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FIELD OF THE INVENTION
This invention relates to a process for the manufacture of institutional towels with the resulting towel having a much longer life expectancy.
BACKGROUND OF THE INVENTION
It is well known to manufacture towels in a process utilizing yarn spun from 100% cotton fibres. In manufacturing such a towel, the yarn is woven, as is well known, on a loom with the 100% cotton yarn being contained in the ground, fill, and pile yarns. In fact it is the 100% cotton aspect of the towel that makes it more “desirable” by the consumer since it is fixed in the mind of the purchaser that 100% cotton towels are more absorbent than other types of towels. However, when considering an institutional towel there are many drawbacks to providing 100% cotton spun yarns woven into towels since there are other issues which must be considered, which from an institutional standpoint creates disadvantages to the institution, for example a hotel chain.
In manufacturing a typical towel through a continuous process, the towel is woven from the yarns accumulated on beams with the output from the loom being a continuous web of interconnected toweling product which must be bleached to remove any materials applied during the slashing process including a washing step. The toweling products are subsequently dyed through a cold pad batch or beck dying process, washed and finally dried, then separated and finished into towels, or other terry products.
The output therefore from the process includes towels of different colours including white, and various other shades. For a towel or a towel product for the retail market, the consumer is quite content to wash the coloured towels without bleaching and to apply a fabric softener either in the wash or in the dryer.
However, with institutional towels the concerns for the life expectancy of the towel becomes very important. Institutional towels are washed with bleach time after time and as a result it can be expected that the colour will fade after as little as ten washings with the colour being substantially gone after twenty washings. This is quite costly for the industry and therefore as a rule most institutional towels are white. By selecting a white colour, the towels may be washed over and over without the risk of fading. Further coloured institutional towels will fade, even without bleach, and will become unacceptable before they wear out.
It is known in the patent literature to provide a towel construction wherein it is suggested that yarns for ground fill, ground warp and the pile warp, although preferably being made of cotton, may also be manufactured from yarns made of blends of cotton and polyester. For example, U.S. Pat. No. 4,726,400 describes this alternative. It is also discussed within U.S. Pat. No. 4,726,400 that a checkered patent may be provided in the terry cloth by utilizing different colour yarns.
There is no discussion however as to how the yarns might be manufactured and coloured. We are also aware of other constructions for towels, for example U.S. Pat. No. 3,721,273 discusses in the Background of the Invention a preference of cotton and alternatively that synthetic fibres may be blended with the cotton fibres. Rayon yarns are also discussed in relation to their absorbency in that the rayon may be woven into the towel in the form of a 3-pick terry weave. U.S. Pat. No. 3,721,272 discusses that terry yarns have been formed of shrinkable synthetic fibres blended with cellulosic fibres, such as cotton. U.S. Pat. No. 3,721,274 teaches a woven terry towel wherein the ground warp and/or the filling yarns are composed of a blend of polyester and cellulosic fibres, but the terry pile is manufactured from 100% cotton. Within the reference is it stated that polyester has been heretofore considered an undesirable fibre for use in terry towels due to its low moisture absorbency characteristics. In fact, U.S. Pat. No. 6,062,272 issued May 16, 2000 teaches an all cotton pile with polyester being in the ground fabric. The pile yarns although desirably all cotton may include small quantities of other fibres such as polyester or rayon which would result in a corresponding decrease in the absorbency of the finished towel product. Specifically in the examples various compositions are described.
However, in spite of the general discussions in the above-mentioned patent literature there is no discussion of the present problems facing the institutions which purchase institutional towels. The towels used in for example, the hotel industry are generally white and if not white then they will be rendered unusable in twenty washing cycles. This is highly undesirable since most institutions bleach their laundry including towels for health reasons and would prefer to present the hotel guests with an attractive set of towels which have an unique colour and which colour match one another, other than a white set of towels.
It is therefore a primary object of this invention to provide an institutional towel and toweling products which are coloured and yet which are colour-fast.
It is a further object of this invention to provide an institutional towel and toweling product which is the result of a manufacturing process resulting in minimum variation from batch to batch of the final product colour.
It is a further object of this invention to provide an institutional towel that has a significantly longer life expectancy.
It is a further object o f this invention to provide an institutional towel ensemble which includes a matching set of toweling products having very little colour variation from item to item.
It is a further object of this invention to provide a process of manufacturing an institutional towel which eliminates the need to dye the towel at the towel mill.
Further and other objects of the invention may become apparent to those skilled in the art when considering the following summary of the invention and a more detailed description of the preferred embodiments illustrated herein.
SUMMARY OF THE INVENTION
According to a primary aspect of the invention there is provided a process for manufacturing toweling products comprising the steps of:
1) Providing cotton fibres;
2) Providing pre-dyed polyester fibres;
3) Orienting the fibres of the cotton in substantially a uniform parallel direction by carding;
4) Orienting the pre-dyed polyester fibres in substantially parallel direction by a carding process;
5) Draw blending the cotton and pre-dyed polyester fibres in a slivering process preferably in a ratio of 8 to 14% of the pre-dyed polyester fibres with the balance being the cotton fibre;
6) Following the intimate draw blending of the pre-dyed polyester and cotton fibres spinning the slivered fibres into twisted yarns having a pre-determined colour which will be imparted to the toweling product;
7) Accumulating the yarns on a loom beam following warping/slashing the yarns in preparation for the weaving process;
8) Weaving said coloured yarn into the ground warp, the fill and the pile warp yarns in the toweling product which preferably is a continuous process;
9) Preferably bleaching and subsequently washing and drying said toweling product prior to finishing;
wherein the colour in the toweling product is obtained by the weaving process only with no subsequent dying process being necessary and wherein the resulting towel products have
i) a minimum colour variation from batch to batch,
ii) are colour fast, the colour being imparted to the toweling product by the predyed polyester fibre allowing all institutional towels resulting from this process to be able to be washed and handled together,
iii) a significantly longer life expectancy of the towel imparted by the polyester fibre, and
iv) the ability of the toweling product to be manufactured into a matching set of toweling products having minimum colour variation from product to product.
The resulting institutional towel from this process overcomes many of the deficiencies and problems experienced in the institutional towel industry having a severe limitation in terms of white only in order to minimize the handling problem which would result should colours have to be separated.
In relation to life expectancy it has been, through experimentation, proven that such a towel manufactured for experimental purposes has undergone 100 washes with bleaching, but it has not lost it's luster and has not faded in spite of having been bleached. The towel was manufactured from the drawn blend yam of a vanilla colour.
The colour therefore in the institutional towel has been imparted to it by spinning yarns of a drawn blend of pre-dyed polyester fibres and natural cotton fibres. The resulting towel therefore is colour-fast, as a result, many times over those towels dyed in conventional manners. Typically as discussed in the background towels may be washed twenty times before one might expect the colour to be significantly altered. The experimental towels produced did not fade and retained their luster through 100 wash cycles.
According to yet another aspect of the invention there is provided an institutional coloured towel (and preferably manufactured from the above-mentioned process) which comprises coloured yarns draw blended of a pre-determined amount of pre-dyed polyester fibre with the remainder being natural cotton fibres resulting in a yarn of predetermined colour, said toweling product having ground warp, fill, and terry loop fibres manufactured from said yarn resulting in said institutional towel having a predetermined colour which is colour fast, has little variance from lot to lot, may be washed and bleached, is conveniently handled by an institution, has an increased life expectancy imparted by the polyester, and which has reproducible colour of the finished towel product from batch to batch.
It is therefore expected that other colours other than a vanilla colour obtained with the 12.5% brown pre-dyed polyester fibre may also be manufactured. Pastel shades of blue, red, green or the like may be manufactured in the form of an institutional towel which is superior when compared to known institutional towels of all cotton construction in terms of convenience and handling through the washing and bleaching cycles with the resulting increase in life expectancy while maintaining its colour and luster. The colour is reproducible from batch to batch and from product to product so that complete bath ensembles can be provided to the institution with matching colours from the face cloth, the bath towel and the hand towel and the bath mats.
According to yet another aspect of the invention there is provided a method of colouring a towel, and preferably an institutional towel, comprising weaving said towel from twisted yarn spun from an intimate, drawn blend of a predetermined amount of pre-dyed polyester fibre, preferably in the range of 8-14%, with the balance being cotton fibre, said coloured yarn thereafter being spun from said drawn blend and all of said ground yams, fill yarns and pile yarns making up said towel being formed from said drawn blended twisted coloured yarn to form said institutional towel which has the properties of: 1) being colourfast; 2) being consistent in colour from batch to batch; 3) being consistent in colour from towel product type to towel product type, for example, for a bath towel, face towel, wash cloth, and bath mat; 4) being capable of being bleached and washed without fading or loosing it's luster; and 5) having an extended life expectancy.
According to yet another aspect of the invention there is provided a towel and preferably an institutional towel, preferably manufactured from the above method comprising twisted yarn spun from an intimate, drawn blend of a predetermined amount of pre-dyed polyester fibre, preferably in the range of 8-14%, with the balance being cotton fibre, said coloured yarn thereafter being spun from said drawn blend and all of said ground yarns, fill yarns and pile yarns making up said towel being formed from said drawn blended twisted coloured yarn to form said institutional towel which has the properties of: 1) being colourfast; 2) being consistent in colour from batch to batch; 3) being consistent in colour from towel product type to towel product type, for example, for a bath towel, hand towel, wash cloth, and bath mat; 4) being capable of being bleached and washed without fading or loosing it's luster; and 5) having an extended life expectancy.
The aspect of providing a colour within an institutional towel is a considerable improvement for the hotel industry which no longer will be required to supply bland white towels or run the risk of having considerable expense if coloured towels are selected. By providing a towel by the above-mentioned method any pastel shade of towel can be manufactured including vanilla, pink, light blue, light green, grey and any other pastel type of shade without sacrificing a great deal of absorbency in the towel. It is considered that the advantages of such an institutional towel or for that matter a coloured towel in the retail trade are more than offset by the minimal loss in absorbency.
According to another aspect of the invention there is provided a coloured institutional towel comprising ground warp, fill, and pile warped yarns, all of said yarns being coloured by intimately draw blending a predetermined amount of pre-dyed polyester fibre with cotton fibre when the yarn is spun and twisted to thereby form a predetermined colour for the institutional towel.
For a preferred vanilla towel the twisted yarn includes a predetermined amount of predyed polyester fibre having a predetermined denier, and tenacity and fibre length. No limitations however to these variables is contemplated for use in the institutional towel. For the vanilla towel the predyed polyester fibre has a beige colour but as discussed it may have a different colour depending on the shade of towel desired. The colour of the predyed polyester is established by trial and error, and specified by a matching comparison with a coloured swatch. The predyed polyester/cotton draw blended twisted yarn is manufactured with a predetermined twist (turns per inch) in the yarn. The ground and fill yams may or may not have substantially the same twist as the pile yarns although they are of course of the same colour.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a flow chart of the Process of Manufacture of the present invention utilized in the manufacture of the Institutional Towel thereof.
FIG. 2 is a schematic perspective view of the towel product manufactured from the process steps of FIG. 1 .
FIG. 3 is a close up perspective view of the yarn elements and how they are woven into the terry product illustrated in FIG. 2 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, a process flow chart is illustrated which describes the manner in which the Institutional Towel is manufactured. The towel product ( 5 ) therefore of FIG. 2 is manufactured so as to overcome many of the deficiencies in prior institutional towels. As discussed in the Background of the Invention, most institutional towels are white because otherwise they would not stand up to the washing and bleaching cycles. It is appreciated that a towel product in a hotel, for example, would be washed on a daily basis. Should these towels and various towel products such as wash cloths, hand towels, bath towels, bath mats, bath robes, etc. be coloured, as is desirable, then they would have to be sorted out from the regular laundry flow and could not be subjected to bleaching. However, if they are not sorted then these toweling products would not stand up and the colour would fade by approximately 20 cycles.
Therefore, to address this problem, the present invention provides an Institutional Towel that is preferably vanilla in colour but may be other pastel shades such as grey, light blue, light green, yellow or the like. The toweling product formed by carrying out the process of FIG. 1 will have the preferred vanilla colour and will have very little shade variance from batch to batch of towels, and from batch to batch of matching toweling products making up a bath assemble. This minimum variation from batch to batch and from toweling product to toweling product is important especially after many washing cycles. It is desirable that the product stand up to the rigors of such washing and bleaching cycles and yet not fade, yet still matching the colour for the bath mat, bath towel, face towel, and wash clothes. It is also a result of this invention that the product is coloured without the necessity of carrying out a dying process at the towel mill. The resulting towel product stands up to many, many washings because of the extra strength imparted to the yarns by the presence of polyester. The polyester is distributed throughout the towel having been blended with cotton in manufacturing the yarn and therefore this strength and resilience of the product is distributed throughout all of the yarns including the ground, fill and pile yarns.
Referring to FIG. 1, the polyester is purchased in raw fibre form, with the fibres having been pre-dyed in this example to a brown colour, which when blended with the cotton fibres will result in a yarn having a vanilla colour. The materials are received in bales and the fibres are somewhat compacted as received. The fibres therefore must be separated sufficiently so as to be able to be properly handled. As is known, the cotton is cleaned. Once the fibres have been broken down in the sense that they have been separated and the bulk density thereof has been drastically reduced, they are in the form that they can be passed through a carding machine in order to take the fibres that are randomly distributed in the pre-dyed polyester and the cotton and to orient them in a generally parallel direction. The result of the carding process is that the fibres are laid out in a parallel direction in a long extended, untwisted rope like element. This is the case with both the pre-dyed polyester and the cotton. The continuous filaments therefore, having been carded are then accumulated to be fed through a slivering machine, and is utilized to create an intimate draw blend of the cotton and pre-dyed polyester carded fibres. The products are slivered together, that is to say draw blended, at a ratio of between 8 to 14% polyester, and the remainder being cotton. The resulting slivered element is continuous and is of considerable larger diameter than the prior carded products. The slivered continuous elements are therefore accumulated and fed into a yarn spinning machine, and the yarn product is spun from the intimately draw blended slivered mixture of polyester and cotton. The resulting twisted yarn is then accumulated again and processed through a warping/slashing process and coated with a compound to enable the yarn to stand up and impart to it a certain robust quality required during the weaving process. The yarn is therefore accumulated on a beam and fed to a loom for the toweling product to be manufactured. The ground yarn, the fill yarn and the pile yarns are all manufactured from the same coloured yarn intimately draw blended to provide the preferred vanilla colour. The resulting towel products are therefore finished and prepared for distribution, once the towels have been washed in caustic and bleached to remove the coating compound and dried to enable finishing. The resulting toweling products therefore have all of the desired qualities of the institutional towel product previously discussed with an unexpectedly much longer extended life than what might have been expected from the use of a draw blended yarn product that is pre-coloured. The towel product is therefore coloured without the necessity of including the dye step in the towel manufacturing process and the handling of chemicals required in order to do so. The safety within the mill therefore is enhanced and the product has proven by experimentation to be much superior to previously known institutional towels and towel products.
The coloured towel product ( 5 ) is illustrated in FIG. 2 with the preferred three pick weaving step shown in close up in FIG. 3 with all of the yarns shown in FIG. 3 therefore including the vanilla colour draw blended twisted yarn previously manufactured at the yarn mill. The towel product therefore includes the pile coloured yarns ( 20 ) the ground coloured yarns ( 30 ) and the fill coloured yarns ( 40 ) which are woven in a manner as is well known on a loom. All of the yarns are those which have a vanilla colour and contain an intimate draw blend of polyester and cotton. The coloured towel product preferably includes 75 threads per inch for the pile yarn, 60 threads per inch for the fill yarn and 45 threads per inch for the ground yarns. Up to three pile picks may be woven between two adjacent weft yarns of ground fabric. The result is a towel without an increase in the amount of polyester therein, but a different significant distribution which imparts the significant advantages identified above.
For the preferred vanilla towel ( 5 ) the twisted yarn ( 20 , 30 , 40 ) includes a predetermined amount of predyed polyester fibre having a predetermined denier, and tenacity and fibre length. No limitations however to these variables is contemplated for use in the institutional towel. For the vanilla towel ( 5 ) the predyed polyester fibre has a beige colour. The colour of the predyed polyester is established by trial and error, and specified by a matching comparison with a coloured swatch. The predyed polyester/cotton draw blended twisted yarn ( 20 , 30 , 40 ) are manufactured with a predetermined twist (turns per inch) in the yarns. The ground and fill yarns ( 30 , 40 ) may or may not have substantially the same twist as the pile yarns ( 20 ) although they are of course of the same colour.
As many changes can be made to the preferred embodiment of the invention without departing from the scope thereof; it is intended that all matter contained herein be considered illustrative of the invention and not in a limiting sense. | A coloured institutional towel comprising ground warp, fill, and pile warped yarns, all of said yarns being colored by intimately draw blending a predetermined amount of pre-dyed polyester fiber with cotton fiber when the yarn is spun and twisted to thereby form a predetermined color for the institutional towel. | 3 |
[0001] This application claims the priority benefit under 35 U.S.C. section 119 of U.S. Provisional Patent Application Nos. 61/609,269 entitled “Additives To Improve Open-Time And Freeze-Thaw Characteristics Of Water-Based Paints And Coatings” filed on Mar. 10, 2012; which is in its entirety herein incorporated by reference.
FIELD OF INVENTION
[0002] The present invention relates to the use of a particular family of alkoxylated compounds and allylglycidy ether derivatives thereof for improving open time characteristics of aqueous coating compositions such as paints, alkyd paints, inks and other paper coating compositions.
[0003] More specifically, this invention is directed to the use of various agents as additives to increase the open time and improve the freeze-thaw stability of water-based latex paint coatings. The agents found to cause such improvements were: Tristyrenated phenols reacted with one or two units of allylglycidyl ether, then ethylene oxide, then possibly sulfamic acid to yield an anion, Distyrenated phenols reacted with one or two units of allylglycidyl ether and then ethylene oxide, Ethoxylated beta naphthol, Dodecyl benzene sulfonic acid neutralized with triethanolamine and formulated with a reverse ethylene oxide/propylene oxide reverse block co-polymer and water.
BACKGROUND OF THE INVENTION
[0004] Waterborne paints, inks, and other coatings are used for a multitude of applications including interior and exterior coatings for paper, wood, architectural surfaces, and many more. These coatings are composed of a number of components such as latex, alkyd, or other binders, pigments or other colorants, water, coalescing agents, thickeners, solvents, and a number of surfactants for various purposes. With strict environmental legislation requiring the reduction of the amount of Volatile Organic Compounds (VOC) in coatings, it is desirable to have paint formulations with little or no VOC content. Common VOC components in paint include coalescing agents and glycol freeze-thaw stability additives, among others. Removing these has resulted in a number of formulation and composition challenges. However, due to competitive pressures, low VOC coatings and paints must maintain or exceed coating performance standards expected in the industry.
[0005] Since waterborne coatings are subject to freezing at low temperatures commonly experienced in shipping or storage in northern latitudes, there is significant interest in improving the freeze/thaw stability of latex paints. As a consequence of reducing or eliminating VOCs in latex paints due to government regulations, simple glycols such as propylene glycol (PG), commonly used to help improve freeze/thaw stability, are being eliminated. Many coalescing solvents such as Texanol (IBT) that are VOCs are also being eliminated requiring softer (lower Tg) latexes to be used instead of the traditional harder (high Tg) latexes. Softer latexes have poorer freeze/thaw stability characteristics than higher Tg latexes further increasing the need for non-VOC freeze/thaw stability additives.
[0006] For low VOC paint binder latexes, the average Tg is close to or below 0° C. so that little or no coalescent is needed to make a good coating after drying. However, latex binders with low Tg often cause grit when subjected to freeze/thaw cycles as well as exposure to mechanical shear. The resulting coating films are softer and tackier, even after fully dried, and are susceptible to blocking and dirt pick-up effects. Also, such low Tg latex binders and resulting latex paints are not stable, and gel in a cold environmental storage or transportation process. Freeze-thaw stability of low Tg latex binders and low VOC paints is critically important for transportation, storage, and practical applications. Thus, there is a need to develop latex paints and latex particle dispersions that meet zero or low VOC requirements and at the same provide excellent mechanical and film performance without sacrificing the freeze-thaw stability of those paints. This requires non-VOC freeze/thaw stability additives.
[0007] In traditional latex binders for architectural coatings, the glass transition temperature is between about 10° C. to about 40° C. These higher Tg latexes do not suffer from the grit, blocking, and other problems that the low Tg latexes do. However, architectural coating formulations based on them usually need coalescent agents and anti-freeze agents, both of which are typically high-VOC solvents. Thus, there is a need for non-VOC freeze/thaw stability additives for use with higher Tg latex binders.
[0008] Latex freeze-thaw (sometimes herein referred to as “F/T”) stability, including the freezing-thawing process, destabilization mechanism, and polymer structures, have been extensively studied since 1950. Blackley, D. C., Polymer Lattices-Science and Technology, 2 nd Ed., Vol. 1, Chapman & Hall, 1997, gives a comprehensive review of colloidal destabilization of latexes by freezing. The freezing process starts with the decrease of temperature, which leads to the formation of ice crystals. The ice crystal structures progressively increase the latex particle concentration in the unfrozen water. Eventually latex particles are forced into contact with each other as the pressure of growing ice crystal structures, resulting in particle aggregation or interparticle coalescence.
[0009] To make a stable latex dispersion in aqueous medium or latex paints with freeze-thaw stability, various approaches have been employed. The addition of antifreeze agents, e.g. glycol derivatives, has been applied to latex paint to achieve freeze-thaw stability. Thus, latex paints include anti-freeze agents to allow the paints to be used even after they have been subjected to freezing conditions. Exemplary anti-freeze agents include ethylene glycol, diethylene glycol, and propylene glycol. For a more detailed discussion see Bosen, S. F., Bowles, W. A., Ford, E. A., and Person, B. D., “Antifreezes,” Ullmann's Encyclopedia of Industrial Chemistry, 5 th Ed., Vol. A3, VCH Verlag, pages 23-32, 1985. However, since these simple glycols are VOCs, a low or no VOC requirement for the formulated paint means that the glycol level has to be reduced or eliminated.
[0010] A number of methods to achieve freeze/thaw stability are known in the art. Farwaha et. al. (U.S. Pat. No. 5,399,617) discloses the use of copolymerizable amphoteric surfactants and discloses latex copolymers comprising the copolymerizable amphoteric surfactants to impart freeze-thaw stability to the latex paints. Zhao et. al. (U.S. Pat. No. 6,933,415 B2) discloses latex polymers including polymerizable alkoxylated surfactants and discloses the low VOC aqueous coatings based on them have excellent freeze-thaw stability. Farwaha et. al. (U.S. Pat. No. 5,610,225) discloses incorporating a monomer with long polyethylene glycol structures to achieve stable freeze-thaw latex. Okubo et. al. (U.S. Pat. No. 6,410,655 B2) discloses freeze-thaw stability of latex polymers including ethylenic unsaturated monomers.
[0011] It is well known that certain nonionic surfactants impart varying degrees of freeze/thaw stability to latexes; however, the levels required to impart freeze/thaw stability vary as a function of the Tg of the polymers and the propylene glycol level. Some of these nonionic surfactants are disclosed in U.S. Pat. No. 7,906,577 and in U.S. Pat. No. 8,304,479. Some of these can also function as open time extenders.
[0012] Another one of the challenges of formulating waterborne coatings is achieving an acceptable balance of properties both during the film application and drying process as well as in the final film. There is a competition between the requirements for adequate workability time of the coating with appropriate film formation and recoat behavior. The period in which irregularities in a freshly applied coating can be repaired without resulting in brush marks is referred to as the open time, while the period in which a coating can be applied over an existing paint film without leaving lap marks is deemed the wet edge time.
[0013] Aqueous coatings generally employ dispersed high molecular weight polymers as binders. These binders often provide short open times when the coating is dried since the dispersed polymer particles tend to be immobilized quickly in the edge region of an applied coating. As a result, the viscosity of the coating increases rapidly, which leads to a limited window of workability. Small molecule alkylene glycols such as ethylene and propylene glycol are routinely incorporated in aqueous coatings as humectants, but are considered to be VOCs. Thus, there is also a need for low VOC additives to improve open time and wet edge in aqueous coatings.
[0014] As mentioned above, surfactants are common components of waterborne coating formulations. They have many functions including dispersing pigments, wetting the substrate, improving flow and leveling, etc. However, once the coating has been applied to a substrate the surfactant is no longer needed. In fact, the presence of the surfactant often degrades the moisture sensitivity of the coating. Other coating properties can be negatively affected as well. This is largely due to the mobility of the surfactant polymers. For example, locally high concentrations of surfactant molecules can form in the coating from the coalescence of surfactant-coated micelle spheres. When the coating is exposed to water, these unbound surfactant molecules can be extracted from the coating leaving thin spots or pathways to the substrate surface. This can result in “blushing” and corrosion of the substrate.
[0015] Since surfactants have a number of deleterious effects on the finished coating and add cost to the coating formulation, minimizing their use would be desirable. A non-VOC additive that had multiple functions in the formulation such as imparting freeze/thaw stability, and extending open time and wet edge, and improving coalescence, could reduce the cost of and improve the performance of the finished coating.
[0016] The present invention provides alkoxylated styrenated phenols and naphthols that have been derivatized with allylglycidyl ether as additives to impart WE/OT to Semigloss paints. Note that the study was done with acrylic latexes. Different results may be obtained with Vinyl Acrylic or Vinyl Acetate Ethylene (VAE) latexes since they are more hydrophilic. The “Martha Stewart Paint was a vinyl acrylic according to the label. Glidden has manufactured the paint under the Martha Stewart label until last year. Now, they still manufacture that paint but under the Glidden Interior Premium Paint (Semigloss) label. The Martha Stewart colors still work with the paint since it identical to the paint made in the past.
SUMMARY OF THE INVENTION
[0017] The invention relates to a coating composition comprising: (a) at least one latex polymer; (b) water; and (c) at least one open time and freeze-thaw additive in an amount effective to increase the open time and freeze thaw properties of the coating composition the additive having the structural formula
[0000]
[0000] where n=2, x=10-12, y=0-10, z=0-10 and t=0-10, BO denotes a moiety derived from butylene oxide and SO denotes a moiety derived from styrene oxide and R is hydrogen or a C 1 -C 22 alkyl group and wherein the additive is present in an amount greater than about 0.5% by weight of the polymer.
[0018] The invention also provides a coating composition comprising: (a) at least one latex polymer; (b) water; and (c) at least one open time and freeze-thaw additive in an amount effective to increase the open time and freeze thaw properties of the coating composition the additive having the structural formula
[0000]
[0000] where n=1-3, x=1-2, y=0-10, z=5-40, W is selected from the group consisting of hydrogen and Z − M + where Z is selected from the group consisting of SO 3 − and PO 3 2− , and M + is selected from the group consisting of Na + , K − , NH 4 + , or an alkanolamine; and wherein the additive is present in an amount greater than about 0.5% by weight of the polymer.
[0019] It is believed that the present invention in part stabilizes the latex particles using steric effects of larger hydrophobic groups to form a protective layer on the surfaces of soft latex particles. The large hydrophobic groups adsorbed or grafted onto the latex particles or co-polymerized into the latex particles prevent these latex particles from approaching the surfaces of other soft latex particles and increase the distance of separation between soft latex particles. The alkylene, e.g., ethylene oxide units from the surfactant of the alkoxylated compounds chains also form a layer which interacts with the aqueous medium.
DETAILED DESCRIPTION OF THE INVENTION
[0020] The instant invention is directed to a coating composition comprising: (a) at least one latex polymer; (b) water; and (c) at least one open time and freeze-thaw additive in an amount effective to increase the open time and freeze thaw properties of the coating composition the additive having the structural formula I:
[0000]
[0000] where n=2, x=10-12, y=0-10, z=0-10 and t=0-10, BO denotes a moiety derived from butylene oxide and SO denotes a moiety derived from styrene oxide and R is hydrogen or a C 1 -C 22 alkyl group and wherein the additive is present in an amount greater than about 0.5% by weight of the polymer.
[0021] The invention is further directed to a coating composition comprising: (a) at least one latex polymer; (b) water; and (c) at least one open time and freeze-thaw additive in an amount effective to increase the open time and freeze thaw properties of the coating composition the additive having the structural formula II:
[0000]
[0000] where n=1-3, x=1-2, y=0-10, z=5-40, W is selected from the group consisting of hydrogen and Z − M + where Z is selected from the group consisting of SO 3 − and PO 3 2− , and M + is selected from the group consisting of Na + , K − , NH 4 + , or an alkanolamine; and wherein the additive is present in an amount greater than about 0.5% by weight of the polymer.
[0022] This compounds of formula I and II provide improvements in water-based latex paints. More specifically, the improvements are (1) the increase of the open time of water based latex paints and (2) the increase in the number of times that the paint can be frozen and then thawed before it looses it integrity as a uniform dispersion.
[0023] Additional compounds which are useful in providing improved properties to the coating compositions of the invention are selected from the group consisting of:
[0000]
[0000] where x=5-40 preferably is x=10; y=0-10, preferably is y=0; W is selected from the group consisiting of H, sulfate (—SO3 − M + ), phosphate (—PO3H − (M)) and carboxylate (OCH2COO − M + ) where M + is selected from the group consisting of Na + , K − , NH4 + and triethanolamine.
[0024] The compounds of the invention can be used in a number of ways for improving open time characteristics, freeze-thaw cycles, as well as drying time characteristics, of latex binders, paints, inks and other coatings. The present invention may optionally employ polymerizable reactive alkoxylated monomers as a reactant during emulsion polymerization to form the latex polymer. The present invention may employ one or more surface active alkoxylated compounds of the formula I or II as a surfactant (e.g., emulsifier) during emulsion polymerization to form the latex polymer. The present invention also uses compounds of the formula I or II as an additive to latex polymer-containing formulations such as coatings, including but not limited to paints; as well as an additive for adhesives, including but not limited to pressure sensitive adhesives; glues; resins; sealants; inks, including but not limited to UV inks, conventional inks, hybrid inks, and water-based inks; and the like.
[0025] The invention also provides a latex paint composition which is freeze-thaw stable with improved open time, wet edge time and drying time characteristics.
[0026] In an alternate embodiment, the latex coating composition contains an open time additive in an amount effective to lengthen the open time of the composition to greater than 4 minutes, typically greater than 6 minutes. In one embodiment, improved open time characteristics means that the open time of a coating or adhesive is made greater than 4 minutes. In another embodiment, improved open time characteristics means that the open time of a coating or adhesive is made greater than 6 minutes. In a further embodiment, improved open time characteristics means that the open time of a coating or adhesive is made greater than 8 minutes. In another embodiment, improved open time characteristics means that the open time of a coating or adhesive is made greater than 10 minutes. In alternate embodiment, improved open time characteristics means that the open time of a coating or adhesive is made greater than 12 minutes.
[0027] The coating compositions of the invention can optionally contain additives such as one or more film-forming aids or coalescing agents. Suitable firm-forming aids or coalescing agents include plasticizers and drying retarders such as high boiling point polar solvents. Other conventional coating additives such as, for example, dispersants, additional surfactants (i.e. wetting agents), rheology modifiers, defoamers, thickeners, biocides, mildewcides, colorants such as colored pigments and dyes, waxes, perfumes, co-solvents, and the like, can also be used in accordance with the invention.
[0028] The aqueous coating compositions of the invention can be subjected to freeze-thaw cycles using ASTM method D2243-82 or ASTM D2243-95 without coagulation.
[0029] In one preferred embodiment of the invention, the aqueous coating composition is a latex paint composition comprising at least one latex polymer derived from at least one acrylic monomer selected from the group consisting of acrylic acid, acrylic acid esters, methacrylic acid, and methacrylic acid esters and at least one compound of the formula I or II; at least one pigment and water. As mentioned above, the at least one latex polymer can be a pure acrylic, a styrene acrylic, a vinyl acrylic or an acrylated ethylene vinyl acetate copolymer.
[0030] The present invention further includes a method of preparing an aqueous coating composition by mixing together at least one latex polymer derived from at least one monomer and mixed with a compound of the formula I or II and at least one pigment. Typically, the latex polymer is in the form of a latex polymer dispersion. The additives discussed above can be added in any suitable order to the latex polymer, the pigment, or combinations thereof, to provide these additives in the aqueous coating composition. In the case of paint formulations, the aqueous coating composition typically has a pH of from 7 to 10.
[0031] In this particular invention, the additives were added to the paint after it was formulated and were mixed in at levels of 0.05%-5.0% using non-aggressive blade mixing.
[0032] The most preferred compounds were found to be (see the introduction to the example table for the key to the abbreviations)
POE(16)DSP reacted with one mole of AGE POE(16)DSP reacted with two moles of AGE POE(10)TSP reacted with one mole of AGE POE(10)TSP reacted with one mole of AGE and then sulfated POE(10)TSP reacted with two moles of AGE POE(10)TSP reacted with two moles of AGE and then sulfated POE(10)betanaphthol DDBSA formulated with TEA, water and a water soluble reverse block copolymer Where the abbreviations stand for: F/T=Freeze/thaw, O/T=Open time, DSP=distyrenated phenol, TSP=tristyrenated phenol, POE=polyoxyethylene polymer chain, AGE=allyl-glycidyl ether and TCDAM=tricyclodecane monomethanol
EXAMPLES
Terms and Abbreviations
[0000]
F/T=Freeze/thaw
O/T=Open time
DSP=distyrenated phenol
TSP=tristyrenated phenol
POE=polyoxyethylene polymer chain
AGE=allylglycidyl ether
TCDAM=tricyclodecane monomethanol
Test Procedure Descriptions
Open-Time Determination
[0049] Two stocks of water-based semigloss latex paints were provided by Behr Paints of California. One was formulated with a standard additive to improve its open time and the other was formulated without it. The version with the additive was tested as the control for the open-time evaluations. Comparisons of the test agents were made by post-adding the agents at various percentages to aliquots of the version of the paint that was formulated without additive and then determining the open times. The post-additions were made by simple ambient mixing using an overhead mixer with a two-inch blade turning at 180 rpm.
[0050] All open-times were determined using the method outlined in ASTM method D 7488-10 and the associated method D-5608. Open-time is the length of time that flaws in a paint film can be smoothed over with a paint brush after the first coat has been applied. The test method consists of drawing down a film of paint at a certain thickness onto a Leneta contrast sheet and scratching “X” marks in the film at various points along its length. This is followed by conditioning the film and then attempting to smooth out the “X” marks at various times using a paint brush that has been presoaked in the paint. The length of time that the “X” marks can be painted smooth is noted for each additive (this is the open-time) and the longer the time, the better. As an additional check, the length of time that the raised edge of the original paint strip can the smoothed is also noted as an open time.
Freeze-Thaw Determinations:
[0051] Commercially available Martha Stewart Living White/Base 1 interior acrylic latex semi-gloss MSL3011 and Martha Stewart Living White/Base 1 interior acrylic latex semi-gloss MSL3011N paints (both having 50 g/L VOC) were found to have no freeze-thaw resistance under the conditions of ASTM method D2243-95. These paints were used interchangeably as a substrate to which the various test additives were post-added at various percentages. The freeze-thaw test consists of placing a container of several ml of the test paint mixture in a chamber at −18 C for 17 hours followed by allowing it to thaw under ambient conditions for 7 hours. A sample was deemed to pass a cycle if after freezing solid it thawed back to its original uniformity and flow characteristics. If the sample passed, the test was repeated up to a maximum of five freeze-thaw cycles.
[0052] The post-addition blends were made by adding the additives to 100 g aliquots of paint and blending the mixtures using an overhead metal blade mixer with a 2-inch blade turning at about 180 rpm under ambient conditions.
[0053] The control additive for the Freeze-Thaw tests was Rhodoline FT-100 (Rhodia) which is a commercially available agent sold as a freeze-thaw improver. The FT-100 is reported to be a trystyrenated phenol with about 10 moles of ethylene oxide reacted to it.
Synthesis of Additives to be Evaluated.
Additives 3-10 (See Table of Compositions, Below.)
[0054] The hydrophobes were added to a stainless steel autoclave at the levels shown in the table below, along with potassium hydroxide at catalytic levels (2-3 grams) and the autoclave sealed and heated to 105 C. Ethylene oxide was then added, at the levels indicated on the table, over the course of several hours. After all of the EO was consumed, the reaction mass was cooled and the catalyst neutralized with the addition of a small amount of acid.
Additives 12-17
[0055] Step one: The hydrophobes, TSP or DSP, are added at the levels shown in the table below to a stainless steel autoclave, along with allylglycidyl ether (AGE) (also at the levels shown) and a catalytic amount of potassium hydroxide (2-3 grams) and the mix heated to 105 C. When all of the AGE was consumed, the reaction mass was cooled, and the product discharged.
[0056] Step 2: The styrenated phenol/AGE adducts from step 1 were then added to another autoclave and heated to 105 C. Ethylene oxide, at the level shown in the table below, was then added over the course of several hours. After all the EO was consumed, the reaction mass was cooled and the catalyst neutralized with the addition of a small amount of acid.
[0057] Step 3 (for Examples 15 and 17): Selected surfactants from steps 1 and 2 were sulfated with sulfamic acid and a trace amount of dicyandiamide catalyst in a glass reactor equipped with a stirrer, thermometer, and reflux condenser by heating to 120 C until the %sulfate was >90%. The products were then isolated as the ammonium salt.
[0000]
Table of compositions for Additives
Sulfamic acid
Hydrophobe
AGE
EO (equiv)/
(equiv.)/(%
Additive
(equiv.)/(% wgt)
(equiv.)/(% wgt)
(% wgt)
agt)
Terminal group
(1) (Behr paint blank
NA
NA
NA
NA
NA
for O/T)
(2) (Commercial
NA
NA
NA
NA
NA
paint with no F/T)
(3) POE(10) TSP
TSP (1)/(45.91%)
NA
(10)/(53.43%)
NA
—OH
(4) POE(11.5) DSP
DSP (1)/
NA
(11.5)/
NA
—OH
(32.92%)
(56.1%)
(5) POE(20)DSP
DSP (1)/
NA
(20)/(76.6%)
—OH
(23.18%)
(6) POE(10) Beta
Beta naphthol (1)
NA
(10)/
NA
—OH
Napthol
(22.92%)
(62.93%)
(7) POE(10)cydecanol
Cydecanol (1)/
NA
(10)/
NA
—OH
(25.35%)
(74.43%)
(8) POE(10)TCDAM
TCDAM (1)/
NA
(10)/
NA
—OH
(27.27%)
(72.33%)
(9) POE(10)4-
4-cumylphenol (1)/
NA
(10)/
NA
—OH
cumylphenol
(32.42%)
(67.36%)
(10) POE(10)4-
4-tertamylphenol
NA
(10)/
NA
—OH
tertamylphenol
(1)/(27.02%)
(72.56%)
(11) POE(16)DSP-AGE
DSP (1)/(27.6%)
(1)/(16.96%)
(16)/
NA
—OH
(61.91%)
(12) POE(15)DSP-
DSP (1)/(25.8%)
(2)/(19.5%)
(15)/
NA
—OH
AGE (2)
(54.68%)
(13) POE(10)TSP-
TSP (1)/(41.06%)
(1)/(11.6%)
(10)/
NA
—OH
AGE
(47.09%)
(14) POE(10)TSP-
TSP (1)/(37.32%)
(1)/(10.55%)
(10)/(42.8%)
(1)/(8.98%)
—OSO3
AGE Sulfated
not neutralized
(15) POE(10)TSP-AGE
TSP (1)/(36.93%)
(2)/(20.84%)
(10)/
NA
—OH
(2)
(41.96%)
(16) POE(10)TSP-
TSP (1)/(33.90%)
(2)/(19.13%)
(10)/
(1)/(8.08%)
—OSO3—
AGE (2) Sulfated
(38.52%)
Not neutralized
[0000]
Table of Open-Time and Freeze-Thaw Test Results
%
%
Additive
Additive
actives on
For
Number of
Additive
Blank for
Edge
“X”
Gloss
Freeze-
cycles
Additive
Description
Open time
Time
Time
60 deg
Thaw
passed
1
Control paint for open time:
?
4 min..
8 min.
55.8
NA
NA
Behr Semigloss with standard
additive
(Control for open time)
2
Commercially available
0.5%
4 min.
6 min.
58.1
0.5%
None
Rhodaline FT-100 in Martha
1.0%
4 min.
8 min.
58.7
1.0%
None
Stewart paint
1.5%
1.5%
None
(Control for Freeze-Thaw)
2.0%
4 min.
8 min.
63.3
2.0%
5
2.5%
5
3.0%
5
3
POE(10) TSP
0.5%
0.5%
None
1.0%
1.0%
5
1.5%
1.5%
5
2.0%
2.0%
5
2.5%
2.5%
5
3.0%
3.0%
5
4
POE(11.5) DSP
0.5%
6 min
8 min.
58.6
0.5%
None
1.0%
6 min
12 min
56.5
1.0%
None
1.5%
1.5%
None
2.0%
10 min
14 min
60.7
2.0%
5
5
POE(20)DSP
0.5%
6 min
10 min.
58.6
0.5%
None
1.0%
8 min
14 min
56.5
1.0%
None
1.5%
1.5%
None
2.0%
10 min
20 min
60.7
2.0%
None
2.5%
2.5%
None
6
POE(10) Beta Napthol
0.5%
4 min.
8 min
0.5%
None
1.0%
6 min.
10 min
59.6
1.0%
4
2.0%
10 min.
14 min
61.2
2.0%
5
7
POE(10)cydecanol
0.5%
4 min.
6 min.
57.2
0.5%
None
1.0%
4 min.
8 min.
58.8
1.0%
None
1.5%
1.5%
None
2.0%
6 min.
12 min.
60.6
2.0%
None
2.5%
2.5%
None
8
POE(10)TCDAM
0.5%
4 min.
6 min.
53.4
0.5%
None
1.0%
6 min.
6 min.
57.2
1.0%
None
2.0%
6 min.
10 min
60.0
2.0%
None
9
POE(10)4-cumylphenol
0.5%
4 min.
8 min.
56.6
0.5%
None
1.0%
6 min.
12 min.
55.6
1.0%
None
1.5%
1.5%
None
2.0%
10 min.
18 min.
62.0
2.0%
None
2.5%
2.5%
None
10
POE(10)4-tertamylphenol
0.5%
0.5%
None
1.0%
6 min.
8 min.
56.9
1.0%
None
1.5%
1.5%
None
2.0%
8 min.
12 min
59.7
2.0%
None
2.5%
2.5%
None
11
POE(16)DSP AGE
0.5%
6 min
10 min
57.3
0.5%
*
1.0%
6 min
14 min
59.2
1.0%
None
1.5%
1.5%
None
2.0%
6 min
12 min
57.0
2.0%
None
12
POE(15) DSP AGE (2)
0.5%
6 min
8 min
58.4
0.5%
*
1.0%
6 min
10 min
58.5
1.0%
None
1.5%
1.5%
None
2.0%
6 min
10 min
62.7
2.0%
1
13
POE(10) TSP AGE
0.5%
6 min
8 min
57.8
0.5%
*
1.0%
4 min
6 min
59.7
1.0%
None
1.5%
1.5%
5 (#5 grainy)
2.0%
4 min
6 min
63.9
2.0%
5
14
POE(IO) TSP AGE
0.5%
6 min
10 min
57.9
0.5%
Sulfated
1.0%
6 min
10 min
58.7
1.0%
None
not neutralized
1.5%
1.5%
1
2.0%
4 min
12 min
60.5
2.0%
5
15
POE(10) TSP AGE (2)
0.5%
4 min
8 min
58.0
0.5%
*
1.0%
4 min
5 min
62.2
1.0%
None
1.5%
1.5%
5 (#5 grainy)
2.0%
4 min
6 min
65.4
2.0%
5
16
POE(10) TSP AGE (2)
0.5%
4 min
10 min
58.3
0.5%
Sulfated
1.0%
6 min
10 min
60.1
1.0%
None
Not neutralized
1.5%
1.5%
2
2.0%
6 min
10 min
61.9
2.0%
5
? Indicates that it is not know whether the commercial paint has additive or not but it is used as a control for comparison purposes.
Example I
[0058] Literature teaches that ethoxylated TSP will offer improvements in the freeze-thaw performance of water-based coating formulations. Comparing additive 3 to additive 2, we see that the internally made POE(10) TSP is an improvement over the commercial material, being stable to 5 F/T cycles at 1.0% additive as opposed to 2%.
Example II
[0059] DSP, with an Appropriate Level of Ethoxylation is as Effective as TSP as a F/T Additive.
[0060] Additive 4 shows that 2% POE(11.5) DSP is as effective as the commercial TSP derivative control of additive 2 in that they both must be present at a minimum of 2%, at which level, they both pass five cycles. This example, further, shows that POE(11.5) DSP yields an O/T performance at 0.5% additive that is equal to that of the commercial standard.
Example III
The Level of Ethoxylation is Important Both to F/T and to O/T Performance of DSP Derivatives.
[0061] Comparing additive 5 to additive 4, it is evident that excessive ethoxylation damages the freeze-thaw performance while improving the O/T.
Example IV
[0062] Derivatives of DSP and TSP other than the Original POE Offer F/T and/or OT Performances Equivalent to those Shown in Control Tests 1 and 2.
[0063] Additives 11 and 12 indicate that POE(16)DSP reacted with one and two AGE groups yields an O/T equal to standard of Test 1.
[0064] Additives 13 and 15, which are POE(10)TSP reacted with 1 and 2 moles of AGE respectively, show open times that are equivalent to the O/T results of the standard in Test 1 together with F/T results that are extensions compared to the results of the standard in Test 2.
[0065] Additives 14 and 16 use the sulfated versions of additives 13 and 15, respectively and indicate that sulfation yields an extension in the OT performance but a slight drop in the F/T performance.
Example V
[0066] There are Additives other than Either DSP or TSP Derivatives that Combine Acceptable F/T and O/T Capabilities.
[0067] Additive 6 compared to additives 1 and 2 indicates that POE(10) betanaphthol causes acceptable open-times and freeze-thaws
Example VI
[0068] Additives 7, 8, 9, and 10, indicate that POE(10)cydecanol, POE(10)TCDAM, POE(10) 4-cumylphenol and POE(10) tetraamylphenol show reasonable O/T performance, compared to the control tests 1 and 2 even though F/T performance was diminished. Again, these are non-DSP and non-TSP agents.
[0069] The contents of all references cited in the instant specifications and all cited references in each of those references are incorporated in their entirety by reference herein as if those references were denoted in the text
[0070] While the many embodiments of the invention have been disclosed above and include presently preferred embodiments, many other embodiments and variations are possible within the scope of the present disclosure and in the appended claims that follow. Accordingly, the details of the preferred embodiments and examples provided are not to be construed as limiting. It is to be understood that the terms used herein are merely descriptive rather than limiting and that various changes, numerous equivalents may be made without departing from the spirit or scope of the claimed invention.
[0071] This Application was filed on Mar. 10, 2013, by Isaac A. Angres, Reg. No. 29,765. | Waterborne coatings are described having an acceptable balance of properties both during the storage of coating, application and drying. The period in which irregularities in a freshly applied coating can be repaired without resulting in brush marks is referred to as the open time. Aqueous coatings generally employ dispersed high molecular weight polymers as binders. These binders often provide short open times when the coating is dried since the dispersed polymer particles tend to be immobilized quickly in the edge region of an applied coating. As a result, the viscosity of the coating increases rapidly, which leads to a limited window of workability. The instant invention provides additives that are not volatile but that will extend the time that the film is malleable after after it is applied without interfering with other attributes, such as the resistance of the coating to freezing while in the can prior to application. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a divisional of U.S. application Ser. No. 12/834,833 filed on Jul. 12, 2010 and titled “HANDRAIL FOR STAIRCASE OR RAMP”.
FIELD OF THE INVENTION
The present invention relates generally to handrails for staircases or ramps, and more particularly to handrails that deter the use of the handrail as a slide.
DESCRIPTION OF THE RELATED ART
Many parks and public areas have staircases or ramps permitting easier navigation from one level to another in the park or public area. Typically, staircases 10 shown in FIG. 1 have handrails 20 on their sides and some in the center as well. Handrails must conform to certain standards so that a person can hold on to them while navigating up or down the stairs. However, handrails have the unintended consequence of providing a convenient track for skateboarders. As shown in FIG. 1 , skateboarders 30 jump their skateboard 40 onto these rails 20 and slide down, possibly damaging the rail or making it unfit for its intended purpose. It would be desirable to curb the actions of skateboarders. Thus, there is a need for a modification of the handrail that would permit people to use it for guiding and stabilizing themselves as they use the staircase or ramp, while at the same time deterring skateboarders from using the handrail.
BRIEF SUMMARY OF THE INVENTION
Embodiments described herein address the aforementioned need. Embodiments modify a conventional handrail in a way that preserves its function, while at the same time preventing or deterring its use by skateboarders.
One embodiment is an improved handrail for a staircase or ramp. The handrail includes an elongated cylinder and riser barriers. The elongated cylinder spans a length of the staircase or ramp is held at a height above the staircase or ramp by external supports. The riser barriers are solely supported by the elongated cylinder at a first set of spaced-apart locations along the elongated cylinder, no location in the second set coinciding with any location in the first set. Each of the riser barriers includes an extender portion and a riser portion, each riser portion being generally vertical and each extender portion being generally horizontal. Each of the extender portions has a length between a proximal end and a distal end, each of the proximal ends having attached thereto an arcuate portion that is adapted and fastened to the curvature of the bottom of the cylinder, and each of the distal ends being fastened to a respective riser portion at a position below the height of the elongated cylinder. The length of each of the extender portion holds a respective riser portion a horizontal distance away from the elongated member to permit passage of a hand along the elongated cylinder. Each of the riser portions has a length that extends above the height of the elongated member so as to deter sliding along the elongated cylinder.
Another embodiment is a plurality of riser barriers for a handrail of a staircase or ramp, where the handrail is an elongated cylinder supported at a height above the staircase or ramp by a plurality of external supports. Each of the riser barriers includes an extender portion and a riser portion. The plurality of riser barriers are solely supported by the elongated cylinder at a first set of spaced-apart locations along the elongated cylinder. The plurality of external supports support the elongated cylinder at a second set of spaced-apart locations along the elongated cylinder, no location in the second set coinciding with any location in the first set, each riser portion being generally vertical and each extender portion being generally horizontal. Each of the extender portions has a length between a proximal end and a distal end, each of the proximal ends having attached thereto an arcuate portion that is adapted and fastened to the curvature of the bottom of the cylinder, and each of the distal ends being fastened to a respective riser portion at a position below the height of the elongated cylinder. The length of each of the extender portion holds a respective riser portion a horizontal distance away from the elongated member to permit passage of a hand along the elongated cylinder. Each of the riser portions has a length that extends above the height of the elongated member so as to deter sliding along the elongated cylinder.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features, aspects and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where:
FIG. 1 depicts a skateboarder using the handrail as a slide;
FIG. 2 depicts a staircase employing an embodiment of the present invention;
FIG. 3A depicts a transverse elevational view showing a first embodiment of the present invention;
FIG. 3B depicts a bottom plan view of the embodiment shown in FIG. 3A ;
FIG. 4A depicts a transverse elevational view showing a second embodiment of the present invention;
FIG. 4B depicts a left transverse elevational view of the embodiment shown in FIG. 4A ;
FIG. 5A depicts a transverse elevational view showing a third embodiment of the present invention;
FIG. 5B depicts a right transverse elevational view of the embodiment shown in FIG. 5A ;
FIG. 6A depicts a transverse elevational showing a fourth embodiment of the present invention; and
FIG. 6B depicts a right transverse elevational view of the embodiment shown in FIG. 6A .
DETAILED DESCRIPTION OF THE INVENTION
Embodiments include a modified handrail 100 that prevents a skateboarder from using the handrail. An impediment or barrier is attached that preserves the functionality of the handrail while at the same time deterring its use by the skateboarder.
The embodiment in FIGS. 3A and 3B includes an elongated cylinder 110 , and a riser barrier 120 with extender portion 120 a and a riser portion 120 b . The elongated cylinder 110 spans the distance of the staircase 10 and is held up by vertical supporting members 22 (see FIG. 2 ) whose centers are spaced at approximately 48 inches. The extender portion 120 a of the riser barrier 120 includes an arcuate portion 130 that is fastened to the elongated cylinder 110 using such fastening devices 150 such as bolts or rivets shown in FIG. 3 . The riser portion 120 b has a length that exceeds the thickness of the extender portion 120 a plus the diameter “c” of the elongated cylinder by dimension “a”. In one embodiment, dimension “a” is about 3 inches and dimension “c” is about 1½ inches. The extender portion 120 a has a length that assures the elongated cylinder 110 spaced away from the riser portion 120 b by dimension “b”, which, in one embodiment, is about 1½ inches. Preferably, the riser barrier has ⅛ inch radius at all corners. The dimension “b” is sufficient to permit a user to slide his or her hand along the cylinder without interference, while the dimension “a” is sufficient to deter sliding on the cylinder.
The embodiment 200 in FIG. 4A and FIG. 4B includes an elongated cylinder 110 and an arcuate riser barrier 210 with a proximal end 220 and a distal end 224 . The proximal end 220 is adapted for affixation to the bottom of the elongated cylinder 110 by conforming its curvature approximately to the curvature at the bottom of the elongated cylinder. The proximal end 220 is affixed to the elongated cylinder 110 by means of tack welds 222 at points on either side of the cylinder 110 nearest to the proximal end 220 of the barrier 210 . The arcuate riser barrier 210 extends laterally and rises vertically so that the distal end 224 is spaced horizontally away from the elongated cylinder 110 by dimension “d”, and vertically away by dimension “e”. In one version, dimension “d” is approximately 1½ inches and dimension “e” is approximately 3 inches. As the arcuate riser barrier 210 rises from its proximal end 220 to its distal end, the riser barrier widens and then narrows. The arc-shaped arm has dimension “g” at its widest point and dimension “h” at its distal end. In one embodiment, dimension “g” is about 1½ inches and dimension “h” is about ¾ inches. Dimension “d” is sufficient to permit a user to slide his or her hand along the cylinder without interference while dimension “e” is sufficient to deter sliding on the cylinder.
The embodiment 300 in FIGS. 5A and 5B includes an elongated cylinder 110 , and a riser barrier having extender portion 320 and riser portion 310 . The extender portion 320 is curved downward between the proximal end 330 and the distal end 340 and holds the elongated cylinder 110 away horizontally from the riser portion 310 by dimension “k” and vertically away by dimension “p”, where, in one embodiment, dimension “k” is about 1½ inches and dimension “p” is about 1½ inches. The horizontal separation between the riser portion 310 and cylinder 110 permits the user to slide his/her hand along the cylinder 110 without interference, the downward curve of the extender portion 320 giving added room for the user's hand. The length of the riser portion 310 deters the skateboarder from sliding on the rail. As shown in the figures, the riser portion 310 has a thickness given by dimension “j”, which in one version is about ½ inch and a width given by dimension “n”, which in one version is about 1 inch. The proximal end 330 of the extender portion 320 is generally arc-shaped to conform and attach to the curvature of the elongated cylinder 110 . The distal end 340 of the extender portion 320 includes a generally flat, rectangular vertical portion. The flat, rectangular vertical portion fastens to the riser portion 310 and being wider than the riser portion 310 has a dimension of “m” by which it overlaps on either side the riser portion 310 . In one version, dimension “m” is about ⅜ inch. Any fastening device 350 , such as a bolt or rivet can be used to connect the flat portion of the distal end 340 to the riser portion 310 . The riser portion extends by dimension “q” below the flat portion 340 of the extender portion 320 . In one version, dimension “q” is about ½ inch.
The embodiment 400 in FIGS. 6A and 6B includes an elongated bar 112 and a riser barrier having extender portion 320 and riser portion 310 . The elongated bar 112 is generally rectangular or square in cross-section and may be hollow (shown) or solid. The extender portion 320 of the riser barrier is curved downward between the proximal end 332 and the distal end 340 and holds the elongated bar 112 away horizontally from the riser portion 310 by dimension “k” and vertically away by dimension “p”, where, in one embodiment, dimension “k” is about 1½ inches and dimension “p” is about 1½ inches. The horizontal separation between the riser portion 310 and bar 112 permits the user to slide his/her hand along the bar 112 without interference, the downward curve of the extender portion 320 giving added room for the user's hand. The length of the riser portion 310 deters the skateboarder from sliding on the rail. As shown in the figures, the riser portion 310 has a thickness given by dimension “j”, which in one version is about ½ inch and a width given by dimension “n”, which in one version is about 1 inch. The proximal end 332 of the extender portion 320 is generally flat to conform and attach to the bottom of the bar 112 . The distal end 340 of the extender portion 320 includes a generally flat, rectangular vertical portion. The flat, rectangular vertical portion fastens to the riser portion 310 and being wider than the riser portion 310 has a dimension of “m” by which it overlaps on either side the riser portion 310 . In one version, dimension “m” is about ⅜ inch. Any fastening device 350 , such as a bolt or rivet can be used to connect the flat portion of the distal end 340 to the riser portion 310 . The riser portion extends by dimension “q” below the flat portion 340 of the extender portion 320 . In one version, dimension “q” is about ½ inch.
In all of the above embodiments, the elongated cylinder or bar and riser barrier are fabricated with a material suited for environment in which the staircase or ramp is present. For example, if the staircase or ramp is outside in the elements, the elongated cylinder or bar and riser barrier may be fabricated in steel. Unless specified otherwise, the steel used has a suitable thickness to prevent bending or breakage. Suitable products that can be used for either the cylinder or bar are rectangular, square or round structural steel tubing such as HSS tubing. For round tubing, a length of 1.660×0.140 structural tubing is sufficient. For rectangular tubing, a length of 2×1.5×⅛ inch tubing is sufficient. Suitable products that can be used for the extender portion are brackets, such as the round saddle bracket 1970R, 1978R, 1990R, 1998R, or flat saddle bracket 1970F, 1978F, 1990F, 1998F, manufactured by The Wagner Companies.
Although embodiments have been described in considerable detail with reference to certain preferred versions thereof, other versions are possible. Therefore, the spirit and scope of the appended claims should not be limited to the description of the preferred versions contained herein. | An improved handrail for a staircase or ramp. In one embodiment, the handrail includes an elongated member such as a cylinder or bar that spans the length of the staircase or ramp and a riser barrier. The riser barrier has an extender portion and a riser portion. The extender portion of the riser barrier keeps the elongated member a sufficient distance horizontally from the riser portion that a person can slide his or her hand on the rail without interference. The riser portion projects vertically a sufficient distance above the elongated member to deter sliding down the elongated member. Thus, sliding on the member is deterred, while the function of the cylinder as a handrail is preserved. | 4 |
FIELD OF THE INVENTION
[0001] The present invention relates in general to a heat dissipation device used in association with electronic components.
DESCRIPTION OF RELATED ART
[0002] With advancement of computer technology, electronic components operate rapidly. It is well known that when the electronic components have become smaller and faster, they generate more heat than ever. If the heat is not dissipated duly, the stability of the operation of the electronic components will be impacted severely. Generally, in order to ensure the electronic components to run normally, heat sinks are used extensively in connection with electronic components. U.S. Pat. No. 5,794,685 discloses an electronic component cooling apparatus. The cooling apparatus includes a heat sink having a cylindrical core and a plurality of radiation fins integrally extending outwards from the core. The radiation fins are formed so as to be limited in their thickness, and a space between two neighboring fins is also limited during manufacture such that number of the fins is limited correspondingly. Such construction fails to provide a sufficient amount of area of fins for radiating the heat, resulting in an insufficient heat dissipation.
SUMMARY OF THE INVENTION
[0003] A heat dissipation device in accordance with an embodiment includes a heat conducting member adapted for contacting with a heat generating electronic device and a fin unit. The fin unit defines a central hole therein and consists of a plurality of fins around the central hole and clasping each other. The fin unit fits around a periphery of the heat conducting member via the heat conducting member extending in the central hole of the fin unit. A clip engages with the heat conducting member and the fin unit for providing a pressure to the fin unit such that the fin unit is intimately fastened to the heat conducting member.
[0004] Other advantages and novel features will become more apparent from the following detailed description of preferred embodiments when taken in conjunction with the accompanying drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] Many aspects of the present device can be better understood with reference to the following drawings. The components in the drawings are not necessarily drawn to scale, the emphasis instead being placed upon clearly illustrating the principles of the present device. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views.
[0006] FIG. 1 is an exploded, isometric view of a heat dissipation device in accordance with a preferred embodiment of the present invention;
[0007] FIG. 2 is an assembled view of FIG. 1
[0008] FIG. 3 is a view similar to FIG. 2 with a part thereof being cut away;
[0009] FIG. 4 is a perspective view of one fin of a fin unit of FIG. 1 ;
[0010] FIG. 5 is an assembled view of a locking plate, a heat conducting member and two fins of FIG. 1 ;
[0011] FIG. 6 is a perspective view of a fin unit of FIG. 1 ;
[0012] FIG. 7 is an inverted view of FIG. 6 ; and
[0013] FIG. 8 is a perspective view of one fin of a heat dissipation device according to an alternative embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0014] Referring to FIGS. 1-3 , a heat dissipation device in accordance with a preferred embodiment of the present invention is shown. The heat dissipation device comprises a fin unit 30 , a heat conducting member 10 received in the fin unit 30 , a locking plate 20 combined to a bottom of the heat conducting member 10 , and a clip 40 for securing the fin unit 30 to the heat conducting member 10 .
[0015] The heat conducting member 10 is a frustum which is formed from a cone with a circular base by cutting off a tip of the cone with a cut perpendicular to the height, forming a lower base (not labeled) and an upper base (not labeled) that are circular and parallel to each other. The lower base has a bigger cross-section than that of the upper base and forms an annular pad 12 extending outwardly from an outer surface thereof. A protrusion 14 (shown in FIG. 3 ) is formed on a bottom of the lower base, for engaging with a heat generating electronic device (not show) located on a printed circuit board (not show). The heat conducting member 10 defines an opening 102 in a top portion thereof having a radius gradually decreased along a top-bottom direction, such that a wall 104 having a thickness gradually increased along the top-bottom direction is formed around the opening 102 . The wall 104 has an inclined surface 106 at an inner surface adjacent to a top thereof. An angle between the inclined surface 106 and an outer surface of the wall 104 is bigger than an angle between the inner surface of the wall 104 and the outer surface of the wall 104 . A bottom of the wall 104 defines a threaded hole 16 located below the opening 102 . The opening 102 is so configured as to reduce the weight of the heat dissipation device and save the cost of the heat dissipation device.
[0016] The locking plate 20 comprises a substantially rectangular body 22 and four fixing legs 24 extending outwardly and downwardly from four corners of the body 22 . Each of the legs 24 has a fixing hole 240 defined in a distal end thereof for fittingly receiving a fastener (not shown) therein. The fasteners are used to attach the heat dissipation device to the printed circuit board. The body 22 has a circular opening 26 defined in a center thereof. A diameter of the opening 26 is smaller than an outer diameter of the annular pad 12 . A gap (not labeled) is formed between an inner surface of the opening 26 and an outer circumferential surface of the heat conducting member 10 when the locking plate 20 is mounted on the annular pad 12 . An engaging portion 28 of the body 22 around the opening 26 is embossed on the locking plate 20 . The engaging portion 28 further extends to the fixing legs 24 to form a star-shaped configuration. The engaging portion 28 is devised for strengthening the locking plate 20 and engaging a bottom of the fin unit 30 .
[0017] The fin unit 30 has a generally cylinder configuration, and comprises a plurality of fins 31 clasping each other to form a central hole 300 therein. The fin unit 30 is mounted around the outer circumferential surface of the heat conducting member 10 by mechanical coupling.
[0018] Please referring to FIG. 4-5 , each of the fins 31 comprises a plane portion 32 and a curved portion 34 integrally extending from the plane portion 32 . The curved portion 34 curves along a circumferential direction of the heat conducting member 10 . The plane portion 32 comprises an inner inclined edge 32 a abutting against the outer circumferential surface of the heat conducting member 10 , an upper edge 32 b connecting with the inner edge 32 a and a lower edge 32 c connecting with the inner edge 32 a . A flange 322 is perpendicularly and forward bent from the inner edge 32 a , for contacting with the outer circumferential surface of the heat conducting member 10 . The flange 322 has a length shorter than that of the inner edge 32 a and a width gradually increased along an up-bottom direction. A wing 324 is perpendicularly and forward bent from the lower edge 32 c . The wing 324 has a width gradually enlarged from an end of the lower edge 32 c adjacent to the inner edge 32 a to another end of the lower edge 32 c far away from the lower edge 32 c along a length direction of the lower edge 32 c . A tongue 325 is perpendicularly and upwardly bent from a front edge of the wing 324 . A though hole 326 is defined in the wing 324 where the wing 324 is connected with the lower edge 32 c of the plane portion 32 . A locating tab 327 is stamped from a center of the plane portion 32 such that a locating hole 328 is defined corresponding to the locating tab 327 . The tongue 325 of the fin 31 is inserted in the through hole 326 of an adjacent fin 31 and the locating tab 327 is inserted in the locating hole 328 of the adjacent fin 31 and abuts against the locating tab 327 of the adjacent fin 31 as two adjacent fins 31 are combined together. A protruding hook 36 is formed at a joint of the inner edge 32 a and the upper edge 32 b . The hook 36 protrudes beyond the inner edge 32 a . The hook 36 has an arcuate edge 36 a connecting with the inner edge 32 a and a slant edge 36 b connecting with the upper edge 32 b . The arcuate edge 36 a is used for engaging with the inclined surface 106 of the wall 104 of the heat conducting member 10 . The upper edge 32 b defines a cutout 362 adjacent to the hook 36 . The cutouts 362 of the fins 31 form an annular channel 304 (shown in FIG. 6 ) for receiving the corresponding clip 40 . A triangular nub 38 is formed at a joint of the inner edge 32 a and the lower edge 32 c , for inserting into the gap between the inner surface of the opening 26 and the outer circumferential surface of the heat conducting member 10 .
[0019] Please referring to FIGS. 6-7 , the fin unit 30 is formed by the fins 31 clasping each other. The flanges 322 of the fins 31 cooperatively form a mating surface 302 mating with the outer circumferential surface of the heat conducting member 10 . The plane portions 32 of the fins 31 are perpendicular to the outer circumferential surface of the heat conducting member 10 . The curved portions 34 are bent obliquely respective to the plane portions 32 . The curved portions 34 are used for allowing an airflow to flow through channels (not labeled) formed between the fins 31 and guiding the airflow to blow towards the bottom portion of the heat conducting member 10 and other electronic components around the heat dissipation device.
[0020] Again referring to FIG. 1 and FIG. 3 , the clip 40 comprises a cap 42 and a screw 43 used for mounting the cap 42 on the heat conducting member 10 . The cap 42 comprises a circular top plate (not labeled) having a concave portion 420 at a center thereof, and a lateral flange 422 extending downwardly from an edge of the top plate. The lateral flange 422 is engaged in the channel 304 of the fin unit 30 . The concave portion 420 defines a through hole 421 at a center thereof, for permitting passage of the screw 43 . Three spaced cuts 423 are defined in a top plate for facilitating a user to manipulate the cap 42 and increasing the resilience of the cap 42 . The screw 43 comprises an expanded head 430 and a shaft 432 extending downwardly from the head 430 . A distal end of the shaft 432 forms external threads.
[0021] In assembly of the heat dissipation device, the locking plate 20 is assembled to the heat conducting member 10 by fitting the heat conducting member 10 into the opening 26 of the locking plate 20 until a top face of the annular pad 12 of the heat conducting member 10 abuts the locking plate 20 . The heat conducting member 10 has an interferential engagement with the body 22 so that the heat conducting member 10 and the locking plate 20 are securely connected together. Thereafter, the fin unit 30 is assembled to the heat conducting member 10 and rests on the locking plate 20 whereby the fins 31 surround the outer circumferential surface of the heat conducting member 10 . The inner edges 32 a of the fins 31 intimately engage with the outer circumferential surface of the heat conducting member 10 . The arcuate edges 36 a of the hooks 36 of the fins 31 abut against the inclined surface 106 of the wall 104 of the heat conducting member 10 . The triangular nubs 38 of the fins 31 are inserted into the gap between the bottom of the outer circumferential surface of the wall 104 and the locking plate 20 . The cap 42 is mounted on the top of the heat conducting member 10 after the fin unit 30 is assembled to the heat conducting member 10 . The lateral flange 422 of the cap 42 is engaged in the channel 304 of the fin unit 30 . The screw 44 passes through the through hole 421 of the cap 42 and extends into the opening 102 of the heat conducting member 10 and further threadedly engaged in the threaded hole 16 of the heat conducting member 10 , whereby the fins 31 are downwardly pressed by the cap 42 to cause the fins 31 to intimately engage with the heat conducting member 10 . Especially, in use of the heat dissipation device, a risk of a vibration by a fan to cause the connection between the fin unit 30 and the heat conducting member 10 to loose is prevented.
[0022] Referring to FIG. 8 , a heat dissipation device in accordance with an alternative embodiment of the present invention is shown. The heat dissipation device is similar to the heat dissipation device of the previous preferred embodiment, but a fin 31 a replaces the fin 31 of the fin unit 30 of the previous preferred embodiment. The fin 31 a comprises a plane portion 32 a , a first bend portion 342 a bent from the plane portion 32 a and a second bend portion 344 a slightly bent from an edge of the first bend portion 342 a . The plane portion 32 a is similar with the plane portion 32 of the preferred embodiment, and comprises a flange 322 a , a wing 324 a and a protruding hook 36 a . A cutout 362 a is defined adjacent to the hook 36 a . A locating tab 327 a is stamped from a center of the second bend portion 344 a such that a locating hole 328 a is defined corresponding to the locating tab 327 a . The first bend portion 342 a and the second bend portion 344 a cooperately form a guide portion for guiding the airflow to blow toward the bottom of the heat conducting member 10 .
[0023] It is believed that the present embodiments and their advantages will be understood from the foregoing description, and it will be apparent that various changes may be made thereto without departing from the spirit and scope of the invention or sacrificing all of its material advantages, the examples hereinbefore described merely being preferred or exemplary embodiments of the invention. | A heat dissipation device includes a heat conducting member ( 10 ) adapted for contacting with a heat generating electronic device and a fin unit ( 30 ). The fin unit defines a central hole ( 300 ) therein and consists of a plurality of fins ( 31 ) around the central hole and clasping each other. The fin unit fits around a periphery of the heat conducting member via the heat conducting member extending in the central hole of the fin unit. A clip ( 40 ) engages with the heat conducting member and the fin unit for providing a pressure to the fin unit such that the fin unit is intimately fastened to the heat conducting member. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application Ser. No. 61/091,567, filed on Aug. 25, 2008. The disclosure of the above application is incorporated herein by reference in its entirety for any purpose.
FIELD OF THE INVENTION
[0002] The present invention generally relates to air cooling, exchange and circulation, and particularly relates to exchanging of inside room air with outside air for energy efficiency.
BACKGROUND OF THE INVENTION
[0003] It is a common experience during warm weather to find that an inside room accumulates and retains heat above the temperature of the outside. This thermal inertia is especially noticeable at night when outside temperatures turn cooler, but room temperature remains uncomfortably warm. Merely opening one or more windows may not cool the room to the outside temperature because there is no natural airflow. If the room has more than one window, if the windows are on different walls, and if there is some airflow outside, a cross-draft can move outside air into the room and inside air out to reduce the inside temperature. However, it is not always possible due to window configuration or outside conditions to create a cross-draft. Even if a cross-draft can be created, heat will often persist at room heights above the highest window opening. This is effectively an inverted well of hot air that is difficult to drain.
[0004] More active solutions include a window fan, which is used either to draw in cooler outside air or expel warmer inside air. However, a window fan without a cross-draft quickly creates a pressure imbalance between inside and outside resisting further exhaust or drawing of air. If a cross-draft can be established, window fans can help exchange some inside air, but they are still largely ineffective in draining the hot air well above the top of the window fan. Another active solution is to use a ceiling fan, but this just circulates and mixes the warm and cooler air in the room without lowering the average temperature. In all these circumstances, despite cooler air outside, a warmer inside space cannot be quickly and effectively cooled.
[0005] Inside cooling can be accomplished easily by air conditioning. However, there are drawbacks to air conditioning. One is electricity cost. A 10,000 BTU/hour window air conditioner consumes 500-1000 watts, which is 10 to 20 times the energy consumption of a single window or ceiling fan. Energy consumption is directly related to global warming effects, which is becoming more of a concern to many people. There are other drawbacks to air conditioners that vary with people's preferences: compressor noise is too loud, cooled air is too cold, the quality of fresh outside air is preferable to air conditioned air, a portable window unit is unsightly, and permanent installation is inconvenient or disallowed in some rental premises.
[0006] It is therefore the objective of the present invention to provide an economical and environmentally friendly air cooling, exchange, and circulating appliance. Particularly, it is the objective of the present invention to provide air circulation (1) when inside room temperature is warmer than desired, and (2) when outside temperature is lower than inside. It is further the objective of the present invention to create a cross-draft inside a room that cools the inside thoroughly and quickly to a more desired temperature. Further, another objective of the present invention is to provide a device that is advantageous in comparison to an air conditioner with respect to cost of operation and its carbon footprint. Yet another objective of the present invention is to provide a system that is portable, that does not require permanent or major installation to the infrastructure, and has an aesthetically pleasing design.
SUMMARY OF THE INVENTION
[0007] According to the present invention, the device is equipped with an upper exhaust chamber directed to exhaust the warm air out of the room; a lower intake chamber to direct outside air through an opening such as a window to the inside room; and a controller to control the operation of the upper and lower chambers and airflow.
[0008] According to one feature of the invention, the input opening of the upper exhaust chamber is positioned relatively high in the room and preferably above the level of the window opening to capture and expel the unwanted warm air that rises from middle and lower level in the room. The input opening of the lower intake chamber is positioned relatively at or below the window seal level to draw in cool fresh outside air to the room and force the warm air inside the room up to a high level in the room, to be exhausted by the upper exhaust chamber. This cross-draft created by this intake and exhaust will cool the room more thoroughly and quickly to the desired temperature.
[0009] According to another feature of the present invention, the device can be operated in cooling mode to reduce room temperature either as an augmentation to standard air conditioning or on its own. When temperature differentials are appropriate between inside and outside, the device brings cool air into the room and expels warmer air. Even if temperature inversion only happens at night, venting of accumulated internal heat at night and into the next day provides cooling into the next day and prevents heat build-up.
[0010] According to yet another feature of the invention, the device can be operated in the air exchange mode to vent inside air out, and replace it with fresh outside air. This function can be used just to freshen otherwise stale air, or to remove odors from rooms such as kitchens and restrooms. In this exchange mode, fresh outside air is prevented from mixing with stale inside air before the stale inside air is expelled, because the input of the exhaust chamber is located at a higher level of the room and the output of the intake chamber is located at a lower level. The exchange mode can be auto or manual. In the Exchange-Auto mode, the air temperature controller assures that this exchange function will not also produce unwanted high or low temperature changes. In the Exchange-Manual mode, the system operates independently of room or outside temperatures.
[0011] According to yet another feature of the invention, the device can be operated in air circulation mode to perform internal air circulation, similar in function to a ceiling fan. An advantage of this device over a ceiling fan is that it is portable and requires no installation. The circulation mode can be auto or manual. In Circulation-Auto mode, the systems operates and shuts off based on the room temperatures. In the Circulation-Manual mode, the system operates independently of room temperatures. For the air circulation mode, the device provides a function even when summer heat has passed and most window fans and air conditioners have been turned off and stored until the next hot season.
[0012] According to yet another feature of the invention, the device controller uses three sensors: one outside temperature sensor and two inside temperature sensors to control the switching of cooling, exchange and circulation modes. One room sensor is preferably located at a high level of the room near the input of the exhaust chamber. The other room sensor is preferably located at a lower level of the room at a similar level of the output of the intake chamber, however the lower level sensor should not be located at the output of the intake chamber because it should measure room temperature air rather than drawn outside air.
[0013] The present invention is advantageous over previous air circulation methods and systems in that the present invention provides a cross-draft of air from low to high inside a room that can efficiently expel unwanted warm air in the room and therefore lower the temperature quickly.
[0014] Further, the advantage of the present invention includes the use of two room temperature sensors in order to take advantage of the cool-to-warm air temperature gradient from low-to-high levels of a room, and thus to provide air circulation and cooling more efficiently based on the need of each individual room.
[0015] For a more thorough understanding of the invention, its objectives and advantages, refer to the following specification and to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:
[0017] FIG. 1 is a view of two physical configurations of the device according to the present invention;
[0018] FIG. 2 is the side view of device set up at window of a room according to the present invention;
[0019] FIG. 3 is the front and side view of device according to the present invention;
[0020] FIG. 4 is an illustration of controller and temperature sensors according to the present invention;
[0021] FIG. 5 is illustration of device designed with the external appearance of a Japanese shoji lamp according to the present invention;
[0022] FIG. 6 is an illustration of airflow for cooling, exchange, and circulation modes according to the present invention;
[0023] FIG. 7 is an illustration of cross-draft through a single window opening according to the present invention;
[0024] FIG. 8 is an illustration of build-in device according to the present invention;
[0025] FIG. 9 is an illustration of transparent and translucent chamber according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0026] The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, application, or uses.
[0027] By way of overview, the present invention essentially discloses three main components: an upper and lower airflow chamber, and a controller, as illustrated in FIGS. 2 , 3 , and 4 .
[0028] 1. Upper Exhaust Chamber. The upper exhaust chamber ( 205 , 301 ) includes a vertical airflow conduit that extends from a high level of the room near the ceiling down to the level of the window opening. This component has an opening or window conduit ( 201 , 305 ) and a fan ( 203 ) or other subcomponent to draw air from an opening ( 304 ) in the top of the chamber and to direct the airflow downward through the chamber ( 205 , 301 ) and through the conduit ( 201 , 305 ) directed to exhaust the air out the window. This component also includes a partition door that opens or closes the exhaust airflow to outside opening conduit ( 201 , 305 ).
[0029] 2. Lower Intake Chamber. The lower intake chamber ( 206 , 302 ) includes a vertical airflow conduit that extends from the window entry level to the same level or a lower level toward the floor. This component has an opening or window conduit ( 202 , 306 ) and a fan ( 204 ) or other subcomponent to draw air from outside, through the conduit ( 202 , 306 ) designed to direct air downward through the chamber ( 206 , 302 ) and toward an exit opening at the bottom of the chamber ( 307 ) to the inside of the room. This component also includes a partition door that opens or closes the airflow to draw in from outside opening conduit ( 202 , 306 ).
[0030] Further in reference to FIG. 3 , the opening conduit 305 and 306 can be positioned at a window opening in combination with a window seal that impedes airflow through parts of the window opening that are not directly open for exit from the upper exhaust chamber and entry into the lower intake chamber.
[0031] 3. Controller. In reference to FIG. 4 , the controller ( 401 ) is a microcontroller that executes software instructions built-in. The controller receives readings wired or wirelessly ( 402 ) from preferably three sensors: outside sensor ( 403 ), indoor sensor at high level of the room toward the ceiling ( 404 ), and indoor sensor at lower level of the room toward the floor ( 405 ), and uses the readings to control the operation of the upper and lower chambers and airflow including the fans and chamber partition doors.
[0032] In reference to FIG. 7 , the basic operation of the device takes advantage of the physical property that warm air rises and accumulates toward the ceiling in a room, as shown in the direction of arrow ( 703 ). This temperature gradient between warm air toward the ceiling at temperature T H ( 707 ), and cooler air at a lower level at temperature T L ( 708 ) dictates that the upper exhaust chamber captures warm air ( 701 ) at its uppermost level and the lower intake chamber expels cooler air ( 705 ) drawn from the outside at temperature T O ( 706 ) into the room at its lowermost level. Efficient operation depends on the cool air filling from floor to ceiling (rather than temperature levels being mixed as is done by ceiling fans and most window fans) because only the warmest air should be expelled at all times.
[0033] A fundamental operating feature of the device is that it effectively creates its own cross-draft through a single window. The cross-draft is essentially vertical, in the direction of arrow ( 703 ), between exit at the lower chamber and entry at the upper chamber. This vertical cross-draft from low to high assures that it is always the warmer air that is being expelled and that incoming cooler air does not mix with the warmer air, and thus be expelled inadvertently. Furthermore, this vertical cross-draft maintains the average room air pressure in equilibrium with the outside air pressure, that is P O =½(P H +P L ), where P H is the pressure toward the ceiling and P L is the pressure toward the floor.
[0034] The device has five possible states of operation: 1) off, 2) intake only, 3) exhaust only, 4) intake and exhaust, and 5) circulate. The states are determined in part by the chosen mode: 1) cool, 2) exchange (automatic or manual), 3) circulate (automatic or manual), and 4) off. Except for the manual and off modes, the state is determined automatically by the controller based on pre-determined conditions, which depend upon absolute and differential inside and outside temperatures as measured by the temperature sensors, and by user-chosen temperature settings. The measured outside temperature is designated T O . There are two inside temperatures, T H measured at a high level toward the ceiling, and T L measured at a lower level, preferably at a level between the lower window opening and the floor. The two user-chosen temperature settings are the goal temperature T G and the minimum temperature T MIN , upon which the condition exists that T G >T MIN . The device has default values for these two settings. An example of these default values is, T G =22° C. (72° F.) and T MIN =18° C. (65° F.). Modes, temperature conditions, and corresponding states are shown in Table 1.
[0000]
TABLE 1
Modes, temperature pre-determined conditions, and
corresponding states.
Mode
Temperatures
State
Cool
(T H > T G AND T H > T O ) AND
intake and exhaust
(T L > T Min OR T O > T Min )
Cool
T H > T G AND T O > T L
exhaust only
Exchange Auto
T L > T Min
intake and exhaust
Exchange Manual
Any
intake and exhaust
Circulate Auto
T H > T Min
circulate
Circulate Manual
Any
circulate
Off
Any
off
[0035] From Table 1, and further in reference to FIG. 6( a ), there are two states in the cool mode. In the first state, both intake and exhaust fans are on, and both these chamber doors are opened to allow airflow from outside ( 604 ) through lower intake chamber ( 605 ) and opening ( 606 ) to the room, and capture warm air in the room at upper exhaust chamber air entry ( 601 ), through the chamber ( 602 ) to exhaust to outside ( 603 ). This state is chosen if the inside high level temperature is above the goal temperature and above the outside temperature, and if the inside low level temperature is above the minimum temperature or the outside temperature is above the minimum temperature. This is the optimum cooling setting and is selected when the inside is hot and the outside is cooler than the inside.
[0036] In the second cool mode state, only the exhaust fan for the upper exhaust chamber is on. The exhaust chamber door is opened to allow outflow to outside ( 603 ) and the intake chamber door is closed to prevent inflow ( 604 ). This state is chosen if the high temperature is above the goal temperature and the outside temperature is above the low level temperature. This setting is selected when it is warm inside, but the outside temperature is too hot to be useful in cooling the room—so only hot ceiling air is vented.
[0037] From Table 1, and further in reference to FIG. 6( a ), there are two exchange options, automatic and manual. The intake and exhaust fans run for both exchange options, so both exhaust ( 603 ) and intake ( 604 ) chamber doors are opened, and both intake airflow ( 605 ) and exhaust airflow ( 602 ) occur. For the automatic option, exchange takes place only when the low level temperature is above the minimum temperature, since we don't want to add airflow cooling to an already cold room. For the manual option, exchange takes place independent of temperature.
[0038] From Table 1, and further in reference to FIG. 6( b ), there are two circulate options, automatic and manual. The circulate mode moves air from a high level through the upper exhaust chamber input opening ( 601 ), through both the upper and lower exhaust chambers ( 607 ), and out into the room through lower intake chamber output opening ( 606 ). Both exhaust and intake fans run. The exhaust door ( 608 ) and intake doors ( 609 ) are both closed to outside air and airflows from upper exhaust chamber to lower intake chamber. Since no window exhaust or intake takes place, the window need not be open and it is not used. For the automatic option, circulation runs when the high level temperature is above the minimum temperature. This causes mixing of air levels and reduction of the floor-to-ceiling temperature gradient when heat has built up toward the ceiling. For the manual option, circulation runs independent of temperature.
[0039] For the off state, both fans are turned off and both chamber doors are closed.
VARIATIONS ON THE PREFERRED EMBODIMENT
[0040] The above describes only one embodiment. Variations of this design can also be made to accomplish the same functions.
[0041] In another embodiment according to the present invention, instead of measuring just temperature, temperature and humidity can be measured by the temperature sensors to yield a temperature-humidity index (THI. The THI is a humidity-adjusted temperature value designed to measure human discomfort to the combined effects of temperature and humidity. A calculation of this is: THI=15+0.4(T d +T w ), or THI=T d −0.55(1−H)(T d −58), where T d and T w are the dry- and wet-bulb temperatures respectively measured in Fahrenheit degrees, and H is the relative humidity in percent. Use of THI versus temperature alone requires that the temperature sensors measure both temperature and humidity.
[0042] In another embodiment according to the present invention, instead of two fans, this can be reduced to one by placing it in a shared intake/exhaust conduit through the window, then enabling the single fan to reverse airflow direction as dictated by the controller, expelling air out for exhaust and drawing air in for intake. For exhaust, a door opens the exhaust chamber and closes the intake chamber. For intake, a door opens the intake chamber and closes the exhaust chamber.
[0043] Yet in another embodiment according to the present invention, instead of an integrated intake fan, this can be omitted and replaced by a fan unit that is separate from the device. The separate device is placed or attached to the exit opening of the lower intake chamber in a way that it draws air through the intake chamber. An air cleaner unit with integrated fan is advantageous here because the drawn outside air would then flow through and be cleaned by the air cleaner.
