accumulated total of the duration of each power outage.
[0023] Thus, after a power outage has occurred, power outage information is displayed to alert a user that a power outage has occurred. Further, the user is alerted of the duration of the power outage. Based on the duration of the power outage, the user can then make an informed decision as to whether or not the contents of the refrigerator are unaffected by the power outage or whether there is some likelihood that the contents of the refrigerator were spoiled or otherwise rendered undesirable by the power outage.
[0024] [0024]FIG. 3 illustrates one embodiment of a system according to the present invention. In FIG. 3, the user interface 20 is operatively connected to an intelligent control 40 . The intelligent control 40 may be one or more microcontrollers, processors, microcomputers, integrated circuits, a portion of an integrated circuit, electronic control circuit, or other type of intelligent control. The intelligent control 40 is also electrically connected to a clock 36 . The clock 36 is preferably a real time clock.
[0025] An external power source 42 is used to power the system of the present invention including the refrigeration system 44 . In addition, a power source 38 is used to provide power to the clock 36 . When there is an interruption in the external power source 42 and a resulting power outage, the power source 38 continues to power the clock 36 . The power source 38 may be a super capacitor of a type known in the art. Alternatively, the power source 38 can be a battery or other power source that functions independently of the external power source 42 . Preferably, the power source 38 is charged or recharged by the external power source 42 while the refrigerator 10 is operating normally. When the external power source 42 is lost, the power source 38 powers the clock 36 . Preferably, the power source 38 functions as a backup power source that is only needed during times of power outage.
[0026] The user interface 20 that is operatively connected to the intelligent control 40 includes the display 22 as well as one or more inputs. The inputs can be used for receiving a user acknowledgement of a power outage. After a power outage has occurred, a duration of one or more power outages can be displayed on the display 22 . Then a user can be instructed to press one or more buttons or to otherwise actively acknowledge that the power outage message has been received by the user.
[0027] The intelligent control 40 is also operatively connected to a memory 46 . The memory 46 is preferably a nonvolatile memory. The present invention contemplates that the memory 46 may be internal to the intelligent control 40 . The memory 46 is used to store time information. For example, the memory 46 can contain prior times during which the refrigerating appliance was in operation and/or one or more durations of a power outage. Where the memory 46 contains a prior time, the intelligent control 40 can determine or compute a duration of the power outage when the intelligent control 40 also uses a current time from the clock 36 . Such a computation can occur upon reset of the intelligent control 40 , such as would happen when a power outage of the external power source 42 results in turning the intelligent control 40 off, and the restoration of power through the external power source 42 results in turning on the intelligent control 40 . Upon the experience of this reset condition, the intelligent control 40 then checks the last stored time in the memory 46 and compares this prior time to a current time from the clock 36 . Comparison of these times allows the intelligent control 40 to determine if a power outage has occurred. If a power outage has occurred this allows the intelligent control to determine the duration of the power outage by determining the difference in time between a stored prior time and the current time. The present invention also contemplates that more than one power outage can be determined by recording the last time before each power outage and storing the then current time once the power outage has been restored. Thus, in this manner multiple power outages can be recorded and their respective durations can be determined. The present invention also provides for the intelligent control 40 being adapted to add or otherwise cumulate multiple power outages so that a total power outage duration can be calculated and displayed. Each of these times can also include a date, so that even extended periods of power outages can be determined.
[0028] The present invention contemplates use in any number of household appliances, including, without limitation, refrigerators, dishwashers, laundry appliances, and other types of household appliances.
[0029] Thus, a power outage duration feature has been disclosed. The present invention contemplates variations in the parts and components used, the specific computations used, the type of alert used, if any, and other variations within the spirit and scope of the invention. | Methods and apparatus for monitoring power outages in a household appliance such as a refrigerator are disclosed. According to the method, a household appliance determines a prior occurrence of a power outage to the appliance. The household appliance then computes a duration of the power outage. Further, the household appliance alerts a user of the duration of the power outage. | 5 |
RELATED APPLICATION
This application is a continuation-in-part of application Ser. No. 09/392,293, filed Sep. 8, 1999, now U.S. Pat. No. 6,102,896.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to disposable injector devices and more specifically it concerns a check valve modification to isolate pressure upon administration of medicament through a patient's skin.
2. Description of the Prior Art
In general, a number of problems and risks have been associated with the parenteral injection for at least a century. For instance, the use of a standard hollow metal needle attached to a syringe requires thirteen steps and creates health risks not only for the patient, but the medical personnel as well.
This process can only be administered by adequately trained medical personnel. The risks of incorrect dilution or dose measurement are apparent. Any failure of sterile technique may lead to infection, ultimately presenting a greater risk to the patient. The final injection step requires training and practice to achieve the correct depth and dexterity in order to deliver the injection quickly and with minimal pain. Due to the lack of trained personnel, this is a major obstacle to successful immunization campaigns.
Advancements have, in fact occurred. Today, most syringes and needles are disposable, however, such disposable syringes are routinely re-used in developing countries and by people who suffer from drug addiction. Because of this re-use, infections such as hepatitis and AIDS are at a higher risk of transmission.
Furthermore, few drugs or vaccines are injection-ready stable liquids, rather the great majority of parenteral preparations are freeze-dried, thus requiring dilution before injection and constant refrigeration during storage.
Finally, patient compliance and compliance with the leading health organizations are at issue and numerous difficulties must be conquered. When standard syringes and needles are used, patients often do not return to field stations for follow-up doses. For instance, infants, who require a series of injections, fail to return due to the pain and anxiety a needle creates. Present parenteral injection technology, the World Health Organization (WHO) claims, is incompatible with requirements for the planned Global Programme of Vaccination and Immunization (GPV) initiatives.
An estimated six additional parenteral vaccines will be recommended for childhood vaccination by the year 2005, requiring a total of 3.6 billion immunization injections per year. The total number of parenteral injections, including injected drugs as well as vaccines, will be roughly ten times this number. Major health care providers such as UNICEF, the WHO and CDC have recently confirmed the requirement of a radical new technology that can be used by personnel with minimal training and that is safer, more convenient, and more comfortable than the syringe and needle. (Jodar L., Aguado T., and Lambert P-H, (1998) Revolutionizing Immunizations Gen. Eng. News, 18, p. 6.) Criteria include: heat stability, no cold chain of refrigerators; affordable; zero risk of cross infection; individual injection devices and vaccine doses packaged together; simple and easy to use; easy and safe disposal; no wastage; minimal discomfort, and minimum volume.
Some delivery devices address these criteria. It is known to package parenteral medications in disposable, single dose delivery devices. One approach is the packaging of single doses of vaccines in simple plastic blisters or collapsible tubes with an integral hypodermic needle attached. (U.S. Pat. Nos. 4,013,073 and 4,018,222). The Uniject™ plastic blister device (Becton Dickinson and Co.) is another example. Known single-use injectors require medical expertise, however, and the naked needle is a drawback.
Certain single-use injectors self-destruct, thereby eliminating the temptation to re-use. Examples are disclosed in U.S. Pat. No. 3,998,224 to Chiquiar-Arias, U.S. Pat. No. 4,233,975 to Yerman, and U.S. Pat. No. 4,391,272 to Staempfli. Another example is the Soloshot™ syringe (manufactured by Becton Dickinson). However, drawbacks include the price, which is more expensive than a standard syringe, and the requirement of medical personnel to effectively use such a device.
Further improvements include breakable tabs and snap rings in plastic container, such as bottles, in order to prevent tampering and ensure sealing. An early example is disclosed in U.S. Pat. No. 3,407,956 to Linkletter, which shows a removable and replaceable bottle cap. The plastic cap possesses an annular bead molded to the inside, which overrides a similar bead molded on the outside of the neck of the bottle. Natural elasticity of the materials used in manufacturing the cap permit it to expand temporarily, allowing the beads to override and then to contract again immediately once the beads have passed each other. This seats the cap firmly on the container, thereby providing an effective seal.
Needleless injectors exist now as well. These injectors use a fine stream of pressurized liquid to penetrate the skin. Pain is considerably less than that experienced during a conventional injection. Early designs used high pressure throughout the injection, to punch a hole through the tough epidermis. However, the bulk of the injection could then be infused along the initial track under much lower pressure. U.S. Pat. No. 2,704,542 to Scherer and U.S. Pat. No. 3,908,651 to Fudge disclose examples of this design. Ultimately, the engineering demands of changing the pressure during the injection and resulting complexity have limited the use of such devices.
Standard high-pressure needleless jet injectors are also inherently complex, requiring precision engineering of a number of machined steel parts. Most of the designs focus on the production of robust, reliable, heavy-duty machines capable of many injections at high rates for mass immunization campaigns. See Ismach U.S. Pat. No. 3,057,349 (1959), Landau U.S. Pat. No. 4,266,541 (1981), U.S. Pat. No. 5,746,714 (1998), D'Antonio et al PCT patent WO98/17332 (1998), Parsons PCT patent WO98/15307 (1998). Infection due to cross-contamination in such jet injectors occurs, most likely due to the high pressure in the tissue. As the tissue is distended by the injection and the pressure simultaneously falls in the injector, the injector sucks the liquid which may be contaminated with blood or interstitial fluid. The development of single-use vials which insert into the jet injector addresses this problem. Such an approach may be combined with a replaceable nozzle and a vaccine fluid path of cheap plastic, as disclosed in U.S. Pat. No. 4,266,541 to Landau.
Developed under the trademark “Intraject”, a mono-dose disposable jet injector by Weston Medical, UK, this injector uses a highly compressed gas in a cannister to propel the vaccine dose. See Lloyd J. S., Aguado M. T., Pre-Filled Monodose Injection Devices: A safety standard for new vaccines, or a revolution in the delivery of immunizations?, Global Programme on Vaccines and Immunization, World Health Organization, May, 1998.
It is known that extraordinary stability can be conferred on very labile biomolecules by drying them in glasses formed from certain sugars. Trehalose is one example. See U.S. Pat. No. 4,891,319 to Roser, and Colaco C., Sen S., Thangavelu M., Pinder S., and Roser, B. J., Extraordinary stability of enzymes dried in trehalose: Simplified molecular biology. Biotechnol. 10 1007-1011 (1992). A similar technique can be applied to stabilized vaccines. See Gribbon E. M., Sen S., Roser B. J. and Kampinga J., Stabilization of Vaccines Using Trehalose (Q-T4) Technology, in F. Brown, (ed) New Approaches to Stabilization of Vaccine Potency Dev Biol Stand Basel Karger 87 193-199-(1996).
More recently, glass-forming preparations utilizing sugar derivatives includes the development of stabilization brought about by the active biomolecules remaining in solid solution in the “solid solvent” phase of the glass matrix. The biomolecules remain stable due to the high viscosity of the inert glass. In these solid solutions, molecular diffusion and molecular motion are negligible. Chemical reactions, which depend on the reactive species being free to diffuse together, are non-existent. Providing the glass itself is chemically non-reactive and dry, the product typically remains stable at temperatures up to the softening point of the glass, often expressed as the “glass-transition temperature” or Tg. Molecular diffusion and degregation commence only upon the softening and melting of the glass. Even at temperatures above the Tg, damage will only occur after a certain period of time. Because degradation reactions are chemical processes with typical kinetics, the factor determining product damage is a mathematical product of the elevated temperature and the time of exposure rather than just the high temperature. Even fragile compounds in these glasses may be briefly exposed to high temperatures with insignificant damage. While the sugar glass formulations have advantages in stability over conventional parenteral preparations, other difficulties of conventional parenteral injection remain, such as dose mismeasurement, pain, and infection risk.
Also suitable for stabilization of parenteral medications (See U.S. Pat. No. 4,698,318), the phosphate glasses are typically much stronger than sugar glasses and because of this strength, phosphate glasses are often used as structural elements in bone repair. Mixtures of metal carboxylates such as the acetate salts of sodium, potassium, calcium and zinc also form excellent glasses, PCT Publication No WO90/11756. Through the use of different mixtures of individual carboxylates and different metal cations, it is possible to tailor these phosphate and carboxylate glasses to dissolve at different, specific rates in body fluids. Composed of simple chemicals normally present in the body, phosphate and carboxylate glasses exhibit low toxicity. However, a major disadvantage exists in that a high temperature is necessary to melt them. Because of this high temperature, most drugs are precluded from being incorporated in the glass in solid solution, and ultimately, their use is restricted to preformed hollow tubes which are loaded with stable powdered drugs. See U.S. Pat. Nos. 4,793,997 and 4,866,097. A difficulty exists in filling narrow tubes with dry powders, therefore, phosphate glass tubes are of large diameter. Large diameter tubes create more physical trauma upon injection, and therefore are suitable only for veterinary applications.
Several approaches address the problem of filling narrow tubes with powdered actives. The powdered drug may be suspended in a non-aqueous liquid in which it is insoluble. These suspensions flow more readily into fine capillary tubes and carry the powdered active with them. Many organic solvents such as ethanol, acetone, dichloromethane, chloroform, and toluene may be used. However, many of these industrial solvents react destructively with biological molecules. By first enclosing the actives in stabilizing sugar glasses, as disclosed in U.S. Pat. No. 5,589,167 and in Gribbon E., Hatley R., Gard T., Blair J., Kampinga J. and Roser B. Q-T4 Stabilisation and novel drug delivery formats, Conf. Report Amer. Assoc. Pharm. Soc., 10th annual meeting, Miami Beach, Fla. (1995), this difficulty is overcome.
Truly disposable liquid jet injectors have previously been developed that operate on the new principle of using only the modest pressure of the human hand to generate a brief pulse of high pressure. This brief pressure punches a narrow hole through the skin to allow the subsequent delivery of the bulk of the dose at lower pressure (Roser, B. Disposable Injector Device U.S. Pat. No. 6,102,896. These designs for a disposable liquid jet injector, however still suffer major disadvantages. Both the reservoir assembly and the injector itself need sterile manufacture and assembly into the final device. Further, the liquid reservoir and the injector device need engineering to withstand high pressure pulses. Additionally, the completion of the power stroke is completely dependent upon the maintenance of hand pressure until the full dose of liquid has been delivered.
The power derived from steady pressure from the hand, which converts to a sharp pulse of high pressure, follows the structural breaking of “snap tabs” or the sudden overcoming of the resistance of “snap rings.” The liquid dose to be injected is located in a centrally located reservoir and the high pressure barrel is located in the base of the injector itself which also has the injection orifice in the base. The existing design generates instantaneous high pressure in the bore from the breaking of the “snap tabs” and the beginning of the movement of the tubular shaft in the bore is transmitted equally and undiminished in all directions throughout the fluid. This creates a pressure of approximately 5,000 psi generated in the bore to be simultaneously applied to the first end of the plunger.
This pressure, applied over a much larger cross sectional area than that of the bore, applies a greater force resisting the downward movement of the plunger. This force is of the order of 25 times that generated in the bore since the diameter of the plunger is five times that of the bore. Enormous resistance to continued movement is generated and ultimately stops the downward motion of the plunger. This defeats the purpose of the injector by arresting the power stroke. The subject of the present invention eliminates this problem.
SUMMARY OF THE INVENTION
The present invention, a modified disposable liquid injector complete with a check valve to isolate pressure overcomes the above described difficulties and drawbacks of the prior art.
A check valve is placed at the tip of the tubular shaft to isolate the pressure in the bore. The check valve in its simplest form is a plug which is a press fit in the free end of the tubular shaft. A shoulder on the plug sits against the butt end of the tubular shaft and seals it against any flow of liquid or the transmission of the high pressure in the bore backward into the reservoir. This allows the tubular shaft to travel to the bottom of the bore, where the pressure in the bore would suddenly drop due to the arrest of the downward movement of the reservoir by contact of the first end of the reservoir barrel with the nozzle end of the tubular cavity.
The plunger begins to move in the reservoir barrel which causes the check valve to open by expelling the plug due to the increase of pressure in the reservoir barrel. The reservoir liquid subsequently flows through the tubular shaft as described before. The narrow bore is modified to accommodate the check valve plug when it is expelled from the free end of the tubular shaft when the plunger “bottoms out.” The present invention with its check valve modification ensures a precise delivery of the medication by effectively isolating and redistributing the pressure.
BRIEF DESCRIPTION OF THE DRAWINGS
Several embodiments of the invention are illustrated and described in the accompanying drawings, forming a part of the specification, wherein:
FIG. 1 is a cross-sectional view of an injector device in the initial position, the injector device having jet injection and a plunger which is struck by a cap after the snap point is reached, creating pressure which is modified by the presence of a check valve.
FIGS. 2A, 2 B, and 2 C are cross-sectional view of an injector device having jet injection means, showing in succession the breaking of the break tabs and contained liquid accelerated towards the nozzle, the formation of the liquid jet which punches a fine hole through the epidermis and dermis and the completed injection with the liquid contents of the reservoir barrel flowing around the dislodged check valve in the widened receptacle.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As can be seen in FIG. 1, the device consists of a cylindrical cap 78 held in place on a base 14 , which is generally tubular, by a combination of several breakable restraining tabs 100 located circumferentially around the inside of the cap 78 . The force at which these tabs fail can be varied over a wide range but is ideally close to 30 Newtons or the force equivalent to a weight of about 3 Kg (6.6 lbs).
The cap is retained in the other direction by a ramp-shaped retaining ring 106 . The cap 78 may have a central section 80 . The central section 80 is generally planar and is preferably either flat or slightly convex. The central section has a periphery 84 . A peripheral section 82 of the cap is attached to the periphery 84 of the central section 80 . The peripheral section of the cap extends approximately perpendicular to the central section and toward the skin surface 16 of a patient. Each of the central and peripheral sections has an outer surface 86 or 88 and an inner surface 90 or 92 respectively. The hand force is applied to the central section 80 of the cap 78 , with the force vector being toward the skin surface. The inner surface 92 of the peripheral section of the cap contacts the outer surface 52 of the base. The moving portion of the plunger section 12 includes the cap. The cap may have one or more grooves 102 between the cap break tabs and the free end of the peripheral section 104 .
The base has a plunger end 48 , a nozzle end 50 , and an outer surface 52 . The base is at least partially composed of plastic, and preferably entirely composed of plastic.
The cavity 46 of the base has a nozzle end 54 and a cavity surface 56 . The longitudinal axis of the cavity 46 is coincident with the longitudinal axis of the plunger. The plunger 24 is located at least partially within the cavity. The plunger slides within the cavity parallel to the longitudinal axis of the cavity. If a barrel is used, the barrel is located between the plunger 24 and the cavity surface 56 . Preferably the base includes a bore 57 , of smaller diameter than the cavity, extending between the nozzle end 54 of the cavity and the nozzle end 50 of the base. The base 14 has a peripheral space 116 between the cavity and the outer surface of the base. A sealing membrane 70 covers the nozzle end 50 of the base.
The base also has an integral tapered nozzle 76 containing a fine orifice. The nozzle forms a pressure seal when the base of the device is pressed against the skin. A cylindrical cavity 46 in the base houses and supports a reservoir barrel 34 that has a sliding fit in the cavity 46 . Several thin collapsible secondary break-tabs 108 with a yield force much lower than the restraining tabs 100 locate the reservoir barrel at the top of the cylindrical cavity 46 .
The plunger section 12 includes a cannula 62 . The cannula is preferably cylindrical, with a circular cross-section. The cannula 62 has an attachment end 64 and a free end 66 . The free end 66 of the cannula 62 is located within the bore 57 when the plunger section 12 is in the initial position. The nozzle end 72 of the bore 57 is sealed by a sealing membrane 70 . The cannula 62 extends from the base of the reservoir barrel 34 and is a snug fit in a fine-bore high-pressure barrel 57 through the base and nozzle. Optionally a section of elastomeric tubing such as silicone, neoprene or butyl rubber forms a pressure-tight sliding seal 74 around the cannula 62 .
One end of the plunger 24 is held loosely by a retaining ring 94 with an inner surface 96 integral with the cap and is a snug liquid-tight fit in the reservoir barrel, containing the liquid 32 to be injected, which is the same liquid as fills the cannula and the fine-bore high-pressure barrel. This liquid is retained within the device by a sealing membrane 70 over the end of the nozzle. The plunger 24 has a first end 26 and a second end 28 . The first end has a periphery 29 . To save weight and materials, the plunger may have a central section 30 which is narrower than the first end 26 . When at least a part of the parenteral medication is a liquid medication 32 contained in a reservoir means, the first end 26 of the plunger is the end which contacts the medication in the reservoir means.
The plunger section 12 may include a barrel 34 . The barrel 34 is tubular and preferably has a circular cross-section. The barrel 34 has a first end 36 and a second end 38 . The first end 36 is at least partially closed, so that the barrel is cup-shaped. The barrel 34 has a reservoir 40 adapted to contain the liquid medication 32 . The longitudinal axis of the barrel is coincident with the longitudinal axis of the plunger 24 . The barrel has an inner surface 42 and an outer surface 44 . The barrel 34 is located at least partially within the cavity 46 of the base 14 .
A check valve consisting of a snug fitting plug 120 is seated at the free end 66 of the cannula 62 with a shoulder acting as a seal against the butt-end of the cannula. Near the nozzle end of the high-pressure barrel 57 , there is a widened area 121 of the barrel bore which acts as a receptacle to house the check valve plug when it is expelled towards the end of the high-pressure phase of the power stroke. The device is pre-loaded with the sterile liquid in a factory. This can be a conventional liquid formulation of a drug or vaccine, which would require that the device be refrigerated. Preferably, a stable non-aqueous ready-to-inject liquid suspension as described in Roser et al U.S. patent application Ser. No. 09/271,204 can be used so that no refrigeration is required. During storage the nozzle is covered by a sterile cap 109 , which is removed just prior to use.
Three distinct stages of the injection can be identified in FIGS. 2A-C. The device is pressed against the skin by hand-pressure which is applied to the cap until the breakable primary restraining tabs 100 suddenly yield. The cap 78 accelerates toward the nozzle 76 and strikes the top 28 of the plunger 24 . This causes the secondary break-tabs 108 to give way resulting in a rapid instantaneous rise in pressure in the liquid 32 in the reservoir barrel 34 and a 25 fold higher pressure in the liquid column in the high-pressure barrel 77 below the check valve 120 . This pressure differential is the result of the cross-sectional area to which the force of the hand pressure is applied in the reservoir barrel being 25 times greater (diameter 0.5 cm) than the cross-sectional area of the end of the cannula in the high-pressure barrel 77 (diameter 1 mm). The central section 30 of the plunger 24 , reservoir-barrel 40 and cannula 62 together with the contained liquid 32 , are then accelerated en bloc toward the nozzle 76 . With a 1 mm diameter fine-bore barrel, the pressure on the liquid in the high-pressure barrel 77 at this stage reaches about 5,000 psi.
The plunger, barrel and cannula, continuing to move en bloc, and drive the small column of liquid, which occupies that part of the high-pressure barrel 77 below the check valve plug 120 in the cannula, through the nozzle 76 . This high-pressure jet 20 punches a fine hole, first through the nozzle membrane 70 then through the epidermis and dermis into the loose subcutaneous (SC) tissue. The cannula is stopped from further movement when a first end 36 of the reservoir barrel 34 strikes the nozzle end 54 of the cylindrical cavity 46 . This abruptly brings to an end the high-pressure phase of the injection, which therefore lasts only a small fraction of a second. The pressure remaining on the liquid 32 in the reservoir barrel then dislodges the check valve plug 120 from the end of the cannula into the widened area or receptacle 121 at the nozzle end of the high-pressure barrel 57 .
With the reservoir barrel arrested, the plunger continues to move inside the reservoir barrel to inject the bulk of the dose of liquid 32 . The pressure in the liquid falls to approximately 200 psi. The liquid contents of the reservoir barrel flow around the dislodged check valve 120 in the widened receptacle 121 , see FIG. 2C, of the high-pressure barrel 77 , through the nozzle 76 and along the track in the epidermal and sub-dermal tissue created by the initial jet of high-pressure liquid 20 and into the subcutaneous tissue. The whole injection is complete in less than a second.
Although specific embodiments of the invention are herein disclosed for purposes of explanation, various modifications thereof, after study of this specification, will be apparent to those skilled in the art to which the invention pertains. | The present invention is a modified single use hand-operated injector device consisting of a plunger, a base, a snap means for resisting plunger movement and an injection means for injecting parenteral medication through a skin surface of a patient. The improvement comprises a check valve seated in a cannula and a widened receptacle area within a high pressure barrel through which the cannula passes. When the check-valve plug expels upon increase in pressure, into the widened receptacle area the parenteral medication efficiently flows around the plug and into the subcutaneous tissue of the patient. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a compound resin wheel, and is particularly concerned with a lightweight and mass-producible compound resin wheel which is surpassing in mechanical characteristics such as impact resistance, bending strength, rigidity, heat resistance, fatigue resistance, creep resistance and the like.
2. Description of the Prior Art
Wheels, or automobile wheels, for example, have ever been made generally of steel or light alloys (such as aluminum alloy and magnesium alloy).
Steel wheels are fabricated by pressing or roll forming, however, a dimensional dispersion is quite unavoidable in most cases, and a deviation is easy to occur particularly on the roundness of a bead seat of the rim. Moreover, the steel wheels are heavy and hence are not preferable for lightweight construction of automobile parts so required.
In the meantime, wheels made of light alloys are stably formed in dimensions and, in addition, sharply reduced in weight to one third of the steel wheels, however, what is disadvantageous is that the material cost is three to five times higher than that of the steel wheels.
Now, the lightweight requirement for the automobile parts is very important from the viewpoint of energy saving on which an emphasis has been placed lately, and thus the wheels must be made lightweight in respect of the fuel cost and the maneuverability.
Under such circumstances, a resin wheel has been proposed for satisfying the lightweight construction and the dimensional stability and the low manufacturing cost. The resin wheel is formed mainly of FRP (fiber-reinforced plastic) obtained from mixing short or long reinforcing fibers in a resin, and hence is light in weight as compared with the metallic wheel, superior in dimensional stability, available for mass production and also for reduction of manufacturing cost, and is excellent, still further, in the aspect of design factors such as coloration and the like.
Meanwhile, almost all of the resin wheels under examination so far and all the resin wheels developed hitherto are those made by the general FRP manufacturing technique, and so formed by pressing a thermosetting resin such as unsaturated polyester, epoxy resin or the like and FRP consisting of glass fiber and others (Japanese Patent Unexamined Publication No. 61-135801). The resin wheels thus obtained are superior in rigidity, strength and so forth, since fibers are not so severely damaged at the time of forming. In addition, the thermosetting resin is used mainly therefor, and hence the resin wheels are also superior in heat resistance and creep resistance. However, such process is not suitable for forming those with a complicated shape (for example, such one as is considerably variable in wall thickness), and a forming cycle is so long, thus leading to an unsatisfactory productivity.
On the other hand, an injection molding may ensure a high productivity and is superior in the aspect of production cost, however, injection moldings are generally 1/3 to 1/5 low in strength as compared with compression moldings. Thus, the injection molding does not satisfy the requirements of strength and rigidity of the products, because the reinforcing, fibers are extremely short in length such as 1 mm or less as compared with materials (such as BMC, SMC and the like) used for compression molding so as to increase the fluidity of the materials.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a compound resin wheel superior remarkably in lightweight construction and reinforced structure, ensuring the effects as:
(1) superior in characteristics in weight, strength particularly bending strength, impact resistance, rigidity, heat resistance, fatigue resistance, creep resistance and so forth;
(2) superior in uniformity, and almost no dispersion of the product quality;
(3) superior in mass productivity to reduce the manufacturing cost; and
(4) a variety of products obtained from splitting the resin wheel into two pieces or more.
Another object of the present invention is to provide a compound resin wheel extremely high in utility.
A further object of the present invention is to provide a compound resin wheel suitable not only for automobiles in a narrow sense such as a passenger car, bus, truck and the like but also for automobiles in a wide sense such as a railway car, subway car, linear motor car, airplane, motorcycle, bicycle, golf cart, and other leisure carts used in recreation parks.
In a compound resin wheel for which two or more divided moldings are integrated, the invention is characterized in that at least one of the two or more divided moldings comprises a long-fiber reinforced thermoplastic resin, the other divided molding or moldings comprising metal and/or FRP.
That is, in order to solve the aforementioned problems inherent in the prior art resin wheel by improving molding materials and molding process, the present invention is to provide a compound resin wheel surpassing in mechanical characteristics, light in weight, superior in mass productivity and moderate in cost by integrating a divided resin molding superior in characteristics such as bending strength, rigidity, impact strength, heat resistance, fatigue resistance, creep resistance and so forth, having a homogeneous property throughout the product, moderate in cost and available for mass production with another divided molding consisting of a metal or FRP different from the divided resin molding.
Next, the present invention will be described in detail.
The compound resin wheel of the invention is fabricated by integrating one or more first members or portions (such as a rim, disk, hub and others) made of a long fiber reinforced thermoplastic resin and one or more residual second members or portions made of FRP, light metal or metal such as iron. The first and second members or portions are fitted and integrated each other by screwing or other means. Each of the first and second members or portions has the shape divided from a wheel, so that the member or portion may be called a "divided part" hereinafter. The first "divided part" made of the long fiber reinforced thermoplastic resin is manufactured by injection molding or injection compression molding.
In this connection, "screwing" is a process for fitting two independent portions together by turning the two in the counter direction to each other to some extent, and a relation between bolt and nut will be one example thereof.
Described first are the divided parts (such as rim or disk or hub portions) formed through an injection molding or injection compression molding with a long fiber reinforced thermoplastic resin of which the compound resin wheel of the present invention is constructed partly.
For reinforcing resins to enhance the mechanical characteristics, a fiber reinforcing process has generally been employed hitherto. In this case, however, while the thermosetting resin compound material reinforced by a continuous fiber exhibits a surpassing mechanical performance including impact resistance, the fluidity is unsatisfactory, and the working cost becomes high. On the other hand, the thermoplastic resin compound material reinforced by a short fiber can easily be formed by the injection molding, and is moderate in the working cost. However, what is disadvantageous is that the short fiber reinforced compound material does not so effectively improve the mechanical characteristics, and is low particularly in impact resistance.
Now, therefore, there is developed a long fiber reinforced thermoplastic resin compound material provided with a superior fluidity inherent in the short fiber reinforced resin compound material and having an effect in improving the mechanical characteristics equivalent to the continuous fiber reinforced thermosetting resin compound material. In the present invention, such long fiber reinforced thermoplastic resin is employed. Here, the short fiber means an ordinary short fiber 0.1 to 0.5 mm in length, and the long fiber indicates a fiber 1 mm or more in length.
The thermoplastic resin (or "matrix resin" otherwise hereinlater) working as a matrix of the long fiber reinforced thermoplastic resin relating to the invention may include various polyamide resins such as, nylon 6, nylon 6.6, nylon 4.6, nylon 6.10, nylon 10, nylon 11 and nylon 12, polybutylene terephthalate (PBT), polyphenylene sulfide (PPS), acetal resin (POM), polycarbonate (PC), polyethylene terephthalate (PET), polypropylene (PP), polyether sulfone (PES), polysulfone (PSF), polyether etherketone (PEEK), polyphenylene oxide (PPO), polyamidimide (PAI), polyimide (PI), polyester, various liquid crystalline polymers and partial aromatic polyamide for which aliphatic principal chain is substituted partially by aromatic group. Of these materials, various polyamide resins, partial aromatic polyamide, PBT, PPS, POM, PC, PES, PI, PAI, PEEK, polyester, and various liquid crystalline polymers are preferable. These thermoplastic resins may be used alone or as a mixture thereof.
On the other hand, fibers made of material such as glass, carbon, graphite, aramide, polyethylene, ceramics (such as SiC and Al 2 O 3 ), metals (such as boron and stainless steel) and so forth are cited as the resin reinforcing fibers used in the present invention, and carbon or glass is effective above all. If the diameter of such reinforcing fibers is too small, then a sufficient reinforcing effect is not obtainable, and if excessively large on the contrary, the injection molding becomes hard to carry out, and the formability will not securely be ensured. Consequently, it is preferable that the diameter of reinforcing fibers come within the range of 0.1 to 100 μm, or 0.5 to 50 μm particularly. Additionally, the fiber length will be 1 mm or longer, 2 to 30 mm particularly, or 3 to 15 mm preferably.
If the amount of reinforcing fibers added is too small, a sufficient effect is not obtainable therefrom, but if excessive on the contrary, then the matrix resin does not affect the formability. For this reason, the ratio of the amount of added reinforcing fibers to the amount of all molding materials will be 5 to 70% by volume, or preferably 10 to 60% by volume.
Then, in case the long fiber reinforced thermoplastic resin materials of the present invention are processed as practical moldings, an addition of a normal short fiber reinforced resin thereto is effective particularly in improving the workability. In such case, the ratio of the added short fiber reinforced resin will be not more than 70% by weight of the total amount, or preferably not more than 60%.
Further, it is preferable that an improver for enhancing a binding efficiency of the matrix resin and the resin reinforcing fiber be added to the long fiber reinforced thermoplastic resin so as to realize superior mechanical characteristics and workability. The improver used here may include polystyrene group polymers such as styrene-butadiene block copolymer (SBS), styrene-isoprene block copolymer (SIS), hydrogen-added styrene-butadiene block copolymer (SEBS), polystyrene (PS), acrylonitrile-butadiene-styrene resin (ABS) and the like; polyolefin group polymers such as polyethylene (PE), polypropylene (PP), ethylene-ethylacrylate copolymer (EEA), ethylenevinyl acetate copolymer (EVA), ethylene-propylene rubber (EPR), ethylenepropylene diene rubber (EPDM) and the like; polyester group polymers such as polyethylene terephthalate (PET), polybutylene terephthalate (PBT) and the like; polyacryl group polymers and polyamide group polymers such as methacrylic resin (PMMA), acrylic rubber and the like; further polyphenylene oxide (PPO), polyphenylene sulfide (PPS), butadiene acrylonitrile rubber (NBR), polyarylate (PAR), polycarbonate (PC), various liquid crystal polymers and others. Of these polymers, polyolefin group polymers and polystyrene group polymers are particularly efficacious.
It is preferable that these improvers be added at 1 to 40 parts by weight, or particularly 2 to 30 parts by weight to 100 parts by weight of the matrix resin.
Further, in the present invention, for the purpose of enhancing the compatibility of these improvers with the matrix resin, it is effective to subject the improvers and the matrix resin or a polymer compatible with the matrix resin to a block or graft copolymerization, or introduce a radical having a reactivity with a radical of the matrix resin into a principal chain or side chain of the improvers for denaturation. In this case, the reactive radical includes epoxy radical, carboxyl radical, maleic anhydride radical, amino radical, sulfone radical and oxazoline radical, of which maleic anhydride radical and epoxy radical are particularly efficacious.
Further, for similar purpose, various admixtures may be used effectively. The admixture may include a copolymer having a compatibility with both the improver and matrix resin or a radical reactive with both the two, and an organic compound denatured by the reactive radical. Generally, copolymers of olefin group, styrene group or acryl group are efficacious, and various copolymers with maleic anhydride radical and/or epoxy radical introduced into a principal chain or side chain are particularly efficacious.
For the purpose of improving weatherability, heat resistance, wear resistance, fluidity, coefficient of thermal expansion, flame resistance, chemical resistance and other characteristics, it is effective to mix necessary amounts of various fillers, age resistors, crosslinking agents, oils, plasticizers, oligomers and elastomers in the long fiber reinforced thermoplastic resin material relating to the present invention.
A method for reinforcing the above-described thermoplastic resin with the resin reinforcing fiber will now be described.
That is, for example, a roving of a continuous fiber delivered from a robbin is drawn out through a molten thermoplastic resin of low viscosity, each monofilament surface is moistened with the resin and then passed through a cooling pipe, thereby aligning the filaments in the direction drawn out for hardening. From cutting the continuous thermoplastic resin impregnated roving into a predetermined length, a reinforcing fiber having the length so cut is obtainable (Japanese Patent Unexamined Publication No. 57-181852).
Then, from processing granular bodies in which a rodlike body 0.5 to 3 mm in diameter has a length of 2 to 30 mm, preferably 3 to 15 mm as a forming material according to the usual process, a product made of the long fiber reinforced thermoplastic resin material of the present invention is easily obtainable. In this case, the contained fiber length can be adjusted arbitrarily by cutting as mentioned above. Further, since such long fibers are formed through drawing, the fibers can be impregnated with the resin satisfactorily in good condition.
In the above-described method, the long fiber reinforced resin may be obtained by adding the improver which is a tertiary component or the improver and the admixture beforehand to the thermoplastic resin which is a primary component, or pelletizing the mixture further as occasion demands, and then impregnating the long fiber which is a secondary component therewith, or otherwise the improver and the admixture may be added later to the long fiber reinforced thermoplastic resin formed beforehand of the primary component and the secondary component.
On the other hand, in the compound resin wheel according to the present invention, other divided parts than the divided part formed by means of the long fiber reinforced thermoplastic resin are formed of conventional base materials such as FRP and/or metal, of which FRP includes such FRP consisting, for example, of thermosetting resin and glass or carbon fiber. Further, the metal includes light metal or light alloy such as aluminum alloy, magnesium alloy, titanium alloy or the like, heavy metal or heavy alloy such as iron or the like, or fiber-reinforced light metal (alloy) comprising a reinforcing fiber in the light metal and light alloy, however, the light metal, light alloy or the fiber reinforced light metal (alloy) are efficacious particularly.
In the compound resin wheel according to the present invention, either one or both of the metallic divided part and FRP divided part may be combined with the divided part consisting of a long fiber reinforced thermoplastic resin.
From combining and integrating the divided part using a long fiber reinforced thermoplastic resin with the divided part using a conventional base materials such as metal and/or FRP, not only characteristics of both the two are enhanced but also the compound resin wheel having surpassing characteristics is obtainable through a synergistic effect.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view representing a compound resin wheel given in one embodiment of the present invention.
FIG. 2 is a sectional view representing a compound resin when given in another embodiment of the present invention.
FIG. 3A is a sectional view representing a compound resin wheel given in a further embodiment of the present invention.
FIG. 3B is a sectional view representing a compound resin wheel given in a still further embodiment of the present invention.
FIG. 4 is a sectional view representing a compound resin wheel given in another embodiment of the present invention.
FIG. 5 is a front view illustrating fitting portions of the compound resin wheel of FIG. 3B.
FIG. 6 is a front view illustrating fitting portions of the compound resin wheel of FIG. 3B.
FIG. 7 is a front view illustrating fitting portions of the compound resin wheel of FIG. 3A.
FIG. 8 is a front view illustrating fitting portions of the compound resin wheel of FIG. 3A.
FIG. 9 is a perspective sectional view showing one example of fitting portions.
FIG. 10 is a perspective sectional view showing another example of the fitting portions.
FIG. 11 is a perspective sectional view showing a further example of the fitting portions.
FIG. 12 is a perspective sectional view showing a still further example of the fitting portions.
FIG. 13 is a perspective sectional view showing another example of the fitting portions.
FIG. 14 is a sectional view taken on line XIV--XIV of FIG. 13.
FIG. 15 is a sectional view showing a further example of the fitting portions.
FIG. 16 is an enlarged sectional view showing one example of threaded forms of the fitting portions.
FIG. 17 is an enlarged sectional view showing another example of threaded forms of the fitting portions.
FIG. 18 is an enlarged sectional view showing a further example of threaded forms of the fitting portions.
FIG. 19 is an enlarged sectional view showing a still further example of threaded forms of the fitting portions.
FIG. 20 is an enlarged sectional view showing another example of threaded forms of the fitting portions.
FIG. 21 is an enlarged sectional view showing a further example of threaded forms of the fitting portions.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Embodiments of the present invention will be described in detail with reference to the drawings.
FIG. 1, FIG. 2, FIG. 3 and FIG. 4 are sectional views representing compound resin wheels according to embodiments of the present invention. Here, FIG. 1 to FIG. 4 are sectional views showing upper half portions of the compound resin wheels, and in FIG. 1 to FIG. 4 and subsequent drawings, a reference numeral 1 denotes a rim, 2 denotes a disk, 3 denotes a hub, and 3A denotes a hub bolt hole. Further in FIG. 1, 4 denotes a bolt coupling the rim 1 and the disk 2 together.
A compound resin wheel 10 indicated in FIG. 1 is divided into the rim 1, the disk 2 and the hub 3, however, in the compound resin wheel of the present invention, no limitation will be particularly placed on the number of divided parts constructing the wheel and also on positions where to divide the wheel. A wheel 11 shown in FIG. 2 comprises divided parts 11A and 11B divided in the rim 1. A wheel 12 shown in FIG. 3A comprises divided parts 12A, and 12B, 12C and 12D divided in the disk 2. A wheel 13 shown in FIG. 4 comprises divided parts 13A, 13B, 13C, 13D and 13E divided in the rim 1 and the disk 2. In FIG. 1 to FIG. 4, each divided part is formed independently, and reference numerals 91 to 99 denote portions whereat the divided parts are fitted together.
In the compound resin wheel 10 of FIG. 1, for example, the rim 1 is made of long fiber reinforced thermoplastic resin, the disk 2 is made of aluminum and the hub 3 is made of aluminum. Further, in FIG. 2 to FIG. 4, the divided parts 2 and 3 are made of long fiber reinforced thermoplastic resin, and the other divided part 1 is made of metal or FRP. These combinations are not particularly limited, and hence various other combinations are conceivable and employable for the resin wheel.
A clamping by the bolt 4 shown in FIG. 1 is the most general process for fitting each divided part. For better binding, it is effective to apply an adhesive to a contact surface of each divided part. While the binding by means of a bolt is simple and moderate in cost as well, it is necessary that portions whereat, for example, both the rim 1 and disk 2 overlap be provided for binding, and since such portions will be joined by a metallic bolt, a disadvantage is such that the weight increases more than that of a one-piece wheel.
Now, therefore, the method wherein each divided part of the compound resin wheel is formed independently, and then the divided parts are fitted into each other for integration by screwing is proposed.
A wheel 120 of FIG. 3B will be described further in detail with reference to FIG. 5 and FIG. 6.
The wheel 120 of FIG. 3B comprises divided parts 121, 122 in the disk. The divided part 121 of the wheel 120 has the rim 1 and a peripheral portion of the disk 2. The divided part 121 has a plurality of notches 124 on the inner periphery. A threaded portion 123 is provided peripherally on the surface free from the notches 124. The divided part 122 has a central portion of the disk 2. The divided part 122 has radial portions 125, and a threaded portion 126 is provided peripherally on the nose surface (outer periphery) of each radial portion 125. The divided part 122 is fitted, as turning, into a central hole 127 of the divided part 121 so as to mate the threaded portion 123 and the threaded portion 126 with each other. Reference characters R 1 and R 2 indicate the directions in which the divided parts 121 and 122 are turned, respectively. Needless to say, one of the divided parts may be kept at rest in this case. Thus, the wheel 120 with windows 128 left open is completed as shown in FIG. 3B.
FIG. 7 and FIG. 8 indicate a method for binding the divided parts 12A, 12B of the wheel 12 of FIG. 3A together. The divided parts 12A and 12B are put together by screwing a threaded portion 131 on an inner periphery of the divided part 12A over a threaded portion 132 on an outer periphery of the divided part 12B in the direction R 1 . A threaded portion on an outer periphery of the divided part 12C is screwed into a threaded portion 133 on an inner periphery of the divided part 12B in the direction R 2 . A threaded portion on an outer periphery of the divided part 12D is screwed into a threaded portion on an inner periphery of the divided part 12C.
Next described is a form of the fitting portions. For the fitting portions to be fitted firmly by screwing, that is, in FIG. 9 (perspective sectional view of the fitting portions), a pair of male and female screw threads is provided generally on fitting surfaces of the divided parts 14A and 14B so as to allow the divided parts 14A and 14B to engage with each other and rotate in the counter directions R 1 and R 2 , respectively, for screwing. The fitting portions can be threaded in multiple stages as shown in FIG. 10, FIG. 11 and FIG. 12, and according to such screw threads provided in multiple stages, both the divided parts 14A and 14B can be fitted together more effectively and firmly.
In the resin wheel of the present invention, the screw threads may be provided in the form of ratchet teeth as shown in FIG. 13 and FIG. 14 so as to prevent the fitting portions from loosening and coming off and also to enhance the strength of the resin wheel.
A wheel 140 comprises a divided part 141 on the rim side and a divided part 142 on the hub center side, and a thread 143 on an inner periphery of the divided part 141 and a thread 144 on an outer periphery of the divided part 142 are screwed each other. Both the threads 143, 144 extend peripherally. Ratchet teeth 145, 146 are provided regularly in the peripheral direction. Accordingly, the divided part 141 can be rotated in the direction indicated by an arrow 147, that is, in the tightening direction, but not in the counter direction, that is in the loosening direction.
In this connection, a method of coupling the multi-stage fitting portions by means of a bolt 16 or a rivet as shown in FIG. 15 is also effective for locking.
Further, for preventing the fitting portions from coming off on counter-acting tensile forces F 1 , F 2 shown in FIG. 16 and disengaging into both divided parts 14A, 14B, improvements of threaded forms of the fitting portions as shown in FIG. 17 to FIG. 21 will be effective.
The forms available for preventing the fitting portions from loosening and coming off as described above are given merely as examples, and hence any other forms may be employed without departing from the spirit and scope of the present invention as long as the object is substantially attained.
Further, in the resin wheel according to the present invention, the construction wherein an adhesive is interposed between concave and convex surfaces whereat both the divided parts 14A and 14B of the fitting portions shown in FIG. 9 to FIG. 21 are fitted together, or in a gap between contact surfaces of both the divided parts 14A and 14B of each stage of the multi-stage fitting portions, thereby binding the divided parts 14A and 14B firmly, or otherwise these portions are bonded together by thermal fusion will be quite effective in improving the strength of the fitting portions and preventing loosening and coming-off of the divided parts.
In the examples given above, the description has been referred for a method for fitting the divided parts together to integration by means of bolts and screwing, however, the invention is not necessarily limited thereto. Other effective method include molding both the divided parts integrally according to a so-called insert process wherein metallic or FRP divided parts are molded by setting them at a predetermined position in a metallic mold, and then injecting a long fiber reinforced thermoplastic resin therein. | A compound resin wheel with two or more moldings integrated to form the resin wheel, wherein at least one of the two or more moldings made of a long fiber reinforced thermoplastic resin, the other molding or moldings made of metal and/or FRP. | 1 |
BACKGROUND OF THE INVENTION
[0001] (a) Field of the Invention
[0002] The invention relates to an in vitro platform for identifying potential compounds as being capable of inducing islet cell neogenesis or duct-to-islet cell transdifferentiation.
[0003] (b) Description of Prior Art
[0000] Diabetes Mellitus
[0004] Diabetes mellitus has been classified as type I, or insulin-dependent diabetes mellitus (IDDM) and type II, or non-insulin-dependent diabetes mellitus (NIDDM). NIDDM patients have been subdivided further into (a) nonobese (possibly IDDM in evolution), (b) obese, and (c) maturity onset (in young patients). Among the population with diabetes mellitus, about 20% suffer from IDDM. Diabetes develops either when a diminished insulin output occurs or when a diminished sensitivity to insulin cannot be compensated for by an augmented capacity for insulin secretion. In patients with IDDM, a decrease in insulin secretion is the principal factor in the pathogenesis, whereas in patients with NIDDM, a decrease in insulin sensitivity is the primary factor. The mainstay of diabetes treatment, especially for type I disease, has been the administration of exogenous insulin.
[0000] Rationale for More Physiologic Therapies
[0005] Tight glucose control appears to be the key to the prevention of the secondary complications of diabetes. The results of the Diabetes Complications and Control Trial (DCCT), a multicenter randomized trial of 1441 patients with insulin dependent diabetes, indicated that the onset and progression of diabetic retinopathy, nephropathy, and neuropathy could be slowed by intensive insulin therapy (The Diabetes Control and Complication Trial Research Group, N. Engl. J. Med., 1993; 29:977-986). Strict glucose control, however, was associated with a three-fold increase in incidence of severe hypoglycemia, including episodes of seizure and coma. As well, although glycosylated hemoglobin levels decreased in the treatment group, only 5% maintained an average level below 6.05% despite the enormous amount of effort and resources allocated to the support of patients on the intensive regime (The Diabetes Control and Complication Trial Research Group, N. Engl. J. Med., 1993; 29:977-986). The results of the DCCT clearly indicated that intensive control of glucose can significantly reduce (but not completely protect against) the long-term microvascular complications of diabetes mellitus.
[0000] Other Therapeutic Options
[0006] The delivery of insulin in a physiologic manner has been an elusive goal since insulin was first purified by Banting, Best, McLeod and Collip. Even in a patient with tight glucose control, however, exogenous insulin has not been able to achieve the glucose metabolism of an endogenous insulin source that responds to moment-to-moment changes in glucose concentration and therefore protects against the development of microvascular complications over the long term.
[0007] A major goal of diabetes research, therefore, has been the development of new forms of treatment that endeavor to reproduce more closely the normal physiologic state. One such approach, a closed-loop insulin pump coupled to a glucose sensor, mimicking β-cell function in which the secretion of insulin is closely regulated, has not yet been successful. Only total endocrine replacement therapy in the form of a transplant has proven effective in the treatment of diabetes mellitus. Although transplants of insulin-producing tissue are a logical advance over subcutaneous insulin-injections, it is still far from clear whether the risks of the intervention and of the associated long-term immunosuppressive treatment are lower those in diabetic patients under conventional treatment.
[0008] Despite the early evidence of the potential benefits of vascularized pancreas transplantation, it remains a complex surgical intervention, requiring the long-term administration of chronic immunosuppression with its attendant side effects. Moreover, almost 50% of successfully transplanted patients exhibit impaired tolerance curves (Wright F H et al., Arch. Surg., 1989;124:796-799; Landgraft R et al., Diabetologia 1991; 34 (suppl 1):S61; Morel P et al., Transplantation 1991; 51:990-1000), raising questions about their protection against the long-term complications of chronic hyperglycemia.
[0009] The major complications of whole pancreas transplantation, as well as the requirement for long term immunosuppression, has limited its wider application and provided impetus for the development of islet transplantation. Theoretically, the transplantation of islets alone, while enabling tight glycemic control, has several potential advantages over whole pancreas transplantation. These include the following: (i) minimal surgical morbidity, with the infusion of islets directly into the liver via the portal vein; (ii) the possibility of simple retransplantation for graft failures; (iii) the exclusion of complications associated with the exocrine pancreas; (iv) the possibility that islets are less immunogenic, eliminating the need for immunosuppression and enabling early transplantation into non-uremic diabetics; (v). the possibility of modifying islets in vitro prior to transplantation to reduce their immunogenicity; (vi) the ability to encapsulate islets in artificial membranes to isolate them from the host immune system; and (vii) the related possibility of using xenotransplantation of islets immunoisolated as part of a biohybrid system. Moreover, they permit the banking of the endocrine cryopreserved tissue and a careful and standardized quality control program before the implantation.
[0000] The Problem of Islet Transplantation
[0010] Adequate numbers of isogenetic islets transplanted into a reliable implantation site can only reverse the metabolic abnormalities in diabetic recipients in the short term. In those that were normoglycemic post-transplant, hyperglycemia recurred within 3-12 mo. (Orloff M, et. al., Transplantation 1988; 45:307). The return of the diabetic state that occurs with time has been attributed either to the ectopic location of the islets, to a disruption of the enteroinsular axis, or to the transplantation of an inadequate islet cell mass (Bretzel R G, et al. In: Bretzel R G, (ed) Diabetes mellitus. (Berlin: Springer, 1990) p.22-9).
[0011] Studies of the long term natural history of the islet transplant, that examine parameters other than graft function, are few in number. Only one report was found in which an attempt was specifically made to study graft morphology (Alejandro R, et. al., J Clin Invest 1986; 78: 1339). In that study, purified islets were transplanted into the canine liver via the portal vein. During prolonged follow-up, delayed failures of graft function occurred. Unfortunately, the graft was only examined at the end of the study, and not over time as function declined. Delayed graft failures have also been confirmed by other investigators for dogs (Warnock G L et. al., Can. J. Surg., 1988; 31: 421 and primates (Sutton R, et. al., Transplant Proc., 1987; 19: 3525). Most failures are presumed to be the result of rejection despite appropriate immunosuppression.
[0012] Because of these failures, there is currently much enthusiasm for the immunoisolation of islets, which could eliminate the need for immunosuppression. The reasons are compelling. Immunosuppression is harmful to the recipient, and may impair islet function and possibly cell survival (Metrakos P, et al., J. Surg. Res., 1993; 54: 375). Unfortunately, micro-encapsulated islets injected into the peritoneal cavity of the dog fail within 6 months (Soon-Shiong P, et. al., Transplantation 1992; 54: 769), and islets placed into a vascularized biohybrid pancreas also fail, but at about one year. In each instance, however, histological evaluation of the graft has indicated a substantial loss of islet mass in these devices (Lanza R P, et. al., Diabetes 1992; 41: 1503). No reasons have been advanced for these changes. Therefore maintenance of an effective islet cell mass post-transplantation remains a significant problem.
[0013] In addition to this unresolved issue, is the ongoing problem of the lack of source tissue for transplantation. The number of human donors is insufficient to keep up with the potential number of recipients. Moreover, given the current state of the art of islet isolation, the number of islets that can be isolated from one pancreas is far from the number required to effectively reverse hyperglycemia in a human recipient.
[0014] In response, three competing technologies have been proposed and are under development. First, islet cryopreservation and islet banking. The techniques involved, though, are expensive and cumbersome, and do not easily lend themselves to widespread adoption. In addition, islet cell mass is also lost during the freeze-thaw cycle. Therefore this is a poor long-term solution to the problem of insufficient islet cell mass. Second, is the development of islet xenotransplantation. This idea has been coupled to islet encapsulation technology to produce a biohybrid implant that does not, at least in theory, require immunosuppression. There remain many problems to solve with this approach, not least of which, is that the problem of the maintenance of islet cell mass in the post-transplant still remains. Third, is the resort to human fetal tissue, which should have a great capacity to be expanded ex vivo and then transplanted. However, in addition to the problems of limited tissue availability, immunogenicity, there are complex ethical issues surrounding the use of such a tissue source that will not soon be resolved. However, there is an alternative that offers similar possibilities for near unlimited cell mass expansion.
[0015] An entirely novel approach, proposed by Rosenberg in 1995 (Rosenberg L et al., Cell Transplantation, 1995;4:371-384), was the development of technology to control and modulate islet cell neogenesis and new islet formation, both in vitro and in vivo. The concept assumed that (a) the induction of islet cell differentiation was in fact controllable; (b) implied the persistence of a stem cell-like cell in the adult pancreas; and (c) that the signal(s) that would drive the whole process could be identified and manipulated.
[0016] In a series of in vivo studies, Rosenberg and co-workers established that these concepts were valid in principle, in the in vivo setting (Rosenberg L et al., Diabetes, 1988;37:334-341; Rosenberg L et al., Diabetologia, 1996;39:256-262), and that diabetes could be reversed.
[0017] The well known teachings of in vitro islet cell expansion from a non-fetal tissue source comes from Peck and co-workers (Corneliu J G et al., Horm. Metab. Res., 1997;29:271-277), who describe isolation of a pluripotent stem cell from the adult mouse pancreas that can be directed toward an insulin-producing cell. These findings have not been widely accepted. First, the result has not proven to be reproducible. Second, the so-called pluripotential cells have never been adequately characterized with respect to phenotype. And third, the cells have certainly not been shown to be pluripotent.
[0018] More recently two other competing technologies have been proposed the use of engineered pancreatic β-cell lines (Efrat S, Advanced Drug Delivery Reviews, 1998;33:45-52), and the use of pluripotent embryonal stem cells (Shamblott M J et al., Proc. Natl. Acad. Sci. USA, 1998;95:13.726-13731). The former option, while attractive, is associated with significant problems. Not only must the engineered cell be able to produce insulin, but it must respond in a physiologic manner to the prevailing level of glucose- and the glucose sensing mechanism is far from being understood well enough to engineer it into a cell. Many proposed cell lines are also transformed lines, and therefore have a neoplastic potential. With respect to the latter option, having an embryonal stem cell in hand is appealing because of the theoretical possibility of being able to induce differentiation in any direction, including toward the pancreatic β-cell. However, the signals necessary to achieve this milestone remain unknown.
[0019] To date, the only in vitro test system for examining the bioactivity of compounds on duct cells that exists, is a duct cell proliferation assay based on hamster pancreatic cells. Cell proliferation is different than islet cell neogenesis.
[0020] The only way available to measure islet cell neogenesis is an in vivo method involving live animals (and not humans).
[0021] It would be highly desirable to be provided with an in vitro platform for identifying potential compounds as being capable of inducing islet cell neogenesis or duct-to-islet cell transdifferentiation. Agents identified according to the platform of the present invention could be used in diabetes therapies, such as for the preparation of dedifferentiated cells derived from post-natal islets of Langerhans, their expansion and the guided induction of islet cell differentiation, leading to insulin-producing cells that can be used for the treatment of diabetes mellitus. Furthermore, it would be desirable to be provided with such a platform using human cells.
SUMMARY OF THE INVENTION
[0022] One aim of the invention is to provide an in vitro platform for identifying potential compounds as being capable of inducing islet cell neogenesis or duct-to-islet cell transdifferentiation.
[0023] In accordance with one embodiment of the present invention there is provided an in vitro platform for screening agents inducing islet cell neogenesis or duct-to-islet cell transdifferentiation, which comprises the steps of:
[0024] a) expanding in vitro cells of a duct-like structure obtained by inducing cystic formation in cells in or associated with post-natal islets of Langerhans; and
[0025] b) treating said expanded cells of said duct-like structure with an agent being screened; and
[0026] c) determining potency of said agent of inducing islet cell differentiation of said duct-like structure in becoming insulin-producing cells.
[0027] Preferably, step a) and step b) are concurrently effected using a solid matrix (such as 3-D collagen type-1 gel matrix), basal feeding medium (such as DMEM/F12 medium) and appropriate growth factors (such as EGF and cholera toxin) to permit the development, maintenance and expansion of a dedifferentiated cell population.
[0028] Preferably, the cells used are human cells.
[0029] In accordance with one embodiment of the present invention there is provided an islet cell culture, which comprises insulin-produding islet cells in a suitable culture medium, wherein said islet cells are characterized.