[0044] In another embodiment according to the present invention, as shown in FIG. 1 , instead of a single unit, the upper exhaust chamber ( 101 ) and lower intake chamber ( 102 ) can be separate units, each with its own stand ( 103 ). This has an advantage of being able to move the exhaust exit away from the intake entry, such that warm exhaust air does not mix with intake air near the window opening.
[0045] Further in another embodiment according to the present invention, instead of running exhaust and intake concurrently for cool mode, they can be run sequentially to reduce mixing exhaust air with intake air. Because pressure equilibrium between inside and outside will not be maintained if either intake or exhaust runs too long, they can run alternately at a timing interval designed to prevent pressure imbalance. Alternatively, pressure imbalance can be determined by measuring fan resistance, and the switch made between intake and exhaust and vice versa when that value is above a chosen threshold.
[0046] Yet in another embodiment according to the present invention, as shown in FIG. 8 , instead of directing airflow through the opening of a window, vents can be placed or built into the wall at a high level ( 802 ) and a lower level ( 803 ). Using the same control logic ( 801 ), exhaust and intake can be performed through these vents.
[0047] In another embodiment according to the present invention, instead of a double-hung window type, where there is a horizontal opening between lower sash and window sill, the device can also work with a casement window (which opens out from hinges at a side). For a casement window, the upper exhaust chamber need only direct airflow from a high level to the top of the casement window opening. The lower intake chamber directs air from the bottom of the casement window opening.
[0048] In another embodiment according to the present invention, the device can be made into an entirely manual system without requiring any temperature sensors. The function of the controller will be only controlling the turning on and off of fans and the partition doors. In the complete manual mode, the device can still be configured to run in the following states: Exhaust only, Intake and Exhaust (Exchange—with outside air) or Intake and Exhaust (Circulate—without outside air).
Form and Function
[0049] The walls of the cylinder can be opaque, transparent, or translucent. The “degree of transparency” describes the degree of visibility of an object through a material, where visibility is dependent upon the amount of light that can travel through the material (transmittance), ranging from opaque to transparent, and the clarity by which the object can be seen through the material (translucence). The present invention has an exemplary form similar to a Japanese shoji lamp. It is a tall, thin, square cylinder, as shown in FIG. 5 . This cylinder comprises the upper exhaust ( 501 ), lower intake chambers ( 502 ) and stand ( 503 ). The chambers have translucent walls made of rice paper. Walls with some non-zero degree of transparency are advantageous to allow light to pass from window through the device if the device is placed in front of a window.
[0050] In another embodiment according to the present invention, instead of an indicator light (usually a small LED light) that many fans use to indicate an ON mode, the device with transparent or translucent chamber walls could indicate ON mode by motion of one or more objects due to airflow. Translucent or transparent walls can also be combined with ribbons, streamers, or some other dynamic object or sculpture placed in a chamber to give a pleasing visual display and to indicate when the device is operating. Transparent or translucent walls also enable dual function of the device as both a fan and lamp. For example, as shown in FIG. 9( a ), the chamber ( 901 ) glows from internal light ( 902 ) when turned on. As shown in FIG. 9( b ), the streamer ( 903 ) inside the chamber moves as the device is turned on and there is vertical airflow ( 905 ). Further, as shown in FIG. 9( c ), the objects such as maple seeds ( 904 ) hanging inside the chamber rotates as the device is turned on and there is vertical airflow ( 905 ).
[0051] The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. For example, the position, size and number of openings for both upper exhaust chamber and lower inlet chamber can vary. Still further, a special opening in the structure of outside wall can be used to exhaust room air and draw in outside air in lieu of a window opening. Still further variations, including combinations and/or alternative implementations, of the embodiments described herein can be readily obtained by one skilled in the art without burdensome and/or undue experimentation. Such variations are not to be regarded as a departure from the spirit and scope of the invention. | An airflow management device is described that assists air cooling, exchange, and circulation of interior spaces by creating inward and outward airflow through a window opening. The device measures temperatures outside and inside a room, and determines when to exhaust warmer ceiling air and to draw cooler outside air. The exhaust component of the device captures warmer air at a higher level of the room and exhausts it through a window opening at a lower level. The intake component of the device draws cooler outside air through the window opening and discharges it into the room at a lower level than exhaust inflow. By expelling air from a high level and drawing it at a lower level, the room vertical temperature gradient is maintained thus optimizing cooling effectiveness. By microcontroller regulation of inflow and outflow, air pressure equilibrium between outside and inside is maintained thus maximizing airflow efficiency. | 5 |
CROSS REFERENCE APPLICATION
[0001] This patent application is a continuation application of non-provisional application Ser. No. 11/531,058 filed 12 Sep. 2006, which is a continuation of non-provisional application Ser. No. 10/637,904 filed 11 Aug. 2003, now U.S. Pat. No. 7,137,978, which claims the benefit of the earlier filed Israeli Patent Application Ser. No. 151486 filed 26 Aug. 2002, and is related to non-provisional application Ser. No. 12/336,866 filed 17 Dec. 2008, all of which applications are hereby incorporated herein by reference in their entirety.
FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable.
BACKGROUND OF THE INVENTION
[0003] There is significant number of patents, especially, the USA patents, which describe different constructions of cryosurgical probes and catheters. An aim of these patents is to solve some main problems, which are common to cryosurgical probes and catheters.
[0004] The problems include construction of relatively cheap and simple probes or catheters with high reliability and sufficiently effective thermal insulation of their lateral non-operating walls. Besides, cryosurgical catheters must have high flexibility, especially, when they are used for cardiac interventions. At the same time the closed distal end (cryotip) of such probe or catheter must provide in many cases high specific freezing capacity at sufficiently low-temperatures.
[0005] Analysis of USA patents related to this field shows, that constructions of the proposed probes and catheters intended for cryosurgery do not conform the above-mentioned requirements.
[0006] For example, U.S. Pat. No. 3,971,383 proposes a cryogenic surgical instrument with a coaxial assembly of the flexible lumens; the inner one being connected to a supply of cryogenic liquid, and the space between the outer wall of the inner lumen and the next lumen forming a return line for evaporated cryogenic liquid which is vented to the atmosphere; and the space between the outermost one of the coaxial lumens and the intermediate lumen containing a gas, such as normal butane, serving for thermal insulation of the inner and intermediate lumens.
[0007] U.S. Pat. No. 5,716,353 describes a probe for cryosurgery which consists of three lumens: an inner lumen for supply a cryogenic refrigerant to a cryotip positioned on the distal end of an outer jacket lumen, and an intermediate lumen situated concentrically around the inner lumen. The channel between the inner and intermediate lumens serves as a venting path for venting cryogenic refrigerant from the freezing zone. This construction is simple, but it does not provide sufficient thermal insulation as required in construction of a cryogenic catheter. Consequently, it may cause over-heating of the venting cryogenic refrigerant, as well as over-cooling of tissues adjacent the intermediate section of the catheter.
[0008] U.S. Pat. No. 5,573,532 describes design of a cryosurgical instrument, which comprises lumens of cryogenic fluid supply and return of cryogenic fluid vapors; these lumens are situated concentrically and the return lumen is sealed with a cryotip. The patent proposes to do vacuum insulation of the return lumen. Such construction is very expensive and has low reliability. Besides, this vacuum insulation limits flexibility of the probe, especially, when it has significant length and is used as a catheter.
[0009] U.S. Pat. No. 5,674,218 describes a cryosurgical instrument, a system and method of cryosurgery. According to this patent a cryogenic liquid (preferably, liquid nitrogen) is preliminary sub-cooled below its normal boiling point and in such condition it is supplied into the open proximal end of the internal supply line. The outer lumen of the cryosurgical instrument is provided with active vacuum insulation.
[0010] Obviously, this construction cannot ensure high flexibility and cannot be used as the base for construction of a catheter for cryosurgery.
[0011] U.S. Pat. No. 5,254,116 describes a cryocatheter with a set of vent holes in the lateral wall of a central feeding lumen; besides, sub-cooled liquid nitrogen is delivered into the central feeding lumen as a cryogenic liquid. This construction does not ensure proper thermal insulation of the cryocatheter.
BRIEF SUMMARY OF THE INVENTION
[0012] This invention proposes novel designs of a cryosurgical instrument and its accessory system. The cryosurgical instrument is constructed from two major sub-units: a distal cryotip, which serves for immediate contact with a target tissue to be treated; freezing action of this cryotip is obtained by evaporation of a cryogenic liquid on its internal surface covered with a porous coating with open porosity; an elongated tubular sub-unit serving for delivery of portions of the cryogenic liquid on the distal cryotip with following removal of vapors generated in the process of boiling this cryogenic liquid in the porous coating of the distal cryotip.
[0013] The elongated tubular sub-unit in turn comprises following details: an external shaft and a central feeding-venting lumen, which serves for immediate supply of portions of the cryogenic liquid to the porous coating of the distal cryotip and, at the same time, for removal of the vapors, generated in the process of boiling the cryogenic liquid on the internal surface of the distal cryotip, into the atmosphere or into a vacuum pump.
[0014] In addition, there is a coaxial tubular piece positioned in the gap between the distal sections of the central feeding-venting lumen and the external shaft; the distal end of this coaxial tubular piece is sealed with the external shaft or with the cryotip itself and the proximal end—with the central feeding-venting lumen. It forms a buffer space between: the internal surface of the cryotip, the central feeding-venting lumen and the coaxial tubular piece, this buffer space facilitates flow of the portion the cryogenic liquid in the central feeding-venting lumen toward the cryotip.
[0015] The proximal section of the external shaft and proximal end of the central feeding-venting lumen are provided with inlet-outlet connections.
[0016] In another version there is a coaxial intermediate lumen, which is situated between the central feeding-venting lumen and the external shaft. This coaxial intermediate lumen substitutes the aforementioned coaxial tubular piece. The distal end of this coaxial intermediate lumen is sealed with the external shaft or with the cryotip itself; the proximal end—with the central feeding-venting lumen, and the proximal end of the external shaft—with the proximal section of the coaxial intermediate lumen. The proximal section of the coaxial intermediate lumen is provided in this case with an outlet connection.
[0017] When the proposed construction is used as a cryocatheter, the external shaft is made preferably from polymer material, it allows to achieve its high flexibility.
[0018] The cryotip of the cryocatheter should be made from material with high thermal conductivity (for example, copper, silver, diamond, BeO). As it has been noted, the internal surface of cryotip is covered with a porous coating with open porosity (for example, this porous coating is obtained by sintering copper powder). This provides high magnitudes of the heat transfer coefficients in the process of boiling the cryogenic liquid. Besides, this porous coating can completely soak one portion of the cryogenic liquid provided by an accessory system during first quarter-period of its operation as it will be described thereafter.
[0019] The proposed cryocatheter can be used for inhibiting restenosis of a blood vessel. In this case the cryotip is constructed in the form of a tubular detail, the distal end of the tubular detail is sealed with a plug from polymer with low thermal conductivity and its tubular section is fabricated from a thin polymer film with high elasticity, the internal surface of the tubular section is coated with a porous polymer layer with open porosity, this porous polymer layer has also high elasticity.
[0020] Construction of the accessory systems for these two designs of the cryocatheter (or cryoprobe) will be described thereafter as well.
[0021] A first version of the accessory system, which ensures desired functioning of the proposed cryosurgical instrument, comprises: a thermo-insulated tank filled with the cryogenic liquid, the thermo-insulated tank is provided with a relief valve which gives possibility to preset the desired pressure in this thermo-insulated tank; a feed pipe which is situated vertically and the lower end of this feed pipe is positioned near the bottom of the thermo-insulated tank. An outlet connection of the feed pipe is joined by a flexible thermo-insulated duct with an inlet connection of a multi-way valve. This multi-way valve is provided with an additional inlet connection which is communicated with a bottle with pressurized gas (for example, nitrogen), an outlet connection which is communicated with atmosphere (or a vacuum pump), and with an inlet-outlet connection which is communicated with an inlet-outlet connection of the central feeding-venting lumen of the cryosurgical instrument itself.
[0022] In addition, there are four shut-off valves, the first shut-off valve is installed on a main duct which communicates the multi-way valve with the inlet-outlet connection of the central feeding-venting lumen of the cryosurgical instrument, the second one—on a duct which communicates the outlet connection of the thermo-insulated tank with the multi-way valve, the third one—on the duct which communicates the bottle with pressurized gas and the multi-way valve, and the fourth—on the thermo-insulated tank itself; this shut-off valve serves for filling the thermo-insulted tank with the cryogenic liquid. The fourth shut-off valve is open during filling the thermo-insulated tank with the cryogenic liquid; the second one serves for cutting off supply of the cryogenic liquid to the multi-way valve, the third one—for cutting off supply of pressurized gas to the multi-way valve and the first one—for putting in action the cryosurgical instrument.
[0023] An electromechanical (or pneumatic) drive ensures periodical with preset frequency changeover of the multi-way valve in such a way, that it is communicating alternatively with: the thermo-insulated tank, the bottle with pressurized gas, and the atmosphere (or the vacuum pump).
[0024] A control unit keeps watch on frequency of changeover of the multi-way valve and, in the case of significant deviation from the preset frequency of changeover or its stoppage, this control unit activates the aforementioned second and third shut-off valves. In addition, it is possible to install pressure and temperature gauges on the main duct of the accessory system. Data provided from these gauges are processed in the control unit. In the case of significant deviations of the measured parameters from the preset values, the control unit cuts off the shut-off valves installed on the main, first and second ducts.
[0025] Significant fraction of the cryogenic liquid, which remains in the porous coating of the cryotip and in the aforementioned buffer space in the period between communication of the central feeding-venting lumen with the inlet connection of the vacuum pump (or with the atmosphere) and communication this central feeding-venting lumen with the feeding pipe of the thermo-insulated tank, generates reasonably high pressure in the central feeding-venting lumen; this pressure prevents introducing the following portion of the cryogenic liquid into the central feeding-venting lumen.
[0026] In the aforementioned case of application of the coaxial intermediate lumen with an outlet connection instead of the coaxial tubular piece, there is an auxiliary shut-off valve installed on a duct communicating the outlet connection of the coaxial intermediate lumen with the atmosphere (or with the vacuum pump); this shut-off valve is joined with the multi-way valve mechanically or electro-mechanically in such a way, that it will be open only at a quarter-period, when the multi-way valve is communicating the main duct with the bottle with pressurized gas.
[0027] In addition, the outlet connection of the intermediate lumen can serve as an inlet-outlet connection. In this case a gas from a special bottle is provided into the gap between the coaxial intermediate and the central feeding-venting lumens; introduction of this gas is performed when the multi-way valve communicates the central feeding-venting lumen with the atmosphere (or the vacuum pump).
[0028] The ducts between the thermo-insulated tank and the multi-way valve, and between this multi-way valve and the inlet-outlet connection of the central feeding-venting lumen can be provided with outer thermal insulation, for example, with vacuum insulation.
[0029] There are several cryogens that can be applied as the cryogenic liquid: liquid nitrogen, liquid argon, liquid R14 and others.
[0030] Besides, it is possible to apply two tanks with different liquids: the first one—a cryogenic liquid with low temperature of boiling (for example, liquid nitrogen), which serves for cryogenic treatment of target tissue, and the second one—with relatively high temperature of boiling (for example, R12B1 that boils at temperature −3.8.degree. C. at atmospheric pressure), this second liquid serves for ice-mapping.
[0031] The second liquid with normal boiling temperature higher than 0.degree. C. (for example, R11, which has normal boiling temperature 23.65.degree. C.) can be used for fast thawing a tissue, which has been previously frozen by the cryogenic liquid.
[0032] Application of two liquids with high difference in their boiling temperatures requires performance of blowing the central feeding-venting lumen, the buffer space and several ducts in the period between the procedures of ice-mapping (or thawing) and following cryogenic treatment.
[0033] The accessory system comprises in this case two accessory sub-systems, each of these accessory sub-systems is constructed much as the accessory system, which has been described above. The accessory sub-systems have a common control unit and a common main duct which splits off into two ducts communicated correspondingly with first and second multi-way valves; a thermo-insulated tank of the first accessory sub-system contains a cryogenic liquid which serves to freeze the target tissue, and a tank of the second accessory subunit contains a liquid with relatively high temperature of boiling (for example, R12B1 or R11), this liquid serves for preliminary ice-mapping (as with R12B1); or for fast thawing this target tissue (as with R11).
[0034] The accessory system comprises in addition an auxiliary accessory sub-system, which serves for blowing the cryosurgical instrument and the ducts communicating the first and second accessory sub-systems with this cryosurgical instrument. The auxiliary accessory sub-system consists of an auxiliary bottle with pressurized gas and an auxiliary three-way valve, which is installed on a duct communicating the auxiliary bottle with the main duct. The auxiliary three-way valve is regulated by the common control unit, and it has two outlet connections, the first outlet connection of this auxiliary three-way valve is communicated with the main duct and the second one—with the atmosphere or a vacuum pump.
[0035] Blowing process is performed by cutting out the shut-off valves installed on the ducts communicating the tanks with their associated multi-way valves and then pressurized gas from the bottle performs blowing the main duct and the ducts generated by its splitting off, the central feeding-venting lumen and the buffer space by charging and purging technique.
[0036] As stated above, the gap between the central feeding-venting lumen (or the coaxial tubular piece) and the external shaft serves for thermal insulating the external shaft, especially, its distal section in order to prevent possibility of negative temperature on its outer surface.
[0037] It is possible to achieve higher degree of thermal insulation of the external shaft of the cryosurgical instrument by preliminary filling the gap between the external shaft and the coaxial tubular piece with a gas, which has very low thermal conductivity, and, on the other hand, condensation temperature of this gas is lower than the boiling temperature of the cryogenic liquid. In order to perform this filling, the proximal section of the external shaft is provided with an inlet-outlet connection; the accessory system comprises a bottle with the aforementioned gas with low thermal conductivity, and a duct, which communicates this bottle with the inlet-outlet connection of the external shaft, is provided with a three-way valve, which is communicated as well with the atmosphere or with a vacuum pump. It allows to perform filling the gap between the external shaft and the coaxial tubular piece by charging and purging technique.
[0038] In order to achieve better characteristics of thermal insulation of the distal section of the external shaft (to prevent negative temperature of its outer surface) it is possible to apply a heat pipe principle.
[0039] In this case, the heat pipe principle is realized in the following manner: the outer surfaces of the coaxial tubular piece and a section of the central feeding-venting lumen mating this coaxial tubular piece are covered with a porous coating with open porosity, this coating is functioning as a wick. The gap between the external shaft and the coaxial tubular piece, and its extension to the gap between the central feeding-venting lumen and the external shaft is filled with such a gas that the temperature of its condensation somewhat higher than the boiling temperature of the cryogenic liquid, but the solidification temperature of this gas should be somewhat lower than the boiling temperature of the cryogenic liquid. This gas can be provided into these gaps via the inlet-outlet connection installed on the proximal section of the external shaft.
[0040] Charging and purging technique can perform it. Such technical solution permits to heat the distal section of the external shaft at the expense of the heat provided to the intermediate and proximal sections of the external shaft from the surroundings.
[0041] It should be noted that the multi-way valve can be substituted for a set of shut-off valves installed on the communicating ducts; coordinated operation of this set of the shut-off valves simulates operation of the aforementioned multi-way valve.
[0042] The cryosurgical instrument constructed according to this invention can be provided with a thermocouple, which is positioned in the cryotip and measures temperature in this cryotip in the process of a cryosurgical operation.
[0043] Besides, if the cryosurgical instrument is designed as a cryocatheter, this cryocatheter should be provided with a steering mechanism allowing bending its distal section.
[0044] The cryotip of the cryocatheter (or cryoprobe) may be provided with an electrode for preliminary detection of electrical signal activity of different places of the organ to be operated.
[0045] Operation of the cryosurgical instrument and its accessory system is performed in a following manner.
[0046] A portion of the cryogenic liquid is introduced via the feed pipe of the thermo-insulated tank into the duct communicating the multi-way valve with the inlet-outlet connection installed on the proximal end of the central feeding-venting lumen (in the following, this duct will be called—the main duct), it occurs at a quarter-period, when the multi-way valve is in such position, that the cryogenic liquid may flow from the feed pipe into the main duct (it is a first quarter-period).
[0047] Thereafter the multi-way valve ceases flow of the cryogenic liquid from the thermo-insulated tank into the main duct and at the following second quarter-period the multi-way valve communicates the bottle with the pressurized gas with the main duct, which provides high velocity to the portion of the cryogenic liquid and this portion passes briefly the main duct and the central feeding-venting lumen, and reaches the porous coating of the cryotip.
[0048] Then supply of the pressurized gas is ceased and the multi-way valve cuts off the proximal end of the main duct. The cryogenic liquid is boiling in the porous coating of the cryotip with elevation of pressure of the cryogenic liquid vapor in the central feeding-venting lumen and the main duct (it is a third quarter-period).
[0049] At the fourth quarter-period the multi-way valve turns on the duct communicating the main duct with the atmosphere or with the vacuum pump. Boiling the cryogenic liquid in the porous coating of the cryotip can be continued in this quarter-period. It is well to bear in mind that all aforementioned quarter-periods may have different duration.
[0050] In the case when the cryosurgical instrument is designed as a cryocatheter, which is intended to treat a blood vessel in order to prevent restenosis and its cryotip is constructed from elastic polymer, it is very important to keep relatively low excessive pressure in the internal chamber of the distal section of this cryocatheter with small deviation from its average value. In order to provide these conditions, the cryocatheter is constructed with the intermediate lumen as it has been described above. The outlet connection of the intermediate lumen is provided with a T-shaped manifold, which comprises a crossbar and a main section intersecting perpendicularly with the crossbar. A pressure gauge is installed on one end of the crossbar and an adjusting valve is installed on the other end, this adjusting valve is connected with the atmosphere or with the vacuum pump. Signals from the pressure gauge are sent to a pressure control unit, which provides in turn desired operation of the adjusting valve. It should be noted that the pressure control unit could be interconnected with the aforementioned control unit, in doing so operations of these control units are correlated.
[0051] It is the primary object of the present invention to provide a flexible catheter with high flexibility, high specific freezing power and sufficiently small diameter for cryosurgical procedures in different areas of medicine.
[0052] It is another object of the invention to provide a rigid probe with high specific freezing power and sufficiently small diameter for cryosurgical procedures in different areas of medicine.
[0053] It is an additional object of the invention to design a cryosurgical instrument and its accessory system for cryosurgical procedures, which have high degree of safety and reliability. It should be noted that the proposed design of the cryosurgical instrument ensures positive temperatures at the distal section of its external shaft, especially, in the immediate vicinity of the cryotip.
[0054] It is another object of this invention to develop a novel method of thermal insulation of the distal section of the external shaft of the cryosurgical instrument, this method is based on the principle of a heat pipe.
[0055] It is another object of this invention to design a cryocatheter that is used for inhibiting restenosis of a blood vessel.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0056] Other objectives of this invention will be apparent from the following detail description taken in conjunction with the accompanying drawings, in which:
[0057] FIG. 1 is a general view of a cryosurgical instrument of the present invention and a block diagram of its accessory system.
[0058] FIG. 2 is a general view of a cryosurgical instrument of the present invention and a block diagram of its accessory system, when there is a coaxial intermediate lumen situated between a central feeding-venting lumen and an external shaft with oscillating flow in the channel between the central feeding-venting and coaxial intermediate lumens.
[0059] FIG. 3 is a general view of a cryosurgical instrument of the present invention and a block diagram of its accessory system, when two different liquids are used for preliminary ice-mapping and following cryogenic treatment. Besides, this drawing demonstrates a general view of a cryosurgical instrument and a block diagram of its accessory system in the case of application of two different liquids for freezing and fast thawing a target tissue.
[0060] FIG. 4 is an axial cross-section of the cryosurgical instrument with application of active thermal insulation based of the principle of a heat pipe.
[0061] FIG. 5 is an axial cross-section of a cryosurgical instrument with a coaxial tubular piece joined at its distal end with the external shaft.
[0062] FIG. 6 demonstrates an axial cross-section of a cryosurgical instrument with application of the coaxial intermediate lumen instead of the coaxial tubular piece.
[0063] FIG. 7 is an axial cross-section of a cryocatheter for preventing restenosis of blood vessels.
DETAILED DESCRIPTION OF THE INVENTION
[0064] FIG. 1 shows the general view of the cryosurgical instrument and its accessory device. The drawing demonstrates following units: a cryosurgical instrument 100 with cryotip 116 and an elongated tubular sub-unit 105 . The accessory system comprises: a thermo-insulated tank (or a Dewar flask) 101 with cryogenic liquid, this thermo-insulated tank 101 is provided with a relief valve 103 , which gives possibility to preset a desired pressure in the thermo-insulated tank, a shut-off valve 102 that serves for filling the thermo-insulated tank 101 with the cryogenic liquid, and manometer 104 .
[0065] A multi-way valve 107 is communicated with: a feeding pipe 106 situated in the thermo-insulated tank 101 ; a vacuum pump or atmosphere (via duct 121 ); the cryosurgical instrument 100 by a main duct 112 : bottle 108 with pressurized gas. Sensor 111 controls preset changeover frequency of the multi-way valve 107 . In addition, there are pressure and temperature gauges 114 and 120 installed on the main duct 112 . Data provided from these sensor and gauges are processed in a control unit 115 . In the case of significant deviations of the measured parameters from the preset values, the control unit 115 cuts off the shut-off valves 109 , 110 and 113 .
[0066] In addition, there is bottle 117 filled with a gas with low thermal conductivity, for example, R14. This bottle is communicated via duct 119 with the external chamber of the cryosurgical instrument 100 (the gaps between the external shaft of the cryosurgical instrument 100 , and its coaxial tubular piece, and the external shaft and the proximal section of the central feeding-venting lumen). A three-way valve 118 installed on duct 119 serves for filling the external chamber by charging and purging technique, this filling should be performed previously to actuating the cryosurgical instrument 100 and performance of cryogenic treatment.
[0067] FIG. 2 shows a cryosurgical instrument 200 and its accessory system in the case, when this cryosurgical instrument comprises a coaxial intermediate lumen instead of the coaxial tubular piece and there is oscillating flow in the channel between the central feeding-venting lumen and the coaxial intermediate lumen of the cryosurgical instrument. The cryosurgical instrument 200 consists of two major sub-units: 1) cryotip 217 ; 2) elongated tubular sub-unit 218 .
[0068] The accessory system comprises a thermo-insulated tank (or a Dewar flask) 201 containing cryogenic liquid, this thermo-insulated tank 201 is provided with a relief valve 203 which gives possibility to preset a desired pressure in the thermo-insulated tank 201 , valve 202 which serves for filling the thermo-insulated tank 201 with the cryogenic liquid, and manometer 204 .
[0069] A multi-way valve 208 of the accessory system is communicated with following details: a feeding pipe 205 situated in the thermo-insulated tank 201 ; a vacuum pump or atmosphere; the cryosurgical instrument 200 (by a main duct 215 ); bottle 210 with pressurized gas. In addition, there is a three-way valve 211 , which is joined mechanically by coupling 212 with the multi-way valve 208 . The three-way valve is communicated with the channel between the coaxial intermediate lumen and the central feeding-venting lumen of the cryosurgical instrument 200 by duct 222 , the atmosphere (or vacuum pump) and bottle 210 with pressurized gas. A shut-off valve 213 is installed on the duct, which communicates bottle 210 with the three-way valve 211 . Coupling 212 is designed in such a way, that when the multi-way valve 208 communicates the main duct 215 with the atmosphere (or vacuum pump), then the three-way valve 211 communicates duct 222 with bottle 210 and vice versa, the three-way valve 211 communicates ducts 222 with the atmosphere (or vacuum pump) when the multi-way valve 208 communicates the main duct 215 with bottle 210 .
[0070] Sensor 209 controls a preset changeover frequency of the multi-way valve 208 . Data provided from this sensor are processed in a control unit 223 . In the case of significant deviations of the measured parameters from the preset values, the control unit 223 cuts off a shut-off valve 207 , which is installed on duct 206 communicating the feeding pipe 205 with the multi-way valve 208 , a shut-off valve 214 installed on a duct communicating bottle 210 with the multi-way valve 208 , a shut-off valve 216 installed on the main duct 215 and the shut-off valve 213 installed on a duct communicating bottle 210 with the three-way valve 211 .
[0071] In addition, there is bottle 219 filled with a gas with low thermal conductivity, for example, R14. This bottle is communicated via duct 220 with the external chamber of the cryosurgical instrument 200 (the gap between the external shaft of the cryosurgical instrument 200 and its coaxial intermediate lumen). A three-way valve 221 installed on duct 220 serves for filling the external chamber of the cryosurgical instrument 200 with the gas with low thermal conductivity by charging and purging technique. This filling should be performed previously to actuating the cryosurgical instrument 200 and performance of cryogenic treatment.
[0072] FIG. 3 shows a general view of a cryosurgical instrument of the present invention and a block diagram of its accessory system, when two different liquids are used for preliminary ice-mapping and following cryogenic treatment.
[0073] In addition, this drawing demonstrates a general view of a cryosurgical instrument and a block diagram of its accessory system in the case of application of two different liquids for freezing and fast thawing a target tissue.
[0074] The drawing shows following units: a cryosurgical instrument 300 with cryotip 332 and an elongated tubular sub-unit 333 . The accessory system comprises: a first tank 301 filled with first liquid with cryogenic boiling temperature (for example, liquid nitrogen), this first tank 301 is provided with: a relief valve 302 , which gives possibility to preset the desired pressure in the first tank 301 ; valve 304 which serves for filling the first tank 301 with the first liquid and manometer 303 .
[0075] A multi-way valve 310 is communicated by duct 306 with following details: a feeding pipe 305 situated in the first tank 301 ; a vacuum pump or the atmosphere; the cryosurgical instrument 300 by a main duct 322 , this main duct splits off into two ducts 313 and 337 ; bottle 308 with a first pressurized gas. A shut-off valve 307 is installed on duct 306 , a shut-off valve 338 is installed on duct 313 and a shut-off valve 309 is installed on a duct that communicates bottle 308 with the multi-way valve 310 . Sensor 312 controls preset changeover frequency of the multi-way valve 310 . Data provided from this sensor are processed in a control unit 331 . In the case of significant deviation of the measured parameter from a preset value, the control unit 331 cuts off the shut-off valves 307 , 338 and 329 .
[0076] In addition, the accessory system comprises a second tank 314 filled with second liquid with relatively high boiling temperature (for example, R12B 1), this second tank 314 is provided with: a relief valve 315 which gives possibility to preset the desired pressure in the second tank 314 ; valve 317 which serves for filling the second tank 314 with the second liquid; manometer 316 .
[0077] A multi-way valve 321 is communicated with following details: by duct 319 with a feeding pipe 318 situated in the second tank 3141 ; a vacuum pump or the atmosphere; the cryosurgical instrument 300 by a main duct 322 and duct 337 ; bottle 323 with a second pressurized gas. A shut-off valve 320 is installed on duct 321 , a shut-off valve 325 is installed on duct 324 communicating bottle 323 with the multi-way valve 321 and a shut-off valve 326 is installed on duct 337 . Sensor 330 controls preset changeover frequency of the multi-way valve 321 . Data provided from this sensor are processed in a control unit 331 . In the case of significant deviation of the measured parameter from a preset value, the control unit 331 cuts off the shut-off valves 320 , 325 and 326 .
[0078] Bottle 328 with a third pressurized gas is communicated by duct 327 with ducts 337 and 322 . A three-way valve 328 is installed on duct 327 , this three-way valve is communicating with the atmosphere as well and the control unit 331 controls it. The three-way valve 329 serves for blowing the ducts and the cryosurgical instrument 300 itself after a stage of ice-mapping (or thawing) in order to remove the second liquid and its vapors. Charging and purging technique performs the blowing process.
[0079] In addition, there is bottle 334 filled with a gas with low thermal conductivity, for example, R14. This bottle is communicated by duct 335 with the external chamber of the cryosurgical instrument 300 (the gap between the external shaft of the cryosurgical instrument 300 , and its coaxial tubular piece and the proximal section of the central feeding-venting lumen). A three-way valve 336 installed on duct 335 and communicated as well with the atmosphere serves for filling the external chamber of the cryosurgical instrument 300 by charging and purging technique, this filling should be performed previously to actuating the cryosurgical instrument 300 and performance of cryogenic treatment.
[0080] FIG. 4 shows an axial cross-section of a cryosurgical instrument 400 with application of active thermal insulation based of the principle of a heat pipe.
[0081] The cryosurgical instrument is constructed from two major sub-units: a distal cryotip 402 , which serves for immediate contact with a target tissue; freezing action of this cryotip is obtained by evaporation of cryogenic liquid on its internal porous coating 403 formed from porous metal with open porosity; an elongated tubular sub-unit serving for delivery of portions of the cryogenic liquid on the internal porous coating 403 with following removal of vapors generated in the process of boiling this cryogenic liquid in the internal porous coating 403 .
[0082] The elongated tubular sub-unit in turn comprises following details: an external shaft 404 ; a central feeding-venting lumen 401 , which serves for immediate supply of portions of the cryogenic liquid to the internal porous coating 403 of the distal cryotip 402 and, at the same time, for removal of the vapors, generated in the process of boiling the cryogenic liquid in this internal coating 403 , into the atmosphere or into a vacuum pump.
[0083] In addition, there is a coaxial tubular piece 405 positioned in the gap between the distal sections of the central feeding-venting lumen and the external shaft 404 ; the distal end of this coaxial tubular piece 405 is sealed with cryotip 402 and the proximal end with the central feeding-venting lumen 401 .
[0084] The outer surfaces of the coaxial tubular piece 405 and a section of the central feeding-venting lumen 401 mating this coaxial tubular piece are covered with a porous coating 406 with open porosity, this porous coating is functioning as a wick when the gap between the external shaft 404 , the coaxial tubular piece 405 and the mating section of the central feeding-venting lumen 401 is filled with vapors of such a gas that its condensation temperature is higher than the boiling temperature of the applied cryogenic liquid.
[0085] The proximal end of the feeding-venting central lumen is provided with an inlet-outlet connection 407 , and the proximal section of the external shaft 404 is provided with an inlet-outlet connection 408 .
[0086] FIG. 5 is an axial cross-section of a cryosurgical instrument with a coaxial tubular piece joined at its distal end with the external shaft.
[0087] Cryocatheter 500 (or cryoprobe) is constructed from two major subunits: a distal cryotip 502 , which serves for immediate contact with a target tissue, freezing action of this cryotip is obtained by evaporation of a cryogenic liquid in its internal porous coating 503 formed from porous metal with open porosity; an elongated tubular sub-unit serving for delivery of portions of the cryogenic liquid on the internal porous coating 503 with following removal of vapors generated in the process of boiling this cryogenic liquid in the internal porous coating 503 .
[0088] The elongated tubular sub-unit in turn comprises following details: an external shaft 504 and a central feeding-venting lumen 501 , which serves for immediate supply of portions of the cryogenic liquid to the internal porous coating 503 of the distal cryotip 502 and, at the same time, for removal of the vapors generated in the process of boiling the cryogenic liquid on this internal porous coating 503 into the atmosphere or into a vacuum pump.
[0089] In addition, there is a coaxial tubular piece 505 positioned in the gap between the distal sections of the central feeding-venting lumen 501 and the external shaft 504 ; the distal end of this coaxial tubular piece 505 is sealed with the external shaft 504 and its proximal end—with the central feeding-venting lumen 501 . The proximal end of the feeding-venting central lumen 501 is provided with an inlet-outlet connection 506 , and the proximal section of the external shaft 504 is provided with an inlet-outlet connection 507 .
[0090] FIG. 6 demonstrates an axial cross-section of the cryosurgical instrument with application of a coaxial intermediate lumen instead of the coaxial tubular piece.
[0091] A cryosurgical instrument 600 is constructed from two major sub-units: a distal cryotip 602 , which serves for immediate contact with a target tissue; freezing action of this cryotip is obtained by evaporation of a cryogenic liquid on its internal porous coating 603 formed from porous metal with open porosity; an elongated tubular sub-unit serving for delivery of portions of the cryogenic liquid on the porous coating with following removal of vapors generated in the process of boiling this cryogenic liquid in the internal porous coating 603 .
[0092] The elongated tubular sub-unit in turn comprises following details: an external shaft 604 and a central feeding-venting lumen 601 , which serves for immediate supply of portions of the cryogenic liquid to the internal porous coating 603 of the distal cryotip 602 and, at the same time, for removal of the vapors, generated in the process of boiling the cryogenic liquid in this internal coating 603 , into the atmosphere or into a vacuum pump.
[0093] In addition, there is a coaxial intermediate lumen 605 positioned in the gap between the central feeding-venting lumen 601 and the external shaft 604 ; the distal end of this coaxial intermediate lumen 605 is sealed with the external shaft 604 and the proximal end—with the central feeding-venting lumen 601 . In addition, the proximal end of the external shaft 604 is sealed with the proximal section of the coaxial intermediate lumen 605 . The proximal end of the feeding-venting central lumen 601 is provided with an inlet-outlet connection 607 , the proximal section of the external shaft 604 is provided with an inlet-outlet connection 609 and proximal section of the coaxial intermediate lumen 605 is provided with an inlet-outlet connection 608 . Significant part of the outer surface of the coaxial intermediate lumen 605 is covered with a porous coating 606 leading off with the proximal end of the intermediate lumen, this porous coating serves as a wick in the case of application of the principle of a heat pipe for heating the distal section of the external shaft.
[0094] FIG. 7 demonstrates an axial cross-section of the catheter for preventing restenosis of blood vessels.
[0095] Cryocatheter 700 is constructed from two major sub-units: a distal cryotip, which serves for immediate contact with a target tissue; freezing action of this cryotip is obtained by evaporation of a cryogenic liquid in an internal porous coating 704 formed from porous elastic polymer with open porosity on the internal surface of an external tubular piece 703 , which is made from elastic polymer as well.
[0096] The distal end of external tubular piece 703 is sealed by plug 702 manufactured from polymer material with low thermal conductivity. | The invention proposes a cryosurgical instrument and its accessory system operating on the base of a refrigerant evaporation. The invention comprises combination of some technical solutions. Flow in a central lumen of the cryosurgical instrument has oscillating character; the refrigerant is provided on the internal surface of the distal cryotip in the form of separated portions. 2. The internal surface of the distal cryotip of the cryosurgical instrument is covered by a porous coating, which soaks completely one portion of the refrigerant. 3. Vapors obtained as a result of the refrigerant boiling on the porous coating of the cryotip are removed through the central lumen into the atmosphere. Combination of these technical solutions allows to construct a safely cryosurgical instrument with high freezing power and small outer diameter. The proposed cryosurgical instrument may be designed as a flexible cryocatheter or as a rigid cryoprobe. | 0 |
FIELD OF THE INVENTION
[0001] The present invention is directed to compounds methods and compositions that are useful as inhibitors of the hepatitis C virus (HCV) NS3 protease, the synthesis of such compounds, and the use of such compounds for treating HCV infection and or reducing the likelihood or severity of symptoms of HCV infection.
[0002] This application claims priority to U.S. Provisional Application No. 61/408,989, filed on Nov. 1, 2010, the contents of which are hereby incorporated by reference for all purposes.
BACKGROUND OF THE INVENTION
[0003] Hepatitis C virus (HCV) has infected more than 180 million people worldwide. It is estimated that three to four million persons are newly infected each year, 70% of whom will develop chronic hepatitis. HCV is responsible for 50-76% of all liver cancer cases, and two thirds of all liver transplants in the developed world. Standard therapy (pegylated interferon alpha plus ribavirin) is only effective in 50-60% of patients; however, its effectiveness is not well understood and it is associated with significant side-effects. Therefore, there is an urgent need for new drugs to treat and/or cure HCV (1: Chen K X, Njoroge F G. A review of HCV protease inhibitors. Curr Opin Investig Drugs. 2009 8, 821-37; 2: Garg G, Kar P. Management of HCV infection: current issues and future options. Trop Gastroenterol. 2009 30, 11-8; 3: Pereira A A, Jacobson I M. New and experimental therapies for HCV. Nat Rev Gastroenterol Hepatol. 2009 7, 403-11).
[0004] The HCV genome comprises a positive-strand RNA enclosed in a nucleocapsid and lipid envelope and consists of 9.6 kb ribonucleotides, which encodes a large polypeptide of about 3000 amino acids (Dymock et al. Antiviral Chemistry & Chemotherapy 2000, 11, 79). Following maturation, this polypeptide is cut into at least 10 proteins. The NS3 serine protease, located in the N-terminal domain of the NS3 protein, mediates all of the subsequent cleavage events downstream in the polyprotein. Because of its role, the NS3 serine protease is an ideal drug target and previous research has shown hexapeptides as well as tripeptides show varying degrees of inhibition, as discussed in U.S. patent applications US2005/0020503, US2004/0229818, and US2004/00229776. Macrocyclic compounds that exhibit anti-HCV activity have also been disclosed in International patent applications nos. W020061119061, W02007/015855 and W02007/016441 (all Merck & Co., Inc.).
[0005] The discovery of novel antiviral strategies to selectively inhibit HCV replication has long been hindered by the lack of convenient cell culture models for the propagation of HCV. This hurdle has been overcome first with the establishment of the HCV replicon system in 1999 (Bartenschlager, R., Nat. Rev. Drug Discov. 2002, 1, 911-916 and Bartenschlager, R., J. Hepatol. 2005, 43, 210-216) and, in 2005, with the development of robust HCV cell culture models (Wakita, T., et al., Nat. Med. 2005, 11, 791-6; Zhong, J., et al., Proc. Natl. Acad. Sci. U.S.A. 2005, 102, 9294-9; Lindenbach, B. D., et al., Science 2005, 309, 623-6).
[0006] It would be advantageous to provide new antiviral or chemotherapy agents, compositions including these agents, and methods of treatment using these agents, particularly to treat drug resistant or mutant viruses. The present invention provides such agents, compositions and methods.
SUMMARY OF THE INVENTION
[0007] The present invention provides compounds, methods and compositions for treating or preventing HCV infection in a host. The compounds have the following general formula:
[0000]
[0008] Where R, J, and J 1 are as defined hereinbelow.
[0009] The methods involve administering a therapeutically or prophylactically-effective amount of at least one compound as described herein to treat or prevent an infection by, or an amount sufficient to reduce the biological activity of HCV infection. The pharmaceutical compositions include one or more of the compounds described herein, in combination with a pharmaceutically acceptable carrier or excipient, for treating a host with HCV. The formulations can further include at least one further therapeutic agent. In addition, the present invention includes processes for preparing such compounds.
[0010] Hepatitis C replicons require viral helicase, protease, and polymerase to be functional in order for replication of the replicon to occur. The replicons can be used in high throughput assays, which evaluate whether a compound to be screened for activity inhibits the ability of HCV helicase, protease, and/or polymerase to function, as evidenced by an inhibition of replication of the replicon.
DETAILED DESCRIPTION
[0011] The compounds described herein show inhibitory activity against HCV. Therefore, the compounds can be used to treat or prevent a viral infection in a host, or reduce the biological activity of the virus. The host can be a mammal, and in particular, a human, infected with HCV. The methods involve administering an effective amount of one or more of the compounds described herein.
[0012] Pharmaceutical formulations including one or more compounds described herein, in combination with a pharmaceutically acceptable carrier or excipient, are also disclosed. In one embodiment, the formulations include at least one compound described herein and at least one further therapeutic agent.
[0013] The present invention will be better understood with reference to the following definitions:
I. Definitions
[0014] The terms “independently” is used herein to indicate that the variable, which is independently applied, varies independently from application to application. Thus, in a compound such as R″XYR″, wherein R″ is “independently carbon or nitrogen,” both R″ can be carbon, both R″ can be nitrogen, or one R″ can be carbon and the other R″ nitrogen.
[0015] As used herein, the term “enantiomerically pure” refers to a compound composition that comprises at least approximately 95%, and, preferably, approximately 97%, 98%, 99% or 100% of a single enantiomer of that compound.
[0016] As used herein, the term “substantially free of” or “substantially in the absence or refers to a compound composition that includes at least 85 to 90% by weight, preferably 95% to 98% by weight, and, even more preferably, 99% to 100% by weight, of the designated enantiomer of that compound. In a preferred embodiment, the compounds described herein are substantially free of enantiomers.
[0017] Similarly, the term “isolated” refers to a compound composition that includes at least 85 to 90% by weight, preferably 95% to 98% by weight, and, even more preferably, 99% to 100% by weight, of the compound, the remainder comprising other chemical species or enantiomers.
[0018] The term “alkyl,” as used herein, unless otherwise specified, refers to' a saturated straight, branched, or cyclic, primary, secondary, or tertiary hydrocarbons, including both substituted and unsubstituted alkyl groups. The alkyl group can be optionally substituted with any moiety that does not otherwise interfere with the reaction or that provides an improvement in the process, including but not limited to but limited to halo, haloalkyl, hydroxyl, carboxyl, acyl, aryl, acyloxy, amino, amido, carboxyl derivatives, alkylamino, dialkylamino, arylamino, alkoxy, aryloxy, nitro, cyano, sulfonic acid, thiol, imine, sulfonyl, sulfanyl, sulfinyl, sulfamonyl, ester, carboxylic acid, amide, phosphonyl, phosphinyl, phosphoryl, phosphine, thioester, thioether, acid halide, anhydride, oxime, hydrazine, carbamate, phosphonic acid, phosphonate, either unprotected, or protected as necessary, as known to those skilled in the art, for example, as taught in Greene, et al., Protective Groups in Organic Synthesis , John Wiley and Sons, Second Edition, 1991, hereby incorporated by reference. Specifically included are CF 3 and CH 2 CF 3
[0019] In the text, whenever the term C(alkyl range) is used, the term independently includes each member of that class as if specifically and separately set out. The term “alkyl” includes C 1-22 alkyl moieties, and the term “lower alkyl” includes C 1-6 alkyl moieties. It is understood to those of ordinary skill in the art that the relevant alkyl radical is named by replacing the suffix “-ane” with the suffix “-yl”.
[0020] The term “alkenyl” refers to an unsaturated, hydrocarbon radical, linear or branched, in so much as it contains one or more double bonds. The alkenyl group disclosed herein can be optionally substituted with any moiety that does not adversely affect the reaction process, including but not limited to but not limited to those described for substituents on alkyl moieties. Non-limiting examples of alkenyl groups include ethylene, methylethylene, isopropylidene, 1,2-ethane-diyl, 1,1-ethane-diyl, 1,3-propane-diyl, 1,2-propane-diyl, 1,3-butane-diyl, and 1,4-butane-diyl.
[0021] The term “alkynyl” refers to an unsaturated, acyclic hydrocarbon radical, linear or branched, in so much as it contains one or more triple bonds. The alkynyl group can be optionally substituted with any moiety that does not adversely affect the reaction process, including but not limited to those described above for alkyl moeities. Non-limiting examples of suitable alkynyl groups include ethynyl, propynyl, hydroxypropynyl, butyn-1-yl, butyn-2-yl, pentyn-1-yl, pentyn-2-yl, 4-methoxypentyn-2-yl, 3-methylbutyn-1-yl, hexyn-1-yl, hexyn-2-yl, and hexyn-3-yl, 3,3-dimethylbutyn-1-yl radicals.
[0022] The term “alkylamino” or “arylamino” refers to an amino group that has one or two alkyl or aryl substituents, respectively.
[0023] The term “protected” as used herein and unless otherwise defined refers to a group that is added to an oxygen, sulfur, nitrogen, or phosphorus atom to prevent its further reaction or for other purposes. A wide variety of oxygen and nitrogen protecting groups are known to those skilled in the art of organic synthesis, and are described, for example, in Greene et al., Protective Groups in Organic Synthesis, supra.
[0024] The term “aryl”, alone or in combination, means a carbocyclic aromatic system containing one, two or three rings wherein such rings can be attached together in a pendent manner or can be fused. Non-limiting examples of aryl include phenyl, biphenyl, or naphthyl, or other aromatic groups that remain after the removal of a hydrogen from an aromatic ring. The term aryl includes both substituted and unsubstituted moieties. The aryl group can be optionally substituted with any moiety that does not adversely affect the process described herein for preparing the compounds, including but not limited to but not limited to those described above for alkyl moieties. Non-limiting examples of substituted aryl include heteroarylamino, N-aryl-N-alkylamino, N-heteroarylamino-N-alkylamino, heteroaralkoxy, arylamino, aralkylamino, arylthio, monoarylamidosulfonyl, arylsulfonamido, diarylamidosulfonyl, monoaryl amidosulfonyl, arylsulfinyl, arylsulfonyl, heteroarylthio, heteroarylsulfinyl, heteroarylsulfonyl, aroyl, heteroaroyl, aralkanoyl, heteroaralkanoyl, hydroxyaralkyl, hydoxyheteroaralkyl, haloalkoxyalkyl, aryl, aralkyl, aryloxy, aralkoxy, aryloxyalkyl, saturated heterocyclyl, partially saturated heterocyclyl, heteroaryl, heteroaryloxy, heteroaryloxyalkyl, arylalkyl, heteroarylalkyl, arylalkenyl, and heteroarylalkenyl, carboaralkoxy.
[0025] The terms “alkaryl” or “alkylaryl” refer to an alkyl group with an aryl substituent. The terms “aralkyl” or “arylalkyl” refer to an aryl group with an alkyl substituent.
[0026] The term “halo,” as used herein, includes chloro, bromo, iodo and fluoro.
[0027] The term “acyl” refers to a carboxylic acid ester in which the non-carbonyl moiety of the ester group is selected from straight, branched, or cyclic alkyl or lower alkyl, alkoxyalkyl including but not limited to methoxymethyl, aralkyl including but not limited to benzyl, aryloxyalkyl such as phenoxymethyl, aryl including but not limited to phenyl optionally substituted with halogen (F, Cl, Br, I), alkyl (including but not limited to C 1 , C 2 , C 3 , and C 4 ) or alkoxy (including but not limited to C 1 , C 2 , C 3 , and C 4 ), sulfonate esters such as alkyl or aralkyl sulphonyl including but not limited to methanesulfonyl, the mono, di or triphosphate ester, trityl or monomethoxytrityl, substituted benzyl, trialkylsilyl (e.g., dimethyl-t-butylsilyl) or diphenylmethylsilyl. Aryl groups in the esters optimally comprise a phenyl group. The term “lower acyl” refers to an acyl group in which the non-carbonyl moiety is lower alkyl.
[0028] The terms “alkoxy” and “alkoxyalkyl” embrace linear or branched oxy-containing radicals having alkyl moieties, such as methoxy radical. The term “alkoxyalkyl” also embraces alkyl radicals having one or more alkoxy radicals attached to the alkyl radical, that is, to form monoalkoxyalkyl and dialkoxyalkyl radicals. The “alkoxy” radicals can be further substituted with one or more halo atoms, such as fluoro, chloro or bromo, to provide “haloalkoxy” radicals. Examples of such radicals include fluoromethoxy, chloromethoxy, trifluoromethoxy, difluoromethoxy, trifluoroethoxy, fluoroethoxy, tetrafluoroethoxy, pentafluoroethoxy, and fluoropropoxy.
[0029] The term “alkylamino” denotes “monoalkylamino” and “dialkylamino” containing one or two alkyl radicals, respectively, attached to an amino radical. The terms arylamino denotes “monoarylamino” and “diarylamino” containing one or two aryl radicals, respectively, attached to an amino radical. The term “aralkylamino”, embraces aralkyl radicals attached to an amino radical. The term aralkylamino denotes “monoaralkylamino” and “diaralkylamino” containing one or two aralkyl radicals, respectively, attached to an amino radical. The term aralkylamino further denotes “monoaralkyl monoalkylamino” containing one aralkyl radical and one alkyl radical attached to an amino radical.
[0030] The term “heteroatom,” as used herein, refers to oxygen, sulfur, nitrogen and phosphorus.
[0031] The terms “heteroaryl” or “heteroaromatic,” as used herein, refer to an aromatic that includes at least one sulfur, oxygen, nitrogen or phosphorus in the aromatic ring or a combination of two or more heteroatoms (O, S, N, P) in an aromatic system. Both five membered and six membered ring heteroaryls are contemplated herein, as are five and six membered ring heteroaryls linked to a benzene ring, such as benzofuran, benzthiophene, benzopyrrole, and the like.
[0032] The term “heterocyclic,” “heterocyclyl,” and cycloheteroalkyl refer to a nonaromatic cyclic group wherein there is at least one heteroatom, such as oxygen, sulfur, nitrogen, or phosphorus in the ring.
[0033] Nonlimiting examples of heteroaryl and heterocyclic groups include furyl, furanyl, pyridyl, pyrimidyl, thienyl, isothiazolyl, imidazolyl, tetrazolyl, pyrazinyl, benzofuranyl, benzothiophenyl, quinolyl, isoquinolyl, benzothienyl, isobenzofuryl, pyrazolyl, indolyl, isoindolyl, benzimidazolyl, purinyl, carbazolyl, oxazolyl, thiazolyl, isothiazolyl, 1,2,4-thiadiazolyl, isooxazolyl, pyrrolyl, quinazolinyl, cinnolinyl, phthalazinyl, xanthinyl, hypoxanthinyl, thiophene, furan, pyrrole, isopyrrole, pyrazole, imidazole, 1,2,3-triazole, 1,2,4-triazole, oxazole, isoxazole, thiazole, isothiazole, pyrimidine or pyridazine, and pteridinyl, aziridines, thiazole, isothiazole, 1,2,3-oxadiazole, thiazine, pyridine, pyrazine, piperazine, pyrrolidine, oxaziranes, phenazine, phenothiazine, morpholinyl, pyrazolyl, pyridazinyl, pyrazinyl, quinoxalinyl, xanthinyl, hypoxanthinyl, pteridinyl, 5-azacytidinyl, 5-azauracilyl, triazolopyridinyl, imidazolopyridinyl, pyrrolopyrimidinyl, pyrazolopyrimidinyl, adenine, N 6 -alkylpurines, N 6 -benzylpurine, N 6 -halopurine, N 6 -vinypurine, N 6 -acetylenic purine, N 6 -acyl purine, N 6 -hydroxyalkyl purine, N 6 -thioalkyl purine, thymine, cytosine, 6-azapyrimidine, 2-mercaptopyrmidine, uracil, N 5 -alkylpyrimidines, N 5 -benzylpyrimidines, N 5 -halopyrimidines, N 5 -vinylpyrimidine, N 5 -acetylenic pyrimidine, N 5 -acyl pyrimidine, N 5 -hydroxyalkyl purine, and N 6 -thioalkyl purine, and isoxazolyl. The heteroaromatic group can be optionally substituted as described above for aryl. The heterocyclic or heteroaromatic group can be optionally substituted with one or more substituent selected from halogen, haloalkyl, alkyl, alkoxy, hydroxy, carboxyl derivatives, amido, amino, alkylamino, dialkylamino. The heteroaromatic can be partially or totally hydrogenated as desired. As a nonlimiting example, dihydropyridine can be used in place of pyridine. Functional oxygen and nitrogen groups on the heterocyclic or heteroaryl group can be protected as necessary or desired. Suitable protecting groups are well known to those skilled in the art, and include trimethylsilyl, dimethylhexylsilyl, t-butyldimethylsilyl, and t-butyldiphenylsilyl, trityl or substituted trityl, alkyl groups, acyl groups such as acetyl and propionyl, methanesulfonyl, and p-toluenelsulfonyl. The heterocyclic or heteroaromatic group can be substituted with any moiety that does not adversely affect the reaction, including but not limited to but not limited to those described above for aryl.
[0034] The term “host,” as used herein, refers to a unicellular or multicellular organism in which the virus can replicate, including but not limited to cell lines and animals, and, preferably, humans. Alternatively, the host can be carrying a part of the viral genome, whose replication or function can be altered by the compounds of the present invention. The term host specifically refers to infected cells, cells transfected with all or part of the viral genome and animals, in particular, primates (including but not limited to chimpanzees) and humans. In most animal applications of the present invention, the host is a human patient. Veterinary applications, in certain indications, however, are clearly contemplated by the present invention (such as for use in treating chimpanzees).
[0035] The term “peptide” refers to various natural or synthetic compounds containing two to one hundred amino acids linked by the carboxyl group of one amino acid to the amino group of another.
[0036] The term “pharmaceutically acceptable salt or prodrug” is used throughout the specification to describe any pharmaceutically acceptable form of a compound that upon administration to a patient, provides the parent compound. Pharmaceutically acceptable salts include those derived from pharmaceutically acceptable inorganic or organic bases and acids. Suitable salts include those derived from alkali metals such as potassium and sodium, alkaline earth metals such as calcium and magnesium, among numerous other acids well known in the pharmaceutical art. Pharmaceutically acceptable prodrugs refer to a compound that is metabolized, for example hydrolyzed or oxidized, in the host to form the compound of the present invention. Typical examples of prodrugs include compounds that have biologically labile protecting groups on functional moieties of the active compound. Prodrugs include compounds that can be oxidized, reduced, aminated, deaminated, hydroxylated, dehydroxylated, hydrolyzed, dehydrolyzed, alkylated, dealkylated, acylated, deacylated, phosphorylated, or dephosphorylated to produce the active compound. The prodrug forms of the compounds of this invention can possess antiviral activity, can be metabolized to form a compound that exhibits such activity, or both.
II. Active Compound
[0037] The compounds described herein have the following general formula:
[0000]
[0000] or a pharmaceutically acceptable salt or prodrug thereof, wherein
[0038] J and J 1 can be present or absent, and when present, are independently selected from lower alkyl (C 1 -C 6 ), aryl, arylalkyl, alkoxy, aryloxy, heterocyclyl, heterocyclyloxy, keto, hydroxy, amino, arylamino, carboxyalkyl, carboxamidoalkyl, halo, cyano, formyl, sulfonyl, or sulfonamido; and
[0039] R is C 1 -C 10 alkyl, C 3-8 cycloalkyl, aryl, heteroaryl, or heterocyclyl.
III. Stereoisomerism and Polymorphism
[0040] The compounds described herein may have asymmetric centers and occur as racemates, racemic mixtures, individual diastereomers or enantiomers, with all isomeric forms being included in the present invention. Compounds of the present invention having a chiral center can exist in and be isolated in optically active and racemic forms. Some compounds can exhibit polymorphism. The present invention encompasses racemic, optically active, polymorphic, or stereoisomeric forms, or mixtures thereof, of a compound of the invention, which possess the useful properties described herein. The optically active forms can be prepared by, for example, resolution of the racemic form by recrystallization techniques, by synthesis from optically active starting materials, by chiral synthesis, or by chromatographic separation using a chiral stationary phase or by enzymatic resolution.
[0041] Optically active forms of the compounds can be prepared using any method known in the art, including but not limited to by resolution of the racemic form by recrystallization techniques, by synthesis from optically-active starting materials, by chiral synthesis, or by chromatographic separation using a chiral stationary phase.
[0042] Examples of methods to obtain optically active materials include at least the following.
i) physical separation of crystals: a technique whereby macroscopic crystals of the individual enantiomers are manually separated. This technique can be used if crystals of the separate enantiomers exist, i.e., the material is a conglomerate, and the crystals are visually distinct; ii) simultaneous crystallization: a technique whereby the individual enantiomers are separately crystallized from a solution of the racemate, possible only if the latter is a conglomerate in the solid state; iii) enzymatic resolutions: a technique whereby partial or complete separation of a racemate by virtue of differing rates of reaction for the enantiomers with an enzyme; iv) enzymatic asymmetric synthesis: a synthetic technique whereby at least one step of the synthesis uses an enzymatic reaction to obtain an enantiomerically pure or enriched synthetic precursor of the desired enantiomer; v) chemical asymmetric synthesis: a synthetic technique whereby the desired enantiomer is synthesized from an achiral precursor under conditions that produce asymmetry (i.e., chirality) in the product, which can be achieved using chiral catalysts or chiral auxiliaries; vi) diastereomer separations: a technique whereby a racemic compound is reacted with an enantiomerically pure reagent (the chiral auxiliary) that converts the individual enantiomers to diastereomers. The resulting diastereomers are then separated by chromatography or crystallization by virtue of their now more distinct structural differences and the chiral auxiliary later removed to obtain the desired enantiomer; vii) first- and second-order asymmetric transformations: a technique whereby diastereomers from the racemate equilibrate to yield a preponderance in solution of the diastereomer from the desired enantiomer or where preferential crystallization of the diastereomer from the desired enantiomer perturbs the equilibrium such that eventually in principle all the material is converted to the crystalline diastereomer from the desired enantiomer. The desired enantiomer is then released from the diastereomer; viii) kinetic resolutions: this technique refers to the achievement of partial or complete resolution of a racemate (or of a further resolution of a partially resolved compound) by virtue of unequal reaction rates of the enantiomers with a chiral, non-racemic reagent or catalyst under kinetic conditions; ix) enantiospecific synthesis from non-racemic precursors: a synthetic technique whereby the desired enantiomer is obtained from non-chiral starting materials and where the stereochemical integrity is not or is only minimally compromised over the course of the synthesis; x) chiral liquid chromatography: a technique whereby the enantiomers of a racemate are separated in a liquid mobile phase by virtue of their differing interactions with a stationary phase (including but not limited to via chiral HPLC). The stationary phase can be made of chiral material or the mobile phase can contain an additional chiral material to provoke the differing interactions; xi) chiral gas chromatography: a technique whereby the racemate is volatilized and enantiomers are separated by virtue of their differing interactions in the gaseous mobile phase with a column containing a fixed non-racemic chiral adsorbent phase; xii) extraction with chiral solvents: a technique whereby the enantiomers are separated by virtue of preferential dissolution of one enantiomer into a particular chiral solvent; xiii) transport across chiral membranes: a technique whereby a racemate is placed in contact with a thin membrane barrier. The barrier typically separates two miscible fluids, one containing the racemate, and a driving force such as concentration or pressure differential causes preferential transport across the membrane barrier. Separation occurs as a result of the non-racemic chiral nature of the membrane that allows only one enantiomer of the racemate to pass through.
[0056] Chiral chromatography, including but not limited to simulated moving bed chromatography, is used in one embodiment. A wide variety of chiral stationary phases are commercially available.
IV. Compound Salt or Prodrug Formulations
[0057] In cases where compounds are sufficiently basic or acidic to form stable nontoxic acid or base salts, administration of the compound as a pharmaceutically acceptable salt may be appropriate. Examples of pharmaceutically acceptable salts are organic acid addition salts formed with acids, which form a physiological acceptable anion, for example, tosylate, methanesulfonate, acetate, citrate, malonate, tartarate, succinate, benzoate, ascorbate, α-ketoglutarate and α-glycerophosphate. Suitable inorganic salts can also be formed, including but not limited to, sulfate, nitrate, bicarbonate and carbonate salts.
[0058] Pharmaceutically acceptable salts can be obtained using standard procedures well known in the art, for example by reacting a sufficiently basic compound such as an amine with a suitable acid, affording a physiologically acceptable anion. Alkali metal (e.g., sodium, potassium or lithium) or alkaline earth metal (e.g., calcium, magnesium) salts of carboxylic acids can also be made.
V. Methods of Treatment
[0059] Hosts, including but not limited to humans, infected with HCV or a gene fragment thereof, can be treated by administering to the patient an effective amount of the active compound or a pharmaceutically acceptable prodrug or salt thereof in the presence of a pharmaceutically acceptable carrier or diluent. The active materials can be administered by any appropriate route, for example, orally, parenterally, intravenously, intradermally, subcutaneously, or topically, in liquid or solid form.
VI. Combination or Alternation Therapy
[0060] In one embodiment, the compounds of the invention can be employed together with at least one other antiviral agent.
[0000]
Table of anti-HCV Compounds Approved or
in Preclinical and Clinical Development
Pharmaceutical
Drug Name
Drug Category
Company
PEGASYS
Long acting interferon
Roche
pegylated interferon
alfa-2a
INFERGEN
Interferon,
InterMune
interferon alfacon-1
Long acting interferon
OMNIFERON
Interferon,
Viragen
natural interferon
Long acting interferon
ALBUFERON
Longer acting
Human Genome
interferon
Sciences
REBIF
Interferon
Ares-Serono
interferon
beta-1a
Omega Interferon
Interferon
BioMedicine
Oral Interferon
Oral Interferon
Amarillo Biosciences
alpha
Interferon
Anti-fibrotic
InterMune
gamma-1b
IP-501
Anti-fibrotic
Interneuron
Merimebodib
IMPDH inhibitor
Vertex
VX-497
(inosine monophosphate
dehydrogenase)
AMANTADINE
Broad Antiviral Agent
Endo Labs
(Symmetrel)
Solvay
IDN-6556
Apotosis regulation
Idun Pharma.
XTL-002
Monclonal Antibody
XTL
HCV/MF59
Vaccine
Chiron
CIVACIR
Polyclonal Antibody
NABI
Therapeutic vaccine
Innogenetics
VIRAMIDINE
Nucleoside Analogue
ICN
ZADAXIN
Immunomodulator
Sci Clone
(thymosin alfa-1)
CEPLENE
Immunomodulator
Maxim
histamine
dihydrochloride
VX 950/
Protease Inhibitor
Vertex/Eli Lilly
LY 570310
ISIS 14803
Antisense
Isis Pharmaceutical/
Elan
IDN-6556
Caspase inhibitor
Idun Pharmaceuticals,
Inc.
http://www.idun.com
JTK 003
Polymerase Inhibitor
AKROS Pharma
Tarvacin
Anti-Phospholipid
Peregrine
Therapy
HCV-796
Polymerase Inhibitor
ViroPharma/Wye
CH-6
Serine Protease
Schering
ANA971
Isatoribine
ANADYS
ANA245
Isatoribine
ANADYS
CPG 10101
Immunomodulator
Coley
(Actilon)
Rituximab
Anti-CD20 Monoclonal
Genetech/IDEC
(Rituxam)
Antibody
NM283
Polymerase Inhibitor
Idenix
(Valopicitabine)
Pharmaceuticals
HepX ™-C
Monclonal Antibody
XTL
IC41
Therapeutic Vaccine
Intercell
Medusa Interferon
Longer acting interferon
Flamel Technologies
E-1
Therapeutic Vaccine
Innogenetics
Multiferon
Long Acting Interferon
Viragen
BILN 2061
Serine Protease
Boehringer - Ingelheim
Interferon beta-1a
Interferon
Ares-Serono
(REBIF)
VII. Pharmaceutical Compositions
[0061] Hosts, including but not limited to humans, infected with hepatitis C virus (“HCV”), or a gene fragment thereof, can be treated by administering to the patient an effective amount of the active compound or a pharmaceutically acceptable prodrug or salt thereof in the presence of a pharmaceutically acceptable carrier or diluent. The active materials can be administered by any appropriate route, for example, orally, parenterally, intravenously, intradermally, subcutaneously, or topically, in liquid or solid form.
[0062] A preferred dose of the compound will be in the range of between about 0.1 and about 100 mg/kg, more generally, between about 1 and 50 mg/kg, and, preferably, between about 1 and about 20 mg/kg, of body weight of the recipient per day. The effective dosage range of the pharmaceutically acceptable salts and prodrugs can be calculated based on the weight of the parent compound to be delivered. If the salt or prodrug exhibits activity in itself, the effective dosage can be estimated as above using the weight of the salt or prodrug, or by other means known to those skilled in the art.
[0063] The compound is conveniently administered in unit any suitable dosage form, including but not limited to one containing 7 to 3,000 mg, preferably 70 to 1400 mg of active ingredient per unit dosage form. An oral dosage of 50-1,000 mg is usually convenient.
[0064] Ideally the active ingredient should be administered to achieve peak plasma concentrations of the active compound from about 0.2 to 70 μM, preferably about 1.0 to 15 μM. This can be achieved, for example, by the intravenous injection of a 0.1 to 5% solution of the active ingredient, optionally in saline, or administered as a bolus of the active ingredient.
[0065] The concentration of active compound in the drug composition will depend on absorption, inactivation and excretion rates of the drug as well as other factors known to those of skill in the art. It is to be noted that dosage values will also vary with the severity of the condition to be alleviated. It is to be further understood that for any particular subject, specific dosage regimens should be adjusted over time according to the individual need and the professional judgment of the person administering or supervising the administration of the compositions, and that the concentration ranges set forth herein are exemplary only and are not intended to limit the scope or practice of the claimed composition. The active ingredient can be administered at once, or can be divided into a number of smaller doses to be administered at varying intervals of time.
[0066] A preferred mode of administration of the active compound is oral. Oral compositions will generally include an inert diluent or an edible carrier. They can be enclosed in gelatin capsules or compressed into tablets. For the purpose of oral therapeutic administration, the active compound can be incorporated with excipients and used in the form of tablets, troches or capsules. Pharmaceutically compatible binding agents, and/or adjuvant materials can be included as part of the composition.
[0067] The tablets, pills, capsules, troches and the like can contain any of the following ingredients, or compounds of a similar nature: a binder such as microcrystalline cellulose, gum tragacanth or gelatin; an excipient such as starch or lactose, a disintegrating agent such as alginic acid, Primogel or corn starch; a lubricant such as magnesium stearate or Sterotes; a glidant such as colloidal silicon dioxide; a sweetening agent such as sucrose or saccharin; or a flavoring agent such as peppermint, methyl salicylate, or orange flavoring. When the dosage unit form is a capsule, it can contain, in addition to material of the above type, a liquid carrier such as a fatty oil. In addition, unit dosage forms can contain various other materials that modify the physical form of the dosage unit, for example, coatings of sugar, shellac, or other enteric agents.
[0068] The compound can be administered as a component of an elixir, suspension, syrup, wafer, chewing gum or the like. A syrup can contain, in addition to the active compound(s), sucrose or sweetener as a sweetening agent and certain preservatives, dyes and colorings and flavors.
[0069] The compound or a pharmaceutically acceptable prodrug or salts thereof can also be mixed with other active materials that do not impair the desired action, or with materials that supplement the desired action, such as antibiotics, antifungals, anti-inflammatories or other antivirals, including but not limited to nucleoside compounds. Solutions or suspensions used for parenteral, intradermal, subcutaneous, or topical application can include the following components: a sterile diluent such as water for injection, saline solution, fixed oils, polyethylene glycols, glycerine, propylene glycol or other synthetic solvents; antibacterial agents such as benzyl alcohol or methyl parabens; antioxidants such as ascorbic acid or sodium bisulfite; chelating agents, such as ethylenediaminetetraacetic acid; buffers, such as acetates, citrates or phosphates, and agents for the adjustment of tonicity, such as sodium chloride or dextrose. The parental preparation can be enclosed in ampoules, disposable syringes or multiple dose vials made of glass or plastic.
[0070] If administered intravenously, preferred carriers are physiological saline or phosphate buffered saline (PBS).
[0071] In a preferred embodiment, the active compounds are prepared with carriers that will protect the compound against rapid elimination from the body, such as a controlled release formulation, including but not limited to implants and microencapsulated delivery systems. Biodegradable, biocompatible polymers can be used, such as ethylene vinyl acetate, polyanhydrides, polyglycolic acid, collagen, polyorthoesters and polylactic acid. For example, enterically coated compounds can be used to protect cleavage by stomach acid. Methods for preparation of such formulations will be apparent to those skilled in the art. Suitable materials can also be obtained commercially.
[0072] Liposomal suspensions (including but not limited to liposomes targeted to infected cells with monoclonal antibodies to viral antigens) are also preferred as pharmaceutically acceptable carriers. These can be prepared according to methods known to those skilled in the art, for example, as described in U.S. Pat. No. 4,522,811 (incorporated by reference). For example, liposome formulations can be prepared by dissolving appropriate lipid(s) (such as stearoyl phosphatidyl ethanolamine, stearoyl phosphatidyl choline, arachadoyl phosphatidyl choline, and cholesterol) in an inorganic solvent that is then evaporated, leaving behind a thin film of dried lipid on the surface of the container. An aqueous solution of the active compound is then introduced into the container. The container is then swirled by hand to free lipid material from the sides of the container and to disperse lipid aggregates, thereby forming the liposomal suspension.
[0073] The terms used in describing the invention are commonly used and known to those skilled in the art. As used herein, the following abbreviations have the indicated meanings:
aq aqueous CDI carbonyldiimidazole DMF N,N-dimethylformamide DMSO dimethylsulfoxide EDC 1-ethyl-3-(3-dimethyllaminopropyl)carbodiimide hydrochloride EtOAc ethyl acetate h hour/hours HOBt N-hydroxybenzotriazole M molar min minute rt or RT room temperature TBAT tetrabutylammonium triphenyldifluorosilicate TBTU O-(Benzotriazol-1-yl)-N,N,N′,N′-tetramethyluronium tetrafluoroborate THF tetrahydrofuran
IX. General Procedures for Preparing Active Compounds
[0088] Methods for the preparation of the compounds of this invention can be prepared as described in detail below in the “Specific Example” section, or by other methods known to those skilled in the art. It will be understood by one of ordinary skill in the art that these schemes are in no way limiting and that variations of detail can be made without departing from the spirit and scope of the present invention.
SPECIFIC EXAMPLES
[0089] Specific compounds which are representative of this invention were prepared as per the following examples and reaction sequences; the examples and the diagrams depicting the reaction sequences are offered by way of illustration, to aid in the understanding of the invention and should not be construed to limit in any way the invention set forth in the claims which follow thereafter. The present compounds can also be used as intermediates in subsequent examples to produce additional compounds of the present invention. No attempt has necessarily been made to optimize the yields obtained in any of the reactions. One skilled in the art would know how to increase such yields through routine variations in reaction times, temperatures, solvents and/or reagents.
[0090] Reagents and solvents were obtained from commercial suppliers and were used without further purification. Methylene chloride was dried and distilled over CaCl 2 and stored over molecular sieves 4 Å under argon. Tetrahydrofuran was dried over sodium/benzophenone ketyl under argon and distilled prior to use. Flash chromatography purifications were performed on Macherey Nalgel silica gel (40-63 μM) as the stationary phase or were conducted using packed RediSep® columns on a Teledyne Isco Combiflash® Companion® apparatus. Analytical High Performance Liquid Chromatography-mass analysis (HPLC-MS):
[0091] HPLC-MS conditions A1: HPLS-MS were performed on a Waters Alliance 2790 apparatus equipped with Photodiode Array Detector Waters 996 and a Waters Micromass Q-Tof using a BDS Hypersil 50×2.1, 3 μm. Eluting conditions comprised a linear gradient: 0% to 80% of MeCN/H 2 O in 20 minutes (containing 0.1% TFA in positive mode and without TFA in negative mode), flow rate 0.2 mL/min.
[0092] HPLC-MS conditions A2: HPLS-MS were performed on a Waters Alliance 2790 apparatus equipped with Photodiode Array Detector Waters 996 and a Waters Micromass Q-Tof using a Nucleodur C18 Pyramid 50×2.1, 3 μm. Eluting conditions comprised a linear gradient: 0% to 80% of MeCN/H 2 O in 20 minutes (containing 0.1% TFA in positive mode and without TFA in negative mode), flow rate 0.3 mL/min.
[0093] HPLC-MS conditions B: HPLS-MS were performed on a Agilent HP-1100 apparatus equipped with Photodiode Array Detector Agilent G1315A, a polymerlabs ELS2100 (DEDL) detector and a Agilent Simple Quad ESI for mass analysis using a Agilent Zorbax XDB-C18 RP C18 45×4.6, 3.5 μm. Eluting conditions comprised a linear gradient: 10% to 100% in 4.5 minutes of MeCN/H 2 O (containing 0.05% TFA), flow rate 1.5 mL/min.
[0094] Low resolution mass spectra (MS) were obtained from an Applied Biosystems SCIEX 3200 QTRAP in Atmospheric Pressure Ionization condition (API) in positive (ES+) or negative (ES−) mode.
[0095] High Resolution Mass Spectroscopy (HRMS) was obtained from a Perkin Elmer apparatus.
[0096] NMR spectra were recorded on Bruker Avance 250 at 250 MHz for 1 H and 63 MHz for 13 C NMR in deuterared solvents and are referenced in ppm relative to the solvent residual peak (see reference Gottlieb H. E. et al. J. Org Chem 1997 (2) 7512-7515).
Example 1
Synthesis of P2 Hydroxyproline Derivative
[0097]
Example 2
Synthesis of 10
[0098]
[0099] Analogs of Compound 10, in which J and J 1 are present, can be prepared, for example, by using a substituted form of the starting material:
[0000]
[0000] where J and J 1 are as defined herein, or, where these moieties would interfere with the coupling chemistry described in Scheme I, are protected groups that can be converted to the desired J and J 1 moieties after the coupling chemistry is completed, or at a later step in the overall synthesis.
[0100] Compounds of this formula are known, and can be prepared using no more than routine experimentation. Those skilled in the art will readily understand that incorporation of substituents onto the aryl ring can be readily realized, either before the core structures are prepared, or afterward (i.e., the substituents can be present during key coupling steps, or can be added after the unsubstituted compound (i.e., without the J and/or J 1 moieties) has been prepared. Such substituents can provide useful properties in and of themselves, or serve as a handle for further synthetic elaboration. One proviso is that such substitution should either survive the synthesis conditions, or should be added after the synthesis is otherwise complete.
[0101] For example, the aryl ring can be halogenated using various known procedures, which vary depending on the particular halogen. Examples of suitable reagents include bromine/water in concentrated HBr, thionyl chloride, pyr-ICl, fluorine and Amberlyst-A. A number of other analogs, bearing substituents in a diazotized position of an aryl ring, can be synthesized from the corresponding aniline compounds, via the diazonium salt intermediate. The diazonium salt intermediates can be prepared using known chemistry, for example, treatment of aromatic amines such as aniline with sodium nitrite in the presence of a mineral acid.
[0102] Diazonium salts can be formed from anilines, which in turn can be prepared from nitrobenzenes (and analogous amine-substituted heteroaryl rings can be prepared from nitro-substituted heteroaryl rings). The nitro derivatives can be reduced to the amine compound by reaction with a nitrite salt, typically in the presence of an acid. Other substituted analogs can be produced from diazonium salt intermediates, including, but are not limited to, hydroxy, alkoxy, fluoro, chloro, iodo, cyano, and mercapto, using general techniques known to those of skill in the art. Likewise, alkoxy analogues can be made by reacting the diazonium salt with alcohols. The diazonium salt can also be used to synthesize cyano or halo compounds, as will be known to those skilled in the art. Mercapto substitutions can be obtained using techniques described in Hoffman et al., J. Med. Chem. 36: 953 (1993). The mercaptan so generated can, in turn, be converted to an alkylthio substitutuent by reaction with sodium hydride and an appropriate alkyl bromide. Subsequent oxidation would then provide a sulfone. Acylamido analogs of the aforementioned compounds can be prepared by reacting the corresponding amino compounds with an appropriate acid anhydride or acid chloride using techniques known to those skilled in the art of organic synthesis.
[0103] Hydroxy-substituted analogs can be used to prepare corresponding alkanoyloxy-substituted compounds by reaction with the appropriate acid, acid chloride, or acid anhydride. Likewise, the hydroxy compounds are precursors of both the aryloxy and heteroaryloxy via nucleophilic aromatic substitution at electron deficient aromatic rings. Such chemistry is well known to those skilled in the art of organic synthesis. Ether derivatives can also be prepared from the hydroxy compounds by alkylation with alkyl halides and a suitable base or via Mitsunobu chemistry, in which a trialkyl- or triarylphosphine and diethyl azodicarboxylate are typically used. See Hughes, Org. React . ( N.Y .) 42: 335 (1992) and Hughes, Org. Prep. Proced. Int. 28: 127 (1996) for typical Mitsunobu conditions.
[0104] Cyano-substituted analogs can be hydrolyzed to afford the corresponding carboxamido-substituted compounds. Further hydrolysis results in formation of the corresponding carboxylic acid-substituted analogs. Reduction of the cyano-substituted analogs with lithium aluminum hydride yields the corresponding aminomethyl analogs. Acyl-substituted analogs can be prepared from corresponding carboxylic acid-substituted analogs by reaction with an appropriate alkyllithium using techniques known to those skilled in the art of organic synthesis.
[0105] Carboxylic acid-substituted analogs can be converted to the corresponding esters by reaction with an appropriate alcohol and acid catalyst. Compounds with an ester group can be reduced with sodium borohydride or lithium aluminum hydride to produce the corresponding hydroxymethyl-substituted analogs. These analogs in turn can be converted to compounds bearing an ether moiety by reaction with sodium hydride and an appropriate alkyl halide, using conventional techniques. Alternatively, the hydroxymethyl-substituted analogs can be reacted with tosyl chloride to provide the corresponding tosyloxymethyl analogs, which can be converted to the corresponding alkylaminoacyl analogs by sequential treatment with thionyl chloride and an appropriate alkylamine. Certain of these amides are known to readily undergo nucleophilic acyl substitution to produce ketones.
[0106] Hydroxy-substituted analogs can be used to prepare N-alkyl- or N-arylcarbamoyloxy-substituted compounds by reaction with N-alkyl- or N-arylisocyanates. Amino-substituted analogs can be used to prepare alkoxycarboxamido-substituted compounds and urea derivatives by reaction with alkyl chloroformate esters and N-alkyl- or N-arylisocyanates, respectively, using techniques known to those skilled in the art of organic synthesis.
[0107] Similarly, benzene rings can be substituted using known chemistry, including the reactions discussed above. For example, the nitro group on nitrobenzene can be reacted with sodium nitrite to form the diazonium salt, and the diazonium salt manipulated as discussed above to form the various substituents on a benzene ring.
[0108] The substituents described above can therefore be added to the starting benzene ring, and incorporated into the final compounds described herein.
Example 3
[0109] Mitochondrial Toxicity Assays in HepG2 Cells:
[0110] i) Effect of compounds on Cell Growth and Lactic Acid Production: The effect on the growth of HepG2 cells was determined by incubating cells in the presence of 0 μM, 0.1 μM, 1 μM, 10 μM and 100 μM drug. Cells (5×10 4 per well) were plated into 12-well cell culture clusters in minimum essential medium with nonessential amino acids supplemented with 10% fetal bovine serum, 1% sodium pyruvate, and 1% penicillin/streptomycin and incubated for 4 days at 37° C. At the end of the incubation period the cell number was determined using a hemocytometer. Also taught by Pan-Zhou X-R, Cui L, Zhou X-J, Sommadossi J-P, Darley-Usmer V M. “Differential effects of antiretroviral nucleoside analogs on mitochondrial function in HepG2 cells”Antimicrob. Agents Chemother. 2000; 44: 496-503. To measure the effects of compounds on lactic acid production, HepG2 cells from a stock culture were diluted and plated in 12-well culture plates at 2.5×10 4 cells per well. Various concentrations (0 μM, 0.1 μM, 1 μM, 10 μM and 100 μM) of test compound were added, and the cultures were incubated at 37° C. in a humidified 5% CO 2 atmosphere for 4 days. At day 4 the number of cells in each well was determined and the culture medium collected. The culture medium was filtered, and the lactic acid content in the medium determined using a colorimetric lactic acid assay (Sigma-Aldrich). Since lactic acid product can be considered a marker for impaired mitochondrial function, elevated levels of lactic acid production detected in cells grown in the presence of test compound would indicate a drug-induced cytotoxic effect.
[0111] ii) Effect on compounds on Mitochondrial DNA Synthesis: a real-time PCR assay to accurately quantify mitochondrial DNA content has been developed (see Stuyver L J, Lostia S, Adams M, Mathew J S, Pai B S, Grier J, Tharnish P M, Choi Y, Chong Y, Choo H, Chu C K, Otto M J, Schinazi R F. Antiviral activities and cellular toxicities of modified 2′,3′-dideoxy-2′,3′-didehydrocytidine analogs. Antimicrob. Agents Chemother. 2002; 46: 3854-60). This assay was used in all studies described in this application that determine the effect of test compound on mitochondrial DNA content. In this assay, low-passage-number HepG2 cells were seeded at 5,000 cells/well in collagen-coated 96-well plates. Compounds were added to the medium to obtain final concentrations of 0 μM, 0.1 μM, 10 μM and 100 μM. On culture day 7, cellular nucleic acids were prepared by using commercially available columns (RNeasy 96 kit; Qiagen). These kits co-purify RNA and DNA, and hence, total nucleic acids were eluted from the columns. The mitochondrial cytochrome c oxidase subunit II (COXII) gene and the β-actin or rRNA gene were amplified from 5 μl of the eluted nucleic acids using a multiplex Q-PCR protocol with suitable primers and probes for both target and reference amplifications. For COXII the following sense, probe and antisense primers are used, respectively: 5′-TGCCCGCCATCATCCTA-3′,5′-tetrachloro-6-carboxyfluorescein-TCCTCATCGCCCTCCCATCCC-TAMRA-3’ and 5′-CGTCTGTTATGTAAAGGATGCGT-3′. For exon 3 of the β-actin gene (GenBank accession number E01094) the sense, probe, and antisense primers are 5′-GCGCGGCTACAGCTTCA-3′,5′-6-FAMCACCACGGCCGAGCGGGATAMRA-3′ and 5′-TCTCCTTAATGTCACGCACGAT-3′, respectively. The primers and probes for the rRNA gene are commercially available from Applied Biosystems. Since equal amplification efficiencies were obtained for all genes, the comparative CT method was used to investigate potential inhibition of mitochondrial DNA synthesis. The comparative CT method uses arithmetic formulas in which the amount of target (COXII gene) is normalized to the amount of an endogenous reference (the β-actin or rRNA gene) and is relative to a calibrator (a control with no drug at day 7). The arithmetic formula for this approach is given by 2-ΔΔCT, where ΔΔCT is (CT for average target test sample—CT for target control)—(CT for average reference test—CT for reference control) (see Johnson M R, K Wang, J B Smith, M J Heslin, R B Diasio. Quantitation of dihydropyrimidine dehydrogenase expression by real-time reverse transcription polymerase chain reaction. Anal. Biochem. 2000; 278:175-184). A decrease in mitochondrial DNA content in cells grown in the presence of drug would indicate mitochondrial toxicity.