[0030] The islet cell culture may be characterized in a genetic, an immunologic or a genomic manner.
[0031] The characterization may be effected using a DNA microarray analysis.
[0032] In accordance with one embodiment of the present invention there is provided an in vitro method for evaluating biological effects of agents on islet cells, which comprises the steps of:
[0033] a) treating the islet cell culture of the present invention with an agent being evaluated for a time sufficient for a biological effect to be occurring; and
[0034] b) determining biological effect of the agent on islet cells by monitoring changes in insulin production compared to a standard curve obtained with a control islet cell culture.
[0035] The agent may selected from the group consisting of immunosuppressive agents, growth factors and anti-apoptotic agents.
[0036] For the purpose of the present invention the following terms are defined below.
[0037] The expression “post-natal islets of Langerhans” is intended to mean islet cells and associated cells, such as duct cells, of any origin, such as human, porcine and canine, among others.
[0038] The expression “dedifferentiated cells” is intended to mean cells of any origin which are stem/progenitor like cells.
BRIEF DESCRIPTION OF THE DRAWINGS
[0039] FIG. 1 illustrates Islet-Duct transformation at isolation day, day 3 and day 10;
[0040] FIG. 2 illustrates Drug A-mediated Duct-to-Islet transformation;
[0041] FIG. 3 illustrates the % transformation of Drug A vs control in Duct-to-Islet Differenciation;
[0042] FIG. 4 illustrates the % of total cells for CK-19 control, CK-19 Drug A, PDX1 control and PDX1 DRUG A in CK-19/PDX1 immunoreactivity essay;
[0043] FIG. 5 illustrates the % of total area for insulin, glucagon and somatostatin in Control and Drug A in Islet hormone immunoreactivity essay;
[0044] FIG. 6 illustrates the insulin secretion in basal media, control and Drug A;
[0045] FIG. 7 illustrates cellular immunoreactivites of new islets derived from ducts;
[0046] FIG. 8A illustrates cellular proliferation in control and Drug A;
[0047] FIG. 8B illustrates cellular apoptosis in control and Drug A;
[0048] FIG. 9 illustrates the regulation of islet differentiation;
[0049] FIG. 10A illustrates Caspase-3 activity at Day 10, Day 14 control and Day 14 Drug A; and
[0050] FIG. 10B illustrates JNK activity at Day 10, Day 14 control and Day 14 Drug A.
DETAILED DESCRIPTION OF THE INVENTION
[0051] Transdifferentiation is a change from one differentiated phenotype to another, involving morphological and functional phenotypic markers (Okada T S., Develop. Growth and Differ. 1986;28:213-321 ). The best-studied example of this process is the change of amphibian iridial pigment cells to lens fibers, which proceeds through a sequence of cellular dedifferentiation, proliferation and finally redifferentiation (Okada T S, Cell Diff. 1983;13:177-183; Okada T S, Kondoh H, Curr. Top Dev. Biol., 1986;20:1-433; Yamada T, Monogr. Dev. Biol., 1977;13:1-124). Direct transdifferentiation without cell division has also been reported, although it is much less common (Beresford Wash., Cell Differ. Dev., 1990;29:81-93). While transdifferentiation has been thought to be essentially irreversible, i.e. the transdifferentiated cell does not revert back into the cell type from which it arose, this has recently been reported not to be the case (Danto S I et al., Am. J. Respir. Cell Mol. Biol., 1995;12:497-502). Nonetheless, demonstration of transdifferentiation depends on defining in detail the phenotype of the original cells, and on proving that the new cell type is in fact descended from cells that were defined (Okada T S, Develop. Growth and Differ. 1986;28:213-321).
[0052] In many instances, transdifferentiation involves a sequence of steps. Early in the process, intermediate cells appear that express neither the phenotype of the original nor the subsequent differentiated cell types, and therefore they have been termed dedifferentiated. The whole process is accompanied by DNA replication and cell proliferation. Dedifferentiated cells are assumed a priori to be capable of forming either the original or a new cell type, and thus are multipotential (Itoh Y, Eguchi G, Cell Differ., 1986;18:173-182; Itoh Y, Eguchi G, Develop. Biology, 1986;115:353-362; Okada T S, Develop. Growth and Differ, 1986;28:213-321).
[0053] Stability of the cellular phenotype in adult organisms is probably related to the extracellular milieu, as well as cytoplasmic and nuclear components that interact to control gene expression. The conversion of cell phenotype is likely to be accomplished by selective enhancement of gene expression, which controls the terminal developmental commitment of cells.
[0054] The pancreas is composed of several types of endocrine and exocrine cells, each responding to a variety of trophic influences. The ability of these cells to undergo a change in phenotype has been extensively investigated because of the implications for the understanding of pancreatic diseases such as cancer and diabetes mellitus. Transdifferentiation of pancreatic cells was first noted nearly a decade ago. Hepatocyte-like cells, which are normally not present in the pancreas, were observed following the administration of carcinogen (Rao M S et al., Am. J. Pathol., 1983;110:89-94; Scarpelli D G, Rao M S, Proc. Nat. Acad. Sci. USA 1981;78:2577-2581) to hamsters and the feeding of copper-depleted diets to rats (Rao M S, et al., Cell Differ., 1986;18:109-117). Recently, transdifferentiation of isolated acinar cells into duct-like cells has been observed by several groups (Arias A E, Bendayan M, Lab Invest., 1993;69:518-530; Hall P A, Lemoine N R, J. Pathol., 1992;166:97-103; Tsao M S, Duguid W P, Exp. Cell Res., 1987;168:365-375). In view of these observations it is probably germane that during embryonic development, the hepatic and pan-creatic anlagen are derived from a common endodermal.
[0055] In accordance with one embodiment of the present invention, the platform technology is based on a combination of observations, incorporating the following components that are necessary and sufficient for the preparation of dedifferentiated intermediate cells from adult pancreatic islets of Langerhans:
1. a solid matrix permitting “three dimensional” culture; 2. the presence of matrix proteins including but not limited to collagen type I and laminin; and 3. the growth factor EGF and promoters of cAMP, including but not limited to cholera toxin and forskolin.
[0059] The preferred feeding medium is DMEM/F12 with 10% fetal calf serum. In addition, the starting tissue must be freshly isolated and cultured without absolute purification.
[0060] The use of a matrix protein-containing solid gel is an important part of the culture system, because extracellular matrix may promote the process of transdifferentiation. This point is highlighted by isolated pancreatic acinar cells, which transdifferentiate to duct-like structures when entrapped in Matrigel basement membrane (Arias A E, Bendayafn M, Lab Invest., 1993;69:518-530), or by retinal pigmented epithelial cells, which transdifferentiate into neurons when plated on laminin-containing substrates (Reh T A et al., Nature 1987;330:68-71). Most recently, Gittes et al. demonstrated, using 11-day embryonic mouse pancreas, that the default path for growth of embryonic pancreatic epithelium is to form islets (Gittes G K et al., Development 1996; 122:439-447). In the presence of basement membrane constituents, however, the pancreatic anlage epithelium appears to programmed to form ducts. This finding again emphasizes the interrelationship between ducts and islets and highlights the important role of the extracellular matrix.
[0061] This completes stage 1 (the production of dedifferentiated intermediate cells) of the process. During the initial 96 h of culture, islets undergo a cystic transformation associated with (Arias A E, Bendayan M, Lab. Invest., 1993;69:518-530) a progressive loss of insulin gene expression, (2) a loss of immunoreactivity for insulin protein, and (3) the appearance of CKA 19, a marker for ductal cells. After transformation is complete, the cells have the ultrastructural appearance of primitive duct-like cells. Cyst enlargement after the initial 96 h is associated, at least in part, with a tremendous increase in cell replication. These findings are consistent with the transdifferentiation of an islet cell to a ductal cell (Yuan et al., Differentiation, 1996; 61:67-75).
[0062] Evidence for the return to an islet cell phenotype includes: (1) the re-appearance of solid spherical structures; (2) loss of CK-19 expression; (3) the demonstration of endosecretory granules on electron microscopy; (4) the re-appearance of pro-insulin mRNA on in situ hybridization; (5) the return of a basal release of insulin into the culture medium.
[0063] 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
Islet Isolation and Purification
[0064] Pancreata from six mongrel dogs of both sexes (body weight 25-30 kg) were resected under general anesthesia in accordance with Canadian Council for Animal Care guidelines (Wang R N, Rosenberg L (1999) J Endocrology 163 181-190). Prior to removal, the pancreatic ducts were cannulated to permit intraductal infusion with Liberase CI® (1.25 mg/ml) (Boehringer Mannheim, Indianapolis, Ind., USA) according to established protocols (Horaguchi A, Merrell R C (1981) Diabetes 30 455-461; Ricordi C (1992) Pancreatic islet cell transplantation. pp 99-112. Ed Ricordi C. Austin: R. G. Landes Co.). Purification was achieved by density gradient separation in a three-step EuroFicoll gradient using a COBE 2991 Cell Processor (COBE BCT, Denver, Colo., USA) (London NJM et al. (1992) Pancreatic islet cell transplantation. pp 113-123. Ed Ricordi C. Austin: R. G. Landes Co.). The final preparation consisted of 95% dithizone-positive structures with diameters ranging from 50 to 500 μm.
EXAMPLE II
Screening compounds for Islet Neogenesis potency
[0065] Adult islets were isolated, where each preparation used was over 95% pure, and transformed 100% of these islets into duct epithelial structures under defined culture conditions. The panel on the left of FIG. 1 is from an inverted microscope and follows a typical islet as it transforms over a 10-day period to a duct epithelial structure. During this transformation process, the appearance, as shown on the panel on the right of FIG. 1 , of the duct epithelial cell marker CK-19 in every cell of the new ductal structures formed indicates a phenotypic switch from islet to duct. Also, there was a complete loss of islet cell hormone expression in all of these duct cells.
[0066] This islet-to-duct model was then used to study the effects of Drug A on this homogeneous population of duct epithelial cells. As you can see from the panels on the left of FIG. 2 , after 4 days of Drug A treatment at a concentration 250 ng/ml, complete islet formation is from the duct was associated with a tremendous increase in PDX-1 expression (3-fold). PDX-1 is a transcription factor associated with islet development and differentiation during pancreatic development. In the control group seen on the right panel of FIG. 2 , which was supplemented with only basal media for 4 days, none of the ducts transformed into islets and there was no increase in PDX-1 expression. What being obtained then here is an in vitro model which mirrors fetal ontogeny of the pancreas where there is new islet formation from the ductal epithelium—and it is shown here that this process is inducible in the adult pancreas using Drug A.
[0067] Of the total amount of ductal structures which accounted for 100% of the tissue in culture, 35% of these structures differentiated into islets after 4 days of Drug A treatment whereas none of the ducts in the control group differentiated into islets as illustrated in FIG. 3 .
[0068] FIG. 4 illustrates that during duct-to-islet transformation, 100% of all cells in the control group continued to express the duct epithelial cell marker CK-19 whereas there was a loss of CK-19 expression after 4-day Drug A treatment as only ½ of these cells expressed CK-19. Also, 4-day Drug A treatment led to a 3-fold increase in PDX-1 expression in all treated cells whereas no increase was seen in the control Group.
[0069] FIG. 5 illustrates that islet cell hormones, insulin, glucagon and somatostatin were all undetectable in all of the cells in the control group after 4 days whereas in the DRUG A group, the presence of these islet cell hormones was detected using immunohistochemistry and were found to be expressed in the same proportions as in normal adult human islets.
[0070] FIG. 6 illustrates that insulin secretion, as measured by ELISA, also increased significantly after Drug A treatment. The control group did not appear to secrete any insulin as the amount measured corresponded to the amount of insulin added to the basal media that was used. Therefore the new islets formed from the ducts do not just store insulin but can also secrete it.
[0071] The results appearing in FIG. 7 show that about 90% of all islet cells express PDX-1, 85% express insulin, 80% express both and none of these islet cells continue to express the duct epithelial cell marker CK-19. Thus, a complete differentiation from duct to islet is obtained with associated morphological, histological and biochemical changes.
[0072] Ilotropin was noted to cause a burst in duct epithelial cell proliferation, a process known to precede new islet formation from the duct. It is shown in FIGS. 8A and 8B that the biologically active component of ilotropin, Drug A, does. indeed cause a significant increase in duct epithelial cell proliferation, as measured by BrdU labeling. In fact, almost all of the duct epithelial cells in the DRUG A group were found to be proliferative.
[0073] Clearly new cells were being formed and new islet cells were developing from the duct epithelium but were these cells surviving? There was a 90% decrease in cellular apoptosis in the DRUG A group, compared to the control, as determined by programmed cell death-specific ELISA.
[0074] While Drug A leads to islet neogenesis from the duct, it was studied which signaling pathways mediate the drug's effects. Based on recent transgenic studies that highlight the importance of the prosurvival and prodifferentiation kinase Akt on pancreatic islet development, Akt activity relative to expression—the expression blot is shown here—was measured using Western Blot Analysis and it was found that DRUG A treatment caused a 4-fold increase in Akt activity as illustrated in FIG. 9 . Interestingly, when the kinase was inhibited immediately upstream of Akt-PI3-Kinase-using Wortmannin, islet formation from the ducts was completely abrogated. Cellular proliferation and survival did not increase, PDX-1 expression did not increase, CK-19 expression persisted and islet cell hormones were not be expressed in the DRUG A/Wortmannin Group. So clearly, the PI3-Kinase signaling pathway is a major mediator of duct-to-islet differentiation.
[0075] The activity of Caspase-3 was also investigated, which is an executioner of apoptosis and in fact, a biomarker of apoptosis. Its activity declined by 80% in the DRUG A group compared to the control again demonstrating DRUG A's antiapoptotic effects as illustrated in FIG. 10B .
[0076] In addition, another molecule widely associated with cell death, JNK, decreased in activity by 40% in the DRUG A group compared with the control, providing more information about the mechanism of how DRUG A mediates islet neogenesis from the duct.
[0077] In summary, Drug A is sufficient to induce islet cell neogenesis from duct epithelial cells in the adult pancreas.
[0078] This process is associated with a 3-fold increase in expression of the transcription factor PDX-1 and with a 4-fold increase in activity of the pro-survival/pro-differentiation kinase Akt. Furthermore, Drug A decreases cellular apoptosis by 80% and decreases Caspase-3 activity by over 90%.
[0079] While the invention has been described in connection with specific embodiments thereof, it will be 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 an in vitro method for screening agents inducing islet cell neogenesis or duct-to-islet cell transdifferentiation, which comprises the steps of: a) expanding in vitro cells of a duct-like structure obtained by inducing cystic formation in cells in or associated with post-natal islets of Langerhans; b) treating said expanded cells of said duct-like structure with an agent screened; and c) determining potency of said agent of inducing islet cell differentiation of said duct-like structure in becoming insulin-producing cells. | 2 |
FIELD OF THE INVENTION
[0001] The present invention relates generally to a radio signal receiver for use in wireless communications, and more particularly, to a radio signal receiver employing bandpass sampling.
BACKGROUND ART OF THE INVENTION
[0002] In wireless communication, the user signal to be transmitted is usually baseband signal with relatively low frequency and limited bandwidth, and in general can be expressed by two orthogonal components as I(t)+jQ(t). The spectrum can be illustrated as in FIG. 1 , where I(t) is the in-phase component and Q(t) is the quadrature component. When the user signal is to be transmitted, the transmitter modulates a carrier signal s, whose frequency is in RF (Radio Frequency) domain, with the user signal and then transmits the RF signal to radio space through the transmitting antenna.
[0003] The receiver receives the RF signal from radio space through the antenna, and converts it into baseband digital signal centred at zero frequency so that the wanted user signal meeting the BER (Bit-Error-Rate) requirement can be recovered through further baseband processing. In current wireless communication systems, most equipments still employ conventional super heterodyne receiver, with architecture as shown in FIG. 2 . In FIG. 2 , receiver 200 receives the RF signal via the antenna. The RF signal is first filtered by bandpass filter 220 , and then amplified by LNA (Low Noise Amplifier) 221 and sent to down -converter 230 . Down -converter 230 down-converts the received RF signal into IF (intermediate frequency) analog signal by exploiting a LO (local oscillator) signal, and the out-of-band interference in IF domain is rejected through IF filter 233 . Afterwards, quadrature demodulation is performed on the IF signal in I/Q separating unit 240 , to get two orthogonal baseband analog signals I(t) and Q(t). Lastly, the two paths of baseband analog signals are converted into digital signals in ADCs (Analog-to-Digital Converter) 250 I and 250 Q, and thus the wan ted user signal can be recovered through the decoding of demodulator 270 .
[0004] During the procedure of converting the RF signal into baseband digital signal as shown in FIG. 2 , IF filter 233 is indispensable, and the effect of IF filtering is directly related with the quality of the output signal. But in conventional super heterodyne receiver, IF filter 233 is implemented by bulky and expensive SAW (Surface Acoustic Wave) devices, making it very hard to be integrated with other circuits. Meanwhile, with the development of multi-mode handsets, the super heterodyne receiver needs a standalone IF SAW filter for every channel bandwidth in every mode, which increases the cost of receivers, and furthermore, the hardware constraints pose an obstacle to the upgrade of equipments. Moreover, analog mixers are used many times in the receiver, thereby problems like nonlinear effects and image frequency interference, is unavoidable.
[0005] To overcome the hardware constraints caused by using bulky devices such as IF filters, a solution is proposed to adopt ZIF (Zero-IF) receiver or direct conversion receiver architectures, to convert the RF signal directly into baseband signal by taking advantage of the LO signal having the same frequency as the RF carrier. Another solution is disclose d in US patent application document US20020181614A1, entitled “Sub -sampling RF receiver architecture”, issued on Dec. 5 th , 2002. In this solution, after being bandpass filtered and low-noise amplified, the received RF signal is sampled and filtered by using bandpass-sampling method, to get the baseband signal. The received signal at the receiver is actually a bandpass signal in which a band-limited signal (shown in FIG. 1 ) is modulated onto a HF carrier, and the lower sideband of the bandpass signal is much higher than the bandwidth of the passband, so sampling can be done by choosing a clock signal whose frequency is lower than the carrier frequency of the received signal, and thus some portion of high -order spectrum components of the sampled signal is placed between the lower sideband of the bandpass signal and zero frequency. The sampling frequency in bandpass sampling is significantly lower than the carrier frequency of the signal, and thus is also called as sub-sampling. Two kinds of sub-sampling receiver architectures are proposed in the patent document, which is incorporated herein as reference. Architecture of the first sub -sampling receiver is shown in FIG. 3 . In FIG. 3 , after being processed at RF bandpass filter 220 and LNA 221 , the received RF signal is sent to sampler and holder 310 , to be bandpass sampled at sampling frequency of
f s = f c M + 1 / 4 > 2 B ,
wherein f c is the carrier frequency, B is the user signal bandwidth for modulating the carrier, and M is any natural number. In this way, the sampled signal will have a high-order spectrum component of the user signal near zero frequency or namely at f s /4. ADC 320 is used for converting the sampled signal into digital signal. The converted digital signal will be quadrature modulated in digital domain independently at digital mixers 330 I and 330 Q. Digital mixers 330 I and 330 Q are used for moving the signal spectrum at f s /4 to zero frequency, so that orthogonal user digital signals can be recovered after being filtered by the digital lowpass filters.
[0006] In this sub-sampling receiver architecture, the analog mixers and the IF filters are omitted, but two digital mixers are needed to implement the second frequency conversion to move the spectrum of the signal to be demodula fed into baseband. Furthermore, a very high sampling frequency (higher than twice the bandwidth of the bandpass signal) is normally required in order to avoid aliases in the receiver. In practical systems, such as GSM mobile phone, it's generally very difficult to remove interference completely through RF bandpass filter 220 , so the input signal of the sampling circuit often contains wideband interference. Therefore, the clock signal selected in practical applications often has a frequency much higher than the theoretical value, which often leads to low efficiency. Additionally, AD (Analog-to-Digital) conversion is needed for the user signal modulated on the carrier of f s /4, so the performance of the AD converter must be high enough.
[0007] To further simplify the receiver architecture, a two -path sub-sampling receiver architecture is disclosed in patent document US20020181614A1, as shown in FIG. 4 . In FIG. 4 , after passing through RF bandpass filter 220 and LNA 221 , the received signal is first divided into two paths, and then respectively sampled by sampler and holder 410 I and 410 Q at frequency of
f s = f c N > B ,
wherein N is a natural number and a phase shift of 90 degree exists between the two paths of clock signals with frequency fi. In the architecture as shown in FIG. 4 , the carrier frequency is multiple times the sampling frequency, so the nth-order spectrum component of the user signal will exist at zero frequency after sampling. The baseband analog signal at zero frequency can be filtered out through lowpass filters. And then baseband digital signal can be gotten after AD converting the baseband analog signal.
[0008] In this two-path sub-sampling method, processing of the digital mixer in the first sub-sampling receiver is omitted and the baseband signal can be AD converted directly. However, when the sampling frequency is chosen, if N is even, the two paths will get the same result after the signal is sampled, and thus we can't obtain the separated orthogonal user signal s I(t) and Q(t). Furthermore, the method as how to separate the orthogonal user signals is not disclosed fully in the patent document.
[0009] With regard to the above modified receiver architecture, bulky devices such as IF filter, are not used any more, but it s fill fails to depart from the idea that the RF signal is first converted into baseband analog signal and then AD converted. In new wireless communication systems, many communication protocols and technologies are updated constantly, thus a better method an d apparatus is needed for converting the received radio signal into baseband digital signal.
SUMMARY OF THE INVENTION
[0010] In the present invention, wideband ADC is required to approach the receiving antenna as near as it can, and AD convert the RF signal directly, then various processing on the received signal should be implemented by programmable DSP (digital signal processing) devices as much as possible. DSP is flexible, costs less and is easy for integration, so this method can realize compatibility of multiple communication protocols and easy for technical upgrade.
[0011] Hence, based on analyzing the feasibility of the two-path sub-sampling method, this invention focuses on proposing a receiver architecture for AD converting the RF signal directly, and a specific method for recovering the wanted user signal as well.
[0012] One object of the present invention is to provide a simple bandpass sampling receiver architecture, for AD converting the RF signal directly, without resorting to analog mixers and digital mixers.
[0013] Another object of the present invention is to provide a simple bandpass sampling receiver architecture, for lowering the requirement for ADC performance as much as possible, and offer the method for recovering the orthogonal digital user signals.
[0014] A bandpass-sampling receiver is proposed for receiving RF signals, comprising: the first ADC, for converting the RF signal into the first path of digital signal under the control of the first sampling clock signal; the second ADC, for converting the RF signal into the second path of digital signal under the control of the second sampling clock signal; a signal separating unit, for separating the in-phase signal and the quadrature signal in the first path of digital signal and the second path of digital signal; wherein t he frequency of said first sampling clock signal and said second sampling clock signal is 1/N of the carrier frequency of said RF signal, and N is a natural number.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] For a detailed description of the preferred embodiments of the invention, reference will now be made to the accompanying drawings in which:
[0016] FIG. 1 displays the frequency spectrum of the baseband user signal;
[0017] FIG. 2 is a block diagram illustrating the architecture of conventional super heterodyne receiver;
[0018] FIG. 3 is a block diagram illustrating the architecture of a normal sub-sampling receiver;
[0019] FIG. 4 is a block diagram illustrating the architecture of a normal two-path sub-sampling receiver;
[0020] FIG. 5 displays the frequency spectrum of the RF signal after the user signal is modulated;
[0021] FIG. 6 displays the frequency spectrum of the RF signal after being sampled with clock signal of
f s = f c N ;
[0022] FIG. 7 is a block diagram illustrating the architecture of the bandpass sampling receiver in an embodiment of the present invention;
[0023] FIG. 8 illustrates structure of the proposed equipment for generating quadrature sampling clock signal in an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0024] To clearly describe the features of the present invention, a n analysis will first be given below to the feasible conditions of the two -path sub-sampling receiver architecture in theory, in conjunction with FIG. 5 and FIG. 6 , then a detailed description will go to the proposed receiver architecture in an embodiment of the present invention in conjunction with FIG. 7 and provide the method for recovering the user signal.
[0025] If the user signal with bandwidth as B shown in FIG. 1 can be expressed by two orthogonal components as I(t)+jQ(t), the RF signal with carrier frequency of f c and quadrature modulated with the user signal can be given by:
S ( t )= I ( t )cos(ω e t +φ)− Q ( t )sin(ω c t +φ) (1)
where ω e =2πf is the circular frequency of the carrier, and φ is the initial phase of the carrier.
[0026] For ease to analyze the spectrum characteristic of the RF signal, some necessary mathematical transforms can be made to equation (1), and thus S(t) can be further expressed as two bandpass components S′(f) and S″(t) with central frequencies as f c and −f c respectively:
S ′ ( t ) = 1 2 { [ I ( t ) cos ( φ ) - Q ( t ) sin ( φ ) ] + j [ I ( t ) sin ( φ ) + Q ( t ) cos ( φ ) ] } ⅇ j w c t ( 2 ) S ″ ( t ) = 1 2 { [ I ( t ) cos ( φ ) - Q ( t ) sin ( φ ) ] + j [ I ( t ) sin ( φ ) + Q ( t ) cos ( φ ) ] } ⅇ - j w c t ( 3 )
[0027] Its spectrum characteristic is shown in FIG. 5 . As the figure shows, S′(t) and S″(f) in equation (2) and equation (3) have difference in amplitude and frequency, but have the same bandwidth.
[0028] When the RF signal is bandpass sampled, to avoid aliases, we can choose a clock signal with frequency as
f s = f c N > B .
The sampled signal spectrum equals to periodic continuation of the original RF signal spectrum (as shown in FIG. 5 ) with sampling frequency f s as the cycle in spectrum domain, as displayed in FIG. 6 . It can be seen from FIG. 6 that the carrier frequency is N times the sampling frequency, superposition of the high-order spectrum components of S′(f) and S″(t) will occur at multiple time s the sampling frequency when spectrum is periodically continued. Thus, there will be a superposed spectrum component with bandwidth of B at zero frequency. The time domain of the signal centered to zero frequency (i.e. its carrier frequency is zero) can b e computed with equations (2) and (3), that is, I(t)cos(φ)-Q(t)sin(p). Apparently, due to aliases, the signal with zero carrier frequency is actually the linear combination of orthogonal user signals I(t) and Q(t). So it is unlikely to recover the separated orthogonal user signals I(t) and Q(t) by merely exploiting the filtered signal from the lowpass filter.
[0029] Therefore, two-path bandpass sampling is necessary to sample the RF signal by using two clock signals at the same frequency but with different phases, to get the linear combination of two different orthogonal user signals, and then I(t) and Q(t) of the user signal can be obtained through the separation procedure. Additionally, signal spectrum exists at zero frequency after sampling, so ADC can be used to convert the sampled signal into digital signal.
[0030] Base on the above ideas, the architecture of the proposed bandpass sampling receiver is shown in FIG. 7 . In FIG. 7 , the RF signal received at the antenna is filtered by bandpass filter 220 and amplified by LNA 221 , divided into two paths, and then AD converted by ADC 710 and 711 respectively. The sampling clock frequencies of the two ADCs are both 1/N of the carrier frequency of the RF signal, but there is a fixed relative delay τ between-the sampling clocks CLK 1 and CLK 2 of the two ADCs. The purpose of introducing the relative delay π lies in that the sampling instants in the two paths correspond to two different carrier phases, and accordingly two different digital sequences can be obtained after AD conversion. The relative delay r is required to be much smaller than the reciprocal of
B ( i . e . , τ << 1 B )
in order that the in-phase component I(t) and the quadrature component Q(t) keep almost constant during the period π. After the two AD converted digital sequences are filtered by digital lowpass filter 720 and digital lowpass filter 721 respectively, the zero frequency component (or namely the baseband digital signal) of the sampled digital sequences can be obtained. Finally, the two paths of baseband digital signals are sent to I/Q separator 730 for necessary digital signal processing, thus the two orthogonal components are separated and sent to subsequent DSP module 740 , and the wanted user signal can be recovered through further processing, such as demodulation, decoding and etc.
[0031] In accordance with the architecture as shown in FIG. 7 , when there exists the relative delay X between the sampling clocks CLK 1 and CLK 2 of the two ADCs, the two sampled baseband digital signals filtered by digital lowpass filter 720 and digital lowpass filter 721 , can respectively be expressed as:
S 1 ( t ) = I ( t ) cos ( φ 1 ) - Q ( t ) sin ( φ 1 ) ( 4 ) S 2 ( t ) = I ( t + τ ) cos ( φ 1 + w c τ ) - Q ( t + τ ) sin ( φ 1 + w c τ ) = I ( t ) cos ( φ 2 ) - Q ( t ) sin ( φ 2 ) ( 5 )
where φ 1 and φ 2 are the initial phases of the carrier relative to the two paths of sampling clocks CLK 1 and CLK 2 , φ 2 =φ 1 +ω c τ, and S 1 (f) and S 2 (f) represent the output signals of digital lowpass filters 720 and 721 respectively.
[0032] Meanwhile, if phase shift between CLK 1 and CLK 2 is 90 degree, that is
τ = 1 ω s π 2 , and ω c ω s = N ,
then
ω c τ = N 2 π .
When N is even,
ω c τ = N 2 π = n π
in equations (4) and (5), so equations (4) and (5) will be identical after being simplified, thus the wanted user signal cannot be recovered.
[0033] From the above analysis, only when ω e τ≠nπ, the user signal can be recovered with the two-path bandpass sampling method, wherein n is an integer. Therefore, ω e τ≠nπ is an indispensable condition to be met for the two-path bandpass sampling method.
[0034] When sin(φp 2 −φ 1 );o, i.e., φ 2 −φ 1 =ω c τ≠nπ, with some mathematical operations of (4) and (5), I(t) and Q(t) can respectively be represented as the linear combination of the output signals S 1 (f) and S 2 (t) of digital lowpass filters 720 and 721 :
I ( t ) = S 1 ( t ) sin ( φ 2 ) - S 2 ( t ) sin ( φ 1 ) sin ( φ 2 - φ 1 ) ( 6 ) Q ( t ) = S 1 ( t ) cos ( φ 2 ) - S 2 ( t ) cos ( φ 1 ) sin ( φ 2 - φ 1 ) ( 7 )
[0035] From equations (6) and (7), it can be known that I(t) and Q(t) are only related with the initial phases φ 1 and φ 2 of the carrier relative to CLK 1 and CLK 2 , and the two baseband digital sequence signals S 1 (f) and S 2 (t) obtained after lowpass filtering. Wherein only the relative initial phases φ 1 and φ 2 are unknown, so I/Q separator 730 still needs an inital phase computing module. After cell search procedure, the midamble signal and pilot signal sent by the transmitter at the sender side have become known signals for the receiver at the receive side, so the initial phase computing module can compute the initial phases φ 1 and φ 2 of the carrier, by using the midamble signal or pilot signal.
[0036] Specifically, assume that the I(f) and Q(t) of the received midamble signal or pilot signal are I 0 (t) and Q 0 (t), and after the received midamble signal or pilot signal is filtered by digital lowpass filters 720 and 721 , the output signals are S 10 (t) and S 20 (t). Thus, from equations (4) and (5), we can get:
S 10 ( t ) = I 0 2 ( t ) + Q 0 2 ( t ) cos { φ 1 + arc tan ( Q 0 ( t ) I 0 ( t ) ) } ( 8 ) S 20 ( t ) = I 0 2 ( t ) + Q 0 2 ( t ) cos { φ 2 + arc tan ( Q 0 ( t ) I 0 ( t ) ) } ( 9 )
Then, φ 1 and φ 2 can be calculated from equations (8) and (9), as follows:
φ 1 = arc cos ( S 10 ( t ) I 0 2 ( t ) + Q 0 2 ( t ) ) - arc tan ( Q 0 ( t ) I 0 ( t ) ) ( 10 ) φ 2 = arc cos ( S 20 ( t ) I 0 2 ( t ) + Q 0 2 ( t ) ) - arc tan ( Q 0 ( t ) I 0 ( t ) ) ( 11 )
[0037] After the initial phase computing module determines φ 1 and φ 2 , I/Q separator 730 can process the received S 1 (f) and S 2 (f) according to equations (6) and (7), to get I(t) and Q(t) of the wanted user signal. I/Q separator 730 is placed behind the ADC, so the processed signal is digital sequence. For ease of explanation in equations, signal is still represented in form of f(t).
[0038] The principle of the bandpass sampling receiver is analyzed above in conjunction with FIG. 7 . In practical applications, the proposed bandpass sampling receiver will operate as follows: first, determining the sampling clock frequency of the ADC
f s = f c N > B
according to the carrier frequency f c and user signal bandwidth B of the received RF signal; then, determining the relative delay τ between the sampling clocks of the two ADCs according to the necessary condition of the two -path bandpass sampling ω c τ≠nπ; afterwards, the receiver receives pilot signal or midamble signal from the transmitter, and determines the relative initial phases of the carrier in the initial phase computing un it in I/Q separator 730 , according to equations (10) and (11); after the relative initial phases of the carrier are determined, the receiver can process the received signal in I/Q separator 730 according to equations (6) and (7) and by using the parameters computed in the above steps, to get two orthogonal digital components of the wanted user signal, and sends them to subsequent DSP unit 740 for further analysis.
[0039] In a preferred embodiment of the present invention, in order to further simplify the I/Q separation procedure, the relative delay τ between the two paths of clock signals CLK 1 and CLK 2 can be further constrained to satisfy
ω c τ = ( 2 n ± 1 2 ) π .
[0040] To ensure the relative delay τ between CLK 1 and CLK 2 can meet condition that
ω c τ = ( 2 n ± 1 2 ) π ,
if assuming
ω c τ = π 2 ,
the relative delay
τ = 1 2 π f c π 2 = 1 4 f c = T c 4 ,
wherein T c is the carrier cycle, and two sampling clock signals can be generated readily with the method as shown in FIG. 8 . As best shown in FIG. 8 , first, LO 801 generates a signal with frequency twice the carrier frequency of the received signal. The signal is split into two paths of orthogonal clock signals having the same frequency as the carrier frequency of the signal by the ½ splitter 802 , thus it can be guaranteed that the phase shift is IC under carrier frequency ω c . Finally, two 1/N splitters 803 and 804 decrease the frequency of the two paths of orthogonal signals to 1/N of the former, i.e. the sampling clock frequency, thus the wanted sampling c locks CLK 1 and CLK 2 can be obtained, wherein ½ splifter 802 is required to ensure that the relative delay X between CLK 1 and CLK 2 can keep unchanged.
[0041] After the RF signal is sampled with the two paths of clock signals satisfying the condition
ω c τ = ( 2 n ± 1 2 ) π ,
equations (6) and (7) can be further simplified.
When φ 2 - φ 1 = ω c τ = ( 2 n + 1 2 ) π , I ( t ) = S 1 ( t ) cos ( φ 1 ) - S 2 ( t ) sin ( φ 1 ) ( 12 ) Q ( t ) = S 1 ( t ) sin ( φ 1 ) - S 2 ( t ) cos ( φ 1 ) ( 13 ) I ( t ) + j Q ( t ) = [ S 1 ( t ) - j S 2 ( t ) ] [ cos ( φ 1 ) - j sin ( φ 1 ) ] = [ S 1 ( t ) - j S 2 ( t ) ] ⅇ - j φ 1
When φ 2 - φ 1 = w c τ = ( 2 n - 1 2 ) π , ( 14 ) I ( t ) = S 1 ( t ) cos ( φ 1 ) + S 2 ( t ) sin ( φ 1 ) ( 15 ) Q ( t ) = - S 1 ( t ) sin ( φ 1 ) + S 2 ( t ) cos ( φ 1 ) ( 16 )
Q ( I )+ jI ( t )=[ S 2 ( t )+ jS 1 ( t )][cos(φ 1 )+ j sin(φ 1 )]=[ S 2 ( t )+ jS 1 ( t )] e jφ1 (17)
[0042] According to equations (12) to (17), I(t) and Q(t) are only related with the initial phase A, of the RF carrier relative to CLK 1 and the two lowpass filtered baseband digital sequence signals S 1 and S 2 , wherein only 100 1 is unknown. Thus, the initial phase computing unit in I/Q separator 730 can compute the relative initial phase φ 1 of the carrier by taking advantage of the known midamble signal or pilot signal, with equation (10).
φ 1 = arc cos ( S 10 ( t ) I 0 2 ( t ) + Q 0 2 ( t ) ) - arc tan ( Q 0 ( t ) I 0 ( t ) ) ( 18 )
[0043] After φ 1 is computed in the initial phase computing unit, I/Q separator 730 can process the received S 1 (t) and S 2 (t) with equations (12) and (13) or (15) and (16), to compute I(t) and Q(t) of the user signal.
[0044] According to equations (14) and (17), I(t) and Q(t) of the user signal can be obtained by rotating the sampled sequence with a certain phase q),. This sampling method is equivalent in effect to the method of using orthogonal carrier signal to quadrature modulate the received signal, and that's why this sampling method is called quadrature bandpass sampling.
[0045] In the I/A separation procedure in the above -mentioned preferred embodiment, if the two clock signals are synchronized with the carrier with specific phase relationship as
φ 1 = 2 k π + n π 2 , n = 0 , 1 , 2 , 3 ,
the I/Q separation procedure can be further simplified, and the orthogonal user signals can be obtained directly from the sampled sequences. But in different situations, there may be sign change between the orthogonal user signals and the output signal of the digital filter, specifically as follows:
When φ 1 = 2 k π and ω c τ = ( 2 n ± 1 2 ) π , I ( t ) = S 1 ( t ) ( 19 ) Q ( t ) = ∓ S 2 ( t )
When φ 1 = ( 2 k + 1 2 ) π and ω c τ = ( 2 n ± 1 2 ) π , ( 20 ) I ( t ) = ∓ S 2 ( t ) ( 21 ) Q ( t ) = - S 1 ( t )
When φ 1 = ( 2 k + 1 ) π and ω c τ = ( 2 n ± 1 2 ) π , ( 22 ) I ( t ) = - S 1 ( t ) ( 23 ) Q ( t ) = ± S 2 ( t )
When φ 1 = ( 2 k + 3 2 ) π and ω c τ = ( 2 n ± 1 2 ) π , ( 24 ) I ( t ) = ± S 2 ( t ) ( 25 ) Q ( t ) = S 1 ( t ) ( 26 )
[0046] When
φ 1 = 2 k π + n π 2 , n = 0 , 1 , 2 , 3
is computed by the initial phase determining unit, I/Q separator 730 can recover the user signal with equations (19-26) under different conditions: using two paths of baseband digital signals as the real part and imaginary part of the complex signal; rotating the phase of the complex signal with n times 90 degree, and then taking the real part and imaginary part of the complex signal as the corresponding separated in-phase signal and the quadrature signal respectively, to simplify the l/Q separation procedure at most.
[0047] The aforementioned I/Q separator and the initial phase computing unit therein can be implemented in software, or in specific hardware to implement the algorithms in the equations, or in combination of both.
[0000] Beneficial Results of the Invention
[0048] As described above, with regard to the bandpass sampling receiver as proposed in the present invention, the baseband signal can be obtained by AD converting the RF signal with bandpass sampling method, and thus this leads to omission of analog mixers and IF filters that are usually bulky, power consuming and difficult to be integrated, which greatly simplifies the receiver. architecture, and avoids problems like nonlinear effects, image frequency interference, DC offset and mixer noise in conventional receivers. With bandpass sampling techniques, the sampling frequency can be significantly lower than the carrier frequency, thus the requirement for ADC's performance can be lowered. The present invention also overcomes the deficiency of two-path sampling methods in prior art, and the proposed receiver architecture can be applied in various situations through setting the delay X between two sampling clock signals to meet the condition ω e τ≠nπ. Moreover, when w e τ=(2± 1 / 2 )π, the computation procedure for I/Q separation can be simplified, especially when the sampling clock signals are phase synchronized with the carrier signal and
φ 1 = 2 k π + n π 2 , n = 0 , 1 , 2 , 3 ,
the orthogonal components of the user signal can be obtained directly from the sampled signal, which can further simplify the computation procedure for I/Q separation. The details of I/Q separation are also offered in the present invention, which is of great help for the proposed receiver to be applied practically.
[0049] It is to be understood by those skilled in the art that the bandpass sampling receiver as disclosed in this invention can be modified considerably without departing from the spirit and scope of the invention as defined by the appended claims. | A bandpass sampling receiver is proposed for receiving RF signals, comprising: the first ADC, for converting the RF signal into the first path of digital signal under the control of the first sampling clock signal; the second ADC, for converting the RF signal into the second path of digital signal under the control of the second sampling clock signal; a signal separating unit, for separating the in-phase signal and the quadrature signal in the first path of digital signal and the second path of digital signal; wherein the frequency of said first sampling clock signal and said second sampling clock signal is l/N of that of said RF signal, and N is a natural number. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. application Ser. No. 12/470,102, filed May 19, 2009, which is a divisional of U.S. application Ser. No. 11/248,064, filed Oct. 12, 2005, which is a continuation-in-part of U.S. application Ser. No. 10/628,320, filed Jul. 28, 2003, now U.S. Pat. No. 7,198,073, which claims priority to U.S. Provisional Application Ser. No. 60/456,746, filed Mar. 21, 2003. U.S. application Ser. No. 11/248,064 also claims priority to U.S. Provisional Application Ser. No. 60/640,000, filed Dec. 29, 2004 and U.S. Provisional Application Ser. No. 60/640,001, filed Dec. 29, 2004.
FIELD OF THE INVENTION
The present invention relates to dispensing a specific amount of material from one container into another container.
BACKGROUND OF THE INVENTION
There are many different types of material dispensers available to the market offering differing levels of automation. Choosing one type of dispenser over another is often a function of what type of material is needing to be dispensed and is further defined by the ability of the material being dispensed to flow (as in the case of a liquid—typically referred to as the materials' viscosity) or change its form (as in the case of a powder) when relieved of a means of containing such material in a cylindrical shape. A machine dispensing material low in viscosity would likely be different in both methodology and apparatus from that of a machine dispensing a more viscous paste-type material.
For purposes of background and by way of illustration, references will be made to common practices found in the ink industry because such practices fairly represent the practices found in other industries requiring the use of accurately dispensing a specific amount of material from one container to another. It should be understood that the various aspects and teachings of the inventions described herein are not limited in their application and are not limited to the ink industry. Indeed, the various aspects, teachings, embodiments and methodologies described herein have application in all industries and in all systems and processes where it is desirable to dispense a specific amount of material from one container to another.
As is known, materials are typically stored and transported by using a number of different containers. Among the most common are steel drums (55 and 30 gallon capacities), HDPE buckets (5, 3½, 2 and 1 gallon capacities), and HDPE jugs (1 gallon capacity). Other containers include cardboard-roll or plastic cylindrical tubes (5″, 3¾″ and 2″ tubes). The 5″ and 3¾″ tubes are typically known in the ink industry as being either HDPE or cardboard-roll tubes and commonly referred to as Sonoco™ or Ritter cartridges. These tubes typically hold 4.4 or 8 lbs of material. The 2″ tubes are typically known in the construction industry as being either HDPE or cardboard-roll tubes and commonly are referred to as caulk tubes that typically hold either 10 ounces or 1 quart of material. Still other known containers include metal cans of 1 and 2 quart capacities. These cans may be made of metal or have a cardboard-roll body that typically hold 1 quart of tint (or colorant) as seen in the paint industry. Still other containers include bags made from a substantially air-tight, flexible, compressible composite material.
Dispensing equipment is seen in virtually every industry requiring a finished product that is created from a formulation. Formulations are often seen in the paint, ink, cosmetics, pharmaceutical, foodservice and chemicals industries. For example, in the ink industry, a printer may need to have a custom color of ink created to satisfy the requirements of a particular project. The custom color of ink is created using a formulation, or a recipe of materials. This combination of pre-determined amounts of specific ingredients is also used in the paint industry, for example, to create a custom color of paint and in the cosmetics industry to create a custom color of facial cream or makeup base.
A current manual method for creating a custom color from a formulation in the ink industry is for the operator to manually transfer one of the formulation components from one container (such as, a 55 gallon drum, 5 or 3½, 2 or 1 gallon (plastic) bucket, or an 8 lb. metal can) into another container, which sits on a precision scale, until the operator adds enough material into the container on the scale to reach the required amount of material called-out in the formulation for that finished product. The operator repeats the process with every component required of the formulation until the operator has “weighed-up” each ingredient. Throughout the process of “weighing-up,” the operator may need to manually add to or deduct from the amount of material placed into the finished product container that sits on the scale in order to attain the target value stated for each component in the formulation. This manual method of creating finished products from a formulation through the use of a container on a scale is referred to as the “Smart Scale” or “Hand Mix” method in a number of industries (hereinafter “Manual Mix Method”).
Another current method for creating a finished product from a formulation is through the use of a dispenser that may have a number of reservoir containers, each of which would contain one of the components required to create a finished product. The component is moved from the reservoir container, through the use of a pumping device connected to the reservoir container, through a length of piping to a dispensing valve that, upon receiving feedback from a computer's controlling software (which receives feedback from a scale that the receiving container sits upon), terminates the flow of material (at a value close to the target amount) and deposits the material into a receiving container. The dispensing valve would need to repeatedly open and close upon feedback from the computer and scale in order to dispense small amounts of a component to reach the target amount. The pumps subsequently would need to push the component through the dispensing valve, which may be rapidly opening and closing. The aforementioned pumping devices typically are piston, positive displacement, gear, diaphragm or peristaltic type pumps that force the material through the piping. Each of the aforementioned pumping device types are best suited for specific applications that relate to, among other things, the viscosity of the material being moved, the volume at which the material is required to pass through it and the level of accuracy required of the pumping device for the application. The aforementioned dispensing valve may be a ball, globe, piston, diaphragm, plug or butterfly type. Each of the aforementioned dispensing valve types are best suited for specific applications that relate to, among other things, the viscosity of the material being moved, the volume at which the material is required to pass through it and the level of accuracy required of the dispensing valve for the application. This automated method of creating finished products from a formulation is often referred to as “Automated Pump Dispensers” method in a number of industries (hereinafter “Gravimetric/Pump Dispenser Method”).
Yet another current type of automated material dispenser uses a number of reservoir containers, each of which contains one of possible components required of any finished formulation and dispenses those components through a volumetric means as opposed to the aforementioned Gravimetric means. The volumetric method (hereinafter “Volumetric Dispensing Method”) uses a positive displacement means of dispensing where a cylinder, filled with a material component, is emptied of some portion of the material (that resides within it) through the use of a piston found within it (located between the material component and the discharge end of the cylinder) that moves a predetermined distance and displaces a predetermined amount of the material component. This Volumetric Dispensing Method assumes that when the piston moves a predetermined distance that the amount of material component dispensed is the same time after time.
Drawbacks and disadvantages exist with respect to the Manual Method of dispensing formulations. For example, operator handling is the most costly expense of creating custom formulations when using the Manual Mix Method. In the ink industry, for instance, 55 gallon steel drums, 5 and 3½ gallon plastic buckets and 5 lb. and 8 lb. tin buckets are the most common container types used for storage and delivery of ink, whether the material is a base component used to create a finished product or is finished ink. The operator must manually remove the component from the container through the use of a spoon or putty knife type of tool. Paste-type ink, for instance, can be extremely dense and highly viscous (4,000-40,000 cps (centipoise) where water=1 cps; honey=5,000 cps). Paste-type ink's “stringing” characteristics (the ability for the material to adhere to itself, even when attempting to be separated) are high. The process of scooping the material from the buckets is physically taxing on the operator and can be a very messy operation due to the stringing nature of the material.
In addition, the accuracy of creating a formulation using the Manual Method is a function of the resolution of the scale (how accurate the scale is (measured in a percentage of the scale's full capacity)) and of operator skill in being able to apply the appropriate amount of material needed for any given formulation. If the material is highly viscous the operator can more easily remove material from the amount added (if the amount added were too high) than if the material were less viscous in which case the material added may disperse into the material already in the receiving container, not allowing for removal of the amount over added. If too much of a given material of the formulation is manually added, additional amounts of the other components required of the formulation would proportionally need to be added, resulting in the creation of more finished product than originally requested, potentially resulting in material waste.
Similarly, there are some drawbacks and disadvantages with the Gravimetric/Pump Dispenser Method. Some of the major drawbacks experienced with this method are dispense valve actuation, dispensing time, accurate reporting, scale cost, effect of vibration and wind currents, pump wear and cost, air fluctuation, and multiple scale cost. More specifically, and by way of example, the dispense valve opens via an electric/pneumatic solenoid valve which is controlled by a Human Machine Interface (HMI) which is the layer or device that separates a human that is operating the machine from the machine itself and, in some instances, is a computer. The HMI either communicates directly with or sends signals to other devices, for example, a program logic controller (PLC) which ultimately provides control of all electrical, pneumatic and mechanical movements and actions of the machine. The HMI sends a signal to a pneumatic solenoid that then in turn sends a pneumatic (air) signal that must physically travel through an air line in order to open and/or close the dispense valve. The delay created in an air signal needing to travel through an air line to the pneumatic solenoid affects how fast the dispense valve can physically open and close. The process of the dispense valve opening and closing in order to accurately dispense a small amount of material is commonly referred to as being in “pulse mode.” Any delay of the air signal traveling through the air line will ultimately affect how long the dispense valve remains in the pulse mode. If the target weight amount is less than or equal to 0.1 grams, the importance of the dispense valve not remaining in the pulse mode becomes critical.
Another drawback involves time delays in dispensing materials. The multiple dispensing valves may need to move in and out of position to accommodate any given material needing to be dispensed. There are time added delays due to the scale needing to completely stop its movement after each dispense in order that the computer can activate the pump to dispense more product, if required. The overall formulation dispense time may therefore increase because of required accuracy or number of components. As the dispense valve opens and closes, some amount of residual liquids, in the form of a drop, can remain on the edge of the dispense valve. When the scale signals the computer that the target value has been reached the computer closes the dispense valve. The residual material can fall into the final receiving container due to gravity. The computer receives a signal that the dispense is complete and does not account for any residual material that may fall into the final dispense container. To resolve this inherent problem, some manufacturers of Gravimetric/Pump Dispensers may have their software “lock-in” the target value for reporting purposes, when in fact the actual dispensed amount may be different.
Yet another disadvantage with Gravimetric/Pump Dispensers relates to the costs of the scales needed with those systems. The scales may vary in cost between $1,500 and $10,000 per scale. Some Gravimetric/Pump Dispensers may use several scales of varying capacities that add significantly to the cost of the Gravimetric/Pump Dispenser.
In addition, scales can be susceptible to vibration and air movement due to their sensitive load cells. Scales used for dispensers are often set to read as accurately as possible. Air movement over the scale or vibration under the scale may cause the scale to interpret the movement as additional weight and relay the information to the computer. The computer may interpret that the dispense valve has added more material to the final dispense when in fact it has not. The computer, therefore, must give the scale time to stabilize before adding more product. This problem could cause time delays and inaccurate readings of the actual dispense if the scale is not shrouded by a cover.
Yet another drawback involves the pumps used with the Gravimetric/Pump Dispensers. These pumps are used to transfer material from the reservoir containers to the dispense valves. A costly pump is required for each material component. The pumps add considerable upfront expense and ongoing maintenance expenses to the system. The cost of maintenance is high due to the fact that the pumps, being mechanical devices, inherently are subject to a high degree of wear and tear. Failure of the seals that provide the pumping ability is the most common maintenance issue with pumps. The pumping system relies on compressed air supplied by the end user of the Gravimetric/Pump Dispensers. Air compressors struggle with the delivery of consistent air pressure which the dispense valve relies on to accurately dispense to the scale. If there is too much fluctuation in delivered air pressure (15-20 psi) the calibration values set in the computer may “over dispense” or “under dispense.”
Moreover, there are disadvantages and drawbacks related to the transportation, storage and disposal of known material containers. For instance, there can be high costs relating to residual waste of material in a container when the material in the container is used and the container is disposed of. Waste is also due to the material curing prior to its intended end use when, in the container, it may develop a film (often referred to as “skinning”) when exposed to certain environmental conditions. The operator may dispose of the container even though it may still have a substantial amount of material remaining in it.
Throughout the course of using any material stored in a bucket container, the bucket's lid may be removed and replaced a multiple number of times, depending on the volume requirement of that particular material for any given formulation. If all of the material in the bucket is not used when the lid is first removed, and the lid is repeatedly removed and replaced, over the course of time the material in the bucket, especially that material that may not have been sufficiently removed from the side walls of the bucket, tends to skin-over or may become crusty, rendering it useless and adding to the amount of wasted material. Occasionally, the dried or contaminated material on the sidewalls contaminates the remaining “good” material in the bottom of the bucket, rendering the good material difficult to work with, making it more subject to operator disposal. Additionally, on the bottom of a bucket, due to the bucket's construction, areas could be present where ink becomes trapped and the complete removal of the ink from the bucket becomes virtually impossible.
Similarly, throughout the course of using any material stored in a HDPE jug container, the HDPE jug container's cap may be removed and replaced a multiple number of times, depending on the volume requirement of that particular material for any given formulation. If all of the material in the HDPE jug container is not used when the cap is first removed, and the cap is repeatedly removed and replaced, over the course of time the material in the HDPE jug container, especially that material that may not have been sufficiently removed from the side walls of the HDPE jug container, tends to skin-over or may become crusty, rendering it useless and adding to the amount of wasted material. Occasionally, the dried or contaminated material on the sidewalls of the HDPE jug container contaminates the remaining “good” material in the bottom of the HDPE jug container, rendering the good material difficult to work with, making it more subject to operator disposal. Additionally, on the bottom and on the sidewalls of an HDPE jug container, due to the HDPE jug container construction and the small opening, areas could be present where ink becomes trapped and the complete removal of the ink from the HDPE jug container becomes virtually impossible.
Additionally, there are drawbacks with respect to known cardboard-roll or plastic tubes that result in material waste in those containers. The known tubes use a movable displacing “puck” that, when pressed downwards towards the bottom of the tube, acts as a plunger to press the material residing in the tube out of the orifice found on the bottom of the tube. However, with known tube designs, an area remains between the puck and the fixed end of the tube, creating a region for the material in the tube to remain and not be discharged thus creating waste when the tube is disposed of.
Other drawbacks and disadvantages exist with respect to known dispensers, material containers and dispensing methods that are overcome by the present inventions described herein.
SUMMARY OF THE INVENTION
The present invention looks to improve on the methodology and apparatus in which materials are dispensed in order to create a desired finished product based on a prescribed mixture of a number of material components typically divided according to their individual requirements by percentages. The present invention additionally looks to improve upon the container in which the material is stored, shipped and used. The present invention also looks to integrate an improved material storage/shipping/dispensing container that may contain a pressure responsive silicone dispense valve configured to allow the dispensing of a specific amount of material through it in a controllable, metered fashion.
The present invention includes numerous methodologies and numerous apparatuses for dispensing materials. In one exemplary embodiment, the invention includes a dispenser that includes a plurality of integral material reservoir cylinders (each of which may or may not contain a separate material bag in which resides a component required for a formulation), or a plurality of alternate material reservoir containers (such as drums that are detached from and are not part of the dispenser but that supply material to the dispenser, with a component required for a formulation residing in each drum), or a combination of both a plurality of integral material reservoir cylinders and a plurality of alternate material reservoir containers, that provides a volume of material through a supply tube into a valve that directs the material to either: 1) a dispense tube and through a dispense valve, through or past a material sensor then into a receiving container that sits upon a scale, or 2) into a dispense cylinder in which resides a piston that, through the use of a piston drive plate actuator and the piston drive plate actuators' piston drive plate, moves the piston and directs the material through a valve which directs the material through a dispense tube, through or past a sensor and in-turn through a dispense valve and into a receiving container that sits upon a scale.
Another exemplary embodiment of the invention is a dispenser that includes a rotary table that holds one or a plurality of material containers on the rotary table. Within each material container resides a single base material which, if required of a desired formulation, in some calculated proportion, is used. In an exemplary application, a rotary table motor rotates the rotary table and positions the material container required by the formulation to the dispense position, which is the area towards the front of the dispenser and under a pressure actuator. The dispenser also includes an HMI, a scale and a feedback sensor. In one method of use, the operator inputs into the HMI a value of the desired finished amount (“target amount” in a value of total weight) of a custom formulation to blend. The HMI calculates the total weight of each of the base material components required (“calculated amount”) to create the target amount. The pressure actuator applies downward pressure on a movable member, such as a puck (residing within the material container used to push the base material out of the container) which pushes the base material through a proportional pressure responsive dispense valve that opens and closes in a rolling manner into a receiving container residing on a scale. As the base material is expelled through the valve, the base material is sensed by a sensor which, along with the scale, sends feedback information to the HMI to increase, decrease or discontinue the pressure being applied to the puck in the material container by the pressure actuator to provide the calculated amount. If the amount of base material expelled does not equal the calculated amount the HMI recalculates the amount of base material required (the “recalculated amount”), recalculates the amount of pressure required of the pressure actuator to attain the recalculated amount, and sends a signal to the pressure actuator to expel the recalculated amount of base material from the material container. The process of expelling a base amount, receiving feedback from the sensor and the scale, calculating if more base material is required and, if required, recalculating the amount of pressure required of the pressure actuator to attain the total recalculated amount continues until the calculated amount is attained. When the calculated amount is attained the HMI positions the next material container required of the formulation, if another is required, into a position under the pressure actuator and repeats the process until the calculated amount of each base material components of the required formulation have been dispensed into the receiving container.
Another embodiment of the dispenser holds one or a plurality of containers in a linear configuration and, within each resides a single base material which, if required of a desired formulation, in some calculated proportion, is used. As above, each material container can be positioned under a pressure actuator. However, with this embodiment, the containers are moved under the pressure actuator, or the pressure actuator is moved over the containers in a linear manner, as opposed to the above-described rotary manner. The dispenser may also include an HMI, a scale and a feedback sensor. The method of use may be similar to the method described above with respect to the rotary table configuration, and will not be repeated here.