[0112] iii) Electron Microscopic Morphologic Evaluation: NRTI induced toxicity has been shown to cause morphological changes in mitochondria (e.g., loss of cristae, matrix dissolution and swelling, and lipid droplet formation) that can be observed with ultrastructural analysis using transmission electron microscopy (see Cui L, Schinazi R F, Gosselin G, Imbach J L. Chu C K, Rando R F, Revankar G R, Sommadossi J P. Effect of enantiomeric and racemic nucleoside analogs on mitochondrial functions in HepG2 cells. Biochem. Pharmacol. 1996, 52, 1577-1584; Lewis W, Levine E S, Griniuviene B, Tankersley K O, Colacino J M, Sommadossi J P, Watanabe K A, Perrino F W. Fialuridine and its metabolites inhibit DNA polymerase gamma at sites of multiple adjacent analog incorporation, decrease mtDNA abundance, and cause mitochondrial structural defects in cultured hepatoblasts. Proc Natl Acad Sci USA. 1996; 93: 3592-7; Pan-Zhou X R, L Cui, X J Zhou, J P Sommadossi, V M Darley-Usmar. Differential effects of antiretroviral nucleoside analogs on mitochondrial function in HepG2 cells. Antimicrob. Agents Chemother. 2000, 44, 496-503). For example, electron micrographs of HepG2 cells incubated with 10 μM fialuridine (FIAU; 1,2′-deoxy-2′-fluoro- 1 -D-arabinofuranosly-5-iodo-uracil) showed the presence of enlarged mitochondria with morphological changes consistent with mitochondrial dysfunction. To determine if compounds promoted morphological changes in mitochondria, HepG2 cells (2.5×10 4 cells/mL) were seeded into tissue cultures dishes (35 by 10 mm) in the presence of 0 ρM, 0.1 ρM, 1 μM, 10 μM and 100 μM test compound. At day 8, the cells were fixed, dehydrated, and embedded in Eponas described previously. Thin sections were prepared, stained with uranyl acetate and lead citrate, and then examined using transmission electron microscopy.
Example 4
[0113] Assay for Bone Marrow Cytotoxicity
[0114] Primary human bone marrow mononuclear cells were obtained commercially from Cambrex Bioscience (Walkersville, Md.). CFU-GM assays were carried out using a bilayer soft agar in the presence of 50 units/mL human recombinant granulocyte/macrophage colony-stimulating factor, while BFU-E assays used a methylcellulose matrix containing 1 unit/mL erythropoietin (see Sommadossi J P, Carlisle R. Toxicity of 3′-azido-3′-deoxythymidine and 9-(1,3-dihydroxy-2-propoxymethyl)guanine for normal human hepatopoietic progenitor cells in vitro. Antimicrob. Agents Chemother. 1987; 31: 452-454; Sommadossi, J P, Schinazi, R F, Chu, C K, and Xie, M Y. Comparison of Cytotoxicity of the (−) and (+) enantiomer of 2′,3′-dideoxy-3′-thiacytidine in normal human bone marrow progenitor cells. Biochem. Pharmacol. 1992; 44:1921-1925). Each experiment was performed in duplicate in cells from three different donors. AZT was used as a positive control. Cells were incubated in the presence of the compound for 14-18 days at 37° C. with 5% CO 2 , and colonies of greater than 50 cells are counted using an inverted microscope to determine IC 50 . The 50% inhibitory concentration (IC 50 ) was obtained by least-squares linear regression analysis of the logarithm of drug concentration versus BFU-E survival fractions. Statistical analysis was performed with Student's t test for independent non-paired samples.
Example 5
[0115] Cytotoxicity Assay
[0116] The toxicity of the compounds was assessed in Vero, human PBM, CEM (human lymphoblastoid), MT-2, and HepG2 cells, as described previously (see Schinazi R. F., Sommadossi J.-P., Saalmann V., Cannon D. L., Xie M.-Y., Hart G. C., Smith G. A. & Hahn E. F. Antimicrob. Agents Chemother. 1990, 34, 1061-67). Cycloheximide was included as positive cytotoxic control, and untreated cells exposed to solvent were included as negative controls. The cytotoxicity IC 50 was obtained from the concentration-response curve using the median effective method described previously (see Chou T.-C. & Talalay P. Adv. Enzyme Regul. 1984, 22, 27-55; Belen'kii M. S. & Schinazi R. F. Antiviral Res. 1994, 25,1-11).
[0000] The data for 10 is
PBM>100 μM (17% inhibition@100 μM) CEM>100 μM (11% inhibition@100 μM) VERO>100 (−0.8% inhibition@100 μM)
Example 6
[0120] HCV Replicon Assay 1
[0121] Huh 7 Clone B cells containing HCV replicon RNA would be seeded in a 96-well plate at 5000 cells/well, and the compounds tested at 10 μM in triplicate immediately after seeding. Following five days incubation (37° C., 5% CO 2 ), total cellular RNA was isolated by using versaGene RNA purification kit from Gentra. Replicon RNA and an internal control (TaqMan rRNA control reagents, Applied Biosystems) were amplified in a single step multiplex Real Time RT-PCR Assay. The antiviral effectiveness of the compounds was calculated by subtracting the threshold RT-PCR cycle of the test compound from the threshold RT-PCR cycle of the no-drug control (ΔCt HCV). A ΔCt of 3.3 equals a 1-log reduction (equal to 90% less starting material) in Replicon RNA levels. The cytotoxicity of the compounds was also calculated by using the ΔCt rRNA values. (2′-Me-C) was used as the control. To determine EC 90 and IC 50 values 2 , ΔCt: values were first converted into fraction of starting material 3 and then were used to calculate the % inhibition.
REFERENCES
[0000]
1. Stuyver L et al., Ribonucleoside analogue that blocks replication or bovine viral diarrhea and hepatitis C viruses in culture. Antimicrob. Agents Chemother. 2003, 47, 244-254.
2. Reed I J & Muench H, A simple method or estimating fifty percent endpoints. Am. J. Hyg. 27: 497, 1938.
3. Applied Biosystems Handbook
[0125] The results are shown in Table 1 below:
[0000]
TABLE 1
Compound
Conc (μM)
DCt HCV
DCt rRNA
HCV
rRNA
EC50
EC90
CC50
10
0.01
1.16
−0.21
54.99
−15.99
0.01
0.03
>0.3
0.03
3.29
−0.49
89.67
−40.10
0.1
6.05
−0.09
98.47
−6.27
0.3
8.72
0.14
99.76
9.35
Example 7
[0126] Bioavailability Assay in Cynomolgus Monkeys
[0127] The following procedure can be used to determine whether the compounds are bioavailable. Within 1 week prior to the study initiation, a cynomolgus monkey can be surgically implanted with a chronic venous catheter and subcutaneous venous access port (VAP) to facilitate blood collection and can undergo a physical examination including hematology and serum chemistry evaluations and the body weight recording. Each monkey (six total) receives compound at a dose level of 2-20 mg/kg, either via an intravenous bolus (3 monkeys, IV), or via oral gavage (3 monkeys, PO). Each dosing syringe is weighed before dosing to gravimetrically determine the quantity of formulation administered. Urine samples are collected via pan catch at the designated intervals (approximately 18-0 hours pre-dose, 0-4, 4-8 and 8-12 hours post-dosage) and processed. Blood samples are collected as well (pre-dose, 0.25, 0.5, 1,2, 3,6, 8, 12 and 24 hours post-dosage) via the chronic venous catheter and VAP or from a peripheral vessel if the chronic venous catheter procedure should not be possible. The blood and urine samples are analyzed for the maximum concentration (Cmax), time when the maximum concentration is achieved (Tmax), area under the curve (AUC), half-life of the dosage concentration (TV,), clearance (CL), steady state volume and distribution (Vss) and bioavailability (F).
Example 8
[0128] Effect of HCV Protease Inhibitors on Selected Human Proteases
[0129] HCV protease inhibitors have demonstrated great antiviral potency in addition to interesting toxicities associated with inhibition of host proteases. In an effort to circumvent similar toxicities, new protease inhibitors were evaluated for inhibition of a panel of important human proteases. The enzymes tested are Elastase (Neutrophil), Plasmin, Thrombin, and Cathepsin S.
[0130] Neutrophil elastase (or leukocyte elastase) also known as ELA2 (elastase 2) is a serine protease in the same family as chymotrypsin and has broad substrate specificity. Secreted by neutrophils during inflammation, one of its primary roles is to destroy bacteria in host tissue. (Belaaouaj et al, Science 289 (5482): 1185-8).
[0131] Plasmin is a serine protease derived from the conversion of plasminogen in blood plasma by plasminogen activators (Collen, D. Circulation, 93, 857 (1996). This enzyme (EC 3.4.21.7) degrades many blood plasma proteins, most notably, fibrin clots. Plasmin is also involved in several pathological and physiological processes such as inflammation, neoplasia, metastasis, wound healing, angiogenesis, embryogenesis and ovulation (Vassalli, J. D. et al, J. Clin. Invest. 88, 1067 (1991).
[0132] Thrombin is a coagulation protein in the blood stream that has many effects in the coagulation cascade, the last enzyme in the clotting cascade. It is a serine protease that converts soluble fibrinogen into insoluble strands of fibrin, as well as catalyzing many other coagulation-related reactions.
[0133] Cathepsin S, a member of the peptidase C1 family, is a lysosomal cysteine protease that may participate in the degradation of antigenic proteins to peptides for presentation on MHC class II molecules, therefore it is key to immune response. The encoded protein can function as an elastase over a broad pH range.
Materials:
[0000]
Victor 3 Plate reader (Perkin Elmer)
Clear 96 well Plates (Phenix Research)
Black 96 well Plates (Perkin Elmer)
RNase and Dnase pure water
Methods:
[0138] Elastase (Human Neutrophil (Cat #16-14-051200 Athens Research and Technology, Athens Ga.)): Reactions were conducted in a sample volume of 100 μL per well in a clear 96 well plate. A 2× assay buffer was made containing 200 mM Tris-HCl (pH 7.5), 150 mM NaCl and 50% glycerol. For each sample 50 μL 2× assay buffer was added to each well. The substrate (MeOSuc-AAPV-pNA, Chromogenic Substrate, Cat #P-213, Enzo Life Sciences, Plymouth Meeting, Pa.; 50 mM stock in DMSO) was added to a final concentration of 1 mM. The drug dilutions were added (25 μL) at 4× concentrations in water. Finally, a mixture was made of 1 μL elastase and 22 μL water for each sample and 23 μL was added to each well. The samples were incubated at room temperature for 30 min. The absorbance at 405 nM was read on the Victor 3 plate reader. All samples were tested in duplicate. Results are shown as blank adjusted (no Elastase) percentages of maximum absorbance, which was given by a no inhibitor control.
[0139] Plasmin and Thrombin(Sensolyte RH110 Plasmin Activity Assay Kit and Sensolyte Thrombin Activity Assay Kit (Anaspec)): Reactions were conducted in a sample volume of 100 μL per well in a black 96 well plate. Protocol A was followed from the kit insert where the 2× assay buffer was diluted 1:1 with deionized water. Included in each assay were a positive control (diluted enzyme and no test compound), inhibitor control (contains diluted enzyme and plasmin inhibitor; component E from the kit or thrombin inhibitor; N-α-NAPAP synthetic inhibitor) and substrate control (assay buffer and substrate). Vehicle and autofluorescence controls were also performed. Drug dilutions were added (10 μL) at 10× concentrations in assay buffer. The enzyme was added at 40 μL/well at a concentration of 0.25 μg/mL (plasmin) and 1 μg/mL (thrombin) to all wells except the substrate control. Finally, 50 μL assay buffer containing substrate was added to each well. The substrate was added to a final concentration of 50 nM (plasmin) or 20 nM (Thrombin). The samples were incubated at room temperature for 30 min. The fluorescence intensity was read on the Victor 3 plate reader at Ex/Em=490 nm/520 nm. All samples were tested in duplicate. Results are shown as substrate control adjusted percentages of maximum absorbance, which was given by the positive control.
[0140] Cathespsin S (Sensolyte Cathepsin S Activity Assay Kit (Anaspec)): Reactions were conducted in a sample volume of 100 μL per well in a black 96 well plate. Protocol A was followed from the kit insert where DTT was added to assay buffer to yield a 5 μM concentration. Included in each assay were a positive control (diluted enzyme and no test compound), inhibitor control (contains diluted enzyme and plasmin inhibitor; component E or thrombin inhibitor; N-a-NAPAP synthetic inhibitor) and substrate control (assay buffer and substrate). Vehicle and autofluorescence controls were also performed. Drug dilutions were added (10 μL) at 10× concentrations in assay buffer. The cathepsin S was added at 40 μL/well at a concentration of 2.5 μg/mL to all wells except the substrate control. Finally, 50 82 L of assay buffer containing substrate was added to each well. The substrate was added to a final concentration of 16 nM. The samples were incubated at room temperature for 30 min. The fluorescence intensity was read on the Victor 3 plate reader at Ex/Em=490 nm/520 nm. All samples were tested in duplicate. Results are shown as substrate control adjusted percentages of maximum absorbance, which was given by the positive control.
[0141] The results are shown in Table 2, below:
[0000]
TABLE 2
Inhibition of Human Proteases (IC 50 , μM)
Drug
Elastase
Cathepsin G
Chymo-trypsin
Kallikrein
Plasmin
Thrombin
Cathepsin S
Chymase
10
>100
>100
>100
47
>100
>100
>100
>100
Example 9
Activity of Compounds Versus Hepatitis C Virus NS3/4A WT and Mutant Protease
[0142] The HCV NS3/4A protease assays were carried out using a SensoLyte® 490 HCV Protease Assay Kit using fluorescence resonance energy transfer (FRET) peptide (AnaSpec).
[0143] The results are shown in Tables 3 and 4 below:
[0000]
TABLE 3
Anti-HCV protease activity
Wild Type
A156T
R155K
D168V
V36M
Code
EC 50 , μM
EC 90 , μM
EC50, μM
EC90, μM
EC50, μM
EC90, μM
EC50, μM
EC90, μM
EC50, μM
EC90, μM
10
0.0049
0.030
0.033
0.130
0.27
2.7
0.040
0.630
0.0034
0.0455
stdev
0.0017
0.029
0.030
NA
0.17
3.0
0.043
NA
0.0037
0.0488
Fold Increase
1.0
1.0
6.7
4.4
55.8
91.4
8.1
21.1
0.7
1.5
[0000]
TABLE 4
Anti-HCV protease activity
A156S
V170A
D168A
T54A
Code
EC50, μM
EC90, μM
EC50, μM
EC90, μM
EC50, μM
EC90, μM
EC50, μM
EC90, μM
10
0.008
0.085
0.0055
0.0095
0.57
8.30
0.07
0.85
stdev
0.000
0.021
0.0007
0.0007
0.01
NA
0.03
NA
Fold Increase
1.6
2.9
1.1
0.3
115.3
278.5
15.0
28.5
[0144] While the foregoing specification teaches the principles of the present invention, with examples provided for the purpose of illustration, it will be understood that the practice of the invention encompasses all of the usual variations, adaptations and/or modifications as come within the scope of the following claims and their equivalents. | The present invention is directed to compounds, compositions and methods for treating or preventing viral infections, in particular, HCV in human patients or other animal hosts. | 2 |
BACKGROUND OF THE INVENTION
Increasing political and environmental pressure is driving the quest for near zero emissive engines and increased efficiency to decrease U.S dependence on foreign oil and reduce greenhouse gas emissions. Fuel cell technology using hydrogen has been widely promoted as an alternative to the fossil fueled internal combustion engine (ICE) due to its perceived superior ability to achieve these goals. Unfortunately, fuel cells have several major hurdles to overcome before widespread use making this possible solution decades away. Meanwhile, the ICE will remain in use until that time.
In the past, the primary advantage of fuel cells over the ICE was potential thermal efficiency. Recent studies by the Department of Energy indicate that the ICE should be capable of producing thermal efficiencies that rival fuel cells. Therefore, a hydrogen fueled ICE promises a much quicker and less expensive option to meet emission and engine efficiency goals.
Using hydrogen as a transportation fuel has several problems. Two important hurdles are the lack of infrastructure to dispense the fuel and storage of hydrogen. Due to the very low density of hydrogen gas, large storage tanks are required to obtain sufficient vehicle range and the storage tanks must withstand relatively high pressures. To avoid these shortcomings, recent work at various research labs has investigated the use of on-board reforming commonly available fuels into higher grade fuels such as syngas and hydrogen. Several test devices have already been successful. While this technology is still being developed, this option appears to be a very promising solution to both the infrastructure and storage problems.
In current Hydrogen engines, backflash, pre-ignition and reduced power are common problems in premixed and port fuel injected engines. One method to minimize or eliminate these shortcomings is to employ direct fuel injection. However, direct injection requires very quick mixing of the hydrogen and air. Often, mixing is incomplete causing misfire, high NO x levels, reduced efficiency, and power loss.
Finally, even with direct injection, pre-ignition remains one of the most difficult challenges to hydrogen use. Compared to gasoline, hydrogen has a much lower ignition energy, wider flammability range and shorter quenching distance making it much more susceptible to engine hot spots and other causes of pre-ignition. New engine architecture is needed not only to address pre-ignition and incomplete mixing, but also other problems associated with conventional hydrogen ICE designs.
SUMMARY OF THE INVENTION
A conventional four stroke poppet valve engine is modified to include a rotary combustion chamber (RCC) and small pre-combustion chamber which sequentially serve all four cylinders of this preferred embodiment engine. More stable hydrogen combustion is possible with this engine as it reduces pre-ignition, misfire, and other combustion problems associated with hydrogen use. Although the RCC shares the benefits of improved hydrogen combustion with indirect injection (IDI) operation, it avoids the thermal efficiency penalty of IDI engines by reducing the operating thermal range of the RCC, increasing the RCC passage opening size, and coating the chamber and passage with ceramics. Preheating of the fuel and air, on-board fuel reforming, multistage and low temperature combustion, charge stratification, jet ignition, and variable compression enabled by a z-crankshaft reduce combustion process and heat transfer losses to further increase engine efficiency.
Other advantages of the present invention will become apparent and obvious from a study of the following description and accompanying drawings which are merely illustrative of such invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front elevation view of the rotary combustion chamber assembly showing the passage from the chamber as well as ring combustion and oil seals.
FIG. 2 is a diagonal cross-sectional view of the engine block and head showing the position of the rotary combustion chamber in the version which receives the entire compression charge. Also shown are the ring type combustion and oil seals, the fuel injector, and the small pre-combustion chamber just above the rotary combustion chamber.
FIG. 3 is an upward cross-sectional view through the block to show the arrangement of the valves in two representative cylinders and positions of the vertical rotary combustion seals.
FIG. 4 is a diagonal cross-sectional view of the engine block and head through 4 - 4 of FIG. 5 illustrating the rotary combustion chamber in conjunction with head combustion chambers in the split compression charge version.
FIG. 5 is an upward cross-sectional view through 5 - 5 of the block of FIG. 4 to show the arrangement of the valves and positions of the vertical rotary combustion seals. Also shown are the vertical seal lubrication jets and head bolt holes used to firmly attach the head to seal the rotary combustion assembly.
FIG. 6 is a cross-sectional view through 6 - 6 of FIG. 4 showing the placement of head bolts, interior intake and exhaust manifolds, and the location of the fuel and intake air pre-heater elements.
FIG. 7 is a 90 degree cross-sectional view through 7 - 7 of FIG. 6 illustrating detail of the vertical rotary combustion chamber seal and spring (cut away section), intake charge heating fins, fuel heating element, and the intake charge pre-heater.
FIG. 8 is a broken cross-section through the head and intake charge pre-heater through 8 - 8 of FIG. 7 .
FIG. 9 is a partial cross-sectional view of the block and simplified z-crankshaft to illustrate the relationship of the z-crankshaft and cylinders. (The rotational control rod and thrust bearings used with the z-crank are not shown.)
DETAILED DESCRIPTION OF THE INVENTION
In order to better understand how the proposed engine would improve hydrogen combustion, the preferred embodiment is now described in more detail. The major novel element is the combustion system which includes a single centrally located rotary combustion chamber (RCC) 30 serving all four cylinders in a four stroke DOHC variable valve actuation (VVA) engine 10 . The RCC assembly 20 contains a spherical combustion chamber 30 with a passage and opening. This opening, combustion valve 40 , sequentially accesses the combustion chamber 50 of each cylinder 52 as it is driven at one half the crankshaft speed by gear 28 . A fuel injector or combination fuel injector/spark plug (FISP) 60 injects fuel directly into RCC 30 . A small pre-combustion chamber 70 is located next to FISP 60 collecting higher concentrations of fuel and is used to initiate combustion.
Conventional ring seals 22 located above and below combustion valve opening 40 on RCC assembly 20 contain combustion gas on one axis while a series of vertical ceramic seals 32 located in the block contain the charge on the other axis. Spring 76 applies pressure to vertical seal 32 keeping it in contact with the exterior of RCC assembly 20 to prevent passage of combustion gas past the seal. After combustion valve 40 closes, a small amount of lubricant is injected in a space behind the vertical seal 32 by lubrication jet 34 to both lubricate and cool these seals. Vertical seal lubrication is achieved by a small amount of lubricant seeping past the seal and being deposited onto the outside of RCC assembly 20 . This film lubricates succeeding vertical seals.
Ring seals 22 located on RCC assembly 20 avoid component failure by several means. First, a dedicated lubricant injector can be located in the block (not shown) to lubricate each of the RCC combustion seals. Second, a groove extending from the adjacent oil seals to the center of each combustion seal can also supply lubricant. Finally, low-friction hard coatings recently developed by Argonne National Laboratory may not require lubrication.
To prevent thermal deformation of RCC assembly 20 , several measures are taken. First, the combustion chamber and passage is ceramic coated. Ideally, these coatings should control the high combustion chamber temperatures, but if not, other means are available to further cool the assembly. Since RCC assembly 20 is fully contained within the block and head, oil can be used to cool and lubricate upper and lower journal bearings 80 and 82 respectively. This oil is contained by oil rings 24 placed between the bearings and RCC combustion rings 22 . Space between the RCC assembly 20 and block and head allows the oil to freely move to cool the assembly. If necessary, oil passages 86 are easily placed within the RCC assembly. Some additional cooling can be generated by transfer of heat to the adjacent head assembly and dissipated by cooling fins 92 located in the intake portion of that assembly. Passages 102 from each cylinder 52 further cool the exterior of RCC assembly 20 as it rotates past each of these openings during non-combustion cycles. Finally, additional coolant passages can be located near the RCC assembly in both the head and block.
Two versions of the RCC engine are illustrated. FIGS. 2 and 3 depict a four cylinder RCC engine in which the entire compression charge is transferred to RCC 30 while the remaining drawings depict a version where the compression charge is split in half. While both versions can operate with spark ignition (SI), diesel operation in the split charge version would be more challenging. As a result, for the purposes of this discussion, the split charge version will be identified as SI, while the other will be designated as diesel. Discrete fuel injectors 120 are provided for each combustion chamber 50 in the SI version while only a single fuel injector is needed for the diesel version. While both use DOHC systems and can incorporate variable valve timing, the intake and exhaust valves in the diesel are at a 45 degree angle with respect to the primary axis of the engine. Generally, the rest of the features are common to both types, and are not illustrated in all the drawings.
In operation, heat exchanger 130 heats the intake air from residual exhaust heat. Next, a supercharger (not shown) forces air into the intake manifold area of the head. This charge is further heated by fins 92 located in the intake passages before it enters the cylinder 52 . In the diesel version, the air is compressed until combustion valve 40 opens late in the compression stroke. All the air is quickly transferred to RCC 30 . During this transfer, the fuel is injected directly into the RCC. Under relatively high pressure, the air rushes with great speed into RCC 30 while the fuel is being injected to produce thorough mixing in a short period of time. The residual rich mixture in pre-combustion chamber 70 quickly ignites and the resulting jet ignites the RCC charge. The charge now passes through cylinder passage 102 into the cylinder 52 providing power to the piston 54 . As shown in FIG. 9 , the expanding gas in the cylinder 52 drives the piston down during the power stroke. The driving rod 56 connects to a Z-shaft assembly 200 that converts the reciprocating motion of the piston in rotational motion of the Z-shaft 210 . After most of the charge has been transferred to the cylinder 52 , combustion valve 40 closes while rotating to the next cylinder 52 to repeat the process. As the charge is exhausted through the head, the exhaust from the interior exhaust valves 152 heats the intake charge while the outer exhaust valves 150 supply heat to the on-board reformer (not shown).
The operation of the SI version has a few differences. A supercharger is also used with the air being heated by it and heat exchanger 130 in the head which then enters the cylinder 52 . However, after intake valves 140 are closed and the air is being compressed, fuel is injected into the cylinder 52 . Half of this charge is then transferred into RCC 30 late in the compression cycle. During this transfer, a small amount of fuel is fed into the pre-combustion chamber 70 . A few crank angle degrees later, SPFI 60 ignites the richer (close to stoichiometric) charge. The resulting jet ignites the RCC 30 charge which in turn ignites the head combustion chamber 50 charge. This combustion sequence is sequentially repeated for each cylinder 52 as the RCC accesses each cylinder combustion chamber 50 . Exhaust is pushed out of the cylinder 52 through the two exhaust valves as in the diesel version previously described.
Another version of the combustion process is possible in either version. Steam produced by waste water and heat recovered from the combustion process and injected during the final stage of the combustion stroke would increase cylinder pressure thereby increasing output. However, both versions would require an additional dedicated injector for each cylinder 52 . Use of this system should increase thermal efficiency and may eliminate the need for a supercharger especially in the diesel version.
Additional variations in fuel injection methods are possible for the depicted SI and diesel RCC engines. With the depicted version splitting the charge, both DI and IDI are used. Further, additional injectors 62 could be added to either location allowing either dual fuel or steam injection. Mostly, similar injector strategies are possible in the un-split charge version.
Supercharging would increase both the output and the thermal efficiency. In a study investigating supercharging in port fuel injected hydrogen engines, Verhelst et. al. found supercharging between 0.5 and 1.0 bar produced the highest efficiency with the greatest power produced at 1.2 bar. Sebastian Verhelst, Joachim Demuynck, Steven Martin, Michael Vermeir and Roger Sierens, “Investigation of Supercharging Strategies for PFI Hydrogen Engines,” SAE technical paper 2010-01-0582. This would support continuous supercharging at the lower levels with increased supercharging to 1.2 bar at maximum power. Due to differences in the combustion system, it is unclear whether this conclusion applies to the RCC engine. It may be possible to increase the amount of supercharging in the split compression charge engine to achieve higher output and greater thermal efficiency. In this version, less compression work is needed to produce higher outputs. This is due to the lower compression ratio used, reduced heat loss, and larger total combustion chamber volume per stroke, and splitting the compression charge.
Since the operation of the RCC serves all four cylinders in a consecutive fashion, the firing order must follow the same sequence. With four cylinders, access to each cylinder 52 in this order necessitates that the cylinders be parallel. To support this arrangement, several crankshaft designs can be used. The most obvious is the dual crankshaft. This design has some advantages such as being compact, and counter-rotating operation reduces vibration. The compactness is somewhat compromised by the central placement of the RCC assembly making the entire engine larger. A more suitable solution is the z-crankshaft which can be made compact and offers the option of variable compression. With these crankshaft options, the engine can be offered in the more popular 3, 4, 6, and 8 cylinder configurations, with the 6 & 8 cylinder versions using opposed cylinders.
The first priority of the RCC engine is to increase thermal efficiency. This is done by addressing the two greatest contributors to enthalpy which are combustion process and heat transfer losses. Heat transfer losses are first addressed. The greatest contributor to reduction in this factor is the RCC. Since the RCC is exposed only to already hot compressed gas from the late compression cycle and the hot gas of the combustion cycle, the operational heat range is significantly reduced, possibly by as much as 40%. Further, since the RCC serves all four cylinders of a four stroke engine, combustion in the RCC is almost continuous creating only very brief exposure to the lower heat range. Low temperature combustion reduces the upper thermal limit, and, ceramic coatings in the RCC and passage provide a barrier to heat loss. Other areas of reduced heat loss include ceramic coated pistons and cylinder combustion chambers. Finally, use of the z-crank reduces side thrust forces on the cylinder walls possibly allowing them to be ceramic coated.
With respect to reducing combustion process losses, several measures are taken. A staged combustion process preheats the reactants closer to chemical equilibrium. First, the incoming intake charge is preheated by the heat exchange with the exhaust with additional heat added by supercharging. The feedstock fuel, (diesel, gasoline, CNG etc.) is preheated in the head and is added to the preheated intake charge which then flows through the reformer to upgrade the fuel to syngas or hydrogen. In the SI version, the fuel is injected into the cylinder combustion chamber during the compression stroke. About 25 crank angle degrees before the piston 54 reaches top dead center (TDC), the rotating RCC assembly opens the combustion valve. As about half of the charge enters the RCC, the pre-combustion chamber injector injects a small amount of fuel into that chamber while the intake charge passing into the RCC mixes with the very hot exhaust residuals from the previous power stroke. The FISP ignites the richer fuel in the pre-combustion chamber producing a hydrogen jet igniting the RCC charge. Ignition of the RCC charge likewise produces a combusting jet to ignite the cylinder combustion chamber charge. The diesel version, lacking a head combustion chamber, skips this last combustion phase but operates at considerably greater compression ratios to increase efficiency. Other elements contributing to increased thermal efficiency include, VVA, z-crank with variable compression, and unthrottled operation.
Hydrogen combustion in the RCC engine is superior to other ICE formats for several reasons. First, DI and IDI eliminate the backflash, pre-ignition and reduced power problems. It should be noted, no reliable high pressure commercial injectors are available to date, but would be expected to become available as hydrogen ICE development progresses. As with conventional DI hydrogen engines, this remains a potential problem with the SI RCC engine. The diesel version avoids this problem by injecting fuel just as the combustion valve opens while the RCC pressure is still very low allowing the use of a low pressure injector.
The RCC engine uses other additional features to counter pre-ignition. Hot spots in the combustion chamber are one of the principal causes of this problem. Flat pistons, flat heads, two exhaust valves per cylinder, low temperature combustion (in the SI version), exhaust gas recirculation, charge stratification, very lean combustion chamber mixtures, placement of the spark plug in the RCC pre-chamber, ceramic coatings, and possible use of water injection all serve to reduce pre-ignition.
Another problem with current DI Hydrogen engines is incomplete mixing of the charge causing misfire, high NOx emissions, reduced efficiency and power loss. Both RCC versions mix the fuel and air better than conventional engines. Principally, this is accomplished by the combustion valve producing a very high velocity stream mixing the incoming charge with residual exhaust gas in the RCC. In the SI version, DI into the early compression cycle cylinder 52 starts the mixing process with a very small amount of fuel added to the pre-combustion chamber in the RCC after the combustion valve opens. In the diesel version, IDI into the RCC while the air charge rushes past the opening from the pre-combustion chamber mixes the charge. In both versions, stable ignition results from the richer pre-combustion chamber charge producing a hydrogen jet to ignite the RCC charge. In the SI version, the pre-combustion chamber 70 can incorporate a related design by MAHLE Powertrain LLC producing multiple ignition sites which they claim decreases combustion variability while increasing fuel economy by 18%. See, William P. Attard, Neil Frazer, Patrick Parsons, Elisa Toulson, “A Turbulent Jet Ignition Pre-Chamber Combustion System for Large Fuel Economy Improvements in a Modern Vehicle Powertrain,” SAE technical paper 2010-01-1457.
Those skilled in ICE technology will quickly recognize the similarities of the RCC engine with IDI Ricardo diesels and will also be aware of the limitations of that technology. Perhaps the greatest disadvantage of the conventional IDI diesel is its' 10-15% lower thermal efficiency. Primarily, this is due to increased heat and throttling losses from larger combustion surface areas and the heat transfer losses of the swirl chamber charge back to the main combustion chamber. Several key design elements of the RCC engine mitigate these problems. First, the combustion valve prevents the compression charge from entering the RCC until late in the cycle. Then, after the compression charge is highly compressed, the combustion valve opens producing a very high velocity stream to mix the RCC charge. Because the velocity of the incoming compression charge is so high, the combustion valve opening can be enlarged and still provide sufficient velocity to mix the charge. A larger opening reduces the throttling losses when the charge exits the RCC. Second, the RCC and passage is ceramic coated to reduce heat transfer. Third, the greatly reduced heat range of the RCC and fourth, shorter duration of exposures to the lower temperature range, and fifth, low temperature combustion all reduce heat loss. With these improvements, it is likely the thermal efficiency of the RCC engine will surpass DI formats.
Another relatively serious problem with IDI engines is uneven thermal loading of the pistons. This is caused by the combustion products contacting the piston areas off center producing hot spots resulting in thermal deformation of the pistons. Both the SI and diesel RCC engine versions minimize this problem by timing the combustion products arrival in the cylinder combustion area after the piston 54 is below the combustion valve opening.
Again, those skilled in ICE technology will also recognize the RCC is a type of rotary valve. Rotary valve engines have not become popular for several reasons. Primarily, poppet valves are more effective sealing the high pressures encountered in the combustion process with rotary valve engines commonly having either excessive oil consumption or inadequate combustion chamber sealing. It should be noted, the RCC is fully contained within the head and block of the engine. The only exit for the combustion gas is through the combustion valve. The rings above the combustion valve opening should be more effective than conventional engine rings because there is no place for the gas to escape past the rings. The vertical seals located around the RCC assembly prevent the movement of gas to adjacent cycles and are modeled on Wankel rotary engine ceramic apex seals. In The RCC engine, these seals are lubricated by oil jets which terminate in the space behind the seals. A small amount of oil seeps past these seals to be deposited on the exterior of the RCC assembly to lubricate the next trailing seal. In this manner, the seals are both lubricated and cooled extending their life cycles. It also serves to increase the sealing capability of the system. If sufficiently cooled, less expensive non-ceramic seals could be used. Finally, “O” ring seal 26 prevents the escape of gas from pre-combustion chamber 70 .
A similar split charge combustion system is illustrated by Muth (U.S. Pat. No. 7,841,308). The RCC engine combustion system is an improved version of that disclosure. The improvements include: use in a poppet valve engine greatly simplifies sealing the combustion chamber; a considerably larger combustion valve opening and shorter passage reduce throttling and heat transfer losses; and high temperature operation of the RCC is much better controlled through improved cooling.
The preferred embodiment, as previously noted, uses a z-crankshaft to produce a barrel type engine. Not withstanding the compactness this arrangement provides, it also increases performance. Shulenberger uses a z-crankshaft in a conventional barrel engine equipped with variable compression (VCR) and claims a 25% thermodynamic gain due to VCR and engine downsizing. This arrangement is easily adapted to the RCC engine. See, Arthur Melvin Shulenberger, Luc Patrick Deschaumes, “Axial piston machines,” U.S. Pat. No. 6,968,751, November 2005.
While Shulenberger uses his design to incorporate VCR using traditional fuels, a study by Y. Nakamura et. al propose using a z-crank with hydrogen gas-jet combustion to produce knock-less and low NOx emissions in a hydrogen fueled engine. See, Y. Nakamura, K. Yamamoto, N. Nakajima, Y. Kidoguchi, K. Miwa, “Noble Hydrogen with Knock-less and Low NOx Emission Employing Hydrogen Gas-Jet Combustion and Z-crankshaft Mechanism,” SAE technical paper 2007-24-0122. A spark plug located close to the injection nozzle initiates combustion just after the start of injection. Increased thermal efficiency is thought to be due to slower piston speeds near TDC producing stable quasi-constant volumetric combustion. Further, the z-crank exhibits less thermal efficiency deterioration at late ignition timed combustion. Although the Nakamura design changes the crankshaft axis, their conclusions should apply to the Shulenberger and RCC engine designs.
The MAHLE, Nakamura and RCC designs all use a common strategy to increase combustion stability; a locally richer mixture jet ignites the main charge. Literally, the SI RCC engine takes this strategy one step farther. Although the charge equivalence ratio is reduced in the RCC compared to the pre-combustion chamber, the RCC fuel injector could slightly enrich the RCC chamber charge by injecting fuel into the RCC. This would set up a series of combustion events where increasing thermal energy (jets) are used to ignite increasingly dilute charges. Therefore, stable combustion should be achieved with even more dilute charges resulting in additional fuel savings.
Before any hydrogen engine can make significant gains towards the goals of reducing greenhouse gas emissions and reducing foreign oil use, the engine must attain high levels of use. This can only happen if the engine is cost competitive. Probably any hydrogen ICE will cost somewhat more than current use engines. Mostly, this is due to most engines making use of a supercharger, VVA, ceramic coatings, and, if available, an on-board reformer. With reference to the reformer cost, the Argonne National Laboratory is pursuing study on less expensive non-noble metal reformers and if the reformer is very effective, the catalytic converter can be eliminated to offset the reformer cost.
Comparing conventional hydrogen engines with the RCC engine, the cost issue is difficult to predict. Since the RCC engine is really an upgraded conventional engine, most costs would be the same. The RCC engine has the additional element of the RCC which would add to the cost. However, only one is needed per engine. Also, the RCC engine should be more efficient allowing downsizing the engine and should produce equivalent output with lower temperature operation. This would allow less expensive fuel injectors to be used in the SI version. In the diesel version, only one low pressure injector would be required which should reduce the total engine cost but would be partially offset by the increased operating combustion pressure adding some cost to the engine. Finally, the RCC engine should solve the pre-ignition and combustion stability problems inherent in conventional hydrogen ICE technology. The costs associated with completely solving these problems with conventional engines are not known because no acceptable solution has yet been found.
Although, the RCC engine was specifically designed to burn hydrogen, most of the thermodynamic improvements would also be realized with more conventional fuels. Due to this, the RCC engine could first be developed as an interim engine using present fuels. This strategy could be taken in lieu of satisfactory development of on-board fuel reforming.
Because the RCC engine is an upgraded conventional ICE, the only difference in building one is the RCC assembly and seals. Since the technology used in the RCC is based on IDI diesel and rotary engine technology, this should not pose significant barriers to development. Therefore, the development of the RCC engine could be relatively quick, given the desire to do so.
Based on the foregoing, it is apparent the rotary combustion chamber engine of the present invention has numerous advantages over conventional poppet valve engines. First, it should have higher thermodynamic efficiency. Second, it should have superior fuel economy. Third, it should exhibit better hydrogen fuel combustion characteristics. Lastly, it should produce fewer emissions.
The present invention may of course, be carried out in other specific ways than those herein set forth without parting from the spirit and essential characteristics of the invention. The presented embodiments are, therefore, to be 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 poppet valve engine incorporates a single rotary combustion chamber serving multiple cylinders to decrease emissions and increase thermodynamic efficiency. Virtually zero emissions are achievable by on-board fuel reforming to hydrogen. Limited heat range exposure of the rotary combustion chamber, low temperature combustion, and ceramic coatings reduce heat loss while three stage combustion, intake and fuel preheating, and fuel reforming reduce combustion process irreversibility. A supercharger increases the power density to allow engine displacement reduction. A z-crankshaft assembly coupled with a pre-combustion chamber allow knock-less and stable hydrogen combustion at virtually all load and speed conditions. Variable compression, possible in certain configurations of the z-crankshaft assembly, further increases thermal efficiency. | 8 |
BACKGROUND
[0001] The present disclosure relates to a refrigerator, and more particularly, to a refrigerator, a door for a refrigerator, and a dispensing apparatus for a refrigerator that enable to obtain contents easily.
[0002] A refrigerator is widely used as a cooling apparatus. The refrigerator is divided into a freezing chamber and a chilling chamber. The chilling chamber is maintained at from 3° C. to 4° C. so as to store foods and vegetables for a long time. The freezing chamber is maintained at below zero so as to store meats and foods in frozen state.
[0003] Recently, the refrigerator includes various functions for offering convenience to a user, for example, an ice-maker, a water storage tank for cold water, a dispenser, or the like. The ice-maker automatically performs sequential process for ice-making such that a user can obtain ice without particular manipulation. The dispenser allows a user to obtain ice or water outside the refrigerator. The ice-maker making ice in the refrigerator, the water storage tank, and the dispenser properly dispensing ice or cold water to the outside are already well-known, and thus description thereof will not be given.
[0004] A related art dispenser includes a receiving space for a container filled with water or ice dispensed from the dispenser. Here, the receiving space is formed in a recessed portion of a door of the refrigerator. Therefore, the dispenser always occupies a certain space even when it is not used, thereby limiting the use of an internal space of the door. Also, since the dispenser occupies the internal space of the door, the door itself becomes thin and a large amount of heat is lost. Additionally, interference occurs between components inside the door, making fabrication of the refrigerator difficult.
[0005] In addition, if the dispenser protrudes more from an inner surface of the door, the dispenser occupies an internal space of the refrigerator, thereby reducing the internal space of the refrigerator.
[0006] Furthermore, since a container having a volume or a length greater than the receiving space cannot be used for obtaining water or ice from the dispenser, there is a limitation on the size of the container.
SUMMARY
[0007] Embodiments provide a refrigerator, a door for a refrigerator, and a dispensing apparatus for a refrigerator capable of increasing an internal space of a refrigerator, obtaining a thickness of a door to reduce a heat loss, preventing interference between components inside a door, and enabling a user to easily obtain contents discharged from a dispensing apparatus regardless of the size and length of a container.
[0008] In an embodiment, there is provided a refrigerator, including: a storage space receiving food; a door selectively opening and closing the storage space; and a dispensing apparatus dispensing contents stored in the storage space without opening the door, wherein the dispensing apparatus substantially protrudes from an outer surface of the door.
[0009] In another embodiment, there is provided a door for a refrigerator, the door including: an outer surface defining an exterior; a body protruding from the outer surface and providing a space the outer surface the body; and a nozzle and/or a chute received in the space and discharging contents through the outer surface.
[0010] In a further environment, there is provided a dispensing apparatus for a refrigerator, the dispensing apparatus including: a dispensing unit protruding from an outer surface of a door of the refrigerator and discharging contents out of the refrigerator; and a body unit covering the discharge unit except a bottom surface of the discharge unit.
[0011] According to the present invention, an internal space formed in a recessed portion of a door can be used as an internal space of a refrigerator, and a user can conveniently obtain ice and water regardless of the size and kind of a container. In addition, the thickness of the door can be obtained, reducing a heat loss. Furthermore, since interference between components inside the door can be prevented, the refrigerator can be fabricated more easily.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a perspective view of a refrigerator according to an embodiment of the present disclosure.
[0013] FIGS. 2 and 3 are bottom views for illustrating arrangements of a nozzle and a chute of the dispensing apparatus of FIG. 1 .
[0014] FIG. 4 is a view of a base unit of a dispensing apparatus attached to and detached from a front surface of a door.
[0015] FIGS. 5 and 6 are views of an auxiliary tray according to an embodiment of the present disclosure.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0016] Reference will now be made in detail to the embodiments of the present disclosure, examples of which are illustrated in the accompanying drawings.
[0017] FIG. 1 is a perspective view of a refrigerator.
[0018] Referring to FIG. 1 , a refrigerator 1 according to embodiments is a side by side type refrigerator with a chilling chamber and a freezing chamber and their doors disposed at right and left sides, respectively. Of course, the freezing chamber and the chilling chamber may be variously configured by a person with ordinary skill in the art. For example, first and second chilling chambers may be disposed at both sides of an upper portion and a freezing chamber may be disposed at a lower portion. Alternatively, a single freezing chamber or a single chilling chamber may be provided in a refrigerator.
[0019] A dispensing apparatus 40 for discharging predetermined food such as water or ice is formed on a front surface of a door 30 of the freezing chamber. The dispensing apparatus 40 protrudes from the front surface of the door 30 . The dispensing apparatus 40 may be formed on a door of a chilling chamber, not the door 30 of the freezing chamber.
[0020] Such a structure can decrease the thickness of the door 30 and enlarge a space of the freezing chamber, compared with when the dispensing apparatus 40 is formed in a concave portion of the door 30 . In addition, a receiving space for water or ice is not formed in a concave portion of the door 30 . That is, the receiving space is separated from other surfaces of the door 30 and does not form a step area extending from an outer surface of the door 30 .
[0021] The dispensing apparatus 40 allows a user to obtain water or ice. The dispensing apparatus 40 may include a chute 46 for obtaining ice and a nozzle 48 for obtaining drinks. The chute 46 and the nozzle 48 protrude from an outer surface of the door 30 . That is, when the outer surface of the freezing door 30 extends from an edge of a portion where the dispensing apparatus 40 is disposed to form a virtual surface corresponding to the dispensing apparatus 40 , the chute 46 and the nozzle 48 are disposed over the virtual surface.
[0022] The configuration of the dispensing apparatus 40 will be described in more detail.
[0023] A body 42 is provided in the dispensing apparatus 40 . The body 42 has a predetermined size and protrudes from the front surface of the door 30 . A display unit 44 is disposed on a front surface of the body 42 .
[0024] The display unit 44 displays operations of the dispensing apparatus 40 . The display unit 44 may include a touch screen, or the like so as to control the operation of the dispensing apparatus 40 . A manipulation button may be formed around the display unit 44 . The display unit 44 may be detached from the dispensing apparatus 40 . The display unit 44 may be detachably formed on the body 42 of the dispensing apparatus 40 . For example, the display unit 44 may include a magnet or have a linkage structure so as to be attached to and detached from the body 42 . Therefore, a user can easily operate the dispensing apparatus 40 without limitation on place. If the display unit 44 controls the operation of the dispensing apparatus 40 , the display unit 44 can serve as a remote controller.
[0025] The chute 46 for ice and the nozzle 48 for drinks may be disposed under the body 42 . Ice made by an ice-making apparatus in the door 30 is guided to the chute 46 along a predetermined guide, and a user can obtain ice outside the door 30 through the chute 46 . The nozzle 48 is connected to a water storage tank provided in the refrigerator 1 . Therefore, a user can obtain drinks outside the door 30 through the nozzle 48 .
[0026] Meanwhile, the chute 46 and the nozzle 48 may be arranged in various forms under the body 42 . This will be described with reference to FIGS. 2 and 3 .
[0027] FIGS. 2 and 3 are bottom views for illustrating arrangements of the nozzle 48 and the chute 46 of the dispensing apparatus of FIG. 1 .
[0028] Referring to FIG. 2 , the chute 46 and the nozzle 48 are arranged in series with the door 30 under the body 42 . That is, the nozzle 48 and the chute 46 may be sequentially arranged outside the door 30 . Alternatively, the chute 46 and the nozzle 48 may be sequentially arranged outside the door 30 . In other words, the chute 46 and the nozzle 48 are arranged in forward and backward direction with respect to the front surface of the door 30 .
[0029] Referring to FIG. 3 , the chute 46 and the nozzle 48 are arranged parallel to each other under the body 42 . That is, the nozzle 48 and the chute 46 may be arranged parallel to each other outside the door 30 . In other words, the nozzle 48 and the chute 46 are arranged in a right and left direction with respect to the front surface of the door 30 .
[0030] Referring to FIG. 1 , again, a button unit 50 is disposed under the chute 46 and the nozzle 48 . The button unit 50 controls opening and closing of the chute 46 and the nozzle 48 . The button unit 50 may control such that the chute 46 and the nozzle 48 are opened at the same time. For example, the chute 46 and the nozzle 48 may be selectively opened depending on the degree of press of the button unit 50 such that water is discharged by short press and ice is discharged by long press. Alternatively, the button unit 50 may include a chute button and a nozzle button individually provided to respectively open the chute 46 and the nozzle 48 . The chute button and the nozzle button selectively open the chute 46 and the nozzle 48 , respectively. This configuration may be more useful in the case of the parallel arrangement of the chute 46 and the nozzle 48 in the right and left direction. Furthermore, both ice and water may be discharged by pressing the button unit 50 longer.
[0031] The dispensing apparatus 40 may further include a base unit 60 . The base unit 60 supports a container for receiving ice and drinks discharged through the chute 46 and the nozzle 48 of the dispensing apparatus 40 .
[0032] The base unit 60 has a flat upper surface such that the container for receiving ice and drinks is seated thereon. A water collection tray may be disposed on the upper surface of the base unit 60 to receive residual water from the chute 46 and the nozzle 48 of the dispensing apparatus 40 .
[0033] The base unit 60 may move vertically on the front surface of the door 30 using various configurations such that the height of the base unit 60 can be adjusted depending on the size and length of the container. For example, a guide groove may he formed in the door 30 and a guide protrusion may be formed at one side of the base unit 60 , as illustrated in FIG. 4 , such that the guide protrusion can be inserted into the guide groove and move. After the guide protrusion is inserted into the guide groove, they may be supported by a frictional force.
[0034] The base unit 60 may be detached from the door 30 such that a user can attach and detach the base unit 60 if necessary.
[0035] FIG. 4 is a view of the base unit 60 of the dispensing apparatus 40 attached to and detached from the front surface of the door 30 .
[0036] Referring to FIG. 4 , a latch groove 34 may be formed in the door 30 and a latching protrusion 64 to be inserted into the latch groove 34 may be formed on the base unit 60 . An auxiliary tray 66 may be disposed at one side of the base unit 60 to enlarge an upper surface of the base unit 60 . The auxiliary tray 66 enlarges an area of the upper surface of the base unit 60 so as to apply a larger container to the dispensing apparatus 40 .
[0037] Various configurations may be employed as the auxiliary tray 66 by those skilled in the art.
[0038] FIGS. 5 and 6 are views of the auxiliary tray 66 according to an embodiment of the present disclosure.
[0039] Referring to FIG. 5 , a sliding guide 67 may be disposed at one side of the base unit 60 , and the auxiliary tray 66 may protrude in a forward direction of the door 30 . Here, the upper surface of the base unit 60 may have the same height as an upper surface of the auxiliary tray 66 that slides and protrudes.
[0040] Referring to FIG. 6 , a hinge 68 may be rotatably disposed between the auxiliary tray 66 and the base unit 60 .
[0041] Hereinafter, operations of the refrigerator 1 having the dispensing apparatus 40 , the door 30 for the refrigerator 1 , and the dispensing apparatus 40 for the refrigerator 1 will be described in detail.
[0042] A user places the container for receiving water or ice under the body 42 of the dispensing apparatus 40 in order to obtain the water or ice from the dispensing apparatus 40 .
[0043] When a user pushes the button for operating the chute 46 of the dispensing apparatus 40 , an outlet of the chute 46 is opened and ice flows from the ice-making unit into the container. On the other hand, when a user pushes the button for operating the nozzle 48 , an outlet of the nozzle 48 is opened and drinks flow from the water container into the container.
[0044] When a user pushes the buttons for operating the chute 46 and the nozzle 48 at the same time in order to obtain both ice and water from the dispensing apparatus 40 , the outlets of the chute 46 and the nozzle 48 are opened, and ice and water flow into the container at the same time. Of course, the configuration and operation of the button unit 50 may include various modified examples as described above.
[0045] Meanwhile, a user may hold the container with hands when water or ice flows into the container from the dispensing apparatus 40 , while the base unit 60 of the dispensing apparatus 40 may support the container.
[0046] Alternatively, the base unit 60 is detachable from the door 30 , and if the container is larger than a space between the body 42 of the dispensing apparatus and the base unit 60 , the base unit 60 may be detached and the container may be applied to the dispensing apparatus 40 .
[0047] Alternatively, the base unit 60 may slide along the guide groove formed in the door 30 to adjust an interval between the body 42 of the dispensing apparatus 40 and the base unit 60 . Therefore, if the container is large, the space between the body 42 and the base unit 60 can be enlarged by moving the base unit 60 .
[0048] The present invention will be apparent to those skilled in the art that various modifications and variations can be made therein without departing from the spirit and scope of the invention.
[0049] A dispensing apparatus is added to an inner surface consecutive with other portion of a door and a body is attached to an outer surface of the door and has the same shape as other portions of up and down, and right and left sides. However, the present invention is not limited thereto. For example, even though the outer surface of the door where the body is placed is recessed in an inward direction of the door to a predetermined depth, this is included in the sprit of the present invention provided that the substantial portion of the body protrudes in an outward direction of the door.
[0050] In this case, the outer surface of the door corresponding to the body in a forward and backward direction may extend to the base unit in an up and down direction for mounting the container.
[0051] In addition, the body including the chute and the nozzle may be separately mounted on the door.
[0052] It is intended that the present invention covers the modifications and variations of this invention that come within the scope of the appended claims and their equivalents.
[0053] According to the present disclosure, the internal structure of a refrigerator door is simplified, and the refrigerator can be easily fabricated. Also, the internal space of the refrigerator is enlarged and a user can use a container of various sizes and shapes. Furthermore, the door is prevented from becoming thin, reducing a heat loss. | There is provided a refrigerator. The refrigerator includes a storage space receiving food, a door, and a dispensing apparatus. The door selectively opens and closes the storage space. The dispensing apparatus dispenses contents stored in the storage space without opening the door. The dispensing apparatus substantially protrudes from an outer surface of the door. According to the refrigerator, since the internal structure of the door is simplified, fabrication of the refrigerator becomes easy. In addition, the internal space of the refrigerator is enlarged and a user can use a container of various sizes and shapes. Furthermore, the thickness of the door is prevented from becoming thin, thereby reducing a heat loss in the refrigerator. | 5 |
FIELD OF THE INVENTION
The invention pertains to the field of jack devices useful for floor installation or repair. More particularly, the invention pertains to a jack designed to aid in the repair and installation of wooden flooring by forcing abutting edges of individual pieces of flooring into proper position until they can be fastened into place.
BACKGROUND OF THE INVENTION
Wooden flooring is usually supplied as boards having tongue-and-groove edges, such that the floor is laid over a subfloor by placing the boards next to each other, forcing the tongue on the edge of one board into the mating groove of the next, and nailing the boards in place through the edge, so that the nails are invisible when the next board is installed. Forcing the tongues into the grooves requires a fair amount of force, and the boards must be held tightly together as the nails are driven.
Traditionally the installation and repair of wooden flooring has required two carpenters. To assure a tight fit between the individual pieces of flooring the first carpenter forces the flooring being installed or repaired into proper position, while the second carpenter securely fastens the flooring being held to the subfloor. To insure that the floor is held tightly together it has generally been the situation that nails are driven into the flooring used at an angle so that as the nail engages with the subfloor, the individual pieces of flooring are driven laterally into a tighter abutment with the piece of flooring previously put in place. In this manner the flooring is constructed, one piece at a time, gradually being laid from the base of a starting wall towards the base of an ending wall where the last piece will be put in place.
A number of devices have been developed in the past to aid in the installation of flooring, but they have had a number of deficiencies which make them difficult to use in the modern method of installation on a subfloor.
Examples of these prior art flooring clamps or jacks are Parrish, "FLOOR CLAMP" U.S. Pat. No. 10,061, issued in 1853; Foster, "FLOOR-CLAMPS", U.S. Pat. No. 136,428, issued in 1873; or Lassahn, "CLAMPING DEVICE FOR CONSTRUCTING FLOORING, DECKING AND THE LIKE", issued in 1964. All of these devices force the flooring into alignment using screw (Parrish), rack-and-pinion (Foster) or hydraulic (Lassahn) force exerted against the floor joists. Obviously, this would not work if the floor is being installed in the present manner over a plywood subfloor.
Masters, "PUSH STICK FOR PLUMB AND LINE ADJUSTMENT OF STUD WALLS", U.S. Pat. No. 4,660,806, issued in 1987, is a more general pushing device using a hydraulic ram, but is not used for flooring.
Powernail Co. Inc, P.O Box 300, Lincolnshire, Ill. 60069, currently markets two models of a flooring jack called a Powerjack™. Both use a ratchet mechanism to exert force on flooring. The Powerjack 100 has a bent leg which hooks over the edge of the tongue-in-groove flooring and a flat pressor foot moved by a ratchet. The unit rides on the flooring to be moved, while the pressor foot pushes against a stationary object such as a wall or a stud nailed to the subfloor, thus pulling the flooring into place. The Powerjack 200 is designed for glue down and gym floor installation by pushing from a subfloor anchor point. It has a flat foot which must be attached by nails or screws to the subfloor, and a second foot which can be moved by a ratchet to press against the tongue-in-groove flooring. Both have relatively restricted maximum distances from their anchor points, and, unless used right next to a wall in the case of the model 100, both require some sort of anchor attached to the subfloor.
SUMMARY OF THE INVENTION
The invention comprises a flooring tool for use in installing tongue-in-groove wooden floor in which a jack is used to push a foot against the strips of flooring to be installed, forcing the strips into alignment for nailing.
A pivoting gripper attaches the jack to a board, allowing use of the invention at widely varying distances from a wall, well in excess of the maximum extension of the jack. For use on boards in the middle of the room, the foot is on the opposite end of the jack from the pivoting gripper, allowing maximum extension and distance. For installing the last few boards, the pivoting gripper may be removed or swiveled out of the way, and the foot moved to the other end of the jack, allowing the tool to exert force against boards only inches from the wall.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 shows the invention being used to install a wooden tongue and groove floor covering.
FIG. 2 shows a side view of the invention, corresponding to FIG. 1.
FIG. 3 shows the invention, configured for use with boards close to a wall.
FIG. 4 shows an end view of the jack of the invention, at the location of the fixed guide, along lines 4--4 in FIG. 1.
FIG. 5 shows an end view of the jack of the invention, at the location of the pivoting gripper, along lines 5--5 in FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIGS. 1 and 2 show the invention in use. The floor jack of the invention uses a jack to exert force, which comprises a movable portion (2) and a fixed portion (1). It will be understood that "fixed portion" and "movable portion" are terms which are adopted herein for convenience, and that, in fact, both sections are movable relative to each other. The fixed portion houses an actuating mechanism such as a worm gear or rack-and-pinion actuated by a crank (9) and handle (10). If desired, the crank (9) and handle (10) can be replaced by a standard 1/4, 3/8, or 1/2 inch drive socket, so that a conventional socket wrench drive could be used as the handle, or by a hex head suitable for actuation by a socket wrench with socket. Alternatively, the fixed portion could contain a hydraulic or pneumatic cylinder driven by a lever or pump, or an electric motor, depending on the form of the jack. Turning the crank (9), or whatever actuation is appropriate for hydraulic or pneumatic jacks, causes the movable portion (2) of the jack to be extended, exerting an outward force.
A conventional trailer jack (that is, a jack which is used to support trailer tongues when the trailer is detached from the towing vehicle) is an appropriate jack for use with the invention. By removal of the swivel wheel or jack plate and addition of the fittings described below, the trailer jack mechanism can form the basis of a flooring jack according to the teachings of the invention. Such jacks are available from a number of manufacturers, in mechanical, electric, pneumatic or hydraulic forms.
The JP214S0317 trailer jack manufactured by Fulton Performance Products of Mosinee, Wis., for example, can provide up to 2000 pounds of force and up to 14 inches of extension. Other models in the Magnum series by the same manufacturer can apply up to 7,000 pounds of force, and still other models have maximum extensions of 27 inches or more.
Some mechanical jacks have the additional benefit that they can exert a force both in extension and retraction, which a hydraulic, pneumatic, or ratchet-type jack could not do. Under some circumstances, this would add to the flexibility of use of the invention.
Two tabs (20) and (22) are attached to opposite ends of the fixed portion (1) of the jack, allowing the pressure foot (15) on push/pull rod (14) to be attached to either end of the jack, for reasons to be explained below. This multiple mounting allows great flexibility in the configuration of the flooring jack of the invention. If desired, a third tab could be added to the movable portion (2) of the jack, and a second foot and rod attached there.
Also attached to the fixed portion (1) of the jack is a fixed guide (3). FIG. 4 is an end view of the jack, showing how the guide (3) is attached to the fixed portion (1) by bolts (4) clamping the guide (3) around the jack. There is sufficient space within the generally U-shaped guide (3), above the upper bolt (4) to allow a board (8), preferably a "2×4" (conventionally 11/2 by 31/2), to be inserted.
A pivoting gripper (5) is attached to the movable end (2) of the jack. FIG. 5 shows a detail of the gripper (5). The gripper (5) is pivotally mounted to the movable end (2), and has a pair of gripping elements (6) for holding the board or brace (8). As can be seen in that figure, the gripper (5) can be made of two plates (24) joined by welded-in pins (6), as shown, or by bars or bolts. Alternatively, the gripper could be made in a U-shape as shown for the guide, and only a single pin (6) used as the second gripping element. The pins (6) are spaced apart sufficiently to allow a board (8), preferably a 2×4, to fit between the pins (6). The gripper (5) is free to pivot around pivot bolt (7), passing through the movable end (2) of the jack. By pivoting the gripper (5), the board (8) will be gripped between the pins (6). The pins may be cylindrical in cross-section, or square, rectangular, hexagonal, oval or any other shape desired.
Referring to FIGS. 1 and 2, the invention can be seen in use. One row of tongue-in-groove flooring (11) has been installed next to a wall (13). A second row of flooring (12) is placed next to the first row (11), and must be forced tightly against the first row, to cause the tongue to fit tightly and fully into the groove, so that the row (12) can be nailed in place.
The foot (15) on its push/pull rod (14), attached to tab (22) on the end of the fixed portion (1) furthest from the movable portion (2) to gain maximum extension, is placed in contact with the row of boards (12) to be forced into place. If the distance between the foot (15) and the end of the movable portion (2) is not enough to allow the movable portion (2) to reach the far wall (17), a long board (8), preferably a 2×4 or the like, is placed through the fixed guide (3) and the pivoting gripper (5), with its far end pressing against the far wall (17). If desired, a facing board (16) between the board (8) and the wall (17) can provide protection from marring the wall (17).
The gripper (5) is pivoted to grip the board (8), and the actuator (here crank (9) and handle (10)) is actuated to cause the movable portion (2) to extend, exerting force between the wall (17) and the foot (15), forcing the flooring (12) into place. With the flooring (12) held in place, nails can then be driven in conventional fashion.
With an 8 foot long 2×4, and a jack with 24" extension, the jack of the invention can thus be used across a room of nearly 10 feet in width. A ten- or twelve-foot board would allow use in even wider rooms, or a temporary brace could be installed on the floor to allow use of the tool over arbitrary distances.
As shown in FIG. 3, as the floor nears completion, the board (8) could be omitted and the movable portion (2) could press directly against the wall (17), perhaps with a facing board (16) between the wall (17) and the movable portion (2). By moving the foot (15) to the tab (20) on the end of the fixed portion (1) closest to the movable portion (2), the jack of the invention can be used up to the last few rows of flooring (30) and (31), right up against the wall (17).
The ability to move the foot (15) from tab (22) at one end of the fixed portion (1) to tab (20) at the other, and to reverse the foot (15) on its push/pull rod (14), plus the ability to use a 2×4 to extend the reach of the jack, gives the invention a flexibility of use unmatched in the prior art.
A single jack can thus be used to press every row of tongue-in-groove flooring into place right across a room. For the first rows of flooring (12) near wall (13), the jack is used at maximum extension, with the end of the board (8) near guide (3), and with the foot on tab (22). As the flooring progresses across the floor, the board (8) can be slid through guide (3), with gripper (5) progressively loosened and tightened. Within two or three feet of the far wall (17), the board can be dispensed with and the movable portion (2) placed against the wall. Alternatively, if a tab is provided on the movable portion, a foot and push/pull rod can be attached to the tab and the foot pressed against the wall (17). Finally, for the last few boards (30), (31), the foot (15) and push/pull rod (14) are reversed and moved to tab (20).
Although the invention has been described herein primarily as a flooring installation tool, it will be understood that the flexible arrangement of the invention allows its use in other applications, as well. With the board (8) vertically arranged, the foot (15) could be mounted to either tab (20) or (22), as needed, and used to support horizontal sheets of wallboard or paneling while they are screwed to studs.
Accordingly, it is to be understood that the embodiments of the invention herein described are merely illustrative of the application of the principles of the invention. References herein to details of the illustrated embodiments are not intended to limit the scope of the claims, which themselves recite those features regarded as essential to the invention. | A flooring tool for the installation or repair of wooden tongue and groove flooring. The tool has a jack for exerting linear force, with a fixed and a movable portion. A pivoting gripper is mounted upon the movable portion, and a guide is mounted upon the fixed portion, which allows a brace such as a 2×4 board to be inserted into the guide and gripper and held in place, extending the reach and usefulness of the tool. A foot upon a push-pull rod extends downwards from the fixed portion of the jack, and pushes upon the flooring planks. In a preferred embodiment, two attachment points are provided for the foot on its rod, at each end of the fixed portion, providing maximum flexibility. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is based on, and claims benefit of and priority to, U.S. Provisional Patent Application No. 61/273,850, filed on Aug. 8, 2009, the contents of which are hereby incorporated by reference in their entirety for all purposes. This application is also based on, and claims benefit of and priority to, U.S. patent application Ser. No. 12/852,924, filed on Aug. 9, 2010, the contents of which are hereby incorporated by reference in their entirety for all purposes. This application is based on, and claims benefit of and priority to, U.S. Provisional Patent Application No. 61/634,154, filed on Feb. 24, 2012, the contents of which are hereby incorporated by reference in their entirety for all purposes.
FIELD OF THE INVENTION
The present invention relates to a device to enhance the novelty associated with a beverage. More specifically, the invention relates to enhancing the entertainment of the process of removing a stopper from a pressurized bottle.
BACKGROUND
Champagne as we know it today—the original type of sparkling wine—was invented about 300 years ago, and the association of Champagne and other sparkling wines with celebrations has been strengthened over hundreds of years. For example, Napoleon's troops celebrated victories with sabrage, in which a bottle of Champagne is dramatically opened by striking the bottle with a saber or long knife. This strike not only removes the stopper, but also the top portion of the glass bottle's neck. Since the late 1800s, when a new boat or ship is officially launched to sea, a bottle of Champagne is smashed (i.e. dramatically opened) on the hull to “christen” the boat. Similarly, it is tradition for professional athletes (e.g. baseball players) to remove Champagne stoppers and shower their teammates with Champagne to celebrate important victories. Commercially, according to a recent study by The Nielsen Company™, there is a strong association of sales volume with official holidays (e.g. Christmas, New Years, Valentine's Day). In brief, sparkling wines have a long, rich and storied connection with celebrations and events (e.g. holidays, parties, personal milestones and victories) in the minds of customers, and stopper removal from the pressurized bottle is central to the excitement and celebration.
Although global sales of non-Champagne sparkling wines is growing (4% compound annual growth rate from 2003-2007), the industry sees a potential opportunity for further growth. While Champagne manufacturers typically enjoy strong brand identities and can command high prices per bottle, the non-Champagne sparkling wine market is relatively commoditized and driven by price. Non-Champagne sparkling wines only account for 45% of total market revenues even though almost 90% of all sparkling wine bottles that are sold are non-Champagne sparkling wines. Therefore, non-Champagne sparkling wine companies see long term potential in brand or product differentiation. Marketing, such as packaging innovation, was emphasized as a differentiation strategy in a September 2008 industry report (just-drinks/IWSR report, Global market review of sparkling wine—forecasts to 2012). According to a summary of the report: “ . . . some marketers argue that the absence of innovation in packaging is one of the reasons for the relative dearth of strong non-Champagne sparkling wine brands, and that the time is right to break that mould and invest in new formats.”
From a customer's perspective, because the ritual of drinking champagne is so tightly associated with celebrations and parties, it is common to buy sparkling wine for events even though the host and guests are not aficionados. There may be some interest while the stopper is removed from the sparkling wine bottle if the person opening the bottle seems inexperienced, then glasses are passed around and the party or event resumes. Therefore, there is a need for manufactures to develop an identity for their sparkling wines, and an opportunity may exist if the entertainment or celebratory spirit of an event were enhanced by packaging improvements. In particular, there is a need for packaging improvements that enhance the novelty of stopper removal and, thus, de-commoditize the non-Champagne sparkling wines.
Surprisingly, there has been little effort to enhance the novelty value of stopper removal from sparkling wines, even though the ritual has existed for centuries. In fact, most ideas are directed towards the notion that stopper removal is difficult or dangerous instead of an opportunity for safe entertainment. Furthermore, widespread customer adoption may be enhanced by customer control regarding whether a novelty item appears or not, as there may be a small subset of circumstances or settings in which a novelty item is not appropriate (e.g. when bottles must be opened in the commercial kitchen of a restaurant instead of in front of guests). In brief, there is a need for a simple, inexpensive, robust, effective and safe design that is amenable to industry adoption.
SUMMARY
Embodiments of the present invention provide a novelty item which may enhance the entertainment value associated with removing a stopper from a pressurized bottle. In one embodiment of the invention, a stopper and novelty item may be injected into a bottle of a beverage (e.g. sparkling wine, sparkling cider). The bottle may be pressurized (e.g. carbonated). Upon removal of the stopper, a novelty device may provide entertainment to the customer (e.g. host, honoree, attendee of an event). In another embodiment, a customer may determine whether a novelty item appears, based upon a selection of a method in which a stopper may be removed from a pressurized bottle.
With these and other advantages and features of embodiments that will become hereinafter apparent, embodiments may be more clearly understood by reference to the following detailed description, the appended claims and the drawings attached herein.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A-1B are side views of prior art stoppers.
FIGS. 2A-2B are side views of stoppers pursuant to some embodiments.
FIG. 3 is a side view of a novelty item pursuant to some embodiments.
FIG. 4 is a side view of a further novelty item pursuant to some embodiments.
FIG. 5 is a side view of a further novelty item pursuant to some embodiments.
FIG. 6 is a side view of a further novelty item pursuant to some embodiments.
FIG. 7 is a side view of a further novelty item pursuant to some embodiments.
FIG. 8 is a side view of a further novelty item pursuant to some embodiments.
DETAILED DESCRIPTION
A number of terms are used herein for clarity and ease of exposition. For example, the term “sparkling wine” is used to refer to a wine with significant levels of carbon dioxide in it. The carbon dioxide can result from a method of natural addition (e.g. fermentation) and/or from artificial addition. The term “champagne” is used to refer to a type of sparkling wine that is produced in the Champagne region of France. The term “non-champagne sparkling wine” is used to refer to a sparkling wine that is not produced in the Champagne region of France.
The term “beverage” is used to refer to one or more of the following: a sparkling wine (e.g. Champagne or a Non-Champagne sparkling wine) or other alcoholic beverage (e.g. beer), a sparkling cider, soda, water or other non-alcoholic drink or similar drinks.
The term “bottle” is used to refer to a container for holding a beverage and may be made of glass or some other material (e.g. plastic or other polymer, metal, etc.) and may have a geometry that is either traditional for sparkling wines or has a modified geometry.
The term “event” is used to refer to an occasion or holiday in which a beverage is provided. The occasion may (but does not need to be) associated with something that is significant or celebratory (e.g. birthday, retirement, Thanksgiving, Independence Day, New Year's Eve, Romantic event, Valentine's Day, graduation, corporate event, thank you, weddings, engagement, political victory, sports victory, anniversary, Mother's Day, Father's Day, new baby, new grandchild, Zodiac significance, new home or boat purchase, Sold home, new job, inauguration, Christmas, an accomplishment, good luck in future, etc.).
The term “customer” is used to refer to a person who purchases, drinks, and/or is involved in opening and/or providing a beverage to attendees at an event. Alternatively and/or additionally, the customer may also be an attendee at the event.
The term “stopper” is used to refer to a closure device for a container, such as a Champagne cork, and the term “bottom of stopper” refers to the surface of the stopper that faces the beverage. The term “side of the stopper” refers to the cylindrical surface of the stopper that contacts and/or rests adjacent to the glass surface of the inside of the neck of the bottle.
The term “novelty item” is used to refer to one or more items of entertainment value that may be released upon removal of the stopper from the bottle.
Referring first to FIG. 1A , an illustration of an existing or prior art stopper is shown. FIG. 1A is a schematic that shows an example of a commercially available plastic stopper 102 . The stopper 102 can be inserted into neck 106 of a bottle 104 by hand and, thus, is amenable for use even if a corking machine is not available. The dotted lines indicate a cylindrical, hollow region 112 inside the stopper 102 . The stopper 102 has a mushroom-shaped portion 114 and a neck 110 which is inserted into the bottle 104 .
FIG. 1B is a schematic showing an example of a commercially available stopper comprised of natural cork. The stopper 102 is typically inserted into the neck 106 of a bottle 104 with a corker machine. For example, the corker machine may squeeze the cork in a vice-like device, and then it may poke or press the cork into the bottle. In one embodiment, a stopper may be a hybrid in that it has an aesthetic natural cork outside region, and a hollow area inside of a rigid plastic sheath that preserves the geometry of the hollow area, in order to protect a novelty item during insertion and removal of the stopper from the bottle.
Embodiments of the present invention allow these types of stopper to be used with a novelty item to enhance enjoyment associated with a beverage. The schematics of FIG. 2 show how both styles of stopper may be inserted or configured to allow use with a novelty item pursuant to the present invention. For example, FIG. 2A is a schematic that shows one particular example of a stopper 202 according to the present invention. The mushroom-shaped portion 214 of the stopper 202 may be made of plastic or other material and may have a cylindrical, hollow region 212 formed inside the stopper 202 (e.g., extending from a bottom opening 208 of a neck 210 into the mushroom-shaped portion 214 ). A disk 216 formed of a material such as natural cork is rested proximate the bottom opening 208 by resting it on the circular rim of the stopper 202 , at the entrance to the cylindrical, hollow region 218 . The disk 216 is generally hockey puck-shaped and serves to seal a material or item (as discussed below) within the region 212 . The stopper 202 is inserted into the neck 206 of a bottle 204 as normal, although the disk 216 is placed into the bottle 204 with the disk 216 . In some embodiments, the disk 216 may be lightly or removably attached to the stopper 202 with a non-toxic adhesive or other material that allows the disk 216 to easily be inserted along with the stopper 202 while allowing the disk 216 to release from the stopper 202 when the stopper 202 is removed from the bottle 204 .
Referring now to FIG. 2B , a schematic is shown illustrating how a cork stopper 202 may be configured for use with embodiments of the present invention. The stopper 202 is comprised of a first portion that is natural cork (e.g. harvested from a Cork Oak tree), and a second portion of plastic 218 that has a cylindrical, hollow region denoted by dotted lines, and a third portion 216 that may be formed of a material such as natural cork and shaped like a hockey puck. The novelty item may be stored in the hollow region, and then the third portion 216 and second portion 218 may be inserted into the bottle 204 (by hand or machine). Then, the first portion may be inserted in a conventional manner via a corker machine. Upon cork removal, the novelty item may emerge from the hollow region.
The two styles of stopper design (shown in FIGS. 2A and 2B ) may be used with novelty items in a variety of different ways. Examples will now be described by reference to FIGS. 3-8 . The following examples are provided to clarify—but not limit the scope of—the invention.
In a first example, illustrated in FIG. 3 , confetti or other material may be ejected during stopper removal. In one example, a plastic champagne stopper 302 that is commercially available is employed. The stopper 302 has a hollow, cylindrical region 312 that is open at the stopper's bottom. Such a stopper may be inserted by hand if a corker for sparkling wine is not available. The stopper is placed upside down and the hollow region is filled with biodegradable/edible confetti 318 through the opening at the stopper bottom. A cover 316 is positioned on top of the opening of the hollow region.
The novelty item (including the stopper 302 , the confetti 318 , and the cover 316 ) is flipped right-side up and inserted into a sparkling wine bottle 304 during disgorgement. The confetti 318 is trapped in the hollow 312 of the stopper 302 , and is isolated from the beverage by the cover 316 . The wire cage and foil are attached to the sparkling wine and it is sold to a customer or distributor.
In one example, a stopper is at least partially comprised of polyethylene. A novelty item (e.g. confetti) is placed in a hollow region of the stopper. An adhered cover (e.g. aluminum foil) is adhered to the stopper using heat to melt the polyethylene and create a bond with the adhered cover. The stopper (containing the novelty item and adhered to the adhered cover) is then inserted into a bottle of sparkling wine during disgorgement. The adhered cover isolates the sparkling wine from the novelty item and vice-versa. Air pressure in the hollow region increases after insertion due to carbon dioxide that passes through the polyethylene walls.
The customer buys the bottle of sparkling wine for her New Year's Eve party. At midnight of New Year's Eve, she removes the stopper 402 and, as it flies into the air, the pressure on the outside of the adhered cover relative to the inside of the adhered cover sufficiently decreases (i.e. a substantial pressure gradient develops across the cover), leading to emergence of confetti that bursts through the adhered cover. Her guests are lightly showered with confetti 418 . Her guests are pleasantly surprised and the celebration is enhanced. The confetti is dry because the cover 416 prevented mixing of confetti 418 with sparkling wine. The removal of the stopper is illustrated in FIG. 4 .
In a further example, a single glass of sparkling wine is ordered and the bottle is opened by a waiter in a busy restaurant kitchen. It is decided that confetti should not emerge in this setting, so the stopper is conventionally or slowly removed into the hand of the waiter. No confetti emerges as the pressure change on the outside of the adhered cover relative to the inside of the adhered cover is too gradual. Later in the evening, a full bottle of sparkling wine is ordered at a table and the waiter decides that confetti should emerge to entertain the dining party. The waiter pops the stopper into the air at the table, lightly showering the dining party with confetti.
In a still further example, an illustrative but not limiting example where both ribbon and confetti is ejected. In the illustrative example (shown in FIG. 5 ), a hollow region 520 is filled with ribbons 518 . For example, the ribbons 518 may be folded back and forth in an accordion shape as they are placed into the hollow region 520 . The accordion folding provides a slight elastic compression to the ribbon to enhance their ejection from the stopper after the stopper 502 is ejected from the bottle 504 . Different shapes, colors and styles of confetti or ribbon may be placed within the hollow opening 520 and the novelty item may be selected based on the type of celebration. For example, for an independence day celebration, red, white and blue ribbons and star-shaped confetti may be used.
The disk 516 is rested on the ribbon-filled hollow region 520 . After the resultant novelty item is flipped right-side up, the novelty item is inserted into the sparkling wine bottle 504 . The bottle of sparkling wine is sold to a distributor and may then be purchased by the end customer. For example, the wine may be purchased from the distributor by a customer who is hosting an Independence Day party on July 4 th . After a town fireworks display is over, guests come over to the party and the customer removes the stopper 502 from the bottle 504 . As the stopper 502 is ejected, the ribbons and confetti 518 are ejected from the hollow region 520 as the disk 516 releases. Because the colored ribbons and stars represent elements of the United States flag, guests are excited and the celebratory spirit is enhanced. Then the sparkling wine is consumed.
A still further illustrative example will now be described by reference to FIGS. 6 and 7 where a parachute with a personalized message is ejected from a stopper of a bottle. In one embodiment, a hollow region 612 of a stopper 602 is filled with a parachute 618 that is tethered to the stopper 602 with string. The parachute 618 has a customized message 630 (shown in FIG. 6 as “Welcome Back, Class of '99, to Cornell!”) printed on it. A disk 616 (e.g., made from a material such as cork or plastic) is placed on the rim of the hollow region 612 , so that the parachute 618 is completely hidden on all sides by stopper or cork. After the resultant novelty item is flipped right-side up, the novelty item is inserted into the sparkling wine bottle 604 . The bottle of sparkling wine is sold to a distributor.
The customer may be an end user or a group or entity (e.g., such as a caterer). In a specific illustrative example, the customer may be a caterer for Cornell University and the customer buys the sparkling wine from the distributor for a 10 th year reunion dinner event. After a speech by the president, waiters at each table pop the stopper from the sparkling wine bottles and the corks fly into the air. The disk and stopper separate in the air, parachutes fall out of the hollow region, and the corks are safely floated down with the parachutes. The champagne is poured for the alumni at each table. The parachute may be produced with different messaging, including offers or the like. For example, a parachute 718 with a message 730 revealing whether a person has won a sweepstakes is shown in FIG. 7 .
A still further example will now be described by reference to FIG. 8 , where ejection of confetti 818 is shown in conjunction with a safety attachment 832 . Similar to the example shown above in conjunction with FIG. 3 and FIG. 4 , a stopper 802 is provided with confetti 818 or other material inside a hollow region 812 . In the example of FIG. 8 , a safety attachment 832 is incorporated into the novelty item for customers that are concerned about where the stopper 802 could land after flying out of the bottle 804 . Confetti 818 is added into the hollow region 812 of the stopper 802 , and one end of a wire is tethered to the back of the stopper. The wire is also tethered to the disk 816 . The other end of the wire is tethered to a rectangular piece of plastic 834 (or other suitable material). The rectangular plastic 834 is shaped like a cylindrical rod. It is flexible and longer—but not wider—than the neck of the bottle 804 . During disgorgement, the stopper 802 is inserted such that the confetti 818 is isolated between the stopper 802 and disk 816 . The rectangular piece of plastic 834 is temporarily bent to insert it into the bottle 804 , past the neck. Upon removal of the stopper 802 , the stopper 802 may only travel the length of the tether 832 (e.g., such as 6 inches or so), before the tethered rectangular piece 834 contacts the narrow bottle neck and prevents further travel. The confetti 818 is ejected from the stopper at this point. Because the wire or stiff string has a bending or buckling rigidity, the stopper 802 does not reverse course and strike the customer (i.e. stopper and wire do not behave like the elastic tether and rubber ball of a paddle ball toy). Finally, because the rectangular piece 834 is long but narrow, its movement does not cause sparkling wine to splash out of the bottle 804 .
Embodiments provide a number of advantages. For example, a beverage manufacturer or distributor may enjoy:
Greatly increased entertainment value with minimal or no cost increases will help distinguish a sparkling wine brand from its competitors, in the eyes of the customer. Many customers take pride in the events that they host or contribute to, and they will purchase accordingly. Long-term branding. For example, the invention provides a means for sparkling wine manufacturers to offer unique benefits, even over Champagne sparkling wine. Branding through third party association. Novelty item may be associated with third party (e.g. sweepstakes for a new sports car), which may increase the prestige of the sparkling wine.
A customer purchasing and using bottles incorporating the present invention may enjoy benefits such as increased entertainment and enjoyment at parties or other events.
Other participants (such as third parties) may further enjoy an opportunity to associate with a sparkling wine, which itself is strongly associated with fun and celebration.
As discussed above, a number of different stopper designs or configurations may be used in conjunction with the present invention. For example, in one embodiment, the stopper comprises 1) a mechanism to close the beverage inside the bottle 2 ) a mechanism to maintain appropriate air pressure in the bottle when closed, 3) a mechanism to remove the stopper, and 4) a region for storing a novelty item until the stopper is removed. In a further embodiment, the stopper may also have a mechanism to isolate the novelty item from the beverage so that the novelty item does not get wet.
In order to facilitate incorporation by the sparkling wine industry, in one embodiment, certain aspects of a commercially available stopper may be—but are not necessarily—incorporated into the design of the stopper.
Referring again to FIG. 2 , the stopper 202 may be comprised of one or more portions. In one embodiment, a hollow region 212 may exist for storage of the novelty item (e.g. confetti, ribbons, and/or a parachute). The novelty item may emerge from the hollow region (e.g. during cork removal and/or cork flight), and several possible means are envisioned for this emergence. In one embodiment, there may be a removable cover that isolates the novelty item from the sparkling wine and is positioned in any of a number of locations on the stopper. In a further embodiment, the cover may be positioned at or on the bottom of the stopper (i.e. parallel to and below the circular cross-section of the stopper). In another embodiment, the cover may be positioned on the cylindrical side of the stopper (i.e. adjacent to the inner surface of the glass bottleneck). For example:
Non-adhered cover: A cover 216 for the hollow region 212 that is not adhered or attached to the hollow region. The non-adhered cover may serve as a barrier that isolates the novelty item from sparkling wine or moisture and/or isolates the sparkling wine from the novelty item. The cover and hollow region separate during stopper removal or stopper flight, allowing for the emergence of the novelty item. In one example, a disk of cork, which sits between the sparkling wine and the novelty item/mushroom-shaped stopper component, is tethered by string to a sleeve that wraps behind the novelty item in the hollow region of the mushroom-shaped stopper component. After stopper removal and during flight, as the cork separates from the mushroom-shaped stopper component, the tether pulls the sleeve and novelty item out of the hollow region. Adhered cover: A cover 216 for the hollow region that is adhered to or attached to the hollow region by any means known in the art (e.g. via a hinge, an adhesive, a press fit, welding or butt welding, a heat seal that adheres the cover to the hollow region, shrink wrap, a combination of one or more attachment means, etc.). The adhered cover may serve as a barrier that isolates the novelty item from sparkling wine or moisture (e.g. aluminum foil, plastic, or other material) and/or isolates the sparkling wine from the novelty item. The cover may open due to one or more of several possible mechanisms (e.g. due to loss of compression from the bottle neck upon cork removal—such as a spring-loaded, hinged door; e.g. due to the force applied to the cork by the pressurized beverage—such as peeling a thin cover from the hollow region during cork removal because the cover may be more tightly tethered to the bottle; e.g. due to a customer, who peels off the cover to reveal an engagement ring after stopper removal). In one embodiment, the adhered cover becomes non-adhered (e.g. peels away) during stopper removal, allowing for emergence of a novelty item. In another embodiment, the adhered cover remains adhered but breaks, ruptures, and/or tears, allowing the novelty item to emerge from the hollow region. No cover: In one embodiment, the novelty item may be positioned between the stopper and the neck of the bottle.
In one embodiment, there may be a high air pressure in the hollow region relative to the ambient air pressure in a room at which an event may occur (e.g. 100 kPa). The high air pressure may be created and or maintained in the hollow region by any of several means known in the art. For example, plastic (e.g. polyethylene) is permeable to carbon dioxide, so the pressure inside a hollow region of a plastic stopper may increase after insertion into the sparkling wine bottle, due to carbon dioxide gas that enters from the high pressure sustained by the carbonated sparkling wine. In another example, the hollow region may be pressurized during manufacturing of the stopper and/or insertion of the stopper into the bottle. In a further embodiment, one or more of the following may be at least one contributor to emergence of the novelty item from the hollow region of the stopper:
a pressure difference between the hollow region inside the stopper and ambient air pressure the means or rate by which pressure changes outside the cover or disk upon removal from the high pressure carbonated environment (e.g. a stopper that is popped or propelled experiences a sharp pressure decrease upon removal, leading to emergence of the novelty item); (e.g. a stopper that is removed conventionally or gradually by restricting its flight and maintaining the stopper in the customer's hand or a hand-held towel experiences a more gradual pressure decrease upon removal, leading to no emergence of the novelty item).
In yet a further embodiment, if a stopper is configured such that the method of separation from the bottle determines whether a novelty item is revealed, the customer may determine whether confetti is appropriate at the point of opening a bottle instead of at a point of purchase. For example, if bottles must be opened in a commercial kitchen during preparation of a catered dinner (e.g. only a single glass is ordered), a waiter may decide that confetti is not to emerge. On the other hand, if an entire bottle is ordered at a table, the waiter may decide that confetti is appropriate.
In another embodiment, a hollow region may not be necessary. For example:
The novelty item remains embedded in or attached to the stopper 202 (e.g. light emitting diodes and/or a small audio speaker, as well as an electrical circuit). The novelty item may be surrounded by stopper portions on top and bottom, and by the glass bottleneck on the sides.
The stopper 202 may fasten to the bottle 204 in a wide variety of methods, as is known in the field. For example:
Hand-insertion: Synthetic or polymer-based stoppers (e.g. plastic—injected and/or extruded) may be inserted by hand. In one embodiment, these stoppers may have one or more outer rings or nubs that press against the inside of the bottle neck due to insertion under compression (e.g. plastic hand-inserted stopper 202 such as shown in FIG. 2A ). Substantially compressed stopper: Plugging the hole with a compressed material as shown in FIG. 2B . The material may be natural cork, synthetic polymer or plastic. bottle caps (e.g. crown cap) screw caps (e.g. Stelvin caps) plastic/glass seals (e.g. Vino-Seal) Zorks wire or wire cage a combination of two or more of the above
The stopper 202 may be fabricated from any of a variety of materials, as is known in the field. It is further envisioned that if the stopper has multiple portions or components (e.g. hollow cork and moisture barrier; e.g. such as shown in the embodiment of FIG. 2B ), each particular portion may be comprised of one or more materials.
For example, the stopper may comprise:
Natural cork, which may be harvested from the Cork Oak tree and may be agglomerated, not agglomerated, or a combination (e.g. 1+1 wine corks) Synthetic/alternative stoppers or corks
Synthetic polymer (e.g. plastic, polyethylene, polycarbonate, fluorinated ethylene-propylene (FEP), shrink wrap plastic) glass rubber metal (e.g. bottle cap, aluminum foil as a moisture barrier and/or cover, Teflon as a moisture barrier) etc.
Another natural material (e.g. another wood, wax, biodegradable material) Glues, resins, or other adhesives Substances to prevent adhesion A combination of two or more of the above
Materials for the stopper, one or more components of the stopper (e.g. hollow region, cover, disk, moisture barrier, stopper) may be selected or optimized for a variety of reasons or design criteria other than the novelty value. For example:
Oxygen permeability properties (e.g. layer of aluminum foil in the stopper) Carbon dioxide permeability properties (e.g. permeability of plastic to promote ejection of novelty item) Moisture barrier properties Mechanical strength (e.g. materials that tear or break, permitting emergence of a novelty item) Biodegradation Ability to withstand pressure in bottle Reproducibility Production and/or packaging considerations Ease of stopper removal or of safe stopper removal for customer Marketing concerns (e.g. materials that do not alter taste of beverage) Resemblance or lack of resemblance to a commercially available stopper Materials approved by an agency (e.g. United States Food and Drug Administration) Design approved by an agency (e.g. a group or organization associated with sparkling wine or Champagne)
The stopper 202 may be inserted into the bottle 204 in any of a variety of methods, as is known in the field, whether the method is currently commercially available or not. For example, the stopper may be inserted by hand, with the aide of a small machine (e.g. hand corker), or with the aide of a large machine (e.g. floor corker). Stopper insertion may occur at any point during or after the process of fabrication of the beverage (e.g. sparkling wine). For example:
insertion into the bottle during the disgorgement process of sparkling wine production. inserted into the bottle after the disgorgement process insertion during the process of first introducing the beverage into the bottle etc.
The novelty item provided within the hollow region 212 (or 218 ) may be any of a number of different items. For example, the novelty item may be:
Confetti (as shown in FIG. 3 , 4 or 8 ) Ribbons (as shown in FIG. 5 ) A parachute (as shown in FIGS. 6 and 7 ) Light stimulation (e.g. a light emitting diode that becomes lit or blinks in association with cork removal) Auditory stimulation
(e.g. a circuit and speakers that provide sound effects and/or an announcement) A small explosive charge (e.g. a party popper or party snaps; the novelty item may comprise the charge and/or the stopper may comprise the charge).
A message or note. (e.g., such as on a parachute as shown in FIGS. 6 and 7 , or on other materials) For example, a message that is associated with a sweepstakes. For example, a message that provides an entertaining fortune for the New Year. A propeller A combination of one or more of the above (e.g. ribbons and confetti—as shown in FIG. 5 )
The design of the novelty item may comprise one or more of the following:
Synthetic material (e.g. plastic) and/or natural material (e.g. wood-based paper) Edible (e.g. sugar-based confetti or cake sprinkles) or non-edible (e.g. metal) Biodegradable (e.g. biodegradable confetti or ribbons) or non-biodegradable Animal safe or not (e.g. rice ingestion can harm some birds) Color, luminescence (or not), shape, size, extent of reflectivity (e.g. glittery material) Toxic or non-toxic (e.g. US Food and Drug Administration grade materials) The behavior of the novelty item during cork removal and/or cork flight
The time duration of “floating” in the air before reaching the ground The behavior of the novelty item while in the air (e.g. twirling, spinning) How long it takes for a parachute to open and/or slow a stopper
Ease of cleanup Designs that enhance surprise, fun or entertainment A keepsake (e.g. an engagement ring, a necklace)
In one embodiment, the novelty item may be personalized or associated with a characteristic of the event and/or the customer (e.g. event host, honoree, and/or attendee).
For example:
Confetti that spells the phrase: “Happy New Year!” emerges upon opening a bottle on New Year's Eve. Ribbons printed with the word: “Congratulations!” burst out for a victory, graduation, accomplishment, or retirement. Red, white and blue ribbons plus white, star-shaped confetti to symbolize the United States flag is the novelty item associated with independence day parties (Refer to FIG. 5 ) In order to improve the spirits of children during Thanksgiving, who are not allowed to drink alcoholic beverages, sparkling cider is provided to the children. Multicolored confetti shaped like turkeys is released. Red confetti that are shaped like socks burst into the air upon opening a bottle in a locker room celebration of the Red Sox after they win the pennant. Images of a victorious presidential candidate may be printed onto confetti for an inauguration day celebration A parachute message greets attendees at an undergraduate alumni reunion (Refer to FIG. 6 ) A photo of a husband and wife are printed onto a parachute for an anniversary An audio speaker attached to the cork or bottle may ask: “Jane, will you marry me?” Furthermore, an engagement ring may be removed from the hollow of the stopper upon stopper removal. A note may provide information regarding a sweepstakes (e.g. “you won $1000) The novelty item may be rose petals, in association with Valentine's Day.
In one embodiment, the novelty item may be associated with a third-party. For example, a particular brand of sparkling wine may be associated with Lexus in order to enhance the perceived prestige of the sparkling wine and the perceived fun and excitement of driving a Lexus. A sweepstakes may be associated with the novelty item, in which the winner is notified via a message on the parachute of the stopper. An example is illustrated in FIG. 7 .
Pursuant to some embodiments, there is an increased pressure inside the closed (i.e. stoppered) bottle 204 relative to outside the bottle. This increased pressure may result from any of a variety of mechanisms as is known in the art. For example:
Carbon dioxide gas produced by yeast during fermentation (e.g. conditioning) Carbon dioxide gas injected into bottle or added to beverage in an artificial or non-biological process (e.g. addition of carbon dioxide to a liquid under pressure) Carbon dioxide gas produced by another organism and/or another chemical process (e.g. sodium bicarbonate mixed with citric acid) Another gas that accumulates in the bottle due to a biological or non-biological process (e.g. nitrogen gas mixed with Guinness Stout)
The stopper 202 may be removed according to any method, whether it is currently, commercially available or not (e.g. by hand, with the aide of champagne pliers or a machine, etc.). In one embodiment, the stopper 202 may be removed so that it flies or sails into the air, due to the increased pressure. Further, a novelty item (e.g. confetti, ribbons, parachute, etc.) may emerge from the stopper 202 during removal and/or flight of the stopper. In another embodiment, the stopper may be prevented from flying in the air (e.g. if novelty item is a valuable engagement ring), by a hand, towel, machine, etc.
In one embodiment, the initial velocity of the stopper 202 at the beginning of the flight of the stopper, may be decreased or increased to improve the entertainment. For example, one or more of the following methods may be employed:
Increase pressure in the bottle (e.g. more carbon dioxide) Decrease the cross-sectional area to which the force is applied to the stopper (e.g. by incorporating a collar that is not removed upon removal of stopper, which effectively narrows the bottle neck; e.g. narrow the bottle neck by increasing the thickness of glass in the bottle neck) Changing the shape or properties of the stopper (e.g. to change aerodynamical properties of stopper in the front and/or back).
In one embodiment, the emergence of the novelty item from the stopper 202 is carefully controlled. For example:
Confetti may be released through a narrowed opening at the bottom of the stopper so that it is released over a longer period of time. A spring may quickly eject a parachute from the back of the stopper to more effectively slow down the stopper. The bottom of the stopper may be sealed with a thin plastic layer to protect an engagement ring. The plastic layer may read “Yes, I will marry you!” and, upon removal, may reveal the engagement ring.
In one embodiment, it may be desirable to control or limit the possibility of flight for the stopper 202 . This may be useful in order to market enhanced safety alongside enhanced entertainment value. There are many inventions or mechanisms known in the art for controlling or limiting the flight of the stopper, and it is anticipated that one or more of these may be incorporated into the invention. Alternatively or additionally, an example of a mechanism to control the flight of the stopper is shown in FIG. 8 . A thin, plastic, cylindrically-shaped rod is tethered to the portions of the stopper via a connection (e.g. wire, plastic, etc.) that has a nontrivial compressive strength. The rod may be inserted into the bottle during insertion of the stopper. Upon stopper removal, the stopper initially flies into the air, but is stopped by the tethered rod, which is wider than the bottleneck. Because the tethering connection has a compressive strength, recoil (e.g. striking the customer who removes the stopper; splashing of the beverage) is prevented. The novelty item may emerge during or after the removal of the stopper. The rod may be pulled out of the bottle before pouring the beverage, or it may be poured around the rod, which does not substantially occlude the opening of the bottle neck. The stiffness of the rod, the length of the tethers, the means of adhering the components, and the compressive and tensile strength of the tethering connection may be selected to optimize length of flight of the stopper, lack of recoil, and/or enhanced release of the novelty item.
The present invention has been described in terms of several embodiments solely for the purpose of illustration. Persons skilled in the art will recognize from this description that the invention is not limited to the embodiments described, but may be practiced with modifications and alterations limited only by the spirit and scope of the appended claims. | Systems, methods, and means for providing a novelty item are provided. In some embodiments, a stopper comprises a body, having an inner chamber and a top portion, a novelty item disposed within said inner chamber, and a cover to open after said inner chamber is removed from a neck of a bottle. | 1 |
BACKGROUND OF THE INVENTION
I. Field of the Invention
The present invention relates generally to gear pumps, and more particularly, to gear pumps which are hydrostatically balanced.
II. Description of the Prior Art
In a gear pump, fluid is carried from an inlet port through a pumping chamber to an outlet port by a pair of meshed gears comprising a drive gear and a driven gear. Fluid enters the pumping chamber via filling a partial vacuum formed near the inlet port by unmeshing of the gear teeth. The fluid is carried in spaces formed between the gear teeth and the pumping chamber. The fluid is forced out of the pumping chamber and through the outlet port as the gears go back into mesh. Usually forces imposed upon the gears are substantially unbalanced. Included are forces due to increasing pressure of fluid moving around the pumping chamber toward the outlet port as well as any excess pressure formed by trapping or compression of fluid between meshing teeth. Also included are reaction forces proportional to drive torque imposed upon the driven gear by the drive gear. Because of these unbalanced forces, drive and driven gears of prior art gear pumps are generally provided with shafts supported by bearings on each side. Fabrication of such an assembly is expensive because of the accuracies required in providing necessary alignment of the various bearings, shafts and mechanical parts used in defining the pumping chambers.
It is known, as disclosed by Schwartz and Grafstern in Pictorial Handbook of Technical Devices, Chemical Publishing Co., Inc., New York, 1971, to provide pressure balancing fluid paths from the inlet port to first opposing chamber segments and the outlet port to second opposing chamber segments through first and second pairs of passages in the housing, respectively. However, such an arrangement does not completely balance the pressure imbalances and does not address the reaction forces at all. Accordingly, it is still necessary to utilize shafts and bearings to support the gears. Further, the first and second pairs of passages result in an enlarged housing that is more expensive to fabricate.
SUMMARY OF THE INVENTION
In a preferred embodiment, an improved gear pump comprising nominally balanced gears is shown. Shafts cantilevered from single bearings are utilized for supporting the gears. Nominal balance for each one of the gears is achieved by a plurality of coupling passages connecting diametrically opposed spaces formed between the teeth. The coupling passages form pressure balancing fluid paths which serve to eliminate pressure differences between the diametrically opposed spaces. However, torque reaction forces are still present and, as a result of partial space masking due to the meshing action of the gears, some pressure imbalance forces are also still present.
Therefore, in an alternative preferred embodiment, balancing pistons which act on spindles utilized for supporting gears in a balanced pump sub-assembly are shown. The spindles act upon bores formed within the gears to substantially oppose the remaining forces. This, in turn, permits the gears to be self guided within pumping chambers formed by a spacer plate and inner and outer side plates whereby no supporting shafts or bearings are utilized. The pistons are mounted in bores formed in the outer side plate. Each bore extends radially from its respective spindle in a direction parallel to the resultant of the sum of force imbalances on its respective gear.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects, features and advantages of the present invention will be apparent from the written description of the drawings, in which:
FIG. 1 is a cross-sectional view of a gear pump in accordance with the preferred embodiment of the invention;
FIG. 2 is a cross-sectional plan view of the gear pump taken along lines 2--2 of FIG. 1;
FIG. 3 is a cross-sectional plan view of the gear pump taken along lines 3--3 of FIG. 2;
FIG. 4A is a plan view of a gear of the pump in accordance with the preferred embodiment of the invention;
FIG. 4B is a side view of a shaft of the pump in accordance with the preferred embodiment of the invention;
FIG. 4C is a cross-sectional view along lines 4C--4C of FIG. 4A showing an assembled gear and shaft of the pump in accordance with the preferred embodiment of the invention;
FIG. 5 is a cross-sectional view of a balanced pump sub-assembly in accordance with the alternate preferred embodiment of the invention;
FIG. 6 is a cross-sectional plan view of the balanced pump sub-assembly taken along lines 6--6 of FIG. 5;
FIG. 7 is a view of the pair of gears shown in FIG. 5;
FIG. 8 is a cross-sectional plan view of the balanced pump sub-assembly taken along lines 8--8 of FIG. 6; and
FIG. 9 is a cross-sectional view of a spindle of the balanced pump sub-assembly in accordance with the alternate preferred embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As best shown in FIGS. 1, 2 and 3, a gear pump 10 in accordance with the preferred embodiment of the invention includes a housing assembly formed of pump housing 14 and shell member 16. Gear pump 10 is particularly adapted for use in supplying pressurized fluid for use to a power steering system (not shown). Although gear pump 10 is particularly suited for power steering systems, principles of the invention may be applied to any gear pump. Pump housing 14 has a generally cylindrical portion 18 defining a cavity for accepting a pump sub-assembly 20. A reservoir of fluid is formed in a chamber 22 defined by shell member 16 and pump housing 14. Shell member 16 is secured to pump housing 14 by bolts 24 and is sealed by O-ring 26 mounted in groove 28 formed in flange 30 extending from pump housing 14.
Gear pump 10 also comprises an induction motor 32 which is mounted within chamber 22. The induction motor 32 includes stator 34 and rotor 36. Stator 34 is mounted between annular lip 38 of shell member 16 and flange 30 of pump housing 14. Rotor 36 is pressed or shrunk fit upon drive shaft 40 which turns drive gear 42 and then driven gear 44.
Pump sub-assembly 20 further includes counter shaft 58 and pumping chambers 46 formed between inner side plate 48, spacer plate 50 and outer side plate 52. Pumping chambers 46 are formed in the shape of a pair of overlapped circles and extend axially through the spacer plate 50 between inner and outer side plates 48 and 52, respectively. As best shown in FIG. 2, pumping chambers 46 are formed to accommodate gears 42 and 44 with minimal leakage either around tips 69 of teeth 68 or gear faces 96. Gears 42 and 44 are pressed or shrunk fit upon small ends 54 and 56 of drive shaft 40 and counter shaft 58, respectively.
Axial bores 60 and 62 are formed in inner side plate 48 to provide journal bearings for drive shaft 40 and counter shaft 58. Performance of the journal bearings may be enhanced via the inclusion of hydrodynamic fluid pumping grooves (not shown) formed according to principles explained under a general subject entitled Pumping Bearings in Gas Film Lubrication by W. A. Gross published by Wiley. (Although the general subject matter of that book is gas film lubrication, much of the matter discussed therein assumes isothermal, non-compressible fluid and is applicable to liquid fluids as well.) Drive shaft 40 and counter shaft 58, and therefore gears 42 and 44, respectively, are located with reference to pumping chamber 46 via inner side plate 48 and spacer plate 50 being held in precise alignment by dowel pins 55.
As particularly shown in FIGS. 2 and 3, fluid flows from chamber 22 to mirror imaged inlet ports 64a and 64b formed in inner and outer side plates 48 and 52, respectively, via axial inlet passage 66 and adjacent spaces formed between teeth 68 of gears 42 and 44 as they unmesh. The incoming fluid is induced to fill these spaces via a partial vacuum created therein by the unmeshing of gears 42 and 44. It is then carried around the pumping chamber 46 until the spaces are adjacent to outlet ports 70a and 70b formed in inner and outer side plates 48 and 52, respectively. As the fluid completes its passage around the pumping chamber 46 it becomes pressurized fluid via being forced through axial outlet passage 72 into a pressure chamber 74 as the spaces collapse due to meshing of gears 42 and 44. The pressurized fluid in the pressure chamber 74 maintains the pump sub-assembly 20 in axial position against shoulder 78 of pump housing 14. Pressure chamber 74 is formed between outer side plate 52 and cover plate 76 which is retained by retaining ring 80 and sealed by O-ring 82. Finally, the pressurized fluid is delivered to a host hydraulic system (not shown) via annular channel 84 and output port 86.
With reference now to FIGS. 4A, 4B and 4C, gears 42 and 44 are each formed with an even number of teeth 68 wherebetween radially directed bores 88 connect lands 90 to bores 92. Radially directed bores 88 are formed in oppositely aligned pairs which are spaced in the axial direction. Small ends 54 and 56 of drive shaft 40 and counter shaft 45, respectively, are each formed with axially spaced circumferential grooves 94 located such that each is substantially in axial alignment with one pair of radially directed bores 88 when gears 42 and 44, respectively, are pressed or shrunk fit thereupon. (Although circumferential grooves are depicted as being formed in small ends 54 and 56 of drive shaft 40 and counter shaft 45, respectively, they could also be formed within bores 92.) As shown in FIG. 4C, opposite ones of the spaces between teeth 68 are thus interconnected to form pressure balancing fluid paths and nominally hydrostatically balance gears 42 and 44 during operation of gear pump 10.
Other details of pump sub-assembly 20 which are necessary but not shown include a suitably vented reservoir cap, pump output fitting, return fitting (i.e., to chamber 22) and electrical connection from an inverter (also not shown) to induction motor 32. In particular, the electrical connection from the inverter to induction motor 32 must be accomplished in a manner that protects both the general environment and the inverter from unacceptable levels of electromagnetic interference.
In operation, the rotor 36 of inductor motor 32 turns drive shaft 40, drive gear 42 and driven gear 44. Radially directed forces from the drive motor, drive torque reaction forces and/or residual forces still present as a result of partial space masking due to the meshing action of gears 42 and 44, are supported by the journal bearings. Gears 42 and 44 (as well as drive and counter shafts 40 and 58, respectively, and rotor 36) are located axially by selected clearance between gear faces 96 and inner and outer side plates 48 and 52, respectively. In any case, lower valued radial gear forces achieved via the above described nominal hydrostatic balance of gears 42 and 44 permits cantilevered shafts with single journal bearings to be used in gear pump 10. The resulting device is highly efficient and compact, and particularly suited for use with a power steering system of electric automobiles. With this arrangement, it is neither necessary to provide the outer side plate 52 to close tolerances nor to closely align it to the rest of the pump sub-assembly 20, thereby reducing the relative expense of gear pump 10.
As shown in FIGS. 5, 6, 7, 8 and 9, a pump sub-assembly 100 in accordance with the alternate preferred embodiment of the invention comprises drive and driven gears 102 and 104, respectively, that rotate upon first and second spindles 106a and 106b, respectively. As best shown in FIGS. 5 and 7, each of the gears 102 and 104 have an enlarged center bore 108. An even number of teeth 110 extend around the outer circumference of gears 102 and 104. Similarly to the hydraulic connection provided by oppositely aligned pairs of radially directed bores 88 shown in FIG. 4A, lands 112 are connected with center bore 108. In pump sub-assembly 100 it is usually convenient to use a larger number of teeth 110 having stub profile and longer axial length. As described above, each pair of holes 114 are in alignment with one of an equal number of grooves 116 formed on outer surface 118 of inner sleeve 120 or 122 to form connecting passages between diametrically opposed pairs of lands 112. Thus, fluid pressure present in diametrically opposed spaces thereabove is substantially equal, thus effecting nominal hydrostatic balance for gears 102 and 104.
The above described remaining imbalance forces on gears 102 and 104 are supported via internal bores 124 of inner sleeves 120 and 122 bearing upon bearing mounted semi-spherical sleeves 126 which revolve about first and second spindles 106a and 106b, respectively. The spindles 106a and 106b are housed in axial bores 130a and 130b, respectively, of outer side plate 132. The spindles 106a and 106b have first semi-spherical surfaces 134 on an opposite end for support within a diametrically reduced section 136 of axial bores 130a and 130b. Spindles 106a and 106b also have second semi-spherical surfaces 138 for engagement with first and second balancing pistons 140a and 140b as discussed below. As shown in FIGS. 5 and 8, spindle 106a is positioned axially by end 150 of drive shaft 148 which, in turn, is positioned axially by retaining ring 152 and washer 154 between inner side plate 156 and cylindrical extension 158 of pump housing 160, respectively. Inner sleeve 120 (and therefore drive gear 102) is driven rotationally from rectangular hole 144 by drive tang 146 extending from drive shaft 148. As shown in FIG. 5, driven gear 104 and spindle 106b are positioned axially by spacing rod 162 mounted in bore 164 of inner side plate 156.
As best shown in FIGS. 6, 7, and 8, the remaining imbalance forces due to torque and the masking of fluid pressure by the meshing of teeth 110 may also be countered by first and second balancing pistons 140a and 140b, respectively, mounted in first and second pressure cylinder bores 166a and 166b, respectively. Pressure cylinder bores 166a and 166b extend radially across respective axial bore 130a or 130b. Pressure cylinder bores 166a and 166b, and therefore first and second balancing pistons 140a and 140b, are in line with second semi-spherical surfaces 138 of spindles 106a and 106b. A passage 168 conveys pressurized fluid from pressure chamber 74 to end 170 of first pressure cylinder bore 166a. Similarly, a second passage 168 (not shown) conveys pressurized fluid from pressure chamber 74 to 172 of second pressure cylinder bore 166b. Thus, pistons 140a and 140b engage semi-spherical surfaces 138 with forces proportional to pump output pressure. Accordingly, the pressure cylinder bores 166a and 166b, and respective ones of pistons 140a and 140b, are positioned parallel but in directions opposed to the respective resultant forces of the sums of the reaction forces due to the masking of fluid pressure by the meshing of the teeth 110. Further, following the procedure outlined below, the diametral size of each of pressure cylinder bores 166a and 166b, and respective pistons 140a and 140b, is chosen so as to optimally balance the resultant forces.
As shown in FIG. 7, normalized reaction forces (i.e., force divided by pump output pressure) on each gear due to torque applied by drive gear 102 to driven gear 104 are calculated as follows:
F.sub.rf /P=(q/r.sub.p)/2=al[in.sup.2 ]
where F rf is reaction force, P is developed pressure, q is volumetric displacement per radian, r p is pitch radius, 2 represents the fact that only half the total drive torque is transmitted to driven gear 104, a is the gear addendum and 1 is gear length.
The average normalized radial force imbalance occurs due to the meshing of gear teeth. The meshing gears mask pressure from a portion of the tooth center line-to-tooth center line interval and is nominally calculated as follows:
F.sub.rfi /P=(πr.sub.p 1)/(2N)[in.sup.2 ]
where F rf1 is radial force imbalance and N is number of teeth on either gear. If the gears have normal proportions, a=(2r p )/N and
F.sub.rf1 /P=(πa1)/4[in.sup.2 ] or f.sub.xf1 =(π/4)F.sub.rf [in.sup.2 ].
Resultants R a and R b are then calculated and are generally in the positions shown in FIG. 7. Resultants R a and R b are the forces that must be applied by the pistons 140a and 140b in order to counteract the imbalance forces F xf and F rf1 . The first and second pressure cylinder bores 166a and 166b, respectively, are then disposed parallel to their respective resultant R a or R b as shown. The diametral size of each of pressure cylinder bores 166a and 166b, and respective pistons 140a and 140b, is chosen such that their areas counteract the product of the respective resultants and the lever length ratio computed by the distance between first semi-spherical surface 134 and second semi-spherical surface 138 divided by the distance between first semi-spherical surface 134 and semi-spherical sleeve 126.
As best shown in FIG. 8, pistons 140a and 140b have grooves 174 to permit fluid to extend therearound for lateral balance within pressure cylinder bores 166a and 166b, respectively. Pressure cylinder bores 166a and 166b intersect each other at a point 176 which is vented to low fluid pressure through first axial bore 130a. Thus, second piston 140b is not required to have grooves 174 on its non-pressurized end 178.
As shown in an exaggerated manner in FIG. 7, smooth rotational operation of gears 102 and 104 is aided by lead-in ramps 180 formed in the leading edges of each of the overlapped circles which define pumping chambers 46' used in pump sub-assembly 100. With the arrangement described above, it is not necessary to produce or align either of side plates 132 or 156 to close tolerances, thereby reducing the relative expense of pump sub-assembly 100.
FIG. 9 shows an enlarged partially cross-sectional veiw of spindle 106a or 106b. Semi-spherical sleeve 126 is supported for rotation by needle bearing 182. | A gear pump is hydrostatically balanced by providing a plurality of coupling passages connecting diametrically opposed spaces formed between teeth of the gears. The coupling passages form pressure balancing fluid paths which serve to eliminate pressure differences between the diametrically opposed spaces. Additionally disclosed are balancing pistons which act on spindles supporting the gears. The balancing pistons are aligned to oppose resultant of the remaining forces. Additionally discloses is an eductor motor positioned within a fluid reservoir and connected for driving the gears. | 5 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of Invention
[0002] The present invention relates generally to data communication systems. More particularly, the present invention relates to systems and methods for providing customer defined data in records generated using remote, wireless transceiver devices.
[0003] 2. Description of the Related Art
[0004] The demand for data communication services is growing at an explosive rate. Much of the increased demand is due to the fact that as the use of computing devices becomes more prevalent, the need for creating networks of computing devices such that resources may be shared between the computing devices also increases. Typically, wired networks such as local area networks (LANS) are used to enable computing devices within an organization to communicate with each other.
[0005] Many organizations which use LANs also use wireless devices that communicate with the LANs. The use of wireless devices such as personal digital assistants (PDAs) and laptop computers enables users of the devices to use the devices in different locations substantially without losing access to computing resources on a LAN. For example, a user of a laptop computer within an organization may use his or her laptop at a first location within a building, then move to a second location within the building. Although the user may physically connect the laptop computer to the LAN using a wired connection at the first and second locations, while the user is “roaming,” or moving, the laptop computer is a roaming device which may not be physically wired to the LAN.
[0006] In order to enable roaming devices to communicate with a LAN, access points are often used. Access points are arranged to interface with conventional, i.e., wired, LANs in order to effectively create a wireless LAN. FIG. 1 is a diagrammatic representation of a wireless LAN which includes access points. A wireless LAN 100 includes a wired LAN 104 which, as will be appreciated by those skilled in the art, generally includes computing devices such as clients and servers which are networked together in a wired network. LAN 104 is in communication with a router 108 across a connection 112 .
[0007] Router 108 is connected to a plurality of access points 116 through wired connections 120 . Access points 116 are effectively fixed devices which enable a roaming device 124 to communicate with LAN 104 . That is, access pints 116 are fixed in desired locations associated with LAN 104 to support communications between roaming device 124 and LAN 104 . Access points 116 may be an Aironet series access points available from Cisco Technology, Inc., of San Jose, Calif., although it should be understood that access points may be substantially any suitable access points.
[0008] Each access point 116 has a corresponding communications range 128 . As shown, roaming device 124 is in communications range 128 a of access point 116 a . In general, the coverage associated with communications range 128 a may vary widely. By way of example, communications range 128 a may extend to approximately 150 feet in any direction from access point 116 a . That is, communications range 128 a may have a radius of approximately 150 feet as measured from access point 116 a.
[0009] Roaming device 124 communicates with access point 116 a in a wireless manner, i.e., using wireless communications, when roaming device 124 is in communications range 128 a . Typically, roaming device 124 includes a wireless networking card which enables roaming device 123 to communicate with access points 116 . When roaming device 124 is in communications range 128 a and attempts to access a resource within LAN 104 , e.g., a database within LAN 104 , roaming device 124 uses wireless communications to communicate with access point 116 a which, in turn, communicates with LAN 104 through wired connections 102 a , 104 and router 108 .
[0010] When roaming device 124 is in communications range 128 a , access point 116 a may create at least one record, e.g., a start record and a stop record, which provides details relating to the existence of roaming device 124 within communications range 128 a . Information in a record generally includes identifying information pertaining to roaming device 124 , a port which roaming device 124 is using for communications over, a type of service used by roaming device 124 , a date and a time associated with the existence of roaming device 124 within communications range 128 a , e.g., a start time in a start record or an end time in a stop record, and a serial number of access point 116 a . The information that is included in a record is generally defined by the manufacturer of access point 116 a . If roaming device 124 moves out of communications range 128 a and into communications range 128 b , access point 116 b will create a record pertaining to the existence of roaming device 124 in communications range 128 b.
[0011] A service provider, e.g., an organization that administers and maintains wireless LAN 100 , often provides detailed record information to users who use wireless LAN 100 . That is, a user of roaming device 124 is generally provided with accounting information that enables both the user and the service provider to track the activities of roaming device 124 . For example, information relating to the amount of time roaming device 124 spends in communications range 128 a may be provided to the user in his or her monthly usage bill. Such information may be used by the service provider to track the usage of access points 116 within LAN 100 . Typically, the detailed record information is obtained by reading start records and end records created by access points 116 .
[0012] Although information stored in start records and end records generally enables a service provider to provide a user with a detailed record of billing information, the information stored in the start records and end records is generally not customizable. In other words, a service provider is not able to configure the records created by access points 116 , as the information stored in the records is typically determined by the manufacturer of access points 116 . While a post-processing filter may be used by the service provider to eliminate some information that is stored in the records from being included in the billing information provided to the user, the service provider is not able to choose the information that is stored in the records.
[0013] In addition to not being able to select the information that is stored in the records maintained by access points 116 , a service provider is also not able to add static information that is to be stored in the records. By way of example, although information pertaining to the physical location of access point 116 a may be useful to a user of roaming device 124 , such information is not included in the records generated by access point 116 a . As such, while billing or usage information provided to the user of roaming device 124 may include a serial number of access point 116 a , the location of access point 116 a is not available to the user. Information pertaining to the location of access points 116 may be useful to the user, for example, for use in determining whether charges for using access points 116 are consistent with the locations of access points 116 .
[0014] Therefore, what is needed are a method and an apparatus which allow a service provider to specify information which is to be stored in records generated and maintained by an access point. Specifically, what is desired is a system which enables a service provider to provide static information such as access point location information which may be included in records created by an access point.
SUMMARY OF THE INVENTION
[0015] The present invention relates to adding static information to records generated by a wireless transceiver device such as an access point. According to one aspect of the present invention, a wireless transceiver device that interfaces with a roaming device includes computer code for causing input information to be accepted from an external source, and a memory that includes an editable field and is arranged to store data. The computer code for causing the input information to be accepted from the source causes the input information to be stored in the editable field. The wireless transceiver device also includes computer code for causing a record associated with the roaming device to be generated. The record includes the input information stored in the editable field and the data, and the computer code for causing the record to be generated also causes the record to be stored on the memory.
[0016] In one embodiment, the wireless transceiver device also includes computer code for obtaining the data when the roaming device is in communication with the wireless transceiver device. In such an embodiment, the computer code for causing the record to be generated includes computer code for causing the record to be generated when the roaming device registers with the wireless transceiver device.
[0017] An access point or, more generally, a remote wireless transceiver device, which is configured to enable a service provider who maintains the access point to specify information to be included in accounting or usage records generated using the access point allows a desired level of detail to be included in the records. For example, adding static information such as a location of the access point to accounting records enables the activities of a roaming device that utilizes the access point to be tracked more efficiently.
[0018] According to another aspect of the present invention, a transceiver device that interfaces with a first device includes means for accepting input information from an external source, means for storing data, and means for generating a record associated with the first device. The means for storing the data further includes means for storing the input information in an editable field when the means for accepting the input information provides the input information to the editable field. The record includes the input information that is stored in the editable field. In general, the means for storing the data also includes means for storing the record.
[0019] According to still another aspect of the present invention, a method for utilizing a transceiver device that has a communications range includes receiving static information into an editable field stored in memory associated with the transceiver device, and storing the static information into the editable field. When an indication that a roaming device is within the communications range is received, a record that includes information associated with the roaming device is created. Once the record is created, the static information is added to the record, and the record is stored in the database. In one embodiment, the static information is received from a source external to the transceiver device. In another embodiment the static information is information associated with a location of the transceiver device.
[0020] In accordance with yet another aspect of the present invention, a method of configuring a transceiver device includes positioning the transceiver device at a desired location, determining an address of the desired location, and storing the address in a memory field associated with the transceiver device. In one embodiment, the address includes at least one of a longitude, a latitude, and an altitude of the desired location. In another embodiment, the address is determined using a global positioning system receiver.
[0021] These and other advantages of the present invention will become apparent upon reading the following detailed descriptions and studying the various figures of the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] The invention may best be understood by reference to the following description taken in conjunction with the accompanying drawings in which:
[0023] FIG. 1 is a diagrammatic representation of a system which includes access points.
[0024] FIG. 2 is a diagrammatic representation of an access point in accordance with an embodiment of the present invention.
[0025] FIG. 3 is a process flow diagram which illustrates the steps associated with configuring an access point in accordance with an embodiment of the present invention.
[0026] FIG. 4 is a process flow diagram which illustrates the steps associated with the functioning of an access point with respect to establishing when a roaming device is within range of the access point in accordance with an embodiment of the present invention.
[0027] FIG. 5 is a diagrammatic representation of an access point with an editable field which is used to store indices in accordance with another embodiment of the present invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0028] When a customer or user of a wireless local area network (LAN) roams within the wireless LAN, he or she may roam into and out of the communications range of different access points within the wireless LAN. Typically, at least one accounting or usage record which reflects a length of time a user has spent within range of a particular access point is generated. While information such as the amount of time spent within range of a particular access point is typically included in accounting records, information pertaining to physical locations of particular access points is generally not available in the accounting records. Such information, i.e., information pertaining to a physical location of a particular access point, is generally not available for inclusion in accounting records due to the fact that the information recorded by an access point is generally predetermined by a manufacturer and does not include location information. In addition, the access point is not configured to enable a service provider who obtains the access point may to add information which is to be included in the recorded information.
[0029] An access point with a text editor which allows a service provider, i.e., an owner of a LAN which includes the access point, to specify information that is to be included in accounting records provides the service provider with the ability to effectively store static information within the access point. Static information is generally information which is not updated during the operation of the access point, until an individual such as a system administrator chooses to overwrite the static information with new static information. Such static information, e.g., information pertaining to the physical location of the access point, may be stored in an editable, non-volatile text field in a database or memory associated with the access point. Allowing the service provider to provide static information to be stored on an access point enables the service provider to effectively customize accounting records, or usage records, associated with the access point. Customizing accounting records to specify a location of an access point that is accessed by a roaming device enables the owner of the roaming device to more clearly ascertain which resources, e.g., access points, he or she has made use of.
[0030] With reference to FIG. 2 , the configuration of an access point, or a remote wireless transceiver device, which accepts text input, e.g., data defined by a service provider, will be described in accordance with an embodiment of the present invention. When an access point 202 is to be set up by an administrator 206 of a LAN that includes access point 202 , administrator 206 may use a locator device 210 to establish a physical location of access point 202 . By way of example, administrator 206 may use locator device 210 to establish a longitude, a latitude, and an altitude of access point 202 . Locator device 210 may be substantially any suitable device, e.g., a global positioning system (GPS) receiver, which enables a location of access point 202 to be identified.
[0031] Access point 202 includes a text editor 214 which is arranged to accept input or information from administrator 206 . In one embodiment, text editor 214 may be a software program, or computer code, which is arranged to be executed by a processor 230 and to accept text input from administrator 206 through the use of an input device such as a keypad or keyboard associated with access point 202 (not shown). The information entered using text editor 214 may be location information obtained through the use of locator device 210 . It should be appreciated, however, that any suitable information may be inputted into text editor 214 . Suitable information may include, but is not limited to, information which may be used by access point 202 to determine the types of information which are to be included in records generated by record generator 218 of access point 202 , and information which specifies an asset number assigned to access point 202 .
[0032] Information that is provided to text editor 214 by administrator 206 is stored as an editable, non-volatile text field 222 in a database 226 within access point 226 . It should be appreciated that database 226 is generally a computer memory and may be, in one embodiment, a hard disk, a computer-readable tape, a floppy disk, or a CD-ROM. In addition to storing editable, non-volatile text field 222 , database 226 typically also stores other information. For instance, information used by record generator 218 to generate accounting records pertaining to the usage of access point 202 is typically obtained from database 226 where the information is stored. Such information may include a user name, a date, and a time which are substantially automatically recorded when a user of a roaming device (not shown) comes into range of access point 226 .
[0033] A record generated by record generator 218 which may be executed by processor 230 may be a start record which is generated when a roaming device registers with access point 202 , or an end record which is generated when the roaming device is deregistered from access point 202 . Such records generally include the information, or at least some representation of the information, contained within editable, non-volatile text field 222 , as well as other information stored in database 226 . Records generated by record generator 218 are typically also stored in database 226 until the records are needed, e.g., by a billing system of a service provider. As will be understood by those skilled in the art, record generator 218 is typically a software program, or computer code, which causes records to be created.
[0034] In general, when a service provider first obtains an access point, the service provider configures the access point for operation. That is, the service provider or, more specifically, a system administrator associated with the service provider, sets up the access point. FIG. 3 is a process flow diagram which illustrates the steps associated with configuring an access point in accordance with an embodiment of the present invention. A process 300 begins at step 304 in which the access point is placed at or positioned in a desired location. Once the access point is properly positioned, power may be provided to the access point in step 308 .
[0035] After power has been provided to the access point, the coordinates of the location at which the access point is positioned are identified in step 312 . The coordinates of the location may be identified using substantially any suitable method. By way of example, the longitude, latitude, and altitude coordinates of the location of the access point may be identified using a GPS receiver at the location at which the access point is positioned.
[0036] Once the coordinates of the location of the access point are identified, the system administrator may manually enter the coordinates into the editable text field associated with the access point in step 316 . As previously mentioned, the system administrator may input the coordinates as text into the editable text field using a text editor associated with the access point. When the coordinates are entered into the editable text field, the coordinates effectively remain static in the editable text field until the system administrator manually overwrites the coordinates, e.g., to provide a new set of coordinates when the access point is to be repositioned in a different location. After the coordinates are entered into the editable text field, the process of configuring the access point is completed.
[0037] When a roaming device comes into range of an access point which has been configured, e.g., as described in FIG. 3 , the roaming device and the access point communicate in order to establish that the roaming device is in range of the access point. FIG. 4 is a process flow diagram which illustrates the steps associated with the functioning of an access point with respect to establishing when a roaming device is within range of the access point in accordance with an embodiment of the present invention. A process 400 of establishing that a roaming device is within the communications range of an access point begins at step 404 in which a roaming device registers itself with the access point. Typically, when a roaming device enters the communications range of an access point, the roaming device and the access point automatically communicate such that the presence of the roaming device in the communications range is effectively acknowledged, as will be appreciated by those skilled in the art. That is, remote authentication is performed between the roaming device and the access point using substantially any suitable authentication protocol.
[0038] Once the roaming device is registered with the access point, the access point creates a start record for the roaming device in step 408 . The start record is generally a data record that includes information that is automatically obtained from the roaming device when the roaming device registers with the access point. Such information may include, but is not limited to, an identifier associated with the roaming device, a port number of the access point on which communications from the roaming device are received, and a time at which the roaming device registered with the access point. In the described embodiment, the start record includes information from the editable text field, e.g. the coordinates of the access point which were entered into the editable text field when the access point was configured.
[0039] After the start record is created, the access point periodically determines if the roaming device is within its communications range in step 412 . In other words, the access point periodically attempts to confirm that the roaming device is within its communications range by polling the roaming device using substantially any suitable method, as will be understood by those skilled in the art. A determination is made in step 416 regarding whether the roaming device is in the communications range of the access point. If it is determined that the roaming device is in range of the access point, then the roaming device is allowed to continue to access a network associated with the access point through the access point, and process flow returns to step 412 in which the access point periodically checks to determine if the roaming device is within range of the access point.
[0040] Alternatively, if it is determined in step 416 that the roaming device is not in range of the access point, then the indication is that the roaming device has been moved, e.g., into range of a different access point. Accordingly, in step 420 , the access point deregisters the roaming device using substantially any suitable method. Once the access point deregisters the roaming device, or otherwise acknowledges that the roaming device is no longer within range of the access point, the access point creates a stop record for the roaming device in step 424 . A stop record generally includes, but is not limited to including, identifying information for the roaming device, and an indication of how long the roaming device was within range of the access point, e.g., the time at which the roaming device was deregistered. In the described embodiment, the stop record also includes information read from the editable text field. After the stop record is created, the process of establishing when a roaming device is within the communications range of the access point is completed.
[0041] As mentioned above, in addition to storing location or identifying information in an editable field of an access point, other types of information may generally be stored in the editable field. Other types of information that may be stored include, but are not limited to, indices or identifiers which may be used to specify the contents of an accounting record. FIG. 5 is a diagrammatic representation of an access point with an editable field which is used to store indices or identifiers in accordance with an embodiment of the present invention. An access point 502 is generally similar to access point 202 of FIG. 2 , and includes a record generator 518 , a database 526 , and an editable, non-volatile field 522 which is stored within database 526 . In the described embodiment, field 522 includes indices 540 which may be input into field 522 using a text editor such as text editor 214 of FIG. 2 .
[0042] Indices 540 are used by record generator 518 to index into a table 544 which is effectively a list of information types which access point 502 may obtain from a device (not shown) within its communications range. Indices 540 are provided by a system administrator to specify the contents or entries 552 of a record 548 generated and stored by record generator 518 in database 526 or, more generally, memory associated with access point 502 . Although all information listed in table 544 may be included in record 548 which may then be filtered by an accounting system (not shown) to identified desired information, the use of indices 540 may substantially eliminate the need to filter information contained in record 548 .
[0043] As shown, index 540 a may be used by record generator 518 to specify that a device identifier (ID) for a roaming device is to be included in record 548 . Index 540 b specifies that a time, e.g., a time at which a roaming device registers with access point 502 or a time at which access point 502 deregisters the roaming device, is to be included in record 548 , while index 540 c specifies that a port number which the roaming device is using to communicate with access point 502 . Indices 540 are effectively matched against entries 552 in table 544 which, typically, correspond to types of information which access point is arranged to acquire from a roaming device. Once indices 540 are matched against entries 552 , information corresponding to entries 552 may be stored in record 548 .
[0044] Although only a few embodiments of the present invention have been described, it should be understood that the present invention may be embodied in many other specific forms without departing from the spirit or the scope of the present invention. By way of example, substantially any static information, or information which is provided to an access point by a system administrator or other individual, may be inputted into an editable, non-volatile text field. Further, the editable, non-volatile field may be a field other than a text field. That is, the non-volatile field which accepts information from the system administrator may be configured to accept non-text information.
[0045] While an editable, non-volatile field has been described as being stored on a database that is part of an access point, such a field may instead be stored on a database that is in communication with the access point. For instance, an access point may be coupled to an external database, or a database that is not encompassed within the access point. Information provided by a system administrator may be stored on the external database, which is accessed by the access point when records are created.
[0046] An editable, non-volatile field such as an editable, non-volatile text field which is associated with an access point enables the static information stored in the field to be maintained even when power to the access point is lost. In one embodiment, in lieu of using a non-volatile field to store static information, a volatile field may be used without departing from the spirit or the scope of the present invention. When a volatile field is used to store static information such as location information within an access point, in the event that power to the access point is lost, an administrator will generally need to re-enter the static information into the volatile field once power is regained.
[0047] In addition to configuring an access point when the access point is initially set up, e.g., purchased and positioned in a desired location, it should be appreciated that the access point may be configured or reconfigured at substantially any time. For example, when the access point is to be relocated to a new location, a system administrator may input the longitude, latitude, and altitude of the new location into the editable field.
[0048] The location of an access point has generally been described as having coordinates, e.g., a longitude, a latitude, and an altitude. As described above, when location information is provided into an editable field associated with an access point, the longitude, the latitude, and the altitude of the location is inputted. It should be appreciated, however, that in lieu of identifying the coordinates of the location at which the access point is positioned, the location may be identified in a variety of other ways. For instance, the location may be identified by specifying an address at which the access point is located, e.g., a street address and a room number. Alternatively, the location may be identified by a name, e.g., “location 12 ,” which may be an identifier for a particular location. By way of example, “location 12 ” may be the identifier for a particular longitude, latitude, and altitude at which the access point is located.
[0049] The present invention may generally be applied to any suitable device. That is, an editable text field which is suitable for storing static information such as a location may be implemented with respect to devices other than access points. For instance, wireless transceiver devices other than access points may be configured include editable text fields. A router may also be configured to include an editable text field. An editable text fields in a router may be used to store location information such that the wiring closet in which the router is located may be identified in an accounting record associated with the router. Such location information may be useful, for example, to identifying a router that may be failing to support dial-in procedures.
[0050] In general, the steps associated with methods of configuring an access point and establishing when a roaming device is within range of the access point may be widely varied. Steps may be added, removed, altered, or reordered without departing from the spirit or the scope of the present invention. For example, in lieu of inputting coordinates of a location into an editable text field when an access point is being configured, an address may instead be inputted. Also, while an access point has been described as periodically determining if a roaming device is within range of the access point in step 412 of FIG. 4 , the access point may instead make a determination that the roaming device is no longer in range of the access point when no signal has been received from the roaming device after a predetermined amount of time has elapsed without departing from the spirit or the scope of the present invention. Therefore, the present examples are to be considered as illustrative and not restrictive, and the invention is not to be limited to the details given herein, but may be modified within the scope of the appended claims. | Methods and apparatus for adding static information to records generated by an access point are disclosed. According to one aspect of the present invention, a wireless transceiver device that interfaces with a roaming device includes computer code for causing input information to be accepted from an external source, and a memory that includes an editable field and is arranged to store data. The computer code for causing the input information to be accepted from the source causes the input information to be stored in the editable field. The wireless transceiver device also includes computer code for causing a record associated with the roaming device to be generated. The record includes the input information stored in the editable field and the data, and the computer code for causing the record to be generated also causes the record to be stored on the memory. | 7 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application claims priority from U.S. Patent Application Ser. No. 60/868,763, filed Nov. 6, 2006, the entire subject matter of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of Invention
[0003] The present invention relates to a vehicle lamp assembly, and to vehicle bulb shield components, and more specifically to a vehicle bulb shield component of a lamp assembly which includes a thermoionic device to improve the energy efficiency of the vehicle headlamp assembly.
[0004] 2. Background of the Related Art
[0005] Thermoionic devices and thermal diodes employ the combination of two semiconductor materials to convert heat into electricity. Recent advances in such devices have realized levels of efficient heat to electrical power conversion as high as 18%, at temperatures between 200 and 300 degrees centigrade. These devices are based on two semiconductors fixed to opposite sides of a barrier layer. One of the semiconductor materials is doped so it is electron rich while the other is depleted of electrons. When installed into an environment where the electron rich semiconductor is a warmer temperature than the temperature of the electron depleted semiconductor, an electrical power flow can be produced. The amount of electrical power produced is related to the difference in temperature between the two semiconductors. A wire lead from each semiconductor serves as the conduit for this electrical power.
[0006] Vehicle headlamps are generally comprised of a light source or bulb, an optical reflector, a lens, and in some instances a bulb shield. The purpose of the bulb shield is to control the headlamp light output. To control headlamp output, the bulb shield is placed in close proximity to the headlamp light bulb and therefore reaches temperatures between 200 ad 300 degrees centigrade. Convection of heat from the headlamp light bulb, and bulb shield produces areas of elevated temperature in the headlamp assembly, primarily the areas directly above the light bulb and shield.
[0007] The present application provides an improved vehicle headlamp assembly which incorporates thermoionic devices into headlamp assemblies to allow the headlamp to function with a significantly lower draw on the vehicle's electrical power system, which reduced electrical power requirement improves the overall energy efficiency of the vehicle headlamp assembly and the vehicle.
BRIEF SUMMARY OF THE INVENTION
[0008] The present application discloses an improved vehicle headlamp assembly having a thermoionic device to convert heat from the headlamp light bulb into electrical energy to assist with the operation of the headlamp light bulb. Thermoionic energy conversion is a method of converting heat energy directly into electrical energy by thermoionic emission. In the process, electrons are thermoionically emitted from the surface of the metal bulb shield during heating of the metal bulb shield as a result of, and during, operation of the vehicle headlamp light bulb.
[0009] In the present improved headlamp assembly, the thermoionic device consists of an electrode connected to a heat source which is the hot interior of the bulb shield, a second electrode connected to a heat sink at the cooler exterior of the bulb shield is separated from the first electrode by an intervening space, leads connect the electrodes to the electrical power system, all within the substantially enclosed vehicle headlamp assembly of the optical reflector and lens, which may be sealed in a conventional manner. The heat source supplies heat at a sufficiently high temperature to one electrode, the emitter, from which electrons are thermionically evaporated into the space. The electrons move through this space toward the other electrode, the collector, which is kept at a lower temperature near the heat sink. There the electrons condense and return to the hot electrode via the electrical leads and the electrical load or electrical power system, connected between the emitter and the collector. The flow of electrons through the electrical load is sustained by the temperature difference between the electrodes.
[0010] Thermoionic devices as described in U.S. Pat. No. 6,906,449 can be attached to, or formed as an integral part of, the headlamp assembly in several ways. The devices can be attached by high temperature thermal adhesives, physical mounting features, or press fit in a form matching or cooperating with that of the interior or exterior of various headlamp assembly components. As the bulb shield absorbs heat from the light bulb, or bulb shield, the thermoionic device begins to produce electric current. The electrical power coming from the thermoionic devices are routed back to the light bulb, directly or through electrical drive circuitry to other electrical vehicle systems.
[0011] The electrical power produced by the thermal diodes or thermoionic devices is generated from otherwise wasted heat, producing a novel headlamp that improves vehicle energy efficiency.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 shows a schematic side view of the improved thermoionic headlamp assembly of the present application;
[0013] FIG. 2 shows a schematic front view of an alternate headlamp assembly design;
[0014] FIG. 3 shows a schematic front view of a bulb shield of the type used within the improved headlamp assembly of the present application; and
[0015] FIG. 4 shows a schematic side view of an alternate bulb shield having alternate thermoionic devices within the headlamp assembly of the present application.
DETAILED DESCRIPTION OF THE INVENTION
[0016] The present application provides an improved vehicle headlamp assembly of the type generally used in vehicle headlamps to control photometric output. As shown in the attached Figures, the depicted vehicle headlamp assembly 20 employs lens member 12 sealed to a mating reflector member 7 about the periphery thereof. Reflector 7 is in the shape of a paraboloidal reflector intersected by planes forming top, bottom, left and right side walls, of which only top wall 16 and bottom wall 18 are illustrated in FIG. 1 . The inner surface of reflector 7 is provided with a coating C of a suitable light-reflecting material such as aluminum or silver. Located in the region of focus of the paraboloidal rear reflecting surface 21 formed by reflector 7 is a hermetically sealed electric vehicle lamp bulb or light bulb 1 which is connected by lead-in conductors 9 a and 9 b to contacts (not shown) within the vehicle electrical power system 22 , in a manner well known in the art. The lamp bulb 1 may be of a conventional halogen or other configuration.
[0017] In accordance with the present improved device, the vehicle headlamp assembly 20 is also provided with a light and heat intercepting bulb shield 2 to partially envelop the lamp bulb 1 in a particular manner. During operation of the lamp forward and rearwardly projecting light rays or photometric output from the lamp bulb 1 , are/is emitted toward the bulb shield 2 and reflector 7 . By reason of its physical location and physical dimensions the depicted bulb shield 2 is thereby positioned to intercept substantially all forwardly projected light rays while still enabling the rearwardly projected light rays not intercepted to reach the reflector 7 . FIGS. 1 and 2 illustrate side and front views of the location of components within the headlamp assembly 20 . The light bulb 1 is mounted to the optical reflector 7 at the rear reflecting surface 21 . The bulb shield 2 is installed in front of the light bulb by an attachment fixture 6 molded into the optical reflector. Wire leads 9 a and 9 b provide the required drive voltage for the light bulb 1 from the vehicle's electrical power system, shown schematically at reference number 22 . The bulb shield 2 is connected to the attachment fixture 6 by a foot feature 3 which can be attached by employing either press-fit, screw, or locking mechanical features.
[0018] Attached to the bulb shield 2 is a thermal diode or thermoionic device 4 . Devices of this type, and of the type shown in U.S. Pat. Nos. 6,906,449 and 7,109,408, are available from ENECO, Inc., Salt Lake City, Utah. As shown in FIGS. 1 and 2 , a secondary thermal diode or thermoionic device 5 is also affixed to the optical reflector 7 above or otherwise away from the light bulb/bulb shield components at a cooler position within the assembly, at least with respect to the temperature at the position of the thermoionic device 4 , which is at a hot location. Wire leads 8 b from the thermal diode or thermoionic device are routed out of the headlamp assembly to an electrical drive circuit 23 which forms part of the vehicle electrical power system 22 . The locations of the thermoionic devices 4 reaches elevated temperatures as high as 200 degrees Celsius as a result of heat convection from the bulb shield and light bulb. Wire leads 8 a and 8 b deliver the electricity produced by devices 4 , 5 to the electrical drive circuit 23 . The thermoionic chips 4 , 5 give off a lot of current but at a low voltage, so multiple devices or chips may be attached to a mounting plate to obtain a higher voltage. Thus, for example, if one device 4 , 5 or chip were to provide 80 millivolts at 3 amps, 8 chips might be used to obtain 6.4 volts.
[0019] FIGS. 1-4 depict bulb shields with thermal diodes or thermoionic devices 4 , 5 installed in various locations. The bulb shield 2 design is affected by the optical requirements of the lamp bulb 1 , mechanical strength requirements of the headlamp assembly, and cosmetic considerations. Therefore each bulb shield 2 will reach different temperatures at different locations. For example, in FIG. 1 the bulb shield 2 is shown with a thermal diode, or thermoionic device installed on the top portion of the bulb shield. This area will generally be the hottest area of the bulb shield 2 due to convection of heat from the light bulb 1 . However, bulb shields 2 are commonly coated with high temperature light absorbing black paint on their interior surface (not illustrated). This paint serves to absorb light emitted by the light bulb 1 . Were this light not absorbed, the reflection of it may reach the optical reflector 7 and alter the headlamp beam or photometric output in an undesirable way. The absorption of light from the light bulb 1 by the black paint or coating causes the areas of the bulb shield which are coated to reach higher temperatures than the unpainted areas.
[0020] FIG. 3 depicts a design situation where the black paint is applied only to the interior front portion of the bulb shield. This condition will cause the front of the bulb shield 2 to reach higher temperatures than other areas. Therefore, the thermal diode or thermoionic device 4 is affixed to the front portion of the bulb shield 2 .
[0021] FIG. 3 also depicts thermal diodes or thermoionic devices 4 applied to portions of the bulb shield 2 above the light bulb 1 location, indicating a situation where a combination of multiple thermal diodes or thermoionic devices 4 are installed. Wire leads 8 a and 8 b deliver the electrical power produced by the thermal diodes or thermoionic devices 4 to the electrical drive circuit 23 .
[0022] FIG. 4 depicts a bulb shield 2 with a thermoionic device 4 formed into a shape to match that of the bulb shield 2 . This method of construction serves to maximize the surface area of the thermoionic device without affecting the bulb shield 2 geometry. Additionally, a heat sink 10 , may be applied to the exterior of device 4 to improve the variance in temperature between the two semiconductors (i.e. the bulb facing semiconductor of device 4 is warmer than the semiconductor in contact with the heat sink). Such heat sink devices are available from CeramTec AG, in Princeton, N.J. See their website information concerning products: http://wwww.ceramtec.com/index/products/ceramcool_ceramic_heatsink/01113.0123.0453,0740.p hp. A similar heat sink could also be applied to the thermoionic device 5 , as shown in FIGS. 1 and 2 , internally or externally of the reflector 7 . The function of the heat sink is to increase the differential in temperature between the thermoionic device positioned at the hot location and the thermoionic device positioned at the cold location within the device. While the use of a heat sink is optional, its use increases the efficiency of the thermoionic devices or chips to a useful level.
[0023] While different embodiments of the invention have been described in detail here, it will be appreciated by those of skill in the art that various modifications and alternatives to the embodiments could be developed in light of the overall teachings of the disclosure. Accordingly, the particular devices and arrangements are illustrative only and are not limiting as to the scope of the invention which is to be given the full breadth of any and all equivalents thereof. | An improved vehicle lamp assembly having a vehicle light bulb and a bulb shield which absorbs heat generated by the vehicle light bulb. The bulb shield is interconnected with a thermoionic device for producing electric current generated as a result of the heat generation and absorption. The thermoionic device redirects the electric current produced to the vehicle lamp assembly or another vehicle electrical system. | 5 |
DESCRIPTION
[0001] The present invention concerns a support (hereinafter “beam”) for a track guided high speed vehicle, especially a magnetically levitated railroad, wherein the beam is supported at intervals on piers and on the outer side of said beam, functional elements are placed for the guidance of a vehicle, in accord with the generic concept of claim 1.
[0002] DE 41 15 935 C2, for example, has made known a travel-way construction for magnetically levitated railroads, in which fittings for the guidance of a vehicle are placed on a beam and directed toward the inside. The beam itself is U-shaped, when seen in cross-section. The beam is supported on piers, whereby, for the better acceptance of the beam, holders are provided, in which the said beams lie. The holders extend themselves around the U-shaped cross-section on the outside and thus stabilize the beam. The holders themselves are in turn supported by bearing surfaces on the piers. Disadvantageous in the case of such a travel-way is, that the beam, exhibits a relatively great degree of elasticity due to the open beam construction. Although the equipment placements must be very exactly aligned with each other in order to guide a vehicle, with this design of the travel-way, the satisfactory stabilization of the beam and the positioning of the equipment components is only possible with the aid of the holder.
[0003] DE 38 25 508 C1 discloses a travel-way which is comprised of a hollow, essentially T-shaped beam. On the outer sides of the upper flanges of the beam are placed functional elements for the guidance of a magnetically levitated vehicle. The beam itself is again supported on individual piers, whereby the piers possess holders, which grip the bases of the beam. Disadvantageous in the case of a beam of this type, is that although the design permits far more precise positioning of the functional elements to one another than is required by the a travel-way constructed according to DE 41 15 935, in spite of this, still the beam shows a poor torsion rigidity.
[0004] This comes into effect particularly during extreme high speeds of a vehicle, such as, for instance, in excess of 500 km./h, often exhibiting itself as a rough ride of a vehicle.
[0005] It is disadvantageous in the case of the above described embodiments of the state of the technology, that especially during the said high speeds of modern magnetically levitated vehicles, the flow resistance of the beams and their supporting means prevent a smooth run of a vehicle. Especially the holders of the beams or the piers, on which the beams are supported, cause periodic buffets on a vehicle, when the pressurized air encounters their resistance.
[0006] Thus the purpose of the invention is, to furnish, by means of an appropriate adaptation of the beam to high speed magnetically levitated railroads, a smooth and comfortable run of magnetically levitated vehicles.
[0007] This purpose is achieved by the features of the claims 1 or 12.
[0008] If the outer surface of the beam is constructed with concern given to a favorable airflow in relation to a vehicle, wherein—as seen in the longitudinal direction of the beam—no cross-sectional changes occur, and the formation of the beam predominately covers the piers in relation to a vehicle, then, in an advantageous and inventive manner, the effect is that the air pushed away from a vehicle can uniformly escape and thus a smooth run of a vehicle is assured. By means of the invented design of the beam, at the same time, a uniform, comfortable run of a vehicle is effected. Because of the fact, that the cross-section of the beam predominately remains unchanged, no repeated flow impacts act against a vehicle. A uniform airflow is also brought about, in that, in relation to a vehicle, the piers are covered and thus the support of the beam does not interfere with the escape of the pressurized air from a vehicle. This also contributes to a uniform run of a vehicle.
[0009] It is particularly of advantage, if the beam is so designed, that it possesses a lower flange, which covers the piers or shields them in a favorable manner in respect to vehicle slipstream. When this is done, because of the shaping of the basic form of the beam, the airflow at any one pier is immediately slides by without impingement. In addition, or alternatively, it can be advantageous if the beam is equipped with a console essentially covering the pier and which console is shaped or located to be air-flow friendly.
[0010] It is of advantage, if the beam has at least one opening for the inspection of its hollow space. In this way, the accessibility and the monitoring of the reliability of the beam will be easier during the regularly scheduled inspections which are to be carried out. Beyond this, personnel can enter through the opening into the interior of the beam to lay and maintain supply lines and/or communication lines which are dependent on or independent of vehicle operation. By means of these uses of the hollow space of the beam, a very economical laying of lines can be carried out. Also, lines, which have nothing to do with the operation of a vehicle, can be laid along the now available stretch of the magnetically levitated railroad and thereby take advantage of a very economical kind of line running.
[0011] Thus it can also be avoided, that separate beams need be installed, for example for communication lines or that these lines must be laid separately underground.
[0012] Advantageously, the beam has an airflow friendly clearance space for the reception of the guide elements, which the functional units of a vehicle occupy. This clearance space is designed to follow the beam in the flange area, without essential cross-sectional changing. In this way, the escape flow of vehicle displaced air is positively influenced. Moreover, essentially, an I-beam is created which possesses a particularly high stability, torsion resistance and load capacity.
[0013] The placement of the beam on the piers is advantageously done in such a manner, that the bearing elements are placed on the lower flange of the beam. The bearing elements as well as the piers are, in this way, covered over by means of the outwardly extending lower flange which covers said piers. Airflow impacts are avoided by this measure.
[0014] A particularly advantageous mode of construction of the beams is found therein, in that the beam is made of concrete, in particular out of precast concrete components. By this means, a very precise and error-free manufacture of the beam can be carried out in a fabrication plant. For instance, in this way, a dependency on weather conditions during the manufacture of the beam, such as site manufacture would entail, is avoided.
[0015] In order to attain a particularly high degree of stability of the beam, it is of advantage if the lower flange is broader than the upper flange. For the rigidity of the beam, it is of advantage if it has a bulkhead or haunches. The cross-sectional shape of the beam can, with this advantage, be made to smaller measurements but still maintain the same structural rigidity. If haunches are placed in the beam, then, besides the increased rigidity, also a simple anchorage-possibility for tensioning members is created.
[0016] Where curving is concerned, the beam advantageously forms a spatial curve, in that the beam is supported about a rotation of its longitudinal axis, and by means of a lengthening and/or a shortening of the cantilever arm, a radius is formed.
[0017] A further possibility for making the curve, would be that the upper flange of the beam is constructed in a rotation about its longitudinal axis and by means of extending or shortening the cantilever arm, a radius is formed.
[0018] A spatial curve of the beam can also be constructed, in that fastening consoles of the functional elements in the run of the longitudinal axis of the beam are offset vertically and by the lengthening or the shortening of the fastening consoles a radius is built.
[0019] It has been determined in an advantageous and inventive manner, that the curve adjustment of the beam can be carried out essentially quicker, more economically and more exactly, if the beam components in the arc are shorter and thereby need less individual adjustment, than is advantageous in the straight-line components, which have fewer supports. The shorter beams can then, while maintaining their rigidity, consume less material, be built less expensively than the straight components which have a greater distance between supports.
[0020] If the hollow space of the beam is open at the bottom, wherein the lower flanges are of two parts, than a less heavy and more economical beam is made, which frequently can fulfill the required demands in regard to structural rigidity.
[0021] If the hollow space possesses bulkheads, then the beam is additionally stiffened.
[0022] Further advantages are to be acquired from the embodiments depicted in the following. There is shown in:
[0023] [0023]FIG. 1 a cross-section through an invented beam,
[0024] [0024]FIG. 2 a cross-section through an invented canted beam,
[0025] [0025]FIG. 3 another cross-section through an invented beam,
[0026] [0026]FIG. 4 a cross-section through an invented beam for a curved section,
[0027] [0027]FIG. 5 a further cross section through an invented beam for a curved section,
[0028] [0028]FIG. 6 a perspective view of an invented beam, and
[0029] [0029]FIG. 7 a perspective view of a further invented beam.
[0030] In FIG. 1 a cross-section of an invented beam 1 is presented. The beam 1 is made from a prefab concrete component and has an upper flange 2 and a lower flange 3 . The upper flange and lower flanges 2 and 3 are bound together by means of webs 4 and so form a hollow space 5 . For entry of inspection personnel or for the laying of lines in the hollow space 5 , an opening 10 is provided. One opening 10 per beam usually suffices, but preferably a plurality of openings 10 is favorable for simple accessibility to the hollow space 5 . If a large number of openings 10 are provided, then this can lead to a clear reduction in the use of concrete and thus also lead to a more favorable manufacturing cost for the beam 1 .
[0031] The webs 4 , in relation to the upper flange 2 and the lower flange 3 , are placed to make a trapezoidal cross-section. This arrangement brings about a still better support of the beam 1 as well as contributing more to its stiffness than is achieved in comparison with the state of the technology. The beam, by means of this formation, is extremely torsion resistant and assures thereby a reliable and disturbance free operation of a vehicle.
[0032] Between the upper flange 2 and the lower flange 3 , a clearance space 6 is allowed, in which the guide components of the magnetically levitated vehicle can find their place. For the guidance of a vehicle, the functional elements 7 serve, which are to be found on both sides of the upper flange. The functional elements 7 are engaged by a vehicle, where by the under, part of a vehicle is to be found in the area of the stator in the clearance space 6 . By means of a non-changing cross-section of the beam 1 , which is not disturbed by holders or bearing means, operation of a vehicle is made possible having favorable airflow and no repetitive impacts.
[0033] The beam 1 is, in the present embodiment, placed on bearing legs 8 which are on the piers 9 . The piers 9 are, in this arrangement, in the area of the airflow-relevant zone completely covered by the lower flange 3 of the beam 1 and thus generate no disturbance of the pressurized air from the passage of a vehicle.
[0034] The invented shaping of the beam 1 provides, besides the above mentioned advantages, a particularly high transverse structural rigidity, and thus assures a comfortable and reliable operation of a vehicle. Especially because of the layout, in which the lower flange 3 is constructed broader than the upper flange 2 , a particularly good stability of the beam 1 is assured. The consumption of material for the invented beam 1 , which is high in comparison to that of the state of the technology, is compensated for by the increased favorable airflow characteristics and the energy saving in operation of the vehicle which the beam 1 allows.
[0035] By means of this shaping, in particular that of the lower flange 3 , of which the upper side is sharply inclined, the entire surface of the beam 1 is so designed that a favorable handling of the slipstream of air away from the beam 1 is attained. The piers 9 are likewise subject to airflow but scarcely affect the dissipation of the escape of the pressurized air.
[0036] In FIG. 2, another beam 1 is depicted, which is similar to the beam 1 of FIG. 1. This beam 1 is presented in a canted position, which means, that for a bow-shaped travel-way, the two functional elements 7 display different heights. In this case, the curve travel for the magnetically levitated vehicle is enabled to be faster and more comfortable. The canting is so brought about, that the beam 1 is not seated directly on the load bearings 8 , but, that load bearing consoles 12 are supplied, which create the banked position. The piers 9 , as well as the thereupon located load bearings 8 , thus act together direct with the load bearing consoles 12 and only indirectly with the beam 1 , This has the advantage that the manufacture of the piers 9 as well as the load bearings 8 can be done without being dependent as to whether the travel-way is to run in straight line or be bow shaped. The compensation of the banked incline is done exclusively by the load bearing clamps 12 . Alternatively, in any case provision may be made, that the piers 8 themselves take on the inclination and therewith the support of the beam 1 in the curves as well as in the straight section runs. In FIG. 3 is shown a beam 1 , altered in contrast to the FIGS. 1, 2. Also, in this case the banking of the beam for a bow shaped run is shown. The beam 1 comprises, essentially a rectangular cross-section with extending upper and lower flanges, respectively 2 and 3 . Also in this case, care has been taken as to the shaping of the beam 1 , so that repeated air impacts during the passage of a magnetically levitated vehicle above are avoided.
[0037] The air, which is pressurized by a vehicle in its slipstream is conducted away over the shape of the beam 1 , which allows a comfortable travel situation on a vehicle. For a shaping of the beam 1 of this kind, especially in the area of its webs 4 , the clearance area 6 for a vehicle is especially well adapted to airflow. The gap between a vehicle and the beam 1 is, as far as elevation is concerned, substantially even, so that even in this aspect a guidance of a vehicle employing streamline technology has been made possible.
[0038] [0038]FIG. 4 shows a differently designed beam 1 . This beam 1 is clearly lower than the previously depicted beams. This becomes possible, in that the support space, in which this beam 1 was constructed was chosen to be essentially shorter. Experience has shown, that beam design, especially for travel in the curves, for which, in the case of beam 1 , i.e. the fastening consoles of the function elements 7 must be adjusted, can be done essentially more favorably, if the individual beams 1 are made shorter. The adjustment on the individual beams is carried out essentially faster and with more exactness due to the shorter chord, which the beam 1 assumes in the travel-way bend. In addition, because of the shorter spacing intervals of the supports, to maintain an equal rigidity of the beam 1 a lesser height of the beam 1 is necessary, whereby, however, construction material is saved, when compared with that used in the case of the straight sections.
[0039] While the beam, in accord with FIG. 4, corresponds in its fundamental shape to the beams of the FIGS. 1 and 2, in a further embodiment shown in FIG. 5, the beam has the basic outline of FIG. 3. It presents the idea, that the beams in the FIGS. 3 and 5 can be combined with one another, and that the beams of the FIGS. 1 or 2 and 4 can be combined with one another. The clearance way is, however, essentially the same for a vehicle, so that similar airflow relationships on the part of a vehicle exist both in straight line travel and in curve travel.
[0040] In the FIGS. 6 and 7, are perspective presentations of beams 1 in accord with the invention, which are designed to be especially airflow favorable. In FIG. 6 a beam 1 is shown, which, over its entire length, the cross-section shape does not change. Air pressure impacts on a vehicle by cross-sectional changes of the beam 1 are thus avoided. The loading consoles 12 in FIG. 7 are placed, in this case, deep on the beam 1 , in order, that the airflow generated by the vehicle passing above can easily escape, that is to say, cannot act further upon a vehicle.
[0041] The beam 1 can also be so constructed, that its hollow space is left open at the bottom. The lower flange, in this case is then in two parts. The opening can run throughout the entire beam, or also be interrupted. In this case special advantages are gained in the manufacture of the beam 1 , since the demolding of the beam 1 is very easy to carry out. A stiffening of such a beam 1 can be done by means of bottom plates, which simultaneous with the molding, or in retrofit fashion can be inserted or also achieved by the use of bulkheads. Instead of the beam with a hollow space, this design can include the beam being solid. The latter is particularly advantageous, if the beams be installed on bridges or primary construction operations and/or the beam lengths are shorter than as is intended for the usual stretches of the railroad.
[0042] The invention is not limited to the depicted-embodiment. Also other beam shapings, which allow the air pressurized by a vehicle to be favorably left to escape and essentially no airstream impacts upon the passing of a vehicle near the piers are generated are objects of the invention. | According to the invention, a support ( 1 ) for a track-guided high-speed vehicle, particularly a magnetically levitated train, is mounted at intervals on pillars ( 9 ). Functional elements ( 7 ) for guiding the vehicle are arranged on the support's outer sides. The outer surfaces of the support ( 1 ) are provided in a streamlined form with regard to the vehicle by virtue of the fact that, when viewing the support ( 1 ) in a longitudinal direction, there are essentially no changes made to the cross-section of the support ( 1 ), and the shaping of the support ( 1 ) covers, to a large extent, the pillars ( 9 ) opposite the vehicle. In curved areas of the travel way, the support ( 1 ) is shorter and, if necessary, lower than in the straight areas of the travel way. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention concerns a process for the preparation of a definite shape of cross-linked synthetic plastic materials including tubular shapes. The plastics utilized include, in particular, polyethylene in its many forms such as low density polyethylene (LDPE), medium density polyethylene (MDPE), and (HDPE) high density polyethylene, polymethacrylate (PMMA), polyvinylacetate (PVA), polymethylacrylate (PMMA), polyvinylchloride (PVC) and ethylenevinylacetate (EVA).
2. Background of the Prior Art:
Synthetic products and in particular synthetic plastic tubing are being used increasingly, for example, in the field of heating and sanitation. These materials have outstanding long term stability even at high temperatures and pressures and are resistant to most of the substances that are utilized or added to heating and sanitation systems. If, for example, the tubing is exposed to extreme bending during installation, in order perhaps to be built into an assembly after being equipped with fittings, the pipes must be fastened and possibly cast in the bent state as relatively strong restoring forces are present in the pipes and tubing and are highly resistant to extreme bending. If a pipe of this type is subjected to angling, for example, a kinking location with a reduced cross section is formed resulting in an area of increased resistance to flow.
Certain subsequent deformations of the molded material cannot be effected without residual stresses, other deformations can be effected only with great difficulty.
SUMMARY OF THE INVENTION
The above-described problem is solved by the process of this invention wherein following the completion of an initial shaping step (A) of the plastic material and a subsequent cross-linking step at temperatures exceeding the crystalline melting point of the material involved, a second shaping step is effected. The second shaping process has a predetermined relationship to the initial shaping. The synthetic plastic product is then subjected to a partial heat treatment at predetermined locations in order to obtain a specific deformation of the shaped product. The magnitude of this deformation lies between the magnitude of the first and the magnitude of the second shaping step. The cross-linking following the shaping step is effected by chemical or physical means.
In a preferred embodiment, the second shaping step is obtained by a reduction of the first deformation by at least 10%, preferably 20%.
In a further embodiment of the invention, the molding compound premixed with cross-linking agents, additives and auxiliary substances is exposed in a known manner to a short term, high pressure treatment in order to obtain adequate cross-linking, followed by an extrusion process such as the type well known for producing pipes, with the mixture being cooled immediately after the deformation and subsequently stretched by at least 10%, preferably 20% in the longitudinal direction of the pipe.
Examples of suitable, synthetic plastics, cross-linking agents, additives and the like are known in the art and are also described in numerous references such as the Textbook of Polymer Science, by F. W. Billmeyer, Jr., John Wiley and Sons, New York, 1962, 601 pp, and Principles of Polymer Chemistry, by P. S. Flory, Cornell University Press, Ithaca, New York, 1953, 672 pp, the pertinent portions of which are incorporated herein by reference.
According to the invention, the partial heat treatment of the synthetic plastic product is effected at a temperature higher than the crystalline melting point of the substance involved, while the adjacent parts of the produce remain in the crystalline state. The heat treatment of the synthetic plastic product is effected preferably with the aid of a flow of air at a temperature in excess of 140° C.
In order to produce a permanent expansion, bend or angle of the shaped article, for example, a pipe formed and stretched according to the invention, the stretched pipe is heated partially at the locations to be deformed.
In a further development of the invention, tubular shapes of cross-linked thermoplastic and high molecular weight synthetics of the above-mentioned type are proposed, wherein the pipe bends and/or pipe expansions and/or pipe angles in their areas of locally increasing or decreasing deformation have correspondingly increasing or decreasing radii and wall diameters compared with the undeformed tubular parts of the shape. This results in the fact that the internal diameter of the pipe is larger at the pipe bends or angles than in the straight sections, while the wall thickness in said areas is also larger in a desirable and advantageous manner. These tubular expansions act to eliminate any additional flow resistance such as those occurring in bent pipes of the conventional type, while simultaneously the material of the wall is reinforced in the curving sections exposed to a higher stress.
According to the invention, tubular shapes may be produced which exhibit within a section of the tubular shape a zone expanded about the entire circumference.
Further tubular shapes may be produced, for example, wherein a tubular section is developed as a Venturi tube with a narrowing and subsequently gradually expanding tubular section. Flange connections may also be effected with different terminal expansions.
Examples of experiments in the production of a certain deformation of a cross-linked material of the above-described type will be presented hereinafter in the following and in the description illustrated by the drawings:
EXAMPLE
Finely divided polyethylene is mixed with 2.5% by weight dicumyl peroxide and the mixture is inserted in a pressure chamber and exposed to high pressure. The temperature of the material at the outlet of the pressure chamber is approximately 110° C. The material is passed through the conduits of an extrusion installation and is then heated to approximately 160° C. At this temperature, the cross-linking reaction procedes rapidly and completely. A pipe of cross-linked polyethylene is obtained at the outlet of the shaping tool. The pipe is continuously drawn in the same working process through a shaping tool and subsequently through a water bath, and cooled. The shaping tool effects a reduction in radius by at least 10%, preferably 20%. Let the original shape be A, then the reduced shape is
B=A-ΔA,
wherein ΔA is between 10% and 20%.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention shall become more apparent with the aid of the drawing: In the drawing
FIG. 1 shows an angled tubular section with a flange element;
FIG. 2 shows a Venturi tube;
FIGS. 3 and 4 illustrate a double tubular section with internal spacing rings and external rings respectively;
FIGS. 5a-5e show a pipe and T-connection.
DETAILED DESCRIPTION OF THE EMBODIMENTS
If, for example, an angular deformation is to be effected, such as that shown in FIG. 1, the side 1 of the pipe produced by the above-described process is exposed to a flow of hot air at a temperature in excess of 140° C. for a certain period of time. In the course of this heating, an expansion of the cross section takes place, whereby the material is tending to assume the original shape A. If the circumferential configuration of the pipe is heated nonuniformly, the pipe will be angled, as the pipe by virtue of the memory effect known in itself, tends to assume its original thickness on the side 1 of the circumference, while on the cooler side 2, this state can no longer be attained. By this heating process, the radius R 1 of the pipe, reduced by 10% to 20%, is expanded to R 2 and finally to R 3, while the radius R 4 is again identical with R 1. The same is true for the wall thickness D 1 of the original wall again reduced by 10% to 20%. The wall thickness D 3 is thus in approximate agreement with the original wall thickness and the latter is greater than D 2 and D 2 is greater than the wall thickness D 1. In this manner, greater radii and wall thicknesses are obtained at the angle locations so that the flow loss otherwise occurring in angle pieces as the result of narrowing, is avoided. The reduction of a pipe produced, for example, by extrusion may be continued by its yield strength so that by means of a corresponding later heat treatment the original state may be restored in the same order of magnitude.
The angle piece produced in this manner has a permanent shape without the action of restoring forces and thus of stresses.
The flange part 12, also shown in FIG. 1, is produced in a similar manner.
A further field of application consists of coating metal pipes on the inside with a synthetic plastic material for example to seal damaged or porous locations in pipes already installed.
For this purpose, a polyethylene pipe produced, for example, by the above-described process is reduced by the extrusion process, for example, by 10%, so that the pipe reduced in this manner may be introduced in the metal pipe to be repaired. The length of the pipe to be inserted is chosen so that the tubular parts to be repaired are bridged over by adequate lengths. Following the introduction of the plastic pipe, the combination of pipes is heated so that the plastic inner pipe will expand by the amount of the reduction and will be in tight contact with the inner wall. The heat treatment generates forces sufficient to provide adequate sealing of the plastic pipe over its entire circumference and in a sufficient length on the inner wall of the pipe to be repaired.
A further field of application is the production of Venturi tubes from a tubular section. A tube of this type is shown in FIG. 2. A Venturi tube consists of a narrowing tubular part 3 and the gradually reexpanding part 4. Starting with an initial pipe 5 with a radius of R 4 and reducing such a pipe to a radius of R 5 leads to the production in a simple manner by means of subsequent heat treatments of the narrowing tubular sections 3 and the gradually expanding sections 4. At the narrowing locations, the wall thickness is increasing and is the largest at the narrowest point with the radius R 5. The highest stresses in the pipe are also found here.
For the production of other desirable deformations of suitably reduced pipes or hose, appropriately shaped dies may be used into which the tubular sections are placed and subsequently heated until they have assumed the configuration given by the shape of the dies. In this manner, accurately reproducible deformations may be effected so that the mass production of preformed tubular sections or the like is possible without difficulty without the accurate observation for predetermined dimensions.
The measures according to the invention may also be of advantage in the production of connections with fittings and pipe connectors so that in some cases no gaskets are required. It is sufficient to use slightly reduced tubing which is suitably heated at connecting locations so that a predetermined adaptation is achieved by means of the heat treatment.
The invention may be applied advantageously to the production of piping systems equipped in the form of double pipes with gas insulating chambers, preferably air chambers. Examples of this embodiment are shown in FIGS. 3 and 4.
As seen in FIG. 3, expansions 7 are provided a predetermined intervals on the circumference of the pipe 6 which in the installed state have the configuration inside the external pipe 8 of bearing supports and gaskets. In this manner, a plurality of gas chambers is formed between successive expansions, providing excellent insulation.
In a similar manner, indentures 9 may be formed in a predetermined spacing in the external pipe 10, which in the mounted state serve as bearing supports and gaskets for the inner pipe 11. Such an embodiment is shown in FIG. 4.
The undeformed pipe may consist of a synthetic plastic or a metal.
FIG. 5 shows a T-connection comprising a hose connection 16, which is passed with its shape 17 through a bore 15 of the tubular section 13. With the aid of a pressure member 18 and screw elements, not shown, the hose connection 16 is clamped together with the tubular section 13 to form a T-connection. The hose connector 16 is provided with threads so that the pressure member is clamped against the tubular section 13, wherein the shape 17 inside the tubular section renders such a clamping possible. The T-connection is established by heating the corresponding tubular section so that the heated part assumes its original shape. The bore 15 is then prepared with dimensions corresponding to the diameter of the hose connection 16. The hose connection 16 is integrally joined with the shape 17 and by virtue of its oval shape this element is passed through the still warm border of the bore 15 with the tubular section 13 fully contacting the shape 17 after cooling. Following the cooling of the vicinity of the bore hole the pressure member is passed over the hose connection 16 and tightened by means of the screw elements, thereby producing a positive and tight T-connection. The tubular section 13 may be shaped so that only a slight or no flow resistance is generated in the tubular section 13.
A particular advantage of the process consists of the fact that a T-connection may be established with already installed lines without having to dismantle them. The hose connector 16 here consists preferably of metal, together with the pressure member 18 and the screw elements, not shown. | Shaped articles, particularly tubular shaped articles, are formed by a process comprising molding a crosslinkable synthetic plastic material into a first molded shape, crosslinking the plastic material at a temperature in excess of the crystalline melting point of the material, subjecting the crosslinked first shape to a working operation to form a second configuration shape and subjecting specific areas of the second shape to a heat treatment thereby forming a deformation in the specific area. Extruded tubular materials subjected to a stretching operation tend to seek their original shape upon heat treatment thereby making the degree of deformation possible nearly equal to the degree of stretching. | 1 |
BACKGROUND
[0001] The present disclosure relates, in general, to surgery, and in particular, to a surgical transaction or cutting tool which may be used to cut tissue alone or as a part of surgical tissue cutting and fastening instrument.