Yet another exemplary embodiment of the dispenser holds one or a plurality of containers in either a linear configuration (through the use of a linear slide) or a rotary configuration (through the use of a rotary table) and, within each resides a single base material which, if required of a desired formulation, in some calculated proportion, is used. Each container can be manually positioned by the operator under a pressure actuator or the pressure actuator can be positioned over the container. The dispenser may also include an HMI, a scale and a feedback sensor. Again, the method of use is similar to that described above.
Still another exemplary embodiment of the dispenser holds one or a plurality of containers in either a linear configuration (through the use of a linear slide) or a rotary configuration (through the use of a rotary table) and, within each resides a single base material which, if required of a desired formulation, in some calculated proportion, is used. Each container is manually positioned by the operator under a pressure actuator. The dispenser may also include an HMI and a scale. In this method of use, the operator inputs into the HMI a value of the desired finished amount of a custom formulation to blend. The HMI calculates the total weight of each of the base material components required to create the target amount. The operator then positions a container to the dispense position which is the area under a pressure actuator. The pressure actuator is manually activated by the operator to apply downward pressure on the movable puck which pushes the base material through a proportional pressure responsive dispense valve that opens and closes in a rolling manner into a receiving container residing on a scale. As the base material is expelled through the dispense valve and falls into the receiving container the base material is weighed by the scale and the operator may increase, decrease or discontinue the pressure being manually applied to the puck in the material container by the pressure actuator to provide the calculated amount. When the operator discontinues applying pressure to the pressure actuator the dispense valve effectively stops expelling the base component from the material container. The operator then reads the scale value and determines if more base material is required to reach the calculated amount. The operator repeats the above steps until the calculated amount required of the formulation is attained. When the calculated amount is attained the operator positions the next material container required of the formulation, if another is required, into a position under the pressure actuator and repeats the process until the calculated amount of each base material components of the required formulation have been dispensed into the receiving container.
Yet another embodiment of the dispenser holds a single material container in which resides a single base material which, if required of a desired formulation, in some calculated proportion, is used. Each material container is manually inserted by the operator into the dispense position under the pressure actuator. The dispenser may also include an HMI, a scale and a feedback sensor. In one method of use, the operator inputs into the HMI a value of the desired finished amount, i.e., the target amount in a value of total weight, of a custom formulation to blend. The HMI calculates the total weight of each of the base material components required to create the target amount. The pressure actuator applies downward pressure on the movable puck which pushes the base material through a proportional pressure responsive dispense valve that opens and closes in a rolling manner into a receiving container residing on a scale. As the base material is expelled through the valve, the base material is sensed by a sensor which, along with the scale, sends feedback information to the HMI to increase, decrease or discontinue the pressure being applied to the puck in the material container by the pressure actuator to provide the calculated amount. If the amount of base material expelled does not equal the calculated amount the HMI recalculates the amount of base material required (the “recalculated amount”), recalculates the amount of pressure required of the pressure actuator to attain the recalculated amount, and sends a signal to the pressure actuator to expel the recalculated amount of base material from the material container. The process of expelling a base amount, receiving feedback from the sensor and the scale, calculating if more base material is required and, if required, recalculating the amount of pressure required of the pressure actuator to attain the total recalculated amount continues until the calculated amount is attained. When the calculated amount is attained the operator removes the material container and inserts the next material container required of the formulation, if another is required, into a position under the pressure actuator and repeats the process until the calculated amount of each base material components of the required formulation have been dispensed into the receiving container.
Still another exemplary embodiment of the dispenser holds a single container within resides a single base material which, if required of a desired formulation, in some calculated proportion, is used. Each container is manually positioned by the operator under a pressure actuator. The dispenser may also include an HMI and a scale. In this method of use, the operator inputs into the HMI a target amount of the desired finished amount of a custom formulation to blend. The HMI calculates the total weight of each of the base material components required to create the target amount. The operator then positions a container to the dispense position which is the area under a pressure actuator. The pressure actuator is manually activated by the operator to apply downward pressure on the movable puck which pushes the base material through a proportional pressure responsive dispense valve that opens and closes in a rolling manner into a receiving container residing on a scale. As the base material is expelled through the dispense valve and falls into the receiving container the base material is weighed by the scale and the operator may increase, decrease or discontinue the pressure being manually applied to the puck in the material container by the pressure actuator to provide the calculated amount. When the operator discontinues applying pressure to the pressure actuator the dispense valve effectively stops expelling the base component from the material container. The operator then reads the scale value and determines if more base material is required to reach the calculated amount. The operator repeats the above steps until the calculated amount required of the formulation is attained. When the calculated amount is attained the operator positions the next material container required of the formulation, if another is required, into a position under the pressure actuator and repeats the process until the calculated amount of each base material components of the required formulation have been dispensed into the receiving container.
Another aspect of the present invention is an improved container that may be used in the dispensing of material. In one exemplary embodiment, the container may be in the form of a material bag that comprises a substantially air-tight, flexible, compressible composite selected from among urethane, vinyl laminated fabric, chloroprene, viscoelastic fabric, buna-N, vinyl, cloth inserted rubber, polytetraflouroethane, elastomeric rubber, polypropylene, fluoroelastomers, rubber, hyplon, polyethylene, neoprene, polyvinylchloride, nitrile, polyolefin films, nylon, prismatic films, lycra, polyurethane, and the like.
The bag has a top, bottom and sides, sealed airtight, and also has a centered opening adjacent to the top in the form of a hole large enough to accept the clear passage of a molded fitting secured into it, becoming an integral part of the material bag. The bag also has a bag spout that provides for: 1) an opening in which to fill the material bag with material; 2) an opening in which to evacuate the material bag of material; 3) a means of connecting material bag to the dispenser; and 4) a means of connecting a pressure responsive silicone dispense valve to it. The material bag may incorporate a proportional elastomeric dispense valve or pressure responsive dispense valve. The material bag may also have a delta seal (a sealed-tight seam on an angle to its starting point) on any one its four corners, each of which may decrease the opportunity for material to become trapped within that area and which directs material in the direction of the bag spout throughout the process of evacuation of material from the material bag when pressure is applied to the material bag.
Another aspect of the present invention is an improved container, such as a cylindrical container or a material cartridge, that incorporates the proportional elastomeric dispense valve or pressure responsive dispense valve into the discharging end of the container. The dispense valve opens and closes rollingly in response to a predetermined discharge force, allowing stored material to precisely discharge from the container.
Still another aspect of the present invention is an improved movable member such as a puck (residing within the material container used to push the base material out of the container). The improved puck includes a number of seals around it's outside edge which effectively presses base material out of the material container through the dispense valve without allowing the material to bypass the puck. Additionally, the puck has a convex center that permits ample room for the dispense valve (found centered on the fixed end of the cartridge container) to close when the puck comes in direct contact with the fixed end of the cartridge. The puck is angled or configured on its bottom in such a way as to mate up with the fixed end of the container to decrease the amount of base material that may remain after the puck comes in contact with the fixed end of the container and subsequently provides the greatest opportunity for all of the base material in the container to be expelled from the container.
There are numerous potential uses for any of the dispensers described herein, including those uses described herein. One of skill in the art will appreciate that the illustrative uses described herein are exemplary of the numerous possible applications and uses of the disclosed dispensers and that the invention is not limited to the described uses. One exemplary use of the dispenser may be when the end-user requires the dispenser to provide large quantities of finished product to satisfy any given project requirements and to create the finished product in a commercially acceptable timeframe. For example, in the ink industry a printer may need to create enough of a custom color (i.e., 50.00 lbs. of finished product) to produce 100,000 sheets of finished printed pages. The formulation may require a majority of the finished product to be made from one or more of the components in the formulation (e.g., 90% of the finished product being made from two components). The end-user may require the dispenser to provide a high-speed, high-flow dispensing manner for any of the components to create the finished product (hereinafter referred to as a “coarse fill method”).
In an aspect of the invention, the coarse-fill method may use a combination of: 1) a plurality of detached alternate drum material reservoirs each having a single drum pump attached and each of which supplies a component to a preferred or to an alternate valve, and thereafter through the dispenser, and 2) a plurality of integral material reservoirs which use a component source possibly in the form of a material bag to supply material to a valve, and thereafter through the dispenser. If the formulation requires a coarse fill method for any of the given components, the dispenser would initially dispense material using the coarse fill method to an amount approximately 1 lb. from the total target amount for that component. The remaining amount of component needed to attain the total amount required by the formulation for that component would be dispensed through the precision metering cylinder manner of dispensing (hereinafter referred to as a “small quantity method”).
Any of the material containers described herein may incorporate the pressure responsive dispense valve of the invention and could be used in an accessory piece of equipment to mechanically assist in expelling material (i.e., inserted into an automated dispenser, inserted into a manual tool (such as a typical caulk gun), or inserted into an automated dispenser that, along with the HMI maintains a given level of material in a receiving container (often seen on printing presses and commonly know in the industry as “Fountain Fillers”)). Any of the containers described herein which incorporate the pressure responsive dispense valve of the invention could be used independent of an automated means of expelling the material (i.e., by physically applying pressure to the container or, if the container is a material bag, to the material bag).
Other features and advantages of the invention will become apparent to those skilled in the art upon review of the following detailed description, claims and drawings in which like numerals are used to designate like features.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of a single component assembly of an exemplary dispenser.
FIGS. 2A-B are schematic diagrams of an exemplary material bag assembly.
FIG. 3 is a schematic diagram of an exemplary piston assembly.
FIG. 4 is a schematic diagram of an exemplary linear actuator assembly.
FIG. 5 is a schematic diagram of an exemplary proportional dispense valve assembly.
FIG. 6 depicts several views of an alternative container with the proportional dispense valve assembly of FIG. 5 .
FIG. 7 depicts a full side view and a partial side view of an alternative container with the proportional dispense valve assembly of FIG. 5 .
FIG. 8 are two exploded schematic diagrams of an alternative dispenser incorporating the alternative container of FIG. 6 .
FIG. 9 is an exploded schematic diagram of the rotary assembly of the dispenser of FIG. 8 .
FIG. 10 is an exploded view of an exemplary container of the invention.
FIG. 11 is a cross-section view of the container of FIG. 10 .
FIG. 12 is an exploded cross-section view of the end of the container of FIG. 11 .
FIG. 13 is a schematic view of the container of FIG. 10 illustrating the mating up of the movable member with the interior bottom of the container.
FIG. 14 is a schematic view similar to FIG. 13 illustrating the movable member in a position away from the interior bottom of the container.
FIG. 15 is an isometric view of an exemplary movable member of the present invention.
FIG. 16 is another isometric view of the movable member of FIG. 15 .
FIG. 17 is a side view of the movable member of FIG. 15 .
Other features and advantages of the invention will become apparent to those skilled in the art upon review of the following detailed description, claims and drawings in which like numerals are used to designate like features.
DETAILED DESCRIPTION OF THE INVENTION
The present invention may be embodied in many forms and many methodologies. As used herein, the following terms have the following broad meaning as understood by those of skill in the art. Note that these definitions are intended to simply assist the reader in understanding the terms used herein and are not meant to provide a limiting definition to each term. The term “material” means a flowable, non-solid substance, such as liquid, paste or powder, or any other substance capable of dispensing. The term “formulation” means a prescribed recipe of a number of material components typically divided, according to their individual requirements, by percentages that, when dispersed or thoroughly mixed together, create a desired finished product. The terms “container” or “material container” mean any and all devices or structures, in which one or more materials may be contained, held, packaged into, received in, stored in or used as delivery package, including without limitation any and all structures identified herein. The term “HMI” means human/machine interface or one or more devices that allow for an interface between those devices and humans for the control of equipment or processes of equipment, and more generally may be defined as the layer or device that separates a human that is operating the equipment from the equipment itself. The term “downwards” means as being towards the direction of the bottom of FIG. 1 . Likewise, the term “upwards” means as being towards the direction of the top of FIG. 1 .
Referring to FIG. 1 , there is depicted a schematic of a dispenser of an exemplary embodiment of the invention. The dispenser may include a human/machine interface or HMI 29 that sends a signal to either a detached drum pump 2 or to bag pressure actuator 3 , depending upon the volume and speed requirements of the component for the formulation. For formulations requiring the coarse fill method of dispensing for any component, HMI 29 would signal supply valve 13 to open entirely and would signal dispense valve 23 to open entirely and would signal detached drum pump 2 to start. Detached drum pump 2 would move the component from alternate material reservoir 1 through supply tube 12 , through supply valve 13 , through dispense tube connecting plate 15 A, into dispense cylinder 19 , through dispense valve 23 , through dispense tube 24 , through dispense valve housing 25 and, in having developed enough pressure throughout the embodiments described above, would cause proportional dispense valve or pressure responsive dispense valve 26 to open rollingly and material would pass through the proportional dispense valve and would pass through material sensor 26 A (a device used to detect the presence of a solid volume of material) and into receiving container 27 which sits upon scale 28 .
The piston assembly (as seen as an assembly in FIG. 3 and as seen as individual embodiments in FIG. 1 ) comprised of piston body 18 which may be formed in a manner to provide for a means of maintaining perpendicularity of the bottom of the piston body to the inside walls of dispense cylinder 19 through the use of a number of piston alignment rings 17 of varying dimension located between the piston seals 16 and a number of (most preferable two) piston seals 16 , that reside within dispense cylinder 19 , and could, as an entire assembly, freely move upwards in direction or freely move downwards in direction within dispense cylinder 19 . The piston assembly ( FIG. 3 ) is prevented from passing through the bottom of dispense cylinder 19 (as seen as being towards the direction of the bottom of FIG. 1 ) through the use of piston stop ring 20 A (as shown in FIG. 1 ). The piston assembly ( FIG. 3 ) is prevented from passing through the top of dispense cylinder 19 (as seen as being towards the direction of the top of FIG. 1 ) through the use of dispense tube connecting plate 15 A (as shown in FIG. 1 ).
The piston assembly ( FIG. 3 ) may move downwards in direction within dispense cylinder 19 due to piston body 18 having pressure exerted onto the top of it by the component when the component is moved: 1) from alternate material reservoir 1 through the use of detached drum pump 2 , or 2) from material bag 8 through the use of bag pressure actuator 3 . Either source of material may cause the voided area created above the piston assembly caused by the downwards movement of the piston assembly in dispenser cylinder 19 to fill with material. In either case, the filling of the void above the piston assembly and the downwards movement of the piston assembly may be assisted by the piston body 18 , when piston body 18 has piston gripper 20 (of which the exemplary embodiment would be piston gripper 20 which has a bladder, which, when expanded with air, firmly attaches itself to the void inside of piston body 18 ) firmly attached to it and when piston assembly is drawn in a downwards direction by piston pressure actuator 22 . The downwards movement of the piston assembly may create a vacuum inside dispense cylinder 19 above piston body 18 and may assist in filling of the void created inside dispense cylinder 19 above piston body 18 . Piston alignment rings 17 would assure that piston body 18 travels in a parallel linear motion to dispense cylinder 19 sidewalls. Piston seals 16 would provide for a substantially leak-free contact between piston body 18 and the interior cylinder walls of dispense cylinder 19 . Piston seals 16 would prevent the component from bypassing piston body 18 and would cause the component to remain in the area of dispense cylinder 19 above piston body 18 .
Two alternative embodiments to supply valve 13 and dispense valve 23 would be: 1) an alternate 4-way valve 14 , or 2) an alternate 3-way valve 15 . With either alternate embodiment to supply valve 13 and dispense valve 23 , detached drum pump 2 would move its component from alternate material reservoir 1 through supply tube 12 and through either: 1) alternate 4-way valve 14 which would, upon receiving a signal from HMI 29 , switch alternate 4-way valve 14 to direct the component to either: a) pass through dispense tube connecting plate 15 A into dispense cylinder 19 (when the small quantity method of dispensing is required to complete the component requirement of a formulation), or b) through dispense tube 24 and onwards through other embodiments as described above (when the coarse-fill method of dispensing is required to satisfy a user requirement) or 2) alternate 3-way valve 15 which would, upon receiving a signal from HMI 29 , switch alternate 3-way valve 15 to direct the component through dispense tube connecting plate 15 A and into dispense cylinder 19 .
When HMI 29 receives a signal from scale 28 that the target value for the component (that uses the coarse fill method of dispensing) has been attained HMI 29 signals detached drum pump 2 to stop.
HMI 29 would signal supply valve 13 to close, or would signal alternate 4-way valve 14 or alternate 3-way valve 15 to switch to direct material from dispense cylinder 19 to the direction of dispense tube 24 , and would signal piston pressure actuator assembly (as seen as an assembly in FIG. 4 and as seen as individual embodiments in FIG. 2 ) to move piston drive plate 21 (which has piston gripper 20 firmly attached to it) upwards to locate and come into positive contact with piston body 18 .
HMI 29 would signal piston pressure actuator assembly to move piston drive plate 21 upwards a defined distance (which defined distance is equal to the amount of incremental movement of piston body 18 upwards that would result in an amount of component being evacuated from that amount of material residing above piston body 18 and in dispense tube 24 ) that would equal some percentage of the component amount (as being an amount identified by HMI 29 and transmitted to scale 28 ) required to equal the total target amount required of that component for the formulation, minus the amount previously dispensed of that component (in the coarse-fill manner described above). Depending upon the allowable percentage of error (hereinafter referred to as “tolerance”) that any particular component may have (of which each tolerance value is related to the target amount of the required component) HMI 29 may require dispenser to dispense component to an amount that is less than the overall required amount of the component. This process of dispensing an amount that is “short” of the required amount continues until the target value has been attained. The upwards movement of piston body 18 would cause component to move through dispense valve 23 , through dispense tube 24 , through dispense valve housing 25 and, in having developed enough pressure throughout the embodiments described above, would cause proportional dispense valve 26 to open rollingly and component would pass through proportional dispense valve 26 , would pass through material sensor 26 A and into receiving container 27 which sits upon scale 28 .
The speed at which piston pressure actuator 22 moves upwards or downwards, and resultantly moves piston body 18 to dispel or fill material into or out of dispense cylinder 19 , may be the same for all component assemblies of the embodiment, but most preferably the speed would be able to be limited and controlled, on a per component assembly basis as a function of the viscosity and rheological properties of the material and by the amount of material needing to be displaced.
Upon reaching the target weight required of the component for the formulation, scale 29 would send a signal to HMI 29 which would cause the piston pressure actuator assembly to stop the upwards movement of piston drive plate 21 . HMI 29 would command piston gripper 20 to positively affix itself to piston body 18 . HMI 29 would command piston pressure actuator 22 to reverse its direction and move downwards a defined distance. The defined distance of downward movement of piston drive plate 21 is equal to the distance required to decrease the amount of pressure created throughout the embodiments due to the process of dispensing which would result in enough reduction in pressure to cause proportional dispense valve 26 to close.
Each proportional dispense valve 26 , of which a single proportional dispense valve 26 is illustrated in FIG. 5 , is a pressure responsive one-way valve of an elastomeric material that resides and is held fast in dispense valve housing 25 . Proportional dispense valve 26 opens rollingly when the force and pressure of material on it forces it open, and closes effectively and completely when the force and pressure exerted drops. Any and all elastomeric valves which open and close in response to a predetermined discharge force may be used with the invention. Silicone is the preferred material used for elastomeric valves; however, other materials may be used.
Proportional dispense valve 26 (as seen in FIG. 5 ) includes a valve head 30 that defines one or more slits 33 that form one or more flaps 35 and that shift outward (as seen as being towards the direction of the bottom of FIG. 5 ) to cause a connector sleeve 31 to double over and extend rollingly, to thereby apply a pressure to the valve head 30 which assists in opening the valve orifice 32 . On release of pressure, valve orifice 32 closes and the valve head 30 shifts to a retracted position. Suitable valves are made by Liquid Molding Systems, Inc. under the trademark SureFlo, and U.S. Pat. Nos. 5,439,143 issued Aug. 8, 1995, 5,339,995 issued Aug. 23, 1994, and 5,213,236 issued May 25, 1993 are understood to describe these valves. The identified patents are incorporated by reference. One of skill in the art will understand that other configurations of the dispense valve may be used with the invention including those that define slits but do not necessarily open and close in the same manner as the illustrated dispense valve 26 , that is, do not open and close in a rolling and extending manner. Rather, valves that include slits to form flaps that open and close may be used with the invention.
Dispense valve housing 25 may have a means of preventing valve orifice 32 from extending beyond its normally closed position thereby prohibiting air from entering into the area above dispense valve 26 . Dispense valve housing 25 utilizing such a means would result in creation of a “one-way” valve, thus allowing material to pass through dispense valve 26 in only one direction. The dispense valve 26 configured with the material containers, including the material bag, describe herein, improves upon the current container design by offering a means to cleanly and effectively stop the flow of a material from such container, thereby overcoming the known problems of the “stringing” of material from the current containers orifice and the ineffective means it provides for stopping the flow of material from the container orifice.
Another use of the dispenser may be when the end-user requires the dispenser to provide small quantities of finished product to satisfy any given project requirements and to create the finished product in a commercially acceptable timeframe. For example, in the ink industry a printer may need to create enough of a custom color (i.e. 10.00 lbs. of finished product) to produce 10,000 sheets of finished printed pages. The end-user may require the dispenser to provide a small-volume of finished product using the small quantity method.
Referring to FIG. 1 , the small quantity method of using the dispenser may use a plurality of integral material reservoirs which use a component source in the form of the previously described material bag to supply material to a preferred or to an alternate valve, and thereafter through the dispenser embodiments as described below.
The operator inserts material bag 8 (as in FIG. 1 ) (which is pre-filled by the ink manufacturer with a material as required by the formulation being created) into the bag reservoir 7 . HMI 29 sends a signal to bag pressure actuator 3 (or any other device capable of exerting enough pressure on material container (material bag 8 described above)) to be able to force the component residing in the material container through the other embodiments as illustrated in FIG. 1 .
For formulations requiring the small volume method of dispensing for any formulation, HMI 28 would signal supply valve 13 to open entirely and would signal dispense valve 23 to open entirely and would signal bag pressure actuator 3 to start. Pressure actuator 3 would move bag drive plate 4 upwards to locate and come into positive contact with bag plate 5 which in turn would press upwards and would move its component from material bag 8 through supply tube 12 , through supply valve 13 , through dispense tube connecting plate 15 A, into dispense cylinder 19 , through dispense valve 23 , through dispense tube 24 , through dispense valve housing 25 and, in having developed enough pressure throughout the embodiments described above, would cause proportional dispense valve 26 to open rollingly and material would pass through proportional dispense valve 26 , would pass through material sensor 26 A (a device used to detect the presence of a solid volume of material, which may be of video or beam-type) and into receiving container 27 which sits upon scale 28 .
The container material bag 8 may have a spout clamp 10 (a spring-release clamp device that securely affixes the material bag 8 to the cylinder material reservoir cover 8 , assuring a leak-free connection) affixed to bag spout 9 . Cylinder material reservoir cover 11 becomes firmly attached to the dispenser and provides for a positive connecting point between bag reservoir 7 and tube supply 12 . Bag overlap seal 6 , being firmly attached to bag plate 5 , extends outwards beyond the diameter of bag plate 5 and is made from an elastomeric material, of which polyester is the most preferred, and comes in positive radial contact with the inside walls of bag reservoir 7 (most preferable tubular polyvinyl chloride, open at both ends, which is integrated into the dispenser and which receives and contains material bag 8 ) and prevents material bag 8 from by-passing bag plate 5 when pressure is exerted on bag plate 5 from bag drive plate 4 (which is driven by bag pressure actuator 3 ).
When material in material bag 8 is fully expelled and when material bag 8 needs to be replaced the operator removes cylinder material reservoir cover 11 from the dispenser, releases spout clamp 10 from cylinder material reservoir cover 11 and from expelled material bag 8 , inserts replacement (filled) material bag 8 into bag reservoir 7 , connects spout clamp 10 to bag spout 9 and to cylinder material reservoir 11 and attaches cylinder material reservoir 11 to the dispenser. When a replacement material bag 8 is placed in bag reservoir 7 , spring 6 B, residing inside bag reservoir 7 and under bag plate 5 , is open throughout its center to allow for free passage of bag drive plate 4 through its open center. Spring 6 B presses upon the underside of bag plate 5 and resultantly presses filled material bag 8 upwards in bag reservoir 7 to prevent stress from exerting on bag spout 9 when filled material bag 8 is inserted in bag reservoir 7 .
The piston assembly (as seen as an assembly in FIG. 3 and as seen as individual embodiments in FIG. 1 ) comprised of piston body 18 which may be formed in a manner to provide for a means of maintaining perpendicularity of the bottom of the piston body to the inside walls of dispense cylinder 19 through the use of a number of piston alignment rings 17 of varying dimension located between the piston seals 16 and a number of (most preferable two) piston seals 16 that reside within dispense cylinder 19 , and could, as an entire assembly, freely move upwards or freely move downwards in direction within dispense cylinder 19 . The piston assembly ( FIG. 3 ) is prevented from passing through the bottom of dispense cylinder 19 (as seen as being towards the direction of the bottom of FIG. 1 ) through the use of piston stop ring 20 A (as shown in FIG. 1 ). The piston assembly ( FIG. 3 ) is prevented from passing through the top of dispense cylinder 19 (as seen as being towards the direction of the top of FIG. 1 ) through the use of dispense tube connecting plate 15 A (as shown in FIG. 1 ).
The piston assembly ( FIG. 3 ) may move downwards in direction within dispense cylinder 19 due to piston body 18 having pressure exerted onto the top of it by the component when the component is moved: 1) from alternate material reservoir 1 through the use of detached drum pump 2 , or 2) from material bag 8 through the use of bag pressure actuator 3 . Either source of material may cause the voided area created above the piston assembly caused by the downwards movement of the piston assembly in dispense cylinder 19 to fill with material. In either case, the filling of the void above the piston assembly and the downwards movement of the piston assembly may be assisted by the piston body 18 , when piston body 18 has piston gripper 20 firmly attached to it and when the piston assembly is drawn in a downwards direction by piston pressure actuator 22 . The downwards movement of the piston assembly may create a vacuum inside dispense cylinder 19 above piston body 18 and may assist in filling of the void created inside dispense cylinder 19 above piston body 18 . Piston alignment rings 17 would assure that piston body 18 travels in a parallel linear motion to dispense cylinder 19 sidewalls. Piston seals 16 would provide for a substantially leak-free contact between piston body 18 and the interior cylinder walls of dispense cylinder 19 . Piston seals 16 would prevent the component from bypassing piston body 18 and would cause to have component remain in the area of dispense cylinder 19 above piston body 18 .
Two alternative embodiments to supply valve 13 and dispense valve 23 would be: 1) alternate 4-way valve 14 , or 2) alternate 3-way valve 15 . With either alternate embodiment to supply valve 13 and dispense valve 23 , bag pressure actuator 3 would move bag drive plate 4 upward to locate and come into positive contact with bag plate 5 which in turn would press upwards and would move the component from material bag 8 through supply tube 12 and through either: 1) alternate 4-way valve 14 which would, upon receiving a signal from HMI 29 , switch alternate 4-way valve 14 to direct the component to either: a) pass through dispense tube connecting plate 15 A into dispense cylinder 19 (when the small quantity method of dispensing is required to complete the component requirement of a formulation), or b) through dispense tube 24 and onwards through other embodiments as described above or 2) alternate 3-way valve 15 which would, upon receiving a signal from HMI 29 , switch alternate 3-way valve 15 to direct the component through dispense tube connecting plate 15 A and into dispense cylinder 19 .
When HMI 29 receives a signal from scale 28 that the target value for the component (that uses the small volume method of dispensing) has been attained HMI 29 signals bag pressure actuator 3 to stop.
HMI 29 would signal supply valve 13 to close, or would signal alternate 4-way valve 14 or alternate 3-way valve 15 to switch to direct material from dispense cylinder 19 to the direction of dispense tube 24 , and would signal piston pressure actuator assembly (as seen as an assembly in FIG. 4 and as seen as individual embodiments in FIG. 2 ) to move piston drive plate 21 (which has piston gripper 20 firmly attached to it) upward to locate and come into positive contact with piston body 18 .
HMI 29 would signal piston pressure actuator assembly to move piston drive plate 21 upward a defined distance (which defined distance is equal to the amount of incremental movement of piston body 18 upward that would result in an amount of component being evacuated (from that amount of material residing above piston body 18 and in dispense tube 24 )) that would equal the component amount (as being an amount identified by HMI 29 and transmitted to scale 28 ) required to equal the total target amount required of that component for the formulation, minus the amount previously dispensed of that component in the dispense manner bypassing dispense cylinder 19 described above). Depending upon the allowable percentage of error (hereinafter referred to as “tolerance”) that any particular component may have (of which each tolerance value is related to the target amount of the required component) HMI 29 may require the dispenser to dispense component to an amount that is less than the overall required amount of the component. This process of dispensing an amount that is “short” of the required amount continues until the target value has been attained. The upwards movement of piston body 18 would cause component to move through dispense valve 23 , through dispense tube 24 , through dispense valve housing 25 and, in having developed enough pressure throughout the embodiments described above, would cause proportional dispense valve 26 to open rollingly and component would pass through proportional dispense valve 26 , would pass through material sensor 26 A and into receiving container 27 which sits upon scale 28 .
The speed at which piston pressure actuator 22 moves upwards or downwards, and resultantly moves piston body 18 to dispel or fill material into or out of dispense cylinder 19 , may be the same for all component assemblies of the embodiment, but most preferably the speed would be able to be limited and controlled on a per component assembly basis as a function of the viscosity and rheological properties of the material and by the amount of material needing to be displaced.
Upon reaching or not reaching the target weight required of the component for the formulation, HMI 29 would receive a reading from scale 28 and would determine whether to stop or not to stop the upwards movement piston pressure actuator 22 and its attached piston drive plate 21 . If the target value for the component was attained HMI 29 would command piston gripper 20 to positively affix itself to piston body 18 . HMI 29 would command piston pressure actuator 22 to reverse its direction and move downwards a defined distance. The defined distance of downward movement of piston drive plate 21 is equal to the distance required to decrease the amount of pressure created throughout the embodiments described above due to the process of dispensing.
The pressure throughout the embodiments would be reduced to an amount equal zero, or to an amount of pressure less that zero, whichever is required to provide enough pressure in the reverse manner to cause proportional dispense valve 26 to close.
In another aspect of the invention, referring to FIG. 6 , an improved container 62 , such as a material cartridge, incorporates a proportional elastomeric dispense valve or pressure responsive dispense valve 26 into the discharging end 50 of the container and held fast to the discharge end 50 by a valve retaining ring 26 A ( FIG. 12 ). In an alternative embodiment, the dispense valve 26 is molded to the container 62 thus eliminating the need for a retaining ring. The dispense valve 26 opens and closes in response to a predetermined discharge force exerted on the stored material by a movable member such as a plunger puck 52 that forms a compression seal within the inner annular wall of the container 62 . In one embodiment, the dispense valve opens and closes in a rolling manner. In another embodiment, the dispense valve may include one or more slits and one or more flaps that may simply open and close. A pressure actuator, plunger or similar device may be used in a controlled manner to exert a force on the movable member (e.g., puck 52 ) to thereby allow the stored material in the container to precisely discharge from the container 62 . The pressure actuator, plunger or similar device may be manually operated or automated.
Referring to FIG. 7 , another exemplary container 62 a is depicted which may be in the form of a caulk tube for dispensing caulk. As shown in this figure, the dispense valve 26 may be incorporated onto the discharge end of the container 62 a and similar to above, the dispense valve 26 may open and close in response to a predetermined discharge force exerted on the stored material by a plunger device. As can be appreciated, the exemplary containers may take on numerous shapes, sizes and configurations, all of which are within the scope of the invention.
Referring to FIGS. 16 and 17 , the movable member, e.g., puck 52 , includes a number of seals, such as seals 62 , 64 and 66 around an outside edge 68 of the puck. The seals may be configured in a number of different ways including the illustrated configuration and may comprise any number of seals including just one seal. In one embodiment, the seals extend outwardly from the outer edge 68 and serve as a means for scraping and effectively pressing the material out of the container 62 through the dispense valve 26 to allow the removal of nearly all the material from the container. Additionally, the puck 52 has a contoured or angled bottom surface 74 that at its center forms a convex center 70 that is configured to permit ample room for the dispense valve 26 (typically centered on the fixed end of the cartridge container as illustrated in FIGS. 11 and 13 ) to close when the bottom surface 74 of the puck 52 comes in direct contact with the fixed end 50 of the container 62 . As illustrated by FIGS. 13 and 14 , the contoured or angled bottom surface 74 is configured to mate up with the interior surface 76 of the fixed end 50 of the container 62 to decrease the amount of base material that may remain in the container after the bottom surface of the puck 52 comes in contact with the fixed end 50 of the container. Significantly, with this configuration, nearly all the base material in the container will be expelled from the container, thereby reducing if not eliminating material waste. It should be understood that the bottom surface 74 may define other configurations that still permit the complete dispensing of material from the container. Additionally, the principles of the puck 52 configuration may be applied to any movable member, such as a press plate 87 ( FIG. 9 ) or other structure, which can be used to push material out of a container. The puck 52 may be made of a plastic material, or any other suitable material.
In another aspect of the invention, and referring to FIG. 8 , a dispenser 60 may be used to dispense any given amount of material, according to a predetermined formulation, using an automated machine that may have a plurality of base material containers 62 , each of which may incorporate a pressure-responsive, proportional dispense value 26 .
Conventionally, specific amounts of base material in the ink, colorants, coatings, foodservice and chemicals industries are often mixed together to create a different finished product. As described above, the process of combining any number of base materials together (blending a formula) has historically been accomplished by a number of methods, including: 1) manually adding a specific amount of a number of base materials from an existing container into a receiving container, according to a predetermined formulation or recipe; or 2) using a piece of equipment (automatic or semi-automatic) that adds the appropriate amount of base material into a receiving container, according to a predetermined formulation or receipt, through the use of computer or program logic controller along with any number of mechanical metering devices that meter, pump and/or control the flow and amount of material being dispensed into the receiving container.
As stated above, the disadvantages with known dispensers is that the dispensers require the base materials to be transferred from a conventional container into a storage vessel that is integrated in the conventional dispenser and some dispensers require a container to be attached to the dispenser through the use of a hose, pump or press-plate from which the dispenser then draws the base material. As indicated above, both manners of supplying base material to the dispenser result in an undesirable amount of labor and creates a significant mess. In addition, when fully expelled, the conventional containers may have residual material remaining in them resulting in wasted material.
In an exemplary embodiment, the present invention seeks to improve upon the ease of use of the known dispensers through the use of the dispenser 60 and a container 62 that incorporates the pressure responsive valve 26 . As described, the container 62 with the valve 26 is capable of effectively stopping the flow of the material through regulation of pressure applied to the material residing within the container. This allows the container to be placed into the exemplary dispenser 60 , as depicted in FIG. 8 , without the need of mechanically connecting it with a hose, or other means, to the dispenser 60 . The exemplary container 62 may be of a shape and configuration similar to a Sonoco cartridge, a caulk tube, a material bag, as described herein, or any other shape or configuration.
Referring to FIG. 8 , the exemplary dispenser 60 is depicted. The dispenser 60 includes a rotary table 61 that holds a plurality of containers 62 on the rotary table 61 , which is housed in the dispenser 60 . In an exemplary application, each container 62 contains a single base material used in some combination with a blend of a custom formulation.
The dispenser 60 also incorporates a computer 64 and a material sensor 71 . In use, the operator inputs into the computer 64 a value of the desired finished amount (weight) of a custom formulation to blend. The rotary table motor 70 rotates rotary table 61 and positions the container 62 required by the formulation to the dispense position, which is the area towards the front of the dispenser 60 , under a pressure actuator 65 and above material sensor 71 . The pressure actuator 65 may or may not have a plate attached to the end of the actuating shaft (such as plate 87 shown in FIG. 9 ), depending on which type of container 62 is being used in the dispenser 60 . The computer 64 sends a signal to an HMI 66 which instructs the pressure actuator 65 to apply downward pressure on the container 62 , and more specifically onto the puck 52 configured within one end of the container 62 (as shown in FIG. 10 ). The maximum amount of pressure allowable, based on the amount required to expel, is exerted by the pressure actuator 65 onto the puck 52 in the container 62 resulting in base material expelling through an orifice found on each container 62 , in which a proportional pressure responsive dispense valve 26 is fixed and through or past a material sensor 71 . The base material is expelled into a receiving container 67 residing on a scale 68 .
As base material is expelled through valve 26 , the valve will open rollingly to permit the base material to flow through, and the base material is sensed by the sensor 71 which, along with the scale 68 sends information to the HMI 66 and computer 64 to increase, decrease or discontinue the pressure being applied to the puck 52 in the container 62 by the pressure actuator 65 . When the weight of base material being expelled into receiving container 67 achieves a predetermined weight, the computer 64 and HMI 66 may send a signal to the pressure actuator 65 to expel a minimal amount of base material from the container 62 (commonly referred to as “pulsing”) in order to expel small amounts of base material to “pulse” up to the required base material amount as determined as a percentage of the total amount of custom formulation entered into the computer 64 . The same process is completed for each base material required of the custom formulation.
In another embodiment, the dispenser may hold one or a plurality of containers in a linear configuration and, within each resides a single base material which, if required of a desired formulation, in some calculated proportion, is used. As above, each material container can be positioned under a pressure actuator. However, with this embodiment, the containers are moved under the pressure actuator 65 , or the pressure actuator is moved over the containers in a linear manner, as opposed to the above-described rotary manner shown in FIGS. 8 and 9 . The dispenser may also include an HMI 66 , a scale 68 and a feedback sensor 71 . The method of use may be similar to the method described above with respect to the rotary table configuration depicted in FIG. 8 .
Yet another exemplary embodiment of the dispenser holds one or a plurality of containers in either a linear configuration (through the use of a linear slide) or a rotary configuration (through the use of a rotary table) and, within each resides a single base material which, if required of a desired formulation, in some calculated proportion, is used. Each container can be manually positioned by the operator under a pressure actuator. The dispenser may also include an HMI 66 , a scale 68 and a feedback sensor 71 . Again, the method of use is similar to that described above.
Still another exemplary embodiment of the dispenser holds one or a plurality of containers in either a linear configuration (through the use of a linear slide) or a rotary configuration (through the use of a rotary table) and, within each resides a single base material which, if required of a desired formulation, in some calculated proportion, is used. Each container is manually positioned by the operator under a pressure actuator, such as actuator 65 . The dispenser may also include an HMI 66 and a scale 68 . In this method of use, the operator inputs into the HMI a value of the desired finished amount of a custom formulation to blend. The HMI calculates the total weight of each of the base material components required to create the target amount. The operator then positions a container to the dispense position which is the area under a pressure actuator. The pressure actuator is manually activated by the operator to apply downward pressure on the movable puck which pushes the base material through a proportional pressure responsive dispense valve that opens and closes in a rolling manner into a receiving container residing on a scale. As the base material is expelled through the dispense valve and falls into the receiving container the base material is weighed by the scale and the operator may increase, decrease or discontinue the pressure being manually applied to the puck in the material container by the pressure actuator to provide the calculated amount. When the operator discontinues applying pressure to the pressure actuator the dispense valve effectively stops expelling the base component from the material container. The operator then reads the scale value and determines if more base material is required to reach the calculated amount. The operator repeats the above steps until the calculated amount required of the formulation is attained. When the calculated amount is attained the operator positions the next material container required of the formulation, if another is required, into a position under the pressure actuator and repeats the process until the calculated amount of each base material components of the required formulation have been dispensed into the receiving container.
Yet another embodiment of the dispenser holds a single material container in which resides a single base material which, if required of a desired formulation, in some calculated proportion, is used. Each material container is manually inserted by the operator into the dispense position under the pressure actuator. The dispenser may also include an HMI 66 , a scale 68 and a feedback sensor 71 . In one method of use, the operator inputs into the HMI a value of the desired finished amount, i.e., the target amount in a value of total weight, of a custom formulation to blend. The HMI calculates the total weight of each of the base material components required to create the target amount. The pressure actuator applies downward pressure on the movable puck which pushes the base material through a proportional pressure responsive dispense valve that opens and closes in a rolling manner into a receiving container residing on a scale. As the base material is expelled through the valve, the base material is sensed by a sensor which, along with the scale, sends feedback information to the HMI to increase, decrease or discontinue the pressure being applied to the puck in the material container by the pressure actuator to provide the calculated amount. If the amount of base material expelled does not equal the calculated amount the HMI recalculates the amount of base material required (the “recalculated amount”), recalculates the amount of pressure required of the pressure actuator to attain the recalculated amount, and sends a signal to the pressure actuator to expel the recalculated amount of base material from the material container. The process of expelling a base amount, receiving feedback from the sensor and the scale, calculating if more base material is required and, if required, recalculating the amount of pressure required of the pressure actuator to attain the total recalculated amount continues until the calculated amount is attained. When the calculated amount is attained the operator removes the material container and inserts the next material container required of the formulation, if another is required, into a position under the pressure actuator and repeats the process until the calculated amount of each base material components of the required formulation have been dispensed into the receiving container.
Still another exemplary embodiment of the dispenser holds a single container within resides a single base material which, if required of a desired formulation, in some calculated proportion, is used. Each container is manually positioned by the operator under a pressure actuator. The dispenser may also include an HMI 66 and a scale 68 . In this method of use, the operator inputs into the HMI a target amount of the desired finished amount of a custom formulation to blend. The HMI calculates the total weight of each of the base material components required to create the target amount. The operator then positions a container to the dispense position which is the area under a pressure actuator. The pressure actuator is manually activated by the operator to apply downward pressure on the movable puck which pushes the base material through a proportional pressure responsive dispense valve that opens and closes in a rolling manner into a receiving container residing on a scale. As the base material is expelled through the dispense valve and falls into the receiving container the base material is weighed by the scale and the operator may increase, decrease or discontinue the pressure being manually applied to the puck in the material container by the pressure actuator to provide the calculated amount. When the operator discontinues applying pressure to the pressure actuator the dispense valve effectively stops expelling the base component from the material container. The operator then reads the scale value and determines if more base material is required to reach the calculated amount. The operator repeats the above steps until the calculated amount required of the formulation is attained. When the calculated amount is attained the operator positions the next material container required of the formulation, if another is required, into a position under the pressure actuator and repeats the process until the calculated amount of each base material components of the required formulation have been dispensed into the receiving container.
The methods of dispensing custom formulations described herein provide a more cost effective means of creating custom formulations in a timelier manner. The methods also reduce operator handling due to the fact that the operator doesn't need to scoop the paste-type ink from a bucket. As known, the operator may need to physically scoop fractional amounts of ink when adjusting the quantity of ink in the formulation container to arrive at the target weight. With the invention, the bag and containers described herein, with their pressure-sensitive proportional valve attached, cleanly cuts the ink and does not requiring operator handling. Additionally, an operator can minimize the wasted material through accurate operation of the present invention. Residual material waste is limited to the amount of material remaining in the spent bag or container. Also, shipping and storage costs are decreased with the present invention due to bag light weight and compact empty state, saving in both shipping weight costs and required facility storage space for both filled and empty containers. Further, the cubic inches required for disposal of a spent bag is decreased with the current invention and is significantly smaller than any of the current material containers used. Still further, with respect to the material bags, the bag uses 1/12 th the amount of plastic in its construction as compared to a typical plastic bucket handling a similar amount of material. Using the bag as a storage and dispensing container there will be less of an impact on the environment at disposal. | The invention includes a material dispenser that further includes a container containing material, a press plate or puck for exerting pressure on the material, a sensor for detecting the material discharged from the container, and a scale for detecting the amount of material discharged from the container. The sensor and scale provide feedback to a computer which controls the amount of pressure exerted on the material. The computer controls the pulsing of additional material from the container until a targeted amount of material has been discharged from the container. The invention permits the dispensing of a specific amount of material in a controllable, metered fashion. | 1 |
FIELD OF THE INVENTION
This invention relates to a system for fastening two substantially flat objects to each other quickly and detachably, and more particularly to a clip-in-grommet fastener by which two substantially flat objects may be quickly attached to or detached from each other with limited sliding movement permitted between the fastened objects in use.
BACKGROUND OF THE PRIOR ART
There are many applications, for example in assembling a variety of substantially flat parts such as sheet metal elements, panels, flanges and the like, in a typical automobile. Some locational tolerance or deliberately provided sliding movement between the fastened parts is sometimes desirable. Elements for providing such fastening should be easy and inexpensive to manufacture and assemble in the finished product.
Subsequent to manufacture and sale to the ultimate purchaser, an automobile may see service for a long time before maintenance and/or repair needs require temporary disassembly of the fastened parts. Unless it is designed appropriately, a person seeking to disassemble the fastening system will encounter problems, e.g., elements may have rusted in place, or water leakage may have caused corrosion and materials deterioration. The typical automobile often is also exposed to significant changes in temperature, humidity, and operational stresses. Therefore, unless the fastening system inherently possesses a certain controlled amount of give or tolerance, the initially correctly assembled parts will very likely be unduly stressed, possibly warped, and difficult to reassemble upon completion of whatever repairs required their disassembly.
Highly economical and efficient fastening systems are known wherein one element is easily located in or affixed to one of the substantially flat parts to be fastened. The other part to be fastened is then placed in a predetermined relationship therewith and a second element of the fastening system is employed to obtain the desired engagement. The actual act of fastening the elements of the fastening system may involve engagement of threads, deformation of expandable segments of the elements of the fastening system, and assorted combinations of twisting, turning and clipping actions.
An example of a known fastening system is taught in British Patent No. 1,588,556, to Shilson, titled "Turn Release Fastener", which employs a quick release stud releasable from a socket by rotation of the stud by a quarter turn. The socket in the system is formed to have a pair of opposed and parallel abutments resiliently biased toward one another and arranged to receive the stud, and is previously attached to one of the substantially flat parts which are to be fastened together. The stud has a partially spherical head provided with a recess for engagement by a turning tool, a straight cylindrical shaft portion and a head portion having a leading end for entering between the abutments. During use, the stud is engaged with the socket by entry of the leading end of the shank of the stud between the amendments, forcing the abutments apart until shoulders provided thereon have been passed through, the abutments thereafter resiliently closing to enter into recesses provided for retention of the stud within the socket. The socket is stamped and formed from a single piece of metal.
British Patent No. 1,519,357, to Wright, titled "Improvements Relating to Fasteners" teaches a fastening system in which a one-piece receptacle includes a pair of clip-like legs, the free ends of which extend toward one another for engagement with depressions or grooves formed in the shank of a complementary stud to retain it once it is pushed into the receptacle. The receptacle is previously attached to one of the substantially flat parts that are to be engaged together, and the stud passes through the other of such parts. The receptacle is preferably formed from spring steel. The stud has a flat domed head, including a recess to receive a tool such as a screw driver, and a shank which includes a first cylindrical part and a second larger diameter cylindrical portion having flat tapering surfaces which converge to form a waist. The end of the stud removed from the head has a generally conical tapered portion including flat chamfered surfaces. The stud is retained within the receptacle by a resilient washer.
Numerous other fastening systems are known and used but none of them provide exactly the right combination of economy, ease of installation and use and, most importantly, a predetermined degree of tolerance or freedom of relative movement for the fastened parts to accommodate the needs of workers assembling the product initially and persons seeking to temporarily unfasten the fastened parts to access other elements located behind the fastened parts or to perform repairs thereon, and finally to allow fastener components to expand and contract with changing temperature.
Accordingly, there is a definite need for a simple, inexpensive, easily installed, readily engageable and disengageable fastening system for fastening together two substantially flat parts with a built-in tolerance or freedom of relative movement therebetween in a selected direction.
SUMMARY OF THE INVENTION
It is a principal object of the present invention to provide a simple, inexpensive, fastening system which enables secure but selectively releasable engagement of two substantially flat parts.
It is a related object of this invention to provide an inexpensive fastening system for securely fastening two substantially flat parts to each other with a predetermined amount of relative movement available between the fastened parts in a selected direction.
It is a further related object of this invention to provide a two-part fastening system, wherein one of the parts is readily attachable to one of two substantially flat elements which are to be fastened together, with a readily releasable element which securely holds the fastened parts together with a predetermined degree of relative movement permitted therebetween in a selected direction, and which can be very easily unfastened even after passage of a substantial period of time with a simple conventional tool such as a screw driver.
These and other related objects of this invention are realized by providing a fastening system for releasably but securely fastening together two substantially flat parts, the system comprising:
a grommet formed of an elastic material, having a pocket-like body with an opening leading into an inside space of oblong cross-section, the grommet having an outer surface formed to be retained to a first object and an inside surface comprising a pair of recesses disposed above oppositely tapering surfaces inclined toward each other at a bottom portion of the inside space to a predetermined minimum first separation distance in an unstressed state; and
a clip having a head and an elongate shank, the shank having a distal end portion of rectangular varying cross-section defined by intersections between two parallel planes spaced apart by a second separation distance larger than the minimum first separation distance and a pair of plane surfaces inclined toward each other to a distal end of the clip to a third separation distance which is smaller than the minimum first separation distance, and a pair of claws disposed intermediate the head and the distal end portion for engagement with the recesses in the grommet.
In another aspect of the invention, there is provided a fastening system comprising:
a clip comprising a first material, formed about a longitudinal axis of symmetry contained within a clip principal plane of symmetry, having a head and an elongate shank extending along the axis of symmetry,
wherein the head is formed to receive a rotational torque, and
wherein the shank has an outer surface defined in part by a pair of parallel plane surfaces which are symmetrically disposed with respect to the axis of symmetry at a separation "w" and are orthogonal to the clip principal plane of symmetry, the pair of parallel plane surfaces extending from the head to a rounded distal end of the clip,
another part of the outer surface of the shank comprising portions of a cylindrical surface of a diameter "d 1 " about the axis of symmetry, wherein "d 1 " is larger than "w", the shank having a cross-section of reduced diameter "d 2 " intermediate the head and the distal end to provide a pair of claws extending between the diameters "d 1 " and "d 2 " and to a first predetermined distance from the distal end,
the shank having a narrowing tapered length extending from a first level beyond the claws to the rounded distal end, the tapered length having a rectangular cross-section defined by intersections between the pair of parallel plane surfaces and a pair of side surfaces inclined symmetrically about the clip principal plane of symmetry; and
a grommet comprising a second material, having a grommet principal plane of symmetry containing an axis of symmetry, comprising a body having a wall of varying thickness and formed as a pocket with a distal rounded closed end and an oblong opening having both a length "c" and a width "x 1 " which are respectively larger than "d 1 ", the opening being surrounded by an annular flange extending generally transversely away from the axis of symmetry,
wherein opposing principal inside wall surfaces of said grommet have portions formed to be oriented generally along the grommet principal plane of symmetry have recesses of predetermined depth and width extending adjacent to and along the flange,
wherein the opposing principal inside wall surfaces taper inwardly toward the grommet principal plane of symmetry to a separation "x 2 " which is less than "d 1 " but greater than "d 2 " and then continue in parallel to a predetermined notch level and then abruptly widen symmetrically to a separation "x 3 " and continue in parallel thereafter for a predetermined notch length to define a grommet notch extending to a point which is at a second predetermined distance above the lowest point of the inside of the grommet body, said grommet notch having a length longer than an axial length of the claws of the clip,
the principal inside wall surfaces of the grommet then turning sharply inwardly toward the grommet principal plane of symmetry and thereafter continuing in planar portions symmetrically inclined about the axis of symmetry to the rounded closed end of the grommet at an inclination of the inside wall surfaces of the grommet corresponding to corresponding inclinations of the tapered length of the clip, but with the closest separation between the inclined inside wall surfaces of the grommet being a distance "x 4 " which is less than "w" but greater than "d 4 ", and
wherein the separation between the grommet notches and the inside surface at the grommet bottom is longer than the separation between the clip claws and the clip distal end.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective view of a clip element of a clip-in-grommet fastening system according to a preferred embodiment of this invention.
FIG. 2 is a side elevation view of the clip of FIG. 1 as viewed in the direction of arrow "A" in FIG. 1.
FIG. 3 is a side elevation view of the clip of FIG. 1 as viewed in the direction of arrow "B" in FIG. 1.
FIG. 4 is a side elevation view of a grommet of the clip-in-grommet fastening system according to the preferred embodiment of this invention, with a grommet washer indicated in phantom lines.
FIG. 5 is a plan view of the grommet of FIG. 4.
FIG. 6 is a plan view of a grommet gasket for use with the grommet of FIG. 4.
FIG. 7 is a side elevation view of the grommet of FIG. 6.
FIG. 8 is a partially sectioned view illustrating the clip and grommet of FIGS. 1 and 4 in use to fasten together two substantially flat parts, the clip being illustrated in the same orientation as in FIG. 2.
FIG. 9 is a partially sectioned view of the clip and grommet, wherein the clip is shown in the same orientation as in FIG. 3 and is in a position to which it must be rotated to be put in a condition to be popped out of the grommet for disengagement therefrom.
FIG. 10 is a partially sectioned perspective view of the clip and grommet according to the preferred embodiment of the invention, to illustrate the manner in which the clip must be rotated from its engaged position to obtain disengagement and pop-out release from the grommet.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As best seen in FIG. 1, clip 100 is a one-piece element, preferably formed of a resinous material although it could also be made of other materials, e.g., a metal. If clip 100 is to be utilized where it may be exposed to ambient moisture, water leakage or the like, it may be provided with a rust proof or anti-corrosive coating. It is important that clip 100 have relatively smooth surfaces and non-sharp edges. If it is made of a metal, it may need to be deburred to ensure that sharpness at its edges has been removed.
Clip 100 has a longitudinal axis of symmetry P--P and generally comprises a head and a shank. The head in the preferred embodiment has a partially spherical portion 102 of diameter "D" and a conical portion 104 tapering to the adjacent shank portion of diameter "d 1 ". To facilitate controlled forced turning of clip 100, curved portion 102 is provided with a selectively shaped recess 106. In the preferred embodiment per FIGS. 1 and 2, recess 106 has the form of a slot into which the blade end of a conventional screwdriver may be inserted to apply a torque.
As indicated in FIG. 2, conical portion 104 of the head of clip 100 is tapered at an angle "α" with respect to axis P--P. In the preferred embodiment, α is selected to have a value of approximately 50°. In principle, however, α may be selected to have any convenient value and may even be made 90°, i.e., the conical portion 104 may be reduced to a flat plane. In the embodiment of FIG. 2, conical portion 104 at a small diameter "d 1 " merges into the shank portion of clip 100. In the embodiment illustrated in FIG. 2, the height of conical portion 104 in the direction of axis P--P is "p 1" .
As best seen in FIG. 2, looking in the direction of arrow "A" per FIG. 1, partially cylindrical shank portion 108 is seen to have a maximum diametral dimension "d 1 " and a reduced transverse dimension "w 1 " corresponding to a pair of extended parallel flat surfaces 124, 124, as best understood with reference to FIGS. 1 and 2. Shank portion 108 has a length "p 2 ", and continues into a tapered portion 110, which has an outer surface that is partially conical, reducing to a smaller diameter "d 2 " over a length "p 3 ". Tapered portion 110 is also partly defined by a continuation of the same flat surfaces 124, 124 as partially define partially cylindrical portion 108.
The shank then continues into a relatively short partially cylindrical portion 112 of length "p 4 " having an outer surface comprising two partially cylindrical portions of diameter "d 2 " and continuations of the same flat surfaces 124, 124 as partially defined earlier-described shank portions 108 and 110.
Shank portion 112 continues into yet another partially cylindrical portion 114, of length "p 5 " which is partially defined by a pair of partially cylindrical surfaces of diameter "d 3 " and the same pair of flat surfaces 124, 124 which partially defined the preceding shank portions 108, 110 and 112.
The changeover from shank portion 112 to shank portion 114 incorporates two symmetrically disposed claws 116, 116, as best seen in FIG. 2. As previously noted, clip 110 is formed to avoid having sharp edges, hence as indicated in FIG. 2, claws 116, 116 have relatively smooth, i.e., non-sharp, extremities.
Shank portion 114 continues to a clip end portion 118 by first reducing somewhat abruptly to a straight sided tapered length between a pair of symmetrically disposed plane faces 120, 120, each of which is symmetrically inclined at an angle "θ c " with respect to axis P--P, as best seen in FIG. 2. Clip 110 ends in a generally rounded tip 122 so that the tapered end portion 118 has a length "p 6" .
For convenience of reference, the pair of plane surfaces 124, 124 which extend from the end of tapered portion 104 almost tot he generally rounded tip 122 are to be understood as normal to a second reference axis Q--Q which is orthogonal to the first reference axis P--P of clip 100, as best understood with reference to FIGS. 1 and 3. Arrow "A" is parallel to axis Q--Q as best seen in FIG. 1, and slot 106 is symmetrical about axis Q in its elongate direction. The plane of intersection of axes P--P and Q--Q will be referred to as the principal plane of clip 100.
For convenience, the clip length from the largest diameter of conical portion 104 of its head and extending to the tips of claws 116, 116 is identified as "p 7 ", as best seen in FIG. 3.
Clip P is utilized in combination with a grommet 200 which is preferably made of a tough plastics material which can be readily formed by known techniques, e.g., by conventional molding processes, to have fairly precise dimensions and hard smooth surfaces. The plastics material selected for grommet 200 must be tough and hard to avoid scratching or tearing in the process of repeatedly engaging and/or disengaging with clip 100. As previously noted, clip 100 is formed to have no sharp edges because the present invention requires forcible engagement between portions of the clip 100 and certain surfaces of grommet 200. The plastics material of which grommet 200 is formed must also be rough under all anticipated conditions of use, e.g., the full range of expected ambient temperatures, ranging from arctic cold to desert heat, without weakening. A preferred material for forming grommet 200 is nylon, although other plastics materials having the desired qualities may be utilized, e.g., actual.
The preferred form of grommet 200 is illustrated in a principal side elevation view in FIG. 4 and in plan vie in FIG. 5. Certain important details of the shape and size at the inside surface of grommet 200 are best understood by reference to the cross-sectional view thereof in FIG. 8.
It is anticipated that for most practical uses of this invention, grommet 200 will be utilized with an elastic washer 300 which is shown in plan and side elevation views, respectively, in FIGS. 6 and 7, and in phantom lines in FIG. 4.