[0002] During many surgical procedures, it is common to use a tissue fastening and cutting device, such as a linear cutter, for fastening and transecting tissue in order to resect the tissue and achieve hemostasis by placing a plurality of laterally spaced rows of staples on opposite sides of a tissue cut or tissue transection line. Surgical fastening and cutting instruments are generally used to make a longitudinal incision in tissue and apply lines of staples on opposing sides of the incision. Such instruments commonly include an end effector having a pair of cooperating jaw members that, if the instrument is intended for endoscopic or laparoscopic applications, are capable of passing through a cannula passageway. One of the jaw members receives a staple cartridge having at least two laterally spaced rows of staples. The other jaw member defines an anvil having staple-forming pockets aligned with the rows of staples in the cartridge. The instrument includes a plurality of reciprocating wedges that, when driven distally, pass through openings in the staple cartridge and engage drivers supporting the staples to effect the firing of the staples toward the anvil. A cutting instrument is drawn distally along the jaw member so that the clamped tissue is cut and fastened (e.g., stapled).
[0003] An example of a surgical fastening and cutting instrument suitable for endoscopic applications is described in U.S. Pat. No. 7,000,818, entitled SURGICAL STAPLING INSTRUMENT HAVING SEPARATE DISTINCT CLOSING AND FIRING SYSTEMS, which issued on Feb. 21, 2006, the entire disclosure of which is hereby incorporated by reference herein. In use, a clinician is able to close the jaw members of the instrument upon tissue to position the tissue prior to firing. Once the clinician has determined that the jaw members are properly gripping tissue, the clinician can then fire the surgical instrument, thereby severing and stapling the tissue. An example of a Motor-driven surgical fastening and cutting instrument is described in U.S. Pat. No. 7,416,101, entitled “MOTOR-DRIVEN SURGICAL CUTTING AND FASTENING INSTRUMENT WITH LOADING FORCE FEEDBACK, which issued on Aug. 26, 2008, the entire disclosure of which is hereby incorporated by reference herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] The novel features of the various embodiments of the invention are set forth with particularity in the appended claims. The various embodiments of the invention, however, both as to organization and methods of operation, together with further objects and advantages thereof, may best be understood by reference to the following description, taken in conjunction with the accompanying drawings as follows.
[0005] FIG. 1 is a prospective view of a surgical cutting instrument including a handle, a shaft and an end effector;
[0006] FIG. 2 is a prospective view of a lower jaw of the end effector of the surgical cutting instrument of FIG. 1 ;
[0007] FIG. 3 is a partial exploded view of the lower jaw of the end effector of the surgical cutting instrument of FIG. 1 ;
[0008] FIG. 4 is a partial cross-sectional view of the lower jaw of the end effector of the surgical cutting instrument of FIG. 1 ;
[0009] FIG. 5 is a partial cross-sectional view of the lower jaw of the end effector of the surgical cutting instrument of FIG. 1 ;
[0010] FIG. 6 is a partial cross-sectional view of the lower jaw of the end effector of the surgical cutting instrument of FIG. 1 ;
[0011] FIG. 7 is a partial cross-sectional view of the lower jaw of the end effector of the surgical cutting instrument of FIG. 1 ;
[0012] FIG. 8 is a prospective view of the end effector of the surgical cutting instrument of FIG. 1 near tissue;
[0013] FIG. 9 is a prospective view of the end effector of the surgical cutting instrument of FIG. 1 clamping tissue;
[0014] FIG. 10 is a prospective view of the end effector of the surgical cutting instrument of FIG. 1 clamping tissue, and a cutting member cutting through the tissue;
[0015] FIG. 11 is a prospective view of tissue cut by the surgical cutting instrument of FIG. 1 ;
[0016] FIG. 12 is a prospective view of a surgical cutting instrument including a handle, a shaft and an end effector;
[0017] FIG. 13 is a prospective view of a lower jaw of the end effector of the surgical cutting instrument of FIG. 12 ;
[0018] FIG. 14 is a partial exploded view of the lower jaw of the end effector of the surgical cutting instrument of FIG. 12 ;
[0019] FIG. 15 is a partial cross-sectional view of the lower jaw of the end effector of the surgical cutting instrument of FIG. 12 ;
[0020] FIG. 16 is a partial cross-sectional view of the lower jaw of the end effector of the surgical cutting instrument of FIG. 12 ;
[0021] FIG. 17 is a partial cross-sectional view of the lower jaw of the end effector of the surgical cutting instrument of FIG. 12 ;
[0022] FIG. 18 is a partial cross-sectional view of the lower jaw of the end effector of the surgical cutting instrument of FIG. 12 ;
[0023] FIG. 19 is a prospective view of a surgical cutting instrument including a handle, a shaft and an end effector;
[0024] FIG. 20 is a prospective view of a lower jaw of the end effector of the surgical cutting instrument of FIG. 19 showing a deployed cutting member;
[0025] FIG. 21 includes two partial prospective views of a driving member of the surgical cutting instrument of FIG. 19 , wherein the view in solid lines illustrates an undeployed cutting member, and the view in broken lines illustrates a deployed cutting member;
[0026] FIG. 22 is a partial cross-sectional view of a driving member of the surgical cutting instrument of FIG. 19 ;
[0027] FIG. 23 is a partial cross-sectional view of a driving member of the surgical cutting instrument of FIG. 19 ;
[0028] FIG. 24 is a partial cross-sectional view of a driving member of the surgical cutting instrument of FIG. 19 ;
[0029] FIG. 25 is a prospective view of a surgical cutting and fastening instrument including a handle, a shaft and an end effector;
[0030] FIG. 26 is a partial exploded prospective view of a staple cartridge of the end effector of the surgical instrument of FIG. 25 ;
[0031] FIG. 27 is a partial cross-sectional view of the staple cartridge of FIG. 26 , and a driving member of the surgical instrument of FIG. 25 ;
[0032] FIG. 28 is a partial cross-sectional view of the staple cartridge of FIG. 26 illustrating an undeployed cutting member;
[0033] FIG. 29 is a partial cross-sectional view of the staple cartridge of FIG. 26 illustrating an undeployed cutting member;
[0034] FIG. 30 is a partial cross-sectional view of the staple cartridge of FIG. 26 illustrating a deployed cutting member;
[0035] FIG. 31 is a partial cross-sectional view of the staple cartridge of FIG. 26 illustrating a deployed cutting member;
[0036] FIG. 32 is a partial exploded prospective view of a staple cartridge of the end effector of the surgical instrument of FIG. 25 ;
[0037] FIG. 33 is a partial cross-sectional view of the staple cartridge of FIG. 32 illustrating an undeployed cutting member;
[0038] FIG. 34 is a partial cross-sectional view of the staple cartridge of FIG. 32 illustrating an undeployed cutting member;
[0039] FIG. 35 is a partial cross-sectional view of the staple cartridge of FIG. 32 illustrating a deployed cutting member;
[0040] FIG. 36 is a partial cross-sectional view of the staple cartridge of FIG. 32 illustrating a deployed cutting member.
SUMMARY
[0041] A surgical cutting instrument may comprise a first jaw member, a second jaw member movably supported relative to the first jaw member for selective movement between an open position and a closed position to clamp tissue therebetween upon application of a closing motion thereto, and a cutting member comprising a tissue cutting edge to cut the tissue clamped between the first jaw member and the second jaw member upon application of a retraction motion to the cutting member.
[0042] A surgical staple cartridge assembly for use with a surgical stapler may include a staple cartridge housing configured to be operably supported in the surgical stapler, wherein the staple cartridge housing may include a top surface, a slot, and at least one staple cavity. The surgical cartridge assembly may further include a cutting member positioned within the staple cartridge housing, the cutting member comprising a tissue cutting edge configured to cut tissue, wherein the cutting member is proximally retractable upon application of a retraction motion thereto, and wherein the tissue cutting edge is proximally presented as the cutting member is proximally retracted through the tissue.
[0043] A surgical cutting and fastening instrument may include an elongate shaft, an elongate channel operably coupled to the elongate shaft and configured to operably support a staple cartridge therein, and an anvil movably supported relative to the elongate channel for selective movement between an open position and a closed position, wherein tissue is clamped between the anvil and a staple cartridge supported within the elongate channel in response to opening and closing motions applied thereto from the elongate shaft. The surgical instrument may further include a cutting member comprising a tissue cutting edge, wherein the cutting member is retractable relative to the elongate channel, and wherein the tissue cutting edge is configured to cut tissue clamped between the anvil and the staple cartridge during retraction of the cutting member.
[0044] A surgical cutting and fastening instrument comprises a first jaw having a housing, the housing including a top surface, a second jaw movably supported relative to the first jaw upon application of opening and closing motions thereto, and a cutting member including a tissue cutting edge, the cutting member being movable from a proximal starting position to a distal ending position upon application of a firing motion thereto, and from the distal ending position to the proximal starting position upon application of a retraction motion thereto, the cutting member being further movably supported within the housing of the first jaw such that when the cutting member is moving from the proximal starting position to the distal ending position, the tissue cutting edge is positioned below the top surface of the housing of the first jaw, and when the cutting member is moving from the distal ending position to the proximal starting position, the tissue cutting edge extends above the top surface of the housing of the first jaw.
[0045] A surgical staple cartridge comprises a cartridge housing including a top surface, the cartridge housing operably supporting a plurality of surgical staples therein, and a cutting member movably supported within the cartridge housing and including a tissue cutting edge, the cutting member being movable from a proximal starting position to a distal ending position, and from the distal ending position to the proximal starting position, the cutting member further being movably supported within the cartridge housing such that when the cutting member is moving from the proximal starting position to the distal ending position, the tissue cutting edge is positioned below the top surface, and when the cutting member is moving from the distal ending position to the proximal starting position, the tissue cutting edge extends above the top surface.
DESCRIPTION
[0046] As generally used herein, the terms “proximal” and “distal” generally refer to a clinician manipulating one end of an instrument used to treat a patient. The term “proximal” generally refers to the portion of the instrument closest to the clinician. The term “distal” generally refers to the portion located furthest from the clinician. It will be further appreciated that for conciseness and clarity, spatial terms such as “vertical,” “horizontal,” “up,” and “down” may be used herein with respect to the illustrated embodiments. However, surgical instruments may be used in many orientations and positions, and these terms are not intended to be limiting and absolute.
[0047] Referring to FIG. 1 , a surgical instrument, generally 100 , can comprise a handle 102 , a shaft 104 , and an end effector 106 . In at least one embodiment, as shown in FIG. 1 , the end effector 106 may comprise a first jaw member 108 and a second jaw member 110 . The end effector 106 may be configured to perform surgical activities in response to drive motions applied thereto. The first jaw member 108 may be movable relative to the second jaw member 110 between a first position and a second position. The first position may be an open position and the second position may be a closed position. In at least one embodiment, referring to FIG. 1 , the first jaw member 108 may be pivotally coupled to the second jaw member 110 . Other suitable arrangements for coupling the first jaw member 108 and the second jaw member 110 are contemplated within the scope of this disclosure.
[0048] Referring again to FIG. 1 , the handle 102 may comprise a closure actuator 112 , a firing actuator 113 , and a rotation actuator 114 . The closure actuator 112 may be pivotally coupled to handle 102 . Actuation of the closure actuator 112 may cause the first jaw member 108 to move relative to the second jaw member 110 . Rotating the rotation actuator 114 may result in rotation of the end effector 106 about a longitudinal axis L-L.
[0049] Referring to FIGS. 2-7 , the second jaw member 110 may comprise a housing 116 including a top surface 118 having a slot 120 extending along the longitudinal axis L-L. As illustrated in FIG. 2 , the housing 116 may include a cutting member 122 which may travel through slot 120 along the longitudinal axis L-L. As illustrated in the exploded view in FIG. 3 , the housing 116 may include a first track 124 , and a second track 126 . Tracks 124 and 126 may extend along the longitudinal axis L-L such that they are parallel with each other. In addition, tracks 124 and 126 may extend in a plane that is substantially perpendicular to the top surface 118 , where, in at least one embodiment, the second track 126 is closer to the top surface 118 than the first track 124 . A distal portion 128 of the first track 124 may converge to intersect with the second track 126 at a junction point 130 . Tracks 124 and 126 may further extend distally beyond junction point 130 forming a common track portion 132 .
[0050] Referring again to FIGS. 2-7 , the cutting member 122 may include a tissue cutting edge 134 , a first pin 136 , a second pin 138 , and an engagement portion 140 . The cutting member 122 may travel between a proximal starting position 142 as illustrated in FIG. 4 , and a distal ending position 144 as illustrated in FIG. 6 . At the proximal starting position 142 , the first pin 136 may ride in the first track 124 , and the second pin 138 may ride in the second track 126 , causing the cutting member 122 to remain in an “undeployed” orientation. In the undeployed orientation, as illustrated in FIG. 4 , the tissue cutting edge 134 is not exposed above the top surface 118 .
[0051] As illustrated in the exploded view in FIG. 3 , the surgical instrument 100 may further comprise a driving member 146 , which may include a retraction hook 148 and a driving tip 150 . The driving member 146 may be operably coupled, at a proximal portion thereof, to the firing actuator 113 such that an operator of the surgical instrument 100 may advance the driving member 146 distally by advancing the firing actuator 113 distally, and may retract the driving member 146 proximally by retracting firing actuator 113 proximally.
[0052] Referring to FIGS. 4 and 5 , advancing the driving member 146 distally may bring the driving tip 150 into mating engagement with engagement portion 140 of cutting member 122 . With the first pin 136 riding in the first track 124 , and the second pin 138 riding in the second track 126 , further advancing of the driving member 146 may enable the cutting member 122 to travel distally from the proximal starting position 142 through slot 120 as illustrated in FIG. 5 .
[0053] Referring to FIGS. 5 and 6 , the cutting member 122 may be advanced distally in an undeployed orientation along tracks 124 and 126 until the first pin 136 enters the distal portion 128 of the first track 124 . The distal portion 128 may comprise a camming surface 152 which may cause the first pin 136 to be lifted toward junction point 130 as the cutting member 122 continues to be advanced distally. In result, the cutting member 122 is transitioned gradually from an undeployed orientation, as illustrated in FIG. 5 , wherein the tissue cutting edge 134 is not exposed above top surface 118 , to a deployed orientation, as illustrated in FIG. 6 , wherein the tissue cutting edge 134 is exposed above top surface 118 . Said another way, advancing the first pin 136 against the camming surface 152 may cause the cutting member 122 to move about an axis transverse to the longitudinal axis L-L resulting in deployment of the tissue cutting edge 134 .
[0054] Referring again to FIGS. 5 and 6 , as the cutting member 122 transitions from an undeployed orientation to a deployed orientation, as described above, the first pin 136 may enter the common track portion 132 . In addition, the engagement portion 140 of the cutting member 122 may be released from mating engagement with the driving tip 150 and may enter into a mating engagement with the retraction hook 148 as illustrated in FIG. 6 .
[0055] Referring now to FIGS. 6 and 7 , the deployed cutting member 122 may then travel proximally from the distal ending position 144 toward the proximal starting position 142 in response to retraction motions by the driving member 146 . As illustrated in FIG. 6 , the tissue cutting edge 134 is proximally presented at the distal ending position 144 . Retraction of the driving member 146 may cause the cutting member 122 to travel proximally along the longitudinal axis L-L. As the cutting member 122 begins to travel proximally, the first pin 136 rides in common track portion 132 , and the second pin 138 rides in the second track 126 . Upon reaching junction point 130 , the first pin 136 is prevented from reentering the distal portion 128 of the first track 124 by driving member 146 . Instead, the first pin 136 enters the second track 126 . As illustrated in FIG. 7 , both pins 136 and 138 may ride in the second track 126 for a remainder of the proximal travel of the cutting member 122 .
[0056] In certain embodiments, the first jaw member 108 may comprise a slot (not shown) corresponding to slot 120 in the second jaw member 110 . The slot of the first jaw member 108 may also extend along the longitudinal axis L-L, and may receive a top portion of the section of the deployed cutting member 122 exposed above top surface 118 during retraction of the cutting member 122 through slot 120 .
[0057] Referring now to FIGS. 8-11 , the surgical instrument 100 can be used in performing a surgical tissue transection procedure. An operator may actuate the closure actuator 112 of the handle 102 to grasp and secure tissue between the first jaw member 108 and the second jaw member 110 as illustrated in FIG. 9 . The operator may then deploy the cutting member 122 by advancing the firing actuator 113 as described above. Upon deployment, the cutting member 122 can be retracted by retracting the firing actuator 113 . The proximally presented tissue cutting edge 134 may cut through the tissue grasped between jaw members 108 and 110 as the cutting member 122 is retracted proximally. Transected tissue may then be released from end effector 106 by actuating the closure actuator 112 to open the jaw members 108 and 110 .
[0058] Referring to FIG. 12 , a surgical instrument, generally 200 , can comprise a handle 202 , a shaft 204 , and an end effector 206 . In at least one embodiment, as shown in FIG. 12 , the end effector 206 may comprise a first jaw member 208 and a second jaw member 210 . The end effector 206 may be configured to perform surgical activities in response to drive motions applied thereto. The first jaw member 208 may be movable relative to the second jaw member 210 between a first position and a second position. The first position may be an open position and the second position may be a closed position. In at least one embodiment, referring to FIG. 12 , the first jaw member 208 may be pivotally coupled to the second jaw member 210 . Other suitable arrangements for coupling the first jaw member 208 and the second jaw member 210 are contemplated within the scope of this disclosure.
[0059] Referring again to FIG. 12 , the handle 202 may comprise a closure actuator 212 , a firing actuator 213 , and a rotation actuator 214 . The closure actuator 212 may be pivotally coupled to handle 202 . Actuation of the closure actuator 212 may cause the first jaw member 208 to move relative to the second jaw member 210 . Rotating the rotation actuator 214 may result in rotation of the end effector 206 about a longitudinal axis L-L.
[0060] Referring to FIGS. 13-18 , the second jaw member 210 may comprise a housing 216 including a top surface 218 having a slot 220 extending along the longitudinal axis L-L. As illustrated in FIG. 13 , the housing 216 may include a cutting member 222 which may travel through slot 220 along the longitudinal axis L-L. As illustrated in the exploded view in FIG. 14 , the housing 216 may include a first track 224 , and a second track 226 . Tracks 224 and 226 may extend along the longitudinal axis L-L such that they are substantially parallel with each other. In addition, tracks 224 and 226 may extend in a plane that is substantially perpendicular to the top surface 218 , wherein the second track 226 is closer to the top surface 218 than the first track 224 . As illustrated in FIG. 15 , the first track 224 may begin at a starting point 225 positioned at a distal portion of the housing 216 ; and the second track 226 may begin a starting point 227 positioned at a proximal portion of the housing 216 . Such arrangement shortens the distance that the cutting member 222 must travel distally before being moved to the deployed orientation.
[0061] Referring again to FIGS. 13-18 , a distal portion 228 of the first track 224 may converge to intersect with the second track 226 at a junction point 230 . Tracks 224 and 226 may further extend distally beyond junction point 230 forming a common track portion 232 . The cutting member 222 may include a tissue cutting edge 234 , a first pin 236 , a second pin 238 , and an engagement portion 240 . The cutting member 222 may travel between a proximal starting position 242 , which may be defined by the starting point 225 of the first track 224 as illustrated in FIG. 15 , and a distal ending position 244 at a distal end of the common track 232 as illustrated in FIG. 17 . At the proximal starting position 242 , the first pin 236 may ride in the first track 224 , and the second pin 238 may ride in the second track 226 , causing the cutting member 222 to remain in an undeployed orientation. In the undeployed orientation, as illustrated in FIG. 15 , the tissue cutting edge 234 of the cutting member 222 is not exposed above the top surface 218 .
[0062] As illustrated in the exploded view in FIG. 14 , the surgical instrument 200 may further comprise a driving member 246 , which may include a retraction hook 248 and a driving tip 250 . The driving member 246 may be operably coupled, at a proximal portion thereof, to the firing actuator 213 such that an operator of the surgical instrument 200 may advance the driving member 246 distally by advancing the firing actuator 213 distally, and may retract the driving member 246 proximally by retracting firing actuator 213 proximally.
[0063] Referring to FIGS. 15 and 16 , advancing the driving member 246 distally may bring the driving tip 250 into mating engagement with engagement portion 240 of cutting member 222 . With the first pin 236 riding in the first track 224 , and the second pin 238 riding in the second track 226 , further advancing of the driving member 246 may enable the cutting member 222 to travel a short distance distally from the proximal starting position 242 through slot 218 as illustrated in FIG. 16 .
[0064] Referring to FIGS. 16 and 17 , the cutting member 222 may be advanced distally in an undeployed orientation a short distance along tracks 224 and 226 until the first pin 236 enters the distal portion 228 of the first track 224 . The distal portion 228 may comprise a camming surface 252 which may cause the first pin 236 to be lifted toward junction point 230 as the cutting member 222 continues to be advanced distally. In result, the cutting member 222 is transitioned gradually from an undeployed orientation, as illustrated in FIG. 16 , wherein the tissue cutting edge 234 is not exposed above top surface 218 , to a deployed orientation, as illustrated in FIG. 17 , wherein the tissue cutting edge 234 is exposed above top surface 218 . Said another way, advancing the first pin 236 against the camming surface 252 may cause the cutting member 222 to move about an axis transverse to the longitudinal axis L-L resulting in deployment of the tissue cutting edge 234 .
[0065] Referring again to FIGS. 16 and 17 , as the cutting member 222 transitions from an undeployed orientation to a deployed orientation, as described above, the first pin 236 may enter the common track portion 232 . In addition, the engagement portion 240 of the cutting member 222 may be released from mating engagement with the driving tip 250 and may enter into a mating engagement with the retraction hook 248 as illustrated in FIG. 17 .
[0066] Referring now to FIGS. 17 and 18 , the deployed cutting member 222 may then travel proximally from the distal ending position 244 in response to retraction motions by the driving member 246 . As illustrated in FIG. 17 , the tissue cutting edge 234 is proximally presented at the distal ending position 244 . Retraction of the driving member 246 may cause the cutting member 222 to travel proximally along the longitudinal axis L-L. As the cutting member 222 begins to travel proximally, the first pin 236 rides in common track portion 232 , and the second pin 238 rides in the second track 226 . Upon reaching junction point 230 , the first pin 236 is prevented from reentering the distal portion 228 of the first track 224 by driving member 246 . Instead, the first pin 236 enters the second track 226 . As illustrated in FIG. 18 , both pins 236 and 238 may ride in the second track 226 for the remainder of the proximal travel of the cutting member 222 .
[0067] In certain embodiments, the first jaw member 208 may comprise a slot (not shown) corresponding to slot 220 in the second jaw member 210 . The slot of the first jaw member 208 may also extend along the longitudinal axis L-L, and may receive a top portion of the section of the deployed cutting member 222 exposed above top surface 218 during retraction of the cutting member 222 through slot 220 .
[0068] Referring to FIG. 19 , a surgical instrument, generally 300 , can comprise a handle 302 , a shaft 304 , and an end effector 306 . In at least one embodiment, as shown in FIG. 19 , the end effector 306 may comprise a first jaw member 308 and a second jaw member 310 . The end effector 306 may be configured to perform surgical activities in response to firing motions applied thereto. The first jaw member 308 may be movable relative to the second jaw member 310 between a first position and a second position. The first position may be an open position and the second position may be a closed position. In at least one embodiment, referring to FIG. 19 , the first jaw member 308 may be pivotally coupled to the second jaw member 310 . Other suitable means for coupling the first jaw member 308 and the second jaw member 310 are contemplated within the scope of this disclosure.
[0069] Referring again to FIG. 19 , the handle 302 may comprise a closure actuator 312 , a firing actuator 313 , and a rotation actuator 314 . The closure actuator 312 may be pivotally coupled to handle 302 . Actuation of the closure actuator 312 may cause the first jaw member 308 to move relative to the second jaw member 310 . Rotating the rotation actuator 314 may result in rotation of the end effector 106 about a longitudinal axis L-L.
[0070] Referring to FIGS. 20-24 , the second jaw member 310 may comprise a housing 316 including a top surface 318 having a slot 320 extending therethrough along the longitudinal axis L-L. As illustrated in FIG. 20 , the housing 316 may include a cutting member 322 which may travel through slot 320 along the longitudinal axis L-L. The cutting member 322 may comprise a tissue cutting edge 334 , and a piercing tip 335 at a distal portion of the cutting member as illustrated in FIG. 21 .
[0071] Referring again to FIGS. 20-24 , the surgical instrument 300 may further comprise a driving member 346 , which may include a stop member 348 oriented at a distal portion thereof as illustrated in FIG. 21 . The driving member 346 in the distal direction may be operably coupled, at a proximal portion thereof, to the firing actuator 313 such that an operator of the surgical instrument 300 may advance the driving member 346 distally by advancing the firing actuator 313 distally, and may retract the driving member 346 proximally by retracting firing actuator 313 proximally.
[0072] Referring to FIGS. 21-24 , the cutting member 322 may be pivotally coupled to a distal portion of the driving member 346 proximal to stop member 348 . For example, a pivot pin 350 can be used to couple the cutting member 322 to the driving member 346 . Other means for coupling the cutting member 322 to the driving member 346 are contemplated within the scope of this disclosure. As illustrated in FIGS. 21-24 , the cutting member 322 may pivot relative to the driving member 346 about an axis through pivot pin 350 and transverse to the longitudinal axis L-L. Pivoting the cutting member 322 , in a counter clockwise direction, about pivot pin 350 may cause the cutting member 322 to transition from an undeployed orientation to a deployed orientation. In the undeployed orientation, the tissue cutting edge 334 and the piercing tip 335 of the cutting member 346 remain below the top surface 318 of the housing 316 as illustrated by the embodiment in solid lines in FIG. 21 . In the fully deployed orientation, however, the tissue cutting edge 334 and the piercing tip 335 of the cutting member 346 are exposed above the top surface 318 of the housing 316 and the cutting member 346 rests against stop member 348 as illustrated by the embodiment in broken lines in FIG. 21 .
[0073] Referring now to FIGS. 22-24 , the housing 316 may comprise a deployment member 356 . As illustrated in FIG. 22 , the cutting member 322 can be advanced distally in an undeployed orientation by advancing the driving member 346 until the cutting member 322 engages the deployment member 356 . Further advancing of the driving member 346 may cause the cutting member 322 to rotate counter clockwise about pivot pin 350 transitioning to a deployed orientation as illustrated in FIG. 23 . Other deployment arrangements for deploying cutting member 322 are contemplated within the scope of the present disclosure.
[0074] The surgical instrument 300 can be used in performing a surgical tissue transection procedure. An operator may actuate the closure actuator 312 to grasp and secure the tissue to be transected between the first jaw member 308 and the second jaw member 310 . The operator may then advance the cutting member 322 distally in an undeployed orientation, as described above, by advancing the firing actuator 313 . Upon engaging the deployment member 356 , the cutting member 322 may be rotated in a clockwise direction causing the piercing tip 335 to penetrate through tissue grasped between the jaw member 308 and 310 . As the operator continues to advance the driving member 346 , the cutting member 322 continues to rotate until the cutting member 322 is stopped by reaching the stop member 348 . The operator may then retract the fully deployed cutting member 322 by retracting the firing actuator 313 . The proximally presented tissue cutting edge 334 may cut through tissue grasped between jaw members 308 and 310 as the cutting member is retracted proximally. Transected tissue may then be released from end effector 306 by actuating the closure actuator 312 to open the jaw member 308 and 310 .
[0075] Referring to FIG. 25 , a surgical fastening and cutting instrument, generally 400 , can comprise a handle 402 , a shaft 404 , and an end effector 406 . In at least one embodiment, as shown in FIG. 25 , the end effector 406 may include a staple cartridge channel 410 for receiving a staple cartridge 411 . The staple cartridge 411 can be configured to operably support surgical staples therein. End effector 406 can further include an anvil 408 , which can be pivotally connected to staple cartridge channel 410 and can be pivoted between open and closed positions by an end effector closure system.
[0076] In order to deploy the staples from staple cartridge 411 , surgical instrument 400 can further include a staple driver configured to traverse staple cartridge 411 and a firing drive configured to advance the staple driver within the staple cartridge. In various embodiments, anvil 408 can be configured to deform at least a portion of the staples as they are deployed from the staple cartridge. Several embodiments of end effector closure systems and firing drives are disclosed in U.S. Pat. No. 6,905,057, entitled SURGICAL STAPLING INSTRUMENT INCORPORATING A FIRING MECHANISM HAVING A LINKED RACK TRANSMISSION, which issued on Jun. 14, 2005, and U.S. Pat. No. 7,044,352, entitled SURGICAL STAPLING INSTRUMENT HAVING A SINGLE LOCKOUT MECHANISM FOR PREVENTION OF FIRING, which issued on May 16, 2006, the entire disclosures of each of these patents are incorporated by reference herein.
[0077] In various embodiments, a surgical instrument in accordance with the present invention can include a system for moving, or articulating, an end effector relative to an elongate shaft assembly of the surgical instrument. For example, surgical instrument 400 can include an articulation joint (not shown) which can movably connect end effector 406 and shaft 404 . In various embodiments, the articulation joint can permit end effector 406 to be moved relative to shaft 404 in a single plane or, alternatively, multiple planes. In either event, the articulation joint can include one or more pivot axes about which end effector 406 can be articulated.
[0078] Surgical instrument 400 can further include a locking mechanism (not shown) which can fix, or lock, the relative relationship between end effector 406 and elongate shaft assembly 404 . Locking mechanisms in accordance with the present disclosure are disclosed in U.S. Pat. No. 7,784,662, entitled SURGICAL INSTRUMENT WITH ARTICULATING SHAFT WITH SINGLE PIVOT CLOSURE AND DOUBLE PIVOT FRAME GROUND, which issued on Aug. 31, 2010, U.S. Pat. No. 7,455,208, entitled SURGICAL INSTRUMENT WITH ARTICULATING SHAFT WITH RIGID FIRING BAR SUPPORTS, which issued on Nov. 25, 2008, and U.S. Patent Application Publication No. 2007/0027469 A1, entitled SURGICAL STAPLING AND CUTTING DEVICE AND METHOD FOR USING THE DEVICE, which was filed on Jul. 24, 2006, the entire disclosures of which are each hereby incorporated by reference herein.
[0079] Referring to FIG. 25 , the handle 402 may comprise a rotation actuator 414 . Actuation of the rotation actuator 414 may result in rotation of the end effector 406 about a longitudinal axis L-L. The handle 402 may further comprise a closure actuator 412 . The closure actuator 412 may be pivotally coupled to handle 402 . Actuation of the closure actuator 412 may cause the anvil 408 to move relative to the cartridge channel 410 . Handles and actuation mechanisms in accordance with the present disclosure are disclosed in U.S. Pat. No. 5,465,895, entitled SURGICAL STAPLER INSTRUMENT, which issued on Nov. 19, 1995, and U.S. patent application Ser. No. 12/830,013, entitled SURGICAL STAPLING INSTRUMENTS, which was filed on Jul. 2, 2010, the entire disclosures of which are each incorporated by reference herein. In an illustrative example, closure actuator 412 may be operably coupled to a closure tube 417 . Actuation of the closure actuator 412 may cause the closure tube 417 to move distally. Distal movement of the closure tube 417 may effect pivotal movement of the anvil 408 toward the cartridge channel 410 , which may effect tissue clamping.
[0080] Referring to FIGS. 25-27 , the handle 402 of the surgical cutting and fastening instrument 400 may further comprise a firing actuator 415 for deploying staples from staple cartridge 411 . The staple cartridge 411 may be divided by a central elongated slot 420 as illustrated in FIG. 26 . A plurality of staple receiving pockets 419 may be formed within the staple cartridge 411 and arranged in laterally spaced longitudinal rows. Staples 423 may be operably supported on corresponding drivers 425 that are movably positioned within the pockets 419 as illustrated in FIG. 27 . The drivers 425 may be arranged in laterally spaced longitudinal rows. Drivers 425 may be slidably received within the pockets 419 . Each driver 425 may support a single staple or plural staples 423 such that movement of the driver 425 through pocket 419 may deploy the staple or staples 423 as illustrated in FIG. 27 .
[0081] The cartridge 411 may further include longitudinal slots (not shown) arranged to receive wedges 421 which are provided at a distal end of a firing driver arrangement (not shown) which in turn may be operably coupled to firing actuator 415 in handle 402 . Actuation of firing actuator 415 may cause wedges 421 to move distally by moving the firing driver distally through shaft 404 . Wedges 421 may be moved distally through the longitudinal slots within cartridge 411 . Each wedge 421 may comprise an elongated portion 421 a and a camming portion 421 b . The camming portion 421 b may include a single-angle upper cam surface 421 c . Upon distal movement of the wedges 421 , cam surfaces 421 c can engage and push upward the drivers 425 in the staple cartridge 411 to effect the firing of the staples 423 toward the anvil 408 . Various exemplary cartridge designs and firing driver arrangements in accordance with the present disclosure are disclosed in U.S. Pat. No. 5,465,895, entitled SURGICAL STAPLER INSTRUMENT, which issued Nov. 19, 1995, and U.S. Pat. No. 7,669,746, entitled STAPLE CARTRIDGES FOR FORMING STAPLES HAVING DIFFERING FORMED STAPLE HEIGHTS, which issued Mar. 2, 2010, the entire disclosures of which are each hereby incorporated by reference herein.
[0082] Referring again to FIGS. 25 and 26 , the surgical cutting and fastening instrument 400 may further include a cutting member actuator 413 , a driving member 446 , and a cutting member 422 . The cutting member 422 may travel through slot 420 along the longitudinal axis L-L. As illustrated in the exploded view in FIG. 26 , the cartridge 411 may include a first track 424 , and a second track 426 . Tracks 424 and 426 may extend along the longitudinal axis L-L such that they are substantially parallel with each other. In addition, tracks 424 and 426 may extend in a plane that is substantially perpendicular to the top surface 418 , wherein the second track 426 is closer to the top surface 418 than the first track 424 . A distal portion 428 of the first track 424 may converge to intersect with the second track 426 at a junction point 430 . Tracks 424 and 426 may further extend distally beyond junction point 430 forming a common track portion 432 .
[0083] Referring to FIGS. 26 , and 28 - 31 , the cutting member 422 may include a tissue cutting edge 434 , a first pin 436 , a second pin 438 , and an engagement portion 440 . The cutting member 422 may travel between a proximal starting position 442 as illustrated in FIG. 28 , and a distal ending position 444 as illustrated in FIG. 30 . At the proximal starting position 442 , the first pin 436 may ride in the first track 424 , and the second pin 438 may ride in the second track 426 , causing the cutting member 422 to remain in an undeployed orientation. In the undeployed orientation, as illustrated in FIG. 28 , the tissue cutting edge 434 of the cutting member 422 is not exposed above the top surface 418 .
[0084] As illustrated in the exploded view in FIG. 26 , the driving member 446 may include a retraction hook 448 and a driving tip 450 . The driving member 446 may be operably coupled, at a proximal portion thereof, to the cutting member actuator 413 such that an operator of the surgical instrument 400 may advance the driving member 446 distally by advancing the cutting member actuator 413 distally, and may retract the driving member 446 proximally by retracting cutting member actuator 413 proximally.
[0085] Referring to FIGS. 28 and 29 , advancing the driving member 446 distally may bring the driving tip 450 into mating engagement with an engagement portion 440 of cutting member 422 . With the first pin 436 riding in the first track 424 , and the second pin 438 riding in the second track 426 , further advancing of the driving member 446 may enable the cutting member 422 to travel distally from the proximal starting position 442 through slot 420 as illustrated in FIG. 29 .
[0086] Referring to FIGS. 29 and 30 , the cutting member 422 may be advanced distally in an undeployed orientation along tracks 424 and 426 until the first pin 436 enters the distal portion 428 of the first track 424 . The distal portion 428 may comprise a camming surface 452 which may cause the first pin 436 to be lifted toward junction point 430 as the cutting member 422 continues to be advanced distally. In result, the cutting member 422 is transitioned gradually from an undeployed orientation, as illustrated in FIG. 29 , wherein the tissue cutting edge 434 is not exposed above top surface 418 , to a deployed orientation, as illustrated in FIG. 30 , wherein the tissue cutting edge 434 is exposed above top surface 418 . Said another way, advancing the first pin 436 against the camming surface 452 may cause the cutting member 422 to move about an axis transverse to the longitudinal axis L-L resulting in deployment of the cutting member 422 .
[0087] Referring again to FIGS. 29 and 30 , as the cutting member 422 transitions from an undeployed orientation to a deployed orientation, as described above, the first pin 436 enters the common track portion 432 . In addition, the engagement portion 440 of the cutting member 422 is released from mating engagement with the driving tip 450 and enters into a mating engagement with the retraction hook 448 as illustrated in FIG. 30 .
[0088] Referring now to FIGS. 30 and 31 , the deployed cutting member 422 may then travel proximally from the distal ending position 444 to the proximal starting position 442 in response to retraction motions by the driving member 446 . As illustrated in FIG. 30 , the tissue cutting edge 434 is proximally presented at the distal ending position 444 . Retraction of the driving member 446 may cause the cutting member 422 to travel proximally along the longitudinal axis L-L. As the cutting member begins to travel proximally, the first pin 436 rides in common track portion 432 , and the second pin 438 rides in the second track 426 . Upon reaching junction point 430 , the first pin 436 is prevented from reentering the distal portion 428 of the first track 424 by driving member 446 . Instead, the first pin 436 enters the second track 426 . As illustrated in FIG. 31 , both pins 436 and 438 may ride in the second track 426 for a remainder of the proximal travel of the cutting member 422 .
[0089] In certain embodiments, the anvil 408 may comprise a slot (not shown) corresponding to slot 420 in the cartridge 411 . The slot of anvil 408 may also extend along the longitudinal axis L-L, and may receive a top portion of the section of the deployed cutting member 422 exposed above top surface 418 during retraction of the cutting member 422 through slot 420 .
[0090] In certain embodiments, wedges 421 may be operably coupled to move simultaneously with the driving member 446 such that a common actuating member (not shown) may simultaneously move wedges 421 and driving member 446 . For example, during a first stroke of the common actuating member, wedges 421 may be advanced distally simultaneously with driving member 446 such that wedges 421 come in contact with drivers 425 as the driving tip 450 of the driving member 446 enters into mating engagement with the engagement portion 440 of the cutting member 422 . During the remainder of the first stroke, the undeployed cutting member 422 may be advanced simultaneously with wedges 421 through staple cartridge 411 as staples 423 are deployed by wedges 421 . At the end of the first stroke, the cutting member 422 may reach a fully deployed orientation with a proximally presented tissue cutting edge 434 at the distal ending position 444 as previously discussed and as illustrated in FIG. 30 . During a second stroke of the common actuating member, the cutting member 422 may be retracted to cut through tissue now stapled with staples 423 . Wedges 421 may be simultaneously retracted with cutting member 422 .
[0091] The surgical instrument 400 can be used in performing a surgical tissue fastening and cutting procedure. An operator may actuate the closure actuator 412 of the handle 402 to grasp and secure tissue between the anvil 408 and the staple cartridge 411 . The operator may then actuate the firing actuator 415 to deploy staples 423 , as described in detail above. Once the staples 423 are fired into tissue, the operator may then advance the cutting member 422 distally in an undeployed orientation by advancing the cutting member actuator 413 . Upon reaching the distal ending position 444 , the cutting member 422 reaches a fully deployed orientation. The operator may then retract the fully deployed cutting member 422 by retracting the cutting member actuator 413 . The proximally presented tissue cutting edge 434 may cut through tissue grasped between anvil 408 and cartridge 411 as the cutting member 422 is retracted proximally. Stapled transected tissue may then be released from end effector 406 by actuating the closure actuator 412 to open anvil 408 .
[0092] Referring to FIGS. 32-36 , in an alternative embodiment, a first track 424 ′ may replace the first track 424 of the staple cartridge 411 . As illustrated in FIG. 33 , the first track 424 ′ may begin at a distal portion along the length of the staple cartridge 411 . The cutting member 422 may travel from a proximal starting position 442 ′ as illustrated in FIG. 33 to the distal ending position 444 as illustrated in FIG. 35 . At the proximal starting position 442 ′, the first pin 436 may ride in the first track 424 ′, and the second pin 438 may ride in the second track 426 , causing the cutting member 422 to remain in an undeployed orientation. As illustrated in FIG. 33 , in an undeployed orientation, the tissue cutting edge 434 of the cutting member 422 is not exposed above the top surface 418 .
[0093] Referring to FIGS. 33 and 34 , advancing the driving member 446 distally may bring the driving tip 450 into mating engagement with engagement portion 440 of cutting member 422 . With the first pin 436 riding in the first track 424 ′, and the second pin 438 riding in the second track 426 , further advancing of the driving member 446 may enable the cutting member 422 to travel a short distance distally from the proximal starting position 242 ′ through slot 420 as illustrated in FIG. 34 .
[0094] Referring to FIGS. 34 and 35 , the cutting member 422 may be advanced distally in an undeployed orientation a short distance along tracks 424 ′ and 426 until the first pin 436 enters a distal portion 428 ′ of the first track 424 ′. The distal portion 428 ′ may comprise a camming surface 452 ′ which may cause the first pin 436 to be lifted toward junction point 430 as the cutting member 422 continues to be advanced distally. In result, the cutting member 422 is transitioned gradually from an undeployed orientation, as illustrated in FIG. 33 , wherein the tissue cutting edge 434 is not exposed above top surface 418 , to a deployed orientation, as illustrated in FIG. 35 , wherein the tissue cutting edge 434 is exposed above top surface 418 . Said another way, advancing the first pin 436 against the camming surface 452 ′ may cause the cutting member 422 to move about an axis transverse to the longitudinal axis L-L resulting in deployment of the tissue cutting edge 434 .
[0095] Referring again to FIG. 35 , as the cutting member 422 transitions from an undeployed orientation to a deployed orientation, as described above, the first pin 436 enters the common track portion 432 . In addition, the engagement portion 440 of the cutting member 422 is released from mating engagement with the driving tip 450 and enters into a mating engagement with the retraction hook 448 as illustrated in FIG. 35 .
[0096] Referring now to FIGS. 35 and 36 , the deployed cutting member 422 may then travel proximally from the distal ending position 444 in response to retraction motions by the driving member 446 . As illustrated in FIG. 35 , the tissue cutting edge 434 is proximally presented at the distal ending position 444 . Retraction of the driving member 446 may cause the cutting member 422 to travel proximally along the longitudinal axis L-L. As the cutting member 422 begins to travel proximally, the first pin 436 rides in common track portion 432 , and the second pin 438 rides in the second track 426 . Upon reaching junction point 430 , the first pin 436 is prevented from reentering the distal portion 428 ′ of the first track 424 ′ by driving member 446 . Instead, the first pin 436 enters the second track 426 . As illustrated in FIG. 36 , both pins 436 and 438 may ride in the second track 426 for the remainder of the proximal travel of the cutting member 422 .
[0097] Various embodiments are described and illustrated in this specification to provide an overall understanding of the elements, steps, and use of the disclosed device and methods. It is understood that the various embodiments described and illustrated in this specification are non-limiting and non-exhaustive. Thus, the invention is not limited by the description of the various non-limiting and non-exhaustive embodiments disclosed in this specification. In appropriate circumstances, the features and characteristics described in connection with various embodiments may be combined, modified, or reorganized with the steps, components, elements, features, aspects, characteristics, limitations, and the like of other embodiments. Such modifications and variations are intended to be included within the scope of this specification. As such, the claims may be amended to recite any elements, steps, limitations, features, and/or characteristics expressly or inherently described in, or otherwise expressly or inherently supported by, this specification. Further, Applicants reserve the right to amend the claims to affirmatively disclaim elements, steps, limitations, features, and/or characteristics that are present in the prior art regardless of whether such features are explicitly described herein. Therefore, any such amendments comply with the requirements of 35 U.S.C. §112, first paragraph, and 35 U.S.C. §132(a). The various embodiments disclosed and described in this specification can comprise, consist of, or consist essentially of the steps, limitations, features, and/or characteristics as variously described herein.
[0098] Any patent, publication, or other disclosure material identified herein is incorporated by reference into this specification in its entirety unless otherwise indicated, but only to the extent that the incorporated material does not conflict with existing definitions, statements, or other disclosure material expressly set forth in this specification. As such, and to the extent necessary, the express disclosure as set forth in this specification supersedes any conflicting material incorporated by reference herein. Any material, or portion thereof, that is said to be incorporated by reference into this specification, but which conflicts with existing definitions, statements, or other disclosure material set forth herein, is only incorporated to the extent that no conflict arises between that incorporated material and the existing disclosure material. Applicants reserve the right to amend this specification to expressly recite any subject matter, or portion thereof, incorporated by reference herein.
[0099] The devices disclosed herein can be designed to be disposed of after a single use, or they can be designed to be used multiple times. In either case, however, the device may be reconditioned for reuse after at least one use. Reconditioning can include a combination of the steps of disassembly of the device, followed by cleaning or replacement of particular pieces, and subsequent reassembly. In particular, the device may be disassembled, and any number of particular pieces or parts of the device can be selectively replaced or removed in any combination. Upon cleaning and/or replacement of particular parts, the device may be reassembled for subsequent use either at a reconditioning facility, or by a surgical team immediately prior to a surgical procedure. Those of ordinary skill in the art will appreciate that the reconditioning of a device may utilize a variety of different techniques for disassembly, cleaning/replacement, and reassembly. Use of such techniques, and the resulting reconditioned device, are all within the scope of the present application.
[0100] Preferably, the invention described herein will be processed before surgery. First a new or used instrument is obtained and, if necessary, cleaned. The instrument can then be sterilized. In one sterilization technique, the instrument is placed in a closed and sealed container, such as a plastic or TYVEK® bag. The container and instrument are then placed in a field of radiation that can penetrate the container, such as ethylene oxide, steam, autoclaving, soaking in sterilization liquid, gamma radiation, x-rays, or higher energy electrons. The radiation kills bacteria on the instrument and in the container. The sterilized instrument can then be stored in the sterile container. The sealed container keeps the instrument sterile until it is opened in the medical facility. | A surgical cutting instrument includes a first jaw member, a second jaw member movably supported relative to the first jaw member for selective movement between an open position and a closed position to clamp tissue therebetween upon application of a closing motion thereto, and a cutting member comprising a tissue cutting edge to cut the tissue clamped between the first jaw member and the second jaw member upon application of a retraction motion to the cutting member. | 0 |
BACKGROUND AND SUMMARY OF THE INVENTION
The present invention relates to a rock breaker tool for use with earth working apparatus. More particularly, the present invention relates to a rock breaking tool which employs a ripper tooth along with a hammer and anvil for use with excavating equipment such as a backhoe. The invention provides a tool which is energy efficient and particularly well suited for use in breaking rocks such as in the construction of roadbeds and for other purposes.
Previous devices employing a ripper tooth have been known in the prior art for use in breaking rock and for similar purposes. Apparatus in which an impact member such as a hammer is associated with a ripper tooth for use in earth working operations is described, for example, in U.S. Pat. No. 4,003,603 to Stemler et al.
By the present invention, there is provided an improved rock breaking tool which utilizes a ripper tooth and a hammer and anvil arrangement located above the upper portion of the tooth. The present tool employs a hammer, preferably operated by air or steam, which can deliver a blow of about 4000 to 6000 lbs. at a rate of about 80 to 250 blows per minute. In the tool of the present invention, a constant force is applied against the ripper tooth during operation. The use of a constant force held or applied against the ripper tooth while the hammer applies force to the tooth through the anvil results in improved operation with less energy being required and with reduced vibration during operation. The present invention has been found to be fully operable in water depths up to eighty feet. The apparatus of the present invention also results in a minimum amount of heat being produced during operation. In addition, ripping operations have been reduced from days to a matter of hours for a comparable job.
In one embodiment of the invention, the rock breaker tool is employed with a backhoe. In a second embodiment, the rock breaker tool is employed with a bulldozer. The rock breaker may also be employed in a third embodiment in conjunction with a ripper bucket.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the rock breaker tool of the present invention as installed on a backhoe.
FIG. 2 shows a front elevation of the rock breaker tool of FIG. 1.
FIG. 3 shows a side elevation from the right side of the rock breaker tool of FIG. 2.
FIG. 4 is a rear elevation of the rock breaker tool of FIG. 2, showing the ripper tooth at an angle relative to the hammer.
FIG. 5 is a rear elevation, similar to FIG. 4, but with the ripper tooth inclined at a different angle relative to the hammer.
FIG. 6 is an enlarged rear elevation of a portion of the ripper tooth employed in the rock breaker tool of FIG. 1.
FIG. 7 is a perspective view of the hammer brace arms employed in the rock breaker tool of FIG. 1.
FIG. 8 is a perspective view of an alternative embodiment of the hammer and anvil employed with the rock breaker tool of FIG. 1.
FIG. 9 is a front elevation of a second embodiment of the rock breaker tool of the present invention.
FIG. 10 is a front elevation of a third embodiment of the rock breaker tool of the present invention.
FIG. 11 is an elevation view of an alternative embodiment of the ripper tooth of the present invention.
FIG. 12. is a perspective view of an alternative embodiment in which the hammer is provided with an anvil guide box.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the embodiment of the invention as shown in FIGS. 1 through 7, there is provided a rock breaker tool 10 for use with a backhoe or other excavating equipment indicated generally at 12 in FIG. 1. The backhoe 12 has a boom or hoist 14 that is attached to a tractor shown at 16. The manner of attaching the boom 14 to the tractor 16 may be of any suitable type known in the art. A pair of boom cylinders 15 is also provided.
The backhoe 12 has a crowd 18 that is pivoted to the boom at 20. A curl 22 is pivoted to the crowd at 24. A crowd cylinder 19 and curl cylinder 23 are provided in a conventional manner. The cylinders 15, 19 and 23 are hydraulic cylinders of conventional type.
At the upper end of the curl 22 there are pivotally attached a pair of telescoping hammer brace arms 32. Each brace arm 32 includes a piston 34 and cylinder 36 portion, as shown in FIG. 7, along with connecting portions 38, 40 to allow the ends of each brace arm 32 to be secured to the curl 22 and the hammer 42, respectively, by means such as brackets 33, 35 as shown in FIG. 2. Suitable conventional means (not shown) such as a pin is provided for locking the piston 34 and cylinder 36 in the desired relative positions after the proper length of each arm 32 has been determined for the particular excavator with which the rock breaker tool 10 is to be employed.
The hammer 42 employed in the present invention may be any suitable hammer which will deliver the necessary energy to the ripper tooth 28. In one embodiment, the hammer 42 is a fluid-valve hammer provided with angle-iron guides or legs 46, with a guide 46 being provided at each of the four corners of the lower end of the hammer 42. A particular hammer and anvil set which has been employed is a MKT fluid valve hammer and associated angle-iron guides sold by Geotechnical Systems of Dover, N.J. The hammer 42 is operated by suitable compressed air or steam means through hose 43.
The anvil is in the form of a pair of parallel arms 51, 53 having inner brace member 59, as shown in detail in FIG. 3. The arms 51, 53 are received at their upper ends by the angle-iron guides 46. The top surfaces of the arms 51, 53 are positioned adjacent the lower end of the hammer 42. In the embodiment as shown, the anvil is not fixed to the hammer. As an alternative, a hammer could be employed which would be mounted so as to be fixed or tied solid to the anvil. In such a construction, the guide legs 46 would be fixed to the anvil.
In an alternative embodiment, as shown in FIG. 8, a plurality of stabilizer spring members 80 are employed to stabilize the relationship between the anvil and the hammer. These springs 80 are in a neutral condition of tension as installed, with the upper end of each spring 80 being connected to a bracket 82 mounted adjacent the base of the hammer 42, and with the lower end of each spring 80 being connected to a bracket 84 mounted on one of the arms 51, 53 of the anvil just below the guides 46. In one embodiment, four springs 80 were employed, with one spring 80 adjacent each of the guides 46.
In a further embodiment, as shown in FIG. 12, an anvil guide box 90 is secured to the angle-iron guides 46 with the upper end of the guide box 90 being positioned just below the bottom of the hammer 42. The guide box 90 is a four-sided structure with four exterior planar faces 92 and serves as a guide to maintain the upper ends of the arms 51, 53 of the anvil in proper position relative to the hammer 42.
It is within the scope of the present invention to utilize the stabilizer springs 80 in combination with the anvil guide box 90. In such an embodiment, the upper ends of the springs 80 would be attached to the guide box 90 and the lower ends of the springs 80 would be attached to the arms 51, 53 of the anvil .
In the embodiment as shown in FIGS. 1 through 6, the ripper tooth 28 of the present invention is in the form of an elongated shank portion 50 with a reinforcing arm portion 52 extending generally outwardly and upwardly from the point of attachment to the shank portion 50. The upper end of the shank 50 is pivotally attached through hole 55 by pivot pin 54 to the parallel arms 51, 53 of the anvil located on either side of the upper end of the shank 50. The upper ends of the arms 51, 53 are retained within the angle-iron guides 46 as previously discussed.
The reinforcing arm 52 terminates at its upper end in a bifurcated portion which provides a pair of parallel vertical hinge plates 56 which serve as the point of attachment of the ripper tooth 28 to the curl 22 and cylinder 23. As shown in FIGS. 2 and 3, the hinge plates 56 are mounted on base plates 61 and are at a level slightly above that of the mid-portion of the length of the shank 50.
Each hinge plate 56 has a vertical slot 58 adjacent the inner end nearest to the shank 50 for receiving a horizontal hinge pin 60. Adjacent the outer end, each hinge plate 56 is connected to the curl 22 by horizontal hinge pin 62 which extends through a hole 57 in each plate 56.
A pair of support arms 64, one on each side of the lower end of the curl 22, are pivotally connected to the curl 22 by pin 66. The support arms 64 are pivotally connected at their opposite ends to a connector bar 68 by means of pin 70 which passes through a bore in the top portion of connector bar 68. The piston 72 which operates in conjunction with cylinder 23 is provided with an enlarged lower end portion having a bore therein which receives the pin 70. Thus the piston 72 is pivotally connected to the connector bar 68. The connector bar 68 has a horizontal bore in the lower end portion which receives pin 60.
The lower end of the ripper tooth terminates in an angled lower end portion 80 for the shank 50 and with the upwardly angled, lower edge surface of the reinforcing arm 52 and the adjacent vertical surface of the shank 50 being beveled to assist in penetration of the ripper tooth during ripping operations. A guard and tip of conventional configuration (not shown) are connected by pins to the lower end of the shank.
In one embodiment, the ripper tooth 28 was constructed of 3 inch steel with the arms 51, 53 of the anvil also being of 3 inch steel. In this embodiment, the vertical slot 58 in each hinge plate 56 was about 7 inches in length and the diameter of the pin 60 was about 3 inches.
In the operation of the rock breaker tool 10 of the present invention as shown in FIGS. 1 through 7, the vertical slots 58 in hinge plates 56 act as a safety to prevent the hammer 42 from transmitting energy directly against the cylinder 23. When the ripper tooth 28 is picked up during rock breaking operations, the pin 60 will move to the top of the slot 58.
In the embodiment as shown in FIG. 11, the ripper tooth 100 is provided with a pair of tips 102, 104 extending downwardly from the lower end 106 of the shank 108. The lower end 106 is angled upwardly away from the operator as in the case of the previous embodiment. The embodiment of FIG. 11 has been found to be particularly advantageous in situations in which the shank 108 is operating at angles of greater than 20 to 25 degrees with the lower end canted toward the operator. In such situations, the configuration of FIG. 11 helps to avoid hammering on the back of the shank 108 and allows the second or upper tooth 102 to start digging in.
The tips 102, 104 are of solid construction and fixed to the shank 108 by pins in a conventional manner. The lower tip 104 is angled in a generally downwardly direction while the upper tip 102 may be angled downwardly and outwardly at an angle such as about 20 to 30 degrees relative to the vertical axis of the tooth 100.
It is within the scope of the present invention for the ripper tooth 100 to be provided with more than two tips, with such plurality of tips being fixed to the lower end portion of the tooth. In such an embodiment, the lower end of the tooth may be angled upwardly as shown in FIG. 11 or, alternatively, may be provided as a downwardly convex surface for attachment of the tips at intervals along such surface.
In FIG. 9 there is shown an embodiment in which the rock breaker tool of the present invention is employed with a bulldozer. In this embodiment, the hammer 110 is mounted in a vertical position in an anvil box 112 which in turn is mounted on the back side of the ripper portion 114 of the bulldozer 115. A gusset 116 in planar form is fixed to the bottom of the anvil box 112 by means such as welding, to assist in transferring the force of the hammer blows more directly to the point of the ripper tooth 118. In this regard, the gusset 116 is not fixed to the tooth 118 itself although the gusset 116 should be positioned closely adjacent and contiguous with the side surface of the tooth 118. In this manner, the tooth 118 can still be maneuvered up and down as the operator controls the tooth 118.
At the upper end of the hammer 110, a pair of brace arms 120, 122 are mounted one on each side of the hammer 110 by suitable means such as pad eyes and pins. The lower ends of the brace arms 120, 122 are mounted on the upper frame 124 of the ripper 114 by means such as pad eyes and pins.
The upper cylinders 126, 128 of the bulldozer 115 which assist in controlling operation of the ripper 114 are mounted to the upper frame 124 by means of a pair of cylinder adapters 130, 132 which are mounted by pins in the locations in which the cylinders would otherwise be pinned to the ripper frame 124. Each cylinder adaptor 130, 132 is provided with a vertical slot 134, 136 which receives the piston of a respective cylinder 126, 128. In this regard, each piston is provided with a pin 133 at the end thereof which is mounted in the respective slot so as to be slideable up and down within the slot. In this manner, the tooth 118 is thus hinged on pivot pin 138 and transfer of force from the hammer 110 directly to the cylinders 126, 128 is substantially reduced or prevented. In one embodiment, the slots 134, 136 were of a length of about 1 foot and the pins 133 were of a diameter of about 2 inches.
In FIG. 10 there is shown an embodiment in which the rock breaker tool of the present invention is employed in conjunction with a ripper bucket. In this embodiment, the invention is employed with a bucket 150 pivotally mounted in a conventional manner on a backhoe 152. The bucket 150 preferably has one or more ripper teeth 154 positioned on the exterior lower surface and lower lip.
The hammer 156 is attached to the curl 158 of the hoe by brace arms 160 and pins in a manner similar to the embodiment of FIG. 2. The anvil is in the form of a bar 162 which is pivotally connected to the base of the hammer 156 by means such as a pad eye 164 and pin 166. At the lower end, the bar 162 is pivotally secured to the bucket 150 by a pad eye 168 and pin 170, with the pad eye 168 being fixed to the back side of the bucket 150 and extending upwardly therefrom so as to serve effectively to transfer force from the hammer 156 to the bucket 150.
A pair of anvil guide arms 172 are attached to the curl 158 and cylinder 174 with pins and extend on either side of the anvil 162 to be mounted by means of a pin 176 in a vertical slot 178 in the anvil 162. Thus the arms 172 replace the manufacturer's arms such as shown in FIG. 2. In one embodiment, the anvil 162 had a length of about 4 to 5 feet, with a width of about 8 inches and a thickness of about 3 inches. The slot 178 was about 1 foot in length with a width of about 2 inches and the diameter of the pin 176 was about 2 inches. As the pin 176 is free to move up and down in the slot 178 during operation of the bucket 150, the transfer of the force of the hammer 156 directly to the cylinder 174 is substantially reduced or prevented.
In the various embodiments as discussed herein, it is seen that a slot and pin configuration is employed in an attempt to reduce or prevent the transfer of force from the hammer directly to the cylinder or cylinders of the excavating mechanism. Generally the slot should be of a length at least 2 to 3 times the diameter of the associated pin.
The present invention provides a versatile tool which is well suited for use with various types of excavating equipment. The present rock breaking tool is especially designed and constructed to accomodate a wide range of needs in the excavating industry.
The invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The present embodiments 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 by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. | A rock breaker tool for use with earth working apparatus is disclosed. The tool includes a ripper tooth employed with a hammer and anvil arrangement located above the upper portion of the tooth. The present invention is so constructed as to minimize the transfer of force directly from the hammer to the hydraulic cylinders of the earth working apparatus. The invention may be employed with various types of earth working apparatus, including backhoes, bulldozers and ripper buckets. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a national stage application, under 35 U.S.C. 371, of PCT/EP2005/008561 filed Aug. 6, 2005, which claims benefit of German Application No. 10 2004 041 850.0 filed Aug. 27, 2004.
BACKGROUND OF THE INVENTION
For the economic utilization of C 4 streams, as can be obtained, for example, from cracking processes or by dehydrogenating butanes, various processes are already known. These starting streams typically comprise relatively large amounts of 1,3-butadiene, 1-butene and 2-butenes. In addition, significant proportions of butanes, and also isobutene in the case of cracking processes, are often present. In order to achieve a very economically viable process, the individual components each have to be converted to salable products of maximum value, without the other components being impaired thereby. Particularly advantageous in this context is also the complete or partial conversion of one C 4 component to another C 4 component which is fed to an economically more attractive use. To this end, generally complex, multistage processes are required, in which the individual C 4 components are processed stepwise. Such processes are described, for example, in DE-A-10118634, EP-A-742 195 and 742 234.
Pure 1,3-butadiene constitutes a sought-after monomer. Pure 1-butene is likewise a high-cost monomer, but after hydroformylation to valeraldehyde and subsequent aldol condensation and hydrogenation to propylheptanol also finds an economically significant outlet as a plasticizer component and surfactant alcohol. Isobutene serves as a starting material for fuel and lubricant additives after polymerization to polyisobutene, as a fuel additive after etherification with methanol to MTBE, and as knock-resistant gasoline alkylate after dimerization to diisobutene and subsequent hydrogenation. In contrast, the direct chemical reaction of 2-butenes is hitherto industrially insignificant. Here, an olefin metathesis with ethene, which converts 2-butenes to the valuable olefin monomer propene, is viable.
BRIEF SUMMARY OF THE INVENTION
The present invention relates to a process for preparing C 5 aldehydes and propene from a 1-butene- and 2-butene-containing C 4 stream.
It is an object of the present invention to develop a process which enables a substantially full and highly economically viable utilization of a C 4 stream to prepare propene and C 5 aldehydes.
Accordingly, a process has been found for preparing C 5 aldehydes and propene from a 1-butene- and 2-butenes-containing C 4 stream which contains up to 1000 ppm by weight of 1,3-butadiene (C 4 starting stream), comprising
a) a hydroformylation stage in which the C 4 starting stream is contacted in the presence of a customary hydroformylation catalyst with hydrogen and carbon monoxide, and the thus formed C 5 aldehydes and the thus formed 2-butene-rich C 4 stream are subsequently separated from one another, and b) a metathesis stage in which the 2-butene-rich C 4 stream formed in the hydroformylation stage is contacted with ethene in the presence of a customary metathesis catalyst and the propene is removed from the thus formed propene-containing hydrocarbon stream.
Suitable C 4 -containing streams are in particular raffinates (raffinate I or II). Such raffinates I can be prepared by 3 different methods:
In the first method, the C 4 starting stream is provided by
Ia) in step Ia, subjecting naphtha or other hydrocarbon compounds to a steamcracking or FCC process and drawing off from the thus formed stream a C 4 olefin mixture which comprises 1-butene, 2-butene and more than 1000 ppm by weight of butadienes, with or without butynes and isobutene, and IIa) preparing from the C 4 olefin mixture formed in step Ia a C 4 hydrocarbon stream consisting substantially of 1-butene and 2-butenes, with or without butanes and isobutene (raffinate 1), by hydrogenating the butadienes and butynes to butenes or butanes by means of selective hydrogenation, or removing the butadienes and butynes by extractive distillation to such an extent that the content of 1,3-butadiene is not more than 1000 ppm by weight.
In the second method, the C 4 starting stream is provided by
Ib) in step Ib, preparing from a hydrocarbon stream comprising butanes, by dehydrogenation and subsequent purification, a C 4 olefin mixture which comprises isobutene, 1-butene, 2-butene and more than 1000 ppm by weight of butadienes, with or without butynes and butanes, IIb) preparing from the C 4 olefin mixture formed in step Ib a C 4 hydrocarbon stream consisting substantially of isobutene, 1-butene and 2-butenes, with or without butanes (raffinate 1), by hydrogenating the butadienes and butynes to butenes or butanes by means of selective hydrogenation, or removing the butadienes and butynes by extractive distillation to such an extent that the content of 1,3-butadiene is not more than 1000 ppm by weight.
In the third method, the C 4 starting stream (in the form of raffinate II) is provided by
Ic) preparing from methanol by dehydrogenation a C 4 olefin mixture (MTO process) which comprises isobutene, 1-butene and 2-butene, with or without butadienes, alkynes and butanes, and Ic) freeing the C 4 olefin mixture of butadienes or alkynes by distillation, selective hydrogenation or extractive distillation.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
The foregoing summary, as well as the following detailed description of the invention, may be better understood when read in conjunction with the appended drawings. For the purpose of assisting in the explanation of the invention, there are shown in the drawings representative embodiments which are considered illustrative. It should be understood, however, that the invention is not limited in any manner to the precise arrangements and instrumentalities shown. In the drawings:
FIG. 1 is a schematic process diagram in accordance with an embodiment of the present invention;
FIG. 2 is a schematic process diagram in accordance with an embodiment of the present invention; and
FIG. 3 is a schematic process diagram in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Raffinate II has substantially the same composition as raffinate I, except for the fact that raffinate II comprises smaller amounts of isobutene. Typically, raffinate II has amounts of less than 10% by weight, preferably less than 5% by weight, of isobutene.
Raffinate II can be prepared from raffinate I by removing from raffinate I the substantial proportion of the isobutene by known chemical, physicochemical or physical methods.
For this purpose, there are in principle three fundamentally different possibilities: a) a distillative removal, b) a removal by etherification/extraction and c) direct polymerization to polyisobutene.
The distillation (method a) takes place in an apparatus suitable therefor, for example a bubble-cap tray column, column having random packing, column having structured packing or dividing wall column. The distillation column is preferably configured with from 20 to 80 theoretical plates. The reflux ratio is generally from 5 to 50. The distillation is generally carried out at a pressure of from 5 to 20 bar.
Owing to the low boiling point of isobutene and 1-butene in comparison to 2-butenes and n-butane, the top stream comprises mainly isobutene and 1-butene, the bottom stream mainly 2-butenes and n-butane. The content of low boilers (isobutene and 1-butene) in the bottom stream is less than 40%, preferably less than 30% and more preferably 5-20%. The content of high boilers (2-butenes and n-butane) in the top stream is less than 40%, preferably less than 30% and more preferably from 5 to 20%.
In method b), the procedure is typically to contact raffinate I with an alkyl alcohol, preferably a C 1 - to C 4 -alkyl alcohol, and a customary catalyst for the formation of alkyl tert-butyl ether, and to remove the alkyl tert-butyl ether formed from the remaining raffinate II. Particularly preferred alcohols: MeOH, BuOH.
The etherification is effected preferably in the presence of an acidic ion exchanger in a three-stage reactor battery, in which flooded fixed bed catalysts are flowed through from top to bottom, at a reactor inlet temperature of from 0 to 60° C., preferably from 10 to 50° C., an outlet temperature of from 25 to 85° C., preferably from 35 to 75° C., a pressure of from 2 to 50 bar, preferably from 3 to 20 bar, and a ratio of alcohol to isobutene of from 0.8 to 2.0, preferably from 1.0 to 1.5.
In method c), the procedure is typically to contact raffinate I with a customary catalyst for the polymerization of isobutene and to remove the polyisobutylene formed from the remaining C 4 starting stream. The catalyst used is preferably a homogeneous or heterogeneous catalyst from the class of the Brønsted or Lewis acids. The catalyst is preferably boron trifluoride.
If it improves economic viability of the overall process, optionally removed isobutene may also be fed to a skeletal isomerization—a combination of distillation and skeletal isomerization in a type of reactive distillation is also possible at this point—in order to increase the amounts of linear olefins and thus to increase the yields in the 1-butene-utilizing stage or the metathesis.
Preference is given to carrying out the extractive distillation in step IIa, IIb or IIc with a butadiene-selective solvent selected from the class of polar aprotic solvents such as acetone, furfural, acetonitrile, dimethylacetamide, dimethylformamide and N-methylpyrrolidone.
The selective hydrogenation in step IIa, IIb or IIc may be used for a substantial reduction of diolefins or acetylenic compounds, since these compounds would impair the downstream process stages. In addition, the selective hydrogenation of a major amount of 1,3-butadiene can also considerably increase the amount of linear monoolefins, which increases the production capacity of downstream stages. Suitable catalysts and methods (for example H 2 supply) allow the 1-butene to 2-butene ratio in the selective hydrogenation to be controlled within certain limits (known as hydroisomerization). Since there are particularly attractive economic means of utilization, especially for the 1-butene, 1-butene to 2-butene ratios of at least 1:3, preferably of at least 2:3, more preferably of more than 1:1, are sought after. Preference is given to carrying out the partial step of selective hydrogenation in the liquid phase over a metal selected from the group of nickel, palladium and platinum, on a support, preferably palladium on alumina, at a temperature of from 20 to 200° C., a pressure of from 1 to 50 bar, a volume flow rate of from 0.5 to 30 m 3 of fresh feed per m 3 of catalyst per hour and a ratio of recycle to feed stream of from 0 to 30 with a molar ratio of hydrogen to diolefins of from 0.5 to 50.
When the content of 1,3-butadiene in the C 4 olefin mixture obtained in step Ia or step Ib is 5% by weight or more, the content of 1,3-butadiene is typically lowered by means of extractive distillation to a content between 1000 ppm by weight and 5% by weight, and the content of 1,3-butadiene is subsequently lowered further by means of selective hydrogenation to 1000 ppm by weight or less.
The C 4 starting stream preferably has a ratio of 1-butene to 2-butenes of from 3:1 to 1:3.
The content of 1,3-butadiene is preferably less than 300 ppm by weight, more preferably less than 100 ppm by weight.
In general, the C 4 starting stream comprises from 2 to 50% by weight of butanes, from 15 to 80% by weight of 2-butenes and from 20 to 60% by weight of 1-butene, from 20 to 1000 ppm by weight of butadienes and from 0 to 50% of isobutene.
The hydroformylation stage may generally be carried out in the manner customary and known to those skilled in the art. A good review with numerous further references can be found, for example, in M. Beller et al., Journal of Molecular Catalysis A, 104, 1995, pages 17 to 85 or in Ullmann's Encyclopedia of Industrial Chemistry, 6 th edition, 2000 electronic release, Chapter “ALDEHYDES, ALIPHATIC AND ARALIPHATIC—Saturated Aldehydes”. The information given there enables those skilled in the art to hydroformylate both the linear and the branched alkenes.
In the hydroformylation stage, valeraldehyde (n-pentanal) is prepared under transition metal catalysis from 1-butene with addition of synthesis gas (CO:H 2 of from 3:1 to 1:3, preferably from 1.5:1 to 1:1.15).
The catalysts used for the hydroformylation reaction are generally rhodium complexes having phosphorus ligands. The phosphorus ligands are typically a mono- or diphosphine, preferably a triarylphosphine, more preferably triphenylphosphine. The hydroformylation is carried out typically at temperatures of from 50 to 150° C., preferably from 70 to 120° C., and pressures of from 5 to 50 bar, preferably from 10 to 30 bar.
After the hydroformylation stage, the C 4 stream (also known as “2-butene-rich C 4 stream”) comprises typically from 3 to 70% by weight of butanes, from 22 to 90% by weight of 2-butenes, from 20 to 1000 ppm by weight of 1,3-butadiene, from 0 to 10% by weight of 1-butene and from 0 to 65% by weight of isobutene.
The ratio of 1-butene to 2-butene in the 2-butene-rich C 4 stream is typically from 1:3 to 1:60.
The 2-butene-rich C 4 stream comprises preferably less than 300 ppm, more preferably less than 100 ppm, of 1,3-butadiene.
The conversion of the 1-butenes in this process stage is preferably greater than 80%, the absolute 1-butenes content in the 2-butene-rich C 4 stream is preferably less than 5%. The ratio of 1-butene to 2-butene in the 2-butene-rich C 4 stream is less than 1:3, preferably less than 1:5.
If the isobutene has not already been removed from the C 4 starting stream, the isobutene removal may be connected downstream of the hydroformylation stage. This is preferred for variants a and c. Suitable for this purpose are the same methods as described above for the preparation of raffinate I from raffinate II.
For a high yield of propene in the metathesis stage, an additional purification is generally initially also necessary, which depletes traces of oxygenates, and also if appropriate acetylenes and dienes. The contents of oxygenates, for example water, acetone or ethanol, after the purification stage should in total be less than 100 ppm, preferably less than 50 ppm, more preferably less than 10 ppm. The contents of diolefins should be less than 300 ppm, preferably less than 150 ppm, more preferably less than 100 ppm. The purification of the 2-butene-rich C 4 stream consists of one or more stages and may also comprise pressure-swing adsorption, but preference is given to at least one adsorptive process. Preference is given to effecting the purification directly before the metathesis, but may also theoretically be fully or partly upstream of other process stages. Optionally, the purification step may also comprise a selective hydrogenation which also removes residual traces of diolefins and acetylene which have not been fully hydrogenated in the first selective hydrogenation stage or might have been newly formed or have accumulated in later process stages. The purification stage preferably comprises at least one adsorber bed based on an alumina or a molecular sieve for removing oxygenates. Particular preference is given to an embodiment in which at least two adsorber beds based on an alumina or molecular sieve are present and each alternate between adsorption and regeneration mode. Preferred adsorbents are a 13× molecular sieve or high-surface area gamma-alumina (for example Selexsorb from Almatis).
The 2-butene-rich C 4 stream is finally fed to a metathesis stage in order to convert the 2-butene into the higher-value propylene monomer. To this end, ethylene is added stoichiometrically (based on 2-butene) or ethylene is added in excess. Although any 1-butene or isobutene present in the stream likewise reacts partly to form higher olefins (C 5 and C 6 ) these may be discharged or else recycled into the metathesis, so that there is only a small, if any, net conversion.
If the propene-containing hydrocarbon stream formed in the metathesis stage comprises C 5 and C 6 olefins, they are removed from the propene and typically recycled into the metathesis stage at least to the extent that the molar ratio of the sum of the unrecycled C 5 and C 6 olefins to propene is not more than 0.2:1.
Unconverted 2-butene and ethylene may also, if appropriate, be recycled into the metathesis stage, since the metathesis reaction is an equilibrium reaction.
For the metathesis, there are in principle two different useful catalyst types: a) rhenium catalysts which are operated at temperatures in the range from 30 to 150° C., preferably in the range from 35 to 110° C., and b) W-containing, Re-free catalysts which are operated in the gas phase at temperatures of from 200 to 600° C., preferably from 220 to 450° C.
The Re catalysts comprise preferably at least 1% by weight of Re in oxidic form on a support which is composed to an extent of at least 75% by weight of a high-surface area alumina, most preferably gamma-alumina. Special preference is given to catalysts which have an Re content of from 5 to 12% by weight and are supported on pure gamma-Al 2 O 3 . To increase the activity, the catalysts may also additionally comprise dopants, for example oxides of Nb, Ta, Zr, Ti, Fe, Mn, Si, Mo, W, phosphate or sulfate. The catalysts preferably have surface areas of at least 100 m 2 /g and pore volumes of at least 0.3 ml/g. Suitable Re catalysts are described, for example, in DE-A 10 2004 009 804.2, DE-A 10 2004 009 805.0 or DE-A 10 2004 009 803.4.
Suitable W-containing and Re-free catalysts comprise preferably at least 3% by weight of W, at least partly in oxidic form, on a support selected from the group of alumina, aluminosilicates, zeolites or, preferably, SiO 2 . The catalysts preferably have a surface area of at least 50 m 2 /g and a pore volume of at least 0.3 ml/g. The activity or isomerization activity may be improved by suitable dopants, for example alkali metal and alkaline earth metal compounds, TiO 2 , ZrO 2 , HfO 2 , or compounds or elements from the group of Ag, Sb, Mn, W, Mo, Zn, Si. If a further increase in the 1-butene content is desired in the metathesis, it is also possible to mix with the W catalyst an isomerization catalyst, for example an alkaline earth metal oxide. This leads in the metathesis to the generation, in addition to propene, also of an additional amount of 1-butene which can in turn be fed to process stage b after distillative removal and increases the capacity here.
It is known to those skilled in the art that all types of metathesis catalysts regularly have to be regenerated oxidatively. To this end, either a construction with fixed beds and at least two reactors is selected, of which at least one reactor is always in regeneration mode, or a moving bed process may alternatively be practiced, in which deactivated catalyst is discharged and regenerated externally.
Especially in the case of the use of a rhenium catalyst, a useful embodiment is that of reactive distillation, in which the metathesis catalyst is placed directly within the distillation column. This embodiment is very suitable in particular in the presence of large amounts of 1-butene in the starting stream. In this case, unconverted ethylene, propene and 1-butene are taken overhead; the heavier olefins remain together with the catalyst in the bottom. If appropriate, discharge of inerts, for instance butanes, has to be ensured. This specific type of reaction allows the conversion of 2-butene to propene without the 1-butene content being altered.
The propene-containing hydrocarbon stream formed in the metathesis stage is worked up preferably by means of distillation. The distillative separation may be effected in a plurality of distillation stages connected in series or the propene-containing hydrocarbon stream formed in the metathesis stage may be fed at any point into the separation apparatus which splits the hydrocarbon mixture formed in the steamcracker into individual fractions.
If a polymer is to be prepared in a subsequent step from the propene, the propene is purified further by customary methods such that it corresponds to the polymer-grade specification. According to this, the following upper limits apply for impurities:
Propylene
>99.5%
by weight
Propane
<5000
ppm by weight
Methane
<200
ppm by weight
Ethane
<300
ppm by weight
Ethylene
<30
ppm by weight
Acetylene
<1
ppm by weight
Water
<10
ppm by weight
EXAMPLES
The examples which follow, which are based on model calculations, are intended to illustrate arrangements for the utilization of C 4 streams. The components shown hereinbelow in dashed lines in the block schemes are in each case stages which are optional in principle. Some of these are also not used in the specific, accompanying text example.
Example 1
Example 1 is Illustrated Further by Scheme 1
From 400 000 tpa (metric tons per annum) of a crude C 4 stream from a naphtha cracker, approx. 75 000 tpa of 1,3-butadiene are removed by a butadiene extraction. After the selective hydrogenation, the remaining 325 000 tpa have the following composition: 30.8% isobutene, 30.8% 1-butene, 30.8% 2-butenes, 80 ppm of 1,3-butadiene, remainder butanes. This feed is fed to a stage for the selective hydroformylation of 1-butene. The 1-butene conversion is 90%; a total of 3% each of the 1-butene are converted in this process to 2-butene and butane respectively. Nearly 130 000 tpa of valeraldehyde are produced. The remaining C 4 stream (approx. 240 000 tpa) consists of 41.6% isobutene, 4.2% 1-butene, 42.7% 2-butenes, 100 ppm of 1,3-butadiene and remainder butanes. This feed is sent initially through a 13× molecular sieve for the removal of oxygenate traces and a total of 51 350 tpa of ethylene are subsequently fed to the metathesis stage. The metathesis runs in the gas phase over a fixed bed catalyst, 10% by weight of WO 3 on an SiO 2 support. The temperature is controlled to balance the advancing loss of activity and is 220° C. at the start of run and 400° C. at the end of run. When the end temperature has been attained after approx. 2 to 3 weeks, the catalyst is regenerated oxidatively at temperatures of approx. 550° C. In this time, a second, parallel reactor (A/B mode) takes over the production. At an average equilibrium conversion of approx. 55%, nearly 85 000 tpa of propene are produced. The stream formed in the metathesis stage is worked up by distillation, either in a separate distillation unit or it is fed for this purpose to the distillation unit which is attached downstream of a steamcracker. In the case of separate distillative workup, the stream is separated into at least 4 different fractions (see scheme): a) a fraction comprising mainly ethylene (fraction a), b) a fraction comprising mainly propene (fraction b), c) a fraction comprising C 4 , C 5 and C 6 olefins, the C 4 olefins being mainly 2-butene, and d) a fraction comprising mainly low-boiling C 4 hydrocarbons (fraction d). Fraction a and c may subsequently be recycled back into the metathesis stage (alternatively: cracker). Fraction (C 4 content without taking the streams into account): c+d (184 000 tpa) is recycled to the cracker for reprocessing.
Example 2
Example 2 is Further Illustrated by Scheme 2
From 400 000 tpa of a crude C 4 stream from a naphtha cracker, approx. 100 000 tpa of 1,3-butadiene are removed by a butadiene extraction. After the selected hydrogenation, the remaining 300 000 tpa have the following composition: 36.7% isobutene, 26.7% 1-butene, 28.4% 2-butenes, 90 ppm of 1,3-butadiene, remainder butanes. This feed is fed to a stage for the selective hydroformylation of 1-butene. The 1-butene conversion is 85%; a total of in each case 4% of the 1-butene are converted in the process to 2-butene and butane respectively. Approx. 96 000 tpa of valeraldehyde are produced. The remaining C 4 stream (approx. 237 000 tpa) consists of 46.3% isobutene, 5.1% 1-butene, 38.1% 2-butenes, 110 ppm of 1,3-butadiene and remainder butanes. In a stage for the selective formation of polyisobutene, the isobutene is depleted to 5%. The acidic catalyst used is BF 3 . Approx. 98 000 tpa of polyisobutene are obtained; the residual stream (approx. 134 000 tpa) consists of 5% isobutene, 8.9% 1-butene, 67.4% 2-butene, 190 ppm of 1,3-butadiene, remainder butanes.
This feed is initially also passed through a selective hydrogenation stage for the reduction of the 1,3-butadiene content to 80 ppm. The 1- to 2-butene content is not changed any further in this stage. Subsequently, a 13× molecular sieve removes oxygenate traces. The C 4 feed is subsequently fed to the metathesis stage together with approx. 45 000 tpa of ethylene. The metathesis runs in the liquid phase over a fixed bed catalyst, 10% by weight of Re 2 O 7 on a gamma-alumina support. The temperature is controlled to balance the progressing loss of activity and is 35° C. at the start of run and 110° C. at the end of run. When the end temperature has been attained after approx. 1 week, the catalyst is regenerated oxidatively at temperatures of approx. 550° C. In this time, a second, parallel reactor (A/B mode) takes over the production. At an average equilibrium conversion of approx. 63%, around 64 000 tpa of propene are produced. The stream formed in the metathesis stage is worked up as described in scheme 1. The amount of the (C 4 content) fractions c+d is approx. 91 000 tpa.
Example 3
Example 3 is Further Illustrated by Scheme 3
375 000 tpa of a crude C 4 stream from a naphtha cracker are fed completely to a selective hydrogenation. Afterward, the stream has the following composition: 33.3% isobutene, 24% 1-butene, 40% 2-butenes, 100 ppm of 1,3-butadiene, remainder butanes. This feed is fed to a stage for the selective hydroformylation of 1-butene. The 1-butene conversion is 90%; a total of in each case 3.5% of the 1-butene are converted in the process to 2-butene and butane respectively. Around 115 000 tpa of valeraldehyde are produced. The remaining C 4 stream (nearly 300 000 tpa) consists of 41.7% isobutene, 3% 1-butene, 50.9% 2-butenes, 120 ppm of 1,3-butadiene and remainder butanes. This feed is split distillatively: the top product (136 000 tpa) consists of 80.5% isobutene, 5.8% 1-butene, 9.5% 2-butenes, 110 ppm of 1,3-butadiene, remainder butanes. The bottom product (163 000 tpa) consists of 9.3% isobutene, 0.7% 1-butene, 85.5% 2-butenes, 10 ppm of 1,3-butadiene, remainder butanes. The bottom product is sent initially through a 13× molecular sieve to remove oxygenate traces and a total of 70 000 tpa of ethylene are subsequently fed to the metathesis stage. The metathesis runs in the liquid phase over a fixed bed catalyst, 10% by weight of Re 2 O 7 on an Al 2 O 3 support. The temperature is controlled to balance the advancing loss of activity and is 40° C. at the start of run and 120° C. at the end of run. When the end temperature has been attained after approx. 6 days, the catalyst is regenerated oxidatively at temperatures of approx. 550° C. In this time, a second, parallel reactor (A/B mode) takes over the production. At an average equilibrium conversion of approx. 63%, nearly 133 000 tpa of propene are produced. The stream formed in the metathesis stage is worked up as described in scheme 1. The amount of fraction (C 4 fraction) c+d is 75 000 tpa. | Processes for preparing a C 5 aldehyde and propene are disclosed, the processes comprising: (a) providing a feedstream, the feedstream comprising butane, 1-butene, 2-butene and 1,3-butadiene, the 1,3-butadiene present in the feedstream in an amount up to 1000 ppm; (b) contacting the feedstream with hydrogen and carbon monoxide in the presence of a hydroformylation catalyst to form a 2-butene-rich butane stream and a C 5 aldehyde; (c) separating the 2-butene-rich butane stream and the C 5 aldehyde; and (d) contacting the 2-butene-rich butane stream with ethene in the presence of a metathesis catalyst to form a propene-containing hydrocarbon stream. | 2 |
CLAIM OF PRIORITY
This application claims priority from the following application, which is hereby incorporated by reference in its entirety:
U.S. Application No. 60/450,991, FRAMEWORK FOR A PERSONALIZED PORTAL, Inventors: Daryl Olander, et al., filed on Feb. 28, 2003.
COPYRIGHT NOTICE
A portion of the disclosure of this patent document contains material which is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever.
CROSS REFERENCE TO RELATED APPLICATIONS
This application is related to the following co-pending applications which are each hereby incorporated by reference in their entirety:
U.S. application Ser. No. 10/788,803, Inventors: Scott Musson, et al., filed on Feb. 27, 2004, SYSTEM AND METHOD FOR CONTAINING PORTLETS.
U.S. application Ser. No. 10/788,530, Inventors: Scott Musson, et al., filed on Feb. 27, 2004, METHOD FOR ENTITLING A USER INTERFACE.
U.S. application Ser. No. 10/789,970, Inventors: Daryl B. Olander, et al., filed on Feb. 27, 2004, GRAPHICAL USER INTERFACE NAVIGATION METHOD.
U.S. application Ser. No. 10/789,016, Inventors: Daryl B. Olander, et al., filed on Feb. 27, 2004, METHOD FOR UTILIZING LOOK AND FEEL IN A GRAPHICAL USER INTERFACE.
U.S. application Ser. No. 10/788,801, Inventors: Scott Musson, et al., filed on Feb. 27, 2004, METHOD FOR PORTLET INSTANCE SUPPORT IN A GRAPHICAL USER INTERFACE.
U.S. application Ser. No. 10/789,135, Inventors: Daryl B. Olander, et al., filed on Feb. 27, 2004, CONTROL-BASED GRAPHICAL USER INTERFACE FRAMEWORK.
U.S. application Ser. No. 10/789,140, Inventors: Daryl B. Olander, et al., filed on Feb. 27, 2004, SYSTEM AND METHOD FOR DYNAMICALLY GENERATING A GRAPHICAL USER INTERFACE.
U.S. application Ser. No. 10/789,137 Inventors: Daryl B. Olander, et al., filed on Feb. 27, 2004, METHOD FOR PROPAGATING LOOK AND FEEL IN A GRAPHICAL USER INTERFACE.
BACKGROUND
Developing graphical user interfaces (GUIs) for distributed applications such as web portals can present many challenges. Not only do end-users expect to customize the content a given GUI presents to them, they might also expect to customize the look and feel of the GUI. Such customization can be coarse-grained, as in changing an overall color scheme, but they can also be fine-grained wherein an end-user may desire to change the textures, arrangement, behaviors and other characteristics of the GUI. This presents many design challenges, especially if such a GUI is deployed in a clustered, multi-threaded runtime environment.
FIELD OF THE DISCLOSURE
The present disclosure relates generally to graphical user interface development.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an illustration of an exemplary web graphical user interface in accordance to an embodiment.
FIG. 2 is an illustration of a web control taxonomy in accordance to an embodiment.
FIG. 3 is an illustration of request processing in an embodiment.
FIG. 4 is diagram of container processing in accordance to one embodiment.
FIG. 5 is diagram of a control tree factory having a JSP page description implementation in accordance to an embodiment.
FIG. 6 is diagram of a control tree factory having a metadata page description implementation accordance to an embodiment.
FIG. 7 is diagram of a control tree factory having a pure JSP page description implementation accordance to an embodiment.
FIG. 8 is a diagram of a system in accordance to an embodiment.
FIG. 9 is a sample skeleton JavaServer Page in accordance to an embodiment.
DETAILED DESCRIPTION
The invention is illustrated by way of example and not by way of limitation in the figures of the accompanying drawings in which like references indicate similar elements. It should be noted that references to “an” or “one” embodiment in this disclosure are not necessarily to the same embodiment, and such references mean at least one.
FIG. 1 is an illustration of an exemplary web graphical user interface in accordance to one embodiment of the invention. In one embodiment, by way of example, page 16 is rendered upon display area 12 , which can be a region in the display area of a device for displaying images and/or producing sounds (e.g., a computer monitor). Page 16 is comprised of several elements. Page selection tabs 20 - 28 can each be selected by a user to render a different page. Pages can be thought of as panels or panes that can be swapped into and out of a display region of the available portal real estate. By way of a non-limiting example, selection of a GUI element can be accomplished with an input device such as a mouse, a motion detector, voice commands, hand or eye gestures, etc. If tab 20 were selected, for example, the page corresponding to that tab could be rendered. Although the tabs 20 - 28 in FIG. 1 are displayed horizontally, in another embodiment the tabs could be displayed vertically or using some other suitable scheme such as a hierarchical menu.
Within page 16 is display area 10 , which includes portlets ( 18 , 30 , 32 ) and other elements. A portlet is an application that manages its own GUI. Portlets can communicate with each other and with other software and hardware components (e.g., Enterprise Java Beans™, Java™ Beans, servlets, applets, etc.). The Java™ programming language, its libraries, environment, and toolkits are available from Sun Microsystems, Inc. of Santa Clara, Calif. The other software and hardware components may be part of the same execution environment as the portlet or may be in a different execution environment. In one embodiment, a portlet can be implemented with JavaServer Pages™. By way of a non-limiting example, portlet 30 displays real-time stock ticker information. A user could configure such a portlet to display certain stocks, for example. In another embodiment, the user can select a given stock displayed in portlet 30 and receive more detailed information, such as the price history, price to earnings ratio, etc.
Portlet 30 can handle user input and responding accordingly. Portlet 32 displays up-to-date information pertaining to a user's checking accounts. Likewise, portlet 32 could provide detailed information on transactions if the user were to select an account. Advertisement portlet 18 displays an advertisement that could be directed specifically to the current user based on demographics or other information. For instance, if a user had an outstanding home loan in good standing, the advertisement could be for a home equity loan. Likewise, if the user had an appropriate amount in a savings account, the advertisement could be for a new car loan. Static area 14 contains text or an image with text.
FIG. 2 is an illustration of a control taxonomy in accordance to an embodiment. One embodiment provides a set of controls that represent corresponding graphical and functional elements in web applications. Controls can have properties that can be read and set, and controls can interact with each other through an event notification mechanism. In addition to properties and events, controls can also have methods which provide services and which may be overridden to provide specialization of the control. In one embodiment, a control can be implemented as one or more classes in an object-oriented programming paradigm. Such an arrangement allows for new properties, events and/or specialized control methods to be provided by extending base control classes related to these features. In a framework, controls can also serve as containers for other controls. By way of a non-limiting example, a page may contain a booklet and a portlet, the booklet may contain one or more pages, the portlet may contain a window, the window may contain a title bar which may contain a close button, etc.
At the top of the taxonomy, there can be one or more web applications 200 . A web application represents a collection of resources and components that can be deployed as a unit in one or more web/application servers. In one embodiment, a web application can represent a J2EE (Java 2 Platform, Enterprise Edition) Enterprise Application. In various embodiments, a web application can contain one or more controls 202 representing one or more portals. From an end-user perspective, a portal is a website whose pages can be navigated. From an enterprise perspective, a portal is a container of resources and functionality that can be made available to end-users. Portals can provide a point of access to applications and information and may be one of many hosted within a web/application server. In one embodiment, a portal can be a J2EE application consisting of EJB (Enterprise Java Bean) components and a set of Web applications. In another embodiment, a portal can be defined by an XML (Extensible Markup Language) file. The portal file can contain all of the components that make up that particular instance, such as booklets, pages, portlets, and look and feel components.
A GUI can contain one or more desktop controls 204 . A desktop control in turn can contain one or more personalized views or user views (not shown). A user can have one or more personalized user views of a desktop. In one embodiment, a user view can result from customizing the layout, content, number, and appearance of elements within a desktop. A default user view can be provided for users who have not yet customized a desktop. A desktop's appearance can be determined by a Look and Feel control 210 . The look and feel control can contain a skin component 220 and a skeleton component 222 . Skins can provide the overall colors, graphics, and styles used by all components in a desktop interface. In one embodiment, skins can include collections of graphics and cascading style sheets (CSS) that allow changes to be made to the look and feel of the GUI without modifying other components directly. References to images and styles can be made in the skin rather than being hard-coded into a GUI definition. A look and feel component can provide a path to a skin directory to be used.
The look and feel file can also provides a path to the skeleton directory to be used. Every type of component, from a desktop to a portlet's title bar, can have an associated JSP (Java ServerPages™) file, called a skeleton file, that renders it. For example, each desktop uses a skeleton file called shell.jsp that simply provides the opening and closing <HTML> (Hypertext Markup Language) tags to render the desktop. A portlet title bar, on the other hand, can have a skeleton file called titlebar.jsp that is more complex. It contains Java calls to various windowing methods in the API, references the button graphics to use on the title bar, and determines the placement of title bar elements with an HTML table definition.
A desktop also can contain a booklet control 206 . A booklet control represents a set of pages linked by a page navigator (menu 214 ) having a user selectable graphical representation (e.g., a series of tabs wherein each tab corresponds to a different page, a series of buttons, a menu, or other suitable means.) A booklet can provide an indication of the currently selected page through visual clues such as highlighting a currently selected tab, displaying text and/or graphics to indicate the current page, etc. Booklets can be nested to n levels. A booklet can optionally include a theme control 212 . In one embodiment, a theme control represents a subset of a skin component and can provide a way of using a different set of styles for individual desktop components. The booklet control can also contain other booklets 216 .
A shell control 208 can render anything surrounding the booklet 206 in the desktop 204 . For example, a shell control might render a desktop's header and footer. These areas usually display such things as personalized content, banner graphics, legal notices, and related links.
A booklet also contains zero or more page controls 218 . A page control can represent a web page in an embodiment. A page is an area of a GUI upon which other elements having GUIs, such as booklets and portlets, can be placed. Pages can also contain booklets and other pages, and can be identified/navigated to by a control such as a menu 214 . A page control can also hold a theme control 224 and a layout control 226 . A layout control determines the physical locations of portlets and other elements on a page. In one embodiment, a layout is can be implemented as an HTML table.
A layout can contain a placeholder control 228 which is comprised of individual cells in a layout in which portlets are placed. A placeholder can contain zero or more booklets 232 and zero or more portlets 230 . A portlet is a self-contained application that can render its own GUI. A portlet is a self-contained application that is responsible for rendering its own content on a page. By way of a non-limiting example, a portlet might be a display of current news headlines, wherein if a user selects a headline the portlet retrieves and the underlying story and displays it for the user. Portlets can communicate with other portlets and with back-end processes such as legacy software, databases, content management systems, enterprise business services, etc. In addition, multiple instances of a portlet can execute simultaneously. A portlet can also contain a theme 234 .
A control tree can represent a particular instance of the control taxonomy. In one embodiment, each node in the control tree can be a subclass of a Control class in an object-oriented paradigm. A control tree can be created with both statically created controls and dynamically created controls. Statically created controls are created during a construction (or “wire-up”) phase of the control tree and, in one embodiment, can be based on static markup. Dynamically created controls are created during a control tree lifecycle, many times in reaction to state, context, and events. Both kinds of controls can create content either dynamically (e.g., by binding to a database table) or statically (e.g., by containing a literal string).
Controls within a control tree can have unique names. In addition, controls can have local names that are qualified into a scope. This can allow for controls to be searched for based upon their “local” name within a naming scope. In one embodiment, the system can use a control's unique name for identifying it in operations such as saving and restoring state during the cycle of HTML postbacks to the page. Postback occurs when a form on a page targets the same page. When the form is submitted, the second request for the page is called a postback. The postback allows the page to handle changes made to data and raise events before either redirecting to a new page or simply displaying the same page again. In one embodiment, multiple control scopes can be provided as described in Table 1.
TABLE 1
Object Scopes in an Embodiment
SCOPE
DESCRIPTION
Request
An object is accessible for the life of the request.
Page
An object is accessible across subsequent requests
to a page. In one embodiment, a page has a lifetime
that can include a postback cycle.
Session
An object is accessible for the life of the session. (This is
available for protocols that support session.)
Webflow
An object is accessible within a named scope defined by a
webflow. A Webflow is a set of states that control
navigation from one web page to another.
Application
An object is accessible globally within the application.
In one embodiment, many of the classes can be sub-classed to provide specializations and custom features. It will be apparent to those skilled in the art that many more such classes are within the scope and spirit of the present disclosure. Table 2 provides an overview of classes in one embodiment.
TABLE 2
Framework Controls in an Embodiment
CLASS/
INTERFACE
DESCRIPTION
Control
The basic framework building block. The base Control class
defines a set of services available to all controls. This class
defines and provides a set of services to subclasses including
lifecycle, naming, and child management.
A lifecycle driver will drive the control-tree through a well
defined set of states. For a control, the lifecycle is defined by a
set of methods representing stages in the lifecycle. A control
can override methods of the lifecycle in order to provide
specialized behavior. For example, most controls will override
beginRender to render its specific representation to an output
stream. The stages provide well defined places to acquire
resources, manage state, raise events, render themselves, etc.
Most lifecycle stages consist of two methods that are called by
the lifecycle driver. The naming pattern of the two methods is
Xxxx and fireXxxx. The Xxxx method is overridden by
subclasses to specialize the lifecycle stage. The fireXxxx
method is overridden if a control wants to change how the event
associated with the lifecycle stage is fired.
Lifecycle
Defines methods called during the control's lifecycle. There are
two methods for most lifecycle events. The lifecycle method
xxx is called first to provide the lifecycle service for the control.
Then an onXxx method is called to raise an event. In one
embodiment, all of the lifecycle stages prior to rendering raise
events through the onXxx method.
NamingScope
The Control and the NamingScope interface interact to provide
support for uniquely naming a control within a tree. Unique
names are generated automatically when controls are added to
an existing control-tree. Unique names are used for state
management. Controls have three types of names:
Id - This is a user assigned value that should be unique within a
name scope.
ScopeId - This is a generated name that is unique within a
scope. It is either the Id or a generated name.
UniqueId - This is the globally unique name of the control.
This name is typically used to identify state and identify the
control within a HTML Form.
Context
Context is an abstract class providing services to controls in the
tree. In one embodiment, these services are protocol-
independent. It is the container's responsibility to create the
context object. The container can create an object that
subclasses Context and provides container aware controls with
additional services such as information about the framework and or protocol.
By way of a non-limiting example, a container can be a servlet
providing a framework. The Context can contain both HTTP-
specific information and web application-specific information.
A Portlet control that is portal-aware can cast the Context into
the subclass and access these services. Well-designed controls,
which are aware of one or more containers, can be written to
work or fail gracefully when they are used within the context of
the generic Context.
Context provides the following services:
Access to the Abstract Data Layer - Context will provide an
object implementing the interface providing an abstract data
layer.
Request Type - The Context contains properties indicating what
type of request is happening such as “new request”, “postback”,
etc.
Request Information - The Context provides information that
comes from the request such as request parameters, requested
URL, etc. This information may be unavailable for protocols
that don't support it.
Generic Services - The context allows controls to access and
register as service providers to other controls. For example, a
StyleBlock control may register as the StyleHandler object that
will create a single style sheet for an output HTML document.
Other controls may push style definitions into the StyleHandler.
These services will typically be used by a set of framework
aware controls and will support things such as styles, URL
rewriting, etc.
Renderer
Renderer is an interface that allows a class to be created and
which acts as a rendering proxy for a control. A control has
rendering methods allowing the control to output its
representation into a stream. There are two primary methods for
rendering; beginRender( ) and endRender( ). Default rendering
can be overridden by setting a control's renderer by providing
an object implementing the Renderer interface.
FIG. 3 is an illustration of request processing in an embodiment. Although this figure depicts functional steps in a particular order for purposes of illustration, the process is not limited to any particular order or arrangement of steps. One skilled in the art will appreciate that the various steps portrayed in this figure could be omitted, rearranged, combined and/or adapted in various ways.
In one embodiment, a GUI is rendered in response to a request (e.g., an HTML request originating from a web browser). In step 300 , a process (e.g., a web/application server or other suitable process) can accept the request and map it to a control tree factory. In step 302 , the identified factory can be used to generate a control tree representing the GUI. In step 304 , the control tree can be evaluated based on the contents of the request. In doing so, the control tree can be driven through a sequence of lifecycles that allow for individual controls in the tree to, by way of a non-limiting example, process the request, interact with each other and a context provided by the container, and produce a response. Finally, in step 306 the process can provide a response to the sender of the request. In one embodiment, this response can contain output for GUI rendering (e.g., HTML or other suitable GUI description) from one or more controls.
In one embodiment a container (not shown) can run the control tree through a sequence of one or more lifecycles by employing the services of an interchangeable lifecycle driver (not shown). In one embodiment, a control or a container can customize the lifecycle. Customization can include removing and/or reordering defined lifecycle stages and/or adding new stages. All of the controls in the control tree can participate in the lifecycle, but do not have to. The purpose of the lifecycle is to advance the control tree though a set of states. These states permit controls to obtain their state and resources, raise and handle events, save their state, communicate with other controls, render themselves, and free resources. The lifecycle is external to the control tree and can be provided by the container. This allows for easy modification of the lifecycle.
In one embodiment, controls can register to raise and catch events to perfect inter-control communication. An event mechanism allows controls to specify (or register for) events that they will raise and/or listen for. In one embodiment, this can be accomplished with two methods. A method named “xxxx” represents the lifecycle method itself and is usually sub-classed to provide specialized behavior for the control. A method named “fireXxxx” can be invoked to cause an event notification that the lifecycle method xxxx has run on the control. This method can be overridden to provide specialization of event firing. By way of a non-limiting example, a control could suppress firing of an event by overriding it and doing nothing. When an event is raised, all controls that have registered to receive it will be given an opportunity to handle the event (e.g., through a call-back mechanism). There is no limit on the number of events that can be raised or caught. By way of a non-limiting example, a form control could raise an event when a user enters text in a text field of a GUI representation of the form. This event could be caught by a button on the same page as the form. The button could then un-dim itself based on a determination of whether a user entered a valid character sequence into the form.
Controls can be dynamically added to the tree at any stage of the lifecycle up until a pre-render stage. When controls are added to an existing tree dynamically, these new controls can participate in the full lifecycle. In one embodiment, a lifecycle catch-up process can drive the new controls through the lifecycle until they catch-up to the current stage. All lifecycle stages before the rendering stage can raise events. In one embodiment, a container can implement the lifecycle stages illustrated in Table 3.
TABLE 3
Lifecycle Stages in an Embodiment
LIFECYCLE
STAGE
DESCRIPTION
Init
Allows a control to perform initialization.
Load State
Load previously saved state from the request. This state
represents the GUI state of the page.
Create Child
Stage used to create child controls.
Controls
Load
Obtain external resources necessary for processing the
request. If the request is a postback, at this point the
controls' states match their states in the client's view,
i.e., saved state has been restored and postback data has
been used to update controls with new values.
Raise Events
This is a two phase stage where controls first indicate
they want to raise events and then all controls who
indicated this are allowed to raise events.
Pre-render
This is the final stage before the rendering stages. At this
point the tree should be stable and all events processed.
Save State
This stage is the first stage in rendering. All controls that
want to save their states are given the opportunity to do
so. Any changes to controls after this point cannot affect
the saved state. This is the page specific GUI state.
Application level state is managed at a different level.
Render
This is the stage where controls create their GUI
representations and control how their children are
rendered.
Unload
This stage allows the control to free resources obtained in
Load.
Dispose
Any final cleanup can be done.
FIG. 4 is diagram of container processing in accordance to one embodiment. Although this diagram depicts objects/processes as functionally separate, such depiction is merely for illustrative purposes. It will be apparent to those skilled in the art that the objects/processes portrayed in this figure can be arbitrarily combined or divided into separate software, firmware or hardware components. Furthermore, it will also be apparent to those skilled in the art that such objects/processes, regardless of how they are combined or divided, can execute on the same computing device or can be distributed among different computing devices connected by one or more networks.
A request 410 can be mapped to a control tree factory 402 by container 400 . In one embodiment, the container use “wire-up” service 404 in the factory which will cause the factory to return the root of a control tree. In one embodiment, the generation of the control tree is based in part on the request. The control tree (not shown) produced by control tree factory can be a page level object or can become a sub-tree of a larger control tree. The control tree factory is independent of container 400 and can be accessed from multiple containers. In one embodiment, the control tree factory can make modifications to the tree such as replacing the default rendering or state methods for a control, including for the page itself. In one embodiment, the container can associate a Context object 408 with the control tree root. A base Context class can provide generic services to controls in a control tree and can be protocol independent. Generally speaking, a container can be associated with both a specific protocol and application framework. However, the container can also provide a subclass of Context to expose protocol and application-specific objects and services.
FIG. 5 is diagram of a control tree factory having a JSP page description implementation in accordance to an embodiment. Although this diagram depicts objects/processes as functionally separate, such depiction is merely for illustrative purposes. It will be apparent to those skilled in the art that the objects/processes portrayed in this figure can be arbitrarily combined or divided into separate software, firmware or hardware components. Furthermore, it will also be apparent to those skilled in the art that such objects/processes, regardless of how they are combined or divided, can execute on the same computing device or can be distributed among different computing devices connected by one or more networks.
In one embodiment, the framework can support JSP as a page description language. The control tree produced by such an implementation can allow for full use of JSP features such as tag extensions, scriptlets and expressions. By way of a non-limiting example, a servlet mapped to the extension “.jsp” can handle all JSP pages 502 mixing JSP and controls and can act as a container. The servlet can provide a request 516 to factory 500 , which will generate a control tree. The factory can use a JSP parser variant 504 to create a metadata representation of a control tree 508 . The parser variant captures the hierarchy of controls and for each control it recognizes, it can also capture information about the properties, events, and model binding that have values set in the page description. The parser variant can also capture template text in the JSP page and create metadata representing the template text as literal controls. By way of a non-limiting example, tag library extensions can represent controls in the JSP page. A standard JSP compiler 506 can also process the .JSP page and produce a .JSP page implementation class 510 that can be used to render JSP in concert with the control tree.
A class 514 is created to process the metadata. The class provides a service 512 that can be used to instantiate a control tree on behalf of a container. If the JSP page contains JSP-specific features, the service can make use of an inner class that implements a Renderer interface (not shown). The Renderer interface can act as a proxy for rendering of the control tree. In one embodiment, this proxy defers to a _jspService( ) method found in the JSP page implementation class. The Renderer interface treats the page implementation class as a servlet and drives it through the lifecycle, providing it a servlet context and other things needed. Tag extensions can be mapped into the control tree during the render lifecycle. The variant parser can create literal controls in the control tree for instances of template data found in the JSP page. In one embodiment, if a JSP page contains only controls and template data, the _jspService( ) method does not to be invoked.
FIG. 6 is diagram of a control tree factory having a metadata page description implementation accordance to an embodiment. Although this diagram depicts objects/processes as functionally separate, such depiction is merely for illustrative purposes. It will be apparent to those skilled in the art that the objects/processes portrayed in this figure can be arbitrarily combined or divided into separate software, firmware or hardware components. Furthermore, it will also be apparent to those skilled in the art that such objects/processes, regardless of how they are combined or divided, can execute on the same computing device or can be distributed among different computing devices connected by one or more networks.
Referring to FIG. 6 , a parser is not relied upon to generate metadata describing a control tree. Instead, a metadata representation 606 is assumed to be available as a resource 602 to the factory 600 . In one embodiment, the metadata representation can be an XML document or Java class file defined by a schema. The factory has an internal wire-up generator 606 that can generate a control tree wireup class 616 based on the metadata. In this scheme, the rendering can be performed by a Renderer object (not shown) that can defer to a _jspService( ) method available in the JSP page implementation 618 , depending on the metadata. In one embodiment, the JSP page implementation is produced by a standard JSP compiler 608 .
FIG. 7 is diagram of a control tree factory having a pure JSP page description implementation accordance to an embodiment. Although this diagram depicts objects/processes as functionally separate, such depiction is merely for illustrative purposes. It will be apparent to those skilled in the art that the objects/processes portrayed in this figure can be arbitrarily combined or divided into separate software, firmware or hardware components. Furthermore, it will also be apparent to those skilled in the art that such objects/processes, regardless of how they are combined or divided, can execute on the same computing device or can be distributed among different computing devices connected by one or more networks.
In one embodiment, JSP container 700 drives the control tree instantiation process with help from a tag library extension that acts as a container of state set on tag attributes that can be pushed into control instances that the tags create. In one embodiment, this process can be demarcated in a page description file 702 with a pair of tags 704 and 712 . One or more tags 706 can locate the metadata description of the control tree and create the control tree. Other tag(s) 708 can create a context for the control tree and drive it through its lifecycle 710 to the render stage. The container then allows its body content to render the page. Then, tag 712 can drive the final portions of the lifecycle.
JSP input can also be supported. One embodiment can utilize a backing file in addition to the JSP file. The backing file can be a Java class that lives beside the JSP file and contains two types of customizations: 1) overloaded method and event handling logic; and 2) declarations for all controls inside the control tree that have an identification property set. Code can be written in overloaded methods such that an event handler has access to these controls. The JSP page extends a Backing class, which gives the wire-up method the ability to use the JSP implementation class as the root of the control tree. The wire-up method can also insure that the declared controls are initialized and that event handlers are wired up. In one embodiment, the variant JSP parser may produce the backing file within the code generated to wire up the tree. The wire up can initialize variables in the backing file and wire-up handlers.
In yet another embodiment, all input can be derived from a JSP file. Code to handle events can be declared (e.g., “<%! . . . %>”) directly in the JSP file as a method. The wire-up process would insure that the proper method would be called. The same could be done for the control variable declarations. In many cases, these declarations would not be written and a Model object would act as an event handler. Thus, one can override methods on control and handle events in this way.
FIG. 8 is a diagram of a system in accordance to one embodiment. Although this diagram depicts objects/processes as functionally separate, such depiction is merely for illustrative purposes. It will be apparent to those skilled in the art that the objects/processes portrayed in this figure can be arbitrarily combined or divided into separate software, firmware or hardware components. Furthermore, it will also be apparent to those skilled in the art that such objects/processes, regardless of how they are combined or divided, can execute on the same computing device or can be distributed among different computing devices connected by one or more networks.
Referring to FIG. 8 , a control container 800 interacts with a client 810 through a request and response protocol. The control container can accept requests from the client and provides responses thereto so that the client may refresh its GUI based on any processing inherent in the request. The control container can map a request to a control factory 808 which it will use to generate a control tree representation of the client GUI (not shown). Controls in the control tree can make use of a persistence interface that acts as a front-end to an interchangeable persistence driver 806 . The persistence interface hides persistence implementation details from controls and allows for a flexible architecture where different persistence providers can be “plugged in” as needed. The control container can use an interchangeable lifecycle driver 804 to drive the control tree through a sequence of states so that the request can be processed. As with the interchangeable persistence driver, an interface is provided to isolate lifecycle driver implementation details from the control container. This allows for different lifecycle implementations to be interchanged as needed. One or more portlet containers 802 are provided to support portlet execution for those controls in the control tree that have associated portlet processes/servlets.
Controls have the ability to persist state across HTTP (Hypertext Transfer Protocol) requests. A state management API can be provided to give each control in the tree the ability to persist itself before rendering an HTTP response. When an HTTP submit to the same page is received, this saved state can be used to re-hydrate or restore the control tree from its persisted state. Thus, the same state can be maintained across different instances of the same control tree with minimal effort to the control author. Controls can be persisted using a state management persistence mechanism.
The Context object can provide access to an interface providing an ADL (Abstract Data Layer). The ADL can provide a named binding to objects within a specific scope support for object activation and creation, caching, named access, etc. The framework can define a binding language that can be used to bind properties on controls to properties on objects.
In one embodiment, state management can be implemented behind a pair of interfaces: ClientStateWriter and ClientStateReader. The ClientStateWriter provides an interface that a control can use to write any primitive type or object into state management. By way of a non-limiting example, the following methods can be exposed:
public void writeByte(byte b);
public void writeShort(short s);
public void writeString(String s);
public void writeObject(Object o);
At a particular stage in the control tree lifecycle, the control has the opportunity to save its state. In one embodiment, when a control calls a saveState( . . . ) method, the control receives a ControlStateWriter object into which it can write its state. A control's contract with state management is that on the page's next submit, the control can re-read this state using the corresponding loadState( . . . ) lifecycle method. A control can read the state in the same order in which the state was written. By way of a non-limiting example, state can be read by using methods defined on the ControlStateReader interface such as:
public byte readByte( );
public short readShort( );
public String readString( );
public Object readObject( );
A control is aware only that it is receiving an interface against which to save any of its state. How the state is actually written and where it is stored are left as implementation details to the implementer of the state management. One approach to state management may be to write the state into a web page and have the state submitted whenever a form from the page is submitted. This approach suffers from problems when the amount of state that is written to the browser is large, though it may keep the server from having to track large and expensive user session objects. The flexibility of this embodiment is that a web application and even a page can be configured to use a particular state management policy for state that a control tree has written into a ControlStateWriter. The resulting state could be stored in the client, as mentioned, the database, a cache system, or even the user session. In one embodiment, state can be written to a page as a hidden field found in a form.
In one embodiment, a state management implementation consists of a ControlStateWriter that writes to a byte array that is Base64 encoded and written to the browser in an input tag within a form tag. When the form is submitted, the state string is contained in the request data and is used to create a ControlStateReader that contains the data for each control. ControlStateReaders can also be chained such that the container can find a ControlStateReader for a particular control instance from any number of locations that may be in a state reader chain. A reader chain is specified with a list of implementations in an external XML file that is parsed at runtime.
The organization of controls in a tree can also be persisted. In one embodiment, it is assumed that some language (e.g., JSP, XML, etc.) can be used to describe the control tree and that control tree factory can process this language and return a representation of the tree. In one embodiment, the language can describe metadata about the control tree, the hierarchical relationship between controls, property/value pairs for controls in the tree, and event handling. In one embodiment, the language can be manipulated as a stream by the framework. A so-called streaming control tree can plug into the framework by implementing a control tree factory.
In one embodiment, a streaming control tree factory creates a control tree from an XML Stream. By way of a non-limiting example, the XML stream may be obtained from multiple sources including the file system, a database, a dynamically constructed Document Object Model (DOM) Tree, etc. In one embodiment, a streaming control tree factory first parses an XML document representation of a control tree into a DOM Tree. The XML document can conform to one or more known schemas which define how a control tree is described. The DOM tree is then processed to create a representation of the control tree. When the streaming control tree factory is asked for an instance of the control tree, the factory will create a new instance of the control tree from the representation.
In one embodiment, after an initial control tree is created, Java Serialization can be used to obtain a serialized (or streamed) view of the control tree. When an instance of the streaming control tree is requested from a control tree factory, the serialized view is deserialized. In another embodiment, Java™ code generation can be used to create a class that will create the control tree. In this embodiment, Java™ code is that knows how to create and initialize the control tree is generated. When a streaming control tree is requested from the factory, the compiled version of Java™ code is executed to obtain the control tree.
In order to increase the performance of controls that use long-running resources such as EJBs (Enterprise Java Beans), database accesses or external site content, portions of the control lifecycle can be modified to support running subtree lifecycles in parallel. By way of a non-limiting example, assume there are two controls, A and B, each which rely on using a long-running resource in their lifecycles. Standard serial lifecycle traversal over these controls will result in total run time greater than the sum of the run times of the long-running resources. However, if these two controls could be run in separate threads, it is likely that the overall runtime will be less than in the serial case.
In one embodiment, two variations of multithreading are enabled for controls: preRender multithreading and render multithreading. PreRender multithreading is the simplest of these, while render multithreading is probably the more useful for the most common performance needs (e.g., where external site content is included into the final control tree output).
In one embodiment, a multithreaded foundation is shared between the two multithreading variations. This foundation includes a ControlTreeWalkerPool class. This class is used to spawn off ControlTreeWalker invocations to process each thread of processing control. Additionally, this class can perform accounting and synchronization of the spawned workers. When a new worker is created and dispatched, a count can be incremented of the workers still performing tasks. At the completion of a task, a worker can decrement the count. The main calling thread can then use the ControlTreeWalkerPool to wait until all workers have completed their tasks before continuing processing a Lifecycle run.
The ControlTreeWalkerPool can internally use instances of WalkerWorkers, specialized to the type of multithreading to be done. A factory can be used to instantiate a specific type of WalkerWorker, after which a set of thread context information is gathered, including the ContextClassLoader and Subject associated with the mainline thread. The assignment and execution of the tasks for a WalkerWorker is performed using the Weblogic kernel facilities for running ExecuteRequests on threads obtained from ExecuteThreadPools. In this case, the each WalkerWorker implements the ExecuteRequest interface, allowing it to be dispatched to a WLS ExecuteThread.
Once a WalkerWorker has been dispatched to an ExecuteThread, it performs two additional steps before the actual control tree walk is performed. First, a ContextClassLoader is transferred to the ExecuteThread. Then, a WalkerWorkerPrivilegedAction class object, which implements a PrivilegedExceptionAction, is created and invoked on the current thread using a Subject saved from the mainline thread. This privileged action is then used to perform a Security.runAs( ) method so that the WalkerWorker task is performed with the same user security privileges as in the mainline thread. At this point, code specific to the type of WalkerWorker is executed via a default pattern, where concrete WalkerWorker classes implement the WalkerWorker method executeWalkerWorker.
Multithreaded preRender is useful in cases where a control can perform the long-running portion of its processing without the need to immediately render its results into the response. This might include cases where EJB's are called or long-running computation is done, the results of which are then saved for use in the render lifecycle phase. The multithreaded preRender implementation is composed of two pieces: a class called LifecycleWorker, which extends WalkerWorker, and a modified version of the ControlTreeWalker's walkRecursive( ) method called walkRecursivePreRender( ).
In one embodiment, the LifecycleWorker class is actually a generic WalkerWorker that can perform a control sub-tree walk for any arbitrary lifecycle stage. It simply captures the control tree root and the lifecycle stage as arguments to its contructor, then uses a new ControlTreeWalker instance to perform a walk on the sub-tree root during the threaded execution.
In one embodiment, the walkRecursivePreRender method is a modified version of ControlTreeWalker.walkRecursive, adding the ability to look for controls that are marked as preRenderForkable and use the ControlTreeWalkerPool to dispatch workers for a subtree. Note that only the first subtree encountered depth-wise is dispatched in a multithreaded manner, meaning that if a sub-tree dispatched in a multithreaded manner also contains a control marked for preRender forking, the inner control will not be executed in an additional thread. However, as long as controls marked for multithreaded preRender aren't descendants of one another, they will be performed in tandem with each other and the main tree walk. At the end of the call to walkRecursivePreRender, the ControlTreeWalker pool is used to wait for the spawned WalkerWorkers to complete their processing before continuing on to the next lifecycle stage.
Multithreaded render is useful in cases where a control's long-running processing requires that the control immediately render into the response. The most common case of this is using a RequestDispatcher to include content that either itself is long-running, or is from an external site. In this case, the implementation is actually composed of three components: a ControlRenderQueue, a class called RenderWorker that extends WalkerWorker, and a modified version of ControlTreeWalker.walkRecursive called walkRecursiveRender. A ControlRenderQueue is used to collect UIControls marked for forkedRender during the pre-render phase, and to collect the render results of those UIControls after they are dispatched to ExecuteThreads. This collection marking phase works similarly to multithreaded preRender qualification, where only the first control depth-wise is collected into the render queue.
During the render lifecycle walk, the render queue is processed before the main control tree is walked. This processing dispatches all of the queued controls to a RenderWorker class so that rendering can take place for each sub-tree in a separate ExecuteRequest. After the processing has been started, the mainline ControlTreeWalker uses the ControlTreeWalkerPool to wait until all worker processing has been completed. In order to allow control rendering to be performed on multiple threads, and to allow this rendering to occur before the mainline render, each RenderWorker creates a BufferedJspContext which is set on the sub-tree it will render. Each BufferedJspContext creates BufferedRequest and BufferedResponse objects that are wrappers for the original HttpServletRequest and HttpServletResponse objects, respectively.
BufferedRequest delegates to the underlying wrapped request, except for access to request attributes, via overrides of the getAttribute, setAttribute and getAttributeNames methods of ServletRequest. Additionally, BufferedRequest implements a method that can be used to transfer the sequence of setAttribute calls back to the original request after all buffered operations are completed. The BufferedRequest is necessary in the netuix framework because communication between various included portions of a portal, such as between the main portal file and .portlet or .jsp files, is accomplished by setting context instances into request attributes before performing RequestDispatcher includes.
BufferedResponse delegates to the underlying wrapped response, except for operations that affect the response Writer or OutputStream. Calls to getWriter or getOutputStream are instead diverted to instances based on an internal ByteArrayOutputStream that serves to buffer render output from a UIControl. After setting the BufferedJspContext onto a control subtree, the RenderWorker initiates a render walk on the control tree. Each control then uses either the BufferedJspContext and its underlying buffered request and response objects as normal, or simply uses the writer object obtained from the buffered response as normal. The usage of these buffered request and response objects are completely transparent to the rendering controls, and there is no special coding or handling that is required to use the buffered versions. However, the render code should be thread-safe.
Once all RenderWorker processing is complete, the mainline render operation begins. When the ControlTreeWalker worker encounters a control that has been previously rendered by a WalkerWorker, instead of performing the regular render visit on that control, it uses the ControlRenderQueue to obtain the render result for the control, and writes that data into the result.
In one embodiment, look and feel (“L&F”) is inherent in an application's GUI. The elements of a GUI that allow a user to functionally interact with it comprise the “feel” of L&F. By way of a non-limiting example, these might be windows, menus, buttons, text fields, etc. The general appearance of these elements comprise the “look” of L&F. By way of a non-limiting example, a look can consist of a button image, the color of a menu, the font in which text is displayed, etc. Thus, a given GUI “feel” may have more than one “look”, and vice versa.
In one embodiment, L&F includes three components: a LookAndFeel control, one or more skins, and one or more skeletons. The LookAndFeel control associates a skeleton with a skin (and other configuration attributes). Skins specify superficial information for a GUI element and provide a means for an GUI to embrace different “looks” while retaining the core functionality laid out by the skeleton (which provides the “feel”). A skeleton provides the general appearance and functioning of a GUI element. A skeleton is married to a skin at render time to perfect its “look”. In one embodiment, a skeleton includes one or more JSP files. The JSPs that together constitute a given skeleton can be assembled in a directory, the name of which is used to identify the skeleton. References to the skeleton can be made by referencing the containing directory and that directory's path if it differs from a default path (e.g., “/framework/skeletons”). Furthermore, a default skeleton can be provided (e.g., named “default”) and located in a default skeleton path. In the absence of skeleton settings to the contrary, the default skeleton in the default location can be assumed by the framework.
In one embodiment, a skeleton can be used to render HTML content. In another embodiment, skeletons can be used to render anything that can be rendered by a JSP. In yet another embodiment, a skeleton can render any of the several forms of XML, either standard or custom (e.g., XHTML, custom XML consumed by Flash MX by Macromedia, etc.). In one embodiment, a skeleton can include a set of JSP files, each of which can be associated with a particular control (sub-classed from PresentationControl) in a control tree.
The PresentationControl superclass provides default rendering using a skeleton in the absence of more explicit rendering. PresentationControl is a superclass for most framework controls, including (but not limited to) the following: Desktop, Shell, Head, Body, Header, Footer, Book, SingleLevelMenu, Page, Layout, Placeholder, Window, Titlebar, and ToggleButton. In one embodiment, for each PresentationControl there is at least one skeleton JSP defined. Situations may arise where a skeleton JSP provided by the chosen skeleton does not meet the needs of a particular instance of a PresentationControl. In this case, the skeleton JSP can be overridden with content from a universal resource identifier (“URI”).
In one embodiment, a skeleton JSP's structure is oriented toward control rendering. Like a control, there are both begin and end render states. In the JSP these phases are represented as “beginRender” and “endRender” tags from a JSP render tag library. In general, the contents of these tags are rendered in turn with a control's children rendered in between. However, much finer-grained control can be achieved if desired. Specific children can be retrieved and rendered in explicit locations in order to provide maximum structural layout potential.
FIG. 9 is a sample skeleton JavaServer Page in accordance to an embodiment. In one embodiment, the skeleton can handle the skin portion of the L&F by either hard-coding the appropriate look, or even by providing and using another mechanism of its own. By way of a non-limiting example and with reference to FIG. 9 , the “render” taglib is responsible for multiple functions. The “beginRender” and “endRender” sections delimit which code is rendered before child rendering (beginRender) and which code is rendered after child rendering (endRender). Child rendering occurs between the two unless a child is rendered explicitly with the renderChild tag. Here, the renderChild tag is used to render a titlebar child. The titlebar can be retrieved as a PresentationContext, which is a read-only facade over the actual control being rendered. In one embodiment, a PresentationContext exists for each child in the current context, and can be accessed as illustrated in the example JSP.
In one embodiment, skins provide a way to alter the overall look of GUI without modifying it's fundamental functionality. The definition of a skin can depend on how the skeleton or skeletons it expects to be used with are defined. By way of a non-limiting example, if a skeleton is defined to use a particular cascading style sheet (CSS) class, then the skin needs to define a corresponding rule for that class. Skins can be identified by the directory in which they live. References to the skin can be made by referencing the containing directory and that directory's path if it differs from a default path (e.g., “/framework/skins”). Furthermore, a default skin can be provided named “default” and located in the default skin path. In the absence of skin settings to the contrary, the default skin in the default location is assumed by the rendering system.
A skin can be described by a properties file (e.g., a file named “skin.properties”) located in the root level of it's containing directory. The properties file can associate the skin with resources. The property images.path can be used to specify a location where skin-related images can be found. Subdirectories of this directory can be used to store alternate image sets for use by themes. In one embodiment, this property is optional and defaults to the value “images”. For example, a properties file might include the following definition:
images.path: images
A link entries section of the properties file can be used to configure link entries, such as CSS references. Such entries are generally HTML-oriented, but could be used by an alternate rendering scheme (e.g. XML) in a way parallel to that described herein. Property entries for this section essentially encapsulate an HTML “link” tag. In one embodiment, this can be accomplished as follows:
(1) All entries for this section begin with the property prefix “link” to scope them as describing link tags (2) A short name is used to group properties related to a single tag name (3) Together, (1) and (2) define a link tag to be generated (4) Finally, the base property prefix formed by the union of (1) and (2) is used to define attributes to be set for the given link tag by appending a value for any valid HTML link tag attribute (e.g., charset, href, hreflang, type, rel, media, etc.) (5) The union of (1)-(4) yields a complete property name usable in this section; as long as at least one attribute is specified with a value in a given link group
An “index” link attribute can be included. This attribute is not rendered in the HTML output, but is instead used to determine the order of the output with respect to link tags representing other property groups. In one embodiment, the index attribute can be any integer value. Rendering of indexed property groups will occur in ascending order, with any remaining, un-indexed groups being rendered last in an arbitrary order relative to one another. This attribute is optional.
For example, these properties:
link.document.href:
css/document.css
link.document.rel:
stylesheet
link.document.media:
screen
link.document.index:
2
link.input.href:
css/input.css
link.input.rel:
stylesheet
link.input.media:
screen
link.input.index:
1
. . . can generate the following HTML:
<link href=“{qualified skin path}/css/input.css”
rel=“stylesheet” media=“screen”/>
<link href=“{qualified skin path}/css/document.css”
rel=“stylesheet” media=“screen”/>
In one embodiment, script entries can be placed in a “script entries” section. This section can be used to configure script entries, such as JavaScript references. Property entries for this section essentially encapsulate an HTML script. By way of a non-limiting example, this can be accomplished as follows:
(1) Entries for this section can begin with the property prefix “script” to scope them as describing script tags. (2) A short name can be used to group properties related to a single tag name. (3) Together, (1) and (2) define a script tag to be generated. (4) Finally, the base property prefix formed by the union of (1) and (2) can be used to define attributes to be set for the given script tag by appending a value for any valid HTML script tag attribute (e.g., carset, type, src, defer, etc.). (5) The union of (1)-(4) yields a complete property name usable in this section; as long as at least one attribute is specified with a value in a given script group
An “index” script attribute can be included. This attribute is not rendered in the HTML output, but is instead used to determine the order of the output with respect to script tags representing other property groups. The index value can be any integer value. Rendering of indexed property groups will occur in ascending order, with any remaining, unindexed groups being rendered last in an arbitrary order relative to one another. This attribute is optional.
For example, these properties:
script.skin.src:
js/skin.js
script.skin.type:
text/javascript
script.skin.index:
2
script.util.src:
js/util.js
script.util.type:
text/javascript
script.util.index:
1
. . . can generate this HTML:
<script src=“{qualified skin path}/js/util.js” type=“text/javascript”></script> <script src=“{qualified skin path}/js/skin.js” type=“text/javascript”></script>
Script hrefs can be defined relative to the “skin.properties” file.
In one embodiment, the properties document.body.onload and document.body.onunload allow a skin to associate a “body” tag's “onload” and “onunload” with event handlers. Doing so will cause the value of either property to be inserted into the beginning of the appropriate event handler's command list before rendering. The end result is the evaluation of said property value after the document has been completely loaded, allowing skin scripts to apply themselves to the document. Typically, the values of these properties are script function calls defined in one of the script declarations from the previous section. For example, this property:
document.body.onload: addSkinEventHandlers( )
. . . will generate this HTML:
<body onload=“addSkinEventHandlers( );”>
If a skin was written to be used specifically with a particular skeleton implementation, the properties default.skeleton.id and default.skeleton.path can be set to specify that skeleton. In the absence of skeleton or skeletonPath attributes of the L&F control the values of these properties is used instead of the catch-all default skeleton and skeletonPath. The path property can be defined relative to the webapp.
Metadata can be predefined by setting the property enable.meta.info. A common use for this data is as a convenience for testing or debugging. For example, adding information about the look and feel in use can aid in test development in that the tests can identify the document style being handled and can adjust it's testing methodologies or reporting as appropriate. In one embodiment, this data manifests in HTML as a series of <meta/> tags located in the document head. Absence of this property or any value other than “true” will yield a false setting, which will mute the output of such meta info.
The resources provided by the skin define what it is, though it's the skeleton and the skin.properties file that bring form to those resources, making them tangible. A skin can consist of any number of resources, and of any type that the target skeleton(s) can take advantage of. The following is a list of several of the most common types, and some notes about their manifestation as elements of a skin.
In one embodiment, a web application can have an images directory associated with it via the Look and Feel, whether or not the images property was specified in the skin.properties file. Of course, if the skeleton never references any images, then no images are used. The images directory can also be set to be equal to the skin directory itself, which is done by setting the skin.properties property images.path to the empty string.
The following set of images are well-known and, while not strictly required, are typically provided by most skins (since most skeletons make use of them). Additional images can be required depending on the requirements of the target skeleton and whether the skin itself defines any of its own images, perhaps via CSS or JavaScript.
titlebar-button-config.gif titlebar-button-config-exit.gif titlebar-button-delete.gif titlebar-button-edit.gif titlebar-button-edit-exit.gif titlebar-button-help.gif titlebar-button-help-exit.gif titlebar-button-maximize.gif titlebar-button-unmaximize.gif titlebar-button-minimize.gif titlebar-button-unminimize.gif
Another component of modern Web sites is the Cascading Style Sheet. Skins are able to strongly leverage their decoupling from skeletons by putting CSS to work. While not required, CSS can be the meat and potatoes of making a skin work. Of course, they won't work gracefully just because the skin wants them to—the skin's target skeleton(s) will need to provide the appropriate hooks (typically in the form of id and class declarations) for them to be maximally effective.
Note, too, that some skeletons allow control-overridden CSS styles and classes via the control declaration in a web application source file. Either situation can cause rendering anomolies (which is usually the purpose of the overrides) that affect the Look and Feel's appearance. Look for this if incorrect rendering behavior seems to appear in the web application.
Scripts can be a powerful ally for client-side dynamic behaviors. Typically manifesting as JavaScript or another ECMAScript-compliant language, client-side scripting can be bootstrapped from the web application's skin. Great amounts of additional interactivity can be added, with or without the help of the underlying skeleton code. For instance, using the skin.properties property document.body.onload and a script declaration one can initialize an entire document to suit a particular purpose or purposes. Suppose it was desired that all well-defined buttons found in window titlebars had a simple rollover effect achieved by swapping images during mouse overs. The following example code makes that simple, and it can all be specified from the skin itself.
For the example, assume that the standard set of images exist in the skin, along with a new version of each named with the indicator “-active” right before the image file extension, as the next example illustrates:
titlebar-button-config.gif
titlebar-button-config-active.gif
Themes can be defined and implemented across skeletons and skins to provide variations of either in explicitly defined contexts. Explicit portions of a GUI can take direct control over the L&F of a rendered region and work within or step outside of the L&F framework described herein; this is accomplished by overriding skeleton infrastructure for particular elements (controls). A theme is a construct that allows subgroups of a portal instance to use different virtual look and feels than the main rendering area. Themes can be useful for creating specialized areas of the portal that would otherwise complicate the baseline look and feel development unnecessarily.
For a skin to be useful to a given skeleton (since skins are typically written for particular skeletons) in the context of a particular theme, the skin can support the same set of themes as the skeleton it naturally targets. In one embodiment, given the name of a theme, the LookAndFeel control searches for theme skeleton components in the directory derived by combining the base directory of the skeleton and the name of the theme. Skin theme image resolution works the same way, only using the configured images directory for the skin as the base location.
In the skeleton case, themes manifest as sets of skeleton JSPs in their theme subdirectory as described above. The sets can be complete sets or subsets of the base JSP set for the skeleton. In the case of subsets, no upward resolution is performed if a theme's skeleton JSP is missing—this is an error condition. Any JSP in the theme set is simply a variation on the base skeleton and is used instead of the base skeleton JSP when the theme's scope is in effect.
A Theme control manifests as a wrapper around other controls and entities. By applying a theme in this way, the theme's children are rendered with the skeleton and skins resources defined by the enveloping theme. The following attributes are particularly noteworthy elements of theme control: “name”, “usingAltSkeleton”, and “usingAltImages”. The “name” attribute is already well known—it defines the unique id as well as the skeleton and skin images subdirectories used when resolving a theme context.
The “usingAltSkeleton” attribute is a boolean switch; a value of “false” indicates that the Look and Feel should not try to use skeleton JSPs from a subdirectory of the base skeleton directory—it should instead use the default skeleton JSPs. A value of “false” can be useful when only the skin side of the theme is of interest to the region of code being themed. The default value is “true”.
The “usingAltImages” attribute is a boolean switch as well; a value of “false” indicates that image resources should not be pulled from the theme-defined subdirectory of the skin images directory, but should instead be pulled from the normal images area. A value of “false” can be useful when only the skeleton side of the theme is of interest to the region being themed. The default value is again “true”.
Example
<netuix:theme name=“MyTheme” usingAltSkeleton=“false”> <netuix:window ...> ... </netuix:window> </netuix:theme>
In this simple case, the enveloped window control instance would be rendered with the skeleton and skin resources identified by the theme named “MyTheme”.
The crux of the concepts, implementations, and controls discussed so far is the LookAndFeel control. The LookAndFeel control has the following attributes in one embodiment:
skeleton skeletonPath skin skinPath defaultWindowIcon defaultWindowIconPath
In one embodiment, a user can customize (or personalize) a web application to suit their needs. A template is a definition of a web application and can reside in a library. Changes made to a template can be propagated to portlet instances, at the discretion of the administrator. Streaming control trees allow for personalized representations of requests. For example, a page can contain only portlets (controls trees) that the user has selected or that entitlement rules have selected for the user. Each user may select different sets of portlets. A streaming control tree factory can map each user into an individual control stream and then construct a control tree from it. The streaming control tree factory hides all the details about how the control tree is generated and how personalization occurs. The control tree representation may be cached and may be regenerated if the stream changes. For example, if a user selects a different set of portlets to be visible.
In one embodiment, a user's attributes (e.g., name, age, position, etc.) and/or group membership can be used to automatically choose a L&F. By way of a non-limiting example, when a user first visits a portal, the user is considered an anonymous visitor and thus will see a default L&F for the portal. Once a user logs into the portal, a L&F can be automatically applied to the portal based on the user's characteristics or other information (e.g., time of day, external data, etc.).
One embodiment may be implemented using a conventional general purpose or a specialized digital computer or microprocessor(s) programmed according to the teachings of the present disclosure, as will be apparent to those skilled in the computer art. Appropriate software coding can readily be prepared by skilled programmers based on the teachings of the present disclosure, as will be apparent to those skilled in the software art. The invention may also be implemented by the preparation of integrated circuits or by interconnecting an appropriate network of conventional component circuits, as will be readily apparent to those skilled in the art.
One embodiment includes a computer program product which is a storage medium (media) having instructions stored thereon/in which can be used to program a computer to perform any of the features presented herein. The storage medium can include, but is not limited to, any type of disk including floppy disks, optical discs, DVD, CD-ROMs, microdrive, and magneto-optical disks, ROMs, RAMs, EPROMs, EEPROMs, DRAMs, VRAMs, flash memory devices, magnetic or optical cards, nanosystems (including molecular memory ICs), or any type of media or device suitable for storing instructions and/or data.
Stored on any one of the computer readable medium (media), the present invention includes software for controlling both the hardware of the general purpose/specialized computer or microprocessor, and for enabling the computer or microprocessor to interact with a human user or other mechanism utilizing the results of the present invention. Such software may include, but is not limited to, device drivers, operating systems, execution environments/containers, and user applications.
The foregoing description of the preferred embodiments of the present invention has been provided for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Many modifications and variations is apparent to the practitioner skilled in the art. Embodiments were chosen and described in order to best describe the principles of the invention and its practical application, thereby enabling others skilled in the art to understand the invention, the various embodiments and with various modifications that are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the following claims and their equivalents. | A method for rendering a portal graphical user interface (GUI), comprising providing for the representation of a GUI desktop, a GUI look and feel, and a GUI book as a set of controls wherein the controls can be organized in a logical hierarchy, traversing the representation, wherein the traversing comprises associating a theme with a first control in the set of controls, rendering the first control according to the theme, rendering any descendents of the first control according to the theme, wherein any descendents of the first control can override the theme, and wherein one of the set of controls can communicate with another of the set of controls. | 6 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates in general to hydro/pneumatic tensioners for applying tension to a riser supported from a floating platform.
[0003] 2. Background of the Invention
[0004] An offshore facility includes a riser extending to a subsea facility such as a subsea well or subsea manifold located at the sea floor. Offshore facilities that float, such as a tension leg platform, move up and down and horizontally relative to the subsea well with the oscillations of the waves and currents. It is often desirous to maintain a desired tension on the riser during these oscillating movements. Tensioners are often utilized in order to react to the movements of offshore facilities moving with the wave oscillations and currents.
[0005] Previous tensioner assemblies, like those on tension leg platforms, include a plurality of piston assemblies suspended from a deck that connect to a tension ring surrounding the riser. One type relied upon gas positioned in a chamber surrounding the piston rod to create tension. These piston assemblies are pull-type piston assemblies because they react when the piston is being pulled through the piston chamber and the fluid surrounding the piston rod is compressed. These assemblies require large piston assemblies to accommodate the necessary fluid for creating tension in reaction to the movements of the platform.
[0006] Other previous tensioner assemblies include ram style or push-type piston assemblies that have the reactive fluid on the side of the piston opposite from the piston rod. Ram style piston assemblies react when the piston is being pushed through the piston chamber. This arrangement allows for smaller piston assemblies because there is no piston rod in the chamber containing the fluid. Moreover, in previous assemblies, the piston rod extends downward to the piston housed with the piston chamber. Therefore, drippings and debris from above often fall onto the piston rods which can damage the seals of the piston assembly. Failure and less reactive tensioning can occur when the seals are damaged.
[0007] In other ram style or push-type piston assemblies, the piston rod extends upward to the piston housed with the piston chamber. In these assemblies, drippings and debris fall from above onto the rods. Such an arrangement typically required expensive coatings to be applied to the outer surface of the piston rods that were exposed to the elements.
SUMMARY OF THE INVENTION
[0008] A surface assembly that communicates with subsea structures includes a working deck on a floating structure. The working deck has an aperture extending axially therethrough. A riser extends from a subsea location to the working deck. The riser extends through the aperture. The surface assembly includes a frame extending circumferentially around the riser. The frame is connected to the riser so that the frame moves axially with the riser. The assembly also includes a tensioner assembly connected between the working deck and the frame. The tensioner assembly comprises a piston, a piston chamber, a sealing portion between the piston and the piston chamber, a piston rod extending from the piston and away from the piston chamber, and a shroud enclosing the piston rod and at least the sealing portion of the piston assembly.
[0009] In another configuration, the sealing portion is between the piston and an interior surface of the shroud. A piston chamber is defined by the sealing portion, the piston, and the shroud. The tensioner assembly can also include a cylinder. The sealing portion can then be located between the piston and the cylinder. The piston chamber is then defined by the sealing portion, the piston, and the cylinder. The shroud typically has a closed upper end, and an open lower end that exposes a portion of its interior surface to atmospheric pressure.
[0010] In yet another configuration, a surface assembly for subsea wells includes a working deck on a floating structure. The working deck has an aperture extending axially therethrough. A riser extends from a subsea location to the working deck and through the aperture. A frame extends circumferentially around the riser. The frame is connected to the riser so that the frame moves axially with the riser. A tensioner assembly is connected between the working deck and the frame. The tensioner assembly includes a piston slidably carried in a piston chamber, a piston rod extending from the piston and away from the piston chamber, and a shroud enclosing the piston rod. The shroud has a plurality of segments with at least one of the shroud segments being movable in unison with the piston rod.
[0011] The plurality of segments can include an inner shroud segment being stationary relative to the piston rod. The plurality of segments can have an inner shroud segment and an outer shroud segment, with the outer shroud segment telescoping over the inner shroud segment when the tensioner assembly is in a contracted position. A substantial portion of the inner shroud segment can be uncovered when the tensioner assembly is in an extended position. Either the outer shroud segment or the inner shroud segment that is fixedly connected to an end portion of the piston chamber that receives the piston rod.
[0012] The plurality of segments can also include an intermediate shroud segment. The intermediate shroud segment telescoping over the inner shroud segment when the tensioner assembly is in a contracted position, and the outer shroud segment telescoping over the intermediate and inner shroud segments when the tensioner assembly is in a contracted position.
[0013] In another configuration a riser tensioner assembly for maintaining tension in a riser extending from a subsea well through an aperture in a working deck of a floating structure includes a piston slidably carried in a piston chamber. A piston rod extends from the piston chamber. The piston rod and piston are movable between a contracted position and an extended position of the tensioner assembly. A shroud surrounds at least part of the piston rod while in the contracted and extended positions. The shroud has a plurality of shroud segments with at least one of the shroud segments being movable in unison with the piston rod and at least one of the shroud segments being fixedly connected to an end portion of the piston chamber that receives the piston rod.
[0014] In the tensioner assembly, the plurality of shroud segments can include an inner shroud segment and an outer shroud segment. The inner shroud segment can have a flange end connected to either the piston chamber or the piston rod and a telescoping end having an outer lip. The outer shroud can also have a flange end connected to the other of the piston chamber or the piston rod and a telescoping end having an inner lip. When the tensioner assembly is in the extended position, the outer lip of the inner shroud engaging another shroud segment telescoping over the inner shroud and the inner lip of the outer shroud engaging another shroud segment telescoping within the outer shroud.
[0015] The plurality of shroud segments can also include an intermediate shroud segment. The intermediate shroud segment telescopes over the inner shroud segment when the tensioner assembly is in a contracted position. The outer shroud segment telescopes over the intermediate and inner shroud segments when the tensioner assembly is in a contracted position.
[0016] Each intermediate shroud segment can have an extension end and a contraction end. The extension end has an outer lip and the contraction end has an inner lip. When the tensioner assembly is in the extended position the outer lip of the intermediate shroud segment engages an interior lip of either another intermediate shroud segment or the outer shroud segment, and the inner lip of the intermediate shroud segment engages an outer lip of either another intermediate shroud segment or the inner shroud segment.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a schematic side view of a riser tensioner constructed in accordance with this invention and shown in an extended position.
[0018] FIG. 2 is a schematic side view of the riser tensioner in FIG. 1 , shown in a contracted position.
[0019] FIG. 3 is a schematic side view of an alternate embodiment of a riser tensioner in accordance with this invention and shown in an extended position.
[0020] FIG. 4 is a schematic side view of an alternate embodiment of a riser tensioner in accordance with this invention and shown in an extended position.
[0021] FIG. 5 is a schematic side view of an alternate embodiment of a riser tensioner in accordance with this invention and shown in an extended position.
[0022] FIG. 6 is a schematic side view of an alternate embodiment of a riser tensioner in accordance with this invention and shown in a partially an extended position.
[0023] FIG. 7 is a schematic side view of another alternate embodiment of a riser tensioner in accordance with this invention and shown in an extended position.
[0024] FIG. 8 is a schematic side view of the riser tensioner in FIG. 7 , shown in a contracted position.
[0025] FIG. 9 is a schematic side view of another alternate embodiment of a riser tensioner in accordance with this invention and shown in an extended position.
[0026] FIG. 10 is a schematic side view of another alternate embodiment of a riser tensioner in accordance with this invention and shown in an extended position.
[0027] FIG. 11 is a schematic side view of the riser tensioner in FIG. 10 , shown in a contracted position.
[0028] FIG. 12 is an exploded view of a cylinder assembly in the riser tensioner shown in FIGS. 7-9 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0029] Referring to FIGS. 1 and 2 , a floating platform deck 11 is schematically shown. Deck 11 may, for example, be a deck of a barge, a tension leg platform, a spar or other types. However, the arrangement of FIG. 1 is particularly suited for a spar. Deck 11 has an opening 13 through which a riser 15 extends.
[0030] Riser 15 is connected on its lower end to a subsea well. In this embodiment, riser 15 is a production riser. Typically, a production tree (not shown) is mounted to the upper end of riser 15 . Well fluids flow from the subsea wellhead of production riser 15 to the tree. Typically, the floating platform will support a number of risers 15 .
[0031] A tensioner assembly comprising a plurality of hydro/pneumatic cylinder assemblies 17 supplies tension to each riser 15 as deck 11 moves upward and downward. Two cylinder assemblies 17 are shown in FIG. 1 , but preferably, at least two more cylinder assemblies 17 will provide tension to each riser 15 . Each cylinder assembly 17 includes a cylinder 19 and a piston 21 that strokes within cylinder 19 . Piston 21 has a rod 23 that protrudes from one end of cylinder 19 . In this embodiment, rod 23 is located on the upper end of cylinder 19 above deck 11 . A closed system of pressurized gas over fluid is utilized to provide force. The pressurized fluid and gas may be internal or external to the cylinder. Both internal and external sources may be used together. An external pressurized fluid and gas source or accumulator 24 is shown. If desired, fluid under atmospheric or low pressure may be placed in the annular space surrounding rod 23 above piston 21 to serve as lubricant for piston 21 . The lubricant may lead to a reservoir for maintaining a constant supply as piston 21 strokes up and down.
[0032] In the preferred embodiment, a plurality of seals 22 surround the circumference of piston 21 . In the embodiment shown in FIGS. 1 and 2 seals 22 engage an interior surface of cylinder 19 . A piston chamber is defined by piston 21 , seals 22 and cylinder 19 . In the embodiment shown in FIGS. 1 and 2 , a plurality of seals 26 also extend from cylinder 19 to sealingly engage rod 23 .
[0033] Cylinder 19 is connected on its lower end to a brace 27 by a pin 25 . In the preferred embodiment, pin 25 is spherical so as to allow pivotal rotation not only in the plane containing the drawing, but also in a Z-plane perpendicular to the plane containing the drawing. Brace 27 in this embodiment is secured to deck 11 , and the lower ends of cylinders 19 are located approximately at the same level as deck 11 .
[0034] Each cylinder assembly 17 inclines relative to riser 15 and deck 11 in the embodiment shown in FIG. 1 and 2 . The upper ends of rods 23 are closer to riser 15 than the lower ends of cylinders 19 . Rods 23 are secured by spherical pins 29 to a top frame 31 . Top frame 31 is mounted to a tension ring 33 that is clamped or otherwise secured to riser 15 for movement therewith. The radial distance from the axis of riser 15 to upper pins 29 is less than the radial distance from the riser axis to lower pins 25 . The angle of each cylinder assembly 17 relative to the riser 15 will change as rods 23 stroke from a retracted position as shown in FIG. 2 to an extended position shown in FIG. 1 . In FIG. 2 , a wave or tidal variation has caused deck 11 to rise relative to riser 15 , causing cylinder assembly 17 to retract. In FIG. 1 , deck 11 has moved downward from that shown in FIG. 2 due to wave movement or tidal action. The pressurized gas over fluid ( FIG. 1 ) maintains pressure on the lower side of piston 21 to cause cylinder assemblies 17 to extend.
[0035] A shroud 35 encloses the exposed portion of rod 23 of each cylinder assembly 17 . Shroud 35 is a cylindrical member having a closed upper end 37 and an open lower end 39 . Each rod 23 extends through a hole in closed end 37 that is preferably sealed to prevent corrosive fluids from contacting rod 23 . Shroud 35 protects rod 23 and seals 26 from any debris falling onto cylinder assemblies 17 from above. The length of shroud 35 is selected so that lower end 39 will be close to the lower ends of cylinders 19 while cylinder assembly 17 is fully retracted as shown in FIG. 2 . When fully extended, as shown in FIG. 3 , lower end 39 of each shroud 35 is spaced below the upper end of cylinder 19 . The interior of shroud 35 is at low or atmospheric pressure.
[0036] Sets of guide rollers 41 are employed to engage riser 15 and maintain riser 15 generally centralized in opening 13 but allow for angular offset of the riser relative to the platform. Although only two guide rollers 41 are shown, preferably more would be employed for each riser 15 . Each guide roller 15 is mounted to an arm 43 that is fixed in length in the preferred embodiment. Arm 43 has an outer end that is secured by a pin 45 to a lug 47 . Lug 47 mounts to deck 11 in this embodiment. Pivot pins 45 allow rods 43 to be pivoted and rotated away from deck opening 13 for other operations, such as when a larger diameter drilling riser is employed in a preliminary operation. In this embodiment, arms 43 are spaced above deck 11 only a short distance, thus provide centralizing to riser 15 at opening 13 .
[0037] An upper deck 51 is located below tensioning ring 33 and above deck 11 in this embodiment. Mounting guide rollers to deck 51 reduces any moment arm on guide rollers 41 due to the failure of a cylinder assembly 17 . Preventing angular movements are desirable during many workover and intervention operations. Preferably, pivot pins 45 allow rods 43 to be pivoted and rotated so that rollers 41 connected to upper deck 51 may be disengaged and pivoted away from riser 15 . This may be desirable during operations where angular movements are allowable, or when a larger diameter drilling riser is employed.
[0038] The embodiment of FIG. 3 is the same as the embodiment of FIGS. 1 and 2 except for placement of guide rollers 41 and upper deck 51 . Consequently, the same numerals will be used except for the different structure. In this embodiment, upper deck 51 is mounted above tension ring 33 and a considerable distance above deck 11 . Arms 43 for guide rollers 41 are mounted to upper deck 51 . An advantage of the embodiment of FIG. 3 occurs if one of the cylinder assemblies 17 loses pressure. A loss in pressure causes a bending moment arm to be applied to riser 15 , which is resisted by guide rollers 41 . Because of the placement above tension ring 33 , the force applied by the moment arm is reduced over that which would exist if rollers 41 were placed as in FIGS. 1 and 2 .
[0039] The embodiment shown in FIG. 4 includes the use of a sleeve or conductor 53 . Conductor 53 is mounted to top frame 31 and extends concentrically around riser 15 . Conductor 53 extends downward a distance that is at least equal to the total stroke of cylinder assemblies 17 . Guide rollers 41 engage conductor 53 rather than directly engaging riser 15 . Conductor 53 provides wear protection to riser 15 due to contact with rollers 41 .
[0040] Referring to the embodiment shown in FIG. 5 , cylinder assemblies 17 are inverted in this alternative embodiment. Piston 21 sealingly engages the interior surface of cylinder 19 which contains pressurized gas as in the previously discussed embodiments. Cylinder 19 has an open lower end for receiving piston 21 , but it does not sealingly engage rod 23 in this embodiment. Accordingly, the lower end of piston 21 , below seals 22 is open to atmospheric pressure. Any fluid or debris dripping onto cylinder assembly 17 from above lands on cylinder 19 , which protects the sealing region between seals 22 and the interior surface of cylinder 19 . There is no separate surrounding rods 23 in this embodiment.
[0041] Referring to another alternative embodiment shown in FIG. 6 , cylinder assemblies 17 and tension ring 33 are located below deck 11 . Cylinder assemblies 17 extend downward at an angle so that the lower ends of cylinder assemblies 17 are radially inward and below the upper ends of cylinder assemblies 17 . Shroud 35 continues to protect rod 23 from any debris falling onto cylinder assemblies 17 from above. This embodiment is particularly useful for replacing tensioner assemblies on existing structures, like existing tension leg platforms, wherein the tension ring is located below the deck. In this embodiment, gas over fluid pressure acts on the annular space between rod 23 and housing 19 to pull housing 19 upward.
[0042] In operation of the embodiments in FIGS. 1-5 , tension ring 33 is mounted to riser 15 , and guide rollers 41 are mounted in engagement with riser 15 or conductor 53 ( FIG. 3 ). Gas pressure in cylinder 19 exerts a desired upward force on riser 15 to maintain a desired tension in riser 15 . As deck 11 moves upward relative to riser 15 , cylinder assemblies 17 retract. As deck 11 moves downward relative to riser 15 , cylinder assemblies 17 extend.
[0043] In each of the embodiments, seals 22 are protected from drippings and debris from above while in both the contracted and retracted positions. Moreover, in the embodiments shown in FIGS. 1-4 , and 6 , shroud 35 also protects rod 23 and seals 26 , in addition to the sealing region located between piston 21 and the interior surface of cylinder 19 .
[0044] In the alternative embodiment of cylinder assembly 17 ′ shown in FIGS. 7-11 , shroud 35 is replaced with a shroud 35 ′ having telescoping shroud portions 35 a ′, 35 b ′, 35 c ′. Similarly, piston and piston rod 22 , 23 , and cylinder 19 from the embodiments shown in FIGS. 1-6 are replaced with piston 22 ′, piston rod 23 ′, and cylinder 19 ′. FIGS. 7 and 8 are similar to the embodiment shown in FIGS. 1 and 2 , with upper deck 51 being positioned below engagement ring 31 . FIG. 7 illustrates the alternative embodiment in an extended position, while FIG. 8 illustrates the alternative embodiment in a contracted position. Likewise, FIG. 9 is similar to the embodiment shown in FIG. 3 such that upper deck 51 is positioned above engagement ring. Finally, FIGS. 10-11 are similar to the embodiment shown FIG. 5 , with cylinder 19 ′ being disposed above piston rod 23 ′ and shroud 35 ′. FIGS. 10 and 11 illustrate this alternative embodiment in both an extended and a contracted position. The alternative embodiments illustrated in FIGS. 7-11 also show cylinder assemblies 17 ′ extending substantially vertical rather than extending at an angle radially inward from lower deck 11 to upper deck 51 .
[0045] Referring to FIGS. 7-12 , shroud 35 ′ includes a plurality of tubular, telescoping shroud portions or segments 35 a ′, 35 b ′, and 35 c ′. In the preferred embodiment, outer shroud segment 35 a ′ has an inner diameter larger enough to receive intermediate shroud segment 35 b ′ and shroud segment 35 c ′. Intermediate shroud segment 35 b ′ preferably has an inner diameter large enough to receive inner or small shroud segment 35 c ′. Outer or large shroud segment 35 a ′ is preferably positioned above intermediate and small shroud segments 35 b ′, 35 c ′ so that shroud 35 ′ shields piston rod 23 ′ from drippings from above when shroud 35 ′ is both extended and contracted, whether cylinder is positioned below shroud 35 ′ ( FIGS. 7-9 ) or below shroud 35 ′ ( FIGS. 10-11 ).
[0046] As is perhaps shown best in FIG. 12 , shroud segments 35 a ′, 35 b ′, 35 c ′ include upper and lower lips 61 , 63 for engaging each other when moving from the contracted position to the extended position. Lower lips 63 are preferably formed on an interior surface of the respective shroud segments for engaging an outer surface of another shroud segment disposed therein. Lower lips 63 are typically formed on a contraction end—or the end in the direction of movement of the shrouds during contraction—of each shroud segment. Upper lips 61 are preferably formed on an outer surface of the respective shroud segments for engaging an inner surface of another shroud. Typically, upper lips 61 are formed on an extension end—or the end in the direction of movement of the shrouds during extension—of each shroud segment. As will be appreciated by those skilled in the art, upper and lower lips 61 , 63 engage each other when shroud 35 ′ is in its extended position and help to define the overall length of shroud 35 ′ when extended.
[0047] In the preferred embodiment, each intermediate segment 35 b′ includes both upper and lower lips 61 b , 63 b because each intermediate shroud segment receives a shroud segment, and is received by a larger shroud segment. In the preferred embodiment, large shroud segment 31 a ′ includes only lower lip 63 a, but has a flange 62 at its upper end for connecting to a piston rod connector flange 67 located on a piston rod connector 65 ( FIGS. 7-9 ), or a flange located at the upper end portion of cylinder 19 ′ ( FIGS. 10-11 ). In the preferred embodiment, small shroud segment 35 c ′ only includes upper lip 63 c. However, small shroud segment 35 c ′ also includes a flange 64 at its lower end for connecting to a flange located at the upper end portion of cylinder 19 ′ ( FIGS. 7-9 ) or to piston rod connector flange 67 ( FIGS. 10-11 ).
[0048] In the embodiments shown in FIGS. 7-12 , piston rod 23 ′ is at least one shroud length longer than piston rod 23 in the previous embodiments because no shroud segment telescope over cylinder 19 ′. As will be readily appreciated by those skilled in the art, in the embodiment shown in FIGS. 7-9 , small shroud segment 35 c ′ could be adapted to telescope over an outer surface of cylinder 19 ′, for example with a lower lip 63 rather than a flange 64 , so that piston rod 23 ′ could have substantially the same length as piston rod 23 .
[0049] In each of the alternative embodiments illustrated in FIGS. 7-12 , seals 22 are protected from drippings and debris from above while in both the contracted and retracted positions. Moreover, in each of the embodiments shown in FIGS. 7-12 , shroud 35 ′ also protects rod 23 ′ and seals 26 , in addition to the sealing region located between piston 21 ′ and the interior surface of cylinder 19 . Protecting the outer surface of piston rod 23 ′ allows for a less expensive manufacture of piston rod 23 ′ because a protective layer will not be necessary.
[0050] While the invention has been shown in only three of its forms, it should be apparent to those skilled in the art that it is not so limited but is susceptible to various changes without departing from the scope of the invention. For example, the number of intermediate shrouds 35 b ′ can be increased or decreased, even such that large shroud 35 a ′ registers with small shroud 35 b ′. Furthermore, the telescoping shroud segments could also be utilized with the tensioner assemblies having the piston rod extending radially inward from the working deck to the tension ring. | A surface assembly that communicates with subsea structures and includes a working deck on a floating structure. The working deck has an aperture extending axially therethrough. A riser extends from a subsea location to the working deck and through the aperture. The surface assembly includes a frame extending circumferentially around the riser so that the frame moves axially with the riser. The assembly also includes a tensioner assembly connected between the working deck and the frame. The tensioner assembly includes a piston slidably carried in a piston chamber, a piston rod extending from the piston and away from the piston chamber, and a shroud enclosing the piston rod. The shroud has a plurality of segments with at least one of the shroud segments being movable in unison with the piston rod. | 4 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates to a centrifugal rotor.
[0002] The technical field of this invention is that of the fluid, liquid or gaseous compression. The invention therefore relates to both pumps as well as compressors which make a supply of liquid or gas respectively possible, from a given pressure to a higher pressure.
[0003] There are many techniques to increase the pressure of a fluid. A common technique consists in centrifuging the fluid upon which stress is exerted which in turn causes an increase in its pressure. For the implementation of this technique, there are many different structures of pumps and compressors depending upon many parameters including the related fluid, the environment (size, etc.) and desired performance (compression rate, etc.). Subsequently, we will focus on pumps and compressors comprising at least one centrifugal rotor associated with an axial diffuser.
[0004] A centrifugal rotor is a rotor having an axis of rotation. It is designed to compress a fluid flowing in a direction parallel to its axis of rotation, the compressed fluid leaving the rotor in a radial direction outwardly. When the compressed fluid must flow axially, one solution is to direct the fluid exiting the rotor so that it changes the direction of flow. The element used for this purpose is a fixed part called an axial diffuser and it has at least one duct to direct the compressed fluid. The downstream end of the duct, that is to say the end which is remote from the centrifugal rotor, is axially oriented in accordance with the direction that one wishes to direct the compressed fluid. The purpose of the axial diffuser is to then take a turn at about 90° to the outgoing fluid from the centrifugal rotor so as to guide it axially.
[0005] Document FR-2874241 discloses a high-efficiency centrifugal rotor which uses truncated blades with a radial diffuser. The wake of the blade recloses in the diffuser and by working with the wakes of the other adjacent blades creates a stratified flow that gradually expands within the diffuser. We thus find in this document a rotor incorporating a diffuser. The very thick blades are located in the lower part of the rotor.
[0006] U.S. Pat. No. 1,447,916 illustrates another embodiment of a rotor incorporating a diffuser. The latter may be a single piece with the rotor portion comprising blades or it may be a separate piece secured to the rotor portion comprising the blades. Although it is noted that in all the figures illustrating the vanes, they only extend over one part of the device (corresponding to the centrifugal rotor) and not to the peripheral output of the device and that the portion corresponding to the centrifugal rotor has a perfectly radial outlet upstream from the diffuser.
[0007] One technical problem encountered with such a structure is that it is the source of pressure loss in the compressed fluid. It is indeed known that when a fluid flows, it undergoes pressure losses that depend on the conduit in which it is found, including any changes in direction undergone.
OBJECTS AND SUMMARY OF THE INVENTION
[0008] It is not possible to eliminate the pressure drop that are particularly related to the nature of the fluid itself (particularly its viscosity) but this invention is to provide the means to minimize as much as possible these losses.
[0009] An object of this invention is thus, for a given compression stage, comprising a centrifugal rotor and an axial diffuser, to increase the performance of this stage, i.e., for example, obtaining a higher compression ratio for a given power or for a given compression reducing the mechanical power needed to be exerted on the rotor to make it turn.
[0010] To this end, this invention proposes a centrifugal rotor including:
[0011] a hub having a longitudinal axis,
[0012] a fluid inlet,
[0013] a first flange, upstream and having an opening around the hub,
[0014] a second flange, separated downstream from said first flange by the vanes thereby forming channels each delimited by the first flange, the second flange and two vanes extending from the fluid inlet to a peripheral outlet.
[0015] According to this invention, in the proximity of the peripheral outlet, the first flange has a concave area oriented towards the channels while the second flange has a convex area oriented towards the channels.
[0016] Due to the form thus given to the outlet channels, the passage of a radial flow within the centrifugal rotor to an axial flow in the diffuser upstream from the rotor is performed less brusquely making it possible to limit the losses in pressure when the fluid changes direction.
[0017] To have a rotor that is simple to produce, the first flange and the second flange advantageously have a circular shape around the longitudinal axis.
[0018] For example it is anticipated that the surface tangent to the concave region of the first flange exiting the channel, forms an angle of between 1° and 45°, preferably between 10° and 30°, with a radial plane perpendicular to the longitudinal axis. Likewise, it is anticipated that the surface tangent to the convex region of the second flange exiting the channel, forms an angle of between 1° and 45°, preferably between 10° and 30°, with a radial plane perpendicular to the longitudinal axis.
[0019] To better guide the fluid in a centrifugal rotor according to the invention, it is advantageously provided that the vanes extend to the outer peripheral exterior edge of the first flange and/or of the second flange.
[0020] To easily create an acceleration of the fluid exiting the centrifugal rotor, the first flange advantageously has an outer peripheral edge adjacent to the channels which have a greater diameter than an outer peripheral edge adjacent to the channels of the second flange. At the edge with the greater diameter, which corresponds to the outside of the curved shape given to the outlet of the centrifugal rotor, the speed is therefore higher. This is preferable because the path to be traveled along the outside of a turn is greater than that of the inside of a turn. In this way, a more uniform distribution of the velocity is promoted when the fluid then moves in a substantially longitudinal direction.
[0021] This invention further relates to a centrifugal compressor and/or a centrifugal pump comprising a centrifugal rotor as described above.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] Details and advantages of this invention will become more apparent from the following description with reference to the accompanying drawings in which:
[0023] FIG. 1 illustrates a centrifugal rotor of the prior art with a cross sectional view of a half rotor mounted in a compressor,
[0024] FIG. 2 is a view similar to that of FIG. 1 for a centrifugal rotor according to a first embodiment of this invention,
[0025] FIG. 3 is a view similar to the preceding views according to a second embodiment of this invention, and
[0026] FIG. 4 is a cross-section view in perspective along the cut line IV-IV of FIG. 2 .
DETAILED DESCRIPTION OF THE INVENTION
[0027] Those skilled in the art will recognize a centrifugal rotor 2 in FIG. 1 mounted inside a housing 4 , for example a compressor housing, and a shaft 6 having a longitudinal axis 8 . The following description will be made with reference to a working air compressor (or more generally a gaseous fluid compressor), but this invention may also be applied to pumps for liquids.
[0028] When the centrifugal rotor 2 is rotated by the shaft 6 , the air (or other gaseous fluid) is drawn into the centrifugal rotor 2 in a longitudinal direction relative to the longitudinal axis 8 , and is driven in a mixed flow motion in the centrifugal rotor 2 while rotating and appear radially with respect to the longitudinal axis 8 .
[0029] The centrifugal rotor 2 is built in one piece and comprises a hub 10 , a first flange or upstream flange 12 , a second flange or downstream flange 14 and vanes 16 .
[0030] The hub 10 enables a connection between the shaft 6 and the centrifugal rotor 2 . It has an overall circular, cylindrical, tubular shape and is provided with a means to fasten it to the shaft 6 . For example, a longitudinal groove is typically provided in the hub 10 and the shaft 6 to receive a longitudinal spline or even grooves, or any other type of connection.
[0031] The downstream flange 14 is connected directly to the hub 10 and extends radially relative to the longitudinal axis 8 . The upstream/downstream direction is defined relative to the direction of the air flow in the centrifugal rotor 2 . Indeed, in FIG. 1 (as well as in the other figures) air is drawn to the right of the rotor and then moves longitudinally to the left before being driven in a radial direction to be oriented finally, after leaving the centrifugal rotor 2 in a longitudinal direction back towards the left of the figure. Thus the upstream elements are arranged to the right of the downstream elements in the figures.
[0032] The upstream flange 12 faces the downstream flange 14 and is connected thereto by the vanes 16 thereby defining the channels for the air between the two flanges. The air is thus introduced between the inner surfaces of the flanges and vanes in a centrifugal radial manner.
[0033] The upstream flange 12 does not extend to the hub 10 but remains at a distance therefrom. A sealing bearing 18 faces the hub 10 in front. Towards the inside of the centrifugal rotor 2 , the front sealing bearing 18 with the hub 10 defines an inlet chamber 20 with an annular opening 22 upstream of the inlet chamber 20 . Towards the exterior, the front sealing bearing 18 is machined to enable it to create a seal of the centrifugal rotor 2 in rotation within the housing 4 . For example, a seal may be used, such as for example a labyrinth ring 24 , as an interface between the centrifugal rotor 2 and the housing 4 . As can be seen in the figures, the centrifugal rotor 2 also includes a further sealing bearing 18 on the downstream side, or a rear sealing bearing, which extends from the downstream flange 14 and receives another labyrinth ring 24 .
[0034] The channels driving air between the upstream flange 12 and downstream flange 14 , each have an outlet 26 ( FIG. 1 ) radially oriented at the largest diameter of the flanges. The air then enters a diffuser 28 in which it is guided so that the air flow is more longitudinal than radial. The channels 30 in the diffuser 28 also make it possible to convert the helical movement of the air flow to a substantially straight movement.
[0035] FIGS. 2 and 4 illustrate a first embodiment of a centrifugal rotor according to this invention. As shown in the drawing, the overall structure is substantially the same in FIG. 1 and in FIGS. 2 to 4 . Thus, the references in FIG. 1 are used in FIGS. 2 to 4 to designate similar elements. A centrifugal rotor is thus found 2 rotatably mounted in a housing 4 around a shaft 6 having a longitudinal axis 8 . The centrifugal rotor 2 is sealed off relative to the housing 4 thusly ensured in particular through the sealing bearings 18 working together with the labyrinth rings 24 (or other type of seal). A hub 10 enables a connection between the rotor and the shaft 6 , for example by means of a spline that is not shown. The centrifugal rotor 2 further comprises an upstream flange 12 and downstream flange 14 interconnected by vanes 16 . The upstream flange 12 has a sealing bearing 18 which with the hub 10 defines an inlet chamber 20 of the annular opening 22 . Again, when the centrifugal rotor 2 rotates around the longitudinal axis 8 of the air (or other fluid) is being drawn through the opening 22 (longitudinal suction) to be compressed in a helico-centrifugal motion and then again become longitudinally oriented within a diffuser 28 optionally provided with channels.
[0036] The differences between a rotor of the prior art and a centrifugal rotor 2 according to this invention are essentially located at the outputs 26 , that is to say at the area having the greatest diameter of the upstream flange 12 , of the downstream flange 14 and the vanes 16 .
[0037] Compared with centrifugal rotors of a compressor (or pump) known in the prior art, this invention proposes to provide an outlet for air flow in a centrifugal rotor (or other fluid) having an improved velocity vector to enter into the longitudinal diffuser. For this purpose, it is expected that the air channels will be slightly bent (defined by the flanges and the vanes) in the centrifugal rotor 2 close to the outlets 26 . A curvature is thus produced at the output of the centrifugal rotor which makes it possible to increase the speed of the air towards the outside of the curvature.
[0038] While in the embodiment of FIG. 1 , it is noted that the inner face of the upstream flange 12 and the surface of the downstream flange 14 are substantially plane (and slightly converging), the inner surface of the upstream flange 12 has, near the output 26 , a concave area 32 and the inner surface of the downstream flange 14 has, near the outlet 26 , opposite the concave area 32 , a convex area 34 .