Referring now to FIG. 4, grommet 200 has the general form of an open pocket with a flange surrounding its opening. This is only a general description, and specific structural aspects of tis form are described more fully in the following paragraphs. The inside and outside surfaces defining the structure of grommet 200 preferably are smoothly contiguous with each other.
Grommet 200 has at an open end an outwardly extended flange portion 202, preferably with a slight turn-in at the outermost edge portions, and conveniently having a generally oblong shape defined by an outer boundary comprising two parallel straight portions contiguous with two curved end portions as best understood with reference to FIG. 5. Such a shape is only preferred and is not restrictive, i.e., the flange portion may have other shapes for particular uses. Flange 202 has a generally annular shape and continues smoothly into the inside of the pocket-like cavity 204 inside the body of grommet 200 through opening 206.
In the following description, for ease of visualization, flange 202 of the grommet is referred to as being at the top, i.e., the rest of the body is disposed therebelow. Also, for convenience of reference, a Cartesian coordinate system, comprising a vertical axis Z--Z disposed at the center of the grommet, as best understood with reference to FIG. 8, may be visualized in such a reference system of Cartesian coordinates, the other two axes X--X and Y--Y, being oriented as best understood with reference to FIG. 5. The plane defined by the intersection of axes Z--Z and Y--Y will be referred to as the principal plane of grommet 200. Various dimensional relationship will then be understood more readily.
At a predetermined distance "z 1 " below the lowest point on flange 202 in its unstressed state, on the outer surfaces of both principal sides of grommet 200, are provided straight horizontal shoulders 208, 208, each of a length "1" along the Y--Y direction, as best understood with reference to FIG. 4. The outer surfaces of grommet 200 immediately above shoulders 208, 208, in their unstressed state are separated by a distance "a", and the shoulders themselves extend outwardly so that the distance between their outermost edges is "b", as best understood with reference to FIG. 5. The outer surfaces of the principal walls of grommet 200, i.e., the walls substantially along the principal plane, then taper downward to blend into substantially parallel portions separated from each other by a distance approximately equal to "a" in their unstressed state. This is best understood by reference to FIG. 8. The outer surfaces of the principal sides of grommet 200 then extend inwardly toward the plane of intersecting axes Y--Y and Z--Z and blend into a rounded bottom portion.
In this region, just above the bottom end on the outside of the principal forces, there are optionally provided a plurality of vertical reinforcement ribs 210, preferably symmetrically disposed in even numbers on opposite sides of the principal plane of the grommet 200. These reinforcement ribs 210, 21 are best seen in FIGS. 4 and 8. Their presence provides additional stiffness and strength to the principal walls of grommet 200 where they are most likely to be stressed in forcible interaction with correspondingly disposed end portions of clip 100 curing engagement and disengagement.
As indicated in FIGS. 4, 6, 7 and 8, an elastic, compliant washer 300, shaped and sized to fit annularly around the body of grommet 200 immediately below flange 202, is employed partly to seal the grommet at its use location and partly to absorb some of the deformation force involved in fitting the grommet to one of the two parts that are to be connected by the clip-in grommet system of this invention. Washer 300 has a generally oval hole 302 formed therein of a shape and size, best understood with reference to FIG. 8, as can be comfortably slipped over the body of grommet 200 to be fitted beneath flange 202 thereof.
Important structural aspects of the inside surface of grommet 200 will now be described. First, past the hole 206 at the top of flange 202, the inside surface has a generally oval shape and comprises two principal substantially parallel vertical plane surfaces which join each other at curved end surfaces. The net effect is to provide an elongate oval opening 206 leading into the cavity 204, as best seen in FIG. 5. The two principal inside plane surfaces of this part of grommet 200 are separated in the direction of axis X--X by a distance "x 1 ", and have a depth "z 2 " which is greater than the some of the lengths "z 1 " and the overall thickness "t 1 " of flange 202 between its uppermost and lowermost parts in its unstressed state. The inside principal surfaces of grommet 200 then taper towards each other at an angle preferably about the same as the angle "θ c " of clip 100, as best understood with reference to FIGS. 2 and 8. The principal inside wall surface portions 212, 212 then have a relatively short expanse in which they are parallel to each other and separated by a distance "x.sub. 2 " and end at a distance "z 3 " below the points at which the parallel surfaces separated by the distance "x 1 " end.
The principal inside surfaces of grommet 200 then project away from the principal plane of the grommet to a point where they are separated by a distance "x 3 " and continue as two surface portions 214, 214 parallel to each other and separated by this distance for a length approximately "z 4 ". This is best understood with reference to FIG. 8, from which it is seen that there is thus created a pair of elongate opposed notch portions or recesses in the inside surface of grommet 200 to engage with and retain claws 116, 116 of clip 100. The principal inside surfaces of grommet 200 then approach each other smoothly as surface portions 216, 216, blending into a pair of opposed plane surface portions 218, 218 respectively inclined at an angle "θ g " to the principal plane of the grommet and eventually meet in a curved inside bottom surface. The total distance from the bottom of the notches just described to the inside bottom of grommet 200 is "z 5 ". As will be appreciated from a review of FIG. 8, the plurality of reinforcement ribs 210 are disposed along the outer surface of grommet 200 in this region, i.e., outside surface portions 218, 218.
During its use, the grommet 200 is pressed into an aperture 402 of suitable shape and size formed in a first substantially flat part 400. This aperture must have a length larger than the span "c" of the body portion of grommet 200 along the Y--Y axis, and a width greater than the distance "a" but smaller than the distance "b", as best understood with reference to FIG. 5. Thus, when the grommet 200 is pressed into aperture 402, due to the outside inclined surfaces immediately below shoulders 208, 208, the principal sides of the grommet will initially deform inward and shoulders 208, 208 of the grommet will slip into aperture 402 and then immediately expand elastically outward to engage with edge portions of the aperture 402 in flat part 400. See, for example, FIG. 8.
As previously indicated, an elastic washer 300 may be disposed immediately between flange 202 and the adjacent surface of substantially flat part 400. As will be understood, because grommet 200 is made of a plastics material that is strong and elastically deformable, by suitable choice of dimensions "t 1 ", "t 2 " and "t 3 ", there will be some deformation of washer 300 and some deformation of flange 202 to create a snug elastic fit of grommet 200 to part 400 at aperture 402. The grommet 200 is thus located in place in one of the two parts that are to be engaged by the clip-in-grommet device according to this invention.
The other substantially flat part 500 which is to be engaged to the first substantially flat part 400 is shown generally in phantom lines in FIG. 8. For reference purposes only, the thickness of flange 202, when installed with a washer 300 into an aperture of the first substantially flat part 400 is "t 1 ". The thickness of washer 300 is assumed to be virtually "t 2 ", i.e., it is assumed that it is not significantly squashed. The thickness of the first substantially flat part 400 is identified as "t 3 38 . The thickness of the second substantially flat part 500 is then determined by the lengthwise dimensions of clip 100, depending on whether or not a thin optional washer 600 is employed as indicated in FIG. 8.
The following dimensional relationships must be satisfied, taking into account the fact that grommet 200 itself has some elastic deformability in all directions and that the second substantially flat part 500 may also be capable of sustaining some elastic or inelastic deformation in use.
For the clip:
d.sub.1 =d.sub.3 >d.sub.2 >d.sub.4 (see FIG. 2);
w.sub.1 =w.sub.2 (because surfaces 124, 124 are parallel);
d.sub.1 >w.sub.1 (or w.sub.2); and
α preferably≈50°.
For the crommet:
x.sub.1 =x.sub.3 >x.sub.2 >x.sub.4 (see FIG. 8).
Clip 100 vis-a-vis crommet 200:
x.sub.1 >d.sub.1;
x.sub.2 >d.sub.2;
x.sub.3 >d.sub.3;
x.sub.4 >d.sub.4;
(p.sub.1 +p.sub.2)>(z.sub.2 +z.sub.3) (see FIGS. 2 and 8);
(z.sub.4 +z.sub.5)>(p.sub.5 +p.sub.6);
θ.sub.c ≈θ.sub.g ; and
β.sub.c ≈β.sub.g.
As shown in FIG. 8, clip 100 according to the preferred embodiment has a slot-like recess 106 formed in its head and this slot is oriented symmetrically about the principal plane of the clip and is perpendicular to the flat planar faces 124, 124. This is best understood by reference to FIGS. 1, 2 and 3. Given this structure, clip 100, with or without the optional thin washer 600, can be forcibly pressed into an aperture 502 formed to receive the same in the second substantially flat part 500.
Clip 100 must then be oriented so that slot 106 and the principal plane of clip 100 are both parallel to the principal plane of grommet 200 and can then be readily pressed therein. This is how fastening engagement is effected.
As will be appreciated from FIG. 8, the relatively narrow tip end portion 118 of tip 110 will enter readily; however, entry of the next portion 114 of width "d 3 " will cause temporary outward elastic deformation of the initially unstressed portion of width "x 2 " of the grommet. Since clip 100 is formed to have non-sharp edges and surfaces, and since the material of grommet 200 is selected to be tough, elastic and relatively hard at smooth surfaces., this forcible intromission of clip 100 into grommet 200 can be effected with only a moderate amount of force. Eventually, claws 116, 116 of clip 100 will slide past the construction defined by surfaces 212, 212 and reach the notched portions or recesses defined by surfaces 214, 214 separated by a distance "x 3 " greater than the width "d 3 " of clip 100. Clip 100, at this point, will be engaged in an interference fit with grommet 200.
It should be noted that the inside span along the direction of axis Y--Y of space 204 in grommet 200 is considerably larger than diameter "d 1 " or "d 3 " of clip 100. Consequently, with the tapered flat faces 120, 120 of clip 100 being prevented from unintended rotation by their close and slidable disposition next to similarly inclined inside plane surfaces 218, 218 of grommet 200, clip 100 may slide along the direction of axis Y--Y while remaining in interference fit engagement with the grommet. Under these circumstances, the first and second substantially flat parts 400 and 500 will remain in engagement with each other with some movement therebetween permitted in the direction of axis Y--Y.
The lower portion 118 of clip 100 has a downwardly tapering length, and everywhere a rectangular cross-section having a constant length "w 2 " always greater than its thickness varying between "d 2 " and "d 4 ", as best seen in FIGS. 2 and 3.
It now remains only to describe how clip 100 may be easily disengaged from grommet 200 by the provision of a torque applied via recess 106 to clip 100.
As best seen with reference to FIGS. 9 and 10, when such a torque is applied about axis P--P to clip 100, rotation of the lower part 118 of clip 100 will cause it to forcibly contact inside initially plane inclined surfaces 218, 218 near the bottom of grommet 200. However, since the dimension "w 2 " is larger than "d 4 " as well as "x 4 ", such forcible rotation of clip 100 in either direction will cause forcible, elastic, outward, local deformation of the lower part of grommet 200, i.e., the grommet portion that is deliberately strengthened by the provision of reinforcement ribs 210 on the outside. FIG. 10 illustrates the-initiation of such a rotation of clip 100 in partial perspective view in conjunction with an immediately adjacent cross-section of grommet 200.
However, as can be seen more clearly in FIG. 9, when clip 100 has been rotated through a quarter so that notch 106 is oriented along the axis X--X the principal planes of the clip 100 and grommet 200 are orthogonal to each other, the forcible outward deformation of the lowest part of grommet 200 will generate opposed reaction forces "F" by the grommet on the curved lowest portion of clip 100 tending to force 200. In FIG. 9, this is indicated by arrows "F, F" at the areas of contact between the curved lowest part of pin 100 so oriented and the immediately adjacent surfaces of the grommet. Each reaction force "F" is oriented at an angle "θ*" which is greater than "θ g ", and has a net upward component acting on clip 100.
In summary, therefore, to engage clip 100 to grommet 200, clip 100 is oriented so that its planar surfaces 124, 124 parallel the width direction of grommet 200 and is then forced into an interference engagement with grommet 200. Then, when an external torque is applied to rotate clip 100 by a quarter turn, forcible deformation in the lower portions of grommet 200 generates a force on the lower curved portion of clip 100 tending to disengage clip 100 and force it out of grommet 200.
As indicated earlier, the use of a washer such as washer 600 is entirely optional, the clip 100 can be particularly sized for a specific application once the thicknesses of the first and second substantially flat parts 400 and 500 are known, and the torque to be applied to clip 100 may be provided by any suitable tool if recess 106 is shaped and sized to receive the same. The clip head may be shaped on the outside, e.g., for engagement by a wrench or even for firm grasping by a pair of pliers.
The exact dimensions of grommet 200 may also be selected at the user's option in light of its intended use. For example, in certain automobiles the cowl structure is covered with a decorative resin grill to provide a pleasing appearance between the hood and the windshield concealing the windshield wiper system and to provide a fresh air intake for the passenger compartment. The grill is located in an area that experiences vibration, temperature cycling, and exposure to water and incidental debris. A resin grill will expand/contract with variations in temperature, so it is highly advantageous to provide secure attachment with a designed-in tolerance for movement in a specified direction about its nominal position. Furthermore, the grill is also required to keep electrical parts safe from moisture, so that seal feature is particularly advantageous for use under a wise variety of operational circumstances.
Further, by the use of a material such as nylon for grommet 200, and the provision of a deformable elastic gasket 300 thereunder, highly effective and inexpensive sealing can be provided and the gasket 300 replaced by a new gasket following disengagement of the clip-in grommet assembly as discussed above. Likewise, should the material of the grommet have suffered physical deterioration over time, the damaged grommet itself can simply be poked out from its initial location and a new grommet pressed into the aperture in the first substantially flat part 400 to provide a replacement grommet.
In this disclosure, there are shown and described only the preferred embodiments of the invention, but, as aforementioned, it is to be understood that the invention is capable of use in various other combinations and environments and is capable of changes or modifications within the scope of the inventive concept as expressed herein. | A fastening system is provided which includes an elongate grommet affixable into a correspondingly shaped aperture in a first object to be retained therein, and a clip passed through an aperture in a second object to be fastened to the first object. The two objects, one with the grommet affixed therein and the other with the clip projecting therethrough are brought together and, in a first orientation of the clip with respect to the grommet the clip is forcibly pressed into the grommet, whereupon a pair of claws formed onto the shank of the clip engage in an interference fit with recesses formed for such engagement into opposite walls of the grommet. The clip has a maximum transverse dimension smaller than an inside dimension of the elongate grommet, so that a predetermined amount of relative motion between the fastened objects is permitted by sliding motion of the clip while in interference engagement with the grommet. | 5 |
CROSS REFERENCE TO RELATED APPLICATION
This is a non-provisional application claiming benefit of U.S. Provisional Application Ser. No. 60/998,504 filed Oct. 11, 2007, and entitled Passive Actinide Self-burner, incorporated herein by reference.
FIELD
Embodiments of the invention relate to the field of nuclear waste (radioactive waste materials) disposal and methods. More particularly, embodiments of the invention relate to the disposal and accelerated destruction of transuranic actinide materials that are the residual products of the chemical dissolution of spent nuclear fuel and other components containing fissile materials.
BACKGROUND
Actinide and/or transuranic material destruction occurs naturally along well-understood decay chains to eventually become a stable non-radioactive element, lead. However, in natural decay, some of these elements remain dangerous to man over hundreds of thousands or millions of years.
Actinides are separated from spent nuclear fuel, and other components containing fissile materials, by chemical means. Fission and actinide products are left over from the splitting of atoms to make power and are the principal residual material in spent nuclear fuel. The fission products are short-lived by comparison to the actinide products, and are destroyed by the natural radioactive decay process in about one thousand years. Most actinide products, on the other hand, remain dangerous for many centuries. It is this extremely long decay process that results in target isolation objectives of the US Department of Energy (DOE) of 1,000,000 years.
In destruction by the natural decay process, the radioactive elements arrive at a stable state by the spontaneous emission of radioactive particles, including alpha particles and neutrons. By increasing the rate at which actinides decay to a stable state, the technological challenge and cost burden of establishing long-lived containment systems for the disposal of spent fuel may be significantly reduced.
The potential benefits of effectively reducing the half life of actinide elements has resulted in extensive experimental and operational programs having the sole objective of hastening the transmutation and decay of these products to a stable, and inherently safe, state.
Most applications directed to the destruction of actinides by transmutation or fission rely upon high neutron flux rates, similar to those found in operating reactors. To that end, many applications propose the inclusion of waste actinides in some portion of an active fuel assembly so that the material is transmuted or destroyed using the high neutron flux of the operating reactor.
While these methods do accelerate transmutation of the actinides to more stable forms thereby reducing the actinide waste quantity requiring disposal, they have the disadvantage of requiring special packaging, high-energy neutron sources and handling of the waste forms, which increases personnel radiation exposure and the risk of accident. The nuclear reactor or particle accelerator operations required by these methods are both complex and expensive.
This invention operates by converting the abundant alpha particles emitted by the actinides into neutrons via an alpha—neutron (alpha, n) reaction that is a property of Beryllium and some other elements such as oxygen. This raises the neutron flux of the container to about one ten thousandth of the level present in a nuclear reactor intended to burn the actinides in one or two years. The invention makes use of its passive nature and the 10,000-year minimum period required by regulations to accomplish the same level of destruction of the actinide waste after emplacement in a geological repository. By utilizing the invention, a million year waste isolation period is no longer required, and the shorter 10,000-year waste isolation period is much less complex to analyze and regulate.
As described herein, the preferred embodiment of the invention is intended for use with the current series of DOE Standard Canisters (herein after “Canisters” or “Canister”) designed for geologic disposal.
SUMMARY
An apparatus that provides for the passive destruction of the actinides meets the waste actinide destruction and disposal needs described above. The invention relies upon the neutrons generated within the waste actinides to achieve accelerated destruction, by reflecting those neutrons back into the actinides for efficiency. No neutrons external to the system are introduced into the apparatus. The invention builds upon the current seal source technology that uses the same principles to generate neutrons for industrial testing and well logging purposes, but significantly extends that art to meet a need for accelerating the decay of very long-lived waste actinide isotopes.
The invention provides for the confinement of actinide or transuranic radioactive wastes, alloyed with beryllium, inside a graphite disk to cause accelerated destruction (burning) of actinide wastes. Actinides, including plutonium, neptunium, americium, and curium, emit alpha particles by radioactive decay. The alpha particles are converted into neutrons by the beryllium through an alpha-neutron (also called an alpha, n) reaction. The neutrons created in this reaction are absorbed by the actinides causing them to transmute to a heavier actinide isotope with a shorter half-life. An outer layer of graphite is provided to moderate and reflect neutrons back into the actinide zone to improve the efficiency of actinide burning. The outer layer could consist of beryllium metal as the neutron moderator and reflector, but its use results in a prohibitively expensive configuration.
The process is passive because the alpha particles that initiate the actinide destruction by radioactive decay are an intrinsic physical property of the actinides. The decay process is accelerated because neutrons that would escape the confinement system are reflected back into the actinide waste where they are captured, reducing the stability of those wastes. The use of a neutron moderator and reflector such as beryllium or graphite to initiate self-burning of actinides allows the quantity of actinides to be reduced much more rapidly than if decay where to occur naturally in accordance with the half-life of the material. Using this method, the actinides can be destroyed in the repository design period of 10,000-year instead of requiring 100,000 years to one million years to attain the same waste reduction by natural radioactive decay alone.
The waste actinides may be either individual actinide elements, or a mixture of actinides, which may also be mixed with beryllium metal, in any convenient solid metal, glass, resin, powder or other stable form. The waste actinide product, in addition to the beryllium, may contain binders or other compounds consistent with the stabilization method used. In the preferred embodiment, the waste actinide and beryllium are melted together to obtain a substantially mixed alloy. Intimate mixing of the waste actinides and beryllium improves alpha,n conversion efficiency.
The ideal configuration for the waste actinide/beryllium mixture or alloy is a sphere, which would be encased by a spherical shell of beryllium. This configuration presents the best volume to surface ratio for heat rejection. However, it also has the highest cost and is not considered suitable for routine use. The preferred embodiment for the waste actinide/beryllium alloy is as a cylinder sized for use with existing Standard Source capsules. This configuration is consistent with current methods of solidifying or stabilizing actinides, and with current storage and disposal package construction and fabrication practice. More importantly, it is consistent with the configuration of DOE Standard Sources capsules that are manufactured using actinides such as americium and curium, which have been separated from recycled spent nuclear fuel and refined. These sources, which emit neutrons by design, are widely used in industry.
Each DOE Standard Source is a cylindrical double-sealed capsule, 0.75 inches in diameter and 2.00 inches in length. The source configuration consists of an inner capsule with domed ends, an outer capsule with domed ends, and the metallic actinide source inside the inner capsule. Double encapsulation is provided to prevent the leakage of radioactive material from the source capsule. The capsules are fabricated from stainless steel.
The typical Standard Source contains 3.0 Curies of americium/beryllium in a metallic alloy form with an atomic ratio of beryllium to americium of 13:1. In the preferred embodiment described for this invention, the atomic ratio remains the same, but the actinide is comprised of unrefined actinides consisting primarily of americium, neptunium and curium, but also including a number of related isotopes, and is referred to herein as “waste actinide.”
The waste actinides in the source produce alpha particles, many of which are converted to neutrons by collision with the beryllium atoms. The neutrons, in turn, are captured by the isotopes of the waste actinide, destroying a portion of the waste actinide and transmuting a larger portion to heavier isotopes. These heavier isotopes are much less stable than the original isotopes and decay more rapidly than the original isotopes. Thus the quantity of waste actinide remaining at any given future time, is less than if the Am and Cm were disposed of in another form to undergo natural decay.
In the preferred embodiment as described herein, individual sealed capsules are placed in wells drilled into a graphite disk. The graphite acts as a moderator for the neutrons created in the alpha, n reaction, allowing the slowed (or thermalized) neutron to transmute other actinide isotopes. Graphite is a cost-effective substitute for beryllium.
To provide for structural integrity and facilitate heat rejection, the exposed graphite surface, including the surface of the wells, is faced with stainless steel or aluminum. Once sealed capsules are inserted in the wells of the graphite disk, a closure plate of the same material, acting as a cover, is welded in place over the capsules. Based on the planned use of the Canister, the graphite would have the external shape of a disk, between 18 and 24 inches in diameter, and approximately 3 inches thick. One or more loaded and sealed graphite disks could be stacked within the Canister.
The number of capsules installed in each disk, and the number of disks placed in each Canister, is limited primarily by the heat of radioactive decay associated with each capsule. Such limit is determined by appropriate analysis to ensure that heat rejection limits of the repository package are not exceeded. In the preferred embodiment, the number of capsules in the 18-inch diameter graphite disk is 21.
BRIEF DESCRIPTION OF THE DRAWINGS
Further advantages of the invention are apparent by reference to the detailed description in conjunction with the figures, wherein elements 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:
FIG. 1 depicts the cylindrical shape of the waste actinide/beryllium mixture.
FIG. 2 depicts the cylindrical capsule that would hold the waste actinide/beryllium mixture or alloy.
FIG. 3 depicts a graphite disk and illustrates typical placement of a capsule within it.
FIG. 4 depicts an alternate graphite disk embodiment incorporating an outer ring of beryllium and a Ricorad™ material lining at each well.
FIG. 5 depicts an alternate spherical embodiment of the invention.
FIG. 6 depicts a flowchart of the typical steps of a method of making a sealed capsule and closing the graphite disk.
DETAILED DESCRIPTION
FIG. 1 depicts the cylindrical shape of the waste actinide/beryllium mixture ( 100 ). In the preferred embodiment, the mixture is an alloy of waste actinide(s) and beryllium.
The passive operation of the actinide self-burner relies upon the close proximity of the waste actinide material to beryllium metal. Close proximity is necessary because of the short mean free path of the alpha particles within the mixture, since in the most effective operation, the alpha particle must encounter a beryllium atom in order to generate the neutron that will hasten actinide destruction.
Consequently, the actinide, or combination of actinides, and beryllium are substantially mixed. Once mixed, the material may be handled as a dry stable powder or alloy.
The cylindrical volume of the mixture is approximately 0.5 inches in diameter (D) and 1.75 inches in length (L). The radioactive contents would be approximately 3 curies of waste actinide material.
FIG. 2 depicts the cylindrical capsule that contains the waste actinide/beryllium alloy.
In the preferred embodiment, each first (outer) capsule ( 200 ) is a cylindrical stainless steel vessel, being 0.75 inches in external diameter (D 2 ) and 2.00 inches in external length (L 2 ). Within this first capsule is a second (inner) capsule ( 210 ) with the necessary reduced external dimensions. Each capsule has domed upper ends such that the domed ends can be welded to the cylindrical body of the capsule. Double encapsulation is provided to prevent the leakage of radioactive material from the source capsule. The capsules are fabricated from stainless steel and are individually welded shut by a suitable process and may be leaked tested to verify closure.
It is intended that DOE Standard Source capsules, or Standard capsules, be used for the purpose of confining the waste actinide/beryllium material. This allows the capsules to be prepared, filled, sealed and handled in accordance with DOE procedures. Further, the capsules are procured in accordance with the applicable DOE specifications. However, use of the Standard Source capsule is not required to achieve the desired results.
Use of the Standard capsules takes advantage of the familiarity of that design to those operators who normally load, handle and maintain these devices. It further ensures the material, welding, testing and handling controls required by the applicable standards for fabrication and use.
In the embodiment shown in FIG. 3 , structure 300 depicts a graphite disk and illustrates typical placement of a capsule ( 200 ) within it. Note that when welded closed, Item 200 contains within it the second sealed capsule ( 210 ) and the actinide/beryllium material ( 100 ).
Structure 300 consists of a 2.5-inch-thick cylindrical graphite reflector disk into which the capsules are inserted. The cylindrical graphite reflector is 17 inches in diameter for the 18″ Canister or 22.75 inches in diameter for the 24″ Canister. The graphite disk is perforated by a number of cylindrical holes or wells 310 (typical) to allow the insertion of the capsules. The disk bottom surface and side is covered with ⅛-inch thick 316 L stainless steel or aluminum ( 320 ). Each well is lined with a 3/16-inch thick 316 L stainless steel tube. Once all of the capsule positions are loaded, the graphite disk top surface is closed with a welded cover ( 330 ) of the same thickness. The stainless steel or aluminum provides structural support and heat conduction for the capsules.
The purpose of the graphite reflector is to slow down the fast neutrons created by the alpha particle collisions with beryllium so that the neutrons can transmute the actinide isotopes. Crumpled aluminum foil or other similar filler material may also inserted into the top and bottom of the cylindrical well that holds each capsule to provide axial support for the capsule and to aid in heat transfer to the stainless steel or aluminum cover of the graphite reflector assembly. The graphite reflector assembly, loaded with source capsules, is seal welded close to provide a third barrier against the release of radioactive material during handling operations.
The heat conduction disks are used as separators for the graphite reflector assemblies when the graphite assemblies are stacked within a Canister. The heat conduction disks are fabricated from copper or aluminum and have the same outside diameter as the graphite reflector assembly. The thickness is nominally ¼ inch for copper and 3/16 inches for aluminum. The disks provide a conduction path to the Canister cavity surface for decay heat generated in the capsules.
The sealed reflector disks ( 300 ), loaded with source capsules ( 200 ), may be stacked into a 10-foot or 15-foot long Canister. Each loaded reflector disk assembly is separated from the one below it by a copper or aluminum heat conduction disk. Extra space at the end of the Canister may be filled, e.g. by aluminum foil, to prevent axial motion of the loaded reflector disks. While a Canister is assumed for geologic disposal of such waste, there is no requirement to use the Canister. Any container qualified for long-term storage or testing could be used.
The preferred embodiment assumes that the actinide waste material is packaged for geologic disposal. Consequently, the graphite disk(s) are sized to fit the Canister, the DOE disposal package. However, any size graphite disk may be used, including a disk that is designed to hold a single capsule. Such configurations may be required for long-term storage that anticipates future disposal, or for testing.
FIG. 4 depicts an alternate graphite disk embodiment in which an outer most 1-inch ring of graphite is replaced by a ring of beryllium and the individual capsule wells are lined with a one half-inch ring of Ricorad™ material. In all other respects, this embodiment is the same as that depicted in FIG. 3 . The inclusion of the outer ring of beryllium significantly improves the effectiveness of the apparatus of FIG. 3 by increasing the number of neutrons that are reflected, while the Ricorad™ liner material improves neutron thermalization. These effects combine to cause additional decay events within the waste actinide material. While the beryllium ring and Ricorad™ improve neutron production by a factor of approximately 2.2, the inclusion of these materials significantly increase the cost of this embodiment.
FIG. 5 depicts an alternate spherical embodiment of the invention. This embodiment consists of a beryllium sphere ( 500 ) approximately 6.0 inches in diameter, having an interior cavity ( 510 ) approximately 2 inches in diameter. In this embodiment, the interior cavity is filled with a waste actinide/beryllium substantially mixed powder ( 100 ). The fill hole is then closed and sealed. In this embodiment, the beryllium sphere acts in the same manner as the graphite disk previously described. The sphere both moderates the fast neutrons developed by the alpha-n reaction and reflects those slowed neutrons back into the waste actinides, thereby accelerating the destruction of the waste actinides.
While this alternate embodiment accomplishes the same objective as the preferred embodiment, the cost of the beryllium shell makes its use unattractive for other than experimental purposes.
An embodiment shown by the diagram in FIG. 6 depicts a flowchart of the typical steps of a method of making a sealed capsule and closing the graphite disk.
The preferred embodiment includes the steps of measuring 602 by volume and material curie content, a first amount of a waste actinide powder, and a second amount of a beryllium metal powder material; blending 604 the powders to form a uniform first mixture; loading 606 the first mixture into a suitable beryllium crucible and heating the crucible and its first mixture contents to 1375° F. in a vacuum chamber to form a first alloy material; shaping 608 the alloy material in a suitable die; loading 610 the alloy ingot into an inner capsule; sealing, inspecting and testing 612 the inner and an outer capsules; loading 614 the sealed capsules into a prepared graphite disk; sealing 616 the graphite disk by welding a top cover plate; and, loading 618 one or more sealed graphite disks into a Canister for disposal or other container.
The measuring step 602 considers that the interior space of the Standard Source capsule volumetrically limits the quantity of the first mixture, but the quantity may also be limited by the curie content of the actinide material. The curie content determines the heat output of each capsule, which must be considered in the managing the total heat load within the Canister. The actinide powder may be comprised of unrefined individual actinide isotopes; or, a mixture of such waste actinides consisting primarily of americium, neptunium and curium, but also including a number of related isotopes. In addition, the quantities of the powders are controlled to achieve a preferred 1:13 atomic ratio of waste actinide to beryllium. The atomic ratio achieved is determined by weighing powders, which may result in some minor deviations from the target ratio. In addition, other ratios can be used, such as 1:167.
The blending step 604 is important since the efficiency of the alpha, n reaction requires that the waste actinide material and the beryllium be in close proximity within the mixture. Consequently, substantial mixing of the two powders is required.
The process step 606 forms the waste actinide/beryllium alloy by loading the mixed the powders into a beryllium oxide crucible. The crucible is heated to 1375° F. in a vacuum oven until the mixture is a molten alloy. A vacuum is applied to draw off any fluorine gases, F 2 , which might be present from the chemical processing of the waste actinide(s). The actual temperature applied is somewhat less important than achieving the molten state necessary to form the alloy. However, a temperature of 1375° F. is typically used, and is considered to be an acceptable target value for this purpose.
The alloy is cooled in a suitable die 608 to establish the form of the ingot that allows it to be inserted in the inner capsule. The cooled ingot is inspected and polished if necessary.
The alloy ingot is inserted 610 into the inner capsule. As previously described, the capsule assembly consists of an inner and outer capsule, which conforms to the design and specifications of the DOE Standard Source capsule. This capsule assembly, and arrangement, are identical to those already supplied to industry as neutron sources, and there are no unique procurement, process or handling steps associated with the use of the Standard Source capsule. While use of the Standard Source capsule is anticipated, its use is not required.
Close 612 the inner and outer capsules welding, and inspect and test the completed capsule for leakage. The post seal welding inspection and test activities are preformed individually on the inner and outer capsules.
Once sealed, the capsules are loaded 614 into wells in the graphite disk assembly. Within each well, the individual capsules may be supported in the axial direction by crumpled aluminum, or other similar filler material, to provide axial support and to aid in the transfer of decay heat away from the capsule.
There are no unique processing activities associated with the graphite disk except to cut or trim the disk to the appropriate dimensions and then to enclose the disk with a stainless steel or aluminum covering to create a disk assembly. The covering lends structural integrity to the graphite disk, protects the graphite from handling damage, facilitates the transfer of decay heat to the walls of the Canister, and allows of the welding of a closure plate to the top of the disk.
A top cover is welded 616 to the disk assembly to seal the assembly and to retain the individual capsules in the wells that are incorporated into the disk to receive the capsules. The closure weld is inspected and tested to verify sealing.
One or more sealed graphite disk assemblies may be loaded 618 into a designed Canister or other container. Individual loaded disk assemblies may be separated by placing copper or aluminum disks between the disk assemblies to assist in transferring decay heat from the capsules to the interior walls of the Canister or container. The diameter of both the disk assembly and heat transfer disks must be determined based on the interior dimensions of the DOE waste disposal Canister or container intended for use. The number of loaded disk assemblies that may be placed inside a Canister in a stacked array may be limited by either the total decay heat load allowed by the Canister specifications or by the available stacking height within the Canister. Since this configuration is not a requirement of the embodiment, its representation is not provided. However, where stacking of graphite disks is used, separating cooper or aluminum disks to improve decay heat transfer should also be use.
The description provided is a preferred embodiment that utilizes a known process and configuration for encapsulating the waste actinide/beryllium alloy. While there are significant benefits in using this encapsulating method, the success of the technique described herein is not dependent upon the use of that encapsulating method. Consequently, in other embodiments, the diameter and length of the alloy ingot and its method of confinement (i.e., such as alloy ingots stacked in a long tube closed at each end) may altered to conform to the intended handling, long-term storage or disposal requirements of given container.
The foregoing description of preferred embodiments for this invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise form disclosed. Obvious modifications or variations are possible in light of the above teachings. The embodiments are 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 to 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. | The invention relates to the confinement of an alloy formed of actinide transuranic radioactive wastes and beryllium metal within a neutron moderating and reflecting apparatus to cause accelerated destruction (burning) of the actinide wastes. Waste actinides, including plutonium, neptunium, americium, and curium, emit alpha particles by radioactive decay. The alpha particles are converted into neutrons by the beryllium through an alpha-neutron (alpha, n) reaction. The neutrons developed by the alpha, n reaction are moderated by a surrounding layer of graphite, which allows the slowed neutrons to cause additional fission or decay events within the waste actinide alloy. This process is passive because the alpha particles that initiate the actinide burning are an intrinsic physical property of the actinides. The burning or decay process is accelerated because neutrons that would ordinarily escape the confinement fixture (a Standard Source capsule) are reflected back into the actinide waste, transmuting them into heavier, less stable isotopes that decay more rapidly. The use of the moderator/reflector material allows the waste actinides to be destroyed in a 10,000-year repository period instead of requiring one million years to attain the same waste reduction by natural radioactive decay alone. Beryllium may also be used as a neutron moderator/reflector, but is not a cost effective choice for large scale use. | 1 |
[0001] This application claims priority to U.S. Provisional Patent Application Serial No. 60/301,370 filed Jun. 27, 2001.
[0002] The U.S. Government may own certain rights in this invention pursuant to the terms of the National Cancer Institute grant CA81656-01.
FIELD OF THE INVENTION
[0003] The present invention relates generally to the analysis of chemically modified macromolecules, and specifically to the detection of modified sites in DNA with the use of oligonucleotide arrays.
BACKGROUND OF THE INVENTION
[0004] Methylation of cytosines in CpG dinucleotides is an important mechanism of transcriptional regulation. It is involved in a variety of normal biological processes such as X chromosome inactivation and transcriptional regulation of imprinted genes. Aberrant methylation of cytosines can also effect transcriptional inactivation of certain tumor suppressor genes, associated with a number of human cancers. Cytosine methylation in CpG-rich areas (CpG islands) located in the promoter regions of some genes is of special regulatory importance. Therefore, wide scope mapping of methylation sites in CpG islands is important for understanding both normal and pathological cellular processes. Furthermore, methylation of certain sites may serve as an important marker for early diagnosis and treatment decisions of some cancers.
[0005] A variety of methods have been used to identify sites of DNA methylation. One common method has relied on the inability of restriction endonucleases to cleave sequences that contain one or more methylated cytosines. Genomic DNA is fragmented with appropriate restriction enzymes and cleavage at the site of interest is probed electrophoretically or by PCR. This method provides an analysis of some potential methylation sites, but it is limited to sites that fall within the recognition sequences of methylation-sensitive restriction enzymes.
[0006] Other methods rely on the differential chemical reactivities of cytosine and 5-methyl cytosine with reagents such as sodium bisulfite, hydrazine, or permanganate. In the case of hydrazine and permanganate, differential strand cleavage between methylated and unmethylated cytosines is examined in a similar fashion to that used when cleavage is done with restriction enzymes. This approach is complicated by the imperfect specificity of the reagents between methylated and unmethylated cytosines and by interference from reaction with thymidines.
[0007] Treatment with sodium bisulfite can be used to convert methylated and unmethylated DNA to different sequences. Under appropriate conditions, unmethylated cytosines in DNA react with sodium bisulfite to yield deoxyuridine, which behaves as thymidine in Watson-Crick hybridization and enzymatic template-directed polymerization. Methylated cytosines, however, are unreactive, and behave as cytosine in Watson-Crick hybridization and enzymatic template-directed polymerization.
[0008] The sequence differences resulting from bisulfite treatment can be assessed in any of several ways. One way is with standard sequencing by primer extension (Sanger sequencing). This method has the disadvantage of limited throughput. Another way, termed methylation-specific PCR, uses a set of PCR primers specific to the sequences resulting from bisulfite treatment of either methylation state at a given site. Effective amplification using one primer from the set indicates methylation, whereas effective amplification using the other primer indicates unmethylated cytosine at the site being amplified. This method has the disadvantage of low sample throughput in addition to the disadvantage that only one potential site of methylation is probed in an assay.
[0009] Thus, there is a need for a high throughput method for the identification of alteration in DNA.
SUMMARY OF THE INVENTION
[0010] The present invention provides a high-throughput method for the parallel analysis of many potential sites of chemical modification (e.g., methylation) in DNA. It makes use of chemical treatment of the DNA to alter its sequence in a way that depends upon the modification of interest and subsequent analysis of the resulting sequence by hybridization to an array of probes. A device, comprising the array of probes, is provided by the invention, and principles and methods for its design and fabrication are also provided.
[0011] In one form the present is a method for the analysis of chemical modification of DNA including the steps of obtaining a sample of DNA to be analyzed and treating the DNA with one or more chemical reagents that result in different base sequences depending upon the presence or absence of the modification of interest, and determining a portion of the base sequence of the resulting DNA.
[0012] Another form of the present invention is an array of one or more nucleic acid probes immobilized on a solid support wherein the probes are designed to detect sites of methylation in DNA.
[0013] Yet another form of the invention is a method for generating DNA probe sequences that includes the steps of inputting a nucleic acid sequence in the 3-prime to 5-prime direction and converting the sequence to account for chemical modification. The complementary sequence to the converted sequence in the 3-prime to 5-prime direction is then generated. A first parent probe is then generated by choosing a first starting position on the complementary sequence and a first ending position on the complementary sequence. A second parent probe is then generated by moving the first starting and first ending position one base unit in the same direction. This process may be repeated as often as desired.
[0014] Another form of the resent invention is a method for generating DNA probe sequences that includes the steps of inputting a nucleic acid sequence in the 3-prime to 5-prime direction and converting the sequence to account for chemical modification. The complementary sequence to the converted sequence in the 3-prime to 5-prime direction is then generated. The complementary sequence is then examined to locate one or more CpG dinucleotide regions within the complementary sequence, and probes are then generated that have one or more nucleic acid bases on each end of the CpG dinucleotide regions.
BRIEF DESCRIPTION OF THE FIGURES
[0015] The above and further advantages of the invention may be better understood by referring to the following detailed description in conjunction with the accompanying drawings in which corresponding numerals in the different FIGURES refer to the corresponding parts in which:
[0016] [0016]FIG. 1 depicts a reaction in accordance with the present invention;
[0017] [0017]FIG. 2 depicts a method of re-sequencing in accordance with the present invention;
[0018] [0018]FIG. 3 depicts a schematic of assay results in accordance with the present invention;
[0019] [0019]FIG. 4 depicts the results of a two-color assay in accordance with the present invention;
[0020] [0020]FIG. 5 depicts a fluorescence scan in accordance with the present invention;
[0021] [0021]FIG. 6 depicts an assay for CpG methylation by (A) treatment with sodium bisulfite to convert unmethylated cytosines to deoxyuracils (4 cytosines) while methylated cytosines remain unconverted (one cytosine denoted as methylated with a superscript Me) and (B) sequence analysis of a labeled representative of the bisulfite-treated DNA by hybridization to an array of oligonucleotides in accordance with the present invention;
[0022] [0022]FIG. 7 depicts the sequence of the 190 base region of the p16 promoter wherein each cytosine in the sequence is numbered in accordance with the present invention;
[0023] [0023]FIG. 8 depicts four probes from an array used to analyze the methylation state of a region of the promoter for p16 showing (A) fluorescence scan of the Cy5 (analyte) channel of the array, (B) fluorescence scan of the Cy3 (reference) channel of the array, (C) overlay of the analyte and reference channels demonstrating the appearance of a methylated site compared with an unmethylated reference in accordance with the present invention; and
[0024] [0024]FIG. 9 is a histogram plots showing Z scores for each cytosine in a CpG dinucleotide using analysis in which the analyte was derived from (A) uniformly methylated DNA, (B) a synthetic duplex simulating unique methylation at cytosine number 25, (C) a mixture of approximately 20% methylated DNA and 80% unmethylated DNA in accordance with the present invention.
DETAILED DESCRIPTION
[0025] While the making and using of various embodiments of the present invention are discussed herein in terms of identification of methylated sites in DNA, it should be appreciated that the present invention provides many applicable inventive concepts that can be embodied in a wide variety of specific contexts. The specific embodiments discussed herein are merely illustrative of specific ways to make and use the invention and are not meant to limit the scope of the invention in any manner.
[0026] The need for high-throughput methods is highlighted by the prevalence of CpG islands in the genome. Computer analysis of the March 2001 Unigene build reveals 32,597 of the 92,152 clusters contain CpG islands. Of the 14,968 clusters with annotation, 10,438 have CpG islands. These islands in the annotated clusters comprise 4,398,560 bp in 5′ non-coding regions, 7,074,411 bp in coding regions, and 492,323 bp in 3′ non-coding regions. A high throughput method of the present invention will be necessary to interrogate even a small fraction of these sites in a given experiment.
[0027] The differential reactivity of bisulfite with cytosine and 5-methylcytosine forms the basis of several techniques for the assessment of DNA methylation; however, new approaches to the read-out of the sequence that results from treatment with bisulfite are desirable. Sequence analysis by hybridization to oligonucleotide arrays is an approach that affords a high degree of parallelism and flexibility. The present invention relies on discrimination between a cytosine and a thymidine in the array hybridization.
[0028] All technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs, unless defined otherwise. Methods and materials similar or equivalent to those described herein may be used in the practice or testing of the present invention, the generally used methods and materials are now described.
[0029] Definitions
[0030] To facilitate the understanding of this invention, a number of terms are defined below. Terms defined herein have meanings as commonly understood by a person of ordinary skill in the areas relevant to the present invention. Terms such as “a”, “an” and “the” are not intended to refer to only a singular entity, but include the general class of which a specific example may be used for illustration. The terminology herein is used to describe specific embodiments of the invention, but their usage does not limit the invention, except as outlined in the claims.
[0031] As used throughout the present specification the following abbreviations are used: TF, transcription factor; ORF, open reading frame; kb, kilobase (pairs); UTR, untranslated region; kD, kilodalton; PCR, polymerase chain reaction; RT, reverse transcriptase.
[0032] The term “homology” refers to the extent to which two nucleic acids are complementary. There may be partial or complete homology. A partially complementary sequence is one that at least partially inhibits a completely complementary sequence from hybridizing to a target nucleic acid and is referred to using the functional term “substantially homologous.” The degree or extent of hybridization may be examined using a hybridization or other assay (such as a competitive PCR assay) and is meant, as will be known to those of skill in the art, to include specific interaction even at low stringency.
[0033] The art knows that numerous equivalent conditions may be employed to achieve low stringency conditions. Factors that affect the level of stringency include: the length and nature (DNA, RNA, base composition) of the probe and nature of the target (DNA, RNA, base composition, present in solution or immobilized, etc.) and the concentration of the salts and other components (e.g., formamide, dextran sulfate, polyethylene glycol). Likewise, the hybridization solution may be varied to generate conditions of low stringency hybridization different from, but equivalent to, the above listed conditions. In addition, the art knows conditions that promote hybridization under conditions of high stringency (e.g., increasing the temperature of the hybridization and/or wash steps, inclusion of formamide, etc.).
[0034] The term “gene” is used to refer to a functional protein, polypeptide or peptide-encoding unit. As will be understood by those in the art, this functional term includes genomic sequences, cDNA sequences, or fragments or combinations thereof, as well as gene products, including those that may have been altered by the hand of man. Purified genes, nucleic acids, protein and the like are used to refer to these entities when identified and separated from at least one contaminating nucleic acid or protein with which it is ordinarily associated.
[0035] The term “portion of a genome for genetic analysis” or “chromosome-specific” is herein defined to encompass the terms “target specific” and “region specific”, that is, when the staining composition is directed to one chromosome or portion of a genome, it is chromosome-specific, but it is also chromosome-specific when it is directed, for example, to multiple regions on multiple chromosomes, or to a region of only one chromosome, or to regions across the entire genome. Likewise, “locus specific” or “loci specific” is defined as locations on one or more chromosomes for a particular gene or allele. Sequence from regions of one or more chromosomes are sources for probes for that region or those regions of the genome. The probes produced from such source material are region-specific probes but are also encompassed within the broader phrase “portion of a genome” probes. The term “target specific” is interchangeably used herein with the term “chromosome-specific” and “portion of a genome”.
[0036] The word “specific” as commonly used in the art has two somewhat different meanings. The practice is followed herein. “Specific” refers generally to the origin of a nucleic acid sequence or to the pattern with which it will hybridize to a genome, e.g., as part of a staining reagent. For example, isolation and cloning of DNA from a specified chromosome results in a “chromosome-specific library.” Shared sequences are not chromosome-specific to the chromosome from which they were derived in their hybridization properties since they will bind to more than the chromosome of origin. A sequence is “locus specific” if it binds only to the desired portion of a genome. Such sequences include single-copy sequences contained in the target or repetitive sequences, in which the copies are contained predominantly in the selected sequence.
[0037] A “probe” as defined herein may be one or more molecules that can hybridize to a nucleic acid target sequence and that can be detected (e.g., nucleic acid fragments or other oligomers that bind nucleic acids). Examples of possible probe molecules include, but are not limited to, DNA, RNA, peptides, minor groove-binding polyamides, peptide nucleic acids (PNA), locked nucleic acids (LNA), and 2′-O-methyl nucleic acids. The probe is labeled so that its binding to the target can be assayed, visualized or detected. In essence the probe is designed to bind a target, also referred to as an analyte, so that the combination of probe and analyte may be assayed, visualized or detected. The probe may be produced from some source of nucleic acid sequences, for example, a collection of clones or a collection of polymerase chain reaction (PCR) products or the product of nick translation or other methods for adding a detectable marker to a nucleic acid binding moiety. For nucleic acids, repetitive sequences are removed or blocked with unlabeled nucleic acid with complementary sequence, so that hybridization with the resulting probe produces staining of sufficient contrast on the target. The word probe may be used herein to refer not only to a molecule that detects a nucleic acid, but also to the detectable nucleic acid in the form in which it is applied to, e.g., the surface of an array. What “probe” refers to specifically should be clear to those of skill in the art from the context in which the word is used.
[0038] The term “labeled” as used herein indicates that there is some method to visualize or detect the bound probe, whether or not the probe directly carries some modified constituent. The terms “staining” or “painting” are herein defined to mean hybridizing a probe of this invention to a genome or segment thereof, such that the probe reliably binds to the targeted region or sequence of chromosomal material and the bound probe is capable of being detected. The terms “staining” or “painting” are used interchangeably. The patterns on the array resulting from “staining” or “painting” are useful for cytogenetic analysis, more particularly, molecular cytogenetic analysis. The staining patterns facilitate the high-throughput identification of normal and abnormal chromosomes and the characterization of the genetic nature of particular abnormalities.
[0039] Multiple methods of probe detection may be used with the present invention, e.g., the binding patterns of different components of the probe may be distinguished, for example, by color or differences in wavelength emitted from a labeled probe.
[0040] A number of different aberrations may be detected with any desired staining pattern on the portions of the genome detected with one or more colors (a multi-color staining pattern) and/or other indicator methods.
[0041] The complexity for a final probe list and array will depend on the application for which it is designed (e.g., location on the genome, complexity of the sequence, etc.) and the mapping resolution that is sought. In general, the larger the target area, the more complex the probe list. The term “complexity” therefore refers to the complexity of the total probe list no matter how many visually distinct loci are to be detected, that is, regardless of the distribution of the target sites over the genome.
[0042] The required contrast (e.g., signal to noise) for detection will depend on the application for which the probe is designed and even the portion of the genome that is the target of the analysis. When visualizing chromosomes and nuclei, etc., microscopically, a contrast ratio of two or greater is often sufficient for identifying whole chromosomes. When quantifying the amount of target region present on an array by fluorescence intensity measurements using a slide reader or quantitative microscopy.
[0043] Identification of a large number of individual methylation sites in a high-throughput, highly parallel assay can be accomplished by specifically converting only unmethylated cytosines to deoxyuridines with sodium bisulfite treatment, as shown in FIG. 1, and rapidly reading out the resulting sequence. Any cytosine remaining in the product is identified as a site of methylation. Oligonucleotide arrays are particularly well suited to rapidly distinguishing between closely related nucleic acid sequences with a method known as re-sequencing.
[0044] The method of re-sequencing is depicted in FIG. 2. A sequence of interest is shown in FIG. 2A, where an unknown base is at a central position, identified in the FIGURE with an N. FIG. 2B shows four oligonucleotide probes used to assay each base position of interest, each probe complementary to the sequence being tested except at the position of the unknown base. At the position of the unknown base, the probes differ, each having a different one of the four possible bases. The probe oligonucleotides may be immobilized on a surface as shown in FIG. 2, but other formats are possible. FIG. 2C shows the DNA to be tested binding to one of the four probes. It binds specifically to the probe with an adenosine in the test position, identifying the unknown base, N, as a thymidine. Specificity is highest when the probed base binds near the center of probe oligonucleotide.
[0045] In practice, re-sequencing with oligonucleotide arrays can be accomplished by a number of means, any of which will be applicable to the present invention. In one standard approach, the array of oligonucleotides is immobilized on a glass surface. An example of a “feature” of the resulting array is defined as a region of the surface in which a single probe sequence predominates. Fabrication of surface-bound oligonucleotide arrays can also be accomplished by a variety of methods known to those with skill in the art.
[0046] A fabrication method that is particularly appropriate for the present invention makes use of light directed chemistry to synthesize the oligonucleotides directly on the surface. The regions of the surface that are illuminated during pre-determined chemical steps of the synthesis determine the sequence synthesized in each feature. Defined regions can be illuminated discretely by, for example, shining light through a physical mask that blocks light from particular regions or by directing light to particular regions with a digital micromirror array. These light-directed approaches are desirable for the present invention, because they currently enable the largest numbers of features per unit area of array surface. Thus, the potential of the current invention for highly parallel analysis of methylation is best met by the very high feature numbers accessible with light-directed methods. However, other methods of array fabrication are amenable to the present invention, including but not limited to delivering the reagents of DNA synthesis to specific regions of the surface and depositing on the surface oligonucleotides that have been pre-synthesized.
[0047] Typically, a solution of the nucleic acid to be analyzed is applied to the surface of the array, and the dissolved nucleic acid is allowed to bind to probes on the surface. After an appropriate time, the unbound and the weakest bound nucleic acid are washed from the array and the bound nucleic acid is detected. Detection of binding can be accomplished in several ways known to those of skill in the art, any of which can be applied to the present invention. In one method, detection is accomplished by labeling the test nucleic acid with a moiety such as a fluorophore and measuring fluorescence associated with each probe. FIG. 2D schematically illustrates the appearance of a fluorescence scan of four features designed to probe a single base following binding and washing. The brightest feature indicates the identity of the probed base position. Many methods are also known for the incorporation of a fluorescent label into a test nucleic acid, including but not limited to nick translation, transcription into RNA using a template-directed RNA polymerase to incorporate labeled nucleotide triphosphates, or amplifying a region of interest with PCR using labeled primers.
[0048] In operation, the present invention may be used, for example, as described herein. A sample of genomic DNA to be analyzed is obtained and treated with bisulfite under conditions for which that reaction converts unmethylated cytosines to deoxyuridines but does not effect methylated cytosines. One or more regions of interest from the resulting DNA are then amplified by PCR and labeled by any of a variety of methods. Design of primers for PCR amplification of bisulfite-treated DNA should be guided by the following considerations: 1) the primers should not contain CpG dinucleotides of unknown methylation state, 2) the primers are restricted to a three-base code (A, G, and T) because all cytosines not in CpG dinucleotides are converted to deoxyuridine, 3) some bisulfite treatment protocols, such as the one described below, cleave the DNA substantially, so amplification of short regions (about 200 base pairs) is most successful, and 4) a different set of primers is required for each strand, because the two initially complementary strands are no longer complementary after bisulfite treatment.
[0049] A solution of the labeled nucleic acid is then contacted with an array of probes comprising probes that bind differentially to the sequences resulting from bisulfite treatment of methylated or unmethylated cytosines of interest. In practice, such probes can be made by creating oligonucleotides that are complementary to a region of DNA surrounding the cytosine of interest, taking into account the conversion of all cytosines not in a CpG dinucleotide to deoxyuridine, which is complementary to adenosine. A typical length for such oligonucleotide probes is between 15 and 30 nucleotides, but longer and shorter probes are possible. The site to be probed should be near the center of the region to which the probe is complementary.
[0050] At least two probes are required for each potential methylation site of interest. In one, the base in apposition to the site to be probed is an adenosine, forming the complement to the deoxyuridine-containing sequence corresponding to the unmethylated state. In the other, the base at the same position is guanosine, forming the complement to the cytosine-containing sequence corresponding to the methylated state. Although methylation state can be determined with these two probes only, it is preferable to use four probes for every site, one with each of the four bases at he variable position, in order to account for the possibility of polymorphism or mutation at the site of interest. Possible results of this assay are shown schematically in FIG. 3. FIG. 3A illustrates a result indicating methylation of the site of interest, the brightest feature being that corresponding to cytosine. FIG. 3B illustrates a result indicating absence of methylation at the site of interest, the brightest feature being that corresponding to thymidine. FIG. 3C illustrates a result indicating polymorphism or mutation at the site of interest to an adenosine.
[0051] Multiple CpG dinucleotides of unknown methylation state will often be sufficiently proximal to each other in sequences to be analyzed that the probe will include one or more CpG dinucleotides in addition to the central one being analyzed. If a methylation state is assumed for these additional sites in the design of the probe sequence, the probe affinity for the analyte will be diminished whenever the assumed methylation state is not the actual methylation state. Including on the array additional probes that accommodate all possible methylation states can compensate for the resulting decrease in signal.
[0052] The array may comprise probes that have been selected by visual inspection of the sequences to be probed or probes that have been selected by automated computational means. Because the present invention is most advantageous when probing a large number of sites in parallel, the preferred method of probe choice is by automated computational means. A process for probe selection is outlined below. Automated searching of genome databases can identify regions of particular interest with a high density of CpG dinucleotides.
[0053] Two or more labels, such as fluorophores with different excitation and emission frequencies, can be used to compare one or more test samples with a reference sample. The reference sample can be a standard of known methylation state, a DNA sample from a reference tissue, such as a healthy tissue proximal to a diseased tissue to be tested, or a sample from the same cellular source as the test sample that has not been treated with bisulfite. The use of a reference sample of known methylation state provides an internal control for expected relative binding to probes, resulting in higher confidence in assignment of methylation state of unknown samples. The use of a reference sample from a reference tissue provides facile identification of methylation that is related to a particular phenotype, such as a disease phenotype. The use of a reference sample from the same cellular source as the test sample provides control for the possibility of a cytosine to thymidine mutation or polymorphism.
[0054] Possible results of a two-color assay with an unmethylated reference sample are shown in FIG. 4. The reference sample is labeled with the red dye, and the sample to be analyzed is labeled with the green dye. FIG. 4A illustrates a result indicating methylation of the site of interest, the brightest green feature being that corresponding to cytosine and the brightest red feature corresponding to thymidine. FIG. 4B illustrates a result indicating absence of methylation at the site of interest, the brightest feature in both data channels being that corresponding to thymidine. FIG. 4C illustrates a result indicating polymorphism or mutation at the site of interest to an adenosine.
[0055] The probes of the array need not be restricted to DNA. Any molecule that binds differentially to the sequences resulting from bisulfite treatment of methylated and unmethylated DNA can be used. Examples of possible probe molecules include, but are not limited to, RNA, peptides, minor groove-binding polyamides, peptide nucleic acids (PNA), locked nucleic acids (LNA), and 2′-O-methyl nucleic acid.
EXAMPLE 1
Analysis of Methylation of a Region of the Promoter for the Tumor Suppressor Gene p16
[0056] Genomic DNA was isolated from two lines of lung tumor cells, H69 and H1618. The promoter region of the tumor suppressor gene P16 is known to be methylated at cytosines in CpG dinucleotides in the line H1618 and is not methylated in the line H69. DNA from both lines was treated with sodium bisulfite as described in the protocol below, which converts unmethylated cytosine to deoxyuridine (essentially equivalent to thymidine in hybridization) but does not react with methylated cytosine. A 145 base pair region from the p16 promoter from each cell line was amplified with labeled primers. Primers labeled with Cy5 were used to amplify the unmethylated promoter (which represents a control or reference sequence) and primers labeled with Cy3 were used to amplify the methylated promoter (which represents the unknown methylation state to be analyzed).