[0039] If we then consider a surface 36 tangent to the inner surface of the downstream flange 14 at the outlet 26 , this surface is substantially conical (cone axis of the longitudinal axis 8 ) and forms, with a radial plane illustrated by a dotted line, angle a. In the embodiment of FIG. 2 , this angle is about 15° and it is about 30° in the embodiment of FIG. 3 . Preferably, this angle will be comprised between 10° and 45°. In the centrifugal rotors of the prior art, as illustrated by FIG. 1 , this angle is substantially zero.
[0040] To avoid overloading the Figures, the surface tangent to the inner surface of the upstream flange 12 was not illustrated. A substantially conical surface is also found here, around the longitudinal axis 8 , which forms, with the radial plane illustrated, an angle which is preferably less than 45°, for example between 10 and 45°.
[0041] FIG. 4 illustrates that the vanes 16 extend into the convex area 34 of the downstream flange 14 . Of course, they extend in a similar manner into the concave zone 32 of the upstream flange 12 . Preferably, as illustrated in this FIG. 4 , the vanes 16 extend to the peripheral edge of the upstream flange 12 and the downstream flange 14 , that is to say, up to the output 26 of the rotor.
[0042] In FIG. 3 , H is referenced by the line having the greatest diameter of the inner surface of the downstream flange 14 and by S for the line having the greatest diameter of the inner surface of the upstream flange 12 . S and H are circles the center of which lies on the longitudinal axis 8 . R S and R H radius respectively. As is apparent from FIG. 3 (this is also visible in FIG. 2 but slightly less pronounced), R S >R H . Thus, for a same average speed over the air outlet surface outside the centrifugal rotor 2 , the peripheral speed of the air in the vicinity of point S is greater than that of the air near the point H. This also applies to the absolute tangential velocity. The air is accelerated from the upstream side (exterior to the exiting “turn” of the rotor), thereby making it possible to have a more uniform speed at the input of a substantially longitudinal section of the diffuser. Therefore, the losses in pressure, if only within the diffuser, are reduced and therefore make it possible to increase the yield of the device.
[0043] The shape of the centrifugal rotor according to this invention thus allows a more gradual transition from a radial air flow to a longitudinal flow. The distribution of fluid velocities through a passage section of the diffuser is more uniform and regular. The pressure drops are thus limited and again in terms of yield is obtained at a time when the fluid passes from an essentially radial flow to an axial flow as it flows into the axial diffuser.
[0044] Note that the channels in the centrifugal rotor 2 have a passage in which the flow is substantially radial. The inner surfaces of the upstream flange and the downstream flange each have an inversion of curvature. And the inner surface of the upstream flange 12 has a convex area near the inlet chamber 20 and then it extends from the hub 10 after a curved area, said inner surface has a concave area as described above. And the inner surface of the upstream flange 14 has a convex area near the inlet chamber 20 and then it extends from the hub 10 after a curved area, said inner surface has a concave area as described above. The trajectory of the fluid in the channels defined by the flanges and the vanes in the centrifugal rotor 2 and thus has a curve.
[0045] To better guide the fluid in the curved rotor, the vanes 16 extend into the curved region (that is to say up to the concave area of the inner surface of the upstream flange and to the convex area of the inner surface of the downstream flange) and guide the fluid preferably to the outlet 26 . The blades 16 thus are also curved. They preferably extend from the inlet chamber 20 to the line H and the line S. or for example up to the vicinity of these lines (to least 10 mm in these lines).
[0046] Of course, this invention is not limited to the preferred embodiments described above as non-limiting examples, but it also relates to the variants within the reach of those skilled in the art.
[0047] It also concerns variations on the embodiment that will be found within the scope of professionals in the field within the framework of the Claims below. | A centrifugal rotor includes a hub ( 10 ) having a longitudinal axis ( 8 ), a fluid inlet ( 20 ), a first flange referred to as upstream flange ( 12 ) and having an opening ( 22 ) around the hub ( 10 ), a second flange referred to as downstream flange ( 14 ) separated from the first flange by blades ( 16 ) thus forming ducts each delimited by the first flange ( 12 ), the second flange ( 14 ) and two blades ( 16 ) and extending from the fluid inlet ( 20 ) to a peripheral outlet ( 26 ), near the peripheral outlet ( 26 ) the first flange ( 12 ) having a concave zone ( 32 ) facing towards the ducts whereas the second flange ( 14 ) has a convex zone ( 34 ) facing towards the ducts. | 5 |
[0001] This application is a continuation of U.S. application Ser. No. 10/463,597, filed Jun. 17, 2003, entitled Process for the Enantiometric Enrichment of CIS-8-Benzyl-7,9-Dioxo-2,8-Diazabicyclo[4.3.0]Nonane, incorporated herein by reference, which claims priority to German Application No. 102 26 923.8, filed Jun. 17, 2002.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a process for the enantiomeric enrichment of cis-8-benzyl-7,9-dioxo-2,8-diazabicyclo-[4.3.0]nonane with the aid of continuous countercurrent chromatography, in particular, SMB chromatography (SMB=simulated moving bed). In a further aspect, the invention relates to a process for the preparation of (1S,6R)-8-benzyl-7,9-dioxo-2,8-diazabicyclo[4.3.0]nonane using the aforementioned process, which furthermore includes a racemization step.
[0004] 2. Brief Description of the Prior Art
[0005] The enantiomers of cis-8-benzyl-7,9-dioxo-2,8-diazabicyclo[4.3.0]nonane (DOPP) are valuable intermediates for the preparation of quinolone- and naphthyridone-carboxylic acid derivatives which, inter alia, have gained great industrial importance as an active constituent of antibacterial agents and food additives (EP-A 550 903).
[0006] (1S,6R)-8-Benzyl-7,9-dioxo-2,8-diazabicyclo[4.3.0]nonane of the formula (Ia)
is, for example, a valuable intermediate for the preparation of (S,S)-2,8-diazabicyclo[4.3.0]nonane (IIa),
into which it can be converted by reduction of the carbonyl groups and debenzylation in a manner known per se (EP-A 350 733). (S,S)-2,8-Diazabicyclo[4.3.0]nonane is, for its part, used for the preparation of the antibiotic moxifloxacin (INN, 1-cyclo-propyl-7-([S,S]-2,8-diazabicyclo[4.3.0]non-8-yl)-6-fluoro-1,4-dihydro-8-methoxy-4-oxo-3-quinolonecarboxylic acid, (III)) (EP-A 350 733): (III)
[0007] The enantiomer (1R,6S)-8-benzyl-7,9-dioxo-2,8-diazabicyclo[4.3.0]nonane (Ib)
is in turn a valuable intermediate for the preparation of (R,R)-2,8-diazabicyclo[4.3.0]nonane (IIb),
which can likewise be used for the preparation of very active antibacterial agents (e.g. Interscience Conference on Antimicrobial Agents and Chemotherapy (ICAAC), 1996, Abstr. No. F-001).
[0008] Processes for the enantiomeric enrichment of cis-8-benzyl-7,9-dioxo-2,8-diazabicyclo[4.3.0]nonane are known in principle.
[0009] Thus, for example, EP-A 550 903 discloses a process for the resolution of cis-8-benzyl-7,9-dioxo-2,8-diazabicyclo[4.3.0]nonane using tartaric acid (Example A, Method IV and Example B, Method II a)). The processes described there require, for the preparation of the (1S,6R)-enantiomer, repeated recrystallization of the diastereomeric D-(−)-tartaric acid salts or reaction with L-(+)-tartaric acid and subsequent reaction of the released mother liquor with D-(−)-tartaric acid and recrystallization. The enantiomeric excesses obtained are, at 93.8% ee for the (1R,6S) enantiomer and 96.6% ee for the (1S,6R) enantiomer, inadequate with respect to the large number of operations and the large amount of chiral auxiliary reagants and thus only of limited suitability for industrial use.
[0010] EP-A 1 192 153 discloses a process for the resolution of cis-8-benzyl-7,9-dioxo-2,8-diazabicyclo[4.3.0]nonane, which, inter alia, employs (−)-2,3:4,6-di-O-iso-propylidene-2-keto-L-gulonic acid and camphorsulphonic acid as chiral auxiliary reagents. However, here too, the amount of chiral auxiliary reagent needed and the large number of working steps restricts industrial use.
[0011] There was therefore the need for an efficient process for the enantiomeric enrichment of cis-8-benzyl-7,9-dioxo-2,8-diazabicyclo[4.3.0]nonane, in which the separated enantiomers can be prepared on an industrial scale and in high absolute and optical purity.
SUMMARY OF THE INVENTION
[0012] Surprisingly, a process for the enantiomeric enrichment of cis-8-benzyl-7,9-dioxo-2,8-diazabicyclo[4.3.0]nonane has now been found, which is characterized in that the enantiomeric enrichment is carried out by continuous countercurrent chromatography.
[0013] The term “enantiomeric enrichment” is to be understood in the context of the invention in that a starting mixture, which contains the two enantiomers of cis-8-benzyl-7,9-dioxo-2,8-diazabicyclo[4.3.0]nonane, (1S,6R)- and (1R,6S)-8-benzyl-7,9-dioxo-2,8-diazabicyclo[4.3.0]nonane, is separated in such a manner that after the separation the enantiomers are present in higher optical purity than before the separation.
[0014] It may be pointed out that in the context of the invention, the definitions, parameters and explanations, which are general or mentioned in preferred ranges, can be combined with one another in any desired manner, i.e. also between the respective ranges and preferred ranges, and these combinations are also included in the scope of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0015] For the process according to the invention, there is preferably employed a starting mixture which contains the enantiomers in a molar ratio of 0.25:1 to 4:1 and preferably 0.8:1 to 1.25:1. Particularly preferably, the starting mixture contains the racemic mixture of the enantiomers.
[0016] The optical purity is indicated below by the “enantiomeric excess” (ee), which is defined as:
ee [S ]=( m[S]−m[R ])/ m ( S+R )
where
ee(S) is the optical purity of the enantiomer S, m(S) is the amount of substance of the enantiomer S and m(R) is the amount of substance of the enantiomer R. It is customarily given in percent enantiomeric excess (% ee=ee/100).
[0017] cis-8-Benzyl-7,9-dioxo-2,8-diazabicyclo[4.3.0]nonane can advantageously be obtained as a racemic mixture according to EP-A 350 733 by nuclear hydrogenation of pyridine-2,3-dicarboxylic acid N-benzylimide. In this preparation method, in principle the trans compounds diastereomeric to the cis compounds can also be obtained as by-products. Furthermore, other organic by-products can also be produced. It has surprisingly been found that the enantiomeric enrichment according to the invention can also be carried out in the presence of these by-products.
[0018] The invention therefore also comprises a process in which the enantiomeric enrichment of cis-8-benzyl-7,9-dioxo-2,8-diazabicyclo-[4.3.0]nonane is carried out in the presence of the enantiomeric trans-8-benzyl-7,9-dioxo-2,8-diazabicyclo-[4.3.0]nonanes and/or other organic by-products originating from the nuclear hydrogenation of pyridine-2,3-dicarboxylic acid N-benzylimide.
[0019] Their mass content, based on the starting mixture employed for the process according to the invention, which contains the enantiomers of cis-8-benzyl-7,9-dioxo-2,8-diaza-bicyclo[4.3.0]nonane, can be, for example, 0.01 to 20%, and customarily 0.5 to 10%.
[0020] The principle of continuous countercurrent chromatography for the separation of chiral compounds is known, for example, from M. Negawa and F. Shoji, J. Chrom. 590, 1992, pages 113-117. Suitable units for carrying out continuous countercurrent chromatography such as, in particular, SMB units are described, for example, in U.S. Pat. No. 2,621,149; U.S. Pat. No. 2,985,589 and WO 92/16274 and are commercially obtainable.
[0021] Here, in general a stream of liquid moving in one direction and optionally circulating is produced in an SMB unit by means of two or more segments connected to one another, each segment having at least one column filled with a chiral stationary phase and being provided in the flow direction at least with a liquid inlet and a liquid outlet and each segment having at least one inlet, via which a feedstream or an eluting agent can be fed to the optionally circulating stream of liquid, and furthermore having at least one outlet, via which solutions of the more weakly adsorbing compound (raffinate) or solutions of the more strongly adsorbing compound (extract) can be removed from the optionally circulating stream of liquid.
[0022] During operation of the SMB unit, the inlets and outlets are periodically, but not necessarily simultaneously, connected further in the direction of the flow of liquid, for example, via valves such as, for example, individual valves, multiway valves, valve blocks, flaps or rotation valves, such that apparently a countercurrent movement of the stream of liquid and stationary phase results. On account of this, the optionally circulating stream of liquid can be divided into four zones, in which the individual segments can have different functions.
[0023] In Zone I, which is situated between the inlet for the eluting agent and the outlet for the extract, the more strongly adsorbing compound is desorbed from the stationary phase.
[0024] In Zone II, which is situated between the outlet for the extract and the inlet for the feedstream, the more weakly adsorbing compound is desorbed from the stationary phase.
[0025] In Zone III, which is situated between the inlet for the feedstream and the outlet for the raffinate, the more strongly adsorbing compound is adsorbed from the stationary phase.
[0026] In Zone IV, which is situated between the outlet for the raffinate and the inlet for the eluting agent, the more weakly adsorbing compound is adsorbed from the stationary phase.
[0027] The zones can consist, for example, of one or more segments. The number of segments per zone can change here, however. In special cases, it can be advantageous that a zone consists during a period of a liquid compound, but not of segments or columns.
[0028] In certain cases, it can be advantageous to connect the individual segments of the abovementioned device one after the other, not in an endless sequence (closed circulation), but in a series of individual segments having an inlet at the beginning of the segment series and an outlet at the end of the segment series. In this case, an open circulation is referred to. Here, a part flow or the entire flow of the fluid, which is obtained via the outlet of the segment series, can be recirculated to the inlet of the segment series directly or after suitable treatment.
[0029] Advantageous treatment methods are, for example, intermediate storage, testing, distillation, removal of components by means of membrane processes, mixing, temperature-controlling and others.
[0030] In the context of the invention, the operation of an SMB unit as a closed circulation (with a circulating stream of liquid) is preferred.
[0031] In the context of the invention, it is advantageous to employ a column number from 4 to 24, preferably 5 to 12 and particularly preferably 5 to 8.
[0032] Preferably, the columns are designed as cylindrical axial flow columns, which have a device for the dynamic compression of the chiral stationary phase in the axial direction. However, columns of other structural designs can also be employed.
[0033] The column diameter, i.e. the diameter of the packing of the chiral phase, can be, for example, 5 to 1500 mm, preferably 50 to 1200 mm and particularly preferably 200 to 1200 mm. The column length, i.e. the length of the packing of the chiral phase in the flow direction, can be, for example, 15 mm to 300 mm, preferably 40 mm to 170 mm.
[0034] It has proved advantageous to use columns whose packing has a diameter-length ratio of 0.25 to 20, particularly preferably 1 to 5.
[0035] Suitable chiral stationary phases are in particular those which contain the derivatives of polysaccharides, chiral polyacrylates or chiral crown ethers and which are optionally and preferably applied to a support material.
[0036] Suitable chiral stationary phases are in particular those which contain derivatives of polysaccharides, optically active poly(acryl)amides, optically active network polymers or chiral crown ethers and which are optionally and preferably applied to a support material.
[0037] Such chiral stationary phases optionally applied to support materials are disclosed, for example, in EP-A 358 129, EP-A 1 118 623, EP-A 978 498, EP-A 625 524, EP-A 527 239 and EP-A 671 975.
[0038] Suitable support materials are, for example, inorganic or organic support materials which are preferably porous. For use in the process according to the invention, porous inorganic support materials are preferred.
[0039] Organic support materials are, for example, polymers such as polystyrenes, polyacrylic acid derivatives or their copolymers.
[0040] Inorganic support materials are, for example, silicon compounds such as silicas, silica gels and silicic acids, silicates such as zeolites, aluminium compounds such as aluminas, aluminium oxides, aluminates, titanium compounds such as titanium dioxides and titanates, magnesium compounds such as magnesia, glasses, kaolin or apatites such as, in particular, hydroxyapatite. Some of the support materials mentioned can occur in various modifications, which are likewise included.
[0041] Silica gels are particularly preferred as support materials.
[0042] The particles of the support material advantageously have an average diameter (based on the particle count) of 0.1 μm to 1 mm, preferably 1 μm to 500 μm.
[0043] Furthermore, the particles of the support material advantageously have an average pore size of 10 Å to 50 μm.
[0044] Preferred polyacrylates are those which contain structural units of the formula (IV)
where in formula (IV)
R represents hydrogen or methyl, R 1 represents an alkyl group having 1 to 18 C atoms or a cycloalkyl group having 3 to 8 C atoms, each of which is optionally substituted by hydroxyl, halogen, alkoxy or cycloalkyl having up to 8 carbon atoms, by an aryl group having up to 14 carbon atoms or by a heteroalkyl having 4 to 14 carbon atoms, which contains 1 or 2 heteroatoms from the group consisting of nitrogen, oxygen and sulphur, where the aryl or heteroaryl groups mentioned are optionally substituted by hydroxyl, halogen, alkyl or alkoxy in each case having 1 to 4 C atoms, R 3 represents hydrogen or together with R 1 represents a tri- or tetramethyllene group, X represents oxygen or an NR 4 group, in which R 4 together with R 2 and the nitrogen atom form a 5- to 7-membered heterocyclic ring, which is optionally substituted with a COO-alkyl group (1 to 4 C atoms) or by 1 or 2 alkyl groups (in each case 1 to 4 C atoms), and R 2 represents a bulky highly space-filling hydrocarbon radical having up to 30 carbon atoms or a heteroaryl radical having 4 to 14 carbon atoms, which contains 1 heteroatom from the group consisting of nitrogen, oxygen or sulphur, where the hydrocarbon and heteroaryl radicals mentioned are optionally substituted by halogen, hydroxyl, alkyl and/or alkoxy in each case having 1 to 8 carbon atoms, with the proviso that, if R 2 is a tertiary butyl group or X represents the radical NR 4 , R must be a methyl group.
[0050] For R 1 , optionally substituted alkyl, cycloalkyl, aralkyl, aryl and heteroaryl radicals which may preferably be mentioned are the following radicals:
[0051] optionally substituted alkyl radicals the methyl, ethyl, i-propyl, n-propyl, n-butyl, i-butyl, sec-butyl, tert-butyl, 1-hydroxyethyl, 2-alkoxycarbonyl, 3-alkoxycarbonyl, 3-N-acylaminopropyl, 4-N-acylaminobutyl or tert-butoxy-methyl radical and the hydroxymethyl radical;
[0000] optionally substituted cycloalkyl radicals the cyclohexyl radical and the tetrahydronaphth-2-yl radical;
[0000] optionally substituted aralkyl radicals the benzyl radical and 4-hydroxybenzyl radical;
[0000] optionally substituted aryl radicals the phenyl radical and naphthyl radical;
[0000] optionally substituted heteroaryl radical the indol-3-yl radical.
[0052] For R 2 , highly space-filling radicals which may be mentioned are, for example:
[0000] tertiary alkyl radicals such as the tert-butyl radical, the neopentyl radical and the adamantyl radical;
[0000] alkyl radicals substituted in the 1-position by cycloalkyl groups, such as the cyclohexylmethyl radical or cyclohexylethyl radical or cyclopropylmethyl radical;
[0053] optionally substituted cycloalkyl radicals such as the cyclohexyl radical and the cyclohexyl radicals substituted by methyl groups or tert-butyl groups such as the 2- or 3-methylcyclohexyl radical, the 4-tert-butyl radical and 2,6-di-tert-butylcyclohexyl radical or the decahydronaphthyl radical;
[0000] aralkyl radicals such as the 1-phenylethyl radical and the 2-phenylpropyl radical;
[0000] optionally substituted phenyl radicals such as the phenyl radical or phenyl radicals substituted by C 1 -C 4 -alkyl groups such as the o-tolyl radical, 2,6-xylyl radical, 4-tert-butyl radical and 2,6-di-tert-butyl-phenyl radical;
[0000] terpenyl radicals such as the menthyl, neomenthyl, bornyl, fenchyl and pinanyl radical.
[0054] Particularly advantageous is the use of optically active radicals for R 2 , e.g. of the d- or I-1-phenylethyl radical or of the d- or I-methyl, d- or I-neomenthyl, d- or I-bornyl, d- or I-fenchyl radical or of the d- or I-pinanyl radical.
[0055] The polyacrylamides which contain the structural elements of the formula (VI) are preferably obtainable by polymerization of optically active N-(meth)acryloylamino acid derivatives of the formula (V)
in which R, R 1 , R 2 and R 3 have the meaning mentioned under the formula (IV). Particularly preferred polyacrylates and N-(meth)acryloylamino acid derivatives of the formula (V) are derived from optically active amino acids such as alanine, aminobutyric acid, valine, norvaline, leucine, isoleucine, terleucine, phenylglycine, phenylalanine, naphthylalanine, cyclohexyl-glycine, cyclohexylalanine, tyrosine, tryptophan, threonine, serine, aspartic acid, glutamic acid, ornithine, lysine or proline.
[0056] Very particularly preferred N-(meth)acryloylamino acid derivatives of the formula (I) are: N-(meth)acryloylalanine menthyl ester, N-(meth) acryloylalanine bornyl ester, N-(meth)acryloylalanine fenchyl ester, N-(meth)acryloylphenyl alanine methyl ester, N-methacryloyl-phenylglycine tert-butyl ester, N-methacryloylleucine tert-butyl ester, N-methacryloyl-phenylalanine tert-butyl ester, N-(meth)acryloyl-valine trans-4-tert-butylcyclohexyl ester, N-methacryloyl-N′-tert-butoxycarbonyl-lysine tert-butyl ester, N-methacryloyl-isoleucine tert-butyl ester, N-methacryloyl-valine tert-butyl ester, N-methacryloyl-cyclohexylalanine tert-butyl ester, N-(meth)-acryloyl-alanine 2-decahydronaphthyl ester, N-methacryloylalanine methylamide, N-methacryloyl-phenyl-alanine methylamide and N-methacryloylphenyl-alanine 1-phenylethylamide.
[0057] The optically active poly(meth)acrylamides containing the structural units of the formula (IV) are preferably present in the form of cross-linked insoluble but swellable polymers or in a form preferably bound to inorganic support materials.
[0058] The cross-linked polymers are furthermore preferably present in the form of finely divided beads having a particle diameter of 5 to 200 μm. They can be prepared in a manner known per se by suspension polymerization of the optically active (meth)acrylamide monomers of the formula (VI) with 0.5 to 50 mol %, preferably 1 to 20 mol %, particularly preferably 3 to 15 mol %, (based on the total amount (moles) of the monomers employed) of a suitable cross-linker.
[0059] Preferred network polymers are those which are derived from optically active diamines, dicarboxylic acids, diols or hydroxycarboxylic acids. Particularly preferred network polymers are those which are derived from tartaric acid derivatives which are disclosed in EP-A 671 975.
[0060] Preferred crown ethers are those of the general formula (VI)
in each case in the R,R or S,S form, having an optical purity of at least 95% ee, preferably at least 98% ee and particularly preferably at least 99% ee
and in which D and E independently of one another, but preferably identically, represent hydrogen, C 1 -C 6 -alkyl, C 6 -C 10 -aryl or C 7 -C 11 -arylalkyl and
R 4 and R 5 in each case independently of one another, but preferably identically, represent radicals which are selected from the group consisting of C 1 -C 30 -alkyl or C 6 -C 10 -aryl, where the number of radicals R 4 and R 5 on the naphthyl unit is in each case zero, one, two or three, but preferably in each case identically zero or one, where in each case substitution in the 6,6′-position is preferred and the sum of n+m is 3 to 10, preferably 4 to 8 and particularly preferably 5 or 6.
[0061] Chiral crown ethers of the formula (VI) in which D and E in each case identically represent phenyl, n+m=5 and the number of the radicals R 4 and R 5 is zero are particularly preferred.
[0062] As stationary chiral phases which contain chiral crown ethers, those are preferred which have crown ethers of the formula (VI) including the preferred ranges mentioned and are applied to silica gel. Such chiral phases are commercially available, for example, under the name Crownpak CR (+,−)® from Daicel.
[0063] Preferred derivatives of polysaccharides are those which are derived from natural or synthetic glucans, mannans, galactans, fructans, xylans or chitosans.
[0064] Preferably, derivatives of those polysaccharides are employed, which are derived from polysaccharides which have a regular mode of bonding in the chain. These are, for example, β-1,3-glucans such as in particular curdlan and schizophyllan, β-1,4-glucans such as in particular cellulose, β-1,6-glucans such as in particular pustulan, β-1,2-glucans such as in particular crown gall polysaccharides, α-1,3-glucans, α-1,4-glucans such as in particular amylose and amylopectin or starches, α-1,6-glucans such as in particular dextrans and cyclodextrans, a α-1,6-mannans, β-1,4-mannans, β-1,4-galactans, β-1,2-fructans such as in particular inulin, β-2,6-fructans such as in particular levan, β-1,3-xylans, β-1,4-xylans, β-1,4-chitosans, α-1,4-N-acetylchitosans such as in particular chitin. Particularly preferably, derivatives of those polysaccharides are employed which are derived from cellulose, chitin and amylose.
[0065] The average degree of polymerization of the polysaccharide (number average) can, for example, be and preferably is 5 to 500 monosaccharide units but in principle is not restricted upwardly.
[0066] The term “derivative of polysaccharides” is to be understood as meaning polysaccharides in which the hydrogen atoms of the hydroxy groups or in each case one hydrogen atom of the amino groups, but preferably the hydrogen atoms of the hydroxy groups, are substituted at least partially by radicals containing up to 30 carbon atoms. Preferably, at least 30%, particularly preferably at least 50% and very particularly preferably at least 80% of the hydrogen atoms of hydroxy groups or in each case of a hydrogen atom of amino groups are substituted. Preferred radicals having up to 30 carbon atoms are those of the formula (VIIa),
R 6 - (VIIa),
in which R 6 represents C 4 -C 14 -aryl, or those of the formula (VIIb)
R 7 —A-CO— (VIIb),
in which R 7 represents C 4 -C 14 -aryl and at the same time A is absent or represents C 1 -C 4 -alkanediyl or C 2 -C 4 -alkenediyl or R 7 represents C 1 -C 4 -alkyl and at the same time A is absent, or those of the formula (VIIc)
R 8 —B-NHCO— (VIIc),
in which R 8 represents C 4 -C 14 -aryl and B is absent or represents C 1 -C 4 -alkanediyl.
[0067] C 4 -C 14 -Aryl here represents, for example and preferably, carbocyclic aromatic radicals or heteroaromatic radicals, which contain no, one or two heteroatoms per cycle, in the entire heteroaromatic radical at least, however, one heteroatom, which are selected from the group consisting of nitrogen, sulphur and oxygen. Furthermore, the carbocyclic aromatic radicals or heteroaromatic radicals can be substituted with one, two, three, four or five substituents per cycle, which in each case independently of one another are selected for example and preferably from the group consisting of C 1 -C 4 -alkyl, nitro, cyano, O—(C 1 -C 4 -alkyl), fluorine, chlorine, bromine, tri(C 1 -C 4 -alkyl)silyl.
[0068] C 1 -C 4 -Alkyl here in each case independently represents a straight-chain, branched or unbranched C 1 -C 4 -alkyl radical such as, for example, methyl, ethyl, n-propyl, iso-propyl, n-butyl, sec-butyl and tert-butyl.
[0069] C 1 -C 4 -Alkanediyl here in each case independently represents a straight-chain, branched or unbranched C 1 -C 4 -alkanediyl radical such as, for example, methylene, (S)-1,1-ethylene, (R)-1,1-ethylene, 1,2-propanediyl and 1,3-propanediyl.
[0070] C 2 -C 4 -Alkenediyl here in each case independently represents a straight-chain, branched or unbranched C 2 -C 4 -alkenediyl radical such as, for example, ethenyl, 1,2-propenyl and 1,3-propenyl.
[0071] In formula (VIIa), R 6 preferably represents phenyl, which is substituted with no, one or two radicals, which in each case independently are selected from the group consisting of methyl, nitro, chlorine, bromine, tri(C 1 -C 4 -alkyl)silyl.
[0072] In formula (VIIb), R 7 and A together preferably represent methyl, 2-phenylethenyl, phenyl or p-tolyl.
[0073] In formula (VIIc), R 8 and B together preferably represent (S) or (R)-phenylethyl, phenyl, 3,5-dimethylphenyl, p-tolyl and p-chlorophenyl, where 3,5-dimethylphenyl is even further preferred.
[0074] Stationary chiral phases in the context of the invention are preferably those which have chiral crown ethers of the formula (VI) including the preferred ranges mentioned and are applied to silica gel. Such chiral phases are commercially available, for example, under the name Crownpak CR (+,−)® from Daicel.
[0075] Furthermore, as stationary chiral phases in the context of the invention those are preferred which have derivatives of polysaccharides including the preferred ranges mentioned and are applied to silica gel. Such chiral phases are commercially available, for example, under the name Chiralpak® (AD, AS)™ or Chiralcel® (OD, OJ, OA, OB, OC, OF, OG, OK)™ from Daicel.
[0076] Particularly preferably, stationary chiral phases used in the context of the invention are those are which contain amylose tris(3,5-dimethylphenyl-phenylcarbamate), amylose tris-[(S)-α-methylbenzylcarbamate], cellulose tris(3,5-dimethylphenylcarbamate), cellulose tris(4-methylbenzoate) or cellulose tris(4-chlorphenylcarbamate) and are applied to silica gel (e.g., obtainable under the name Chiralpak® (AD, AS)™ or Chiralcel (OD, OJ, OF)™ from Daicel).
[0077] Very particularly preferred stationary chiral phases in the context of the invention are those which contain amylose tris(3,5-dimethylphenyl-carbamate) or cellulose tris(3,5-dimethylphenylcarbamate) and are applied to silica gel (e.g. obtainable under the name Chiralpak® (AD)™ or Chiralcel® (OD)™ from Daicel), where as stationary chiral phases those are even further preferred which contain amylose tris(3,5-dimethylphenylcarbamate) and are applied to silica gel [Chiralpak® (AD)™].
[0078] The starting mixture employed for the separation of enantiomers, which contains the enantiomers of cis-8-benzyl-7,9-dioxo-2,8-diazabicyclo-[4.3.0]nonane, is supplied to the circulating stream of liquid dissolved in a solvent as a “feedstream”.
[0079] The proportion of the starting mixture in the feedstream can be, for example, 1 to 35 mass %, preferably 5 to 30 mass % and particularly preferably 15 to 30 mass %.
[0080] Suitable solvents are organic solvents. These are, for example and preferably, aliphatic hydrocarbons having 6 to 12 carbon atoms such as preferably methyl-cyclohexane, cyclohexane, n-hexane and n-heptane, ethers such as preferably tetrahydrofuran, aliphatic alcohols having 1 to 6 carbon atoms such as preferably methanol, ethanol and isopropanol, nitrites such as preferably acetonitrile, benzonitrile and benzyl nitriles or mixtures of such solvents.
[0081] n-Hexane, n-heptane, isopropanol and acetonitrile or mixtures thereof are particularly preferred, acetonitrile being even further preferred.
[0082] An eluting agent is furthermore supplied to the optionally circulating stream of liquid. The eluting agent is more advantageously an organic solvent, the abovementioned details including the preferred ranges applying in the same way. Particularly preferably, the same solvents are employed for the feedstream and the eluting agent.
[0083] If mixtures of solvents are employed, it is furthermore possible to change the composition during the addition of the eluting agent, which can take place, for example, at intervals or continuously in the form of a gradient.
[0084] In the context of the invention, it is preferred, however, to work at constant composition of the solvent. Even further preferred is the use of only one solvent.
[0085] Advantageously, organic solvents are used which have a water content of 3 mass % or less, preferably 0.3 mass % or less and particularly preferably 0.03 mass % or less.
[0086] The pressure during the addition of the feedstream and of the eluting agent can be, for example, 0.5 bar to 100 bar, 1 bar to 60 bar being preferred.
[0087] The temperature during the enantiomeric enrichment can be, for example, 0 to 80° C., preferably 10 to 40° C., particularly preferably 18 to 32° C. and very particularly preferably 20 to 28° C.
[0088] The raffinate and the extract can then be removed from the SMB unit, these fractions in each case containing an enriched enantiomer of cis-8-benzyl-7,9-dioxo-2,8-diazabicyclo[4.3.0]nonane, it being possible for the enriched enantiomers to be obtained by removal of the solvent, for example by evaporation.
[0089] In the manner according to the invention, the enantiomers of cis-8-benzyl-7,9-dioxo-2,8-diazabicyclo[4.3.0]nonane, in particular (1S,6R)-8-benzyl-7,9-dioxo-2,8-diazabicyclo[4.3.0]nonane, can be obtained, for example, with optical purities of 70% ee or more, preferably 85% ee or more, particularly preferably 90% ee or more and very particularly preferably 95% ee or more.
[0090] In the manner according to the invention, the enantiomer of the raffinate, preferably (1S,6R)-8-benzyl-7,9-dioxo-2,8-diazabicyclo[4.3.0]nonane, can be obtained, for example, with absolute purities of 90% or more, preferably 95% or more and particularly preferably 98% or more.
[0091] Furthermore, in the manner according to the invention, the enantiomer of the extract, preferably (1R,6S)-8-benzyl-7,9-dioxo-2,8-diazabicyclo-[4.3.0]nonane, can be obtained, for example, with absolute purities of 85% or more, preferably 90% or more and particularly preferably 95% or more.
[0092] The yields, based on the maximally obtainable amount of the enantiomers of cis-8-benzyl-7,9-dioxo-2,8-diazabicyclo[4.3.0]nonane, in particular (1S,6R)-8-benzyl-7,9-dioxo-2,8-diazabicyclo[4.3.0]nonane, can be 60% or more, preferably 80% or more and particularly preferably 95% or more.
[0093] It is a particular characteristic of the process according to the invention that the enantiomers of cis-8-benzyl-7,9-dioxo-2,8-diazabicyclo-[4.3.0]nonane, in particular (1S,6R)-8-benzyl-7,9-dioxo-2,8-diazabicyclo-[4.3.0]nonane, can be obtained in optical purities of 95% ee or more with yields based on the maximally obtainable amount of the enantiomer of over 95%.
[0094] Furthermore, the enantiomers of cis-8-benzyl-7,9-dioxo-2,8-diazabicyclo[4.3.0]nonane, in particular (1S,6R)-8-benzyl-7,9-dioxo-2,8-diazabicyclo[4.3.0]nonane, can be obtained in optical purities of 90% ee or more with a productivity of over 0.2 kg, preferably over 0.8 kg and particularly preferably over 3.0 kg, per kg of chiral stationary phase per day [kg/(kg CSP ·d)].
[0095] If for a subsequent step only one enantiomer is of interest, it is advantageous to racemize the enriched undesired enantiomer and to add it again to the continuous countercurrent chromatography.
[0096] In a preferred embodiment, (1S,6R)-8-benzyl-7,9-dioxo-2,8-diazabicyclo-[4.3.0]nonane is obtained from the raffinate and the enantiomer (1R,6S)-8-benzyl-7,9-dioxo-2,8-diazabicyclo[4.3.0]nonane is racemized and added again to the continuous countercurrent chromatography.
[0097] The racemization is known in principle from EP-A 1067 129 and carried out by addition of base.
[0098] In this case, for the racemization, for example, pure (1R,6S)-8-benzyl-7,9-dioxo-2,8-diazabicyclo[4.3.0]nonane or mixtures can be employed which contain, for example, over 70% by weight, preferably over 85% by weight, of (1R,6S)-8-benzyl-7,9-dioxo-2,8-diazabicyclo[4.3.0]nonane. Making up to 100%, these mixtures can contain, for example, (1S,6R)-8-benzyl-7,9-dioxo-2,8-diazabicyclo[4.3.0]nonane.
[0099] Furthermore, it is possible and preferred to employ the enantiomer to be racemized, preferably (1R,6S)-8-benzyl-7,9-dioxo-2,8-diazabicyclo-[4.3.0]nonane, directly in the form of the raffinate or extract solution from the enantiomeric enrichment. Customarily, (1R,6S)-8-benzyl-7,9-dioxo-2,8-diazabicyclo[4.3.0]nonane is obtained in the form of the extract solution.
[0100] Optionally, the raffinate or extract solution can be concentrated by evaporation of solvent.
[0101] Suitable bases for the racemization are, for example, alkoxides of the formula (VIII),
MOR 9 (VIII),
in which
M represents lithium, sodium or potassium, preferably sodium or potassium and R 9 represents a straight-chain or branched C 1 -C 6 -alkyl, preferably methyl or tert-butyl.
[0104] Preferred individual compounds of the formula (VIII) are sodium methoxide, sodium tert-butoxide and potassium tert-butoxide. Potassium tert-butoxide is particularly preferred.
[0105] Preferably, the base is employed in an amount of from 1 to 20 mol based on the amount of cis-8-benzyl-7,9-dioxo-2,8-diazabicyclo[4.3.0]nonane to be racemized.
[0106] The alkoxides can be added in solid form or dissolved in a solvent. Suitable solvents are, for example, alcohols and aprotic solvents, for example the alcohol which corresponds to the alkoxide employed in each case, and straight-chain, branched and cyclic ethers as well as aromatic hydrocarbons. Individual examples of aprotic solvents are: methyl tert-butyl ether, tetrahydrofuran, dioxane, toluene and xylene. Preferred alkoxide solutions are: potassium tert-butoxide in tert-butanol and in tetrahydrofuran and sodium methoxide in methanol.
[0107] In a preferred embodiment, the alkoxide is added to the solvent which serves as the eluting agent in the chromatographic separation.
[0108] The racemization can be carried out, for example, at temperatures between −10 and 40° C.
[0109] The racemization according to the invention is in general complete after, at the latest, 5 hours. Under suitable reaction conditions (e.g. appropriate choice of the base, of the solvent and of the temperature), the reaction time necessary can be significantly shorter and can be, for example, 15 minutes or even less.
[0110] The reaction mixture present after the racemization can be worked up such that the base employed is firstly neutralized, e.g. by addition of an organic acid, e.g. of a C 1 -C 6 -carboxylic acid, of a mineral acid, e.g. sulphuric acid or phosphoric acid, of carbonic acid or of an acidic ion exchanger. The amount of the acid or of the acidic ion exchanger can be, for example, 0.9 to 1.1 equivalents per equivalent of base employed. Preferably, this amount is 0.97 to 1.03 equivalents per equivalent of base employed, in particular the acid or the acidic ion exchanger is employed in equivalent amount, based on the base employed. Afterwards, the solvent can be removed, e.g. by distillation, optionally under reduced pressure. A racemization mixture remains which contains the enantiomers of cis-8-benzyl-7,9-dioxo-2,8-diazabicyclo-[4.3.0]nonanes in a molar ratio of 1:1 to 1.5:1, preferably 1:1 to 1.1:1, it of course being possible for only that enantiomer to be present in an excess which was employed in enriched form for the racemization.
[0111] If before, during or after implementation, solvents are removed which were employed as eluting agents, these can be employed again for the process according to the invention.
[0112] The racemization mixture can then either be stored or added again to the enantiomeric enrichment. This process course, enantiomeric enrichment, racemization, enantiomeric enrichment, can be repeated as often as desired, optionally with continuous readdition of starting mixture, so that, in the manner according to the invention, finally, for example, the racemic mixture of cis-8-benzyl-7,9-dioxo-2,8-diazabicyclo[4.3.0]nonanes obtained in the nuclear hydrogenation of pyridine-2,3-dicarboxylic acid N-benzylimide can be converted completely into an enriched enantiomer, preferably (1S,6R)-8-benzyl-7,9-dioxo-2,8-diazabicyclo[4.3.0]nonane with high absolute and optical purity.
[0113] The enriched enantiomers (1S,6R)-8-benzyl-7,9-dioxo-2,8-diazabicyclo-[4.3.0]nonane and (1R,6S)-8-benzyl-7,9-dioxo-2,8-diazabicyclo-[4.3.0]nonane obtainable in the manner according to the invention are suitable, in particular, in a process for the preparation of antibacterial agents and food additives.
[0114] Furthermore, the enriched enantiomer (1S,6R)-8-benzyl-7,9-dioxo-2,8-diazabicyclo-[4.3.0]nonane obtainable in the manner according to the invention is suitable for the preparation of (S,S)-2,8-diazabicyclo[4.3.0]nonane and moxifloxacin (INN, 1-cyclopropyl-7-([S,S]-2,8-diazabicyclo[4.3.0]non-8-yl)-6-fluoro-1,4-dihydro-8-methoxy-4-oxo-3-quinolonecarboxylic acid, the enriched enantiomer (1R,6S)-8-benzyl-7,9-dioxo-2,8-diazabicyclo[4.3.0]nonane for the preparation of (R,R)-2,8-diazabicyclo[4.3.0]nonane.
[0115] The process according to the invention is distinguished in that, in a continuous process, (1S,6R)-8-benzyl-7,9-dioxo-2,8-diazabicyclo-[4.3.0]nonane and (1R,6S)-8-benzyl-7,9-dioxo-2,8-diazabicyclo-[4.3.0]nonane can be obtained in high purity, optical purity and high yield with unexpected productivity. By means of a downstream racemization and recycling to the separation process, it is furthermore possible in a particularly advantageous manner to obtain a single target enantiomer, in particular (1S,6R)-8-benzyl-7,9-dioxo-2,8-diazabicyclo[4.3.0]nonane, in a very highly efficient manner.
EXAMPLES
Example 1
[0116] A continuously operating countercurrent chromatography unit from NovaSep, France, was employed (type: LICOSEP 8-200). Characteristic components of the unit are 8 axial flow columns (diameter in each case 200 mm) having a device for the dynamic axial compression of the stationary phase.
[0117] All external feeds and drains are in each case fed to specific sites or drained by means of appropriate connections, which correspond with the recirculating concentration profile. The following quantitative flows are established:
Zone I: 500 l/h Zone II: 260.0 l/h Zone III: 274.5 l/h Zone IV: 200.0 l/h Eluting agent: 300 l/h (acetonitrile, water content: <300 ppm) Feedstream: 14.5 l/h with 199.4 mg of rac-DOPP/ml (solvent: acetonitrile, water content <300 ppm) Raffinate: 74.5 l/h of (1S,6R)-8-benzyl-7,9-dioxo-2,8-diazabicyclo[4.3.0]nonane in acetonitrile Extract: 240.0 l/h h of (1R,6S)-8-benzyl-7,9-dioxo-2,8-diazabicyclo[4.3.0]nonane in acetonitrile Cycle time: 0.72 min Temperature: 25° C. Chiral stationary phase: Chiralpak®AD™, 20 μm
[0130] The compositions of the feedstream and of the extract are specified in Table 1 below. The yield is quantitative.
TABLE 1 Extract Raffinate Productivity % ee %* % ee %* kg rac /kg CSP /d 95.6 96.4 98.4 98.8 5.42 *Product stream without solvent or eluting agent
Example 2
[0131] A continuously operating countercurrent chromatography unit from NovaSep, France, was employed (type: LICOSEP 8-200). Characteristic components of the unit are 7 axial flow columns (diameter in each case 200 mm) having a device for the dynamic axial compression of the stationary phase, which used the configuration 2:2:2:1 (Zone1:Zone2:Zone3:Zone4).
[0132] All external feeds and drains are fed to specific sites or drained by means of appropriate connections, which correspond with the recirculating concentration profile. The following quantitative streams were established:
Zone I: 500 l/h Zone II: 286.5 l/h Zone III: 297.0 l/h Zone IV: 200.0 l/h Eluting agent: 300 l/h (acetonitrile, water content: <300 ppm) Feedstream: 10.5 l/h with 202.7 mg of rac-DOPP/ml (solvent: acetonitrile, water content <300 ppm) Raffinate: 97 l/h of (1S,6R)-8-benzyl-7,9-dioxo-2,8-diazabicyclo[4.3.0]nonane in acetonitrile Extract: 213.5 l/h of (1R,6S)-8-benzyl-7,9-dioxo-2,8-diazabicyclo[4.3.0]nonane in acetonitrile Cycle time: 0.69 min Temperature: 27° C. Chiral stationary phase: Chiralpak®AD™, 20 μm
[0145] The compositions of the feedstream and of the extract are specified in Table 2 below. The yield is quantitative.
TABLE 2 Extract Raffinate Productivity % ee %* % ee %* kg rac /kg CSP /d >99.9 96.3 >99.9 98.9 4.56 *Product stream without solvent or eluting agent
[0146] Although the invention has been described in detail in the foregoing for the purpose of illustration, it is to be understood that such detail is solely for that purpose and that variations can be made therein by those skilled in the art without departing from the spirit and scope of the invention except as it may be limited by the claims. | The present invention relates to a process for the enantiomeric enrichment of cis-8-benzyl-7,9-dioxo-2,8-diazabicyclo[4.3.0]nonane with the aid of continuous countercurrent chromatography, which is also described as SMB chromatography (SMB=simulated moving bed). In a further aspect, the invention relates to a process for the preparation of (1S,6R)-8-benzyl-7,9-dioxo-2,8-diazabicyclo[4.3.0]nonane using the aforementioned process, which furthermore includes a racemization step. | 2 |
BACKGROUND OF THE INVENTION
This invention relates generally to wood pulp bleaching processes and more particularly to wood pulp bleaching processes employing gaseous bleaching reagents.
Wood pulp bleaching with gaseous reagents, such as oxygen and ozone, promise significant reduction of objectionable pulp mill effluent to streams and other bodies of water. Elimination of chlorine compounds from the bleaching sequence promises great economic and ecological benefits. However, incorporation of these bleaching reagents can impose significant capital costs on the pulp mill.
For example, the incorporation of ozone has been hindered in commercial applications to a large extent by high capital costs which are inherent to common prior art bleaching sequences which usually require that an ozone bleaching stage is followed by a pulp washing step. From the washer, the pulp is pumped at medium consistency to a mixer wherein alkaline chemicals, such as caustic soda together with any one of a number of reinforcing agents, eg. oxygen, hydrogen peroxide, sodium hypochlorite, or the like are added to the pulp. At the same time, the pulp is heated to increase its temperature above that at which it was discharged from the ozone reactor. The heated and alkalized pulp is then discharged from the mixer to the alkaline extraction stage.
Addition of the cost of the washer and pump to the cost of an existing bleaching operation in order to incorporate an ozone bleaching stage, when considered together with other difficulties and costs associated with ozone bleaching, often makes ozone bleaching economically undesirable. Any reduction of capital equipment requirements clearly would improve the acceptance of ozone bleaching and would increase its use.
The foregoing illustrates limitations known to exist in present devices and methods. Thus, it is apparent that it would be advantageous to provide an alternative directed to overcoming one or more of the limitations set forth above. Accordingly, a suitable alternative is provided including features more fully disclosed hereinafter.
SUMMARY OF THE INVENTION
In one aspect of the present invention, this is accomplished by a method for transporting pulp to subsequent bleaching stages from an initial gaseous bleaching stage for medium consistency pulp, including retaining gas pressure of the initial bleaching stage, discharging pulp from the initial bleaching stage under retained gas pressure, and allowing the retained gas pressure to transport the pulp to a mixer and onward through subsequent stages.
The foregoing and other aspects will become apparent from the following detailed description of the invention when considered in conjunction with the accompanying drawing figures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view illustrating a gaseous bleaching stage in a portion of a pulp processing line of the prior art;
FIG. 2 is a schematic view illustrating a portion of a pulp processing line as in FIG. 1 this time incorporating the present invention;
FIG. 3 is a view as in FIG. 2 illustrating another embodiment of the present invention; and
FIG. 4 presents another possible embodiment.
DETAILED DESCRIPTION
FIG. 1 shows a portion of a pulp processing line incorporating (as an example) an ozone bleaching stage of the prior art. The pulp is washed in washer 10 and discharged through conduit 15 to thick stock pump 20 , from which it is pumped through conduit 25 to ozone mixer 30 . Ozone from the ozone supply, together with its carrier gas, is added to the pulp in the mixer, and the mixture is fed through conduit 35 to ozone/pulp contactor 40 .
After reaction with and finally separation from the pulp in contactor 40 , the remaining ozone and its carrier gas, together with gaseous reaction products, are removed through conduit 49 for reprocessing or other disposition. The pulp is discharged through conduit 45 into washer 42 and from there into medium consistency pump 50 through conduit 48 . It is then pumped through conduit 55 to mixer and heater 60 , where its temperature is increased and alkaline chemicals are added.
The resulting heated mixture is fed through conduit 65 to alkaline extraction reactor 70 . After a required reaction time, the pulp is discharged through conduit 75 to subsequent washing and other processing. It should be noted that discharge, from the contactor 40 , of residual ozone, together with its carrier gas and gaseous reaction products, through conduit 49 results in a decrease of pressure in the system downstream of the pulp ozone contactor reactor 40 . This necessitates addition of pump 246 to transport the pulp to the washer, and a pump 50 to transport the pulp beyond washer 42 . If there is sufficient hydrostatic head, there should be no need for pump 246 prior to washer 42 in the sequence. Pump 50 , provides the pressure necessary to transport the pulp, usually at medium consistency, to mixer 60 and on through the balance of the subsequent alkaline stage.
Referring to FIG. 2, an embodiment of the present invention can be seen, as applied to ozone bleaching followed by an alkaline stage, in which washer 10 , thick stock pump 20 , and ozone mixer 30 and their connecting conduits 15 , 25 , and 35 are the same as in FIG. 1 . However, ozone/pulp contactor 140 is somewhat different in that it has no conduit 49 through which to vent gases. Rather, the ozone and carrier gas which enter through conduit 35 must exit with the pulp and gaseous reaction products only through conduit 47 . This limitation retains the gas pressure developed in the ozone bleaching stage and enables the retained gas pressure to transport the pulp from contactor 140 , through conduit 47 , into mixer 60 and onward to at least an immediately subsequent bleaching stage comprising the alkaline stage.
In mixer 60 , the pulp temperature is increased by heating, and alkaline chemicals needed for the alkaline stage are added to the pulp. The resulting mixture is discharged from mixer 60 , still under the retained gas pressure, through conduit 65 into alkaline reactor 70 . Upon substantial completion of the alkaline reaction, the treated pulp, still under the retained gas pressure, is discharged through conduit 75 to subsequent processing.
The embodiment of FIG. 3 is, in all respects except one, identical to that of FIG. 2 . In this embodiment, mixer 80 is incorporated in place of the mixer ( 60 ) shown in FIG. 2 . Mixer 80 has a gas discharge conduit 87 through which a portion of the retained gas pressure may be released through pressure regulating device 90 . This purges a sufficient quantity of the retained gas to leave only sufficient pressure in the mixer for transport of the pulp to or to and through alkaline reactor 70 . FIG. 4 illustrates yet another embodiment of the invention which provides relatively fine pressure tuning capability for the bleaching system.
By incorporating gas separator 200 , the quantity of gas purged can be more accurately controlled. The prior art system of FIG. 1 has gas separation in the ozone/pulp contactor 40 as a consequence of its operating characteristics, and substantially all of the residual gas is removed. The embodiment of FIG. 3 takes advantage of the gas separation which tends to occur naturally in a gas/liquid system. This allows a portion of the gas pressure to be purged, as already described, but such purging is limited so that a desirable quantity of gas carries forward with the pulp to the subsequent bleaching stage.
In most cases, even though FIGS. 1-4 show either upflow or downflow through the vessels, flow may be in either direction according to conduit arrangements which are determined by desired operating conditions. Clearly, downflow of the pulp is aided by gravity, while upflow requires a driving pressure to overcome gravity. Accordingly, the pressure regulation of the present invention provides a degree of versatility which is not normally available without the use of pumps.
It is also clear that, due to the thermal balance in the system, it may be desirable to have an additional mixer to heat the pulp (usually using steam).
In the scheme of FIG. 4, a pressure reduction device 190 is interposed between ozone/pulp contactor 140 and gas separator 200 . The pulp from the gas separator flows into mixer 160 in which the temperature is increased by heating and alkaline chemicals are blended with the pulp as required by the alkaline stage.
The blended and heated pulp is discharged through conduit 165 to alkaline vessel 70 . After the reaction is finished, the pulp is discharged to subsequent processing through conduit 75 .
Gas from gas separator 200 is routed through conduit 205 to pressure regulator 90 and exhausted for reprocessing or other appropriate disposal through conduit 100 . The gas in gas separator 200 acts as a pneumatic spring whose stiffness is determined by the backpressure imposed by pressure regulator 90 . This maintains a relatively constant driving force for the pulp through mixer 160 and alkaline vessel 70 .
Of course, depending on the configurations of the vessels of the system, either upflow or downflow of the pulp may be desirable for given operating conditions. This will dictate the degree of pressure regulation required and will determine whether the embodiment of FIG. 2, with no pressure regulation, FIG. 3, with limited pressure regulation, or FIG. 4 with full pressure regulation, is the preferred embodiment, recognizing that each embodiment results in specific quantities of gas carried forward to subsequent bleaching stages.
Liebergott, et.al (1992 Non-Chlorine Bleaching Conference) showed that there may be a beneficial effect in delignification efficiency by eliminating the washing step between an ozone bleaching stage and an alkaline extraction stage. Of course, elimination of the washing step will require additional alkali to be used due to carry forward of acid from the first stage, but this is partially offset by savings in capital equipment costs. The result of this invention is to eliminate additional equipment to further reduce the capital cost of the project, and provide for oxygen gas to be carried forward into the subsequent stage or stages which has a further beneficial effect in delignification efficiency. This process is applicable to all systems employing bleaching agents in which the subsequent stage is enhanced by the presence of oxygen gas or is at least not affected in a negative manner. This is very desirable since the cost of purchasing and maintaining pumps which transport pulp at medium consistency is quite high and represents a financial burden on mill operations.
According to this invention, the second stage may be any alkaline stage whose performance is enhanced by exposing the pulp and reactants to oxygen gas, i.e., sodium hydroxide (E) alone or with hydrogen peroxide (P), or sodium hypolchlorite (H). In this example the performance of the stage is enhanced, or reinforced by oxygen. The conventional designations of these enhanced stages then are E O , E OP , or E OH . It is understood that additional bleaching reagents which operate in an acid environment in the subsequent stage of bleaching may become commercially viable in the future, so this invention is not limited to that in which the first stage is acid and the second stage is alkaline. Therefore, according to this invention, the two or more stages of bleaching in which the motive force for transporting pulp through the subsequent stages is the gas pressure of the first stage, may be any combination of acid or alkaline stages.
By the methods of the invention described herein, it is possible to eliminate a pulp washer and a pulp transfer pump from a pulp processing line, thereby substantially reducing the cost of the pulp processing system. | A pulp bleaching line has an initial stage using gaseous bleaching reagent followed by its subsequent stages without intervening washing or pumping steps. The pulp is transported from the initial stage through a mixer in which the pulp is heated and/or dosed with bleaching chemicals and through the subsequent stage by retained gas pressure developed in the initial stage. A portion of the retained gas may be separated and purged from the mixer through a pressure regulating device to optimize pressure for processes which follow the mixer/heater. This permits elimination of a washer and pump normally provided between the initial reactor and subsequent bleaching stage. | 3 |
TECHNICAL BACKGROUND
The present invention concerns a detergent dissolution device of a washing machine which comprises a detergent receptacle for containing a detergent and a casing for receiving the detergent receptacle.
Conventionally, the detergent is put into the water of a washing basket together with clothes when the clothes washing machine starts a washing operation. Alternatively, a detergent dissolution device can be provided in the upper part of the washing machine to automatically dissolve a powdered detergent with the help of supplied water and to put the dissolved detergent into the washing basket.
FIG. 13 schematically illustrates such a conventional detergent dissolution device, which includes, as shown in FIG. 14, a detergent receptacle 2 retractably mounted in the upper part of the housing 1 of a washing machine for containing a detergent, and a casing 3 fixedly attached in the upper part of the housing 1 for receiving the detergent receptacle 2. The detergent receptacle 2 has a handle at the front surface, and projections 5 at the side surfaces for limiting the retracting motion. The casing 3 is provided with a pair of guide grooves 6, which have stops at their respective front ends to obstruct the projections 5 when retracting the detergent receptacle 2, as typically shown in U.S. patent application Ser. No. 08/399,148 (filed on Mar. 6, 1995).
When it is required to refill the detergent receptacle, the detergent receptacle must be firstly pulled out manually, and pushed into the casing again manually after being refilled, thereby causing inconvenience to a user. Particularly, as the detergent dissolution device is mounted at the rear side of the upper part of the washing machine for the detergent to be automatically dissolved in the water supplied through a water supply pipe, it becomes more difficult to manually work the detergent dissolution device. In addition, when the detergent receptacle and casing are too firmly connected, unnecessarily strong force must be applied to pull out the detergent receptacle, so that the detergent receptacle may be separated from the casing broken.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a detergent dissolution device of a clothes washing machine which facilitates the retraction and insertion of the detergent receptacle.
It is another object of the present invention to provide a detergent dissolution device of a clothes washing machine in which automatic retraction of the detergent is possible.
It is still another object of the present invention to provide a detergent dissolution of a clothes washing machine which damps the retraction speed of the detergent receptacle so as to prevent the detergent receptacle from being separated from the casing.
It is further another object of the present invention to provide a detergent dissolution device wherein the cover of the detergent receptacle automatically opens and closes respectively according to the retraction and insertion of the detergent receptacle.
According to an embodiment of the present invention, a detergent dissolution device of a clothes washing machine comprises an outer casing mounted at the upper part of the housing of a clothes washing machine so as to receive the water supplied to a washing basket, an inner casing mounted in the outer casing so as to slidably move in a direction of retraction and insertion, a detergent receptacle included in the inner casing for containing a detergent to be dissolved in the water, a locking means for interlocking or releasing the inner and outer casings relative to each other according to a given force applied to the inner casing, and an automatic retraction means for automatically retracting the inner casing upon a releasing of the locking means.
The present invention will now be described more specifically with reference to the drawings attached only by way of example.
BRIEF DESCRIPTION OF THE ATTACHED DRAWINGS
FIG. 1 is an exploded perspective view for illustrating a detergent dissolution device mounted in a clothes washing machine according to an embodiment of the present invention;
FIG. 2 is a plan view of the inventive detergent dissolution device partly cut away;
FIG. 3 is a cross sectional view taken along line 3--3 in FIG. 2;
FIG. 4 is a cross sectional view taken along line 4--4 of FIG. 2;
FIG. 5 is a cross sectional side view for illustrating the inner casing of the detergent dissolution device of FIG. 4 inserted into the outer casing;
FIG. 6 is an enlarged cross sectional view for illustrating the locked state of the locking means indicated by circle "A" in FIG. 4;
FIG. 7 is an enlarged cross sectional view for illustrating the released state of the locking means;
FIG. 8 is a cross sectional view of a locking pin taken along line 8--8 of FIG. 6;
FIG. 9 is a cross sectional view of the locking pin taken along line 9--9 of FIG. 7;
FIG. 10 is a cross sectional view for illustrating the movement of the locking pin from the position of FIG. 8 to the position of FIG. 9;
FIG. 11 is a view similar to FIG. 10, showing the movement of the locking pin from the position of FIG. 9 to the position of FIG. 8;
FIG. 12 is an enlarged cross sectional view for illustrating a speed reducing means indicated by circle "B" in FIG. 3;
FIG. 13 is a perspective view for illustrating a conventional detergent dissolution device mounted in a clothes washing machine; and
FIG. 14 is a cross sectional view for illustrating the conventional detergent dissolution device inserted into the casing provided in a clothes washing machine.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring to FIG. 1, the housing 10 of a clothes washing machine includes a washing basket 11, and is provided with an upper cover 13 having an opening 12 for enabling clothes to be placed into the washing basket 11. A detergent dissolution device is mounted on the upper cover 13, including an outer casing 20 fixedly attached to the upper cover 13 and an inner casing 30 retractably mounted in the outer casing 20. The water supplied to the washing basket 11 passes through the detergent dissolution device.
The outer casing 20 has its front end opened and its upper surface 21 provided with a water inlet 22 for guiding the water supplied from a water cock, as shown in FIG. 2. At both sides 23 of the outer casing 20 there is provided a fixing flange 24 to attach the outer casing 20 to the upper cover 13 by means of screws penetrating holes 25.
The inner casing 30 is shaped like a box retractably inserted into the outer casing 20. When the inner casing 30 is inserted into the outer housing 20, the front end surface 36 of the inner casing is arranged almost in line with the inside of the upper cover 13. Of course, when the inner casing 30 is retracted, the front end surface is projected into the opening 12. The inner casing 30 includes a detergent receptacle 31 for containing a powdered detergent and a rinse receptacle 32 for containing a rinse agent isolated from the detergent receptacle by means of a partition 30p. As shown in FIGS. 2 and 3, the upper end of the detergent receptacle 31 is opened or closed by means of a cover 33, which is connected to the inner casing 30 by means of a hinge structure 34 provided with a torsion spring 35 so that the outer cover 33 is opened by the resilient force of the spring 35 upon the retraction of the inner casing out of the outer casing. The cover 33 is pushed downward by the upper part 21 of the outer casing 20 to cover the detergent receptacle 31 upon the insertion of the inner casing 30 into the outer casing 20. The cover 33 is provided with a water inlet 37 while the bottom of the detergent receptacle 31 is provided with an outlet 38. Provided around the water inlet 37 is a net structure 37N, and the outlet 38 is also formed of a net structure 38N, so that the dissolved detergent is discharged from the detergent receptacle 31 through the net structure 37N into the outer casing 20 and then into the washing basket 11.
The inner casing 30 is locked to or released from the outer casing 20 by means of a locking device 40 as applying a force to the front end 36, which locking device 40 is hereinafter described with reference to FIGS. 3 and 4. A hook 27 is provided on the inside surface 26 of the rear part of the outer casing 20. The rear part of a body of the inner casing 30 has a recess for receiving a catch housing 42 the latter forming a recess for receiving a catch member 41, which catch housing 42 is provided at the portion of the rear part of the inner casing 30 facing towards the hook 27. The catch housing 42 is inserted into the inner casing 30 so that the front end 42F thereof is arranged substantially in line with the rear end surface 30E of the inner casing 30, as shown in FIG. 6.
The catch member 41 has a resilient hook 43 for catching the hook 27, when the hook 27 is retractably inserted into a housed position within the catch housing 42. The resilient hook 43 is pressed downward by the ceiling 42G of the catch housing 42 to catch the hook 27 upon the insertion of the catch member 41 into the catch housing 42. The hook 43 recovers the original position by its resilient force to release the hook 27 upon the retraction of the catch member out of the catch housing 42, as shown in FIGS. 6 and 7. Mounted between the catch member 41 and the housing 42 is a compression spring 44, which is compressed upon the insertion of the catch member 41 into the catch housing, as shown in FIG. 6. Upon releasing the catch member 41, the compression spring 44 resiliently recuperates for the catch member 41 to automatically project forwards to a projecting position, as shown in FIG. 7.
A stopping hook 45 is provided in the catch housing 42 in order to keep the catch member 41 inserted into or projected from the catch housing. The stopping hook 45 has a vertical end 45S fixed to the catch housing 42 and another free end 45F holding the catch member 41. The catch member 41 has a guide groove 46 formed at the bottom 41a to guide the stopping hook 45. Referring to FIGS. 8 to 11, the guide groove 46 includes a projection catch part 46a for catching the free end 45 in a first state of the stopping hook 45 upon the projection of the catch member 41 out of the catch housing 42 as shown in FIGS. 7 and 9, and an insertion catch part 46b for catching the free end 45F in second state upon the insertion of the catch member 41 into the catch housing 42 as shown in FIGS. 6 and 8. Additionally included in the guide groove 46 are an insertion guide part 46c for guiding the free end 45F of the stopping hook 45 from the projection catch part 46a to the insertion catch part 46b upon the insertion of the catch member 41 into the catch housing 42 as shown in FIG. 11, and a projection guide part 46d for guiding the free end 45F from the insertion catch part 46b to the projection catch part 46a upon the projection of the catch member 41 out of the catch housing 42 as shown in FIG. 10. The insertion guide part 46c is inclined away from the projection catch part 46a and offset downward from the insertion catch part 46b.
A holding part 46e is formed between the insertion guide part 46c and the insertion catch part 46b, deeper than the former and shallower than the latter. A step or level difference S1 lies between the insertion guide part 46c and the holding part 46e, a step S2 lies between the holding part 46e and the insertion catch part 46b, a step S3 lies between the insertion catch part 46b and the projection guide part 46d, and a step S4 lies between the projection guide part 46d and the projection catch part 46a. The insertion guide part 46c is formed shallower than the holding part 46e at the level difference S1, the holding part 46e shallower than the insertion catch part 46b at the level difference S2, the insertion catch part 46b shallower than the projection guide part 46d at the level difference S3, and the projection guide part 46d shallower than the projection guide part 46a at the level difference S4. The insertion guide part 46c becomes gradually shallower away from the projection catch part 46a with no level difference or step formed between parts 46a, 46c. The insertion guide part 46c and the projection guide part 46d are almost symmetrically formed to give a continuous heart shape.
The catch housing 42 has a plate spring 47 for resiliently pushing the stopping hook 45 so as to continuously keep it against the bottom of the guide groove 46 as shown in FIGS. 6 and 7, which cooperates with the level differences to guide the free end 45F in one direction. Namely, as the front end 36 of the inner casing 30 is pushed into the outer casing 20, the free end 45F, as shown by the arrow lines in FIG. 8, starts from the insertion catch part 46b and transverses the projection guide part 46c to the projection catch part 46b.
An automatic retraction mechanism 50 is provided to automatically retract the inner casing 30 from the outer casing 20, which is described with reference to FIGS. 2, 4 and 5. The automatic retraction mechanism 50 includes a roll 51 mounted beneath the rear part of the inner casing 30, a guide member 52 extended from the front end to the rear end of the bottom of the outer casing 20 to guide the roll 51, and a plate spring 53 wound around the roll 51. The roll 51 is shaped like a yarn spindle. One end 53a of the plate spring 53 is fixedly attached to the front end of the guide member 52, so that the plate spring 53 is unwound when the roll 51 and the inner casing 20 move into the outer casing 30. In this state, the plate spring 53 is spread on the guide member 52 as shown in FIG. 5. Upon releasing, the plate spring resiliently recuperates to push the inner casing 30 forwards, i.e, to the right in FIG. 4. The guide member 52 is fixedly mounted on the bottom of the outer casing 20 by means of screws 55 as shown in FIG. 4.
Referring to FIG. 12, there is provided a speed reducing mechanism 60 to reduce the retracting speed of the inner casing 30. Upon being released from the outer casing 20, the inner casing 30 will be abruptly retracted by the resilient recuperative force of the plate spring 53. The speed reducing mechanism 60 is to reduce the retraction speed of the inner casing, and includes a rack 61 provided at one side of the guide member 52 as shown in FIG. 3, a gear wheel 62 mounted beneath the rear end of the inner casing 30 to engage with the rack 61, a rotating shaft 63 with one end connected to the gear wheel 62, and an oil reservoir 64 for containing oil to impart a resistance to the other end of the rotating shaft 63. Namely, the other end of the rotating shaft 63 has an impeller 65 having a plurality of blades rotating in the oil to damp the rotational speed of the rotating shaft 63. The rack may be provided separately from the guide member 52.
In operation, when the inner casing 30 is locked in the outer casing 20 as shown in FIGS. 5 and 6, the catch member 41 is disposed within the catch housing 42 to catch the hook 27 of the outer casing 20, and the plate spring 53 is unwound from the roll 51 as shown in FIG. 5. In this case, the free end 45F of the stopping hook 45 is hooked by the insertion catch part 46b of the guide groove with the compression spring 44 compressed, as shown in FIGS. 8 and 6.
In this state, the user pushes inwardly against the front end 36 of the inner casing 30 with a suitable force, whereupon the compression spring 44 is compressed to cause the free end 45F of the stopping hook 45 to move away from the insertion catch part 46b into the projection guide part 46d as shown in FIG. 10, so that the resilient recuperative force of the compression spring 44 causes the catch member 41 to project out of the catch housing 42 as shown in FIG. 7. When the projecting motion of the catch member 41 is completed, the free end 45F of the stopping hook 45 is positioned in the projection catch part 46a as shown in FIG. 9. Meanwhile, as the catch member 41 is retracted from the catch housing 42, the resilient hook 43 of the catch member 41 is released from the hook 27 because the ceiling 42G moves out of the overlying relationship with the hook 43, thus releasing the inner casing 30 from the outer casing 20. Namely, upon releasing the resilient hook 43, the inner casing 30 starts the retracting motion by means of the resiliently recuperative force of the plate spring 53. In this case, the gear wheel 62 mounted on the inner casing 30 rotates engaged with the rack 61, whereupon the impeller 65 attached to the rotating shaft 63 rotates, retarded by the oil of the oil reservoir 64 so as to reduce the retraction speed of the inner casing 30. Then, the cover 33 of the detergent receptacle 31 is automatically opened by the resiliently recuperative force of the torsion spring 35.
In this state, the detergent or rinse agent is put into the detergent receptacle 31 or rinse receptacle, and then the front end of the inner casing 30 is pressed in order to lock the inner casing in the outer casing 20. Namely, upon pushing the front end 36 of the inner casing 30, the plate spring 53 is unwound from the roll 51, and the rear end of the inner casing 30 reaches the rear end 26 of the outer casing 20. Then, as the catch member 41 enters into the catch housing 42 as shown in FIG. 11, the resilient hook 43 is resiliently pressed by the ceiling 42G of the housing 42 to catch the hook 27 as shown in FIG. 6. Meanwhile, the cover 33 of the detergent receptacle 31 provided in the inner casing 30 is automatically closed by the catch housing 42.
As described above, the inventive detergent dissolution device provides means for facilitating the insertion and retraction of the detergent receptacle 30 characterized in that the roll 51 and plate spring 53 causes the inner casing to be automatically inserted or retracted only by pressing the front end 36 of the inner casing 30. In addition, the cover 33 of the detergent receptacle is automatically opened or closed simultaneously with the retraction or insertion of the detergent receptacle. | A clothes washing machine includes a detergent dissolving assembly comprised of an outer casing mounted in a housing of the machine, and an inner casing mounted in the outer casing so as to be slidable in and out with respect thereto. The inner casing includes a detergent receptacle for receiving powdered detergent which is to become dissolved by inflowing wash water. The inner casing is automatically locked to the outer casing upon being pushed thereinto. To access the inner casing, an inward push is applied thereto, whereupon the inner casing becomes automatically unlocked from the outer casing and displaced outwardly to a detergent-receiving position by a spring. A speed damper is provided for damping the speed of travel of the inner casing. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method of integrated circuit manufacture. More specifically, the invention relates to a method of combining a plurality of semiconductor regions each defined by a reticle image.
2. Description of the Related Art
Integrated circuits are typically fabricated using photolithography techniques to produce a desired pattern from a photographic mask on a substrate material prior to a processing setup such as an etching step. Prior to photolithographic masking, a semiconductor wafer is cleaned, then covered with a solution of photoresist by spincoating, spraying or immersion. The solution is allowed to dry and then exposed to light or near ultraviolet radiation through the mask.
A photolithographic system for selectively irradiating a semiconductor wafer includes a radiation source, a lens or mirror and a mask or reticle. Photographic masks and photographic reticles are used to selectively pattern a semiconductor wafer. The mask and reticle differ in that a mask transfers a pattern onto an entire wafer in a single exposure. A reticle transfers a pattern onto only a portion of the wafer. In a photolithographic system that employs projection printing, the radiation source illuminates through the mask or reticle to the lens or mirror, and the lens or mirror focuses an image of the mask or reticle onto the photoresist coating of the semiconductor wafer.
One projection printing technique employs a projection scanner to transfer a pattern from a mask or reticle to a semiconductor wafer. The projection scanner uses a reflective spherical mirror to project an image onto a wafer by scanning the wafer and the mask with a narrow arc of radiation.
Another projection printing technique uses a step and repeat system, which is also called a stepper, to project an reticle image only onto a portion of the wafer. Multiple images of the reticle pattern are stepped and repeated over the entire wafer using multiple exposures. The reticle pattern is typically reduced 2× to 10× by the lens to form a small size but high-resolution image on the wafer surface, although non-reduction (1×) lens are available to cover a larger field on the wafer.
A photolithographic system uses an illumination source, such as a mercury-vapor lamp, to transfer a pattern to a wafer. A mercury-vapor lamp creates a discharge arc of high-pressure mercury vapor and emits a characteristic spectrum that contains several sharp lines in the ultraviolet region including the I-line at a wavelength of 365 nm, the H-line at a 405 nm wavelength and the G-line at a 436 nm wavelength. Generally photolithographic systems operate using the either the G-line, the I-line, a combination of the lines, or in the deep UV wavelengths of around 240 nm. A suitable illumination is attained using high power mercury-vapor lamps which draw 200 to 1,000 watts and generate an ultraviolet intensity of approximately 100 milliwatts/cm 2 .
A typical reticle is constructed from glass with relatively defect-free surfaces and a high optical transmission at the radiation wavelength. Reticle glasses include soda-lime glass, borosilicate glass, and quartz. Quartz advantageously has a low thermal expansion coefficient and high transmission for near and deep ultraviolet light.
The term resolution refers to the ability of an optical system to distinguish closely spaced objects. The minimum resolution of a photolithographic system is the dimension of minimum linewidth or space that the system adequately prints or resolves. Optical photolithography currently attains a resolution of 0.35μ or less. Feature sizes approach 0.25μ and below with the features extending across wafer areas of a square inch and more. To improve resolution various alternative technologies are under development, including electron-beam, ion-beam, and x-ray technologies. These alternative technologies have achieved patterning capabilities that exceed limits of optical systems. Electron-beams and ion-beams can also directly write image patterns onto the photoresist without the use of a mask or reticle, for instance by using a controlled stage to position the wafer beneath the tool. However, these alternative approaches have certain drawbacks. For instance, electron-beam lithography has low throughput, x-ray lithography has difficulties with fabricating suitable masks, and ion-beam lithography has low throughput and difficulties with obtaining reliable ion sources.
One problem that arises with imaging of a wafer using a plurality of reticle images is the difficulty of achieving a suitable registration between the image fields on the semiconductor wafer. In particular, structures in different reticle fields are typically connected by overlapping of continuous lines that span the exposure fields of several reticles. Errors in registration can cause a connecting line between exposure fields to become laterally displaced and, therefore, disconnected. For electrically conductive structures, such as polysilicon and conductive metals, that are intended to form a conductive loop in a continuous circuit, a disconnection between structures constitutes an open circuit. For an electrically conductive loop having a registration error that does not result in a disconnected but rather a significantly attenuated line width, the line resistance may be substantially elevated, thereby impacting the performance of the circuit. In addition, a metal line such as an aluminum line that is significantly narrowed may become susceptible to high resistance or open lines due to electromigration. Disconnected lines and narrowed lines caused by misregistration between reticle image fields are typically stitched by depositing metal contacts over the ends of line segments. This approach disadvantageously requires additional processing steps for depositing and etching the metal contacts.
Another problem arising with fabrication of circuits by imaging using reticle image fields is that substantial silicon area is lost at the boundaries between reticle imaging fields.
What is needed is a technique for stitching line segments defined by adjacent reticle image patterns projected onto a photoresist layer overlying a semiconductor wafer so that segments are suitably interconnected.
SUMMARY OF THE INVENTION
In accordance with the present invention, each region of multiple regions on a semiconductor substrate is imaged in an exposure field defined by a reticle. The regions are separated and electrically isolated within the semiconductor substrate by an isolation such as a field oxide or trench isolation. The regions are interconnected by imaging using a stitching reticle having an exposure field overlapping a plurality of the regions. The combination of reticle-imaged fields effectively increases the size of a field formed using a step and repeat technique while achieving high imaging resolution within the combined regions.
Also in accordance with an embodiment of the present invention, a plurality of integrated chip sets, including microprocessor, memory, and support chips, are constructed on a single semiconductor wafer using separate reticle imaging of each of the plurality of integrated chip sets. The different circuits are interconnected using a stitch mask and etch operation that combines the regions.
Many advantages are achieved by the disclosed method and apparatus. One advantage is that the interconnection of different reticle fields increases the effective size of a circuit while maintaining a high imaging resolution. Another advantage is that the combination of a plurality of imaged regions reduces the silicon area lost in the areas outside the individual imaged regions. A further advantage is that a plurality of different integrated circuits may be interconnected using the described method. For example, a semiconductor wafer may be fabricated including a microprocessor, memory and support chips. The individual circuits are connected using the described method so that a highly fictional combination circuit is constructed.
A further advantage is that interconnections are formed using the described method to supply a metal plug forming a low impedance local interconnect between source/drain regions of transistors. It is advantageous that interconnections are made between multiple integrated circuit devices and structures while maintaining a planar structure through multiple layers.
BRIEF DESCRIPTION OF THE DRAWINGS
The features of the described embodiments believed to be novel are specifically set forth in the appended claims. However, embodiments of the invention relating to both structure and method of operation, may best be understood by referring to the following description and accompanying drawings. The appended drawings illustrate the general concepts of a suitable fabrication method but are not necessarily drawn to scale. Analogous or similar structures may be designated by the same reference number in the drawings.
FIGS. 1A and 1B through 5A and 5B, are respectively a top plan view (FIGS. 1A through 5A) and a corresponding cross-sectional view (FIGS. 1B through 5B) showing successive processing steps of a method for stitching two circuit fields.
FIGS. 6A through 6E are a sequence of cross-sectional diagrams of a semiconductor wafer during processing for combining a plurality of fields defined by a reticle image using segment stitching.
FIG. 7 is an overhead view of a semiconductor wafer showing four fields or regions which may use a stitch mask that covers all four fields to connect the fields.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to a sequence of paired FIGS. 1A and 1B through 5A and 5B, a top plan view (FIGS. 1A through 5A) and a corresponding cross-sectional view (FIGS. 1B through 5B) are illustrated for successive processing steps of a method for stitching two circuit fields, a field A 100 and a field B 101. In FIGS. 1A and 1B, a silicon substrate 102 is covered by a layer of gate oxide 104. Overlying the gate oxide 104 is a layer of polysilicon 106. A photoresist layer 108 is formed on the surface of the gate oxide layer 104. A first image pattern 110 is etched into the photoresist layer 108. The first image pattern 110 is bounded by an outer border 112 and defines a first segment 114 and a contact region 116 between irradiated regions of the first image pattern 110.
In one embodiment, the silicon substrate 102 is suitable for integrated circuit fabrication and includes a P-type epitaxial surface layer with a <100> orientation, a thickness of 8μ and a resistivity of 12 Ω-cm. The epitaxial surface layer is formed on a P+ base layer (not shown). The gate oxide layer 104 typically is composed from silicon dioxide and is formed on the top surface of the silicon substrate 102 using thermal oxidation in a diffusion tube at a temperature of from 700° C. to 1000° C. in an O 2 ambient. The gate oxide layer 104 typically has a thickness in a range from 30 Å to 150 Å. The polysilicon layer 106 is not doped and is deposited to a thickness of 1500 Å to 2500 Å by low pressure chemical vapor deposition on the surface of the gate oxide layer 104. The polysilicon layer 106 may be doped subsequently, either in situ during deposition or prior to etching, for example by implanting arsenic with a dosage in a range from 1×10 15 to 5×10 15 atoms/cm 2 and an energy in a range from 2 to 50 kiloelectron-volts. The photoresist layer 108 is typically deposited on the polysilicon layer 106 as a continuous layer and selectively irradiated using a photolithographic system (not shown), such as a step-and-repeat optical projection system. The step-and-repeat optical projection system, for example, may project I-line ultraviolet light from a mercury-vapor lamp through a reticle and a focusing lens to illuminate the first image pattern 110 on the photoresist layer 108. In other embodiments, other illuminating systems such as electron-beam and x-ray illumination systems may be employed, depending on the integrated circuits to be fabricated.
In one embodiment, the first segment 114 has a line width (LW) of about 3500 Å. The contact region 116 has a width (W) of about 5500 Å and a length (L) of approximately 2000 Å. In the illustrative embodiment, the first segment 114 is centered in the y-direction with respect to the contact region 116 so that the contact region 116 protrudes about 1000 Å beyond adjoining sidewalls (not shown) of the first segment 114.
The irradiation for projecting the first image pattern 110 is terminated and, in a second irradiation step shown in FIGS. 2A and 2B, the photoresist layer 108 is again selectively irradiated, for example using the step and repeat system, and a second image pattern 120 is projected onto the photoresist layer 108. Thus the first image pattern 110 and the second image pattern 120 are projected using separate exposure steps with the first image pattern 110 projected onto the photoresist layer 108, the exposure discontinued, and then the second image pattern 120 is projected onto the photoresist layer 108. The second image pattern 120 has an outer border 122 and defines a second segment 124 between irradiated regions of the second image pattern 120. One end of the second segment 124 is adjacent to the outer border 122. Outer borders 112 and 122 are mutually parallel and offset by a selected length in the x-direction so that image patterns 110 and 120 partially overlap between the outer borders 112 and 122. The first segment 114 and the second segment 124 are mutually misaligned with respect to one another in both the x-direction and the y-direction. The second segment 124 is positioned to extend into the contact region 116 to form an electrical contact between the field A 100 and the field B 101.
In one embodiment, outer borders 112 and 122 are mutually parallel and offset by approximately 500 Å in the x-direction. First segment 114 and second segment 124 are displaced in the x-direction by approximately 1500 Å and displaced in the y-direction by about 500 Å so that the second segment 124 extends about 500 Å into the contact region 116 and is spaced from the upper edge of the contact region 116 by about 500 Å and spaced from the lower edge of the contact region 116 by about 1500 Å. The entire end of the second segment 124 overlaps the contact region 116 so that the contact region 116 accommodates the misalignment between the first segment 114 and the second segment 124 and assures that the stitching between segments 114 and 124 has a linewidth of about 3500 Å.
Referring to FIGS. 3A and 3B, the photoresist layer 108 is developed. The photoresist layer 108 is positive-acting so that portions of the photoresist layer 108 that are irradiated by the first image pattern 110, the second image pattern 120, or both image patterns 110 and 120 are removed. The removed areas of the photoresist layer 108 leave openings 130 that selectively expose a portion of the polysilicon layer 106 which correspond to the first image pattern 110 and the second image pattern 120. The portion of the photoresist layer 108 that remains after patterning covers the first segment 114, the second segment 124, and a portion 132 of the contact region 116. Portion 132 of the contact region 116 is outside the outer border 122. The portion 132 of the contact region 116 inside the outer border 122 corresponds, or is converted, to the end of the second segment 124, where the second segment 124 overlaps the contact region 116.
Referring to FIGS. 4A and 4B, an anisotropic dry etch that is highly selective of the polysilicon layer 106 is applied through the openings 130. The photoresist layer 108 protects the underlying polysilicon layer 106 from the etch while the exposed portion of the polysilicon layer 106 is etched and removed. The anisotropic etch is highly selective of polysilicon and non-selective of silicon dioxide so that only a negligible amount of the gate oxide layer 104 beneath the exposed portion of the polysilicon layer 106 is removed. The silicon substrate 102 is not etched by the anisotropic etch.
Referring to FIGS. 5A and 5B, the photoresist layer 108 is stripped. The first segment 114 and the second segment 124 are stitched by the portion 132 of the contact region 116 to form a continuous circuit despite possible misalignment between the segments 114 and 124. In one embodiment, the segments 114 and 124 are stitched to form a continuous minimum linewidth of approximately 3500 Å despite any misalignment between the segments.
Various other embodiments of the method disclosed in paired FIGS. 1A and 1B through 5A and 5B, which are described more fully in the copending U.S. Patent Application entitled, "Method of Stitching Segments Defined by Adjacent Image Patterns During the Manufacture of a Semiconductor Device," Ser. No. 08/805,534, naming H. Jim Fulford, Jr. et al. as inventors. In various embodiments, for example, the images for field A 100 and field B 101 are patterned in a reversed order. The first and second segments are formed in sequence using two photoresist layers, rather than being formed simultaneously using a single photoresist layer. In another embodiment, the segments and the contact region are fabricated as trenches formed in silicon beneath the image patterns, rather than protruding regions of polysilicon outside the image patterns.
FIGS. 6A through 6E are a sequence of cross-sectional diagrams of a semiconductor wafer 600 during processing for combining a plurality of fields defined by a reticle image using segment stitching. Referring to FIG. 6A, a cross-sectional view of a semiconductor wafer 600 shows a field A 602 and a field B 604. Field A 602 and field B 604 are formed using separate masking steps as is depicted in paired FIGS. 1A and 1B through 5A and 5B for one or more reasons. For example, field A 602 and field B 604 may be formed in different masking steps because the combination of fields is too large for masking using a single reticle. Alternatively, field A 602 and field B 604 may be fabricated using different resolution and quality reticles, or different layout rules, design rules or illumination technologies (for example, x-ray, ion-beam and electron-beam illumination). Furthermore, macrochips including a variety of circuit fields such as a microprocessor, a DRAM storage, an SRAM storage and the like may be fabricated using a plurality of reticles, masked and etched in separate processing sequences for the plurality of circuit fields. In other circuits, different circuit structures may be fabricated in the plurality of circuit fields such as a block of P-channel transistors and a block of N-channel transistors in a static RAM circuit.
Although each field typically includes a plurality of devices and structures, a transistor A 612 and transistor B 614 are shown in FIGS. 6A through 6E for illustrative purposes since a discussion of two devices fully but concisely describes the improved method.