[0057] The two samples were mixed together with the labeled control oligonucleotide and applied to the array. The array, fabricated by light-directed chemistry using a digital micromirror array, had two sets of features in addition to the control features. One set of features (upper half of array) was a standard re-sequencing tiling for the sequence expected without methylation (i.e., all Cs converted to T). The other set was a standard re-sequencing tiling for the sequence expected with methylation of every C in each CpG step. The set of probes used in the array appears as TABLE 1. A two-color fluorescence scan of the array after hybridization for 16 hours at room temperature and washing with 1×SSPE is shown in FIG. 5. Overall methylation state is evident by the labeled sample which binds best to each set of features, the Cy5 labeled, unmethylated sample binding best to the upper tiles for unmethylated sequence (highest signal red) and the Cy3 labeled, methylated sample binding best to the lower tiles for methylated sequence (highest signal green). Specific sites of methylation can be observed by reading sequence directly and by visually identifying columns in which the feature for C is green and the feature for T is red (easily visualized in both sets of probes).
TABLE 1 Probes Used in the Array SEQ ID NO Nucleotide Sequence for Probe SEQ ID NO: 1 AACCAACCAATAATCTCCCAC SEQ ID NO: 2 ACCAACCAATTATCTCCCACC SEQ ID NO: 3 CCAACCAATATTCTCCCACCC SEQ ID NO: 4 CAACCAATAATCTCCCACCCC SEQ ID NO: 5 AACCAATAATTTCCCACCCCA SEQ ID NO: 6 ACCAATAATCTCCCACCCCAC SEQ ID NO: 7 CCAATAATCTTCCACCCCACC SEQ ID NO: 8 CAATAATCTCTCACCCCACCT SEQ ID NO: 9 AATAATCTCCTACCCCACCTA SEQ ID NO: 10 ATAATCTCCCTCCCCACCTAA SEQ ID NO: 11 TAATCTCCCATCCCACCTAAC SEQ ID NO: 12 AATCTCCCACTCCACCTAACT SEQ ID NO: 13 ATCTCCCACCTCACCTAACTC SEQ ID NO: 14 TCTCCCACCCTACCTAACTCA SEQ ID NO: 15 CTCCCACCCCTCCTAACTCAC SEQ ID NO: 16 TCCCACCCCATCTAACTCACA SEQ ID NO: 17 CCCACCCCACTTAACTCACAC SEQ ID NO: 18 CCACCCCACCTAACTCACACA SEQ ID NO: 19 CACCCCACCTTACTCACACAA SEQ ID NO: 20 ACCCCACCTATCTCACACAAA SEQ ID NO: 21 CCCCACCTAATTCACACAAAC SEQ ID NO: 22 CCCACCTAACTCACACAAACC SEQ ID NO: 23 CCACCTAACTTACACAAACCA SEQ ID NO: 24 CACCTAACTCTCACAAACCAC SEQ ID NO: 25 ACCTAACTCATACAAACCACC SEQ ID NO: 26 ATATAGTTTCGTCATTCATC SEQ ID NO: 27 TACATTGCCCATGTAATTAA SEQ ID NO: 28 ATATAGTTTCGTCATTCATC SEQ ID NO: 29 TACATTGCCCATGTAATTAA SEQ ID NO: 30 AGATAGTTTTGTCATTCATC SEQ ID NO: 31 AGATAGTTTCTTCATTCATC SEQ ID NO: 32 AGATAGTTTCGTCATTCATC SEQ ID NO: 33 AGATAGTTTCGTTATTCATC SEQ ID NO: 34 CCTAACTCACTCAAACCACCA SEQ ID NO: 35 CTAACTCACATAAACCACCAA SEQ ID NO: 36 TAACTCACACTAACCACCAAC SEQ ID NO: 37 AACCAACCAAGAATCTCCCAC SEQ ID NO: 38 ACCAACCAATGATCTCCCACC SEQ ID NO: 39 CCAACCAATAGTCTCCCACCC SEQ ID NO: 40 CAACCAATAAGCTCCCACCCC SEQ ID NO: 41 AACCAATAATGTCCCACCCCA SEQ ID NO: 42 ACCAATAATCGCCCACCCCAC SEQ ID NO: 43 CCAATAATCTGCCACCCCACC SEQ ID NO: 44 CAATAATCTCGCACCCCACCT SEQ ID NO: 45 AATAATCTCCGACCCCACCTA SEQ ID NO: 46 ATAATCTCCCGCCCCACCTAA SEQ ID NO: 47 TAATCTCCCAGCCCACCTAAC SEQ ID NO: 48 AATCTCCCACGCCACCTAACT SEQ ID NO: 49 ATCTCCCACCGCACCTAACTC SEQ ID NO: 50 TCTCCCACCCGACCTAACTCA SEQ ID NO: 51 CTCCCACCCCGCCTAACTCAC SEQ ID NO: 52 TCCCACCCCAGCTAACTCACA SEQ ID NO: 53 CCCACCCCACGTAACTCACAC SEQ ID NO: 54 CCACCCCACCGAACTCACACA SEQ ID NO: 55 CACCCCACCTGACTCACACAA SEQ ID NO: 56 ACCCCACCTAGCTCACACAAA SEQ ID NO: 57 CCCCACCTAAGTCACACAAAC SEQ ID NO: 58 CCCACCTAACGCACACAAACC SEQ ID NO: 59 CCACCTAACTGACACAAACCA SEQ ID NO: 60 CACCTAACTCGCACAAACCAC SEQ ID NO: 61 ACCTAACTCAGACAAACCACC SEQ ID NO: 62 TACATTGCCCATGTAATTAA SEQ ID NO: 63 ATATAGTTTCGTCATTCATC SEQ ID NO: 64 TACATTGCCCATGTAATTAA SEQ ID NO: 65 ATATAGTTTCGTCATTCATC SEQ ID NO: 66 AGATAGTTTGGTCATTCATC SEQ ID NO: 67 AGATAGTTTCGTCATTCATC SEQ ID NO: 68 AGATAGTTTCGGCATTCATC SEQ ID NO: 69 AGATAGTTTCGTGATTCATC SEQ ID NO: 70 CCTAACTCACGCAAACCACCA SEQ ID NO: 71 CTAACTCACAGAAACCACCAA SEQ ID NO: 72 TAACTCACACGAACCACCAAC SEQ ID NO: 73 AACCAACCAACAATCTCCCAC SEQ ID NO: 74 ACCAACCAATCATCTCCCACC SEQ ID NO: 75 CCAACCAATACTCTCCCACCC SEQ ID NO: 76 CAACCAATAACCTCCCACCCC SEQ ID NO: 77 AACCAATAATCTCCCACCCCA SEQ ID NO: 78 ACCAATAATCCCCCACCCCAC SEQ ID NO: 79 CCAATAATCTCCCACCCCACC SEQ ID NO: 80 CAATAATCTCCCACCCCACCT SEQ ID NO: 81 AATAATCTCCCACCCCACCTA SEQ ID NO: 82 ATAATCTCCCCCCCCACCTAA SEQ ID NO: 83 TAATCTCCCACCCCACCTAAC SEQ ID NO: 84 AATCTCCCACCCCACCTAACT SEQ ID NO: 85 ATCTCCCACCCCACCTAACTC SEQ ID NO: 86 TCTCCCACCCCACCTAACTCA SEQ ID NO: 87 CTCCCACCCCCCCTAACTCAC SEQ ID NO: 88 TCCCACCCCACCTAACTCACA SEQ ID NO: 89 CCCACCCCACCTAACTCACAC SEQ ID NO: 90 CCACCCCACCCAACTCACACA SEQ ID NO: 91 CACCCCACCTCACTCACACAA SEQ ID NO: 92 ACCCCACCTACCTCACACAAA SEQ ID NO: 93 CCCCACCTAACTCACACAAAC SEQ ID NO: 94 CCCACCTAACCCACACAAACC SEQ ID NO: 95 CCACCTAACTCACACAAACCA SEQ ID NO: 96 CACCTAACTCCCACAAACCAC SEQ ID NO: 97 ACCTAACTCACACAAACCACC SEQ ID NO: 98 ATATAGTTTCGTCATTCATC SEQ ID NO: 99 TACATTGCCCATGTAATTAA SEQ ID NO: 100 ATATAGTTTCGTCATTCATC SEQ ID NO: 101 TACATTGCCCATGTAATTAA SEQ ID NO: 102 AGATAGTTTCGTCATTCATC SEQ ID NO: 103 AGATAGTTTCCTCATTCATC SEQ ID NO: 104 AGATAGTTTCGCCATTCATC SEQ ID NO: 105 AGATAGTTTCGTCATTCATC SEQ ID NO: 106 CCTAACTCACCCAAACCACCA SEQ ID NO: 107 CTAACTCACACAAACCACCAA SEQ ID NO: 108 TAACTCACACCAACCACCAAC SEQ ID NO: 109 AACCAACCAAAAATCTCCCAC SEQ ID NO: 110 ACCAACCAATAATCTCCCACC SEQ ID NO: 111 CCAACCAATAATCTCCCACCC SEQ ID NO: 112 CAACCAATAAACTCCCACCCC SEQ ID NO: 113 AACCAATAATATCCCACCCCA SEQ ID NO: 114 ACCAATAATCACCCACCCCAC SEQ ID NO: 115 CCAATAATCTACCACCCCACC SEQ ID NO: 116 CAATAATCTCACACCCCACCT SEQ ID NO: 117 AATAATCTCCAACCCCACCTA SEQ ID NO: 118 ATAATCTCCCACCCCACCTAA SEQ ID NO: 119 TAATCTCCCAACCCACCTAAC SEQ ID NO: 120 AATCTCCCACACCACCTAACT SEQ ID NO: 121 ATCTCCCACCACACCTAACTC SEQ ID NO: 122 TCTCCCACCCAACCTAACTCA SEQ ID NO: 123 CTCCCACCCCACCTAACTCAC SEQ ID NO: 124 TCCCACCCCAACTAACTCACA SEQ ID NO: 125 CCCACCCCACATAACTCACAC SEQ ID NO: 126 CCACCCCACCAAACTCACACA SEQ ID NO: 127 CACCCCACCTAACTCACACAA SEQ ID NO: 128 ACCCCACCTAACTCACACAAA SEQ ID NO: 129 CCCCACCTAAATCACACAAAC SEQ ID NO: 130 CCCACCTAACACACACAAACC SEQ ID NO: 131 CCACCTAACTAACACAAACCA SEQ ID NO: 132 CACCTAACTCACACAAACCAC SEQ ID NO: 133 ACCTAACTCAAACAAACCACC SEQ ID NO: 134 TACATTGCCCATGTAATTAA SEQ ID NO: 135 ATATAGTTTCGTCATTCATC SEQ ID NO: 136 TACATTGCCCATGTAATTAA SEQ ID NO: 137 ATATAGTTTCGTCATTCATC SEQ ID NO: 138 AGATAGTTTAGTCATTCATC SEQ ID NO: 139 AGATAGTTTCATCATTCATC SEQ ID NO: 140 AGATAGTTTCGACATTCATC SEQ ID NO: 141 AGATAGTTTCGTAATTCATC SEQ ID NO: 142 CCTAACTCACACAAACCACCA SEQ ID NO: 143 CTAACTCACAAAAACCACCAA SEQ ID NO: 144 TAACTCACACAAACCACCAAC SEQ ID NO: 145 AACTCACACATACCACCAACA SEQ ID NO: 146 ACTCACACAATCCACCAACAC SEQ ID NO: 147 CTCACACAAATCACCAACACC SEQ ID NO: 148 TCACACAAACTACCAACACCT SEQ ID NO: 149 CACACAAACCTCCAACACCTC SEQ ID NO: 150 ACACAAACCATCAACACCTCT SEQ ID NO: 151 CACAAACCACTAACACCTCTC SEQ ID NO: 152 ACAAACCACCTACACCTCTCC SEQ ID NO: 153 CAAACCACCATCACCTCTCCC SEQ ID NO: 154 AAACCACCAATACCTCTCCCC SEQ ID NO: 155 AACCACCAACTCCTCTCCCCC SEQ ID NO: 156 ACCACCAACATCTCTCCCCCT SEQ ID NO: 157 CCACCAACACTTCTCCCCCTC SEQ ID NO: 158 CACCAACACCTCTCCCCCTCT SEQ ID NO: 159 ACCAACACCTTTCCCCCTCTC SEQ ID NO: 160 CCAACACCTCTCCCCCTCTCA SEQ ID NO: 161 CAACACCTCTTCCCCTCTCAT SEQ ID NO: 162 AACACCTCTCTCCCTCTCATC SEQ ID NO: 163 ACACCTCTCCTCCTCTCATCC SEQ ID NO: 164 CACCTCTCCCTCTCTCATCCA SEQ ID NO: 165 ACCTCTCCCCTTCTCATCCAT SEQ ID NO: 166 CCTCTCCCCCTCTCATCCATC SEQ ID NO: 167 ATATAGTTTCGTCATTCATC SEQ ID NO: 168 TACATTGCCCATGTAATTAA SEQ ID NO: 169 ATATAGTTTCGTCATTCATC SEQ ID NO: 170 TACATTGCCCATGTAATTAA SEQ ID NO: 171 AGATAGTTTTGTCATTCATC SEQ ID NO: 172 AGATAGTTTCTTCATTCATC SEQ ID NO: 173 AGATAGTTTCGTCATTCATC SEQ ID NO: 174 AGATAGTTTCGTTATTCATC SEQ ID NO: 175 CTCTCCCCCTTTCATCCATCA SEQ ID NO: 176 TCTCCCCCTCTCATCCATCAC SEQ ID NO: 177 CTCCCCCTCTTATCCATCACC SEQ ID NO: 178 TCCCCCTCTCTTCCATCACCC SEQ ID NO: 179 CCCCCTCTCATCCATCACCCA SEQ ID NO: 180 CCCCTCTCATTCATCACCCAC SEQ ID NO: 181 AACTCACACAGACCACCAACA SEQ ID NO: 182 ACTCACACAAGCCACCAACAC SEQ ID NO: 183 CTCACACAAAGCACCAACACC SEQ ID NO: 184 TCACACAAACGACCAACACCT SEQ ID NO: 185 CACACAAACCGCCAACACCTC SEQ ID NO: 186 ACACAAACCAGCAACACCTCT SEQ ID NO: 187 CACAAACCACGAACACCTCTC SEQ ID NO: 188 ACAAACCACCGACACCTCTCC SEQ ID NO: 189 CAAACCACCAGCACCTCTCCC SEQ ID NO: 190 AAACCACCAAGACCTCTCCCC SEQ ID NO: 191 AACCACCAACGCCTCTCCCCC SEQ ID NO: 192 ACCACCAACAGCTCTCCCCCT SEQ ID NO: 193 CCACCAACACGTCTCCCCCTC SEQ ID NO: 194 CACCAACACCGCTCCCCCTCT SEQ ID NO: 195 ACCAACACCTGTCCCCCTCTC SEQ ID NO: 196 CCAACACCTCGCCCCCTCTCA SEQ ID NO: 197 CAACACCTCTGCCCCTCTCAT SEQ ID NO: 198 AACACCTCTCGCCCTCTCATC SEQ ID NO: 199 ACACCTCTCCGCCTCTCATCC SEQ ID NO: 200 CACCTCTCCCGCTCTCATCCA SEQ ID NO: 201 ACCTCTCCCCGTCTCATCCAT SEQ ID NO: 202 CCTCTCCCCCGCTCATCCATC SEQ ID NO: 203 TACATTGCCCATGTAATTAA SEQ ID NO: 204 ATATAGTTTCGTCATTCATC SEQ ID NO: 205 TACATTGCCCATGTAATTAA SEQ ID NO: 206 ATATAGTTTCGTCATTCATC SEQ ID NO: 207 AGATAGTTTGGTCATTCATC SEQ ID NO: 208 AGATAGTTTCGTCATTCATC SEQ ID NO: 209 AGATAGTTTCGGCATTCATC SEQ ID NO: 210 AGATAGTTTCGTGATTCATC SEQ ID NO: 211 CTCTCCCCCTGTCATCCATCA SEQ ID NO: 212 TCTCCCCCTCGCATCCATCAC SEQ ID NO: 213 CTCCCCCTCTGATCCATCACC SEQ ID NO: 214 TCCCCCTCTCGTCCATCACCC SEQ ID NO: 215 CCCCCTCTCAGCCATCACCCA SEQ ID NO: 216 CCCCTCTCATGCATCACCCAC SEQ ID NO: 217 AACTCACACACACCACCAACA SEQ ID NO: 218 ACTCACACAACCCACCAACAC SEQ ID NO: 219 CTCACACAAACCACCAACACC SEQ ID NO: 220 TCACACAAACCACCAACACCT SEQ ID NO: 221 CACACAAACCCCCAACACCTC SEQ ID NO: 222 ACACAAACCACCAACACCTCT SEQ ID NO: 223 CACAAACCACCAACACCTCTC SEQ ID NO: 224 ACAAACCACCCACACCTCTCC SEQ ID NO: 225 CAAACCACCACCACCTCTCCC SEQ ID NO: 226 AAACCACCAACACCTCTCCCC SEQ ID NO: 227 AACCACCAACCCCTCTCCCCC SEQ ID NO: 228 ACCACCAACACCTCTCCCCCT SEQ ID NO: 229 CCACCAACACCTCTCCCCCTC SEQ ID NO: 230 CACCAACACCCCTCCCCCTCT SEQ ID NO: 231 ACCAACACCTCTCCCCCTCTC SEQ ID NO: 232 CCAACACCTCCCCCCCTCTCA SEQ ID NO: 233 CAACACCTCTCCCCCTCTCAT SEQ ID NO: 234 AACACCTCTCCCCCTCTCATC SEQ ID NO: 235 ACACCTCTCCCCCTCTCATCC SEQ ID NO: 236 CACCTCTCCCCCTCTCATCCA SEQ ID NO: 237 ACCTCTCCCCCTCTCATCCAT SEQ ID NO: 238 CCTCTCCCCCCCTCATCCATC SEQ ID NO: 239 ATATAGTTTCGTCATTCATC SEQ ID NO: 240 TACATTGCCCATGTAATTAA SEQ ID NO: 241 ATATAGTTTCGTCATTCATC SEQ ID NO: 242 TACATTGCCCATGTAATTAA SEQ ID NO: 243 AGATAGTTTCGTCATTCATC SEQ ID NO: 244 AGATAGTTTCCTCATTCATC SEQ ID NO: 245 AGATAGTTTCGCCATTCATC SEQ ID NO: 246 AGATAGTTTCGTCATTCATC SEQ ID NO: 247 CTCTCCCCCTCTCATCCATCA SEQ ID NO: 248 TCTCCCCCTCCCATCCATCAC SEQ ID NO: 249 CTCCCCCTCTCATCCATCACC SEQ ID NO: 250 TCCCCCTCTCCTCCATCACCC SEQ ID NO: 251 CCCCCTCTCACCCATCACCCA SEQ ID NO: 252 CCCCTCTCATCCATCACCCAC SEQ ID NO: 253 AACTCACACAAACCACCAACA SEQ ID NO: 254 ACTCACACAAACCACCAACAC SEQ ID NO: 255 CTCACACAAAACACCAACACC SEQ ID NO: 256 TCACACAAACAACCAACACCT SEQ ID NO: 257 CACACAAACCACCAACACCTC SEQ ID NO: 258 ACACAAACCAACAACACCTCT SEQ ID NO: 259 CACAAACCACAAACACCTCTC SEQ ID NO: 260 ACAAACCACCAACACCTCTCC SEQ ID NO: 261 CAAACCACCAACACCTCTCCC SEQ ID NO: 262 AAACCACCAAAACCTCTCCCC SEQ ID NO: 263 AACCACCAACACCTCTCCCCC SEQ ID NO: 264 ACCACCAACAACTCTCCCCCT SEQ ID NO: 265 CCACCAACACATCTCCCCCTC SEQ ID NO: 266 CACCAACACCACTCCCCCTCT SEQ ID NO: 267 ACCAACACCTATCCCCCTCTC SEQ ID NO: 268 CCAACACCTCACCCCCTCTCA SEQ ID NO: 269 CAACACCTCTACCCCTCTCAT SEQ ID NO: 270 AACACCTCTCACCCTCTCATC SEQ ID NO: 271 ACACCTCTCCACCTCTCATCC SEQ ID NO: 272 CACCTCTCCCACTCTCATCCA SEQ ID NO: 273 ACCTCTCCCCATCTCATCCAT SEQ ID NO: 274 CCTCTCCCCCACTCATCCATC SEQ ID NO: 275 TACATTGCCCATGTAATTAA SEQ ID NO: 276 ATATAGTTTCGTCATTCATC SEQ ID NO: 277 TACATTGCCCATGTAATTAA SEQ ID NO: 278 ATATAGTTTCGTCATTCATC SEQ ID NO: 279 AGATAGTTTAGTCATTCATC SEQ ID NO: 280 AGATAGTTTCATCATTCATC SEQ ID NO: 281 AGATAGTTTCGACATTCATC SEQ ID NO: 282 AGATAGTTTCGTAATTCATC SEQ ID NO: 283 CTCTCCCCCTATCATCCATCA SEQ ID NO: 284 TCTCCCCCTCACATCCATCAC SEQ ID NO: 285 CTCCCCCTCTAATCCATCACC SEQ ID NO: 286 TCCCCCTCTCATCCATCACCC SEQ ID NO: 287 CCCCCTCTCAACCATCACCCA SEQ ID NO: 288 CCCCTCTCATACATCACCCAC SEQ ID NO: 289 CCCTCTCATCTATCACCCACC SEQ ID NO: 290 CCTCTCATCCTTCACCCACCA SEQ ID NO: 291 CTCTCATCCATCACCCACCAC SEQ ID NO: 292 TCTCATCCATTACCCACCACC SEQ ID NO: 293 CTCATCCATCTCCCACCACCC SEQ ID NO: 294 TCATCCATCATCCACCACCCC SEQ ID NO: 295 CATCCATCACTCACCACCCCT SEQ ID NO: 296 ATCCATCACCTACCACCCCTC SEQ ID NO: 297 TCCATCACCCTCCACCCCTCA SEQ ID NO: 298 CCATCACCCATCACCCCTCAT SEQ ID NO: 299 CATCACCCACTACCCCTCATC SEQ ID NO: 300 ATCACCCACCTCCCCTCATCA SEQ ID NO: 301 TCACCCACCATCCCTCATCAT SEQ ID NO: 302 CACCCACCACTCCTCATCATA SEQ ID NO: 303 ACCCACCACCTCTCATCATAC SEQ ID NO: 304 CCCACCACCCTTCATCATACC SEQ ID NO: 305 CCACCACCCCTCATCATACCT SEQ ID NO: 306 CACCACCCCTTATCATACCTC SEQ ID NO: 307 ACCACCCCTCTTCATACCTCA SEQ ID NO: 308 ATATAGTTTCGTCATTCATC SEQ ID NO: 309 TACATTGCCCATGTAATTAA SEQ ID NO: 310 ATATAGTTTCGTCATTCATC SEQ ID NO: 311 TACATTGCCCATGTAATTAA SEQ ID NO: 312 AGATAGTTTTGTCATTCATC SEQ ID NO: 313 AGATAGTTTCTTCATTCATC SEQ ID NO: 314 AGATAGTTTCGTCATTCATC SEQ ID NO: 315 AGATAGTTTCGTTATTCATC SEQ ID NO: 316 CCACCCCTCATCATACCTCAA SEQ ID NO: 317 CACCCCTCATTATACCTCAAC SEQ ID NO: 318 ACCCCTCATCTTACCTCAACC SEQ ID NO: 319 CCCCTCATCATACCTCAACCA SEQ ID NO: 320 CCCTCATCATTCCTCAACCAC SEQ ID NO: 321 CCTCATCATATCTCAACCACC SEQ ID NO: 322 CTCATCATACTTCAACCACCA SEQ ID NO: 323 TCATCATACCTCAACCACCAC SEQ ID NO: 324 CATCATACCTTAACCACCACC SEQ ID NO: 325 CCCTCTCATCGATCACCCACC SEQ ID NO: 326 CCTCTCATCCGTCACCCACCA SEQ ID NO: 327 CTCTCATCCAGCACCCACCAC SEQ ID NO: 328 TCTCATCCATGACCCACCACC SEQ ID NO: 329 CTCATCCATCGCCCACCACCC SEQ ID NO: 330 TCATCCATCAGCCACCACCCC SEQ ID NO: 331 CATCCATCACGCACCACCCCT SEQ ID NO: 332 ATCCATCACCGACCACCCCTC SEQ ID NO: 333 TCCATCACCCGCCACCCCTCA SEQ ID NO: 334 CCATCACCCAGCACCCCTCAT SEQ ID NO: 335 CATCACCCACGACCCCTCATC SEQ ID NO: 336 ATCACCCACCGCCCCTCATCA SEQ ID NO: 337 TCACCCACCAGCCCTCATCAT SEQ ID NO: 338 CACCCACCACGCCTCATCATA SEQ ID NO: 339 ACCCACCACCGCTCATCATAC SEQ ID NO: 340 CCCACCACCCGTCATCATACC SEQ ID NO: 341 CCACCACCCCGCATCATACCT SEQ ID NO: 342 CACCACCCCTGATCATACCTC SEQ ID NO: 343 ACCACCCCTCGTCATACCTCA SEQ ID NO: 344 TACATTGCCCATGTAATTAA SEQ ID NO: 345 ATATAGTTTCGTCATTCATC SEQ ID NO: 346 TACATTGCCCATGTAATTAA SEQ ID NO: 347 ATATAGTTTCGTCATTCATC SEQ ID NO: 348 AGATAGTTTGGTCATTCATC SEQ ID NO: 349 AGATAGTTTCGTCATTCATC SEQ ID NO: 350 AGATAGTTTCGGCATTCATC SEQ ID NO: 351 AGATAGTTTCGTGATTCATC SEQ ID NO: 352 CCACCCCTCAGCATACCTCAA SEQ ID NO: 353 CACCCCTCATGATACCTCAAC SEQ ID NO: 354 ACCCCTCATCGTACCTCAACC SEQ ID NO: 355 CCCCTCATCAGACCTCAACCA SEQ ID NO: 356 CCCTCATCATGCCTCAACCAC SEQ ID NO: 357 CCTCATCATAGCTCAACCACC SEQ ID NO: 358 CTCATCATACGTCAACCACCA SEQ ID NO: 359 TCATCATACCGCAACCACCAC SEQ ID NO: 360 CATCATACCTGAACCACCACC SEQ ID NO: 361 CCCTCTCATCCATCACCCACC SEQ ID NO: 362 CCTCTCATCCCTCACCCACCA SEQ ID NO: 363 CTCTCATCCACCACCCACCAC SEQ ID NO: 364 TCTCATCCATCACCCACCACC SEQ ID NO: 365 CTCATCCATCCCCCACCACCC SEQ ID NO: 366 TCATCCATCACCCACCACCCC SEQ ID NO: 367 CATCCATCACCCACCACCCCT SEQ ID NO: 368 ATCCATCACCCACCACCCCTC SEQ ID NO: 369 TCCATCACCCCCCACCCCTCA SEQ ID NO: 370 CCATCACCCACCACCCCTCAT SEQ ID NO: 371 CATCACCCACCACCCCTCATC SEQ ID NO: 372 ATCACCCACCCCCCCTCATCA SEQ ID NO: 373 TCACCCACCACCCCTCATCAT SEQ ID NO: 374 CACCCACCACCCCTCATCATA SEQ ID NO: 375 ACCCACCACCCCTCATCATAC SEQ ID NO: 376 CCCACCACCCCTCATCATACC SEQ ID NO: 377 CCACCACCCCCCATCATACCT SEQ ID NO: 378 CACCACCCCTCATCATACCTC SEQ ID NO: 379 ACCACCCCTCCTCATACCTCA SEQ ID NO: 380 ATATAGTTTCGTCATTCATC SEQ ID NO: 381 TACATTGCCCATGTAATTAA SEQ ID NO: 382 ATATAGTTTCGTCATTCATC SEQ ID NO: 383 TACATTGCCCATGTAATTAA SEQ ID NO: 384 AGATAGTTTCGTCATTCATC SEQ ID NO: 385 AGATAGTTTCCTCATTCATC SEQ ID NO: 386 AGATAGTTTCGCCATTCATC SEQ ID NO: 387 AGATAGTTTCGTCATTCATC SEQ ID NO: 388 CCACCCCTCACCATACCTCAA SEQ ID NO: 389 CACCCCTCATCATACCTCAAC SEQ ID NO: 390 ACCCCTCATCCTACCTCAACC SEQ ID NO: 391 CCCCTCATCACACCTCAACCA SEQ ID NO: 392 CCCTCATCATCCCTCAACCAC SEQ ID NO: 393 CCTCATCATACCTCAACCACC SEQ ID NO: 394 CTCATCATACCTCAACCACCA SEQ ID NO: 395 TCATCATACCCCAACCACCAC SEQ ID NO: 396 CATCATACCTCAACCACCACC SEQ ID NO: 397 CCCTCTCATCAATCACCCACC SEQ ID NO: 398 CCTCTCATCCATCACCCACCA SEQ ID NO: 399 CTCTCATCCAACACCCACCAC SEQ ID NO: 400 TCTCATCCATAACCCACCACC SEQ ID NO: 401 CTCATCCATCACCCACCACCC SEQ ID NO: 402 TCATCCATCAACCACCACCCC SEQ ID NO: 403 CATCCATCACACACCACCCCT SEQ ID NO: 404 ATCCATCACCAACCACCCCTC SEQ ID NO: 405 TCCATCACCCACCACCCCTCA SEQ ID NO: 406 CCATCACCCAACACCCCTCAT SEQ ID NO: 407 CATCACCCACAACCCCTCATC SEQ ID NO: 408 ATCACCCACCACCCCTCATCA SEQ ID NO: 409 TCACCCACCAACCCTCATCAT SEQ ID NO: 410 CACCCACCACACCTCATCATA SEQ ID NO: 411 ACCCACCACCACTCATCATAC SEQ ID NO: 412 CCCACCACCCATCATCATACC SEQ ID NO: 413 CCACCACCCCACATCATACCT SEQ ID NO: 414 CACCACCCCTAATCATACCTC SEQ ID NO: 415 ACCACCCCTCATCATACCTCA SEQ ID NO: 416 TACATTGCCCATGTAATTAA SEQ ID NO: 417 ATATAGTTTCGTCATTCATC SEQ ID NO: 418 TACATTGCCCATGTAATTAA SEQ ID NO: 419 ATATAGTTTCGTCATTCATC SEQ ID NO: 420 AGATAGTTTAGTCATTCATC SEQ ID NO: 421 AGATAGTTTCATCATTCATC SEQ ID NO: 422 AGATAGTTTCGACATTCATC SEQ ID NO: 423 AGATAGTTTCGTAATTCATC SEQ ID NO: 424 CCACCCCTCAACATACCTCAA SEQ ID NO: 425 CACCCCTCATAATACCTCAAC SEQ ID NO: 426 ACCCCTCATCATACCTCAACC SEQ ID NO: 427 CCCCTCATCAAACCTCAACCA SEQ ID NO: 428 CCCTCATCATACCTCAACCAC SEQ ID NO: 429 CCTCATCATAACTCAACCACC SEQ ID NO: 430 CTCATCATACATCAACCACCA SEQ ID NO: 431 TCATCATACCACAACCACCAC SEQ ID NO: 432 CATCATACCTAAACCACCACC SEQ ID NO: 433 ATCATACCTCTACCACCACCC SEQ ID NO: 434 TCATACCTCATCCACCACCCC SEQ ID NO: 435 CATACCTCAATCACCACCCCT SEQ ID NO: 436 ATACCTCAACTACCACCCCTC SEQ ID NO: 437 TACCTCAACCTCCACCCCTCA SEQ ID NO: 438 ACCTCAACCATCACCCCTCAT SEQ ID NO: 439 CCTCAACCACTACCCCTCATC SEQ ID NO: 440 CTCAACCACCTCCCCTCATCA SEQ ID NO: 441 TCAACCACCATCCCTCATCAT SEQ ID NO: 442 CAACCACCACTCCTCATCATA SEQ ID NO: 443 AACCACCACCTCTCATCATAC SEQ ID NO: 444 ACCACCACCCTTCATCATACC SEQ ID NO: 445 CCACCACCCCTCATCATACCT SEQ ID NO: 446 CACCACCCCTTATCATACCTC SEQ ID NO: 447 ACCACCCCTCTTCATACCTCA SEQ ID NO: 448 CCACCCCTCATCATACCTCAA SEQ ID NO: 449 ATATAGTTTCGTCATTCATC SEQ ID NO: 450 TACATTGCCCATGTAATTAA SEQ ID NO: 451 ATATAGTTTCGTCATTCATC SEQ ID NO: 452 TACATTGCCCATGTAATTAA SEQ ID NO: 453 AGATAGTTTTGTCATTCATC SEQ ID NO: 454 AGATAGTTTCTTCATTCATC SEQ ID NO: 455 AGATAGTTTCGTCATTCATC SEQ ID NO: 456 AGATAGTTTCGTTATTCATC SEQ ID NO: 457 CACCCCTCATTATACCTCAAA SEQ ID NO: 458 ACCCCTCATCTTACCTCAAAA SEQ ID NO: 459 CCCCTCATCATACCTCAAAAA SEQ ID NO: 460 CCCTCATCATTCCTCAAAAAC SEQ ID NO: 461 CCTCATCATATCTCAAAAACC SEQ ID NO: 462 CTCATCATACTTCAAAAACCA SEQ ID NO: 463 TCATCATACCTCAAAAACCAA SEQ ID NO: 464 CATCATACCTTAAAAACCAAC SEQ ID NO: 465 ATCATACCTCTAAAACCAACT SEQ ID NO: 466 TCATACCTCATAAACCAACTA SEQ ID NO: 467 CATACCTCAATAACCAACTAA SEQ ID NO: 468 ATACCTCAAATACCAACTAAC SEQ ID NO: 469 ATCATACCTCGACCACCACCC SEQ ID NO: 470 TCATACCTCAGCCACCACCCC SEQ ID NO: 471 CATACCTCAAGCACCACCCCT SEQ ID NO: 472 ATACCTCAACGACCACCCCTC SEQ ID NO: 473 TACCTCAACCGCCACCCCTCA SEQ ID NO: 474 ACCTCAACCAGCACCCCTCAT SEQ ID NO: 475 CCTCAACCACGACCCCTCATC SEQ ID NO: 476 CTCAACCACCGCCCCTCATCA SEQ ID NO: 477 TCAACCACCAGCCCTCATCAT SEQ ID NO: 478 CAACCACCACGCCTCATCATA SEQ ID NO: 479 AACCACCACCGCTCATCATAC SEQ ID NO: 480 ACCACCACCCGTCATCATACC SEQ ID NO: 481 CCACCACCCCGCATCATACCT SEQ ID NO: 482 CACCACCCCTGATCATACCTC SEQ ID NO: 483 ACCACCCCTCGTCATACCTCA SEQ ID NO: 484 CCACCCCTCAGCATACCTCAA SEQ ID NO: 485 TACATTGCCCATGTAATTAA SEQ ID NO: 486 ATATAGTTTCGTCATTCATC SEQ ID NO: 487 TACATTGCCCATGTAATTAA SEQ ID NO: 488 ATATAGTTTCGTCATTCATC SEQ ID NO: 489 AGATAGTTTGGTCATTCATC SEQ ID NO: 490 AGATAGTTTCGTCATTCATC SEQ ID NO: 491 AGATAGTTTCGGCATTCATC SEQ ID NO: 492 AGATAGTTTCGTGATTCATC SEQ ID NO: 493 CACCCCTCATGATACCTCAAA SEQ ID NO: 494 ACCCCTCATCGTACCTCAAAA SEQ ID NO: 495 CCCCTCATCAGACCTCAAAAA SEQ ID NO: 496 CCCTCATCATGCCTCAAAAAC SEQ ID NO: 497 CCTCATCATAGCTCAAAAACC SEQ ID NO: 498 CTCATCATACGTCAAAAACCA SEQ ID NO: 499 TCATCATACCGCAAAAACCAA SEQ ID NO: 500 CATCATACCTGAAAAACCAAC SEQ ID NO: 501 ATCATACCTCGAAAACCAACT SEQ ID NO: 502 TCATACCTCAGAAACCAACTA SEQ ID NO: 503 CATACCTCAAGAACCAACTAA SEQ ID NO: 504 ATACCTCAAAGACCAACTAAC SEQ ID NO: 505 ATCATACCTCCACCACCACCC SEQ ID NO: 506 TCATACCTCACCCACCACCCC SEQ ID NO: 507 CATACCTCAACCACCACCCCT SEQ ID NO: 508 ATACCTCAACCACCACCCCTC SEQ ID NO: 509 TACCTCAACCCCCACCCCTCA SEQ ID NO: 510 ACCTCAACCACCACCCCTCAT SEQ ID NO: 511 CCTCAACCACCACCCCTCATC SEQ ID NO: 512 CTCAACCACCCCCCCTCATCA SEQ ID NO: 513 TCAACCACCACCCCTCATCAT SEQ ID NO: 514 CAACCACCACCCCTCATCATA SEQ ID NO: 515 AACCACCACCCCTCATCATAC SEQ ID NO: 516 ACCACCACCCCTCATCATACC SEQ ID NO: 517 CCACCACCCCCCATCATACCT SEQ ID NO: 518 CACCACCCCTCATCATACCTC SEQ ID NO: 519 ACCACCCCTCCTCATACCTCA SEQ ID NO: 520 CCACCCCTCACCATACCTCAA SEQ ID NO: 521 ATATAGTTTCGTCATTCATC SEQ ID NO: 522 TACATTGCCCATGTAATTAA SEQ ID NO: 523 ATATAGTTTCGTCATTCATC SEQ ID NO: 524 TACATTGCCCATGTAATTAA SEQ ID NO: 525 AGATAGTTTCGTCATTCATC SEQ ID NO: 526 AGATAGTTTCCTCATTCATC SEQ ID NO: 527 AGATAGTTTCGCCATTCATC SEQ ID NO: 528 AGATAGTTTCGTCATTCATC SEQ ID NO: 529 CACCCCTCATCATACCTCAAA SEQ ID NO: 530 ACCCCTCATCCTACCTCAAAA SEQ ID NO: 531 CCCCTCATCACACCTCAAAAA SEQ ID NO: 532 CCCTCATCATCCCTCAAAAAC SEQ ID NO: 533 CCTCATCATACCTCAAAAACC SEQ ID NO: 534 CTCATCATACCTCAAAAACCA SEQ ID NO: 535 TCATCATACCCCAAAAACCAA SEQ ID NO: 536 CATCATACCTCAAAAACCAAC SEQ ID NO: 537 ATCATACCTCCAAAACCAACT SEQ ID NO: 538 TCATACCTCACAAACCAACTA SEQ ID NO: 539 CATACCTCAACAACCAACTAA SEQ ID NO: 540 ATACCTCAAACACCAACTAAC SEQ ID NO: 541 ATCATACCTCAACCACCACCC SEQ ID NO: 542 TCATACCTCAACCACCACCCC SEQ ID NO: 543 CATACCTCAAACACCACCCCT SEQ ID NO: 544 ATACCTCAACAACCACCCCTC SEQ ID NO: 545 TACCTCAACCACCACCCCTCA SEQ ID NO: 546 ACCTCAACCAACACCCCTCAT SEQ ID NO: 547 CCTCAACCACAACCCCTCATC SEQ ID NO: 548 CTCAACCACCACCCCTCATCA SEQ ID NO: 549 TCAACCACCAACCCTCATCAT SEQ ID NO: 550 CAACCACCACACCTCATCATA SEQ ID NO: 551 AACCACCACCACTCATCATAC SEQ ID NO: 552 ACCACCACCCATCATCATACC SEQ ID NO: 553 CCACCACCCCACATCATACCT SEQ ID NO: 554 CACCACCCCTAATCATACCTC SEQ ID NO: 555 ACCACCCCTCATCATACCTCA SEQ ID NO: 556 CCACCCCTCAACATACCTCAA SEQ ID NO: 557 TACATTGCCCATGTAATTAA SEQ ID NO: 558 ATATAGTTTCGTCATTCATC SEQ ID NO: 559 TACATTGCCCATGTAATTAA SEQ ID NO: 560 ATATAGTTTCGTCATTCATC SEQ ID NO: 561 AGATAGTTTAGTCATTCATC SEQ ID NO: 562 AGATAGTTTCATCATTCATC SEQ ID NO: 563 AGATAGTTTCGACATTCATC SEQ ID NO: 564 AGATAGTTTCGTAATTCATC SEQ ID NO: 565 CACCCCTCATAATACCTCAAA SEQ ID NO: 566 ACCCCTCATCATACCTCAAAA SEQ ID NO: 567 CCCCTCATCAAACCTCAAAAA SEQ ID NO: 568 CCCTCATCATACCTCAAAAAC SEQ ID NO: 569 CCTCATCATAACTCAAAAACC SEQ ID NO: 570 CTCATCATACATCAAAAACCA SEQ ID NO: 571 TCATCATACCACAAAAACCAA SEQ ID NO: 572 CATCATACCTAAAAAACCAAC SEQ ID NO: 573 ATCATACCTCAAAAACCAACT SEQ ID NO: 574 TCATACCTCAAAAACCAACTA SEQ ID NO: 575 CATACCTCAAAAACCAACTAA SEQ ID NO: 576 ATACCTCAAAAACCAACTAAC SEQ ID NO: 577 TACCTCAAAATCCAACTAACC SEQ ID NO: 578 ACCTCAAAAATCAACTAACCA SEQ ID NO: 579 CCTCAAAAACTAACTAACCAA SEQ ID NO: 580 CTCAAAAACCTACTAACCAAC SEQ ID NO: 581 TCAAAAACCATCTAACCAACC SEQ ID NO: 582 CAAAAACCAATTAACCAACCA SEQ ID NO: 583 AAAAACCAACTAACCAACCAA SEQ ID NO: 584 AAAACCAACTTACCAACCAAT SEQ ID NO: 585 AACCAACCAATAATCTCCCAC SEQ ID NO: 586 ACCAACCAATTATCTCCCACC SEQ ID NO: 587 CCAACCAATATTCTCCCACCC SEQ ID NO: 588 CAACCAATAATCTCCCACCCC SEQ ID NO: 589 AACCAATAATTTCCCACCCCG SEQ ID NO: 590 ATATAGTTTCGTCATTCATC SEQ ID NO: 591 TACATTGCCCATGTAATTAA SEQ ID NO: 592 ATATAGTTTCGTCATTCATC SEQ ID NO: 593 TACATTGCCCATGTAATTAA SEQ ID NO: 594 AGATAGTTTTGTCATTCATC SEQ ID NO: 595 AGATAGTTTCTTCATTCATC SEQ ID NO: 596 AGATAGTTTCGTCATTCATC SEQ ID NO: 597 AGATAGTTTCGTTATTCATC SEQ ID NO: 598 ACCAATAATCTCCCACCCCGC SEQ ID NO: 599 CCAATAATCTTCCACCCCGCC SEQ ID NO: 600 CAATAATCTCTCACCCCGCCT SEQ ID NO: 601 AATAATCTCCTACCCCGCCTA SEQ ID NO: 602 ATAATCTCCCTCCCCGCCTAG SEQ ID NO: 603 TAATCTCCCATCCCGCCTAGC SEQ ID NO: 604 AATCTCCCACTCCGCCTAGCT SEQ ID NO: 605 ATCTCCCACCTCGCCTAGCTC SEQ ID NO: 606 TCTCCCACCCTGCCTAGCTCA SEQ ID NO: 607 CTCCCACCCCTCCTAGCTCAC SEQ ID NO: 608 TCCCACCCCGTCTAGCTCACG SEQ ID NO: 609 CCCACCCCGCTTAGCTCACGC SEQ ID NO: 610 CCACCCCGCCTAGCTCACGCA SEQ ID NO: 611 CACCCCGCCTTGCTCACGCAA SEQ ID NO: 612 ACCCCGCCTATCTCACGCAAG SEQ ID NO: 613 TACCTCAAAAGCCAACTAACC SEQ ID NO: 614 ACCTCAAAAAGCAACTAACCA SEQ ID NO: 615 CCTCAAAAACGAACTAACCAA SEQ ID NO: 616 CTCAAAAACCGACTAACCAAC SEQ ID NO: 617 TCAAAAACCAGCTAACCAACC SEQ ID NO: 618 CAAAAACCAAGTAACCAACCA SEQ ID NO: 619 AAAAACCAACGAACCAACCAA SEQ ID NO: 620 AAAACCAACTGACCAACCAAT SEQ ID NO: 621 AACCAACCAAGAATCTCCCAC SEQ ID NO: 622 ACCAACCAATGATCTCCCACC SEQ ID NO: 623 CCAACCAATAGTCTCCCACCC SEQ ID NO: 624 CAACCAATAAGCTCCCACCCC SEQ ID NO: 625 AACCAATAATGTCCCACCCCG SEQ ID NO: 626 TACATTGCCCATGTAATTAA SEQ ID NO: 627 ATATAGTTTCGTCATTCATC SEQ ID NO: 628 TACATTGCCCATGTAATTAA SEQ ID NO: 629 ATATAGTTTCGTCATTCATC SEQ ID NO: 630 AGATAGTTTGGTCATTCATC SEQ ID NO: 631 AGATAGTTTCGTCATTCATC SEQ ID NO: 632 AGATAGTTTCGGCATTCATC SEQ ID NO: 633 AGATAGTTTCGTGATTCATC SEQ ID NO: 634 ACCAATAATCGCCCACCCCGC SEQ ID NO: 635 CCAATAATCTGCCACCCCGCC SEQ ID NO: 636 CAATAATCTCGCACCCCGCCT SEQ ID NO: 637 AATAATCTCCGACCCCGCCTA SEQ ID NO: 638 ATAATCTCCCGCCCCGCCTAG SEQ ID NO: 639 TAATCTCCCAGCCCGCCTAGC SEQ ID NO: 640 AATCTCCCACGCCGCCTAGCT SEQ ID NO: 641 ATCTCCCACCGCGCCTAGCTC SEQ ID NO: 642 TCTCCCACCCGGCCTAGCTCA SEQ ID NO: 643 CTCCCACCCCGCCTAGCTCAC SEQ ID NO: 644 TCCCACCCCGGCTAGCTCACG SEQ ID NO: 645 CCCACCCCGCGTAGCTCACGC SEQ ID NO: 646 CCACCCCGCCGAGCTCACGCA SEQ ID NO: 647 CACCCCGCCTGGCTCACGCAA SEQ ID NO: 648 ACCCCGCCTAGCTCACGCAAG SEQ ID NO: 649 TACCTCAAAACCCAACTAACC SEQ ID NO: 650 ACCTCAAAAACCAACTAACCA SEQ ID NO: 651 CCTCAAAAACCAACTAACCAA SEQ ID NO: 652 CTCAAAAACCCACTAACCAAC SEQ ID NO: 653 TCAAAAACCACCTAACCAACC SEQ ID NO: 654 CAAAAACCAACTAACCAACCA SEQ ID NO: 655 AAAAACCAACCAACCAACCAA SEQ ID NO: 656 AAAACCAACTCACCAACCAAT SEQ ID NO: 657 AACCAACCAACAATCTCCCAC SEQ ID NO: 658 ACCAACCAATCATCTCCCACC SEQ ID NO: 659 CCAACCAATACTCTCCCACCC SEQ ID NO: 660 CAACCAATAACCTCCCACCCC SEQ ID NO: 661 AACCAATAATCTCCCACCCCG SEQ ID NO: 662 ATATAGTTTCGTCATTCATC SEQ ID NO: 663 TACATTGCCCATGTAATTAA SEQ ID NO: 664 ATATAGTTTCGTCATTCATC SEQ ID NO: 665 TACATTGCCCATGTAATTAA SEQ ID NO: 666 AGATAGTTTCGTCATTCATC SEQ ID NO: 667 AGATAGTTTCCTCATTCATC SEQ ID NO: 668 AGATAGTTTCGCCATTCATC SEQ ID NO: 669 AGATAGTTTCGTCATTCATC SEQ ID NO: 670 ACCAATAATCCCCCACCCCGC SEQ ID NO: 671 CCAATAATCTCCCACCCCGCC SEQ ID NO: 672 CAATAATCTCCCACCCCGCCT SEQ ID NO: 673 AATAATCTCCCACCCCGCCTA SEQ ID NO: 674 ATAATCTCCCCCCCCGCCTAG SEQ ID NO: 675 TAATCTCCCACCCCGCCTAGC SEQ ID NO: 676 AATCTCCCACCCCGCCTAGCT SEQ ID NO: 677 ATCTCCCACCCCGCCTAGCTC SEQ ID NO: 678 TCTCCCACCCCGCCTAGCTCA SEQ ID NO: 679 CTCCCACCCCCCCTAGCTCAC SEQ ID NO: 680 TCCCACCCCGCCTAGCTCACG SEQ ID NO: 681 CCCACCCCGCCTAGCTCACGC SEQ ID NO: 682 CCACCCCGCCCAGCTCACGCA SEQ ID NO: 683 CACCCCGCCTCGCTCACGCAA SEQ ID NO: 684 ACCCCGCCTACCTCACGCAAG SEQ ID NO: 685 TACCTCAAAAACCAACTAACC SEQ ID NO: 686 ACCTCAAAAAACAACTAACCA SEQ ID NO: 687 CCTCAAAAACAAACTAACCAA SEQ ID NO: 688 CTCAAAAACCAACTAACCAAC SEQ ID NO: 689 TCAAAAACCAACTAACCAACC SEQ ID NO: 690 CAAAAACCAAATAACCAACCA SEQ ID NO: 691 AAAAACCAACAAACCAACCAA SEQ ID NO: 692 AAAACCAACTAACCAACCAAT SEQ ID NO: 693 AACCAACCAAAAATCTCCCAC SEQ ID NO: 694 ACCAACCAATAATCTCCCACC SEQ ID NO: 695 CCAACCAATAATCTCCCACCC SEQ ID NO: 696 CAACCAATAAACTCCCACCCC SEQ ID NO: 697 AACCAATAATATCCCACCCCG SEQ ID NO: 698 TACATTGCCCATGTAATTAA SEQ ID NO: 699 ATATAGTTTCGTCATTCATC SEQ ID NO: 700 TACATTGCCCATGTAATTAA SEQ ID NO: 701 ATATAGTTTCGTCATTCATC SEQ ID NO: 702 AGATAGTTTAGTCATTCATC SEQ ID NO: 703 AGATAGTTTCATCATTCATC SEQ ID NO: 704 AGATAGTTTCGACATTCATC SEQ ID NO: 705 AGATAGTTTCGTAATTCATC SEQ ID NO: 706 ACCAATAATCACCCACCCCGC SEQ ID NO: 707 CCAATAATCTACCACCCCGCC SEQ ID NO: 708 CAATAATCTCACACCCCGCCT SEQ ID NO: 709 AATAATCTCCAACCCCGCCTA SEQ ID NO: 710 ATAATCTCCCACCCCGCCTAG SEQ ID NO: 711 TAATCTCCCAACCCGCCTAGC SEQ ID NO: 712 AATCTCCCACACCGCCTAGCT SEQ ID NO: 713 ATCTCCCACCACGCCTAGCTC SEQ ID NO: 714 TCTCCCACCCAGCCTAGCTCA SEQ ID NO: 715 CTCCCACCCCACCTAGCTCAC SEQ ID NO: 716 TCCCACCCCGACTAGCTCACG SEQ ID NO: 717 CCCACCCCGCATAGCTCACGC SEQ ID NO: 718 CCACCCCGCCAAGCTCACGCA SEQ ID NO: 719 CACCCCGCCTAGCTCACGCAA SEQ ID NO: 720 ACCCCGCCTAACTCACGCAAG SEQ ID NO: 721 CCCCGCCTAGTTCACGCAAGC SEQ ID NO: 722 CCCGCCTAGCTCACGCAAGCC SEQ ID NO: 723 CCGCCTAGCTTACGCAAGCCG SEQ ID NO: 724 CGCCTAGCTCTCGCAAGCCGC SEQ ID NO: 725 GCCTAGCTCATGCAAGCCGCC SEQ ID NO: 726 CCTAGCTCACTCAAGCCGCCA SEQ ID NO: 727 CTAGCTCACGTAAGCCGCCAA SEQ ID NO: 728 TAGCTCACGCTAGCCGCCAAC SEQ ID NO: 729 AGCTCACGCATGCCGCCAACG SEQ ID NO: 730 GCTCACGCAATCCGCCAACGC SEQ ID NO: 731 ATATAGTTTCGTCATTCATC SEQ ID NO: 732 TACATTGCCCATGTAATTAA SEQ ID NO: 733 ATATAGTTTCGTCATTCATC SEQ ID NO: 734 TACATTGCCCATGTAATTAA SEQ ID NO: 735 AGATAGTTTTGTCATTCATC SEQ ID NO: 736 AGATAGTTTCTTCATTCATC SEQ ID NO: 737 AGATAGTTTCGTCATTCATC SEQ ID NO: 738 AGATAGTTTCGTTATTCATC SEQ ID NO: 739 CTCACGCAAGTCGCCAACGCC SEQ ID NO: 740 TCACGCAAGCTGCCAACGCCT SEQ ID NO: 741 CACGCAAGCCTCCAACGCCTC SEQ ID NO: 742 ACGCAAGCCGTCAACGCCTCT SEQ ID NO: 743 CGCAAGCCGCTAACGCCTCTC SEQ ID NO: 744 GCAAGCCGCCTACGCCTCTCC SEQ ID NO: 745 CAAGCCGCCATCGCCTCTCCC SEQ ID NO: 746 AAGCCGCCAATGCCTCTCCCC SEQ ID NO: 747 AGCCGCCAACTCCTCTCCCCC SEQ ID NO: 748 GCCGCCAACGTCTCTCCCCCT SEQ ID NO: 749 CCGCCAACGCTTCTCCCCCTC SEQ ID NO: 750 CGCCAACGCCTCTCCCCCTCT SEQ ID NO: 751 GCCAACGCCTTTCCCCCTCTC SEQ ID NO: 752 CCAACGCCTCTCCCCCTCTCA SEQ ID NO: 753 CAACGCCTCTTCCCCTCTCAT SEQ ID NO: 754 AACGCCTCTCTCCCTCTCATC SEQ ID NO: 755 ACGCCTCTCCTCCTCTCATCC SEQ ID NO: 756 CGCCTCTCCCTCTCTCATCCA SEQ ID NO: 757 CCCCGCCTAGGTCACGCAAGC SEQ ID NO: 758 CCCGCCTAGCGCACGCAAGCC SEQ ID NO: 759 CCGCCTAGCTGACGCAAGCCG SEQ ID NO: 760 CGCCTAGCTCGCGCAAGCCGC SEQ ID NO: 761 GCCTAGCTCAGGCAAGCCGCC SEQ ID NO: 762 CCTAGCTCACGCAAGCCGCCA SEQ ID NO: 763 CTAGCTCACGGAAGCCGCCAA SEQ ID NO: 764 TAGCTCACGCGAGCCGCCAAC SEQ ID NO: 765 AGCTCACGCAGGCCGCCAACG SEQ ID NO: 766 GCTCACGCAAGCCGCCAACGC SEQ ID NO: 767 TACATTGCCCATGTAATTAA SEQ ID NO: 768 ATATAGTTTCGTCATTCATC SEQ ID NO: 769 TACATTGCCCATGTAATTAA SEQ ID NO: 770 ATATAGTTTCGTCATTCATC SEQ ID NO: 771 AGATAGTTTGGTCATTCATC SEQ ID NO: 772 AGATAGTTTCGTCATTCATC SEQ ID NO: 773 AGATAGTTTCGGCATTCATC SEQ ID NO: 774 AGATAGTTTCGTGATTCATC SEQ ID NO: 775 CTCACGCAAGGCGCCAACGCC SEQ ID NO: 776 TCACGCAAGCGGCCAACGCCT SEQ ID NO: 777 CACGCAAGCCGCCAACGCCTC SEQ ID NO: 778 ACGCAAGCCGGCAACGCCTCT SEQ ID NO: 779 CGCAAGCCGCGAACGCCTCTC SEQ ID NO: 780 GCAAGCCGCCGACGCCTCTCC SEQ ID NO: 781 CAAGCCGCCAGCGCCTCTCCC SEQ ID NO: 782 AAGCCGCCAAGGCCTCTCCCC SEQ ID NO: 783 AGCCGCCAACGCCTCTCCCCC SEQ ID NO: 784 GCCGCCAACGGCTCTCCCCCT SEQ ID NO: 785 CCGCCAACGCGTCTCCCCCTC SEQ ID NO: 786 CGCCAACGCCGCTCCCCCTCT SEQ ID NO: 787 GCCAACGCCTGTCCCCCTCTC SEQ ID NO: 788 CCAACGCCTCGCCCCCTCTCA SEQ ID NO: 789 CAACGCCTCTGCCCCTCTCAT SEQ ID NO: 790 AACGCCTCTCGCCCTCTCATC SEQ ID NO: 791 ACGCCTCTCCGCCTCTCATCC SEQ ID NO: 792 CGCCTCTCCCGCTCTCATCCA SEQ ID NO: 793 CCCCGCCTAGCTCACGCAAGC SEQ ID NO: 794 CCCGCCTAGCCCACGCAAGCC SEQ ID NO: 795 CCGCCTAGCTCACGCAAGCCG SEQ ID NO: 796 CGCCTAGCTCCCGCAAGCCGC SEQ ID NO: 797 GCCTAGCTCACGCAAGCCGCC SEQ ID NO: 798 CCTAGCTCACCCAAGCCGCCA SEQ ID NO: 799 CTAGCTCACGCAAGCCGCCAA SEQ ID NO: 800 TAGCTCACGCCAGCCGCCAAC SEQ ID NO: 801 AGCTCACGCACGCCGCCAACG SEQ ID NO: 802 GCTCACGCAACCCGCCAACGC SEQ ID NO: 803 ATATAGTTTCGTCATTCATC SEQ ID NO: 804 TACATTGCCCATGTAATTAA SEQ ID NO: 805 ATATAGTTTCGTCATTCATC SEQ ID NO: 806 TACATTGCCCATGTAATTAA SEQ ID NO: 807 AGATAGTTTCGTCATTCATC SEQ ID NO: 808 AGATAGTTTCCTCATTCATC SEQ ID NO: 809 AGATAGTTTCGCCATTCATC SEQ ID NO: 810 AGATAGTTTCGTCATTCATC SEQ ID NO: 811 CTCACGCAAGCCGCCAACGCC SEQ ID NO: 812 TCACGCAAGCCGCCAACGCCT SEQ ID NO: 813 CACGCAAGCCCCCAACGCCTC SEQ ID NO: 814 ACGCAAGCCGCCAACGCCTCT SEQ ID NO: 815 CGCAAGCCGCCAACGCCTCTC SEQ ID NO: 816 GCAAGCCGCCCACGCCTCTCC SEQ ID NO: 817 CAAGCCGCCACCGCCTCTCCC SEQ ID NO: 818 AAGCCGCCAACGCCTCTCCCC SEQ ID NO: 819 AGCCGCCAACCCCTCTCCCCC SEQ ID NO: 820 GCCGCCAACGCCTCTCCCCCT SEQ ID NO: 821 CCGCCAACGCCTCTCCCCCTC SEQ ID NO: 822 CGCCAACGCCCCTCCCCCTCT SEQ ID NO: 823 GCCAACGCCTCTCCCCCTCTC SEQ ID NO: 824 CCAACGCCTCCCCCCCTCTCA SEQ ID NO: 825 CAACGCCTCTCCCCCTCTCAT SEQ ID NO: 826 AACGCCTCTCCCCCTCTCATC SEQ ID NO: 827 ACGCCTCTCCCCCTCTCATCC SEQ ID NO: 828 CGCCTCTCCCCCTCTCATCCA SEQ ID NO: 829 CCCCGCCTAGATCACGCAAGC SEQ ID NO: 830 CCCGCCTAGCACACGCAAGCC SEQ ID NO: 831 CCGCCTAGCTAACGCAAGCCG SEQ ID NO: 832 CGCCTAGCTCACGCAAGCCGC SEQ ID NO: 833 GCCTAGCTCAAGCAAGCCGCC SEQ ID NO: 834 CCTAGCTCACACAAGCCGCCA SEQ ID NO: 835 CTAGCTCACGAAAGCCGCCAA SEQ ID NO: 836 TAGCTCACGCAAGCCGCCAAC SEQ ID NO: 837 AGCTCACGCAAGCCGCCAACG SEQ ID NO: 838 GCTCACGCAAACCGCCAACGC SEQ ID NO: 839 TACATTGCCCATGTAATTAA SEQ ID NO: 840 ATATAGTTTCGTCATTCATC SEQ ID NO: 841 TACATTGCCCATGTAATTAA SEQ ID NO: 842 ATATAGTTTCGTCATTCATC SEQ ID NO: 843 AGATAGTTTAGTCATTCATC SEQ ID NO: 844 AGATAGTTTCATCATTCATC SEQ ID NO: 845 AGATAGTTTCGACATTCATC SEQ ID NO: 846 AGATAGTTTCGTAATTCATC SEQ ID NO: 847 CTCACGCAAGACGCCAACGCC SEQ ID NO: 848 TCACGCAAGCAGCCAACGCCT SEQ ID NO: 849 CACGCAAGCCACCAACGCCTC SEQ ID NO: 850 ACGCAAGCCGACAACGCCTCT SEQ ID NO: 851 CGCAAGCCGCAAACGCCTCTC SEQ ID NO: 852 GCAAGCCGCCAACGCCTCTCC SEQ ID NO: 853 CAAGCCGCCAACGCCTCTCCC SEQ ID NO: 854 AAGCCGCCAAAGCCTCTCCCC SEQ ID NO: 855 AGCCGCCAACACCTCTCCCCC SEQ ID NO: 856 GCCGCCAACGACTCTCCCCCT SEQ ID NO: 857 CCGCCAACGCATCTCCCCCTC SEQ ID NO: 858 CGCCAACGCCACTCCCCCTCT SEQ ID NO: 859 GCCAACGCCTATCCCCCTCTC SEQ ID NO: 860 CCAACGCCTCACCCCCTCTCA SEQ ID NO: 861 CAACGCCTCTACCCCTCTCAT SEQ ID NO: 862 AACGCCTCTCACCCTCTCATC SEQ ID NO: 863 ACGCCTCTCCACCTCTCATCC SEQ ID NO: 864 CGCCTCTCCCACTCTCATCCA SEQ ID NO: 865 GCCTCTCCCCTTCTCATCCAT SEQ ID NO: 866 CCTCTCCCCCTCTCATCCATC SEQ ID NO: 867 CTCTCCCCCTTTCATCCATCG SEQ ID NO: 868 TCTCCCCCTCTCATCCATCGC SEQ ID NO: 869 CTCCCCCTCTTATCCATCGCC SEQ ID NO: 870 TCCCCCTCTCTTCCATCGCCC SEQ ID NO: 871 CCCCCTCTCATCCATCGCCCG SEQ ID NO: 872 ATATAGTTTCGTCATTCATC SEQ ID NO: 873 TACATTGCCCATGTAATTAA SEQ ID NO: 874 ATATAGTTTCGTCATTCATC SEQ ID NO: 875 TACATTGCCCATGTAATTAA SEQ ID NO: 876 AGATAGTTTTGTCATTCATC SEQ ID NO: 877 AGATAGTTTCTTCATTCATC SEQ ID NO: 878 AGATAGTTTCGTCATTCATC SEQ ID NO: 879 AGATAGTTTCGTTATTCATC SEQ ID NO: 880 CCCCTCTCATTCATCGCCCGC SEQ ID NO: 881 CCCTCTCATCTATCGCCCGCC SEQ ID NO: 882 CCTCTCATCCTTCGCCCGCCG SEQ ID NO: 883 CTCTCATCCATCGCCCGCCGC SEQ ID NO: 884 TCTCATCCATTGCCCGCCGCC SEQ ID NO: 885 CTCATCCATCTCCCGCCGCCC SEQ ID NO: 886 TCATCCATCGTCCGCCGCCCC SEQ ID NO: 887 CATCCATCGCTCGCCGCCCCT SEQ ID NO: 888 ATCCATCGCCTGCCGCCCCTC SEQ ID NO: 889 TCCATCGCCCTCCGCCCCTCA SEQ ID NO: 890 CCATCGCCCGTCGCCCCTCAT SEQ ID NO: 891 CATCGCCCGCTGCCCCTCATC SEQ ID NO: 892 ATCGCCCGCCTCCCCTCATCA SEQ ID NO: 893 TCGCCCGCCGTCCCTCATCAT SEQ ID NO: 894 CGCCCGCCGCTCCTCATCATA SEQ ID NO: 895 GCCCGCCGCCTCTCATCATAC SEQ ID NO: 896 CCCGCCGCCCTTCATCATACC SEQ ID NO: 897 CCGCCGCCCCTCATCATACCT SEQ ID NO: 898 CGCCGCCCCTTATCATACCTC SEQ ID NO: 899 GCCGCCCCTCTTCATACCTCA SEQ ID NO: 900 CCGCCCCTCATCATACCTCAG SEQ ID NO: 901 GCCTCTCCCCGTCTCATCCAT SEQ ID NO: 902 CCTCTCCCCCGCTCATCCATC SEQ ID NO: 903 CTCTCCCCCTGTCATCCATCG SEQ ID NO: 904 TCTCCCCCTCGCATCCATCGC SEQ ID NO: 905 CTCCCCCTCTGATCCATCGCC SEQ ID NO: 906 TCCCCCTCTCGTCCATCGCCC SEQ ID NO: 907 CCCCCTCTCAGCCATCGCCCG SEQ ID NO: 908 TACATTGCCCATGTAATTAA SEQ ID NO: 909 ATATAGTTTCGTCATTCATC SEQ ID NO: 910 TACATTGCCCATGTAATTAA SEQ ID NO: 911 ATATAGTTTCGTCATTCATC SEQ ID NO: 912 AGATAGTTTGGTCATTCATC SEQ ID NO: 913 AGATAGTTTCGTCATTCATC SEQ ID NO: 914 AGATAGTTTCGGCATTCATC SEQ ID NO: 915 AGATAGTTTCGTGATTCATC SEQ ID NO: 916 CCCCTCTCATGCATCGCCCGC SEQ ID NO: 917 CCCTCTCATCGATCGCCCGCC SEQ ID NO: 918 CCTCTCATCCGTCGCCCGCCG SEQ ID NO: 919 CTCTCATCCAGCGCCCGCCGC SEQ ID NO: 920 TCTCATCCATGGCCCGCCGCC SEQ ID NO: 921 CTCATCCATCGCCCGCCGCCC SEQ ID NO: 922 TCATCCATCGGCCGCCGCCCC SEQ ID NO: 923 CATCCATCGCGCGCCGCCCCT SEQ ID NO: 924 ATCCATCGCCGGCCGCCCCTC SEQ ID NO: 925 TCCATCGCCCGCCGCCCCTCA SEQ ID NO: 926 CCATCGCCCGGCGCCCCTCAT SEQ ID NO: 927 CATCGCCCGCGGCCCCTCATC SEQ ID NO: 928 ATCGCCCGCCGCCCCTCATCA SEQ ID NO: 929 TCGCCCGCCGGCCCTCATCAT SEQ ID NO: 930 CGCCCGCCGCGCCTCATCATA SEQ ID NO: 931 GCCCGCCGCCGCTCATCATAC SEQ ID NO: 932 CCCGCCGCCCGTCATCATACC SEQ ID NO: 933 CCGCCGCCCCGCATCATACCT SEQ ID NO: 934 CGCCGCCCCTGATCATACCTC SEQ ID NO: 935 GCCGCCCCTCGTCATACCTCA SEQ ID NO: 936 CCGCCCCTCAGCATACCTCAG SEQ ID NO: 937 GCCTCTCCCCCTCTCATCCAT SEQ ID NO: 938 CCTCTCCCCCCCTCATCCATC SEQ ID NO: 939 CTCTCCCCCTCTCATCCATCG SEQ ID NO: 940 TCTCCCCCTCCCATCCATCGC SEQ ID NO: 941 CTCCCCCTCTCATCCATCGCC SEQ ID NO: 942 TCCCCCTCTCCTCCATCGCCC SEQ ID NO: 943 CCCCCTCTCACCCATCGCCCG SEQ ID NO: 944 ATATAGTTTCGTCATTCATC SEQ ID NO: 945 TACATTGCCCATGTAATTAA SEQ ID NO: 946 ATATAGTTTCGTCATTCATC SEQ ID NO: 947 TACATTGCCCATGTAATTAA SEQ ID NO: 948 AGATAGTTTCGTCATTCATC SEQ ID NO: 949 AGATAGTTTCCTCATTCATC SEQ ID NO: 950 AGATAGTTTCGCCATTCATC SEQ ID NO: 951 AGATAGTTTCGTCATTCATC SEQ ID NO: 952 CCCCTCTCATCCATCGCCCGC SEQ ID NO: 953 CCCTCTCATCCATCGCCCGCC SEQ ID NO: 954 CCTCTCATCCCTCGCCCGCCG SEQ ID NO: 955 CTCTCATCCACCGCCCGCCGC SEQ ID NO: 956 TCTCATCCATCGCCCGCCGCC SEQ ID NO: 957 CTCATCCATCCCCCGCCGCCC SEQ ID NO: 958 TCATCCATCGCCCGCCGCCCC SEQ ID NO: 959 CATCCATCGCCCGCCGCCCCT SEQ ID NO: 960 ATCCATCGCCCGCCGCCCCTC SEQ ID NO: 961 TCCATCGCCCCCCGCCCCTCA SEQ ID NO: 962 CCATCGCCCGCCGCCCCTCAT SEQ ID NO: 963 CATCGCCCGCCGCCCCTCATC SEQ ID NO: 964 ATCGCCCGCCCCCCCTCATCA SEQ ID NO: 965 TCGCCCGCCGCCCCTCATCAT SEQ ID NO: 966 CGCCCGCCGCCCCTCATCATA SEQ ID NO: 967 GCCCGCCGCCCCTCATCATAC SEQ ID NO: 968 CCCGCCGCCCCTCATCATACC SEQ ID NO: 969 CCGCCGCCCCCCATCATACCT SEQ ID NO: 970 CGCCGCCCCTCATCATACCTC SEQ ID NO: 971 GCCGCCCCTCCTCATACCTCA SEQ ID NO: 972 CCGCCCCTCACCATACCTCAG SEQ ID NO: 973 GCCTCTCCCCATCTCATCCAT SEQ ID NO: 974 CCTCTCCCCCACTCATCCATC SEQ ID NO: 975 CTCTCCCCCTATCATCCATCG SEQ ID NO: 976 TCTCCCCCTCACATCCATCGC SEQ ID NO: 977 CTCCCCCTCTAATCCATCGCC SEQ ID NO: 978 TCCCCCTCTCATCCATCGCCC SEQ ID NO: 979 CCCCCTCTCAACCATCGCCCG SEQ ID NO: 980 TACATTGCCCATGTAATTAA SEQ ID NO: 981 ATATAGTTTCGTCATTCATC SEQ ID NO: 982 TACATTGCCCATGTAATTAA SEQ ID NO: 983 ATATAGTTTCGTCATTCATC SEQ ID NO: 984 AGATAGTTTAGTCATTCATC SEQ ID NO: 985 AGATAGTTTCATCATTCATC SEQ ID NO: 986 AGATAGTTTCGACATTCATC SEQ ID NO: 987 AGATAGTTTCGTAATTCATC SEQ ID NO: 988 CCCCTCTCATACATCGCCCGC SEQ ID NO: 989 CCCTCTCATCAATCGCCCGCC SEQ ID NO: 990 CCTCTCATCCATCGCCCGCCG SEQ ID NO: 991 CTCTCATCCAACGCCCGCCGC SEQ ID NO: 992 TCTCATCCATAGCCCGCCGCC SEQ ID NO: 993 CTCATCCATCACCCGCCGCCC SEQ ID NO: 994 TCATCCATCGACCGCCGCCCC SEQ ID NO: 995 CATCCATCGCACGCCGCCCCT SEQ ID NO: 996 ATCCATCGCCAGCCGCCCCTC SEQ ID NO: 997 TCCATCGCCCACCGCCCCTCA SEQ ID NO: 998 CCATCGCCCGACGCCCCTCAT SEQ ID NO: 999 CATCGCCCGCAGCCCCTCATC SEQ ID NO: 1000 ATCGCCCGCCACCCCTCATCA SEQ ID NO: 1001 TCGCCCGCCGACCCTCATCAT SEQ ID NO: 1002 CGCCCGCCGCACCTCATCATA SEQ ID NO: 1003 GCCCGCCGCCACTCATCATAC SEQ ID NO: 1004 CCCGCCGCCCATCATCATACC SEQ ID NO: 1005 CCGCCGCCCCACATCATACCT SEQ ID NO: 1006 CGCCGCCCCTAATCATACCTC SEQ ID NO: 1007 GCCGCCCCTCATCATACCTCA SEQ ID NO: 1008 CCGCCCCTCAACATACCTCAG SEQ ID NO: 1009 CGCCCCTCATTATACCTCAGC SEQ ID NO: 1010 GCCCCTCATCTTACCTCAGCC SEQ ID NO: 1011 CCCCTCATCATACCTCAGCCG SEQ ID NO: 1012 CCCTCATCATTCCTCAGCCGC SEQ ID NO: 1013 ATATAGTTTCGTCATTCATC SEQ ID NO: 1014 TACATTGCCCATGTAATTAA SEQ ID NO: 1015 ATATAGTTTCGTCATTCATC SEQ ID NO: 1016 TACATTGCCCATGTAATTAA SEQ ID NO: 1017 AGATAGTTTTGTCATTCATC SEQ ID NO: 1018 AGATAGTTTCTTCATTCATC SEQ ID NO: 1019 AGATAGTTTCGTCATTCATC SEQ ID NO: 1020 AGATAGTTTCGTTATTCATC SEQ ID NO: 1021 CCTCATCATATCTCAGCCGCC SEQ ID NO: 1022 CTCATCATACTTCAGCCGCCG SEQ ID NO: 1023 TCATCATACCTCAGCCGCCGC SEQ ID NO: 1024 CATCATACCTTAGCCGCCGCC SEQ ID NO: 1025 ATCATACCTCTGCCGCCGCCC SEQ ID NO: 1026 TCATACCTCATCCGCCGCCCC SEQ ID NO: 1027 CATACCTCAGTCGCCGCCCCT SEQ ID NO: 1028 ATACCTCAGCTGCCGCCCCTC SEQ ID NO: 1029 TACCTCAGCCTCCGCCCCTCA SEQ ID NO: 1030 ACCTCAGCCGTCGCCCCTCAT SEQ ID NO: 1031 CCTCAGCCGCTGCCCCTCATC SEQ ID NO: 1032 CTCAGCCGCCTCCCCTCATCA SEQ ID NO: 1033 TCAGCCGCCGTCCCTCATCAT SEQ ID NO: 1034 CAGCCGCCGCTCCTCATCATA SEQ ID NO: 1035 AGCCGCCGCCTCTCATCATAC SEQ ID NO: 1036 GCCGCCGCCCTTCATCATACC SEQ ID NO: 1037 CCGCCGCCCCTCATCATACCT SEQ ID NO: 1038 CGCCGCCCCTTATCATACCTC SEQ ID NO: 1039 GCCGCCCCTCTTCATACCTCA SEQ ID NO: 1040 CCGCCCCTCATCATACCTCAA SEQ ID NO: 1041 CGCCCCTCATTATACCTCAAA SEQ ID NO: 1042 GCCCCTCATCTTACCTCAAAA SEQ ID NO: 1043 CCCCTCATCATACCTCAAAAG SEQ ID NO: 1044 CCCTCATCATTCCTCAAAAGC SEQ ID NO: 1045 CGCCCCTCATGATACCTCAGC SEQ ID NO: 1046 GCCCCTCATCGTACCTCAGCC SEQ ID NO: 1047 CCCCTCATCAGACCTCAGCCG SEQ ID NO: 1048 CCCTCATCATGCCTCAGCCGC SEQ ID NO: 1049 TACATTGCCCATGTAATTAA SEQ ID NO: 1050 ATATAGTTTCGTCATTCATC SEQ ID NO: 1051 TACATTGCCCATGTAATTAA SEQ ID NO: 1052 ATATAGTTTCGTCATTCATC SEQ ID NO: 1053 AGATAGTTTGGTCATTCATC SEQ ID NO: 1054 AGATAGTTTCGTCATTCATC SEQ ID NO: 1055 AGATAGTTTCGGCATTCATC SEQ ID NO: 1056 AGATAGTTTCGTGATTCATC SEQ ID NO: 1057 CCTCATCATAGCTCAGCCGCC SEQ ID NO: 1058 CTCATCATACGTCAGCCGCCG SEQ ID NO: 1059 TCATCATACCGCAGCCGCCGC SEQ ID NO: 1060 CATCATACCTGAGCCGCCGCC SEQ ID NO: 1061 ATCATACCTCGGCCGCCGCCC SEQ ID NO: 1062 TCATACCTCAGCCGCCGCCCC SEQ ID NO: 1063 CATACCTCAGGCGCCGCCCCT SEQ ID NO: 1064 ATACCTCAGCGGCCGCCCCTC SEQ ID NO: 1065 TACCTCAGCCGCCGCCCCTCA SEQ ID NO: 1066 ACCTCAGCCGGCGCCCCTCAT SEQ ID NO: 1067 CCTCAGCCGCGGCCCCTCATC SEQ ID NO: 1068 CTCAGCCGCCGCCCCTCATCA SEQ ID NO: 1069 TCAGCCGCCGGCCCTCATCAT SEQ ID NO: 1070 CAGCCGCCGCGCCTCATCATA SEQ ID NO: 1071 AGCCGCCGCCGCTCATCATAC SEQ ID NO: 1072 GCCGCCGCCCGTCATCATACC SEQ ID NO: 1073 CCGCCGCCCCGCATCATACCT SEQ ID NO: 1074 CGCCGCCCCTGATCATACCTC SEQ ID NO: 1075 GCCGCCCCTCGTCATACCTCA SEQ ID NO: 1076 CCGCCCCTCAGCATACCTCAA SEQ ID NO: 1077 CGCCCCTCATGATACCTCAAA SEQ ID NO: 1078 GCCCCTCATCGTACCTCAAAA SEQ ID NO: 1079 CCCCTCATCAGACCTCAAAAG SEQ ID NO: 1080 CCCTCATCATGCCTCAAAAGC SEQ ID NO: 1081 CGCCCCTCATCATACCTCAGC SEQ ID NO: 1082 GCCCCTCATCCTACCTCAGCC SEQ ID NO: 1083 CCCCTCATCACACCTCAGCCG SEQ ID NO: 1084 CCCTCATCATCCCTCAGCCGC SEQ ID NO: 1085 ATATAGTTTCGTCATTCATC SEQ ID NO: 1086 TACATTGCCCATGTAATTAA SEQ ID NO: 1087 ATATAGTTTCGTCATTCATC SEQ ID NO: 1088 TACATTGCCCATGTAATTAA SEQ ID NO: 1089 AGATAGTTTCGTCATTCATC SEQ ID NO: 1090 AGATAGTTTCCTCATTCATC SEQ ID NO: 1091 AGATAGTTTCGCCATTCATC SEQ ID NO: 1092 AGATAGTTTCGTCATTCATC SEQ ID NO: 1093 CCTCATCATACCTCAGCCGCC SEQ ID NO: 1094 CTCATCATACCTCAGCCGCCG SEQ ID NO: 1095 TCATCATACCCCAGCCGCCGC SEQ ID NO: 1096 CATCATACCTCAGCCGCCGCC SEQ ID NO: 1097 ATCATACCTCCGCCGCCGCCC SEQ ID NO: 1098 TCATACCTCACCCGCCGCCCC SEQ ID NO: 1099 CATACCTCAGCCGCCGCCCCT SEQ ID NO: 1100 ATACCTCAGCCGCCGCCCCTC SEQ ID NO: 1101 TACCTCAGCCCCCGCCCCTCA SEQ ID NO: 1102 ACCTCAGCCGCCGCCCCTCAT SEQ ID NO: 1103 CCTCAGCCGCCGCCCCTCATC SEQ ID NO: 1104 CTCAGCCGCCCCCCCTCATCA SEQ ID NO: 1105 TCAGCCGCCGCCCCTCATCAT SEQ ID NO: 1106 CAGCCGCCGCCCCTCATCATA SEQ ID NO: 1107 AGCCGCCGCCCCTCATCATAC SEQ ID NO: 1108 GCCGCCGCCCCTCATCATACC SEQ ID NO: 1109 CCGCCGCCCCCCATCATACCT SEQ ID NO: 1110 CGCCGCCCCTCATCATACCTC SEQ ID NO: 1111 GCCGCCCCTCCTCATACCTCA SEQ ID NO: 1112 CCGCCCCTCACCATACCTCAA SEQ ID NO: 1113 CGCCCCTCATCATACCTCAAA SEQ ID NO: 1114 GCCCCTCATCCTACCTCAAAA SEQ ID NO: 1115 CCCCTCATCACACCTCAAAAG SEQ ID NO: 1116 CCCTCATCATCCCTCAAAAGC SEQ ID NO: 1117 CGCCCCTCATAATACCTCAGC SEQ ID NO: 1118 GCCCCTCATCATACCTCAGCC SEQ ID NO: 1119 CCCCTCATCAAACCTCAGCCG SEQ ID NO: 1120 CCCTCATCATACCTCAGCCGC SEQ ID NO: 1121 TACATTGCCCATGTAATTAA SEQ ID NO: 1122 ATATAGTTTCGTCATTCATC SEQ ID NO: 1123 TACATTGCCCATGTAATTAA SEQ ID NO: 1124 ATATAGTTTCGTCATTCATC SEQ ID NO: 1125 AGATAGTTTAGTCATTCATC SEQ ID NO: 1126 AGATAGTTTCATCATTCATC SEQ ID NO: 1127 AGATAGTTTCGACATTCATC SEQ ID NO: 1128 AGATAGTTTCGTAATTCATC SEQ ID NO: 1129 CCTCATCATAACTCAGCCGCC SEQ ID NO: 1130 CTCATCATACATCAGCCGCCG SEQ ID NO: 1131 TCATCATACCACAGCCGCCGC SEQ ID NO: 1132 CATCATACCTAAGCCGCCGCC SEQ ID NO: 1133 ATCATACCTCAGCCGCCGCCC SEQ ID NO: 1134 TCATACCTCAACCGCCGCCCC SEQ ID NO: 1135 CATACCTCAGACGCCGCCCCT SEQ ID NO: 1136 ATACCTCAGCAGCCGCCCCTC SEQ ID NO: 1137 TACCTCAGCCACCGCCCCTCA SEQ ID NO: 1138 ACCTCAGCCGACGCCCCTCAT SEQ ID NO: 1139 CCTCAGCCGCAGCCCCTCATC SEQ ID NO: 1140 CTCAGCCGCCACCCCTCATCA SEQ ID NO: 1141 TCAGCCGCCGACCCTCATCAT SEQ ID NO: 1142 CAGCCGCCGCACCTCATCATA SEQ ID NO: 1143 AGCCGCCGCCACTCATCATAC SEQ ID NO: 1144 GCCGCCGCCCATCATCATACC SEQ ID NO: 1145 CCGCCGCCCCACATCATACCT SEQ ID NO: 1146 CGCCGCCCCTAATCATACCTC SEQ ID NO: 1147 GCCGCCCCTCATCATACCTCA SEQ ID NO: 1148 CCGCCCCTCAACATACCTCAA SEQ ID NO: 1149 CGCCCCTCATAATACCTCAAA SEQ ID NO: 1150 GCCCCTCATCATACCTCAAAA SEQ ID NO: 1151 CCCCTCATCAAACCTCAAAAG SEQ ID NO: 1152 CCCTCATCATACCTCAAAAGC SEQ ID NO: 1153 CCTCATCATATCTCAAAAGCC SEQ ID NO: 1154 ATATAGTTTCGTCATTCATC SEQ ID NO: 1155 TACATTGCCCATGTAATTAA SEQ ID NO: 1156 ATATAGTTTCGTCATTCATC SEQ ID NO: 1157 TACATTGCCCATGTAATTAA SEQ ID NO: 1158 AGATAGTTTTGTCATTCATC SEQ ID NO: 1159 AGATAGTTTCTTCATTCATC SEQ ID NO: 1160 AGATAGTTTCGTCATTCATC SEQ ID NO: 1161 AGATAGTTTCGTTATTCATC SEQ ID NO: 1162 CTCATCATACTTCAAAAGCCA SEQ ID NO: 1163 TCATCATACCTCAAAAGCCAA SEQ ID NO: 1164 CATCATACCTTAAAAGCCAAC SEQ ID NO: 1165 ATCATACCTCTAAAGCCAACT SEQ ID NO: 1166 TCATACCTCATAAGCCAACTA SEQ ID NO: 1167 CATACCTCAATAGCCAACTAA SEQ ID NO: 1168 ATACCTCAAATGCCAACTAAC SEQ ID NO: 1169 TACCTCAAAATCCAACTAACC SEQ ID NO: 1170 ACCTCAAAAGTCAACTAACCA SEQ ID NO: 1171 CCTCAAAAGCTAACTAACCAA SEQ ID NO: 1172 CTCAAAAGCCTACTAACCAAC SEQ ID NO: 1173 TCAAAAGCCATCTAACCAACC SEQ ID NO: 1174 CAAAAGCCAATTAACCAACCA SEQ ID NO: 1175 AAAAGCCAACTAACCAACCAA SEQ ID NO: 1176 AAAGCCAACTTACCAACCAAT SEQ ID NO: 1177 ATATAGTTTCGTCATTCATC SEQ ID NO: 1178 TACATTGCCCATGTAATTAA SEQ ID NO: 1179 ATATAGTTTCGTCATTCATC SEQ ID NO: 1180 TACATTGCCCATGTAATTAA SEQ ID NO: 1181 AGATAGTTTTGTCATTCATC SEQ ID NO: 1182 AGATAGTTTCTTCATTCATC SEQ ID NO: 1183 AGATAGTTTCGTCATTCATC SEQ ID NO: 1184 AGATAGTTTCGTTATTCATC SEQ ID NO: 1185 CCTCATCATAGCTCAAAAGCC SEQ ID NO: 1186 TACATTGCCCATGTAATTAA SEQ ID NO: 1187 ATATAGTTTCGTCATTCATC SEQ ID NO: 1188 TACATTGCCCATGTAATTAA SEQ ID NO: 1189 ATATAGTTTCGTCATTCATC SEQ ID NO: 1190 AGATAGTTTGGTCATTCATC SEQ ID NO: 1191 AGATAGTTTCGTCATTCATC SEQ ID NO: 1192 AGATAGTTTCGGCATTCATC SEQ ID NO: 1193 AGATAGTTTCGTGATTCATC SEQ ID NO: 1194 CTCATCATACGTCAAAAGCCA SEQ ID NO: 1195 TCATCATACCGCAAAAGCCAA SEQ ID NO: 1196 CATCATACCTGAAAAGCCAAC SEQ ID NO: 1197 ATCATACCTCGAAAGCCAACT SEQ ID NO: 1198 TCATACCTCAGAAGCCAACTA SEQ ID NO: 1199 CATACCTCAAGAGCCAACTAA SEQ ID NO: 1200 ATACCTCAAAGGCCAACTAAC SEQ ID NO: 1201 TACCTCAAAAGCCAACTAACC SEQ ID NO: 1202 ACCTCAAAAGGCAACTAACCA SEQ ID NO: 1203 CCTCAAAAGCGAACTAACCAA SEQ ID NO: 1204 CTCAAAAGCCGACTAACCAAC SEQ ID NO: 1205 TCAAAAGCCAGCTAACCAACC SEQ ID NO: 1206 CAAAAGCCAAGTAACCAACCA SEQ ID NO: 1207 AAAAGCCAACGAACCAACCAA SEQ ID NO: 1208 AAAGCCAACTGACCAACCAAT SEQ ID NO: 1209 TACATTGCCCATGTAATTAA SEQ ID NO: 1210 ATATAGTTTCGTCATTCATC SEQ ID NO: 1211 TACATTGCCCATGTAATTAA SEQ ID NO: 1212 ATATAGTTTCGTCATTCATC SEQ ID NO: 1213 AGATAGTTTGGTCATTCATC SEQ ID NO: 1214 AGATAGTTTCGTCATTCATC SEQ ID NO: 1215 AGATAGTTTCGGCATTCATC SEQ ID NO: 1216 AGATAGTTTCGTGATTCATC SEQ ID NO: 1217 CCTCATCATACCTCAAAAGCC SEQ ID NO: 1218 ATATAGTTTCGTCATTCATC SEQ ID NO: 1219 TACATTGCCCATGTAATTAA SEQ ID NO: 1220 ATATAGTTTCGTCATTCATC SEQ ID NO: 1221 TACATTGCCCATGTAATTAA SEQ ID NO: 1222 AGATAGTTTCGTCATTCATC SEQ ID NO: 1223 AGATAGTTTCCTCATTCATC SEQ ID NO: 1224 AGATAGTTTCGCCATTCATC SEQ ID NO: 1225 AGATAGTTTCGTCATTCATC SEQ ID NO: 1226 CTCATCATACCTCAAAAGCCA SEQ ID NO: 1227 TCATCATACCCCAAAAGCCAA SEQ ID NO: 1228 CATCATACCTCAAAAGCCAAC SEQ ID NO: 1229 ATCATACCTCCAAAGCCAACT SEQ ID NO: 1230 TCATACCTCACAAGCCAACTA SEQ ID NO: 1231 CATACCTCAACAGCCAACTAA SEQ ID NO: 1232 ATACCTCAAACGCCAACTAAC SEQ ID NO: 1233 TACCTCAAAACCCAACTAACC SEQ ID NO: 1234 ACCTCAAAAGCCAACTAACCA SEQ ID NO: 1235 CCTCAAAAGCCAACTAACCAA SEQ ID NO: 1236 CTCAAAAGCCCACTAACCAAC SEQ ID NO: 1237 TCAAAAGCCACCTAACCAACC SEQ ID NO: 1238 CAAAAGCCAACTAACCAACCA SEQ ID NO: 1239 AAAAGCCAACCAACCAACCAA SEQ ID NO: 1240 AAAGCCAACTCACCAACCAAT SEQ ID NO: 1241 ATATAGTTTCGTCATTCATC SEQ ID NO: 1242 TACATTGCCCATGTAATTAA SEQ ID NO: 1243 ATATAGTTTCGTCATTCATC SEQ ID NO: 1244 TACATTGCCCATGTAATTAA SEQ ID NO: 1245 AGATAGTTTCGTCATTCATC SEQ ID NO: 1246 AGATAGTTTCCTCATTCATC SEQ ID NO: 1247 AGATAGTTTCGCCATTCATC SEQ ID NO: 1248 AGATAGTTTCGTCATTCATC SEQ ID NO: 1249 CCTCATCATAACTCAAAAGCC SEQ ID NO: 1250 TACATTGCCCATGTAATTAA SEQ ID NO: 1251 ATATAGTTTCGTCATTCATC SEQ ID NO: 1252 TACATTGCCCATGTAATTAA SEQ ID NO: 1253 ATATAGTTTCGTCATTCATC SEQ ID NO: 1254 AGATAGTTTAGTCATTCATC SEQ ID NO: 1255 AGATAGTTTCATCATTCATC SEQ ID NO: 1256 AGATAGTTTCGACATTCATC SEQ ID NO: 1257 AGATAGTTTCGTAATTCATC SEQ ID NO: 1258 CTCATCATACATCAAAAGCCA SEQ ID NO: 1259 TCATCATACCACAAAAGCCAA SEQ ID NO: 1260 CATCATACCTAAAAAGCCAAC SEQ ID NO: 1261 ATCATACCTCAAAAGCCAACT SEQ ID NO: 1262 TCATACCTCAAAAGCCAACTA SEQ ID NO: 1263 CATACCTCAAAAGCCAACTAA SEQ ID NO: 1264 ATACCTCAAAAGCCAACTAAC SEQ ID NO: 1265 TACCTCAAAAACCAACTAACC SEQ ID NO: 1266 ACCTCAAAAGACAACTAACCA SEQ ID NO: 1267 CCTCAAAAGCAAACTAACCAA SEQ ID NO: 1268 CTCAAAAGCCAACTAACCAAC SEQ ID NO: 1269 TCAAAAGCCAACTAACCAACC SEQ ID NO: 1270 CAAAAGCCAAATAACCAACCA SEQ ID NO: 1271 AAAAGCCAACAAACCAACCAA SEQ ID NO: 1272 AAAGCCAACTAACCAACCAAT SEQ ID NO: 1273 TACATTGCCCATGTAATTAA SEQ ID NO: 1274 ATATAGTTTCGTCATTCATC SEQ ID NO: 1275 TACATTGCCCATGTAATTAA SEQ ID NO: 1276 ATATAGTTTCGTCATTCATC SEQ ID NO: 1277 AGATAGTTTAGTCATTCATC SEQ ID NO: 1278 AGATAGTTTCATCATTCATC SEQ ID NO: 1279 AGATAGTTTCGACATTCATC SEQ ID NO: 1280 AGATAGTTTCGTAATTCATC
[0058] Procedure for Probe Design
[0059] The design of a probe begins with the input of a sequence file into a computer in the five prime to three prime direction. The sequence file is then converted to account for sodium bisulfite treatment. The complementary sequence of the converted sequence file is then is then generated in the three prime to five prime direction.
[0060] A parent probe list is then created from the complementary sequence. This is accomplished by standard re-sequencing, where every base is queried. For this method the first probe starts at position X, and extend a number of bases, N. The next probe starts at position X+1, and extends N bases also. A second method to create the parent probe set is to identify all CpG dinucleotides and only create probes with a CpG dinucleotide in the middle.
[0061] Once prepared, the parent probe list is filtered to remove probes that are deemed not to be suitable for re-sequencing analysis. Factors such as low sequence complexity are taken into account. Each parent probe is used as a template to create new probes to query for possible changes at a particular position in the reference sequence. Each parent probe generates at least three new probes, one for each single nucleotide polymorphism at the central base. The parent probe and daughter probes created from it represent the position query probe partners. Additional position query probe partners may be required if multiple CpG islands are on one probe. In this case every possible combination of methylation sites from the parent probe must be created. This creates a list of sub parent probes each of whose central position is then altered to represent all possible single nucleotide polymorphisms. The collection of these probes are that position's position query probe partners.
[0062] Once the complete set of position query probe partners has been calculated, a file is generated containing all the partners for each position in the reference sequence, or those designated by the user for interrogation. A probe set generated in this manner for a portion of p16 is attached as Appendix 1.
[0063] Sodium Bisulfite Treatment Protocol
[0064] The concentration of DNA used in this protocol is 1 μg of DNA per 10 μl of sample. Samples are prepared in an autoclaved tube with 1 μg of DNA diluted to 50 μl using autoclaved water. 5.5 μl of 2M sodium hydroxide (3.6 g in 45 ml of water) is then added and the sample is maintained at 37° C. for ten minutes in a water bath. The sample tube is removed from the water bath and centrifuged. 30 μl of freshly prepared hydroquinone solution (55 mg in 50 ml of water) is added to the sample tube and the sample becomes yellow. 520 μl of freshly prepared sodium bisulfite solution (3.76 g in 10 ml of water) is then added and the resulting solution is mixed well. The sample tube is then sealed with parafilm and placed in a water bath at 60° C. for 16 hours. The tubes are removed from the water bath and the sample purified using the Wizard DNA resin (Promega) according to the manufacturer's protocol. The DNA is eluted with 50 μl of water to which is added 8.25 μl of 2M sodium hydroxide solution. The DNA is then precipitated using ethanol and a glycogen carrier. The precipitated DNA is then resuspended in 200 μl of water.
[0065] Protocol for PCR Amplification of 145 bp Region of the Promoter for p16
[0066] The primers listed below are examples of those used for the amplification.
Primer Sequences: 5′ (Cy3/Cy5) GTTTTCCCAGTCACGACTTGGTTGGTTATTAGAGGGTGG 3′ (SEQ ID NO.: 1281) 5′ (Cy3/Cy5) AAACAGCTATGACCATGACCATAACCAACCAATCAACC 3′ (SEQ ID NO.: 1282) The entire 145 base sequence: 5′CTGGCTG GTCACCAGAGGGTGGGGCGG ACCGAGTGCG CTCGGCGGCT (SEQ ID NO.: 1283) GCGGAGAGGG GTAGAGCAGG CAGCGGGCGGCGGGGAGCAG CATGGAGCCG GCGGCGGGGA GCAGCATGGA GCCTTCGGCT GACTGGCTGG CCACGGC3′
[0067] The following procedure is typically done 50 times, and the resulting material combined to form a single sample. Each amplification is accomplished by adding 3.2 μl of dNTP mixture (1.25 μM in each base), 2.5 μl of 10×PCR buffer, 1 μl of primer mixture (25 μM for each primer), 17 μl of water, 0.2 μl Taq polymerase (5 units/μl) and 1 μl of template DNA from the bisulfite treatment protocol described above.
[0068] The thermocycler is then programmed to 95° C. for 12 minutes. This is followed by two cycles of treatment at 94° C. for 20 seconds, 66° C. for 40 seconds and 72° C. for 20 seconds with touchdown of −1° C. This is followed by 35 cycles of treatment at 94° C. for 20 seconds, 66° C. for 30 seconds and 72° C. for 20 seconds with touchdown of −1° C. The sample is then kept at 72° C. got 7 minutes and stored at 4° C.
EXAMPLE 2
Analysis of Methylation of a Region of the Promoter for the Tumor Suppressor Gene p16 with Oligonucleotide Arrays
[0069] An example of a method for mapping individual sites of CpG methylation in genomic DNA is further presented herein. The method of the present invention allows parallel and simultaneous analysis of many individual potential sites of methylation in widely separated regions of the genome.
[0070] Array Fabrication
[0071] Corning 1″×3″ glass microscope slides were cleaned and coated with 3-glycidoxypropyltrimethoxysilane (Aldrich) and polyethlyeneglycol (M a 300, Aldrich) as described by Maskos and Southern. Slides were stored in a dessicator at room temperature until use. In preparation for microarray fabrication, the synthesis area of a slide was reacted with a 1:1 (vol:vol) mixture of 0.1 M protected linker phosphoramidite (MeNPOC-hexaethylene glycol β-cyanoethyl phosphoramidite) and tetrazole in acetonitrile (Annovis, Aston, Pa.). The mixture was allowed to react for two minutes with the glass surface and then washed with acetonitrile.
[0072] An array of oligonucleotide probes was synthesized in situ on the resulting surface using light directed phosphoramidite synthesis. MenPOC-protected phosphoramidites were used in the synthesis. Light for each photochemical deprotection step was spatially addressed with a Texas Instruments Digital Light Processor (DLP™). The DLP was illuminated with the 365 nm peak from a 200 W Hg/Xe arc lamp. Illumination of the DLP and projection of the reflected image were accomplished with a custom optical system designed by Brilliant Technologies (Denton, Tex.). The image of the DLP was projected onto the reactive surface without magnification. The DLP was coordinated with a home-built fluidics system for automated DNA synthesis. Custom software generated the patterns of illumination required to fabricate the desired array of oligonucleotides. Final deprotection of the synthesized array was with a 1:1 (vol:vol) solution of ethylenediamine and ethanol for two hours at room temperature.
[0073] Preparation of DNA and Amplification of Promoter Regions
[0074] Cell lines H1299 and H69 were established as described by Phelps and co-workers (Phelps R, Johnson B, Ihde D, et al., NCI-Navy medical oncology branch cell line data base, Journal of Cellular Biochemistry Supplement. 24: 32-91, 1996) and have been deposited in the American Type Culture Collection. The cells were cultured in RPMI 1640 (Invitrogen) supplemented with 5% fetal bovine serum. Genomic DNA was purified from these cell lines as described by Fong et al. (Fong L, Zimmerman P, and Smith P, Correlation of loss of heterozygosity at 11 p with tumour progression and survival in non-small cell lung cancer, Genes, Chromosomes, Cancer. 10: 183-189, 1994). The extracted, purified DNA was treated with sodium bisulfite. Thep16 promoter region was amplified in a PCR reaction using 50 ng sodium bisulfite-treated genomic DNA as template and the following primers: 5′[Cy3 or biotin] TTAGAGGATTTGAGGGAT3′ (SEQ ID NO.: 1284) and 5′AAAACTCCATACTACTCC 3′ (SEQ ID NO.: 1285). Primers were purchased from Operon Technologies (Alameda, Calif.).
[0075] A touchdown method was used for the first 14 cycles of amplification, starting at an annealing temperature of 68° C. and decreasing the annealing temperature 1° C. per cycle. Amplification was continued for an additional 30 cycles with an annealing temperature of 55° C. Denaturation and extension were carried out at 94° C. and 72° C., respectively. The product of this amplification was used as the template for a second set of PCR reactions. The products were de-salted (NAP column, Amersham Pharmacia Biotech) and precipitated with ethanol and sodium acetate prior to dissolving in hybridization buffer.
[0076] Array Hybridization
[0077] The hybridization mixture contained, 0.1-1 μM labeled analyte sample, 0.1-1 μM labeled reference sample, 1 μM Control Oligo 1 (SEQ ID NO.: 1286, 5′[Cy3] CTTGGCTGTCCCAGAATGCAAGAAGCCCAGACGGAAACCGTAGCTGCCCTGGTA GGTTTT), and 1 μM Control Oligo 2 (SEQ ID NO.: 1287, 5′[Cy3] TATATCAAAGCAGTAAGTAG) in 3M tetramethyl ammonium chloride, 0.05% Trition X-100,1 mM EDTA, 10 mM Tris HCl pH7.5. The sample was applied to the array surface under a 22×22 mm cover slip. Hybridization was carried out in a closed chamber containing a pool of hybridization buffer. The array with sample was heated to 95° C. for 20 minutes followed by warming at 60° C. for one hour. After hybridization, the array was washed three times with 6×SSPE (Sigma), 0.09% Tween, followed by three washes with 0.8×SSPE, 0.01% Tween at room temperature. After this wash, the array was dried centrifugally, stained with 2 μg/ml of CyS-Streptavidin (vendor) for 5 minutes at room temperature, washed with 6×SSPE, 0.09% Tween. Finally, the array was scanned using an Axon Genepix 3000 scanner to detect Cy3 and Cy5 fluorescence intensity. The signal intensity for each feature was determined using custom analysis software.
[0078] TA Cloning and Sequencing
[0079] The 190 base pair amplicon of sodium bisulfite treated DNA was cloned into plasmid pCR®2.1 using a TA cloning kit (Invitrogen, Carlsbad, Calif.) and manufacturer recommended protocols. Plasmid was isolated from 18 individual colonies, and the insert was sequenced. Sequencing was done on an ABI3100 sequencer with T7 and M13 primers using dye terminated DNA sequencing protocols.
[0080] Construction of 190 bp Duplex for Heterogeneous Methylation Study
[0081] A 190 base pair duplex with simulated methylation at position 25 was created. Oligonucleotides were obtained from Operon Technologies. The following oligonucleotides were obtained from Operon Technologies: Oligo A (SEQ ID NO.: 1288, 5′CCACCCTCTAATAACCAACCAACCCCTCCTCTTTCTTCCTCCAATACTAACAAA AAAACCCCCTCCAACCCTATCCCTCAAATCCTCTAA), Oligo B (SEQ ID NO.: 1289, 5′GTGTGTTTGGTGGTTG C GGAGAGGGGGAGAGTAGGTAGTGGGTGGTGGGGAGT AGTATGGAGTTGGTGGTGGGGAGTAGTATGGAGTTTT), Oligo C (SEQ ID NO.: 1290, 5′TTAGAGGATTTGAGGGATAGGGTTGGAGGGGGTTTTTTTGTTAGTATTGGAGG AAGAAAGAGGAGGGGTTGGTTGGTTATTAGAGGGTGGGGTGGATTGT), and Oligo D (SEQ ID NO.: 1291, 5′AAAACTCCATACTACTCCCCACCACCAACTCCATA CTACTCCCCACCACCCACTACCTACTCTCCCCCTCTCC G CAACCACCAAACACAC ACAATCCACC). Oligos A and B (70 pmoles each) were phosphorylated with polynucleotide kinase (New England BioLabs). The phosphorylated DNA was phenol extracted, chloroform extracted, then ethanol precipitated. Phosphorylated Oligo A was annealed with Oligo C, and phosphorylated Oligo B was annealed with Oligo D. The resulting duplexes were mixed in equimolar amounts and ligated with T4 ligase at 14° C. overnight. The resulting 190 base pair duplex was amplified as described above for the p16 promoter region.
[0082] Assay for Methylation by Hybridization to an Array of Oligonucleotide Probes
[0083] An example of one ore more essential features of the present invention is shown schematically in FIG. 6. For FIG. 6, oligonucleotide probes are covalently bound to a substrate. The central base of each probe for a given position is varied to test for the identity of the base by hybridization. The probe with which the most label is associated identifies the base at the central position. A cytosine at the probed position indicates methylation that prevented conversion by sodium bisulfite. A sample of genomic DNA is treated with sodium bisulfite under conditions that convert unmethylated cytosines to deoxyuridines. Methylated cytosines remain unconverted (FIG. 6A). At least one region of interest is amplified by PCR, which recapitulates the deoxyuracils in the template as thymidines. The product is labeled during amplification with an easily detectable tag such as a fluorophore. The presence of a cytosine or a thymidine at each position corresponding to a site of potential methylation is assayed by hybridization to a set of complementary oligonucleotide probes covalently bound to a substrate (FIG. 6B). Each probe for a given position is identical, except for a center base substitution used to determine the analyte sequence by hybridization. Many different CpG sites may be simultaneously queried with an array of many oligonucleotide probes.
[0084] A region of the promoter for the tumor suppressor gene p16 is tested using the method of the present invention. Hypermethylation of this promoter is known to repress transcription of p16 and is associated with a number of cancers. Samples of genomic DNA from lung tumor cell lines are treated with sodium bisulfite. In addition, a190 bp region of the p16 promoter is amplified and labeled. The sequence of the 190 base region of interest (prior to treatment with sodium bisulfite) is shown in FIG. 7 (GenBank accession number AL449423). After treatment with bisulfite, the strand shown was amplified and labeled. The region contains 36 cytosines. The numbers correspond to those are depicted in TABLE 2; 16 cytosines are within CpG dinucleotides (shaded) and 20 cytosines are not within CpG dinucleotides. The amplified DNA was analyzed by hybridization to an array of oligonucleotide probes, each 21 bases in length, synthesized directly on a glass surface by light-directed methods. Spatially patterned illumination for the photodeprotection step of the synthesis was accomplished using a digital micromirror device.
[0085] The result of hybridization and scanning of four probes designed to query a single cytosine (cytosine number 1) is shown in FIG. 8. The array was hybridized, washed, and scanned for fluorescence. Each 21 -nucleotide probe is complementary to the sequence surrounding cytosine number 1, with a different base for each probe in apposition to cytosine number 1. For example, the probe for A has a thymidine in that central position. The DNA analyzed with the Cy5 label was from a lung tumor cell line (H1299) in which all of the CpG dinucleotides in the 190-base analyzed region were previously found to be methylated (by using dye terminated sequencing of bisulfite treated DNA). The feature with the highest signal of the four features shown is the one probing for a cytosine (the variable base in the probe is a guanine). The ratio of the signal for this feature to the next highest signal (in the feature probing for a guanine) is 2.8, identifying the base in the analyte as a cytosine. A cytosine at this position was anticipated as the outcome of bisulfite treatment of the methylated base.
[0086] One comparison relevant to detection of methylation is between the signal in the feature that probes for a cytosine at each position and the signal in the feature that probes for a thymidine at the same position in the bisulfite treated DNA. The ratio of these signals (C:T) is listed for each of the cytosines in the analyzed sequence in TABLE 2. Cytosines outside of CpG dinucleotides that are not methylated serve as an internal indicator for the effectiveness of the bisulfite treatment in converting unmethylated cytosines to deoxyuracils and for the discrimination between cytosines and thymidines by the probes on the array. The ratio of signals in those features ranges from 0.24 to 1.09. Independent sequence analysis of the bisulfite-treated DNA confirmed complete conversion of all unmethylated cytosines to deoxyuracils. At the position queried by the probes shown in FIG. 8, the ratio of signals (C:T) is 3.57. The values range from 1.91 to 13.8 for cytosines in CpG dinucleotides (TABLE 2), in all cases considerably higher than the highest ratio of signals for the unmethylated cytosines.
TABLE 2 Summary of Signal Intensity Ratios for Each Analyzed Cytosine H1299 & H69 d 25th C Duplex e Cytosine C:T Ratio C:T Ratio Analyte(C:T)/ C:T Ratio C:T Ratio Analyte(C:T)/ Number g Analyte a Reference a Ref(C:T) b Score c Analyte a Reference a Ref(C:T) b Z Score c 1 3.57 0.52 6.80 10.7 0.86 0.88 0.99 −0.90 2 0.46 0.54 0.85 −1.50 0.74 0.69 1.08 −0.29 3 0.44 0.36 1.23 −0.72 0.75 0.75 1.00 −0.82 4 0.39 0.29 1.34 −0.50 0.87 0.86 1.01 −0.76 5 13.8 0.39 35.7 69.7 0.90 0.89 1.01 −0.75 6 0.24 0.22 1.13 −0.94 1.07 0.96 1.12 −0.08 7 0.34 0.36 0.94 −1.33 1.01 0.99 1.01 −0.72 8 0.36 0.41 0.88 −1.45 0.70 0.58 1.22 0.58 9 0.33 0.27 1.23 −0.73 0.68 0.65 1.05 −0.50 10 9.28 0.41 22.5 42.8 0.82 0.68 1.20 0.46 11 0.93 0.53 1.76 0.36 0.85 0.88 0.97 −1.00 12 1.09 0.48 2.29 1.44 1.01 0.72 1.41 1.79 13 0.65 0.52 1.23 −0.69 0.85 0.76 1.11 −0.10 14 0.65 0.51 1.23 −0.60 0.83 0.80 1.05 −0.52 15 1.08 0.60 1.81 0.44 0.92 0.93 0.99 −0.87 16 3.55 0.54 6.64 10.3 0.94 0.72 1.30 1.12 17 0.27 0.11 2.44 1.75 0.62 0.56 1.11 −0.11 18 1.99 0.46 4.34 5.62 0.9 1.06 0.85 −1.76 19 2.36 0.60 3.91 4.75 1.10 0.76 1.45 2.08 20 1.91 0.53 3.63 4.18 1.01 0.82 1.23 0.68 21 0.40 0.18 2.27 1.39 0.51 0.45 1.14 0.08 22 3.11 0.69 4.54 6.05 0.82 0.71 1.16 0.24 23 3.38 0.59 5.73 8.46 1.07 0.68 1.56 2.77 24 0.45 0.27 1.68 0.20 0.60 0.49 1.22 0.62 25 3.55 0.52 6.81 10.7 1.48 0.62 2.38 7.97 26 0.62 0.29 2.11 1.07 0.81 0.75 1.08 −0.29 27 0.46 0.29 1.58 −0.01 0.7 0.74 0.94 −1.17 28 2.88 0.52 5.52 8.02 1.00 0.89 1.12 −0.04 29 2.11 0.43 4.85 6.66 0.93 0.58 1.59 2.95 30 3.40 0.42 8.09 13.3 1.01 0.62 1.67 3.47 31 0.70 0.38 1.87 0.57 0.77 0.58 1.32 1.23 32 0.60 0.34 1.75 0.33 0.79 0.50 1.57 2.82 33 0.37 0.18 2.04 0.93 0.57 0.50 1.14 0.09 34 2.14 0.52 4.10 5.13 0.82 0.63 1.30 1.09 35 2.11 0.44 4.77 6.51 1.21 0.72 1.69 3.55 36 4.48 0.49 9.15 15.5 1.18 0.80 1.47 2.20 20:80 Mixture f Cytosine C:T Ratio C:T Ratio Analyte(C:T)/ Number g Analyte a Reference a Ref(C:T) b Z Score c 1 0.99 0.52 1.92 4.61 2 0.70 0.70 1.00 1.01 3 0.39 0.32 1.20 1.80 4 0.44 0.36 1.22 1.88 5 1.16 0.49 2.35 6.29 6 0.32 0.64 0.5 −0.97 7 0.50 0.76 0.65 −0.37 8 0.36 0.62 0.58 −0.64 9 0.34 0.64 0.53 −0.85 10 1.43 0.67 2.15 5.51 11 0.62 0.90 0.69 −0.20 12 0.70 0.55 1.28 2.08 13 0.61 0.93 0.66 −0.35 14 0.51 0.68 0.74 −0.02 15 0.61 0.98 0.62 −0.48 16 1.90 0.86 2.21 5.71 17 0.20 0.51 0.39 −1.41 18 0.50 0.42 1.19 1.73 19 1.04 0.57 1.83 4.25 20 1.99 1.04 1.92 4.58 21 0.35 0.62 0.57 0.69 22 2.17 1.39 1.56 3.19 23 2.20 1.41 1.59 3.32 24 0.34 0.49 0.70 0.17 25 1.12 0.74 1.51 2.99 26 0.69 0.78 0.89 0.59 27 0.49 0.87 0.56 −0.73 28 1.24 0.63 1.98 4.82 29 0.93 0.96 0.96 0.85 30 0.91 1.11 0.82 0.29 31 0.59 0.73 0.81 0.25 32 0.53 0.67 0.80 0.21 33 0.30 0.59 0.51 −0.93 34 1.16 0.63 1.85 4.33 35 1.31 1.33 0.98 0.93 36 2.28 1.66 1.38 2.48
[0087] To provide an objective standard for discrimination between methylated and unmethylated cytosines and to facilitate visualization of changes in methylation state, a reference sequence containing a different label was co-hybridized with the array. DNA from a different lung tumor cell line (H69) in which the p16 promoter has been found to be unmethylated at each CpG in the 190 base region of interest was used a model reference sequence. Results were confirmed using dye terminated sequencing of bisulfite-treated DNA. The same 190 base region (FIG. 7) of H69 was amplified with a primer labeled with Cy3.
[0088] The result for cytosine number 1 is shown in FIGS. 8B and 8C. The probe for thymidine has the highest signal intensity, and the C:T ratio for the reference strand is 0.52 at this position. A useful method for judging changes in methylation state is to compare the C:T ratio for a set of probes with the analyte fluorophore to the C:T ratio for the same probes with the reference fluorophore. In FIG. 8 the ratio of sample fluorophore (Cy5) C:T ratio to reference fluorophore (Cy3) C:T ratio is 6.8. Using a ratio of ratios in this manner may, for example, reduce the effects of imperfect hybridization specificity on the results.
[0089] The ratio of ratios was computed for each cytosine in the original sequence and is listed in TABLE 2. Cytosines not part of a CpG were used as an internal standard for unmethylated positions. The ratios of signal ratios for these cytosines had a mean of 1.59 and a standard deviation of 0.49 (n=20) and were distributed normally. In the H1299 sample, the values for all 16 cytosines in CpGs were at least four standard deviations from the mean of values for cytosines not in CpGs (FIG. 9A; Z scores listed in TABLE 2). A study in which the dye labels were reversed between the analyte and reference samples yielded equivalent results.
[0090] Specificity for Detection of Heterogeneous Methylation
[0091] The example of the present invention shows that the region of the p16 promoter is uniformly methylated at all CpG sites in the H1299 cell line. For non-uniformity of methylation that may have important biological consequences (e.g., because methylation of all CpG sites within a promoter region does not have equal effect on transcription), the ability for the assay to independently discriminate methylation states at different CpG sites is essential.
[0092] The present invention may detect methylation at an individual site and define the threshold for assignment of methylation state. This may be shown, for example, by creating an 190 base pair test duplex (using chemical synthesis and ligation). One strand of the duplex is identical in sequence to bisulfite-treated H69 genomic DNA, except the position of the 25th cytosine simulates methylation by being a cytosine rather than a thymidine. The test duplex was labeled by amplification with a labeled primer, and bisulfite-treated DNA from H69 lung tumor cells was amplified and labeled for use as a reference sequence. Co-hybridization of the analyte and reference samples to the array resulted in the ratios of analyte(C:T) to reference(C:T) listed in TABLE 2 for all 36 cytosines.
[0093] The site of simulated methylation had an analyte(C:T):reference(C:T) ratio of 2.38, nearly eight standard deviations (Z score=7.97) from the mean of that ratio for the cytosines not in CpG dinucleotides (1.13±0.16,n=20). This ratio for the other cytosines in CpGs ranged from 0.91 to 1.64. These differed from the mean for the internal standard cytosines by −1.8 to 3.6 standard deviations (FIG. 9B and TABLE 2). Thus, the authentic cytosine could be clearly distinguished from the other potential positions of methylation by its considerably larger variation from the internal standards. The range of ratios for the positions simulating unmethylated CpGs suggests a threshold Z score of greater than 3.6 (i.e., greater than 3.6 standard deviations from the mean of the internal standards) to indicate a genuine difference from an unmethylated cytosine. In FIG. 9, the threshold for calling methylation is set to 3.6, indicated by the horizontal line at that value. In each case the reference sample was derived from unmethylated DNA.
[0094] Detection of Methylated DNA in the Presence of Unmethylated DNA
[0095] The present invention is able to detect methylated cytosines within analytes that contain a significant amount of DNA that is not methylated, a feature that may be particularly useful with biological samples of genomic DNA that include individual CpG sites that are partially but not exhaustively methylated.
[0096] The 190 base region shown in FIG. 7 was amplified separately from bisulfite-treated samples of genomic DNA from H1299 and H69. The amount of amplified DNA from each sample was estimated by visualization on an agarose gel, and the amplified samples were mixed in a ratio of approximately 20:80 (H1299:H69). This mixture approximates a sample in which 20% of each CpG is methylated. The mixture was labeled by an additional amplification with a labeled primer. A reference sample (derived purely from H69) was also amplified and labeled, and the analyte mixture and reference were co-hybridized to the methylation probe array.
[0097] The results of this hybridization are summarized in TABLE 2. Of the 16 cytosines in CpG dinucleotides, 8 had Z scores greater than 3.6, identifying them as partially methylated (FIG. 9C). The remaining 8 could not be distinguished from bases converted entirely to deoxyuracils by treatment with bisulfite.
[0098] The comparison to a sample of reference methylation state is especially useful, because information about differences in methylation state is important. Many comparisons may be used, such as, for example, comparing the difference between the analyte sample and a sample known to be unmethylated, comparing DNA from diseased tissue to a matched sample from healthy tissue or DNA from tissue at different points along a disease progression. In FIG. 8C, co-hybridization with a reference sample containing a different label facilitates visualization of changes in methylation state; the presence of two colors in one set of four probes may then be observed.
[0099] Other aspects of variability of the present invention may be assessed using the known unmethylated positions as internal standards (generally performed after the context-dependence of variability is accounted for). For example, a calculated Z score offers a measure of the statistical significance of the difference between the analyte to reference ratio of a given interrogated cytosine and those known to be unmethylated. The use of an empirically determined threshold Z score to judge methylation state is analogous to the use of an empirically determined threshold signal ratio to identify nucleotides in standard array-based sequence analysis. As used herein, the calculated Z score correlates with methylation state, and a single cytosine corresponding to a uniquely methylated position is distinguished from the unmethylated cytosines.
[0100] The present invention may detect methylation at an individual cytosine by hybridization to probes synthesized in situ using internal controls such as cytosines outside of CpG dinucleotides and a co-hybridized reference sample. The assay is designed to interrogate independent sites for methylation. With use of the present invention, additional probes may be included to interrogate other possible strands of DNA that reflect methylation status of a region. For example, after bisulfite treatment, the two strands of genomic DNA are no longer mutually complementary. Amplification of each produces two complementary strands of different sequence. Therefore, information about the methylation state of the initial sequence is contained in four different sequences of DNA, each of which can be analyzed independently on the same array.
[0101] With the present invention, as few as two array features can be used to effectively probe each cytosine in a region of interest. For example, using light directed methods of high feature density array synthesis, hundreds of thousands of features can be created on a single array to probe, in parallel, hundreds of thousands of potential methylation sites in widely dispersed regions of the genome. This method of array synthesis that allows for high feature densities and facile changes in probe content is particularly valuable for the de novo discovery of sites of aberrant methylation states.
[0102] Although the invention has been described in connection with specific embodiments, it should be understood that the invention as claimed should not be unduly limited to such specific embodiments. Modifications and variations of the described compositions and methods of the invention will be apparent to those skilled in the art without departing from the scope and spirit of the invention. Indeed, various modifications of the described compositions and modes of carrying out the invention that are obvious to those skilled in molecular biology or related arts are intended to be within the scope of the following claims.
1
1291
1
21
DNA
Homo sapiens
1
aaccaaccaa taatctccca c 21
2
21
DNA
Homo sapiens
2
accaaccaat tatctcccac c 21
3
21
DNA
Homo sapiens
3
ccaaccaata ttctcccacc c 21
4
21
DNA
Homo sapiens
4
caaccaataa tctcccaccc c 21
5
21
DNA
Homo sapiens
5
aaccaataat ttcccacccc a 21
6
21
DNA
Homo sapiens
6
accaataatc tcccacccca c 21
7
21
DNA
Homo sapiens
7
ccaataatct tccaccccac c 21
8
21
DNA
Homo sapiens
8
caataatctc tcaccccacc t 21
9
21
DNA
Homo sapiens
9
aataatctcc taccccacct a 21
10
21
DNA
Homo sapiens
10
ataatctccc tccccaccta a 21
11
21
DNA
Homo sapiens
11
taatctccca tcccacctaa c 21
12
21
DNA
Homo sapiens
12
aatctcccac tccacctaac t 21
13
21
DNA
Homo sapiens
13
atctcccacc tcacctaact c 21
14
21
DNA
Homo sapiens
14
tctcccaccc tacctaactc a 21
15
21
DNA
Homo sapiens
15
ctcccacccc tcctaactca c 21
16
21
DNA
Homo sapiens
16
tcccacccca tctaactcac a 21
17
21
DNA
Homo sapiens
17
cccaccccac ttaactcaca c 21
18
21
DNA
Homo sapiens
18
ccaccccacc taactcacac a 21
19
21
DNA
Homo sapiens
19
caccccacct tactcacaca a 21
20
21
DNA
Homo sapiens
20
accccaccta tctcacacaa a 21
21
21
DNA
Homo sapiens
21
ccccacctaa ttcacacaaa c 21
22
21
DNA
Homo sapiens
22
cccacctaac tcacacaaac c 21
23
21
DNA
Homo sapiens
23
ccacctaact tacacaaacc a 21
24
21
DNA
Homo sapiens
24
cacctaactc tcacaaacca c 21
25
21
DNA
Homo sapiens
25
acctaactca tacaaaccac c 21
26
20
DNA
Homo sapiens
26
atatagtttc gtcattcatc 20
27
20
DNA
Homo sapiens
27
tacattgccc atgtaattaa 20
28
20
DNA
Homo sapiens
28
atatagtttc gtcattcatc 20
29
20
DNA
Homo sapiens
29
tacattgccc atgtaattaa 20
30
20
DNA
Homo sapiens
30
agatagtttt gtcattcatc 20
31
20
DNA
Homo sapiens
31
agatagtttc ttcattcatc 20
32
20
DNA
Homo sapiens
32
agatagtttc gtcattcatc 20
33
20
DNA
Homo sapiens
33
agatagtttc gttattcatc 20
34
21
DNA
Homo sapiens
34
cctaactcac tcaaaccacc a 21
35
21
DNA
Homo sapiens
35
ctaactcaca taaaccacca a 21
36
21
DNA
Homo sapiens
36
taactcacac taaccaccaa c 21
37
21
DNA
Homo sapiens
37
aaccaaccaa gaatctccca c 21
38
21
DNA
Homo sapiens
38
accaaccaat gatctcccac c 21
39
21
DNA
Homo sapiens
39
ccaaccaata gtctcccacc c 21
40
21
DNA
Homo sapiens
40
caaccaataa gctcccaccc c 21
41
21
DNA
Homo sapiens
41
aaccaataat gtcccacccc a 21
42
21
DNA
Homo sapiens
42
accaataatc gcccacccca c 21
43
21
DNA
Homo sapiens
43
ccaataatct gccaccccac c 21
44
21
DNA
Homo sapiens
44
caataatctc gcaccccacc t 21
45
21
DNA
Homo sapiens
45
aataatctcc gaccccacct a 21
46
21
DNA
Homo sapiens
46
ataatctccc gccccaccta a 21
47
21
DNA
Homo sapiens
47
taatctccca gcccacctaa c 21
48
21
DNA
Homo sapiens
48
aatctcccac gccacctaac t 21
49
21
DNA
Homo sapiens
49
atctcccacc gcacctaact c 21
50
21
DNA
Homo sapiens
50
tctcccaccc gacctaactc a 21
51
21
DNA
Homo sapiens
51
ctcccacccc gcctaactca c 21
52
21
DNA
Homo sapiens
52
tcccacccca gctaactcac a 21
53
21
DNA
Homo sapiens
53
cccaccccac gtaactcaca c 21
54
21
DNA
Homo sapiens
54
ccaccccacc gaactcacac a 21
55
21
DNA
Homo sapiens
55
caccccacct gactcacaca a 21
56
21
DNA
Homo sapiens
56
accccaccta gctcacacaa a 21
57
21
DNA
Homo sapiens
57
ccccacctaa gtcacacaaa c 21
58
21
DNA
Homo sapiens
58
cccacctaac gcacacaaac c 21
59
21
DNA
Homo sapiens
59
ccacctaact gacacaaacc a 21
60
21
DNA
Homo sapiens
60
cacctaactc gcacaaacca c 21
61
21
DNA
Homo sapiens
61
acctaactca gacaaaccac c 21
62
20
DNA
Homo sapiens
62
tacattgccc atgtaattaa 20
63
20
DNA
Homo sapiens
63
atatagtttc gtcattcatc 20
64
20
DNA
Homo sapiens
64
tacattgccc atgtaattaa 20
65
20
DNA
Homo sapiens
65
atatagtttc gtcattcatc 20
66
20
DNA
Homo sapiens
66
agatagtttg gtcattcatc 20
67
20
DNA
Homo sapiens
67
agatagtttc gtcattcatc 20
68
20
DNA
Homo sapiens
68
agatagtttc ggcattcatc 20
69
20
DNA
Homo sapiens
69
agatagtttc gtgattcatc 20
70
21
DNA
Homo sapiens
70
cctaactcac gcaaaccacc a 21
71
21
DNA
Homo sapiens
71
ctaactcaca gaaaccacca a 21
72
21
DNA
Homo sapiens
72
taactcacac gaaccaccaa c 21
73
21
DNA
Homo sapiens
73
aaccaaccaa caatctccca c 21
74
21
DNA
Homo sapiens
74
accaaccaat catctcccac c 21
75
21
DNA
Homo sapiens
75
ccaaccaata ctctcccacc c 21
76
21
DNA
Homo sapiens
76
caaccaataa cctcccaccc c 21
77
21
DNA
Homo sapiens
77
aaccaataat ctcccacccc a 21
78
21
DNA
Homo sapiens
78
accaataatc ccccacccca c 21
79
21
DNA
Homo sapiens
79
ccaataatct cccaccccac c 21
80
21
DNA
Homo sapiens
80
caataatctc ccaccccacc t 21
81
21
DNA
Homo sapiens
81
aataatctcc caccccacct a 21
82
21
DNA
Homo sapiens
82
ataatctccc cccccaccta a 21
83
21
DNA
Homo sapiens
83
taatctccca ccccacctaa c 21
84
21
DNA
Homo sapiens
84
aatctcccac cccacctaac t 21
85
21
DNA
Homo sapiens
85
atctcccacc ccacctaact c 21
86
21
DNA
Homo sapiens
86
tctcccaccc cacctaactc a 21
87
21
DNA
Homo sapiens
87
ctcccacccc ccctaactca c 21
88
21
DNA
Homo sapiens
88
tcccacccca cctaactcac a 21
89
21
DNA
Homo sapiens
89
cccaccccac ctaactcaca c 21
90
21
DNA
Homo sapiens
90
ccaccccacc caactcacac a 21
91
21
DNA
Homo sapiens
91
caccccacct cactcacaca a 21
92
21
DNA
Homo sapiens
92
accccaccta cctcacacaa a 21
93
21
DNA
Homo sapiens
93
ccccacctaa ctcacacaaa c 21
94
21
DNA
Homo sapiens
94
cccacctaac ccacacaaac c 21
95
21
DNA
Homo sapiens
95
ccacctaact cacacaaacc a 21
96
21
DNA
Homo sapiens
96
cacctaactc ccacaaacca c 21
97
21
DNA
Homo sapiens
97
acctaactca cacaaaccac c 21
98
20
DNA
Homo sapiens
98
atatagtttc gtcattcatc 20
99
20
DNA
Homo sapiens
99
tacattgccc atgtaattaa 20
100
20
DNA
Homo sapiens
100
atatagtttc gtcattcatc 20
101
20
DNA
Homo sapiens
101
tacattgccc atgtaattaa 20
102
20
DNA
Homo sapiens
102
agatagtttc gtcattcatc 20
103
20
DNA
Homo sapiens
103
agatagtttc ctcattcatc 20
104
20
DNA
Homo sapiens
104
agatagtttc gccattcatc 20
105
20
DNA
Homo sapiens
105
agatagtttc gtcattcatc 20
106
21
DNA
Homo sapiens
106
cctaactcac ccaaaccacc a 21
107
21
DNA
Homo sapiens
107
ctaactcaca caaaccacca a 21
108
21
DNA
Homo sapiens
108
taactcacac caaccaccaa c 21
109
21
DNA
Homo sapiens
109
aaccaaccaa aaatctccca c 21
110
21
DNA
Homo sapiens
110
accaaccaat aatctcccac c 21
111
21
DNA
Homo sapiens
111
ccaaccaata atctcccacc c 21
112
21
DNA
Homo sapiens
112
caaccaataa actcccaccc c 21
113
21
DNA
Homo sapiens
113
aaccaataat atcccacccc a 21
114
21
DNA
Homo sapiens
114
accaataatc acccacccca c 21
115
21
DNA
Homo sapiens
115
ccaataatct accaccccac c 21
116
21
DNA
Homo sapiens
116
caataatctc acaccccacc t 21
117
21
DNA
Homo sapiens
117
aataatctcc aaccccacct a 21
118
21
DNA
Homo sapiens
118
ataatctccc accccaccta a 21
119
21
DNA
Homo sapiens
119
taatctccca acccacctaa c 21
120
21
DNA
Homo sapiens
120
aatctcccac accacctaac t 21
121
21
DNA
Homo sapiens
121
atctcccacc acacctaact c 21
122
21
DNA
Homo sapiens
122
tctcccaccc aacctaactc a 21
123
21
DNA
Homo sapiens
123
ctcccacccc acctaactca c 21
124
21
DNA
Homo sapiens
124
tcccacccca actaactcac a 21
125
21
DNA
Homo sapiens
125
cccaccccac ataactcaca c 21
126
21
DNA
Homo sapiens
126
ccaccccacc aaactcacac a 21
127
21
DNA
Homo sapiens
127
caccccacct aactcacaca a 21
128
21
DNA
Homo sapiens
128
accccaccta actcacacaa a 21
129
21
DNA
Homo sapiens
129
ccccacctaa atcacacaaa c 21
130
21
DNA
Homo sapiens
130
cccacctaac acacacaaac c 21
131
21
DNA
Homo sapiens
131
ccacctaact aacacaaacc a 21
132
21
DNA
Homo sapiens
132
cacctaactc acacaaacca c 21
133
21
DNA
Homo sapiens
133
acctaactca aacaaaccac c 21
134
20
DNA
Homo sapiens
134
tacattgccc atgtaattaa 20
135
20
DNA
Homo sapiens
135
atatagtttc gtcattcatc 20
136
20
DNA
Homo sapiens
136
tacattgccc atgtaattaa 20
137
20
DNA
Homo sapiens
137
atatagtttc gtcattcatc 20
138
20
DNA
Homo sapiens
138
agatagttta gtcattcatc 20
139
20
DNA
Homo sapiens
139
agatagtttc atcattcatc 20
140
20
DNA
Homo sapiens
140
agatagtttc gacattcatc 20
141
20
DNA
Homo sapiens
141
agatagtttc gtaattcatc 20
142
21
DNA
Homo sapiens
142
cctaactcac acaaaccacc a 21
143
21
DNA
Homo sapiens
143
ctaactcaca aaaaccacca a 21
144
21
DNA
Homo sapiens
144
taactcacac aaaccaccaa c 21
145
21
DNA
Homo sapiens
145
aactcacaca taccaccaac a 21
146
21
DNA
Homo sapiens
146
actcacacaa tccaccaaca c 21
147
21
DNA
Homo sapiens
147
ctcacacaaa tcaccaacac c 21
148
21
DNA
Homo sapiens
148
tcacacaaac taccaacacc t 21
149
21
DNA
Homo sapiens
149
cacacaaacc tccaacacct c 21
150
21
DNA
Homo sapiens
150
acacaaacca tcaacacctc t 21
151
21
DNA
Homo sapiens
151
cacaaaccac taacacctct c 21
152
21
DNA
Homo sapiens
152
acaaaccacc tacacctctc c 21
153
21
DNA
Homo sapiens
153
caaaccacca tcacctctcc c 21
154
21
DNA
Homo sapiens
154
aaaccaccaa tacctctccc c 21
155
21
DNA
Homo sapiens
155
aaccaccaac tcctctcccc c 21
156
21
DNA
Homo sapiens
156
accaccaaca tctctccccc t 21
157
21
DNA
Homo sapiens
157
ccaccaacac ttctccccct c 21
158
21
DNA
Homo sapiens
158
caccaacacc tctccccctc t 21
159
21
DNA
Homo sapiens
159
accaacacct ttccccctct c 21
160
21
DNA
Homo sapiens
160
ccaacacctc tccccctctc a 21
161
21
DNA
Homo sapiens
161
caacacctct tcccctctca t 21
162
21
DNA
Homo sapiens
162
aacacctctc tccctctcat c 21
163
21
DNA
Homo sapiens
163
acacctctcc tcctctcatc c 21
164
21
DNA
Homo sapiens
164
cacctctccc tctctcatcc a 21
165
21
DNA
Homo sapiens
165
acctctcccc ttctcatcca t 21
166
21
DNA
Homo sapiens
166
cctctccccc tctcatccat c 21
167
20
DNA
Homo sapiens
167
atatagtttc gtcattcatc 20
168
20
DNA
Homo sapiens
168
tacattgccc atgtaattaa 20
169
20
DNA
Homo sapiens
169
atatagtttc gtcattcatc 20
170
20
DNA
Homo sapiens
170
tacattgccc atgtaattaa 20
171
20
DNA
Homo sapiens
171
agatagtttt gtcattcatc 20
172
20
DNA
Homo sapiens
172
agatagtttc ttcattcatc 20
173
20
DNA
Homo sapiens
173
agatagtttc gtcattcatc 20
174
20
DNA
Homo sapiens
174
agatagtttc gttattcatc 20
175
21
DNA
Homo sapiens
175
ctctccccct ttcatccatc a 21
176
21
DNA
Homo sapiens
176
tctccccctc tcatccatca c 21
177
21
DNA
Homo sapiens
177
ctccccctct tatccatcac c 21
178
21
DNA
Homo sapiens
178
tccccctctc ttccatcacc c 21
179
21
DNA
Homo sapiens
179
ccccctctca tccatcaccc a 21
180
21
DNA
Homo sapiens
180
cccctctcat tcatcaccca c 21
181
21
DNA
Homo sapiens
181
aactcacaca gaccaccaac a 21
182
21
DNA
Homo sapiens
182
actcacacaa gccaccaaca c 21
183
21
DNA
Homo sapiens
183
ctcacacaaa gcaccaacac c 21
184
21
DNA
Homo sapiens
184
tcacacaaac gaccaacacc t 21
185
21
DNA
Homo sapiens
185
cacacaaacc gccaacacct c 21
186
21
DNA
Homo sapiens
186
acacaaacca gcaacacctc t 21
187
21
DNA
Homo sapiens
187
cacaaaccac gaacacctct c 21
188
21
DNA
Homo sapiens
188
acaaaccacc gacacctctc c 21
189
21
DNA
Homo sapiens
189
caaaccacca gcacctctcc c 21
190
21
DNA
Homo sapiens
190
aaaccaccaa gacctctccc c 21
191
21
DNA
Homo sapiens
191
aaccaccaac gcctctcccc c 21
192
21
DNA
Homo sapiens
192
accaccaaca gctctccccc t 21
193
21
DNA
Homo sapiens
193
ccaccaacac gtctccccct c 21
194
21
DNA
Homo sapiens
194
caccaacacc gctccccctc t 21
195
21
DNA
Homo sapiens
195
accaacacct gtccccctct c 21
196
21
DNA
Homo sapiens
196
ccaacacctc gccccctctc a 21
197
21
DNA
Homo sapiens
197
caacacctct gcccctctca t 21
198
21
DNA
Homo sapiens
198
aacacctctc gccctctcat c 21
199
21
DNA
Homo sapiens
199
acacctctcc gcctctcatc c 21
200
21
DNA
Homo sapiens
200
cacctctccc gctctcatcc a 21
201
21
DNA
Homo sapiens
201
acctctcccc gtctcatcca t 21
202
21
DNA
Homo sapiens
202
cctctccccc gctcatccat c 21
203
20
DNA
Homo sapiens
203
tacattgccc atgtaattaa 20
204
20
DNA
Homo sapiens
204
atatagtttc gtcattcatc 20
205
20
DNA
Homo sapiens
205
tacattgccc atgtaattaa 20
206
20
DNA
Homo sapiens
206
atatagtttc gtcattcatc 20
207
20
DNA
Homo sapiens
207
agatagtttg gtcattcatc 20
208
20
DNA
Homo sapiens
208
agatagtttc gtcattcatc 20
209
20
DNA
Homo sapiens
209
agatagtttc ggcattcatc 20
210
20
DNA
Homo sapiens
210
agatagtttc gtgattcatc 20
211
21
DNA
Homo sapiens
211
ctctccccct gtcatccatc a 21
212
21
DNA
Homo sapiens
212
tctccccctc gcatccatca c 21
213
21
DNA
Homo sapiens
213
ctccccctct gatccatcac c 21
214
21
DNA
Homo sapiens
214
tccccctctc gtccatcacc c 21
215
21
DNA
Homo sapiens
215
ccccctctca gccatcaccc a 21
216
21
DNA
Homo sapiens
216
cccctctcat gcatcaccca c 21
217
21
DNA
Homo sapiens
217
aactcacaca caccaccaac a 21
218
21
DNA
Homo sapiens
218
actcacacaa cccaccaaca c 21
219
21
DNA
Homo sapiens
219
ctcacacaaa ccaccaacac c 21
220
21
DNA
Homo sapiens
220
tcacacaaac caccaacacc t 21
221
21
DNA
Homo sapiens
221
cacacaaacc cccaacacct c 21
222
21
DNA
Homo sapiens
222
acacaaacca ccaacacctc t 21
223
21
DNA
Homo sapiens
223
cacaaaccac caacacctct c 21
224
21
DNA
Homo sapiens
224
acaaaccacc cacacctctc c 21
225
21
DNA
Homo sapiens
225
caaaccacca ccacctctcc c 21
226
21
DNA
Homo sapiens
226
aaaccaccaa cacctctccc c 21
227
21
DNA
Homo sapiens
227
aaccaccaac ccctctcccc c 21
228
21
DNA
Homo sapiens
228
accaccaaca cctctccccc t 21
229
21
DNA
Homo sapiens
229
ccaccaacac ctctccccct c 21
230
21
DNA
Homo sapiens
230
caccaacacc cctccccctc t 21
231
21
DNA
Homo sapiens
231
accaacacct ctccccctct c 21
232
21
DNA
Homo sapiens
232
ccaacacctc cccccctctc a 21
233
21
DNA
Homo sapiens
233
caacacctct ccccctctca t 21
234
21
DNA
Homo sapiens
234
aacacctctc cccctctcat c 21
235
21
DNA
Homo sapiens
235
acacctctcc ccctctcatc c 21
236
21
DNA
Homo sapiens
236
cacctctccc cctctcatcc a 21
237
21
DNA
Homo sapiens
237
acctctcccc ctctcatcca t 21
238
21
DNA
Homo sapiens
238
cctctccccc cctcatccat c 21
239
20
DNA
Homo sapiens
239
atatagtttc gtcattcatc 20
240
20
DNA
Homo sapiens
240
tacattgccc atgtaattaa 20
241
20
DNA
Homo sapiens
241
atatagtttc gtcattcatc 20
242
20
DNA
Homo sapiens
242
tacattgccc atgtaattaa 20
243
20
DNA
Homo sapiens
243
agatagtttc gtcattcatc 20
244
20
DNA
Homo sapiens
244
agatagtttc ctcattcatc 20
245
20
DNA
Homo sapiens
245
agatagtttc gccattcatc 20
246
20
DNA
Homo sapiens
246
agatagtttc gtcattcatc 20
247
21
DNA
Homo sapiens
247
ctctccccct ctcatccatc a 21
248
21
DNA
Homo sapiens
248
tctccccctc ccatccatca c 21
249
21
DNA
Homo sapiens
249
ctccccctct catccatcac c 21
250
21
DNA
Homo sapiens
250
tccccctctc ctccatcacc c 21
251
21
DNA
Homo sapiens
251
ccccctctca cccatcaccc a 21
252
21
DNA
Homo sapiens
252
cccctctcat ccatcaccca c 21
253
21
DNA
Homo sapiens
253
aactcacaca aaccaccaac a 21
254
21
DNA
Homo sapiens
254
actcacacaa accaccaaca c 21
255
21
DNA
Homo sapiens
255
ctcacacaaa acaccaacac c 21
256
21
DNA
Homo sapiens
256
tcacacaaac aaccaacacc t 21
257
21
DNA
Homo sapiens
257
cacacaaacc accaacacct c 21
258
21
DNA
Homo sapiens
258
acacaaacca acaacacctc t 21
259
21
DNA
Homo sapiens
259
cacaaaccac aaacacctct c 21
260
21
DNA
Homo sapiens
260
acaaaccacc aacacctctc c 21
261
21
DNA
Homo sapiens
261
caaaccacca acacctctcc c 21
262
21
DNA
Homo sapiens
262
aaaccaccaa aacctctccc c 21
263
21
DNA
Homo sapiens
263
aaccaccaac acctctcccc c 21
264
21
DNA
Homo sapiens
264
accaccaaca actctccccc t 21
265
21
DNA
Homo sapiens
265
ccaccaacac atctccccct c 21
266
21
DNA
Homo sapiens
266
caccaacacc actccccctc t 21
267
21
DNA
Homo sapiens
267
accaacacct atccccctct c 21
268
21
DNA
Homo sapiens
268
ccaacacctc accccctctc a 21
269
21
DNA
Homo sapiens
269
caacacctct acccctctca t 21
270
21
DNA
Homo sapiens
270
aacacctctc accctctcat c 21
271
21
DNA
Homo sapiens
271
acacctctcc acctctcatc c 21
272
21
DNA
Homo sapiens
272
cacctctccc actctcatcc a 21
273
21
DNA
Homo sapiens
273
acctctcccc atctcatcca t 21
274
21
DNA
Homo sapiens
274
cctctccccc actcatccat c 21
275
20
DNA
Homo sapiens
275
tacattgccc atgtaattaa 20
276
20
DNA
Homo sapiens
276
atatagtttc gtcattcatc 20
277
20
DNA
Homo sapiens
277
tacattgccc atgtaattaa 20
278
20
DNA
Homo sapiens
278
atatagtttc gtcattcatc 20
279
20
DNA
Homo sapiens
279
agatagttta gtcattcatc 20
280
20
DNA
Homo sapiens
280
agatagtttc atcattcatc 20
281
20
DNA
Homo sapiens
281
agatagtttc gacattcatc 20
282
20
DNA
Homo sapiens
282
agatagtttc gtaattcatc 20
283
21
DNA
Homo sapiens
283
ctctccccct atcatccatc a 21
284
21
DNA
Homo sapiens
284
tctccccctc acatccatca c 21
285
21
DNA
Homo sapiens
285
ctccccctct aatccatcac c 21
286
21
DNA
Homo sapiens
286
tccccctctc atccatcacc c 21
287
21
DNA
Homo sapiens
287
ccccctctca accatcaccc a 21
288
21
DNA
Homo sapiens
288
cccctctcat acatcaccca c 21
289
21
DNA
Homo sapiens
289
ccctctcatc tatcacccac c 21
290
21
DNA
Homo sapiens
290
cctctcatcc ttcacccacc a 21
291
21
DNA
Homo sapiens
291
ctctcatcca tcacccacca c 21
292
21
DNA
Homo sapiens
292
tctcatccat tacccaccac c 21
293
21
DNA
Homo sapiens
293
ctcatccatc tcccaccacc c 21
294
21
DNA
Homo sapiens
294
tcatccatca tccaccaccc c 21
295
21
DNA
Homo sapiens
295
catccatcac tcaccacccc t 21
296
21
DNA
Homo sapiens
296
atccatcacc taccacccct c 21
297
21
DNA
Homo sapiens
297
tccatcaccc tccacccctc a 21
298
21
DNA
Homo sapiens
298
ccatcaccca tcacccctca t 21
299
21
DNA
Homo sapiens
299
catcacccac tacccctcat c 21
300
21
DNA
Homo sapiens
300
atcacccacc tcccctcatc a 21
301
21
DNA
Homo sapiens
301
tcacccacca tccctcatca t 21
302
21
DNA
Homo sapiens
302
cacccaccac tcctcatcat a 21
303
21
DNA
Homo sapiens
303
acccaccacc tctcatcata c 21
304
21
DNA
Homo sapiens
304
cccaccaccc ttcatcatac c 21
305
21
DNA
Homo sapiens
305
ccaccacccc tcatcatacc t 21
306
21
DNA
Homo sapiens
306
caccacccct tatcatacct c 21
307
21
DNA
Homo sapiens
307
accacccctc ttcatacctc a 21
308
20
DNA
Homo sapiens
308
atatagtttc gtcattcatc 20
309
20
DNA
Homo sapiens
309
tacattgccc atgtaattaa 20
310
20
DNA
Homo sapiens
310
atatagtttc gtcattcatc 20
311
20
DNA
Homo sapiens
311
tacattgccc atgtaattaa 20
312
20
DNA
Homo sapiens
312
agatagtttt gtcattcatc 20
313
20
DNA
Homo sapiens
313
agatagtttc ttcattcatc 20
314
20
DNA
Homo sapiens
314
agatagtttc gtcattcatc 20
315
20
DNA
Homo sapiens
315
agatagtttc gttattcatc 20
316
21
DNA
Homo sapiens
316
ccacccctca tcatacctca a 21
317
21
DNA
Homo sapiens
317
cacccctcat tatacctcaa c 21
318
21
DNA
Homo sapiens
318
acccctcatc ttacctcaac c 21
319
21
DNA
Homo sapiens
319
cccctcatca tacctcaacc a 21
320
21
DNA
Homo sapiens
320
ccctcatcat tcctcaacca c 21
321
21
DNA
Homo sapiens
321
cctcatcata tctcaaccac c 21
322
21
DNA
Homo sapiens
322
ctcatcatac ttcaaccacc a 21
323
21
DNA
Homo sapiens
323
tcatcatacc tcaaccacca c 21
324
21
DNA
Homo sapiens
324
catcatacct taaccaccac c 21
325
21
DNA
Homo sapiens
325
ccctctcatc gatcacccac c 21
326
21
DNA
Homo sapiens
326
cctctcatcc gtcacccacc a 21
327
21
DNA
Homo sapiens
327
ctctcatcca gcacccacca c 21
328
21
DNA
Homo sapiens
328
tctcatccat gacccaccac c 21
329
21
DNA
Homo sapiens
329
ctcatccatc gcccaccacc c 21
330
21
DNA
Homo sapiens
330
tcatccatca gccaccaccc c 21
331
21
DNA
Homo sapiens
331
catccatcac gcaccacccc t 21
332
21
DNA
Homo sapiens
332
atccatcacc gaccacccct c 21
333
21
DNA
Homo sapiens
333
tccatcaccc gccacccctc a 21
334
21
DNA
Homo sapiens
334
ccatcaccca gcacccctca t 21
335
21
DNA
Homo sapiens
335
catcacccac gacccctcat c 21
336
21
DNA
Homo sapiens
336
atcacccacc gcccctcatc a 21
337
21
DNA
Homo sapiens
337
tcacccacca gccctcatca t 21
338
21
DNA
Homo sapiens
338
cacccaccac gcctcatcat a 21
339
21
DNA
Homo sapiens
339
acccaccacc gctcatcata c 21
340
21
DNA
Homo sapiens
340
cccaccaccc gtcatcatac c 21
341
21
DNA
Homo sapiens
341
ccaccacccc gcatcatacc t 21
342
21
DNA
Homo sapiens
342
caccacccct gatcatacct c 21
343
21
DNA
Homo sapiens
343
accacccctc gtcatacctc a 21
344
20
DNA
Homo sapiens
344
tacattgccc atgtaattaa 20
345
20
DNA
Homo sapiens
345
atatagtttc gtcattcatc 20
346
20
DNA
Homo sapiens
346
tacattgccc atgtaattaa 20
347
20
DNA
Homo sapiens
347
atatagtttc gtcattcatc 20
348
20
DNA
Homo sapiens
348
agatagtttg gtcattcatc 20
349
20
DNA
Homo sapiens
349
agatagtttc gtcattcatc 20
350
20
DNA
Homo sapiens
350
agatagtttc ggcattcatc 20
351
20
DNA
Homo sapiens
351
agatagtttc gtgattcatc 20
352
21
DNA
Homo sapiens
352
ccacccctca gcatacctca a 21
353
21
DNA
Homo sapiens
353
cacccctcat gatacctcaa c 21
354
21
DNA
Homo sapiens
354
acccctcatc gtacctcaac c 21
355
21
DNA
Homo sapiens
355
cccctcatca gacctcaacc a 21
356
21
DNA
Homo sapiens
356
ccctcatcat gcctcaacca c 21
357
21
DNA
Homo sapiens
357
cctcatcata gctcaaccac c 21
358
21
DNA
Homo sapiens
358
ctcatcatac gtcaaccacc a 21
359
21
DNA
Homo sapiens
359
tcatcatacc gcaaccacca c 21
360
21
DNA
Homo sapiens
360
catcatacct gaaccaccac c 21
361
21
DNA
Homo sapiens
361
ccctctcatc catcacccac c 21
362
21
DNA
Homo sapiens
362
cctctcatcc ctcacccacc a 21
363
21
DNA
Homo sapiens
363
ctctcatcca ccacccacca c 21
364
21
DNA
Homo sapiens
364
tctcatccat cacccaccac c 21
365
21
DNA
Homo sapiens
365
ctcatccatc ccccaccacc c 21
366
21
DNA
Homo sapiens
366
tcatccatca cccaccaccc c 21
367
21
DNA
Homo sapiens
367
catccatcac ccaccacccc t 21
368
21
DNA
Homo sapiens
368
atccatcacc caccacccct c 21
369
21
DNA
Homo sapiens
369
tccatcaccc cccacccctc a 21
370
21
DNA
Homo sapiens
370
ccatcaccca ccacccctca t 21
371
21
DNA
Homo sapiens
371
catcacccac cacccctcat c 21
372
21
DNA
Homo sapiens
372
atcacccacc ccccctcatc a 21
373
21
DNA
Homo sapiens
373
tcacccacca cccctcatca t 21
374
21
DNA
Homo sapiens
374
cacccaccac ccctcatcat a 21
375
21
DNA
Homo sapiens
375
acccaccacc cctcatcata c 21
376
21
DNA
Homo sapiens
376
cccaccaccc ctcatcatac c 21
377
21
DNA
Homo sapiens
377
ccaccacccc ccatcatacc t 21
378
21
DNA
Homo sapiens
378
caccacccct catcatacct c 21
379
21
DNA
Homo sapiens
379
accacccctc ctcatacctc a 21
380
20
DNA
Homo sapiens
380
atatagtttc gtcattcatc 20
381
20
DNA
Homo sapiens
381
tacattgccc atgtaattaa 20
382
20
DNA
Homo sapiens
382
atatagtttc gtcattcatc 20
383
20
DNA
Homo sapiens
383
tacattgccc atgtaattaa 20
384
20
DNA
Homo sapiens
384
agatagtttc gtcattcatc 20
385
20
DNA
Homo sapiens
385
agatagtttc ctcattcatc 20
386
20
DNA
Homo sapiens
386
agatagtttc gccattcatc 20
387
20
DNA
Homo sapiens
387
agatagtttc gtcattcatc 20
388
21
DNA
Homo sapiens
388
ccacccctca ccatacctca a 21
389
21
DNA
Homo sapiens
389
cacccctcat catacctcaa c 21
390
21
DNA
Homo sapiens
390
acccctcatc ctacctcaac c 21
391
21
DNA
Homo sapiens
391
cccctcatca cacctcaacc a 21
392
21
DNA
Homo sapiens
392
ccctcatcat ccctcaacca c 21
393
21
DNA
Homo sapiens
393
cctcatcata cctcaaccac c 21
394
21
DNA
Homo sapiens
394
ctcatcatac ctcaaccacc a 21
395
21
DNA
Homo sapiens
395
tcatcatacc ccaaccacca c 21
396
21
DNA
Homo sapiens
396
catcatacct caaccaccac c 21
397
21
DNA
Homo sapiens
397
ccctctcatc aatcacccac c 21
398
21
DNA
Homo sapiens
398
cctctcatcc atcacccacc a 21
399
21
DNA
Homo sapiens
399
ctctcatcca acacccacca c 21
400
21
DNA
Homo sapiens
400
tctcatccat aacccaccac c 21
401
21
DNA
Homo sapiens
401
ctcatccatc acccaccacc c 21
402
21
DNA
Homo sapiens
402
tcatccatca accaccaccc c 21
403
21
DNA
Homo sapiens
403
catccatcac acaccacccc t 21
404
21
DNA
Homo sapiens
404
atccatcacc aaccacccct c 21
405
21
DNA
Homo sapiens
405
tccatcaccc accacccctc a 21
406
21
DNA
Homo sapiens
406
ccatcaccca acacccctca t 21
407
21
DNA
Homo sapiens
407
catcacccac aacccctcat c 21
408
21
DNA
Homo sapiens
408
atcacccacc acccctcatc a 21
409
21
DNA
Homo sapiens
409
tcacccacca accctcatca t 21
410
21
DNA
Homo sapiens
410
cacccaccac acctcatcat a 21
411
21
DNA
Homo sapiens
411
acccaccacc actcatcata c 21
412
21
DNA
Homo sapiens
412
cccaccaccc atcatcatac c 21
413
21
DNA
Homo sapiens
413
ccaccacccc acatcatacc t 21
414
21
DNA
Homo sapiens
414
caccacccct aatcatacct c 21
415
21
DNA
Homo sapiens
415
accacccctc atcatacctc a 21
416
20
DNA
Homo sapiens
416
tacattgccc atgtaattaa 20
417
20
DNA
Homo sapiens
417
atatagtttc gtcattcatc 20
418
20
DNA
Homo sapiens
418
tacattgccc atgtaattaa 20
419
20
DNA
Homo sapiens
419
atatagtttc gtcattcatc 20
420
20
DNA
Homo sapiens
420
agatagttta gtcattcatc 20
421
20
DNA
Homo sapiens
421
agatagtttc atcattcatc 20
422
20
DNA
Homo sapiens
422
agatagtttc gacattcatc 20
423
20
DNA
Homo sapiens
423
agatagtttc gtaattcatc 20
424
21
DNA
Homo sapiens
424
ccacccctca acatacctca a 21
425
21
DNA
Homo sapiens
425
cacccctcat aatacctcaa c 21
426
21
DNA
Homo sapiens
426
acccctcatc atacctcaac c 21
427
21
DNA
Homo sapiens
427
cccctcatca aacctcaacc a 21
428
21
DNA
Homo sapiens
428
ccctcatcat acctcaacca c 21
429
21
DNA
Homo sapiens
429
cctcatcata actcaaccac c 21
430
21
DNA
Homo sapiens
430
ctcatcatac atcaaccacc a 21
431
21
DNA
Homo sapiens
431
tcatcatacc acaaccacca c 21
432
21
DNA
Homo sapiens
432
catcatacct aaaccaccac c 21
433
21
DNA
Homo sapiens
433
atcatacctc taccaccacc c 21
434
21
DNA
Homo sapiens
434
tcatacctca tccaccaccc c 21
435
21
DNA
Homo sapiens
435
catacctcaa tcaccacccc t 21
436
21
DNA
Homo sapiens
436
atacctcaac taccacccct c 21
437
21
DNA
Homo sapiens
437
tacctcaacc tccacccctc a 21
438
21
DNA
Homo sapiens
438
acctcaacca tcacccctca t 21
439
21
DNA
Homo sapiens
439
cctcaaccac tacccctcat c 21
440
21
DNA
Homo sapiens
440
ctcaaccacc tcccctcatc a 21
441
21
DNA
Homo sapiens
441
tcaaccacca tccctcatca t 21
442
21
DNA
Homo sapiens
442
caaccaccac tcctcatcat a 21
443
21
DNA
Homo sapiens
443
aaccaccacc tctcatcata c 21
444
21
DNA
Homo sapiens
444
accaccaccc ttcatcatac c 21
445
21
DNA
Homo sapiens
445
ccaccacccc tcatcatacc t 21
446
21
DNA
Homo sapiens
446
caccacccct tatcatacct c 21
447
21
DNA
Homo sapiens
447
accacccctc ttcatacctc a 21
448
21
DNA
Homo sapiens
448
ccacccctca tcatacctca a 21
449
20
DNA
Homo sapiens
449
atatagtttc gtcattcatc 20
450
20
DNA
Homo sapiens
450
tacattgccc atgtaattaa 20
451
20
DNA
Homo sapiens
451
atatagtttc gtcattcatc 20
452
20
DNA
Homo sapiens
452
tacattgccc atgtaattaa 20
453
20
DNA
Homo sapiens
453
agatagtttt gtcattcatc 20
454
20
DNA
Homo sapiens
454
agatagtttc ttcattcatc 20
455
20
DNA
Homo sapiens
455
agatagtttc gtcattcatc 20
456
20
DNA
Homo sapiens
456
agatagtttc gttattcatc 20
457
21
DNA
Homo sapiens
457
cacccctcat tatacctcaa a 21
458
21
DNA
Homo sapiens
458
acccctcatc ttacctcaaa a 21
459
21
DNA
Homo sapiens
459
cccctcatca tacctcaaaa a 21
460
21
DNA
Homo sapiens
460
ccctcatcat tcctcaaaaa c 21
461
21
DNA
Homo sapiens
461
cctcatcata tctcaaaaac c 21
462
21
DNA
Homo sapiens
462
ctcatcatac ttcaaaaacc a 21
463
21
DNA
Homo sapiens
463
tcatcatacc tcaaaaacca a 21
464
21
DNA
Homo sapiens
464
catcatacct taaaaaccaa c 21
465
21
DNA
Homo sapiens
465
atcatacctc taaaaccaac t 21
466
21
DNA
Homo sapiens
466
tcatacctca taaaccaact a 21
467
21
DNA
Homo sapiens
467
catacctcaa taaccaacta a 21
468
21
DNA
Homo sapiens
468
atacctcaaa taccaactaa c 21
469
21
DNA
Homo sapiens
469
atcatacctc gaccaccacc c 21
470
21
DNA
Homo sapiens
470
tcatacctca gccaccaccc c 21
471
21
DNA
Homo sapiens
471
catacctcaa gcaccacccc t 21
472
21
DNA
Homo sapiens
472
atacctcaac gaccacccct c 21
473
21
DNA
Homo sapiens
473
tacctcaacc gccacccctc a 21
474
21
DNA
Homo sapiens
474
acctcaacca gcacccctca t 21
475
21
DNA
Homo sapiens
475
cctcaaccac gacccctcat c 21
476
21
DNA
Homo sapiens
476
ctcaaccacc gcccctcatc a 21
477
21
DNA
Homo sapiens
477
tcaaccacca gccctcatca t 21
478
21
DNA
Homo sapiens
478
caaccaccac gcctcatcat a 21
479
21
DNA
Homo sapiens
479
aaccaccacc gctcatcata c 21
480
21
DNA
Homo sapiens
480
accaccaccc gtcatcatac c 21
481
21
DNA
Homo sapiens
481
ccaccacccc gcatcatacc t 21
482
21
DNA
Homo sapiens
482
caccacccct gatcatacct c 21
483
21
DNA
Homo sapiens
483
accacccctc gtcatacctc a 21
484
21
DNA
Homo sapiens
484
ccacccctca gcatacctca a 21
485
20
DNA
Homo sapiens
485
tacattgccc atgtaattaa 20
486
20
DNA
Homo sapiens
486
atatagtttc gtcattcatc 20
487
20
DNA
Homo sapiens
487
tacattgccc atgtaattaa 20
488
20
DNA
Homo sapiens
488
atatagtttc gtcattcatc 20
489
20
DNA
Homo sapiens
489
agatagtttg gtcattcatc 20
490
20
DNA
Homo sapiens
490
agatagtttc gtcattcatc 20
491
20
DNA
Homo sapiens
491
agatagtttc ggcattcatc 20
492
20
DNA
Homo sapiens
492
agatagtttc gtgattcatc 20
493
21
DNA
Homo sapiens
493
cacccctcat gatacctcaa a 21
494
21
DNA
Homo sapiens
494
acccctcatc gtacctcaaa a 21
495
21
DNA
Homo sapiens
495
cccctcatca gacctcaaaa a 21
496
21
DNA
Homo sapiens
496
ccctcatcat gcctcaaaaa c 21
497
21
DNA
Homo sapiens
497
cctcatcata gctcaaaaac c 21
498
21
DNA
Homo sapiens
498
ctcatcatac gtcaaaaacc a 21
499
21
DNA
Homo sapiens
499
tcatcatacc gcaaaaacca a 21
500
21
DNA
Homo sapiens
500
catcatacct gaaaaaccaa c 21
501
21
DNA
Homo sapiens
501
atcatacctc gaaaaccaac t 21
502
21
DNA
Homo sapiens
502
tcatacctca gaaaccaact a 21
503
21
DNA
Homo sapiens
503
catacctcaa gaaccaacta a 21
504
21
DNA
Homo sapiens
504
atacctcaaa gaccaactaa c 21
505
21
DNA
Homo sapiens
505
atcatacctc caccaccacc c 21
506
21
DNA
Homo sapiens
506
tcatacctca cccaccaccc c 21
507
21
DNA
Homo sapiens
507
catacctcaa ccaccacccc t 21
508
21
DNA
Homo sapiens
508
atacctcaac caccacccct c 21
509
21
DNA
Homo sapiens
509
tacctcaacc cccacccctc a 21
510
21
DNA
Homo sapiens
510
acctcaacca ccacccctca t 21
511
21
DNA
Homo sapiens
511
cctcaaccac cacccctcat c 21
512
21
DNA
Homo sapiens
512
ctcaaccacc ccccctcatc a 21
513
21
DNA
Homo sapiens
513
tcaaccacca cccctcatca t 21
514
21
DNA
Homo sapiens
514
caaccaccac ccctcatcat a 21
515
21
DNA
Homo sapiens
515
aaccaccacc cctcatcata c 21
516
21
DNA
Homo sapiens
516
accaccaccc ctcatcatac c 21
517
21
DNA
Homo sapiens
517
ccaccacccc ccatcatacc t 21
518
21
DNA
Homo sapiens
518
caccacccct catcatacct c 21
519
21
DNA
Homo sapiens
519
accacccctc ctcatacctc a 21
520
21
DNA
Homo sapiens
520
ccacccctca ccatacctca a 21
521
20
DNA
Homo sapiens
521
atatagtttc gtcattcatc 20
522
20
DNA
Homo sapiens
522
tacattgccc atgtaattaa 20
523
20
DNA
Homo sapiens
523
atatagtttc gtcattcatc 20
524
20
DNA
Homo sapiens
524
tacattgccc atgtaattaa 20
525
20
DNA
Homo sapiens
525
agatagtttc gtcattcatc 20
526
20
DNA
Homo sapiens
526
agatagtttc ctcattcatc 20
527
20
DNA
Homo sapiens
527
agatagtttc gccattcatc 20
528
20
DNA
Homo sapiens
528
agatagtttc gtcattcatc 20
529
21
DNA
Homo sapiens
529
cacccctcat catacctcaa a 21
530
21
DNA
Homo sapiens
530
acccctcatc ctacctcaaa a 21
531
21
DNA
Homo sapiens
531
cccctcatca cacctcaaaa a 21
532
21
DNA
Homo sapiens
532
ccctcatcat ccctcaaaaa c 21
533
21
DNA
Homo sapiens
533
cctcatcata cctcaaaaac c 21
534
21
DNA
Homo sapiens
534
ctcatcatac ctcaaaaacc a 21
535
21
DNA
Homo sapiens
535
tcatcatacc ccaaaaacca a 21
536
21
DNA
Homo sapiens
536
catcatacct caaaaaccaa c 21
537
21
DNA
Homo sapiens
537
atcatacctc caaaaccaac t 21
538
21
DNA
Homo sapiens
538
tcatacctca caaaccaact a 21
539
21
DNA
Homo sapiens
539
catacctcaa caaccaacta a 21
540
21
DNA
Homo sapiens
540
atacctcaaa caccaactaa c 21
541
21
DNA
Homo sapiens
541
atcatacctc aaccaccacc c 21
542
21
DNA
Homo sapiens
542
tcatacctca accaccaccc c 21
543
21
DNA
Homo sapiens
543
catacctcaa acaccacccc t 21
544
21
DNA
Homo sapiens
544
atacctcaac aaccacccct c 21
545
21
DNA
Homo sapiens
545
tacctcaacc accacccctc a 21
546
21
DNA
Homo sapiens
546
acctcaacca acacccctca t 21
547
21
DNA
Homo sapiens
547
cctcaaccac aacccctcat c 21
548
21
DNA
Homo sapiens
548
ctcaaccacc acccctcatc a 21
549
21
DNA
Homo sapiens
549
tcaaccacca accctcatca t 21
550
21
DNA
Homo sapiens
550
caaccaccac acctcatcat a 21
551
21
DNA
Homo sapiens
551
aaccaccacc actcatcata c 21
552
21
DNA
Homo sapiens
552
accaccaccc atcatcatac c 21
553
21
DNA
Homo sapiens
553
ccaccacccc acatcatacc t 21
554
21
DNA
Homo sapiens
554
caccacccct aatcatacct c 21
555
21
DNA
Homo sapiens
555
accacccctc atcatacctc a 21
556
21
DNA
Homo sapiens
556
ccacccctca acatacctca a 21
557
20
DNA
Homo sapiens
557
tacattgccc atgtaattaa 20
558
20
DNA
Homo sapiens
558
atatagtttc gtcattcatc 20
559
20
DNA
Homo sapiens
559
tacattgccc atgtaattaa 20
560
20
DNA
Homo sapiens
560
atatagtttc gtcattcatc 20
561
20
DNA
Homo sapiens
561
agatagttta gtcattcatc 20
562
20
DNA
Homo sapiens
562
agatagtttc atcattcatc 20
563
20
DNA
Homo sapiens
563
agatagtttc gacattcatc 20
564
20
DNA
Homo sapiens
564
agatagtttc gtaattcatc 20
565
21
DNA
Homo sapiens
565
cacccctcat aatacctcaa a 21
566
21
DNA
Homo sapiens
566
acccctcatc atacctcaaa a 21
567
21
DNA
Homo sapiens
567
cccctcatca aacctcaaaa a 21
568
21
DNA
Homo sapiens
568
ccctcatcat acctcaaaaa c 21
569
21
DNA
Homo sapiens
569
cctcatcata actcaaaaac c 21
570
21
DNA
Homo sapiens
570
ctcatcatac atcaaaaacc a 21
571
21
DNA
Homo sapiens
571
tcatcatacc acaaaaacca a 21
572
21
DNA
Homo sapiens
572
catcatacct aaaaaaccaa c 21
573
21
DNA
Homo sapiens
573
atcatacctc aaaaaccaac t 21
574
21
DNA
Homo sapiens
574
tcatacctca aaaaccaact a 21
575
21
DNA
Homo sapiens
575
catacctcaa aaaccaacta a 21
576
21
DNA
Homo sapiens
576
atacctcaaa aaccaactaa c 21
577
21
DNA
Homo sapiens
577
tacctcaaaa tccaactaac c 21
578
21
DNA
Homo sapiens
578
acctcaaaaa tcaactaacc a 21
579
21
DNA
Homo sapiens
579
cctcaaaaac taactaacca a 21
580
21
DNA
Homo sapiens
580
ctcaaaaacc tactaaccaa c 21
581
21
DNA
Homo sapiens
581
tcaaaaacca tctaaccaac c 21
582
21
DNA
Homo sapiens
582
caaaaaccaa ttaaccaacc a 21
583
21
DNA
Homo sapiens
583
aaaaaccaac taaccaacca a 21
584
21
DNA
Homo sapiens
584
aaaaccaact taccaaccaa t 21
585
21
DNA
Homo sapiens
585
aaccaaccaa taatctccca c 21
586
21
DNA
Homo sapiens
586
accaaccaat tatctcccac c 21
587
21
DNA
Homo sapiens
587
ccaaccaata ttctcccacc c 21
588
21
DNA
Homo sapiens
588
caaccaataa tctcccaccc c 21
589
21
DNA
Homo sapiens
589
aaccaataat ttcccacccc g 21
590
20
DNA
Homo sapiens
590
atatagtttc gtcattcatc 20
591
20
DNA
Homo sapiens
591
tacattgccc atgtaattaa 20
592
20
DNA
Homo sapiens
592
atatagtttc gtcattcatc 20
593
20
DNA
Homo sapiens
593
tacattgccc atgtaattaa 20
594
20
DNA
Homo sapiens
594
agatagtttt gtcattcatc 20
595
20
DNA
Homo sapiens
595
agatagtttc ttcattcatc 20
596
20
DNA
Homo sapiens
596
agatagtttc gtcattcatc 20
597
20
DNA
Homo sapiens
597
agatagtttc gttattcatc 20
598
21
DNA
Homo sapiens
598
accaataatc tcccaccccg c 21
599
21
DNA
Homo sapiens
599
ccaataatct tccaccccgc c 21
600
21
DNA
Homo sapiens
600
caataatctc tcaccccgcc t 21
601
21
DNA
Homo sapiens
601
aataatctcc taccccgcct a 21
602
21
DNA
Homo sapiens
602
ataatctccc tccccgccta g 21
603
21
DNA
Homo sapiens
603
taatctccca tcccgcctag c 21
604
21
DNA
Homo sapiens
604
aatctcccac tccgcctagc t 21
605
21
DNA
Homo sapiens
605
atctcccacc tcgcctagct c 21
606
21
DNA
Homo sapiens
606
tctcccaccc tgcctagctc a 21
607
21
DNA
Homo sapiens
607
ctcccacccc tcctagctca c 21
608
21
DNA
Homo sapiens
608
tcccaccccg tctagctcac g 21
609
21
DNA
Homo sapiens
609
cccaccccgc ttagctcacg c 21
610
21
DNA
Homo sapiens
610
ccaccccgcc tagctcacgc a 21
611
21
DNA
Homo sapiens
611
caccccgcct tgctcacgca a 21
612
21
DNA
Homo sapiens
612
accccgccta tctcacgcaa g 21
613
21
DNA
Homo sapiens
613
tacctcaaaa gccaactaac c 21
614
21
DNA
Homo sapiens
614
acctcaaaaa gcaactaacc a 21
615
21
DNA
Homo sapiens
615
cctcaaaaac gaactaacca a 21
616
21
DNA
Homo sapiens
616
ctcaaaaacc gactaaccaa c 21
617
21
DNA
Homo sapiens
617
tcaaaaacca gctaaccaac c 21
618
21
DNA
Homo sapiens
618
caaaaaccaa gtaaccaacc a 21
619
21
DNA
Homo sapiens
619
aaaaaccaac gaaccaacca a 21
620
21
DNA
Homo sapiens
620
aaaaccaact gaccaaccaa t 21
621
21
DNA
Homo sapiens
621
aaccaaccaa gaatctccca c 21
622
21
DNA
Homo sapiens
622
accaaccaat gatctcccac c 21
623
21
DNA
Homo sapiens
623
ccaaccaata gtctcccacc c 21
624
21
DNA
Homo sapiens
624
caaccaataa gctcccaccc c 21
625
21
DNA
Homo sapiens
625
aaccaataat gtcccacccc g 21
626
20
DNA
Homo sapiens
626
tacattgccc atgtaattaa 20
627
20
DNA
Homo sapiens
627
atatagtttc gtcattcatc 20
628
20
DNA
Homo sapiens
628
tacattgccc atgtaattaa 20
629
20
DNA
Homo sapiens
629
atatagtttc gtcattcatc 20
630
20
DNA
Homo sapiens
630
agatagtttg gtcattcatc 20
631
20
DNA
Homo sapiens
631
agatagtttc gtcattcatc 20
632
20
DNA
Homo sapiens
632
agatagtttc ggcattcatc 20
633
20
DNA
Homo sapiens
633
agatagtttc gtgattcatc 20
634
21
DNA
Homo sapiens
634
accaataatc gcccaccccg c 21
635
21
DNA
Homo sapiens
635
ccaataatct gccaccccgc c 21
636
21
DNA
Homo sapiens
636
caataatctc gcaccccgcc t 21
637
21
DNA
Homo sapiens
637
aataatctcc gaccccgcct a 21
638
21
DNA
Homo sapiens
638
ataatctccc gccccgccta g 21
639
21
DNA
Homo sapiens
639
taatctccca gcccgcctag c 21
640
21
DNA
Homo sapiens
640
aatctcccac gccgcctagc t 21
641
21
DNA
Homo sapiens
641
atctcccacc gcgcctagct c 21
642
21
DNA
Homo sapiens
642
tctcccaccc ggcctagctc a 21
643
21
DNA
Homo sapiens
643
ctcccacccc gcctagctca c 21
644
21
DNA
Homo sapiens
644
tcccaccccg gctagctcac g 21
645
21
DNA
Homo sapiens
645
cccaccccgc gtagctcacg c 21
646
21
DNA
Homo sapiens
646
ccaccccgcc gagctcacgc a 21
647
21
DNA
Homo sapiens
647
caccccgcct ggctcacgca a 21
648
21
DNA
Homo sapiens
648
accccgccta gctcacgcaa g 21
649
21
DNA
Homo sapiens
649
tacctcaaaa cccaactaac c 21
650
21
DNA
Homo sapiens
650
acctcaaaaa ccaactaacc a 21
651
21
DNA
Homo sapiens
651
cctcaaaaac caactaacca a 21
652
21
DNA
Homo sapiens
652
ctcaaaaacc cactaaccaa c 21
653
21
DNA
Homo sapiens
653
tcaaaaacca cctaaccaac c 21
654
21
DNA
Homo sapiens
654
caaaaaccaa ctaaccaacc a 21
655
21
DNA
Homo sapiens
655
aaaaaccaac caaccaacca a 21
656
21
DNA
Homo sapiens
656
aaaaccaact caccaaccaa t 21
657
21
DNA
Homo sapiens
657
aaccaaccaa caatctccca c 21
658
21
DNA
Homo sapiens
658
accaaccaat catctcccac c 21
659
21
DNA
Homo sapiens
659
ccaaccaata ctctcccacc c 21
660
21
DNA
Homo sapiens
660
caaccaataa cctcccaccc c 21
661
21
DNA
Homo sapiens
661
aaccaataat ctcccacccc g 21
662
20
DNA
Homo sapiens
662
atatagtttc gtcattcatc 20
663
20
DNA
Homo sapiens
663
tacattgccc atgtaattaa 20
664
20
DNA
Homo sapiens
664
atatagtttc gtcattcatc 20
665
20
DNA
Homo sapiens
665
tacattgccc atgtaattaa 20
666
20
DNA
Homo sapiens
666
agatagtttc gtcattcatc 20
667
20
DNA
Homo sapiens
667
agatagtttc ctcattcatc 20
668
20
DNA
Homo sapiens
668
agatagtttc gccattcatc 20
669
20
DNA
Homo sapiens
669
agatagtttc gtcattcatc 20
670
21
DNA
Homo sapiens
670
accaataatc ccccaccccg c 21
671
21
DNA
Homo sapiens
671
ccaataatct cccaccccgc c 21
672
21
DNA
Homo sapiens
672
caataatctc ccaccccgcc t 21
673
21
DNA
Homo sapiens
673
aataatctcc caccccgcct a 21
674
21
DNA
Homo sapiens
674
ataatctccc cccccgccta g 21
675
21
DNA
Homo sapiens
675
taatctccca ccccgcctag c 21
676
21
DNA
Homo sapiens
676
aatctcccac cccgcctagc t 21
677
21
DNA
Homo sapiens
677
atctcccacc ccgcctagct c 21
678
21
DNA
Homo sapiens
678
tctcccaccc cgcctagctc a 21
679
21
DNA
Homo sapiens
679
ctcccacccc ccctagctca c 21
680
21
DNA
Homo sapiens
680
tcccaccccg cctagctcac g 21
681
21
DNA
Homo sapiens
681
cccaccccgc ctagctcacg c 21
682
21
DNA
Homo sapiens
682
ccaccccgcc cagctcacgc a 21
683
21
DNA
Homo sapiens
683
caccccgcct cgctcacgca a 21
684
21
DNA
Homo sapiens
684
accccgccta cctcacgcaa g 21
685
21
DNA
Homo sapiens
685
tacctcaaaa accaactaac c 21
686
21
DNA
Homo sapiens
686
acctcaaaaa acaactaacc a 21
687
21
DNA
Homo sapiens
687
cctcaaaaac aaactaacca a 21
688
21
DNA
Homo sapiens
688
ctcaaaaacc aactaaccaa c 21
689
21
DNA
Homo sapiens
689
tcaaaaacca actaaccaac c 21
690
21
DNA
Homo sapiens
690
caaaaaccaa ataaccaacc a 21
691
21
DNA
Homo sapiens
691
aaaaaccaac aaaccaacca a 21
692
21
DNA
Homo sapiens
692
aaaaccaact aaccaaccaa t 21
693
21
DNA
Homo sapiens
693
aaccaaccaa aaatctccca c 21
694
21
DNA
Homo sapiens
694
accaaccaat aatctcccac c 21
695
21
DNA
Homo sapiens
695
ccaaccaata atctcccacc c 21
696
21
DNA
Homo sapiens
696
caaccaataa actcccaccc c 21
697
21
DNA
Homo sapiens
697
aaccaataat atcccacccc g 21
698
20
DNA
Homo sapiens
698
tacattgccc atgtaattaa 20
699
20
DNA
Homo sapiens
699
atatagtttc gtcattcatc 20
700
20
DNA
Homo sapiens
700
tacattgccc atgtaattaa 20
701
20
DNA
Homo sapiens
701
atatagtttc gtcattcatc 20
702
20
DNA
Homo sapiens
702
agatagttta gtcattcatc 20
703
20
DNA
Homo sapiens
703
agatagtttc atcattcatc 20
704
20
DNA
Homo sapiens
704
agatagtttc gacattcatc 20
705
20
DNA
Homo sapiens
705
agatagtttc gtaattcatc 20
706
21
DNA
Homo sapiens
706
accaataatc acccaccccg c 21
707
21
DNA
Homo sapiens
707
ccaataatct accaccccgc c 21
708
21
DNA
Homo sapiens
708
caataatctc acaccccgcc t 21
709
21
DNA
Homo sapiens
709
aataatctcc aaccccgcct a 21
710
21
DNA
Homo sapiens
710
ataatctccc accccgccta g 21
711
21
DNA
Homo sapiens
711
taatctccca acccgcctag c 21
712
21
DNA
Homo sapiens
712
aatctcccac accgcctagc t 21
713
21
DNA
Homo sapiens
713
atctcccacc acgcctagct c 21
714
21
DNA
Homo sapiens
714
tctcccaccc agcctagctc a 21
715
21
DNA
Homo sapiens
715
ctcccacccc acctagctca c 21
716
21
DNA
Homo sapiens
716
tcccaccccg actagctcac g 21
717
21
DNA
Homo sapiens
717
cccaccccgc atagctcacg c 21
718
21
DNA
Homo sapiens
718
ccaccccgcc aagctcacgc a 21
719
21
DNA
Homo sapiens
719
caccccgcct agctcacgca a 21
720
21
DNA
Homo sapiens
720
accccgccta actcacgcaa g 21
721
21
DNA
Homo sapiens
721
ccccgcctag ttcacgcaag c 21
722
21
DNA
Homo sapiens
722
cccgcctagc tcacgcaagc c 21
723
21
DNA
Homo sapiens
723
ccgcctagct tacgcaagcc g 21
724
21
DNA
Homo sapiens
724
cgcctagctc tcgcaagccg c 21
725
21
DNA
Homo sapiens
725
gcctagctca tgcaagccgc c 21
726
21
DNA
Homo sapiens
726
cctagctcac tcaagccgcc a 21
727
21
DNA
Homo sapiens
727
ctagctcacg taagccgcca a 21
728
21
DNA
Homo sapiens
728
tagctcacgc tagccgccaa c 21
729
21
DNA
Homo sapiens
729
agctcacgca tgccgccaac g 21
730
21
DNA
Homo sapiens
730
gctcacgcaa tccgccaacg c 21
731
20
DNA
Homo sapiens
731
atatagtttc gtcattcatc 20
732
20
DNA
Homo sapiens
732
tacattgccc atgtaattaa 20
733
20
DNA
Homo sapiens
733
atatagtttc gtcattcatc 20
734
20
DNA
Homo sapiens
734
tacattgccc atgtaattaa 20
735
20
DNA
Homo sapiens
735
agatagtttt gtcattcatc 20
736
20
DNA
Homo sapiens
736
agatagtttc ttcattcatc 20
737
20
DNA
Homo sapiens
737
agatagtttc gtcattcatc 20
738
20
DNA
Homo sapiens
738
agatagtttc gttattcatc 20
739
21
DNA
Homo sapiens
739
ctcacgcaag tcgccaacgc c 21
740
21
DNA
Homo sapiens
740
tcacgcaagc tgccaacgcc t 21
741
21
DNA
Homo sapiens
741
cacgcaagcc tccaacgcct c 21
742
21
DNA
Homo sapiens
742
acgcaagccg tcaacgcctc t 21
743
21
DNA
Homo sapiens
743
cgcaagccgc taacgcctct c 21
744
21
DNA
Homo sapiens
744
gcaagccgcc tacgcctctc c 21
745
21
DNA
Homo sapiens
745
caagccgcca tcgcctctcc c 21
746
21
DNA
Homo sapiens
746
aagccgccaa tgcctctccc c 21
747
21
DNA
Homo sapiens
747
agccgccaac tcctctcccc c 21
748
21
DNA
Homo sapiens
748
gccgccaacg tctctccccc t 21
749
21
DNA
Homo sapiens
749
ccgccaacgc ttctccccct c 21
750
21
DNA
Homo sapiens
750
cgccaacgcc tctccccctc t 21
751
21
DNA
Homo sapiens
751
gccaacgcct ttccccctct c 21
752
21
DNA
Homo sapiens
752
ccaacgcctc tccccctctc a 21
753
21
DNA
Homo sapiens
753
caacgcctct tcccctctca t 21
754
21
DNA
Homo sapiens
754
aacgcctctc tccctctcat c 21
755
21
DNA
Homo sapiens
755
acgcctctcc tcctctcatc c 21
756
21
DNA
Homo sapiens
756
cgcctctccc tctctcatcc a 21
757
21
DNA
Homo sapiens
757
ccccgcctag gtcacgcaag c 21
758
21
DNA
Homo sapiens
758
cccgcctagc gcacgcaagc c 21
759
21
DNA
Homo sapiens
759
ccgcctagct gacgcaagcc g 21
760
21
DNA
Homo sapiens
760
cgcctagctc gcgcaagccg c 21
761
21
DNA
Homo sapiens
761
gcctagctca ggcaagccgc c 21
762
21
DNA
Homo sapiens
762
cctagctcac gcaagccgcc a 21
763
21
DNA
Homo sapiens
763
ctagctcacg gaagccgcca a 21
764
21
DNA
Homo sapiens
764
tagctcacgc gagccgccaa c 21
765
21
DNA
Homo sapiens
765
agctcacgca ggccgccaac g 21
766
21
DNA
Homo sapiens
766
gctcacgcaa gccgccaacg c 21
767
20
DNA
Homo sapiens
767
tacattgccc atgtaattaa 20
768
20
DNA
Homo sapiens
768
atatagtttc gtcattcatc 20
769
20
DNA
Homo sapiens
769
tacattgccc atgtaattaa 20
770
20
DNA
Homo sapiens
770
atatagtttc gtcattcatc 20
771
20
DNA
Homo sapiens
771
agatagtttg gtcattcatc 20
772
20
DNA
Homo sapiens
772
agatagtttc gtcattcatc 20
773
20
DNA
Homo sapiens
773
agatagtttc ggcattcatc 20
774
20
DNA
Homo sapiens
774
agatagtttc gtgattcatc 20
775
21
DNA
Homo sapiens
775
ctcacgcaag gcgccaacgc c 21
776
21
DNA
Homo sapiens
776
tcacgcaagc ggccaacgcc t 21
777
21
DNA
Homo sapiens
777
cacgcaagcc gccaacgcct c 21
778
21
DNA
Homo sapiens
778
acgcaagccg gcaacgcctc t 21
779
21
DNA
Homo sapiens
779
cgcaagccgc gaacgcctct c 21
780
21
DNA
Homo sapiens
780
gcaagccgcc gacgcctctc c 21
781
21
DNA
Homo sapiens
781
caagccgcca gcgcctctcc c 21
782
21
DNA
Homo sapiens
782
aagccgccaa ggcctctccc c 21
783
21
DNA
Homo sapiens
783
agccgccaac gcctctcccc c 21
784
21
DNA
Homo sapiens
784
gccgccaacg gctctccccc t 21
785
21
DNA
Homo sapiens
785
ccgccaacgc gtctccccct c 21
786
21
DNA
Homo sapiens
786
cgccaacgcc gctccccctc t 21
787
21
DNA
Homo sapiens
787
gccaacgcct gtccccctct c 21
788
21
DNA
Homo sapiens
788
ccaacgcctc gccccctctc a 21
789
21
DNA
Homo sapiens
789
caacgcctct gcccctctca t 21
790
21
DNA
Homo sapiens
790
aacgcctctc gccctctcat c 21
791
21
DNA
Homo sapiens
791
acgcctctcc gcctctcatc c 21
792
21
DNA
Homo sapiens
792
cgcctctccc gctctcatcc a 21
793
21
DNA
Homo sapiens
793
ccccgcctag ctcacgcaag c 21
794
21
DNA
Homo sapiens
794
cccgcctagc ccacgcaagc c 21
795
21
DNA
Homo sapiens
795
ccgcctagct cacgcaagcc g 21
796
21
DNA
Homo sapiens
796
cgcctagctc ccgcaagccg c 21
797
21
DNA
Homo sapiens
797
gcctagctca cgcaagccgc c 21
798
21
DNA
Homo sapiens
798
cctagctcac ccaagccgcc a 21
799
21
DNA
Homo sapiens
799
ctagctcacg caagccgcca a 21
800
21
DNA
Homo sapiens
800
tagctcacgc cagccgccaa c 21
801
21
DNA
Homo sapiens
801
agctcacgca cgccgccaac g 21
802
21
DNA
Homo sapiens
802
gctcacgcaa cccgccaacg c 21
803
20
DNA
Homo sapiens
803
atatagtttc gtcattcatc 20
804
20
DNA
Homo sapiens
804
tacattgccc atgtaattaa 20
805
20
DNA
Homo sapiens
805
atatagtttc gtcattcatc 20
806
20
DNA
Homo sapiens
806
tacattgccc atgtaattaa 20
807
20
DNA
Homo sapiens
807
agatagtttc gtcattcatc 20
808
20
DNA
Homo sapiens
808
agatagtttc ctcattcatc 20
809
20
DNA
Homo sapiens
809
agatagtttc gccattcatc 20
810
20
DNA
Homo sapiens
810
agatagtttc gtcattcatc 20
811
21
DNA
Homo sapiens
811
ctcacgcaag ccgccaacgc c 21
812
21
DNA
Homo sapiens
812
tcacgcaagc cgccaacgcc t 21
813
21
DNA
Homo sapiens
813
cacgcaagcc cccaacgcct c 21
814
21
DNA
Homo sapiens
814
acgcaagccg ccaacgcctc t 21
815
21
DNA
Homo sapiens
815
cgcaagccgc caacgcctct c 21
816
21
DNA
Homo sapiens
816
gcaagccgcc cacgcctctc c 21
817
21
DNA
Homo sapiens
817
caagccgcca ccgcctctcc c 21
818
21
DNA
Homo sapiens
818
aagccgccaa cgcctctccc c 21
819
21
DNA
Homo sapiens
819
agccgccaac ccctctcccc c 21
820
21
DNA
Homo sapiens
820
gccgccaacg cctctccccc t 21
821
21
DNA
Homo sapiens
821
ccgccaacgc ctctccccct c 21
822
21
DNA
Homo sapiens
822
cgccaacgcc cctccccctc t 21
823
21
DNA
Homo sapiens
823
gccaacgcct ctccccctct c 21
824
21
DNA
Homo sapiens
824
ccaacgcctc cccccctctc a 21
825
21
DNA
Homo sapiens
825
caacgcctct ccccctctca t 21
826
21
DNA
Homo sapiens
826
aacgcctctc cccctctcat c 21
827
21
DNA
Homo sapiens
827
acgcctctcc ccctctcatc c 21
828
21
DNA
Homo sapiens
828
cgcctctccc cctctcatcc a 21
829
21
DNA
Homo sapiens
829
ccccgcctag atcacgcaag c 21
830
21
DNA
Homo sapiens
830
cccgcctagc acacgcaagc c 21
831
21
DNA
Homo sapiens
831
ccgcctagct aacgcaagcc g 21
832
21
DNA
Homo sapiens
832
cgcctagctc acgcaagccg c 21
833
21
DNA
Homo sapiens
833
gcctagctca agcaagccgc c 21
834
21
DNA
Homo sapiens
834
cctagctcac acaagccgcc a 21
835
21
DNA
Homo sapiens
835
ctagctcacg aaagccgcca a 21
836
21
DNA
Homo sapiens
836
tagctcacgc aagccgccaa c 21
837
21
DNA
Homo sapiens
837
agctcacgca agccgccaac g 21
838
21
DNA
Homo sapiens
838
gctcacgcaa accgccaacg c 21
839
20
DNA
Homo sapiens
839
tacattgccc atgtaattaa 20
840
20
DNA
Homo sapiens
840
atatagtttc gtcattcatc 20
841
20
DNA
Homo sapiens
841
tacattgccc atgtaattaa 20
842
20
DNA
Homo sapiens
842
atatagtttc gtcattcatc 20
843
20
DNA
Homo sapiens
843
agatagttta gtcattcatc 20
844
20
DNA
Homo sapiens
844
agatagtttc atcattcatc 20
845
20
DNA
Homo sapiens
845
agatagtttc gacattcatc 20
846
20
DNA
Homo sapiens
846
agatagtttc gtaattcatc 20
847
21
DNA
Homo sapiens
847
ctcacgcaag acgccaacgc c 21
848
21
DNA
Homo sapiens
848
tcacgcaagc agccaacgcc t 21
849
21
DNA
Homo sapiens
849
cacgcaagcc accaacgcct c 21
850
21
DNA
Homo sapiens
850
acgcaagccg acaacgcctc t 21
851
21
DNA
Homo sapiens
851
cgcaagccgc aaacgcctct c 21
852
21
DNA
Homo sapiens
852
gcaagccgcc aacgcctctc c 21
853
21
DNA
Homo sapiens
853
caagccgcca acgcctctcc c 21
854
21
DNA
Homo sapiens
854
aagccgccaa agcctctccc c 21
855
21
DNA
Homo sapiens
855
agccgccaac acctctcccc c 21
856
21
DNA
Homo sapiens
856
gccgccaacg actctccccc t 21
857
21
DNA
Homo sapiens
857
ccgccaacgc atctccccct c 21
858
21
DNA
Homo sapiens
858
cgccaacgcc actccccctc t 21
859
21
DNA
Homo sapiens
859
gccaacgcct atccccctct c 21
860
21
DNA
Homo sapiens
860
ccaacgcctc accccctctc a 21
861
21
DNA
Homo sapiens
861
caacgcctct acccctctca t 21
862
21
DNA
Homo sapiens
862
aacgcctctc accctctcat c 21
863
21
DNA
Homo sapiens
863
acgcctctcc acctctcatc c 21
864
21
DNA
Homo sapiens
864
cgcctctccc actctcatcc a 21
865
21
DNA
Homo sapiens
865
gcctctcccc ttctcatcca t 21
866
21
DNA
Homo sapiens
866
cctctccccc tctcatccat c 21
867
21
DNA
Homo sapiens
867
ctctccccct ttcatccatc g 21
868
21
DNA
Homo sapiens
868
tctccccctc tcatccatcg c 21
869
21
DNA
Homo sapiens
869
ctccccctct tatccatcgc c 21
870
21
DNA
Homo sapiens
870
tccccctctc ttccatcgcc c 21
871
21
DNA
Homo sapiens
871
ccccctctca tccatcgccc g 21
872
20
DNA
Homo sapiens
872
atatagtttc gtcattcatc 20
873
20
DNA
Homo sapiens
873
tacattgccc atgtaattaa 20
874
20
DNA
Homo sapiens
874
atatagtttc gtcattcatc 20
875
20
DNA
Homo sapiens
875
tacattgccc atgtaattaa 20
876
20
DNA
Homo sapiens
876
agatagtttt gtcattcatc 20
877
20
DNA
Homo sapiens
877
agatagtttc ttcattcatc 20
878
20
DNA
Homo sapiens
878
agatagtttc gtcattcatc 20
879
20
DNA
Homo sapiens
879
agatagtttc gttattcatc 20
880
21
DNA
Homo sapiens
880
cccctctcat tcatcgcccg c 21
881
21
DNA
Homo sapiens
881
ccctctcatc tatcgcccgc c 21
882
21
DNA
Homo sapiens
882
cctctcatcc ttcgcccgcc g 21
883
21
DNA
Homo sapiens
883
ctctcatcca tcgcccgccg c 21
884
21
DNA
Homo sapiens
884
tctcatccat tgcccgccgc c 21
885
21
DNA
Homo sapiens
885
ctcatccatc tcccgccgcc c 21
886
21
DNA
Homo sapiens
886
tcatccatcg tccgccgccc c 21
887
21
DNA
Homo sapiens
887
catccatcgc tcgccgcccc t 21
888
21
DNA
Homo sapiens
888
atccatcgcc tgccgcccct c 21
889
21
DNA
Homo sapiens
889
tccatcgccc tccgcccctc a 21
890
21
DNA
Homo sapiens
890
ccatcgcccg tcgcccctca t 21
891
21
DNA
Homo sapiens
891
catcgcccgc tgcccctcat c 21
892
21
DNA
Homo sapiens
892
atcgcccgcc tcccctcatc a 21
893
21
DNA
Homo sapiens
893
tcgcccgccg tccctcatca t 21
894
21
DNA
Homo sapiens
894
cgcccgccgc tcctcatcat a 21
895
21
DNA
Homo sapiens
895
gcccgccgcc tctcatcata c 21
896
21
DNA
Homo sapiens
896
cccgccgccc ttcatcatac c 21
897
21
DNA
Homo sapiens
897
ccgccgcccc tcatcatacc t 21
898
21
DNA
Homo sapiens
898
cgccgcccct tatcatacct c 21
899
21
DNA
Homo sapiens
899
gccgcccctc ttcatacctc a 21
900
21
DNA
Homo sapiens
900
ccgcccctca tcatacctca g 21
901
21
DNA
Homo sapiens
901
gcctctcccc gtctcatcca t 21
902
21
DNA
Homo sapiens
902
cctctccccc gctcatccat c 21
903
21
DNA
Homo sapiens
903
ctctccccct gtcatccatc g 21
904
21
DNA
Homo sapiens
904
tctccccctc gcatccatcg c 21
905
21
DNA
Homo sapiens
905
ctccccctct gatccatcgc c 21
906
21
DNA
Homo sapiens
906
tccccctctc gtccatcgcc c 21
907
21
DNA
Homo sapiens
907
ccccctctca gccatcgccc g 21
908
20
DNA
Homo sapiens
908
tacattgccc atgtaattaa 20
909
20
DNA
Homo sapiens
909
atatagtttc gtcattcatc 20
910
20
DNA
Homo sapiens
910
tacattgccc atgtaattaa 20
911
20
DNA
Homo sapiens
911
atatagtttc gtcattcatc 20
912
20
DNA
Homo sapiens
912
agatagtttg gtcattcatc 20
913
20
DNA
Homo sapiens
913
agatagtttc gtcattcatc 20
914
20
DNA
Homo sapiens
914
agatagtttc ggcattcatc 20
915
20
DNA
Homo sapiens
915
agatagtttc gtgattcatc 20
916
21
DNA
Homo sapiens
916
cccctctcat gcatcgcccg c 21
917
21
DNA
Homo sapiens
917
ccctctcatc gatcgcccgc c 21
918
21
DNA
Homo sapiens
918
cctctcatcc gtcgcccgcc g 21
919
21
DNA
Homo sapiens
919
ctctcatcca gcgcccgccg c 21
920
21
DNA
Homo sapiens
920
tctcatccat ggcccgccgc c 21
921
21
DNA
Homo sapiens
921
ctcatccatc gcccgccgcc c 21
922
21
DNA
Homo sapiens
922
tcatccatcg gccgccgccc c 21
923
21
DNA
Homo sapiens
923
catccatcgc gcgccgcccc t 21
924
21
DNA
Homo sapiens
924
atccatcgcc ggccgcccct c 21
925
21
DNA
Homo sapiens
925
tccatcgccc gccgcccctc a 21
926
21
DNA
Homo sapiens
926
ccatcgcccg gcgcccctca t 21
927
21
DNA
Homo sapiens
927
catcgcccgc ggcccctcat c 21
928
21
DNA
Homo sapiens
928
atcgcccgcc gcccctcatc a 21
929
21
DNA
Homo sapiens
929
tcgcccgccg gccctcatca t 21
930
21
DNA
Homo sapiens
930
cgcccgccgc gcctcatcat a 21
931
21
DNA
Homo sapiens
931
gcccgccgcc gctcatcata c 21
932
21
DNA
Homo sapiens
932
cccgccgccc gtcatcatac c 21
933
21
DNA
Homo sapiens
933
ccgccgcccc gcatcatacc t 21
934
21
DNA
Homo sapiens
934
cgccgcccct gatcatacct c 21
935
21
DNA
Homo sapiens
935
gccgcccctc gtcatacctc a 21
936
21
DNA
Homo sapiens
936
ccgcccctca gcatacctca g 21
937
21
DNA
Homo sapiens
937
gcctctcccc ctctcatcca t 21
938
21
DNA
Homo sapiens
938
cctctccccc cctcatccat c 21
939
21
DNA
Homo sapiens
939
ctctccccct ctcatccatc g 21
940
21
DNA
Homo sapiens
940
tctccccctc ccatccatcg c 21
941
21
DNA
Homo sapiens
941
ctccccctct catccatcgc c 21
942
21
DNA
Homo sapiens
942
tccccctctc ctccatcgcc c 21
943
21
DNA
Homo sapiens
943
ccccctctca cccatcgccc g 21
944
20
DNA
Homo sapiens
944
atatagtttc gtcattcatc 20
945
20
DNA
Homo sapiens
945
tacattgccc atgtaattaa 20
946
20
DNA
Homo sapiens
946
atatagtttc gtcattcatc 20
947
20
DNA
Homo sapiens
947
tacattgccc atgtaattaa 20
948
20
DNA
Homo sapiens
948
agatagtttc gtcattcatc 20
949
20
DNA
Homo sapiens
949
agatagtttc ctcattcatc 20
950
20
DNA
Homo sapiens
950
agatagtttc gccattcatc 20
951
20
DNA
Homo sapiens
951
agatagtttc gtcattcatc 20
952
21
DNA
Homo sapiens
952
cccctctcat ccatcgcccg c 21
953
21
DNA
Homo sapiens
953
ccctctcatc catcgcccgc c 21
954
21
DNA
Homo sapiens
954
cctctcatcc ctcgcccgcc g 21
955
21
DNA
Homo sapiens
955
ctctcatcca ccgcccgccg c 21
956
21
DNA
Homo sapiens
956
tctcatccat cgcccgccgc c 21
957
21
DNA
Homo sapiens
957
ctcatccatc ccccgccgcc c 21
958
21
DNA
Homo sapiens
958
tcatccatcg cccgccgccc c 21
959
21
DNA
Homo sapiens
959
catccatcgc ccgccgcccc t 21
960
21
DNA
Homo sapiens
960
atccatcgcc cgccgcccct c 21
961
21
DNA
Homo sapiens
961
tccatcgccc cccgcccctc a 21
962
21
DNA
Homo sapiens
962
ccatcgcccg ccgcccctca t 21
963
21
DNA
Homo sapiens
963
catcgcccgc cgcccctcat c 21
964
21
DNA
Homo sapiens
964
atcgcccgcc ccccctcatc a 21
965
21
DNA
Homo sapiens
965
tcgcccgccg cccctcatca t 21
966
21
DNA
Homo sapiens
966
cgcccgccgc ccctcatcat a 21
967
21
DNA
Homo sapiens
967
gcccgccgcc cctcatcata c 21
968
21
DNA
Homo sapiens
968
cccgccgccc ctcatcatac c 21
969
21
DNA
Homo sapiens
969
ccgccgcccc ccatcatacc t 21
970
21
DNA
Homo sapiens
970
cgccgcccct catcatacct c 21
971
21
DNA
Homo sapiens
971
gccgcccctc ctcatacctc a 21
972
21
DNA
Homo sapiens
972
ccgcccctca ccatacctca g 21
973
21
DNA
Homo sapiens
973
gcctctcccc atctcatcca t 21
974
21
DNA
Homo sapiens
974
cctctccccc actcatccat c 21
975
21
DNA
Homo sapiens
975
ctctccccct atcatccatc g 21
976
21
DNA
Homo sapiens
976
tctccccctc acatccatcg c 21
977
21
DNA
Homo sapiens
977
ctccccctct aatccatcgc c 21
978
21
DNA
Homo sapiens
978
tccccctctc atccatcgcc c 21
979
21
DNA
Homo sapiens
979
ccccctctca accatcgccc g 21
980
20
DNA
Homo sapiens
980
tacattgccc atgtaattaa 20
981
20
DNA
Homo sapiens
981
atatagtttc gtcattcatc 20
982
20
DNA
Homo sapiens
982
tacattgccc atgtaattaa 20
983
20
DNA
Homo sapiens
983
atatagtttc gtcattcatc 20
984
20
DNA
Homo sapiens
984
agatagttta gtcattcatc 20
985
20
DNA
Homo sapiens
985
agatagtttc atcattcatc 20
986
20
DNA
Homo sapiens
986
agatagtttc gacattcatc 20
987
20
DNA
Homo sapiens
987
agatagtttc gtaattcatc 20
988
21
DNA
Homo sapiens
988
cccctctcat acatcgcccg c 21
989
21
DNA
Homo sapiens
989
ccctctcatc aatcgcccgc c 21
990
21
DNA
Homo sapiens
990
cctctcatcc atcgcccgcc g 21
991
21
DNA
Homo sapiens
991
ctctcatcca acgcccgccg c 21
992
21
DNA
Homo sapiens
992
tctcatccat agcccgccgc c 21
993
21
DNA
Homo sapiens
993
ctcatccatc acccgccgcc c 21
994
21
DNA
Homo sapiens
994
tcatccatcg accgccgccc c 21
995
21
DNA
Homo sapiens
995
catccatcgc acgccgcccc t 21
996
21
DNA
Homo sapiens
996
atccatcgcc agccgcccct c 21
997
21
DNA
Homo sapiens
997
tccatcgccc accgcccctc a 21
998
21
DNA
Homo sapiens
998
ccatcgcccg acgcccctca t 21
999
21
DNA
Homo sapiens
999
catcgcccgc agcccctcat c 21
1000
21
DNA
Homo sapiens
1000
atcgcccgcc acccctcatc a 21
1001
21
DNA
Homo sapiens
1001
tcgcccgccg accctcatca t 21
1002
21
DNA
Homo sapiens
1002
cgcccgccgc acctcatcat a 21
1003
21
DNA
Homo sapiens
1003
gcccgccgcc actcatcata c 21
1004
21
DNA
Homo sapiens
1004
cccgccgccc atcatcatac c 21
1005
21
DNA
Homo sapiens
1005
ccgccgcccc acatcatacc t 21
1006
21
DNA
Homo sapiens
1006
cgccgcccct aatcatacct c 21
1007
21
DNA
Homo sapiens
1007
gccgcccctc atcatacctc a 21
1008
21
DNA
Homo sapiens
1008
ccgcccctca acatacctca g 21
1009
21
DNA
Homo sapiens
1009
cgcccctcat tatacctcag c 21
1010
21
DNA
Homo sapiens
1010
gcccctcatc ttacctcagc c 21
1011
21
DNA
Homo sapiens
1011
cccctcatca tacctcagcc g 21
1012
21
DNA
Homo sapiens
1012
ccctcatcat tcctcagccg c 21
1013
20
DNA
Homo sapiens
1013
atatagtttc gtcattcatc 20
1014
20
DNA
Homo sapiens
1014
tacattgccc atgtaattaa 20
1015
20
DNA
Homo sapiens
1015
atatagtttc gtcattcatc 20
1016
20
DNA
Homo sapiens
1016
tacattgccc atgtaattaa 20
1017
20
DNA
Homo sapiens
1017
agatagtttt gtcattcatc 20
1018
20
DNA
Homo sapiens
1018
agatagtttc ttcattcatc 20
1019
20
DNA
Homo sapiens
1019
agatagtttc gtcattcatc 20
1020
20
DNA
Homo sapiens
1020
agatagtttc gttattcatc 20
1021
21
DNA
Homo sapiens
1021
cctcatcata tctcagccgc c 21
1022
21
DNA
Homo sapiens
1022
ctcatcatac ttcagccgcc g 21
1023
21
DNA
Homo sapiens
1023
tcatcatacc tcagccgccg c 21
1024
21
DNA
Homo sapiens
1024
catcatacct tagccgccgc c 21
1025
21
DNA
Homo sapiens
1025
atcatacctc tgccgccgcc c 21
1026
21
DNA
Homo sapiens
1026
tcatacctca tccgccgccc c 21
1027
21
DNA
Homo sapiens
1027
catacctcag tcgccgcccc t 21
1028
21
DNA
Homo sapiens
1028
atacctcagc tgccgcccct c 21
1029
21
DNA
Homo sapiens
1029
tacctcagcc tccgcccctc a 21
1030
21
DNA
Homo sapiens
1030
acctcagccg tcgcccctca t 21
1031
21
DNA
Homo sapiens
1031
cctcagccgc tgcccctcat c 21
1032
21
DNA
Homo sapiens
1032
ctcagccgcc tcccctcatc a 21
1033
21
DNA
Homo sapiens
1033
tcagccgccg tccctcatca t 21
1034
21
DNA
Homo sapiens
1034
cagccgccgc tcctcatcat a 21
1035
21
DNA
Homo sapiens
1035
agccgccgcc tctcatcata c 21
1036
21
DNA
Homo sapiens
1036
gccgccgccc ttcatcatac c 21
1037
21
DNA
Homo sapiens
1037
ccgccgcccc tcatcatacc t 21
1038
21
DNA
Homo sapiens
1038
cgccgcccct tatcatacct c 21
1039
21
DNA
Homo sapiens
1039
gccgcccctc ttcatacctc a 21
1040
21
DNA
Homo sapiens
1040
ccgcccctca tcatacctca a 21
1041
21
DNA
Homo sapiens
1041
cgcccctcat tatacctcaa a 21
1042
21
DNA
Homo sapiens
1042
gcccctcatc ttacctcaaa a 21
1043
21
DNA
Homo sapiens
1043
cccctcatca tacctcaaaa g 21
1044
21
DNA
Homo sapiens
1044
ccctcatcat tcctcaaaag c 21
1045
21
DNA
Homo sapiens
1045
cgcccctcat gatacctcag c 21
1046
21
DNA
Homo sapiens
1046
gcccctcatc gtacctcagc c 21
1047
21
DNA
Homo sapiens
1047
cccctcatca gacctcagcc g 21
1048
21
DNA
Homo sapiens
1048
ccctcatcat gcctcagccg c 21
1049
20
DNA
Homo sapiens
1049
tacattgccc atgtaattaa 20
1050
20
DNA
Homo sapiens
1050
atatagtttc gtcattcatc 20
1051
20
DNA
Homo sapiens
1051
tacattgccc atgtaattaa 20
1052
20
DNA
Homo sapiens
1052
atatagtttc gtcattcatc 20
1053
20
DNA
Homo sapiens
1053
agatagtttg gtcattcatc 20
1054
20
DNA
Homo sapiens
1054
agatagtttc gtcattcatc 20
1055
20
DNA
Homo sapiens
1055
agatagtttc ggcattcatc 20
1056
20
DNA
Homo sapiens
1056
agatagtttc gtgattcatc 20
1057
21
DNA
Homo sapiens
1057
cctcatcata gctcagccgc c 21
1058
21
DNA
Homo sapiens
1058
ctcatcatac gtcagccgcc g 21
1059
21
DNA
Homo sapiens
1059
tcatcatacc gcagccgccg c 21
1060
21
DNA
Homo sapiens
1060
catcatacct gagccgccgc c 21
1061
21
DNA
Homo sapiens
1061
atcatacctc ggccgccgcc c 21
1062
21
DNA
Homo sapiens
1062
tcatacctca gccgccgccc c 21
1063
21
DNA
Homo sapiens
1063
catacctcag gcgccgcccc t 21
1064
21
DNA
Homo sapiens
1064
atacctcagc ggccgcccct c 21
1065
21
DNA
Homo sapiens
1065
tacctcagcc gccgcccctc a 21
1066
21
DNA
Homo sapiens
1066
acctcagccg gcgcccctca t 21
1067
21
DNA
Homo sapiens
1067
cctcagccgc ggcccctcat c 21
1068
21
DNA
Homo sapiens
1068
ctcagccgcc gcccctcatc a 21
1069
21
DNA
Homo sapiens
1069
tcagccgccg gccctcatca t 21
1070
21
DNA
Homo sapiens
1070
cagccgccgc gcctcatcat a 21
1071
21
DNA
Homo sapiens
1071
agccgccgcc gctcatcata c 21
1072
21
DNA
Homo sapiens
1072
gccgccgccc gtcatcatac c 21
1073
21
DNA
Homo sapiens
1073
ccgccgcccc gcatcatacc t 21
1074
21
DNA
Homo sapiens
1074
cgccgcccct gatcatacct c 21
1075
21
DNA
Homo sapiens
1075
gccgcccctc gtcatacctc a 21
1076
21
DNA
Homo sapiens
1076
ccgcccctca gcatacctca a 21
1077
21
DNA
Homo sapiens
1077
cgcccctcat gatacctcaa a 21
1078
21
DNA
Homo sapiens
1078
gcccctcatc gtacctcaaa a 21
1079
21
DNA
Homo sapiens
1079
cccctcatca gacctcaaaa g 21
1080
21
DNA
Homo sapiens
1080
ccctcatcat gcctcaaaag c 21
1081
21
DNA
Homo sapiens
1081
cgcccctcat catacctcag c 21
1082
21
DNA
Homo sapiens
1082
gcccctcatc ctacctcagc c 21
1083
21
DNA
Homo sapiens
1083
cccctcatca cacctcagcc g 21
1084
21
DNA
Homo sapiens
1084
ccctcatcat ccctcagccg c 21
1085
20
DNA
Homo sapiens
1085
atatagtttc gtcattcatc 20
1086
20
DNA
Homo sapiens
1086
tacattgccc atgtaattaa 20
1087
20
DNA
Homo sapiens
1087
atatagtttc gtcattcatc 20
1088
20
DNA
Homo sapiens
1088
tacattgccc atgtaattaa 20
1089
20
DNA
Homo sapiens
1089
agatagtttc gtcattcatc 20
1090
20
DNA
Homo sapiens
1090
agatagtttc ctcattcatc 20
1091
20
DNA
Homo sapiens
1091
agatagtttc gccattcatc 20
1092
20
DNA
Homo sapiens
1092
agatagtttc gtcattcatc 20
1093
21
DNA
Homo sapiens
1093
cctcatcata cctcagccgc c 21
1094
21
DNA
Homo sapiens
1094
ctcatcatac ctcagccgcc g 21
1095
21
DNA
Homo sapiens
1095
tcatcatacc ccagccgccg c 21
1096
21
DNA
Homo sapiens
1096
catcatacct cagccgccgc c 21
1097
21
DNA
Homo sapiens
1097
atcatacctc cgccgccgcc c 21
1098
21
DNA
Homo sapiens
1098
tcatacctca cccgccgccc c 21
1099
21
DNA
Homo sapiens
1099
catacctcag ccgccgcccc t 21
1100
21
DNA
Homo sapiens
1100
atacctcagc cgccgcccct c 21
1101
21
DNA
Homo sapiens
1101
tacctcagcc cccgcccctc a 21
1102
21
DNA
Homo sapiens
1102
acctcagccg ccgcccctca t 21
1103
21
DNA
Homo sapiens
1103
cctcagccgc cgcccctcat c 21
1104
21
DNA
Homo sapiens
1104
ctcagccgcc ccccctcatc a 21
1105
21
DNA
Homo sapiens
1105
tcagccgccg cccctcatca t 21
1106
21
DNA
Homo sapiens
1106
cagccgccgc ccctcatcat a 21
1107
21
DNA
Homo sapiens
1107
agccgccgcc cctcatcata c 21
1108
21
DNA
Homo sapiens
1108
gccgccgccc ctcatcatac c 21
1109
21
DNA
Homo sapiens
1109
ccgccgcccc ccatcatacc t 21
1110
21
DNA
Homo sapiens
1110
cgccgcccct catcatacct c 21
1111
21
DNA
Homo sapiens
1111
gccgcccctc ctcatacctc a 21
1112
21
DNA
Homo sapiens
1112
ccgcccctca ccatacctca a 21
1113
21
DNA
Homo sapiens
1113
cgcccctcat catacctcaa a 21
1114
21
DNA
Homo sapiens
1114
gcccctcatc ctacctcaaa a 21
1115
21
DNA
Homo sapiens
1115
cccctcatca cacctcaaaa g 21
1116
21
DNA
Homo sapiens
1116
ccctcatcat ccctcaaaag c 21
1117
21
DNA
Homo sapiens
1117
cgcccctcat aatacctcag c 21
1118
21
DNA
Homo sapiens
1118
gcccctcatc atacctcagc c 21
1119
21
DNA
Homo sapiens
1119
cccctcatca aacctcagcc g 21
1120
21
DNA
Homo sapiens
1120
ccctcatcat acctcagccg c 21
1121
20
DNA
Homo sapiens
1121
tacattgccc atgtaattaa 20
1122
20
DNA
Homo sapiens
1122
atatagtttc gtcattcatc 20
1123
20
DNA
Homo sapiens
1123
tacattgccc atgtaattaa 20
1124
20
DNA
Homo sapiens
1124
atatagtttc gtcattcatc 20
1125
20
DNA
Homo sapiens
1125
agatagttta gtcattcatc 20
1126
20
DNA
Homo sapiens
1126
agatagtttc atcattcatc 20
1127
20
DNA
Homo sapiens
1127
agatagtttc gacattcatc 20
1128
20
DNA
Homo sapiens
1128
agatagtttc gtaattcatc 20
1129
21
DNA
Homo sapiens
1129
cctcatcata actcagccgc c 21
1130
21
DNA
Homo sapiens
1130
ctcatcatac atcagccgcc g 21
1131
21
DNA
Homo sapiens
1131
tcatcatacc acagccgccg c 21
1132
21
DNA
Homo sapiens
1132
catcatacct aagccgccgc c 21
1133
21
DNA
Homo sapiens
1133
atcatacctc agccgccgcc c 21
1134
21
DNA
Homo sapiens
1134
tcatacctca accgccgccc c 21
1135
21
DNA
Homo sapiens
1135
catacctcag acgccgcccc t 21
1136
21
DNA
Homo sapiens
1136
atacctcagc agccgcccct c 21
1137
21
DNA
Homo sapiens
1137
tacctcagcc accgcccctc a 21
1138
21
DNA
Homo sapiens
1138
acctcagccg acgcccctca t 21
1139
21
DNA
Homo sapiens
1139
cctcagccgc agcccctcat c 21
1140
21
DNA
Homo sapiens
1140
ctcagccgcc acccctcatc a 21
1141
21
DNA
Homo sapiens
1141
tcagccgccg accctcatca t 21
1142
21
DNA
Homo sapiens
1142
cagccgccgc acctcatcat a 21
1143
21
DNA
Homo sapiens
1143
agccgccgcc actcatcata c 21
1144
21
DNA
Homo sapiens
1144
gccgccgccc atcatcatac c 21
1145
21
DNA
Homo sapiens
1145
ccgccgcccc acatcatacc t 21
1146
21
DNA
Homo sapiens
1146
cgccgcccct aatcatacct c 21
1147
21
DNA
Homo sapiens
1147
gccgcccctc atcatacctc a 21
1148
21
DNA
Homo sapiens
1148
ccgcccctca acatacctca a 21
1149
21
DNA
Homo sapiens
1149
cgcccctcat aatacctcaa a 21
1150
21
DNA
Homo sapiens
1150
gcccctcatc atacctcaaa a 21
1151
21
DNA
Homo sapiens
1151
cccctcatca aacctcaaaa g 21
1152
21
DNA
Homo sapiens
1152
ccctcatcat acctcaaaag c 21
1153
21
DNA
Homo sapiens
1153
cctcatcata tctcaaaagc c 21
1154
20
DNA
Homo sapiens
1154
atatagtttc gtcattcatc 20
1155
20
DNA
Homo sapiens
1155
tacattgccc atgtaattaa 20
1156
20
DNA
Homo sapiens
1156
atatagtttc gtcattcatc 20
1157
20
DNA
Homo sapiens
1157
tacattgccc atgtaattaa 20
1158
20
DNA
Homo sapiens
1158
agatagtttt gtcattcatc 20
1159
20
DNA
Homo sapiens
1159
agatagtttc ttcattcatc 20
1160
20
DNA
Homo sapiens
1160
agatagtttc gtcattcatc 20
1161
20
DNA
Homo sapiens
1161
agatagtttc gttattcatc 20
1162
21
DNA
Homo sapiens
1162
ctcatcatac ttcaaaagcc a 21
1163
21
DNA
Homo sapiens
1163
tcatcatacc tcaaaagcca a 21
1164
21
DNA
Homo sapiens
1164
catcatacct taaaagccaa c 21
1165
21
DNA
Homo sapiens
1165
atcatacctc taaagccaac t 21
1166
21
DNA
Homo sapiens
1166
tcatacctca taagccaact a 21
1167
21
DNA
Homo sapiens
1167
catacctcaa tagccaacta a 21
1168
21
DNA
Homo sapiens
1168
atacctcaaa tgccaactaa c 21
1169
21
DNA
Homo sapiens
1169
tacctcaaaa tccaactaac c 21
1170
21
DNA
Homo sapiens
1170
acctcaaaag tcaactaacc a 21
1171
21
DNA
Homo sapiens
1171
cctcaaaagc taactaacca a 21
1172
21
DNA
Homo sapiens
1172
ctcaaaagcc tactaaccaa c 21
1173
21
DNA
Homo sapiens
1173
tcaaaagcca tctaaccaac c 21
1174
21
DNA
Homo sapiens
1174
caaaagccaa ttaaccaacc a 21
1175
21
DNA
Homo sapiens
1175
aaaagccaac taaccaacca a 21
1176
21
DNA
Homo sapiens
1176
aaagccaact taccaaccaa t 21
1177
20
DNA
Homo sapiens
1177
atatagtttc gtcattcatc 20
1178
20
DNA
Homo sapiens
1178
tacattgccc atgtaattaa 20
1179
20
DNA
Homo sapiens
1179
atatagtttc gtcattcatc 20
1180
20
DNA
Homo sapiens
1180
tacattgccc atgtaattaa 20
1181
20
DNA
Homo sapiens
1181
agatagtttt gtcattcatc 20
1182
20
DNA
Homo sapiens
1182
agatagtttc ttcattcatc 20
1183
20
DNA
Homo sapiens
1183
agatagtttc gtcattcatc 20
1184
20
DNA
Homo sapiens
1184
agatagtttc gttattcatc 20
1185
21
DNA
Homo sapiens
1185
cctcatcata gctcaaaagc c 21
1186
20
DNA
Homo sapiens
1186
tacattgccc atgtaattaa 20
1187
20
DNA
Homo sapiens
1187
atatagtttc gtcattcatc 20
1188
20
DNA
Homo sapiens
1188
tacattgccc atgtaattaa 20
1189
20
DNA
Homo sapiens
1189
atatagtttc gtcattcatc 20
1190
20
DNA
Homo sapiens
1190
agatagtttg gtcattcatc 20
1191
20
DNA
Homo sapiens
1191
agatagtttc gtcattcatc 20
1192
20
DNA
Homo sapiens
1192
agatagtttc ggcattcatc 20
1193
20
DNA
Homo sapiens
1193
agatagtttc gtgattcatc 20
1194
21
DNA
Homo sapiens
1194
ctcatcatac gtcaaaagcc a 21
1195
21
DNA
Homo sapiens
1195
tcatcatacc gcaaaagcca a 21
1196
21
DNA
Homo sapiens
1196
catcatacct gaaaagccaa c 21
1197
21
DNA
Homo sapiens
1197
atcatacctc gaaagccaac t 21
1198
21
DNA
Homo sapiens
1198
tcatacctca gaagccaact a 21
1199
21
DNA
Homo sapiens
1199
catacctcaa gagccaacta a 21
1200
21
DNA
Homo sapiens
1200
atacctcaaa ggccaactaa c 21
1201
21
DNA
Homo sapiens
1201
tacctcaaaa gccaactaac c 21
1202
21
DNA
Homo sapiens
1202
acctcaaaag gcaactaacc a 21
1203
21
DNA
Homo sapiens
1203
cctcaaaagc gaactaacca a 21
1204
21
DNA
Homo sapiens
1204
ctcaaaagcc gactaaccaa c 21
1205
21
DNA
Homo sapiens
1205
tcaaaagcca gctaaccaac c 21
1206
21
DNA
Homo sapiens
1206
caaaagccaa gtaaccaacc a 21
1207
21
DNA
Homo sapiens
1207
aaaagccaac gaaccaacca a 21
1208
21
DNA
Homo sapiens
1208
aaagccaact gaccaaccaa t 21
1209
20
DNA
Homo sapiens
1209
tacattgccc atgtaattaa 20
1210
20
DNA
Homo sapiens
1210
atatagtttc gtcattcatc 20
1211
20
DNA
Homo sapiens
1211
tacattgccc atgtaattaa 20
1212
20
DNA
Homo sapiens
1212
atatagtttc gtcattcatc 20
1213
20
DNA
Homo sapiens
1213
agatagtttg gtcattcatc 20
1214
20
DNA
Homo sapiens
1214
agatagtttc gtcattcatc 20
1215
20
DNA
Homo sapiens
1215
agatagtttc ggcattcatc 20
1216
20
DNA
Homo sapiens
1216
agatagtttc gtgattcatc 20
1217
21
DNA
Homo sapiens
1217
cctcatcata cctcaaaagc c 21
1218
20
DNA
Homo sapiens
1218
atatagtttc gtcattcatc 20
1219
20
DNA
Homo sapiens
1219
tacattgccc atgtaattaa 20
1220
20
DNA
Homo sapiens
1220
atatagtttc gtcattcatc 20
1221
20
DNA
Homo sapiens
1221
tacattgccc atgtaattaa 20
1222
20
DNA
Homo sapiens
1222
agatagtttc gtcattcatc 20
1223
20
DNA
Homo sapiens
1223
agatagtttc ctcattcatc 20
1224
20
DNA
Homo sapiens
1224
agatagtttc gccattcatc 20
1225
20
DNA
Homo sapiens
1225
agatagtttc gtcattcatc 20
1226
21
DNA
Homo sapiens
1226
ctcatcatac ctcaaaagcc a 21
1227
21
DNA
Homo sapiens
1227
tcatcatacc ccaaaagcca a 21
1228
21
DNA
Homo sapiens
1228
catcatacct caaaagccaa c 21
1229
21
DNA
Homo sapiens
1229
atcatacctc caaagccaac t 21
1230
21
DNA
Homo sapiens
1230
tcatacctca caagccaact a 21
1231
21
DNA
Homo sapiens
1231
catacctcaa cagccaacta a 21
1232
21
DNA
Homo sapiens
1232
atacctcaaa cgccaactaa c 21
1233
21
DNA
Homo sapiens
1233
tacctcaaaa cccaactaac c 21
1234
21
DNA
Homo sapiens
1234
acctcaaaag ccaactaacc a 21
1235
21
DNA
Homo sapiens
1235
cctcaaaagc caactaacca a 21
1236
21
DNA
Homo sapiens
1236
ctcaaaagcc cactaaccaa c 21
1237
21
DNA
Homo sapiens
1237
tcaaaagcca cctaaccaac c 21
1238
21
DNA
Homo sapiens
1238
caaaagccaa ctaaccaacc a 21
1239
21
DNA
Homo sapiens
1239
aaaagccaac caaccaacca a 21
1240
21
DNA
Homo sapiens
1240
aaagccaact caccaaccaa t 21
1241
20
DNA
Homo sapiens
1241
atatagtttc gtcattcatc 20
1242
20
DNA
Homo sapiens
1242
tacattgccc atgtaattaa 20
1243
20
DNA
Homo sapiens
1243
atatagtttc gtcattcatc 20
1244
20
DNA
Homo sapiens
1244
tacattgccc atgtaattaa 20
1245
20
DNA
Homo sapiens
1245
agatagtttc gtcattcatc 20
1246
20
DNA
Homo sapiens
1246
agatagtttc ctcattcatc 20
1247
20
DNA
Homo sapiens
1247
agatagtttc gccattcatc 20
1248
20
DNA
Homo sapiens
1248
agatagtttc gtcattcatc 20
1249
21
DNA
Homo sapiens
1249
cctcatcata actcaaaagc c 21
1250
20
DNA
Homo sapiens
1250
tacattgccc atgtaattaa 20
1251
20
DNA
Homo sapiens
1251
atatagtttc gtcattcatc 20
1252
20
DNA
Homo sapiens
1252
tacattgccc atgtaattaa 20
1253
20
DNA
Homo sapiens
1253
atatagtttc gtcattcatc 20
1254
20
DNA
Homo sapiens
1254
agatagttta gtcattcatc 20
1255
20
DNA
Homo sapiens
1255
agatagtttc atcattcatc 20
1256
20
DNA
Homo sapiens
1256
agatagtttc gacattcatc 20
1257
20
DNA
Homo sapiens
1257
agatagtttc gtaattcatc 20
1258
21
DNA
Homo sapiens
1258
ctcatcatac atcaaaagcc a 21
1259
21
DNA
Homo sapiens
1259
tcatcatacc acaaaagcca a 21
1260
21
DNA
Homo sapiens
1260
catcatacct aaaaagccaa c 21
1261
21
DNA
Homo sapiens
1261
atcatacctc aaaagccaac t 21
1262
21
DNA
Homo sapiens
1262
tcatacctca aaagccaact a 21
1263
21
DNA
Homo sapiens
1263
catacctcaa aagccaacta a 21
1264
21
DNA
Homo sapiens
1264
atacctcaaa agccaactaa c 21
1265
21
DNA
Homo sapiens
1265
tacctcaaaa accaactaac c 21
1266
21
DNA
Homo sapiens
1266
acctcaaaag acaactaacc a 21
1267
21
DNA
Homo sapiens
1267
cctcaaaagc aaactaacca a 21
1268
21
DNA
Homo sapiens
1268
ctcaaaagcc aactaaccaa c 21
1269
21
DNA
Homo sapiens
1269
tcaaaagcca actaaccaac c 21
1270
21
DNA
Homo sapiens
1270
caaaagccaa ataaccaacc a 21
1271
21
DNA
Homo sapiens
1271
aaaagccaac aaaccaacca a 21
1272
21
DNA
Homo sapiens
1272
aaagccaact aaccaaccaa t 21
1273
20
DNA
Homo sapiens
1273
tacattgccc atgtaattaa 20
1274
20
DNA
Homo sapiens
1274
atatagtttc gtcattcatc 20
1275
20
DNA
Homo sapiens
1275
tacattgccc atgtaattaa 20
1276
20
DNA
Homo sapiens
1276
atatagtttc gtcattcatc 20
1277
20
DNA
Homo sapiens
1277
agatagttta gtcattcatc 20
1278
20
DNA
Homo sapiens
1278
agatagtttc atcattcatc 20
1279
20
DNA
Homo sapiens
1279
agatagtttc gacattcatc 20
1280
20
DNA
Homo sapiens
1280
agatagtttc gtaattcatc 20
1281
39
DNA
Homo sapiens
1281
gttttcccag tcacgacttg gttggttatt agagggtgg 39
1282
38
DNA
Homo sapiens
1282
aaacagctat gaccatgacc ataaccaacc aatcaacc 38
1283
144
DNA
Homo sapiens
1283
ctggctggtc accagagggt ggggcggacc gagtgcgctc ggcggctgcg gagaggggta 60
gagcaggcag cgggcggcgg ggagcagcat ggagccggcg gcggggagca gcatggagcc 120
ttcggctgac tggctggcca cggc 144
1284
18
DNA
Homo sapiens
1284
ttagaggatt tgagggat 18
1285
18
DNA
Homo sapiens
1285
aaaactccat actactcc 18
1286
60
DNA
Homo sapiens
1286
cttggctgtc ccagaatgca agaagcccag acggaaaccg tagctgccct ggtaggtttt 60
1287
20
DNA
Homo sapiens
1287
tatatcaaag cagtaagtag 20
1288
90
DNA
Homo sapiens
1288
ccaccctcta ataaccaacc aacccctcct ctttcttcct ccaatactaa caaaaaaacc 60
ccctccaacc ctatccctca aatcctctaa 90
1289
90
DNA
Homo sapiens
1289
gtgtgtttgg tggttgcgga gagggggaga gtaggtagtg ggtggtgggg agtagtatgg 60
agttggtggt ggggagtagt atggagtttt 90
1290
100
DNA
Homo sapiens
1290
ttagaggatt tgagggatag ggttggaggg ggtttttttg ttagtattgg aggaagaaag 60
aggaggggtt ggttggttat tagagggtgg ggtggattgt 100
1291
100
DNA
Homo sapiens
1291
aaaactccat actactcccc accaccaact ccatactact ccccaccacc cactacctac 60
tctccccctc tccgcaacca ccaaacacac acaatccacc 100 | The present invention provides a high-throughput method for the parallel analysis of many potential sites of chemical modification (e.g., methylation) in DNA. It makes use of chemical treatment of the DNA to alter its sequence in a way that depends upon the modification of interest and subsequent analysis of the resulting sequence by hybridization to an array of probes. A device, comprising the array of probes, is provided by the invention, and principles and methods for its design and fabrication are also provided. | 2 |
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