Field A 602 and field B 604 are separated by an isolation 606 which in various embodiments is a trench isolation or a field oxide isolation. The isolation 606 is formed to mutually isolate the fields of a multiple-field semiconductor wafer. A field oxide isolation is formed by thermal growth on the silicon substrate 608, for example by wet oxidation at temperatures of around 1000° C. for 2 to 4 hours to grow field oxide thickness of 0.8μ-1.0μ. A trench isolation may take the form of a single trench or multiple trenches. For example, if shallow trench isolation is used, multiple trenches are advantageously employed to assure a sufficient isolating fill. A trench or plurality of trenches is etched and the trenches are filled, for example using a LOCOS fill, a deposited fill, or a spin-on-glass (SOG) for filling narrow trenches. A suitable trench isolation has a width in a range from approximately 1.0μ to about 100μ.
The devices, transistor A 612 and transistor B 614 are previously formed in different masking steps using suitable device processing steps including formation of gate oxide, gate polysilicon, source/drain and isolation. For example, in one embodiment the field A 602 is masked and etched in a first sequence of steps and the field B 604 is masked and etched in a second sequence of steps. Masking of field A 602 and field B 604 are mutually independent, by projecting radiation respectively through a reticle A (not shown) and, at a different time, through a reticle B (not shown). The reticle A and the reticle B are typically different reticles, although in some embodiments, the same reticle may be used to mask both field A 602 and field B 604, although separate mask steps are necessary since multiple exposures are used to form a desired circuit size. Both the printing of field A 602 and field B 604 are performed with a controlled registration tolerance.
The transistor A 612 includes a gate 620 and a source/drain region 622 implanted into a substrate 608. The transistor B 614 includes a gate 630 and a source/drain region 632 implanted into the substrate 608. A dielectric layer 616 is deposited overlying the devices transistor A 612 and transistor B 614. The dielectric layer 616 is deposited as a continuous layer overlying the silicon substrate 608.
In one embodiment, the gate is formed by applying a first photoresist mask on the gate material and etching a first portion of the gate material through the opening in the first mask. The first photoresist mask is then removed and a second photoresist mask is formed on the gate material so that a second portion of the gate material is etched through the opening in the second mask. In this embodied method, the first and second edges of the gate electrode are formed in sequence. An advantage of this etching procedure is that the gate electrode can have an extremely narrow length of approximately 0.1μ or less.
Following formation of the gate electrode, source and drain regions are formed by implanting dopants of a conductivity type (P or N) which is complementary (N or P) to the conductivity type of the semiconductor substrate using a patterned gate as a mask. The source and drain regions are thus self-aligned to the gate electrode, improving packing density and reducing parasitic overlap capacitances between the gate electrode and the source and drain.
Photolithographic techniques are commonly used to create patterns in the photoresist mask that define the gate electrode. Typically, the wafer is cleaned and prebaked to drive off moisture and promote adhesion, an adhesion promoter is deposited on the wafer, a few drops of photoresist are deposited onto the spinning wafer to provide a uniform layer, the wafer is soft baked to drive off remaining solvents, the wafer is put into a photolithographic system and exposed to a radiation pattern, and then the photoresist is developed.
Positive photoresist is typically used so that the developer removes the irradiated regions. The photoresist is hard-baked to improve resistance, and then the wafer is doped using an additive process, such as ion implantation, or a subtractive process, such as etching, using the photoresist as a mask. The photoresist is then stripped.
Referring to FIG. 6B, a cross-sectional view of the semiconductor wafer 600 shows a field A 602 and a field B 604 following masking and etching of the dielectric layer 616 using a stitch mask which is applied in accordance with the technique disclosed in the discussion of paired FIGS. 1A and 1B through 5A and 5B. The stitch mask and etch operation is applied throughout the entire wafer surface or in a portion of the wafer surface in various applications. A photoresist layer (not shown) is deposited as a continuous layer and is irradiated using a photolithographic system. In one embodiment of a fabrication method, the photolithographic system is a step and repeat optical projection system where I-line ultraviolet light from a mercury-vapor lamp is projected through a reticle and a focusing lens to imposed a selected image pattern in the photoresist layer. The stitch mask overlaps both the field A 602 and the field B 604. In some embodiments, the stitch mask covers both the field A 602 and the field B 604. In embodiments including many circuit fields, the stitch mask may cover all fields. For example, an overhead view of a semiconductor wafer 700 shown in FIG. 7 shows four fields A 702, B 704, C 706, and D 708 which may use a stitch mask 710 that covers all four fields. In other embodiments, the stitch mask covers a same size area or a smaller area than the area of a single of the fields A 602 and B 604 but is positioned to overlap field A 602 and field B 604.
The stitch mask is applicable in circumstances in which field A 602 and field B 604 are formed using different masks. If field A 602 and field B 604 can be formed using a single mask, a stitch mask is not necessary.
In various embodiments, the stitch mask is applied using a reticle that has the same resolution as the reticles for masking field A 602 and field B 604 or a different resolution. In some embodiments, field A 602 and field B 604 are masked using a 4× or 5× reticle. A stitch mask that covers both the entire field A 602 and field B 604 may, for example, be applied using a large 1× reticle. A large 1× reticle does not attain the resolution of a 4× or 5× reticle, but the registration tolerances to be attained by the stitch mask are not critical in comparison to the tolerances in the field A 602 and the field B 604.
The photoresist layer is developed and the irradiated portions are removed to form openings including a via 640 in the dielectric layer 616. The dielectric layer 616 is etched to selectively expose the source/drain regions of transistors so that the source/drain regions are subsequently connected. In the illustrative example, the source/drain region 622 of transistor A 612, the source/drain region 632 of transistor B 614 and the isolation 606 separating field A 602 and field B 604 are uncovered by etching of the dielectric layer 616. The dielectric layer 616 is masked using a stitch mask traversing a plurality of separately masked field areas A 602 and B 604 and etched to form the via 640 for making a local interconnect between devices transistor A 612 and transistor B 614 crossing the isolation 606.
Referring to FIG. 6C, a cross-sectional view of the semiconductor wafer 600 shows a field A 602 and a field B 604 following masking and etching of the dielectric layer 616 using two contact masks, one applied to field A 602 and one applied to field B 604. The contact mask steps are performed to form a contact via 650 to transistor A 612 and a contact via 652 to transistor B 614.
Referring to FIG. 6D, a metal plug 642 is formed in the via 640 formed by etching following application of the stitch mask and metal plugs 654 and 656 are also formed in the respective vias 650 and 652 formed by the contact mask and etch steps. The metal plugs are typically formed from tungsten or aluminum. The metal plug 642 forms a low impedance local interconnect between source/drain regions of transistors in separately masked and etched fields A 602 and B 604. The metal plugs 654 and 656 are formed using a suitable technique such as a chemical-vapor deposition (CVD) or plasma-enhanced chemical-vapor deposition (PECVD) technique followed by chemical-mechanical polishing (CMP), simultaneous deposition of a metal-1 layer and the plug film followed by two-mask patterning of the plug and metal-1 lines, or etching of the plugs from a thin metal film using contrast-enhancement lithography.
Subsequent processing of the metal plugs depends on the circuit application. In some embodiments, a polishing step such as a chemical-mechanical polishing (CMP) is applied after formation of the metal plugs. CMP involves simultaneous chemically etching and mechanical polishing or grinding of a surface so that a combined chemical reaction and mechanical polishing removes a desired material from the substrate surface in a controlled manner. The resulting structure is a planarized substrate surface with protruding surface topography leveled. CMP is typically performed by polishing a substrate surface against a polishing pad that is soaked with a slurry including an acidic or basic solvent, an abrasive agent and a suspension fluid. In other embodiments, polishing is not performed and the metal plug 642 is simply filled and capped with a topside metal layer. In some embodiments, the metal plug 642 is deposited and planarized or formed by a continuous aluminum fill.
Referring to FIG. 6E, a cross-section view of the semiconductor wafer 600 illustrates the formation of a metal line A 660 printed on the field A 602 and a metal line B 662 printed on the field B 604, forming a local-interconnect layer 670 by depositing a metal such as aluminum or tungsten and defining the layer. In one embodiment, the metal line A 660 and the metal line B 662 are formed by deposition of hot aluminum, tungsten or other suitable metal and polished. The metal line A 660 and the metal line B 662 may be deposited by chemical vapor deposition (CVD), sputter-deposition, or by evaporated-film deposition. CVD deposition attains a better step coverage. CVD of tungsten is typically performed in either a hot-wall, low-pressure CVD system or a cold-wall low-temperature system. The tungsten is selectively deposited from either WF 6 or WCl 6 using hydrogen reduction-blanket CVD W deposition and etchback. CVD of aluminum is typically performed by pyrolysis of triisobutyl aluminum (TIBA) or by selective deposition through thermal decomposition of TIBA.
While the invention has been described with reference to various embodiments, it will be understood that these embodiments are illustrative and that the scope of the invention is not limited to them. Many variations, modifications, additions and improvements of the embodiments described are possible. For example, although the illustrative connections are made with source/drain regions of transistors, the disclosed method is applicable to structures other than source/drain regions and transistor devices. Any interconnections made be made using the disclosed method. | Each region of multiple regions on a semiconductor substrate is imaged in an exposure field defined by a reticle. The regions are separated and electrically isolated within the semiconductor substrate by an isolation such as a field oxide or trench isolation. The regions are interconnected by imaging using a stitching reticle having an exposure field overlapping a plurality of the regions. The combination of reticle-imaged fields effectively increases the size of a field formed using a step and repeat technique while achieving high imaging resolution within the combined regions. Similarly, a plurality of integrated chip sets, including microprocessor, memory, and support chips, are constructed on a single semiconductor wafer using separate reticle imaging of each of the plurality of integrated chip sets. The different circuits are interconnected using a stitch mask and etch operation that combines the regions. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
BACKGROUND OF THE INVENTION
[0001] Commercial food preparation is, in effect, a manufacturing operation in which a team of skilled workers operates together to produce meals from component ingredients. Such preparation involves several major activity areas centered on appliances such as a stove, an oven, a refrigerator, a sink, and one or more preparation tables where food ingredients may be chopped or peeled or mixed or set for cooling or staging.
[0002] Unlike conventional manufacturing operations, much of the work in kitchens is performed manually using equipment and methods that differ only in slight degrees from those used hundreds of years ago. The work preparing food can be difficult, especially in commercial quantities, which may involve moving of large and bulky food containers that may be hot, in an environment where spills and moisture are inevitable. Mixing and cutting large quantities of food can involve repetitive manual activities that may promote repetitive motion injuries.
[0003] The variety and range of tasks undertaken in a commercial kitchen nevertheless require great flexibility in the equipment. Space is normally at a premium and specialized equipment that may be appropriate in a manufacturing environment may be commercially impractical in a commercial kitchen operating in a highly competitive environment.
BRIEF SUMMARY OF THE INVENTION
[0004] The present invention provides a novel new appliance for use in commercial and other kitchens providing a mobile stove unit including a food transfer platform. Motorized columns allow change in height of the food transfer platform and stove-top, allowing the mobile stove unit to be used for transferring heavy or bulky items in the kitchen environment. The stove unit also allows the appliance to be used as a conventional stove, eliminating the need for space that would be required for two separate devices. In addition to height adjustment, the invention allows conventional mixing or food preparation activities to take place at an appropriate height for a range of individuals so as to reduce repetitive motion injuries.
[0005] Specifically, then, the present invention comprises a kitchen appliance having a base with a plurality of downwardly extending wheels, to engage the floor and allow the base to move across a floor and providing a food transfer platform, sized to allow food preparation. The food transfer platform holds least one heating element for cooking, supported by the top of the food transfer platform. The appliance further has an extendible column that has a motor to adjust the height. The column is extendible by using a control panel providing electrical switches to control the motor. The appliance is powered by a power cord having an electrical plug to engage an electrical outlet and provide energy to at least one heating element.
[0006] It is thus one aspect of one embodiment of the invention that it provides a stove unit that can be used for preparation and transfer of food items in a kitchen.
[0007] In one embodiment of the invention, the column is extendible by more than 12 inches. This allows the cooking and food transfer platform to extend between about 27 inches and about 42 inches.
[0008] It is one aspect of one embodiment of the invention to cover the proper working height for up to 90 percent of the population for a variety of cooking tasks. This aspect of the invention allows the food transfer platform to move up and down to accommodate different areas of the kitchen. For example, a user may move the stove over to the refrigerator, adjust the height of the food transfer platform to equal the height of the refrigerator shelf and slide a heavy pot from the refrigerator to the food transfer platform, eliminating the need for picking up the pot and carrying it. The user could then move the appliance to a different area and adjust the food transfer platform to a height suitable for that particular user's needs.
[0009] In one embodiment, the heating element is an electrical resistance heater. This allows an electrical heating element to evenly distribute heat for cooking, sauteing, or keeping food warm.
[0010] It is one aspect of one embodiment of the invention to provide a simple and familiar stove unit.
[0011] In one embodiment, the heating element is alternatively an induction heater. An induction heater only warms the pot or pan on the heater, but when an induction heater is turned off, the heating element is immediately cool to the touch.
[0012] It is one aspect of one embodiment of the invention to allow the appliance to easily transfer from cooking use to food preparation use.
[0013] The invention may further include a set of upwardly extending glide rails affixed to the top of the food transfer platform.
[0014] It is one aspect of one embodiment of the invention to facilitate the transfer of heavy pots and the like to allow easy motion in a parallel direction to the rails, but difficulty to slide objects in a perpendicular direction to the rails. The guide rails may corral pots and pans when the user is moving the height-adjustable appliance from one area to another.
[0015] The appliance may further include at least one sensor that perceives an adjacent surface and communicates with the control panel and motor to adjust the height of the food transfer platform to a height of an adjacent surface.
[0016] Thus it is another aspect of at least one embodiment of the invention to automatically adjust to the height of an adjacent surface. Such a feature allows a user to be able to slide a heavy stockpot from a standard counter to the invention's food transfer platform, without needing to pick up the pot and risk injury.
[0017] More particularly, the appliance may include a sensor that may read particular encoded signals from infrared transmitters on adjacent work surfaces to automatically change the height to be compatible with those work surfaces.
[0018] The appliance may further include, on the periphery of the food transfer platform, along its vertical surface, pressure-sensitive switches and/or sensors, such as infrared or ultrasonic sensors that may sense the proximity or contact of the edge of the food transfer platform and other surfaces.
[0019] It is thus another aspect of one embodiment of the invention to reduce the possibility of finger pinching when the food transfer platform is raised or lowered.
[0020] The invention may further include at least one brake affixed to the wheels.
[0021] It is an aspect of one embodiment to allow a user to secure the height-adjustable appliance in place during cooking or food preparation.
[0022] The brake may be electromechanical and may communicate with the control panel, such that the brake locks in place if the heating element is in use.
[0023] It is therefore another aspect of at least one embodiment of the invention to prevent moving the appliance while it is being used to cook food.
[0024] The electromechanical brake may communicate with the power cord such that the brake locks in place when the power cord is engaged with an electrical outlet.
[0025] It is thus another aspect of an embodiment of the invention to prevent a user from inadvertently attempting to move the height-adjustable appliance when it is still plugged into an electrical outlet.
[0026] The appliance may include a battery, wherein the battery powers the motor that elevates the food transfer platform. One aspect of one embodiment allows a user to use the height-adjustable appliance as a food transfer platform alone. The user can move the food transfer platform vertically, using only battery power. Therefore, such a user need not be near an electrical outlet when using the height-adjustable appliance for food preparation only or adjusting to surfaces after moving.
[0027] The battery may be capable of recharging when the power cord is engaged with an electrical outlet. One aspect of one embodiment allows the food transfer platform to be moved vertically even when the appliance's power cord is not plugged into an electrical outlet. This allows the appliance to be used as an extra food preparation area, with the ability to provide proper height for up to 90 percent of the population.
[0028] A waste receptacle may be affixed to the food transfer platform. In one embodiment, there is an opening in the food transfer platform surface, with a waste receptacle underneath. Another embodiment may include an inset bin that may slide in underneath an aperture in the food transfer platform, for receiving waste during food preparation. One aspect of at least one embodiment allows the user to immediately discard excess or inedible parts of food during food preparation and cooking.
[0029] The appliance may also include a pull-out storage in the form of drawers in the food transfer platform. One aspect of one embodiment allows pots, pans, or utensils to be stored conveniently with the appliance. More particularly, plastic food preparation items, such as bowls or utensils, could be stored with the appliance, unlike with conventional electric ranges.
[0030] The appliance may have an adjustment mechanism between the column and the food transfer platform to allow the food transfer platform to be leveled or tilted.
[0031] The appliance may include a charger for charging the battery when the unit is stationary or not in use through the use of a separate low amperage charging cord. The motor controller may further provide a power converter to provide a necessary conversion of voltage between the battery, for example, a sealed lead acid battery, and the motor units.
[0032] The base may further include an upper cowling at each end and an upper cover that are upwardly convex to prevent items from being rested or stacked on the upper cowling or cover or balanced thereon.
[0033] The invention may further include a frame that supports and surrounds a downwardly extending tray which provides a bottom that is substantially below the frame allowing the extendible columns to descend to a point allowing the food transfer platform and heating element height to be as low as 27 inches and to extend as high as 42 inches. The bottom of the tray, as well as a battery and other circuitry provide the base.
[0034] One aspect of at least one embodiment of the invention is that the height-adjustable appliance has an extremely low center of gravity and an extremely low mounting point for the extendable columns.
[0035] It is specifically intended that the present invention not be limited to the embodiments and illustrations contained herein, but that modified forms of those embodiments including portions of the embodiments and combinations of elements of different embodiments also be included as coming within the scope of the following claims.
[0036] Various other features, objects and advantages of the invention will be made apparent from the following description taken together with the drawings. These particular features and advantages may apply to only some embodiments falling within the claims and thus do not define the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0037] FIG. 1 is a perspective view of a height-adjustable appliance such as may incorporate the present invention;
[0038] FIG. 2 is a fragmentary partial cross-section of the height-adjustable appliance; and
[0039] FIG. 3 is a schematic block diagram of the electrical connections of the height-adjustable appliance.
DETAILED DESCRIPTION OF THE INVENTION
[0040] Referring now to FIG. 1 , a height-adjustable appliance 10 of the present invention may include a generally horizontal and planar food transfer platform 12 , such as may be used for food preparation or as a cooking surface.
[0041] Preferably, the food transfer platform 12 is formed of a stainless steel sheet, for example a 16 gauge stainless steel sheet, and may have an upper area as much as thirty inches by sixty inches. The edges of food transfer platform 14 may be raised to provide a drip edge containing spilled liquids and upwardly extending glide rails 16 may be embossed in the food transfer platform 12 , providing upward ridges whose crests support the bottoms of pans or the like (not shown) to limit contact between the food transfer platform 12 and the pans reducing sliding friction, heat transfer, and contact with spilled liquids.
[0042] A heating element 18 , for example an induction heating unit, may be installed in the food transfer platform 12 , allowing for cooking of foods. The induction heating unit reduces the incidental heating of the food transfer platform and eliminates flame such as may ignite oils or the like. Alternatively element 18 may be a standard resistance type heating element.
[0043] Opposed ends of the food transfer platform 12 are supported by two corresponding extendible columns 20 whose upper ends attach to an underside of the food transfer platform 12 and whose lower ends are supported on a base 22 .
[0044] The base 22 provides a rectangular platform roughly the size of the food transfer platform 12 and may include wheels 24 in each corner to allow the base 22 to roll over a smooth floor 34 or the like. The base 22 includes an upper cowling 28 covering the upper surfaces of the base 22 which is upwardly convex to prevent items from being rested or stacked on the base 22 or balanced thereon.
[0045] Referring now also to FIG. 2 , the base 22 may have a frame 32 being in a preferred embodiment a rectangular frame of square tube steel elevated sufficiently above the floor to receive on its underside the wheels 24 , which may be of food grade quality and which may provide foot actuated or electrically activated brakes 66 , and offset swivels as is understood in the art allowing the wheels 24 to rotate to align with the direction in which the base 22 is pushed.
[0046] The frame 32 supports and surrounds a downwardly extending tray 36 which provides a bottom supporting the bottom of the columns 20 that is substantially below the frame allowing the food transfer platform 12 and heating element 18 height to be as low as about 27 inches and to extend as high as about 42 inches. The bottom of the tray 36 also supports the batteries 40 and other circuitry as will be described providing the base 22 and thus the height-adjustable appliance with an extremely low center of gravity.
[0047] Referring to FIGS. 1 and 3 , the heating element 18 may receive power from a retractable power cord 46 such as may be optionally provided with a spring-loaded retractor 47 . The cord 46 may extend from the base 22 to be plugged into a stationary outlet 48 when the height-adjustable appliance is positioned for cooking. Conductors of the cord 46 may pass through an elastomerically extensible tube 50 , such as a molded bellow, joining the base 22 and the food transfer platform 12 to restrain and guide the conductors. Alternatively or in addition, the conductors (not shown) extending between the base 22 and the food transfer platform 12 , may be coiled as with a telephone cable to reduce the chance of the conductors kinking or breaking throughout a range of extensions corresponding to different heights of the food transfer platform 12 .
[0048] At the food transfer platform 12 , power from the cord 46 may also be routed to two ground fault circuit interrupter (GFCI) outlets 26 that may be positioned on edges of the food transfer platform 12 .
[0049] The power from the cord 46 may also be routed to a controller 60 that may monitor the power, for example, to operate the electromagnetic brake or to provide a warning signal.
[0050] The periphery of the food transfer platform 12 along its vertical surface may include pressure-sensitive switches 54 and/or sensors 56 , such as infrared or ultrasonic sensors that may sense the proximity or contact of the edge of the food transfer platform 12 and other surfaces 68 to reduce the possibility of finger pinching when the food transfer platform 12 is raised or lowered. These switches 54 and sensors 56 may also communicate with controller 60 . Further, the sensors 56 may allow for automatic height adjustment when the food transfer platform 12 is moved between surfaces of different heights, for example, in the transfer of materials from one surface to another, aligning the top of the food transfer platform 12 with the adjacent surface to aid in the loading and unloading of materials. The sensors 56 may read particular encoded signals from infrared transmitters on adjacent work surfaces to signal the controller 60 to automatically change the height to be compatible with those work surfaces.
[0051] A control panel 58 may also be placed conveniently on an edge of the food transfer platform 12 to allow for control of the elevation through simple button presses communicated to the controller 60 . The control panel 58 may employ membrane switches 54 that may be easily cleaned. Similar standard controls 55 may be used for the induction or resistance heating elements 18 .
[0052] Referring still to FIG. 3 , the motor controller 60 receives power from the battery 40 at a low voltage, for example, twelve volts, to provide power to motor units 38 controlling the extension or telescoping of the columns 20 . The motor units 38 may include height feedback signals through encoders or limit switches allowing the motor controller 60 to provide infinitely variable height adjustment from 27 inches to 42 inches as well as up to four pre-programmed height settings that may be accessed through preset buttons on the control panel 58 .
[0053] A charger 62 may be provided for charging the battery 40 when the unit is stationary through the use of a separate low amperage charging cord 64 . Alternatively, and, in addition, the charger 62 may connect to the cord 46 to provide charging when the cord 46 is plugged in.
[0054] An inset bin 70 may slide in underneath an aperture in the food transfer platform 12 , for example, for receiving waste during food preparation. Pull-out storage may be provided in the form of drawers in the food transfer platform (not shown). Adjustments may be provided between the columns 20 and the food transfer platform 12 to allow the food transfer platform 12 to be leveled or tilted.
[0055] An electromechanical brake 66 may be adjacent to the wheels 24 . The brake 66 may connect to the controller 60 to provide energy to engage the brake 66 when the power cord 46 is connected to an electrical outlet 48 . The controller 60 may also connect to the control 55 so that the brake 66 is engaged when the heating element 18 is energized.
[0056] Various alternatives and embodiments are contemplated as being within the scope of the following claims particularly pointing out and distinctly claiming the subject matter regarded as the invention.
[0057] The present invention has been described in terms of the preferred embodiment, and it is recognized that equivalents, alternatives, and modifications, aside from those expressly stated, are possible and within the scope of the appending claims. | A food transfer platform incorporating a stove unit elevates to different heights, by an extendible column, and can move along a floor. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a scan converter with an interpolating function.
This application is based on Japanese Patent Application No. Hei 10-208259, the contents of which are incorporated herein by reference.
2. Background Art Including Information Disclosed Under 37 CFR 1.97 and 1.98
In general, scan converter circuits for converting the scan mode have become widely used, for example, to display a computer format video signal on a television monitor, or to record the computer format video signal on a video tape recorder. The scan system of the standard computer format video signal such as VGA or Super VGA (SVGA) differs from that of the general television signal such as NTSC (National Television System Committee) or PAL (Phase Alternation by line). Because these scan systems employ different scan frequencies, a frame buffer for temporarily storing video data is required to convert the scan mode.
Further, VGA and SVGA employ the non-interlaced scan (progressive scan) system while NTSC and PAL employ the interlaced scanning system. To avoid deterioration of the image quality after the conversion of the scan frequency, images must be interpolated. The interpolation requires a plurality of line buffers which can store data for one horizontal line.
Japanese Unexamined Patent Application, First Publication No. Hei 7-225562 discloses the scan converter using the frame buffer and the line buffers. Japanese Unexamined Patent Applications, First Publication Nos. Hei 6-105229, 7-212652, 10-098694, and 10-126748 also disclose the scan converter.
However, the above background technique using the frame buffer and the line buffers increases the scale of the circuitry. That is, the frame buffer and the line buffers must be semiconductor memories with large storage capacities because a video signal generally includes a large amount of data. The frame buffer and the line buffers with the large storage capacities increase the scale of the circuitry, the size of the device, and the costs.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a scan converter with an interpolating function which reduces the scale of the circuitry.
In one aspect of the present invention, the scan converter with an interpolating function comprises: a plurality of frame buffers for dividing and storing video data of a first scan system and for reading the video data at a timing in accordance with a second scan system; and an interpolator for performing interpolation in the vertical direction for the video data read from the frame buffers.
In another aspect of the present invention, the scan converter with an interpolating function comprises: a high speed readable frame buffer for storing video data of a first scan system and for reading a plurality of pixel video data at a timing in accordance with a second scan system within a time to display one pixel; a plurality of temporary memories for temporarily storing the neighboring pixel video data read from the frame buffer; and an interpolator for performing interpolation in the vertical direction for the video data read from the frame buffers.
According to the present invention, the scan converter with the interpolating function can reduce the scale of the circuitry because it does not need a line buffer.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram showing the first embodiment of the scan converter with an interpolating function according to the present invention.
FIG. 2 is a block diagram showing in detail the structure of an interpolator in the first embodiment of the present invention.
FIG. 3 is a block diagram showing the second embodiment of the scan converter with an interpolating function according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The best mode of the scan converter with the interpolating function, according to an embodiment of the present invention, will be explained.
[First Embodiment]
The first embodiment of the present invention will be explained with reference to FIGS. 1 and 2.
FIG. 1 is a block diagram showing the construction of the first embodiment. Reference numeral 1 denotes a write controller, reference numerals 2 A to 2 C denote frame buffers, reference numeral 3 denotes a read controller, and reference numeral 4 denotes an interpolator. The write controller 1 controls a process to write a video data 10 to the frame buffers 2 A to 2 C. The video data 10 is a computer format video signal (digital signal), such as a VGA or SVGA signal, in the non-interlaced scan system.
Each frame buffer 2 A to 2 C has a memory capacity sufficinet to store ⅓ of the image undergoing the scan conversion process, and stores the video data 10 . The read controller 3 controls a process to read the video data 21 to 23 from the frame buffers 2 A to 2 C, and reads the video data 21 to 23 at the timing of an NTSC signal, a PAL signal, or a television signal.
The interpolator 4 interpolates the video data 21 to 23 read by the read controller 3 , and outputs converted data 30 with a scan frequency in an interlaced mode according to the NTSC or PAL signal format.
FIG. 2 is a block diagram showing the structure of the interpolator 4 in detail. The interpolator 4 comprises multipliers 5 A to 5 C, an adder 6 , and a divider 7 .
The video data 21 to 23 are neighboring each other in the vertical direction. The multipliers 5 A to 5 C increase the video data 21 to 23 by a factor of two or outputs the data as they are, to produce the video data 21 a, 22 a, and 23 a. The adder 6 adds up the video data 21 a to 23 a to produce the video data 24 . The divider 7 divides the video data 24 by, for example, 4, to produce converted video data 30 . For example, the multiplier 5 simply comprises a one-bit left shifter and a selector, and the divider 7 also simply comprises a 2-bit right shifter.
The operation of the first embodiment will now be explained.
The write controller 1 writes one horizontal line of the video data 10 at a time at a scan timing for the personal computer video signal to the frame buffers 2 A, 2 B, and 2 C. For instance, the first line, the fourth line, the seventh line, . . . , the (3n+1) line are written in the frame buffer 2 A. The second line, the fifth line, the eighth line, . . . , the (3n+2) line are written in the frame buffer 2 B. The third line, the sixth line, the ninth line, . . . , the 3n line are written in the frame buffer 2 C. Here, n is a nonnegative integer.
On the other hand, the read controller 3 reads the video data 21 to 23 from the frame buffers 2 A, 2 B, and 2 C at a scan timing for the NTSC or PAL signal. For example, when reading the M line of the video data, the data of the (M−1) line, the M line, and the (M+1) line are simultaneously read out. The simultaneity is achieved because the video data 21 to 23 are written in the different frame buffers 2 A, 2 B, and 2 C by the write controller 1 .
The video data 21 to 23 successive in the vertical direction are input to the interpolator 4 . The interpolator 4 generates, based on the video data 21 to 23 , the converted video data 30 through a predetermined processing.
Specifically, the interpolator 4 performs interpolation for one pixel based on two dots above and below the target pixel in the vertical direction. That is, from pixel data F(m) in the m line, pixel data F(m−1) in the (m−1) line, and pixel data F(m+1) in the (m+1) line, the interpolated video data F′(m) is obtained by a weighting of 1:2:1, from the equation:
F ′( m )={ F ( m− 1)+2 F ( m )+ F ( m+ 1)}/4
The multipliers 5 A to 5 C can select a 1x mode or an 2x mode. The video data 21 to 23 are the data of the (m−1) line, the m line, and the (m+1) line. By switching only the multiplier for the data of the m line (for example, the multiplier 5 B) to the x2 mode while switching the other multipliers 5 A and 5 C to the x1 mode, the above weighting is obtained.
The weighted outputs 21 a, 21 b, and 21 c from the multipliers 5 A to 5 C are added up by the adder 6 , and the output from the adder 6 is divided by 4 by the divider 7 . Thus, the interpolated video data F′(m) can be obtained.
In the first embodiment, the scan converter having an interpolating function can be constructed without a line buffer and without increasing the capacities of the frame buffers, reducing the scale of the circuity.
[Second Embodiment]
Next, the second embodiment of the present invention will be explained with reference to FIG. 3 . In FIG. 3, reference numerals which are identical to those of FIG. 1 indicate elements which are identical to those of the first embodiment, therefore, explanations thereof will be omitted.
As shown in FIG. 3, instead of the frame buffers 2 A to 2 C, the second embodiment has one frame buffer 2 D and three temporary memories 8 A to 8 C. The frame buffer 2 D is a high speed memory which can perform more than three read operations within one pixel time for a TV signal (a time required to display one pixel). The frame buffer 2 D has a storage capacity sufficient to store data for one image. The write controller 1 A writes the video data 10 to a frame buffer 2 D at the timing for a computer format video signal. The read controller 3 A reads the video data from the frame buffer 2 D at a timing for a TV signal.
When reading pixel data at the coordinates (X, Y) on the image from the frame buffer 2 D, the read controller 3 A also reads data of the two neighboring points (X, Y−1) and (X, Y+1), and stores the data in the temporary memories 8 A to 8 C each of which can store data for one pixel. The frame buffer 2 D is a high speed memory, and reads the data of the three pixels within one pixel time.
The video data 21 to 23 stored in the temporary memories 8 A to 8 C is simultaneously read and are input to the interpolator 4 , which produces the converted video data 30 . The second embodiment requires only one frame buffer, thereby reducing the number of parts and the cost.
According to the present invention, the scan converter with the interpolating function can reduce the scale of the circuitry because it does not need a line buffer.
This invention may be embodied in other forms or carried out in other ways without departing from the spirit thereof. The present embodiments are therefore to be considered in all respects illustrative and not limiting, the scope of the invention being indicated by the appended claims, and all modifications falling within the meaning and range of equivalency are intended to be embraced therein. | The present invention relates to a scan converter with an interpolating function comprising: a plurality of frame buffers for dividing and storing video data of a first scan system and for reading the video data at a timing in accordance with a second scan system; and an interpolator for performing interpolation in the vertical direction for the video data read from the frame buffers. | 6 |
This application is a continuation of application Ser. No. 217,275 filed Feb. 28, 1989 now abandoned and also entitled "MANUFACTURE OF OPHTHALMIC LENSES BY EXCIMER LEASER", which is a division of application Ser. No. 919,206 filed Oct. 14, 1986 now U.S. Pat. No. 4,842,782 which issued Jun. 27, 1989.
FIELD OF THE INVENTION
This invention relates to the manufacture of ophthalmic lenses such as a contact, corneal implant, and intramic ocular lenses, or of other small plastic or glass objects of similar shape, and more particularly to a method of making such lenses or objects with a high degree of precision at low cost by using an excimer laser.
BACKGROUND OF THE INVENTION
Ophthalmic lenses are normally manufactured by a mechanical process in which a block of polymethylmethacrylate (PMMA) is machined while being adhesively held on a support. The machining is quite difficult because of the small size of the lens and the intricacy of the shape into which the lens must be machined.
Typically, three operations must be performed to shape a lens:
1) the workpiece must be cut out from a blank to form, e.g., an integral optic and haptic;
2) the surface of the workpiece must be machined to the desired optical specifications (which may include convexities or concavities of varying radii at different points on the surface of the lens; and
3) the edges of the workpiece must be radiused or rounded.
In the prior art, the edge rounding step alone typically required 7-14 days of gemstone tumbling, and precision was hard to accomplish in all of the steps.
SUMMARY OF THE INVENTION
The present invention provides a method of fabricating ophthalmic lenses or similar small objects quickly and accurately by using a laser, and particularly an excimer laser, to cut, surface-model and bevel a workpiece which is preferably made of PMMA but may, for appropriate purposes, be made of other plastics or of glass. The type and tuning of the laser is dependent upon the material of the blank.
In accordance with the invention, the workpiece is first cut to shape by shining a laser beam through a mask outlining the form of the cut required to shape (in the case of an ophthalmic lens) the optic and haptic. Considerable precision can be obtained in this step by expanding the laser beam in front of the mask and then reducing it beyond the mask to provide fine detail from a relatively large mask. The depth of the cut can be controlled by the number and energy of the pulses.
The surface modeling of the lens is next achieved by masking a laser beam in such a way that its energy distribution varies across the surface of the workpiece so as to ablate it to differing degrees at different points of the surface. This can be achieved by using a mask of varying opacity or a semi-transparent mirror with a coating of varying thickness at different points on the surface. This step, if desired, may be performed before the cutting step.
Finally, a laser beam is masked and focused generally into the form of a hollow cone whose tip is the focal point of the beam. By exposing the workpiece to the beam on one side of the focal point and then on the other, two bevel cuts are made along the perimeter of the upper and lower surfaces, respectively, of the workpiece. When combined with a vertical section of the side of the workpiece, these bevel cuts form an approximation of a rounded edge which is further softened by the slight melting of the workpiece material produced by the heat generated by the laser during cutting.
It is therefore the object of the invention to quickly and accurately produce a complex small object such as an ophthalmic lens from a blank entirely by the use of a laser.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an intraocular lens to be manufactured by the method of this invention;
FIG. 2 is a schematic diagram of a laser optic used in the cutting step of the invention;
FIG. 3 is a plan view of the mask used in the cutting step;
FIG. 4 is a schematic diagram illustrating the surface modeling step of this invention;
FIG. 5 is a plan view of the mask used in the surface modeling step;
FIG. 6 is a schematic diagram illustrating the edge beveling step of this invention;
FIG. 7 is a plan view of the mask used in the beveling step;
FIG. 8 is a fragmentary detail section of the workpiece after the first beveling step; and
FIG. 9 is a fragmentary detail section of the workpiece after the second beveling step.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In the preferred embodiment of the invention, which is the manufacture of ophthalmic lenses from a PMMA blank, the method of this invention is carried out with an excimer laser, i.e. a laser operating in the high ultraviolet wavelengths. An argon-fluoride laser operating at a wavelength of 193 nm in 250 millijoule pulses is preferred, but broadly any ultraviolet wavelength substantially absorbed by the material of the workpiece may be used. The choice of the laser is dictated by its ability to break up the large molecules of the workpiece material (as in the case of plastic) or to melt the material (as in the case of glass) so that the material will ablate.
FIG. 1 shows a typical intraocular lens which may be produced by the method of this invention. The workpiece 10 has an optic 12 which forms the actual lens, and a haptic 14 by which the lens is anchored in the patient's eye. In the prior art, polypropylene is usually used for the haptic 14, and PMMA is used for the optic 12. However, both the optic 12 and the haptic 14 may be formed of PMMA, and in the process of this invention this is preferable because the entire workpiece can be cut as a single piece. Of course, other ultraviolet-absorbing materials than PMMA (e.g. silicone) may be used for the workpiece if they are medically acceptable and properly ablatable.
FIG. 2 shows an arrangement useful in cutting the workpiece 10 from a block of PMMA. An excimer laser 16 emits a beam 18 of coherent ultraviolet light. Because the diameter of beam 18 is fairly small, a conventional laser beam expander 20 is used to expand the beam 18 to a diameter of several centimeters. The beam 18 is collimated between the beam expander 20 and the mask 22 (FIG. 2). A mask 22 best shown in FIG. 3 is formed integrally wi the beam expander 20 or placed into the path of the expanded beam 18 to allow only a narrow strip of light in the shape of the outline 24 of the workpiece 10 to pass through the mask 22.
A beam converger or focusing optic 26 is used to project a reduced image of the outline 24 onto the PMMA block 28. Repeated pulses of the laser 16 will ablate the material of the block 28 until the profiled lens or workpiece 10 is very precisely cut out of the block 28. The precision of the cut is enhanced (and the power density of the beam increased) by the use of a relatively large mask 22 and a substantial reduction of the mask image on the block 28.
After being cut out from the block 28, the workpiece 10 is placed into the path of an excimer laser beam 30 (FIG. 4) which has a uniform energy distribution across its area. A mask 32 is interposed between the workpiece 10 and beam 32.
As best shown in FIG. 5, the mask 32 has different degrees of transparency at different points on the mask 32. For example, the mask 32 may have a coating of variable transmission characteristics, or it may be a neutral density filter (such as a polarizing or haze filter) with non-uniform transmission characteristic. In any event, the mask 32 transmits a large amount of beam energy in the areas 34 corresponding to desired depressions in the workpiece 10, and a small amount in the areas 36 corresponding to desired protrusions in the workpiece 10.
By appropriately controlling the transmission characteristics of the mask 32, it is possible to model or shape the surface 38 of the workpiece 10 in any desired manner without complex machining, and to do so precisely in a small amount of time.
In an alternative embodiment of the invention, the mask 32 may take the form of a semi-transparent mirror with a reflective coating whose thickness varies along its surface. In that embodiment, the laser energy not used for ablation is reflected away from the workpiece.
After the shaping or modeling step of FIGS. 4 and 5, the workpiece is fully formed but has sharp vertical edges which are not suitable for intraocular use. In the prior art, the edges of the workpiece were radiused or rounded by gemstone tumbling for 7-14 days, but besides being time-consuming, this prior art method often defeated the carefully achieved precision of the workpiece.
In accordance with the invention, an excimer laser beam 40 (FIG. 6) is expanded by a beam expander or (preferably) by a pair of curved mirrors 42, 44. The use of reflective rather than refractive beam expanding optics is preferred because it permits higher power transfer with smaller optics while avoiding damage to the optics.
The expanded beam 46 is conducted through a mask 48 best shown in FIG. 7 to a focusing lens 50. As a result, a beam generally in the form of a hollow cone is produced, with the tip of the cone being the focal point 52.
In order to round its edges, the workpiece 10 is first positioned below the focal point 52 at 54, and the laser is turned on. The conical shape of the beam will produce a bevel 56 (FIG. 8) on the edges of the workpiece 10. The ends of the bevel 56 are slightly rounded at 58, 60 by the small amount of heat which is produced during the ablation of workpiece material which forms the bevel 56.
When the bevel 56 has been fully formed, the workpiece 10 is positioned above the focal point 52 at 62, and the beam is turned on again. This time, the conical shape of the beam results in cutting a bevel 64 (FIG. 9) whose edges are slightly rounded at 66, 68 for the same reason as described above.
When combined with the vertical surface 70, the bevels 56, 64 and their rounded extremities provide a sufficient approximation of a rounded edge for the workpiece 10 to make it suitable for implantation in a patient's eye without danger of irritation.
It will be seen that the above-described process provides a fast and accurate way of manufacturing intraocular lenses without the use of complex machining equipment. The invention can, of course, be carried out with variations: for example, a very narrow laser beam may be moved around the periphery of the workpiece in the cutting and beveling steps, rather than cutting or beveling the entire periphery at once; or a mask may be scanned rather than being exposed all at once. | Complex small objects such as ophthalmic lenses are quickly and accurately fabricated from plastic or glass blanks of ablatable material such as plastic or glass by cutting, shaping, and radiusing the blank entirely by laser light, using appropriate masks and focusing optics. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a seedling transportation apparatus for a transplantation machine wherein a seedling taken out from a seedling tray transported horizontally is transported by a seedling carrying out conveyor disposed on the downstream side of the seedling tray in a transportation direction.
2. Description of the Related Art
Various seedling transportation apparatus of the type mentioned are known, and an exemplary one of such seedling transportation apparatus is shown in FIG. 14.
Referring to FIG. 14, the seedling transportation apparatus shown uses a seedling tray 3 wherein a tray body 1 formed from a foamed resin material or the like and having a generally plate like profile has a large number of seedling accommodating cells 2 formed therein such that each of them has a diameter which gradually decreases from an opening 2a to a bottom portion 2b thereof. The seedling transportation apparatus holds the seedling tray 3 uprightly such that the seedling accommodating cells 2 may extend horizontally as seen in FIG. 14. In this condition, the seedling tray 3 is successively fed downwardly with a fixed pitch while seedlings P in the seedling accommodating cells 2 of the tray body 1 are successively taken out by a seedling taking out needle 4. The seedlings P taken out are successively transferred to a seedling carrying out conveyor 5 located sidewardly of the seedling tray 3.
In the seedling transportation apparatus, seedlings P must be taken out from the seedling tray 3 while the seedling tray 3 is kept uprightly. Further, in order to allow a new seedling tray 3' to be supplied, the seedling tray 3 from which all of the seedlings P have been taken out must be removed immediately.
Another seedling transportation apparatus is constructed such that a seedling tray is transported along an inclined path, and at a predetermined position during the transportation, a seedling is taken out from the seedling tray. Then, the seedling tray from which seedlings are successively taken out is transported in a discharging direction while it is curved or bent gradually.
In the seedling transportation apparatus just described, since a seedling tray from which seedlings are taken out so that it is emptied is curved or bent along a predetermined path so that it may not interfere with a next seedling to be taken out, the transportation mechanism for a seedling tray is complicated.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a seedling transportation apparatus wherein, also where a seedling tray having a generally plate-like profile is used, a new seedling tray can be supplied readily without immediately removing an old seedling tray which has been emptied as seedlings have been taken out from it.
It is another object of the present invention to provide a seedling transportation apparatus of a simple structure wherein a seedling tray which is moved toward the downstream side in a transportation direction does not interfere with a transportation operation for a seedling.
In order to attain the objects described above, according to the present invention, there is provided a seedling transportation apparatus for a transplantation machine, comprising a seedling taking out apparatus for taking out a seedling upwardly from a seedling tray having seeding accommodating cells in which seedlings are accommodated, a tray transportation apparatus having a horizontal transport path for transporting the seedling tray toward the seedling taking out apparatus, a seedling carrying out conveyor disposed at a location higher than the horizontal transport path of the tray transportation apparatus, and a transferring apparatus for transferring the seedling taken out by the seedling taking out apparatus onto the seedling carrying out conveyor.
In the seedling transportation apparatus for a transplantation machine, the tray transportation apparatus horizontally transports a seedling tray along the horizontal transport path thereof, and the seedling taking out apparatus takes out a seedling upwardly from the seedling tray which is in a horizontal condition. Then, the transferring apparatus transfers the seedling taken out by the seedling taking out apparatus onto the seedling carrying out conveyor disposed at a location higher than the horizontal transport path of the tray transportation apparatus.
Accordingly, such operations that are performed by a conventional seedling transportation apparatus as to transport a seedling tray in an upright condition or along a bent or curved path or to take out a seedling from a seedling tray being transported need not be performed, and a series of operations necessary for transportation of seedlings can be performed accurately by a comparatively simple construction.
Further, different from a conventional seedling transportation apparatus, the seedling transportation apparatus of the present invention can transport a seedling tray, which has become emptied, to the downstream side as it is without removing it immediately to the outside of the transport path. Consequently, handling of a seedling tray from which seedlings have been removed to put the seedling tray into an empty condition is facilitated.
The seedling taking out apparatus may include a seedling pushing out mechanism for pushing out a seedling upwardly from the seedling tray and a seedling holding mechanism for holding the seedling pushed out by the seedling pushing out mechanism.
The transferring apparatus may move the seedling holding mechanism back and forth between a seedling penetrating position at which the seedling holding mechanism receives a seedling in a cell of the seedling tray and a seedling releasing position at which the seedling holding mechanism releases the received seedling toward the seedling carrying out conveyor.
The seedling transportation apparatus for a transplantation machine may further comprise means defining a tray space formed on the downstream side of the tray transportation apparatus below the seedling carrying out conveyor.
Where the tray space is formed in this manner, seedling trays which have become emptied can be placed temporarily one on another in the tray space, and handling of seedling trays is further facilitated.
The above and other objects, features and advantages of the present invention will become apparent from the following description and the appended claims, taken in conjunction with the accompanying drawings in which like parts or elements are denoted by like reference characters.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of a seedling transplantation machine on which a seedling transportation apparatus to which the present invention is applied is carried;
FIG. 2 is a front elevational view of the seedling transplantation machine of FIG. 1;
FIG. 3 is a side elevational view showing the seedling transportation apparatus shown in FIG. 1 in a condition wherein the first or leading cell row of a seedling tray stops at a seedling taking out position;
FIG. 4 is a similar view but showing the seedling transportation apparatus in another condition wherein a trailing cell row of a preceding one of two successive seedling trays placed on a tray transportation apparatus shown in FIG. 1 stops at the seedling taking out position;
FIG. 5 is a front elevational view of the seedling transportation apparatus shown in FIG. 1;
FIG. 6 is an enlarged front elevational view showing details of a portion of the seedling transportation apparatus of FIG. 5 around the seedling taking out position;
FIG. 7 is a schematic perspective view of a seedling tray to be used with the seedling transplantation machine of FIG. 1;
FIG. 8 is a partial enlarged sectional view taken along line I--I of FIG. 7;
FIG. 9 is a block diagram showing an electric circuit of a driving control section of the seedling transplantation apparatus of FIG. 1;
FIG. 10 is an enlarged side elevational view of the seedling transportation apparatus of FIG. 5 particularly showing a seedling taking out apparatus and associated elements when the leading cell row of a seedling tray stops at the seedling taking out position;
FIG. 11 is a similar view but showing the seedling taking out apparatus when the second cell row of the seedling tray stops at the seedling taking out position;
FIG. 12 is an enlarged side elevational view of a transferring apparatus and a seedling holding mechanism of the seedling transportation apparatus of FIG. 5;
FIG. 13 is a front elevational view of the transferring apparatus and the seedling holding mechanism of FIG. 12; and
FIG. 14 is a schematic view showing part of a conventional seedling transportation apparatus.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring first to FIGS. 1 and 2, there is shown a seedling transplantation machine on which a seedling transportation apparatus to which the present invention is applied is carried.
The seedling transplantation machine shown includes a main frame 9 having pairs of upper and lower connection members 6 and 7 for connection to a tractor (not shown) formed on the front side thereof such that they project forwardly as seen in FIG. 2 and having a pair of driving wheels 8 provided on the rear side thereof, and a movable frame 11 mounted for upward and downward pivotal motion around a shaft 10 mounted horizontally at a front portion of the main frame 9. Successively located from the front side to the rear side on the movable frame 11 are a pair of rolling coulters 12 for cutting disturbing substances, a pair of openers 13 for forming furrows, a pair of seedling planting wheels 14 (only one is shown in FIG. 1) for planting seedlings P into the furrows formed by the openers 13, and two sets of pressing down wheels 15 for pressing down the seedlings P planted by the seedling planting wheels 14. Further, a pair of left and right seedling transportation apparatus A for supplying seedlings P to the seedling planting wheels 14, to which the present invention is applied, are carried on the movable frame 11.
Each of the seedling transportation apparatus A includes a seedling taking out apparatus B for taking out seedlings P upwardly from a seedling tray T, a tray transportation apparatus C for transporting the seedling tray T horizontally toward the seedling taking out apparatus B, and a transferring apparatus E for transferring the seedlings P taken out by the seedling taking out apparatus B to a seedling carrying out conveyor D. The seedling taking out apparatus B, tray transportation apparatus C and transferring apparatus E are carried in an integrated relationship on a machine frame 16 mounted uprightly at a front portion of the movable frame 11.
Referring to FIGS. 7 and 8, the seedling tray T is generally in the form of a plate made of foamed styrene which cannot be bent during transportation, and has a plurality of seedling accommodating cells (hereinafter referred to simply as cells) Ta formed in a concave condition in a matrix having a pitch a equal in the perpendicular directions on a plane of the seedling tray T. Each of the cells Ta is formed such that the diameter thereof gradually decreases from an upper opening Tb to a bottom portion Td of the cell Ta, and has a rod insertion hole Tc formed in the bottom portion Td thereof.
Referring back to FIGS. 1 and 2, such seedling trays T are placed horizontally on the tray transportation apparatus C in an upright posture in which leaves Pa of seedlings P accommodated in the cells Ta thereof extend upwardly.
Referring to FIGS. 1 to 6, the tray transportation apparatus C includes tray receiving rollers 17a to 17j arranged horizontally for individual rotation at predetermined distances such that two seedling trays T may be placed along upper edges of a pair of left and right base plates 18 between a location adjacent front ends 18a and another location adjacent rear ends 18b of the left and right base plates 18.
A plurality of tray moving bars 20 for a moving seedling tray T are mounted horizontally in a predetermined spaced relationship from each other on a pair of left and right roller chains 19. The roller chains 19 extend along the tray receiving rollers 17a to 17j, and to this end, a pair of chain stretching shafts 21 and 22 are provided in parallel to each other on the front side with respect to the tray receiving roller 17a and the rear side with respect to the tray receiving roller 17j, respectively. A further chain stretching shaft 24 is mounted between a pair of left and right leg plates 23 of the left and right base plates 18 which extend downwardly below the tray receiving roller 17a as seen in FIGS. 3 to 6.
Pairs of sprocket wheels 25 for keeping the roller chains 19 taut are secured at the opposite end portions of the chain stretching shafts 21, 22 and 24. A motor Ml is connected to the chain stretching shaft 21 via a roller chain 27 which extends between the motor M1 and a sprocket wheel 26 secured to an intermediate portion of the chain stretching shaft 21.
When the motor Ml is energized, the roller chains 19 are driven to move a seedling tray T toward the seedling taking out apparatus B. Consequently, the seedling tray T is pushed by one of the tray moving bars 20 so that it is moved toward a seedling taking out position R1 at which seedlings P are taken out from the seedling tray T by the seedling taking out apparatus B.
A tray space SP is formed along the upper edges of the left and right base plates 18 adjacent the front ends 18a, that is, along a transport path of a seedling tray T below the seedling carrying out conveyor D, so that a seedling tray T may temporarily stay there. Thus, a seedling tray T after it is emptied as seedlings P are taken out therefrom at the seedling taking out position R1 is moved to the tray space SP.
In particular, a seedling tray T moved by one of the tray moving bars 20 is moved toward the tray space SP while seedlings P are successively taken out therefrom at the seedling taking out position R1 such that, after those seedlings P accommodated in the last cell row Tn of the seedling tray T are taken out from the seedling tray T, the thus emptied seedling tray T stays in the tray space SP (refer to FIGS. 4 and 7).
Driving of the tray transportation apparatus C is controlled by a driving control section F formed from a sequencer or the like. A rotary encoder EN (FIG. 6) connected to an end of the chain stretching shaft 21, a pair of tray detecting sensors S1 and S1' (FIGS. 5 and 6) provided at upper edge portions of the left and right base plates 18 on the rear side with respect to the chain stretching shaft 21 and a timing signal line TS from the seedling taking out apparatus B are connected to the input side of the driving control section F while the motor M1 is connected to the output side of the driving control section F (FIG. 9).
The driving control section F has the following functions:
(1) to stop, when a leading end face Tt of a seedling tray T is detected by means of the tray detecting sensors S1 and S1', energization of the motor M1 to stop movement of the seedling tray T to stop the first cell row T1 of the seedling tray T at the seedling taking out position R1 (FIG. 3);
(2) to calculate the distance of movement of the seedling tray T based on the angle of rotation of the chain stretching shaft 21 detected by the rotary encoder EN; and
(3) to discriminate whether or not the calculated distance of movement coincides with the pitch a of the cells Ta formed on the seedling tray T and stop energization of the motor M1 when it coincides with the pitch α. Consequently, the following cell rows are successively stopped at the seedling taking out position R1.
When the leading end face Tt of a seedling tray T placed on the tray receiving rollers 17a to 17j is detected by the tray detecting sensors S1 and S1', the first cell row T1 of the seedling tray T stops at the seedling taking out position R1. Then, while the first cell row T1 stops there, a taking out operation of seedlings P by the seedling taking out apparatus B is performed.
Then, when an end signal of the taking out operation is outputted from the seedling taking out apparatus B, the driving control section F re-starts energization of the motor M1 to transport the seedling tray T again. Then, when the transport distance of the seedling tray T becomes coincident with the pitch α between the cells Ta formed on the seedling tray T again, the driving control section F stops energization of the motor M1 again so that the next cell row may be stopped at the seedling taking out position R1. The following cell rows are successively stopped at the seedling taking out position R1 in this manner.
Referring to FIGS. 3, 4, 10 and 11, the seedling taking out apparatus B includes a seedling holding mechanism H which position seedling holding needles 42, which will be hereinafter described, serving as seedling holding elements in the proximity of the upper openings Tb of those cells Ta stopping at the seedling taking out position R1 for penetrating seedlings P pushed out from the cells Ta, and a seedling pushing out mechanism G for pushing out the seedlings P to be pushed out from the cells Ta until trailing ends Pb of the seedlings P move to the outside of the upper openings Tb.
The seedling pushing out mechanism G includes a pair of pushing up arms 29 secured at base end portions thereof to a shaft 28 which is supported for rotation on and extends between the left and right base plates 18. A bracket 30 is secured to an intermediate portion of the shaft 28, and a driving rod K1a of a hydraulic or pneumatic fluid pressure cylinder K1 is connected to the bracket 30. The fluid pressure cylinder K1 is mounted by means of a bracket 31a on a connection pipe 31 extending horizontally between the left and right leg plates 23.
Referring to FIGS. 10 and 11, a rod supporting member 33 having a plurality of seedling pushing out rods 32 formed uprightly thereon extends horizontally between end portions of the pushing up arms 29. The rod supporting member 33 has a pair of downwardly extending vertically elongated guide elements 35 formed on a lower face thereof, and a guide roller 34 is mounted for rotation at a lower end portion of each of the vertically elongated guide elements 35.
A guide plate 36 having a pair of left and right bent lugs 36a is secured to the connection pipe 31, and a pair of arcuate guideways 36b for guiding the guide roller 34 are formed in the bent lugs 36a such that, when the guide roller 34 move along the arcuate guideways 36b, the seedling pushing out rods 32 may be moved upwardly and downwardly substantially in alignment with the seedling taking out position R1.
Referring to FIGS. 5 and 6, each of the seedling pushing out rods 32 is a round bar member having a thickness with which it can be fitted in the rod insertion hole Tc of a cell Ta of a seedling tray T, and the seedling pushing out rods 32 are disposed in a row in the same pitch α as that of the cells Ta such that they are opposed to the cells Ta which make a row.
If the driving rod K1a of the fluid pressure cylinder K1 is driven to extend, then the pushing up arms 29 are pivoted around the shaft 28 so that the free end portions thereof may move downwardly. On the other hand, if the driving rod K1a is driven to contract, then the pushing up arms 29 are pivoted around the shaft 28 so that the free end portions thereof may move upwardly.
Consequently, the seedling pushing out rods 32 are moved back and forth between a pushing out start position R2 at which seedling contacting end faces 32a thereof are spaced downwardly from the rod insertion holes Tc of the opposing cells Ta and a pushing out end position R3 in which the seedling contacting end faces 32a project upwardly through the upper openings Tb of the opposing cells Ta (FIG. 10).
In this manner, seedlings P in those cells Ta stopping at the seedling taking out position R1 are pushed out upwardly from within the cells Ta when the seedling pushing out rods 32 move to the pushing out end position R3, and then when the seedling pushing out rods 32 further move to the pushing out end position R3, the trailing ends Pb of the seedlings P are moved upwardly away from the upper openings Tb of the cells Ta.
The seedling holding mechanism H is supported by the transferring apparatus E, which will be hereinafter described in detail, such that seedling holding needles 42 for penetration into seedlings P to be pushed out from those cells Ta stopping at the seedling taking out position R1 may be movable back and forth between a seedling penetrating position R4 at which they are located in the proximity of the upper openings Tb of the cells Ta and a seedling releasing position R5 above the seedling carrying out conveyor D at which they transfer the seedlings P to the seedling carrying out conveyor D.
The seedling holding mechanism H particularly when it moves the seedling holding needles 42 to the seedling penetrating position R4 will be described below with reference to FIGS. 10 to 13.
A pair of left and right side plates 37 are supported for upward and downward pivotal motion at lower end portions of pivotal levers 65 of the transferring apparatus E by means of a pair of shafts 65a. A shaft 38 extends horizontally between front portions of the left and right side plates 37, and a pair of needle pulling in levers 40 are supported at base end portions thereof for pivotal motion on the shaft 38. A pair of tension springs 39 (only one is shown in FIGS. 10 and 11) extend between the needle pulling in levers 40 and the left and right side plates 37 (FIGS. 10, 11 and 13).
A guide shaft 41 extends horizontally between end portions of the needle pulling in levers 40, and a needle supporting member 43 having a plurality of downwardly extending seedling holding needles 42 provided thereon is supported for pivotal motion on the guide shaft 41 via a bracket 44. A pair of guide rollers 45 (only one is shown in FIGS. 10 and 11) are mounted for rotation at a pair of bent lugs 44a of the bracket 44 via support pieces 46.
The seedling holding needles 42 are moved upwardly and downwardly while keeping the downwardly extending postures thereof as the needle pulling in levers 40 are pivoted upwardly and downwardly around the shaft 38.
The left and right side plates 37 have arcuate guideways 37a formed therein for guiding the guide shaft 41, and a pair of guide plates 47 in which arcuate guideways 47a for guiding the guide rollers 45 are formed in inner walls of the left and right side plates 37 (FIGS. 10, 11 and 13).
A pair of hooks 48 for arresting the guide shaft 41 moved to a position at the lower ends of the arcuate guideways 37a are mounted for rotation on shafts 48a on outer faces of the left and right side plates 37.
Each of the hooks 48 has a substantially L-shape in side elevation and has a guide shaft arresting portion 48b formed at one of a pair of legs thereof for arresting the guide shaft 41 while a spring mounting piece 48c to which an end of a coil spring 49 having the other end attached to a bent lug 37b of a corresponding one of the left and right side plates 37 is to be attached is formed at the other leg of the hook 48 (FIG. 12). Consequently, the hooks 48 are normally biased by the coil springs 49 in a direction in which the guide shaft arresting portions 48b thereof approach the guide shaft 41.
The seedling holding needles 42 have a linear profile and located in pairs at intervals of the pitch a between the cells Ta of a seedling tray T in a row extending along a row of cells. A seedling releasing plate 50 is provided between lower end portions of the left and right side plates 37 and has formed therein needle loosely fitting holes 50a in which the seedling holding needles 42 are individually fitted loosely (FIGS. 10, 11 and 12).
Located on inner faces of a pair of left and right support plates 53 of the transferring apparatus E are a pair of stoppers 51 for moving the guide shaft 41 of the seedling holding mechanism H moved to the seedling penetrating position R4 to the lower ends of the arcuate guideways 37a until the guide shaft 41 is arrested by the hooks 48, and a pair of arrest releasing members 52 having contacting rollers 52a for contacting with the hooks 48 of the seedling holding mechanism H moved to the seedling releasing position R5 to cancel the arrested condition of the guide shaft 41 by the hooks 48.
In the seedling penetrating position R4, the guide shaft 41 is arrested by the hooks 48, and consequently, the seedling holding needles 42 are held at pushed down positions in which the lower ends thereof are positioned in the proximity of the upper openings Tb of opposing cells Ta so that seedlings P which are pushed out from the cells Ta may be penetrated by the lower ends of the guide shaft 41 immediately after they start to be pushed out.
Seedlings P in those cells Ta moved to the seedling taking out position R1 are penetrated and held by the seedling holding needles 42 of the seedling holding mechanism H at the seedling penetrating position R4 immediately after they start to be pushed out by the seedling pushing out rods 32, and as they are thereafter pushed out further by the seedling pushing out rods 32, they are penetrated gradually deeply by the seedling holding needles 42.
Then, when the the seedling pushing out rods 32 are moved to the pushing out end position R3, that is, when the trailing ends Pb of the seedlings P in the pushing out direction are pushed out to locations above the upper openings Tb of the cells Ta, the seedling holding needles 42 penetrate fully from the leading ends to the trailing ends Pb of the seedlings P in the pushing out direction (FIG. 10).
The transferring apparatus E is constructed in the following manner. In particular, the left and right support plates 53 are provided uprightly on a pair of mounting frames 54 which are mounted between an upper end portion of the machine frame 16 and intermediate portions of the left and right base plates 18 such that they extend across the tray space SP (FIGS. 1 to 5).
A connection plate 55 extends horizontally between upper end portions of the left and right support plates 53 and has support legs 56 to 58 extending downwardly from a lower face thereof. A support shaft 60 extends through and is supported for rotation on the support legs 56 to 58, and has a pair of brackets 59 secured at the opposite left and right ends thereof. A motor M2 is secured between the support legs 56 and 57, and a driving gear 62 is held in meshing engagement with a gear secured to a driving shaft of the motor M2. The driving gear 62 is secured to an inner end portion of a rotary shaft 63 which is supported for rotation on and extends horizontally between the support legs 56 and 57 (FIGS. 12 and 13).
A lever supporting shaft 64 extends horizontally between front side upper end portions of the left and right support plates 53, and the pivotal levers 65 having the left and right side plates 37 of the seedling holding mechanism H supported for pivotal motion at lower end portions thereof are supported for pivotal motion at upper ends thereof on the lever supporting shaft 64. Further, a connection member 66 extends horizontally between the pivotal levers 65, and a bracket 67 is provided at an intermediate portion of the connection member 66. A connection rod 68 is mounted for rotation at the opposite ends thereof on the bracket 67 and an eccentric mounting pin 62a provided projectingly and eccentrically on the driving gear 62.
If the eccentric mounting pin 62a of the driving gear 62 is rotated forwardly and reversely between a driving start position R6 and a driving end position R7, then the pivotal levers 65 are rocked so that the seedling holding mechanism H may be moved between the seedling penetrating position R4 and the seedling releasing position R5.
A small gear 69 is secured to a central portion of the support shaft 60 and is held in meshing engagement with the driving gear 62. A pair of support levers 71 are mounted at upper end portions thereof on the brackets 59 provided at the opposite left and right end portions of the support shaft 60, and the left and right side plates 37 of the seedling holding mechanism H are supported for pivotal motion on a shaft 70 extending horizontally between lower end portions of the support levers 71.
When the driving gear 62 rotates in the direction indicated by an arrow mark 62' in FIG. 12, the eccentric mounting pin 62a moves from the driving start position R6 toward the driving end position R7, whereupon the brackets 59 are pivoted upwardly. Thereupon, the left and right side plates 37 of the seedling holding mechanism H are acted upon by a force to pivot them upwardly around the shafts 65a of the pivotal levers 65. Consequently, the seedling holding mechanism H is pivoted upwardly by 90 degrees around the shafts 65a to a posture in which the seedling holding needles 42 extend horizontally, and is moved to the seedling releasing position R5 while keeping the posture.
If the motor M2 rotates reversely, then the seedling holding mechanism H moves back from the seedling releasing position R5 to seedling penetrating position R4 following the locus of movement described above reversely.
The seedling carrying out conveyor D is supported above the tray space SP formed adjacent the front ends 18a of the left and right base plates 18, and a vertical conveyor 72 for transporting a seedling P toward the corresponding seedling planting wheel 14 is provided adjacent the last end of the seedling carrying out conveyor D in the carrying out direction.
Subsequently, a series of seedling supplying operations by the seedling transportation apparatus A having the construction described above will be described.
Before a taking out operation for seedlings P is started, the seedling holding mechanism H is moved to the seedling penetrating position R4.
If seedling trays T are placed on the tray transportation apparatus C and a moving operation of them is started, then the seedling trays T are transported horizontally toward the seedling taking out apparatus B and a preceding one of them is stopped when the first cell row T1 thereof comes to the seedling taking out position R1.
Then, a pushing out operation for the seedlings P of the first cell row T1 of the seedling tray T is started by the seedling pushing out rods 32 of the seedling pushing out mechanism G so that the seedlings P are individually penetrated by the corresponding seedling holding needles 42 until they are held by the seedling holding needles 42.
After completion of the penetration operation into the seedlings P, the seedling pushing out rods 32 are moved back to the pushing out start position R2, and the seedling holding mechanism H is moved from the seedling penetrating position R4 toward the seedling releasing position R5 while it is pivoted upwardly by 90 degrees around the shafts 65a.
When the seedling holding mechanism H comes to the seedling releasing position R5, the hooks 48 are brought into contact with the contacting rollers 52a of the arrest releasing members 52 to cancel the arrested condition of the guide shaft 41 by the hooks 48, and consequently, the seedling holding needles 42 are pulled in rapidly between the left and right side plates 37.
By the pulling in operation, the seedlings P which have been penetrated by the seedling holding needles 42 are pulled out and released by the seedling releasing plate 50 and placed onto the seedling carrying out conveyor D therebelow. The seedlings P placed on the seedling carrying out conveyor D are thereafter transferred to the vertical conveyor 72 and transported toward the seedling planting wheel 14 by the vertical conveyor 72.
When the seedlings P are released, the seedling holding mechanism H is moved back toward the seedling penetrating position R4, and the seedling pushing out rods 32 of the seedling pushing out mechanism G are moved back to the pushing out start position R2. Then, also the tray transportation apparatus C is driven to move the seedling tray T so that the next cell row may come to the seedling taking out position R1. Consequently, the seedling tray T is moved gradually into the tray space SP by the driving of the tray transportation apparatus C.
After taking out of the seedlings P accommodated in the seedling tray T is completed in this manner, the entire seedling tray T is moved to the tray space SP, in which it thereafter stays for a certain period of time.
Then, when seedlings P accommodated in a following seedling tray T are started to be taken out from the seedling tray T in a similar manner to that from the preceding seedling tray T, the leading end of the following seedling tray T is brought into contact with and urges the rear end of the preceding seedling tray T to move the preceding seedling tray T.
It is to be noted that the present invention is not limited to the specific embodiment described above, but can be embodied in various forms within the spirit and scope of the invention.
For example, while, in the embodiment described above, the tray space is constructed such that a single seedling tray T may temporarily stay therein, it may be constructed otherwise such that a seedling tray moved later may be placed on another seedling tray moved earlier so that several seedling trays may temporarily stay in a piled up condition in the tray space. With the alternative construction, the time until seedling trays staying in the tray space must be removed can be set comparatively long, and the seedling tray exchanging operation can be further moderated.
Or, the tray space for allowing a seedling tray to temporarily stay therein need not be formed, but upon transferring operation of seedlings to the seedling carrying out conveyor, a seedling tray may be moved successively to a location below the seedling carrying out conveyor.
Having now fully described the invention, it will be apparent to one of ordinary skill in the art that many changes and modifications can be made thereto without departing from the spirit and scope of the invention as set forth herein. | The invention provides a seedling transportation apparatus of a simple structure wherein a new seedling tray can be supplied readily without immediately removing an emptied old seedling tray and does not interfere, when it is moved toward the downstream side in a transportation direction, with a transportation operation for a seedling. To this end, transportation of a seedling tray is performed not in an upright condition or in a curved or bent condition but in a horizontal condition. The seedling transportation apparatus for a transplantation machine includes a seedling taking out apparatus for taking out a seedling upwardly from a seedling tray having seeding accommodating cells in which seedlings are accommodated, a tray transportation apparatus having a horizontal transport path for transporting the seedling tray toward the seedling taking out apparatus, a seedling carrying out conveyor disposed at a location higher than the horizontal transport path of the tray transportation apparatus, and a transferring apparatus for transferring the seedling taken out by the seedling taking out apparatus onto the seedling carrying out conveyor. | 8 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of Ser. No. 498,470 filed May 26, 1983, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a process of treating iron chloride wastes such as those generated when chlorinating titanium ores or chlorinating aluminum ores to make them suitable for disposal, such as landfill.
2. Prior Art
U.S. Pat. No. 4,229,399 discloses mixing the iron chloride waste stream from a titanium ore chlorinator with an alkaline material and thereafter adding water and granulating the resulting mixture.
SUMMARY OF THE INVENTION
The present invention relates to a process of treating iron chloride wastes such as those generated in the chlorination of titanium ores to form titanium dioxide or chlorinating bauxite in the production of aluminum chloride and electrolytic aluminum. The process involves contacting the iron chloride wastes with limestone, dolomitic limestone, dolomite, or MgCO 3 in a bath of molten CaCl 2 .xH 2 O, where x is from 3-6, at from 50°-200° C., and preferably between 100°-150° C.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic flowsheet of a first method of performing the process of the present invention.
FIG. 2 is a schematic flowsheet of a second method of performing the process of the present invention.
FIG. 3 is a plot of % conversion vs. reaction time as described in Examples 5-10.
FIG. 4 is a plot of % conversion vs. reaction time as described in Examples 11-13.
DETAILED DESCRIPTION OF THE DRAWINGS
Referring now to FIG. 1, iron chloride wastes from a titanium ore chlorinator in line 11 are fed to mixer 12. Pulverized limestone in line 13 is also fed to the mixer 12. From mixer 12 the iron chloride wastes and limestone are fed via line 14 to molten salt reactor 15 containing CaCl 2 .xH 2 O wherein the iron chloride is converted to iron oxide and the limestone to calcium chloride. Air is fed to molten salt reactor 15 via line 16 and defoamer via line 17. Carbon dioxide and water vapor are removed from molten salt reactor 15 via line 18. The surface of the molten salt in reactor 15 is skimmed and the resulting impurities such as coke and a small amount of CaCl 2 .xH 2 O are removed via line 19 and sent to unit 20 where defoaming action is performed. The CaCl 2 .xH 2 O-impregnated coke is removed from unit 20 via line 21 and disposed of. The reaction products from molten salt reactor 15 are removed via line 23 and sent to sedimentation or centrifuging separation unit 26. The titanium ore which settles to the bottom of sedimentation or centrifuging separation unit 26 is removed via line 27 and sent to washing unit 28. Wash water is fed to washing unit 28 via line 29. Washed titanium ore is removed from washing unit 28 via line 31 and sent to drier 32. Water vapor is removed from drier 32 via line 33 and titanium ore via line 34. Water is removed from washing unit 28 and sent to molten salt reactor 15 as make-up water via line 35. Recycle CaCl 2 .xH 2 O is removed from sedimentation or centrifuging separation unit 26 via line 36 and recycled to molten salt reactor 15. A mixture of CaCl 2 .xH 2 O and iron oxide composed of approximately 70-80% CaCl 2 .xH 2 O and 20-30% FeO Y where Y is 1-1.5, is removed from sedimentation or centrifuging separation unit 26 via line 37 and disposed of.
Referring now to FIG. 2, iron chloride wastes from a titanium ore chlorinator are fed to molten salt bath 41 containing CaCl 2 .xH 2 O at 50°-200° C. via line 42. The molten salt and iron chloride wastes are fed from molten salt bath 41 to sedimentation unit 43 via line 44. Titanium ore settles in sedimentation unit 43 and is removed in line 45 and sent to washer 46. Wash water is fed to washer 46 via line 47. Washed titanium ore is removed from washer 46 via line 48 and sent to drier 49. Water vapor is removed from drier 49 via line 51 and washed and dried titanium ore is recovered via line 52 and returned to a chlorination unit (not shown). Molten salt and entrained and/or dissolved iron chloride is removed from sedimentation unit 43 via 53 and sent to molten salt reactor 54 via line 55. Water is removed from washer 46 via line 56 and sent to molten salt bath 41 via line 57 and to molten salt reactor 54 via line 58 as make-up water. Limestone is fed to molten salt reactor 54 via line 59. Defoamer is fed to molten salt reactor 54 via line 61. Air is fed to molten salt reactor via line 62. Carbon dioxide and water vapor are removed from molten salt reactor via line 63. Molten salt reactor is fitted with a skimmer which feeds line 64 with coke and molten salt. The molten salt and coke are defoamed and condensed in unit 65. Molten salt and iron oxide are sent from molten salt reactor 54 to sedimentation unit 71 via line 72. Molten CaCl 2 .xH 2 O and entrained iron oxide are removed from the bottom of sedimentation unit 71 via line 73 and disposed of. Molten salt is removed from sedimentation unit 71 via 74 and recycled to molten salt reactor 54 via line 55 and to molten salt bath 41 via line 75.
DETAILED DESCRIPTION
The present invention involves the discovery that the iron chloride wastes from a titanium dioxide ore chlorinator can be treated or neutralized with limestone at a modest temperature in a molten salt reactor. The reaction is fast and generates a great deal of carbon dioxide. This generation of carbon dioxide combined with elevated temperature serves to strip water from the system and thus maintain the desired water content in the system as well as to agitate the reaction mixture. Any water deficiency in the system is corrected with make-up water. Generally the temperature is in the range of from about 50°-200° C. with 100°-150° C. being preferred. The molten salt used in the process of the invention is CaCl 2 .xH 2 O where x is between 3 and 6 and more preferably between 4 and 5. The case where x=3 is in reality a mixture of CaCl.2H 2 O and CaCl 2 .4H 2 O. The amount of water of hydration is important because it controls the melting range (without boiling) of the salt which, in turn affects the reaction rate and the viscosity of the melt. The process minimizes the pressure needed to prevent boiling, at the required reaction temperature, but does not exclude pressurization if still higher temperatures are desired.
The low pressure afforded by the present invention facilitates removal of the gaseous CO 2 which is generated by the reaction and thus avoids suppression of the reaction which can be caused by the use of pressure required when using an aqueous system at near and/or beyond the boiling point of water.
The reactions are generally fast with over half the reactions being sufficiently complete in less than 10 minutes for the ferric system for the product to be landfilled. In the process of the present invention, ferric chloride reacts fast even at temperatures as low as 110° C. Ferrous chloride reacts slower and requires a temperature of about 150° C. to reach a significant rate but is rendered land-fillable rapidly at lower temperatures when reacted with calcium carbonate in admixture with ferric chloride. Most of the other trace metal chlorides commonly associated with the iron chlorides waste from a titanium ore chlorinator will also be neutralized along with the iron chlorides. The iron chlorides and the other trace metal chlorides appear to first dissolve in the molten salt followed by adsorption, CaCO 3 dissociation, and finally neutralization. Representative reactions which occur can be summarized as follows:
CaCO.sub.3 +FeCl.sub.2 →FeO+CaCl.sub.2 +CO.sub.2 ↑
3FeO+1/2O.sub.2 →Fe.sub.3 O.sub.4 (if O.sub.2 is present)
3CaCO.sub.3 +2FeCl.sub.3 →Fe.sub.2 O.sub.3 +3CaCl.sub.2 +3CO.sub.2 ↑
The process of the present invention offers numerous advantages over the dry lime (CaO) neutralization process. First the low-temperature and atmospheric-pressure operation simplifies material handling, storage and reactor design. The process allows recovery of blowover coke and titanium ore, which are entrained in the chlorination gases, either before or after the neutralization reaction. The process allows 100% use of limestone which would otherwise require an energy intensive calcination temperature in excess of 500° C. to produce CaO which has to be handled and stored dry. Further, the high temperatures promote the production of more soluble forms of some impurities such as chromium and manganese. The limestone neutralization also avoids the danger of any high-temperature runaway reaction, such as the reaction between FeCl 3 and CaO as well as any hydrogen gas hazard which is characteristically associated with the lime-neutralization at high temperatures. The CaCl 2 .xH 2 O molten salt is nonhazardous. Another advantage of the process is that no external source of molten salt is needed because the molten salt is also one of the major reaction products, which is recycled to the reactor.
Surprisingly the product produced by the present invention is a stable, nonleaching material which is less water permeable than clay when handled properly. The product of the present invention sets up when placed in a land-fill and is impermeable to water even if some ferrous chloride is present. The fact that the product is nonleaching and impermeable to water is surprising, because of the presence of a large amount of calcium chloride which is very soluble in water. The material appears to set up in a manner somewhat analogous to cement setting up, but the set up material is not strong enough to use as a structural substitute for cement.
The self-sealing product is obtained when the molten, melt-neutralized material is poured into a test tube or landfill providing:
1. That the starting material FeCl 3 /FeCl 2 , contains at least about 10% by weight FeCl 3 , and
2. The FeO Y , where Y equals 1.0-1.5, in admixture with CaCl 2 , has been concentrated to a weight ratio of CaCl 2 .xH 2 O (calculated as CaCl 2 .2H 2 O)/FeO Y of from 1/9 to 4/1 preferably about 1/2.
The samples produced from pure FeCl 2 starting material never sealed under any circumstances.
The concentration of FeO Y in the molten salt can be achieved by either settling or centrifuging.
The self-sealing property can also be achieved by first dehydrating the melt-neutralized product from CaCl 2 .4H 2 O to CaCl 2 .2H 2 O by heating at about 200° C. followed by wetting with water shortly before packing or landfilling.
EXAMPLES
EXAMPLE 1
Calcium chloride hydrate containing two molecules of hydration (147 g) is mixed with 36 g of water in a three-necked 1000 ml flask equipped with a stirrer, thermometer and gas connections. After hardening, the contents of the flask are heated to 125° C. with stirring. Fifteen grams of calcium carbonate are mixed with 21.35 g of FeCl 3 and added to the flask. After 2 minutes 10 ml of water containing 0.5 ml antifoam agent are added to the flask. Nitrogen gas is passed through the flask at a rate of 750 ml/minute as measured at standard temperature and pressure. Samples of off-gas from the flask are taken at 130° C. and analyzed for carbon dioxide with the results reported in Table I. The production of CO 2 is an indication of the rate of reaction, thus in 15 minutes the reaction was essentially complete.
TABLE I______________________________________ Time CO.sub.2 Minutes %______________________________________ 1 27.57 3 22.06 6 8.30 10 3.13 15 0.45 20 0.12 30 0.02______________________________________
EXAMPLE 2
Example 1 is repeated except the flask is heated to 150° C. before adding the calcium carbonate and ferric chloride and 22.5 g of calcium carbonate are added to the flask. Twenty-six minutes into the sampling time the material in the flask has thickened to a paste and 10 ml of water are added. The results of the off-gas sampling are reported in Table II.
TABLE II______________________________________ Temperature CO.sub.2Time °C. %______________________________________35 sec 140 42.78 1 min, 45 sec 140 28.97 4 min 145 17.27 7 min 148 9.7010 min 146 3.7421 min 155 2.2530 min 1.29______________________________________
EXAMPLE 3
Example 1 is repeated except that the flask is heated to 110° C. before the ferric chloride and calcium carbonate are added to the flask and that 40.14 g of calcium carbonate was added to the flask. The analyses of the off-gas from the flask are separated in Table III.
TABLE III______________________________________ Temperature CO.sub.2Time °C. %______________________________________55 sec 111 42.94 1 min, 55 sec 112 29.54 5 min. -- 21.9210 min 115 3.9915 min 114 2.4120 min 113 1.1930 min 110 0.68______________________________________
EXAMPLE 4
Example 3 is repeated except the contents of the flask are heated to 130° C. before adding the ferric chloride and calcium carbonate. The analyses of the off-gas from the flask are reported in Table IV.
TABLE IV______________________________________ Temperature CO.sub.2Time °C. %______________________________________50 sec 125 40.23 2 min 125 26.07 5 min 127 21.1210 min 131 5.6815 min 130 3.4920 min 127 1.5530 min 130 0.69______________________________________
EXAMPLE 5
Calcium chloride hydrate containing two molecules of hydration (147.0 g) is mixed with 36.0 g of water in a three-necked, 1000 ml flask equipped with a stirrer, thermometer and gas connections. The water reacts with the CaCl 2 .2H 2 O to form CaCl 2 .4H 2 O which forms as a hard solid. The contents of the flask are heated to 145° C. with continuous stirring until the molten CaCl 2 .4H 2 O salt is water-like. A stoichiometric mixture of FeCl 2 and CaCO 3 powder is added to the melt in the flask. The initial mole ratio of CaCl 2 .4H 2 O/(FeCl 2 +CaCO 3 ) is 1.0/0.4. After about two minutes, 10 ml of water containing 0.5 ml antifoam agent are added to the flask. Air is bubbled through the flask at a rate of 750 ml/minute as measured at standard temperature and pressure. A reflux condenser is fitted to the exit neck of the flask, thereby minimizing the loss of H 2 O from the flask. Samples of the off-gas from the flask are taken periodically and analyzed for carbon dioxide content at selected intervals of time, the results of which are reported as broken line curve (2) in FIG. 3.
EXAMPLE 6
Example 5 is repeated except that an equimolar amount of magnesium carbonate is substituted for the calcium carbonate. The results are reported as broken line curve (1) in FIG. 3. As can be seen from FIG. 3, magnesium carbonate exhibits a faster reaction role than calcium carbonate.
EXAMPLE 7
Example 5 is repeated except that an equimolar amount of sodium carbonate is substituted for the calcium carbonate. The results are reported as broken line curve (3) in FIG. 3. As can be seen, the sodium carbonate is less reactive than the calcium carbonate.
EXAMPLE 8
Example 5 is repeated except that an equimolar amount of ferric chloride is substituted for the ferros chloride. The results are reported as solid line curve (2) in FIG. 3.
EXAMPLE 9
Example 5 is repeated except an equimolar amount of magnesium carbonate is substituted for the calcium carbonate and an equimolar amount of ferric chloride is substituted for the ferrous chloride. The results are reported as solid line curve (1) in FIG. 3. As can be seen the magnesium carbonate is more reactive than the calcium carbonate.
EXAMPLE 10
Example 5 is repeated except an equimolar amount of sodium carbonate is substituted for the calcium carbonate and an equimolar amount of ferric chloride is substituted for the ferrous chloride. The results are reported as solid line curve (3) in FIG. 3. As can be seen the sodium carbonate is less reactive than the calcium carbonate.
EXAMPLE 11
Example 5 is repeated except an equimolar amount of an equimolar mixture of ferric chloride and ferrous chloride is substituted for the ferrous chloride. The results are reported as line (1) in FIG. 4.
EXAMPLE 12
Example 5 is repeated except an equimolar amount of an equimolar mixture of ferric chloride and ferrous chloride is substituted for the ferrous chloride and an equimolar amount of magnesium carbonate is substituted for the calcium carbonate. The results are reported as line (2) in FIG. 4. Again the magnesium carbonate is more reactive than the calcium carbonate.
EXAMPLE 13
Example 5 is repeated except that an equimolar amount of an equimolar mixture of ferric chloride and ferrous chloride is substituted for the ferrous chloride and an equimolar amount of sodium carbonate is substituted for the calcium carbonate. The results are reported as curve (3) in FIG. 4. Again the sodium carbonate is less reactive than the calcium carbonate.
EXAMPLES 14-16
Example 5 is repeated except 40.0 g of a mixture of solid chloride waste from a titanium ore chlorinator is added to the molten CaCl 2 .4H 2 O in the flask. After one hour of reaction, the molten mass is centrifuged at 1,840 rpm in a laboratory bench-top centrifuge heated to 150° C. After ten minutes of centrifuging, the supernatant molten salt is poured out of the centrifuge tubes. The solidified reddish mass in the bottom layer comprises approximately 30 weight percent iron oxides and 70 weight percent CaCl 2 .xH 2 O. This solid mass is pulverized and subjected to the Environment Protection Agency's E.P. Toxicity leaching test and analysis as reported in the Federal Register V. 45 No. 98, May 18, 1980 pp. 33122, 33127-33128. Although chromium and especially chromium in the hexavalent state are of major concern in the titanium ore chlorinator solid waste materials tested, due to their being one of the eight elements listed by E.P.A. for the regulation of hazardous waste solids, Fe, Mn and V are also analyzed to determine the extent of insolubilization of each element as a result of the treatment. Titanium ore chlorinator solid waste from two plants A and B are tested. The data are summarized in Table V. In Table V Mg stands for milligrams, and ND stands for not detectable.
EXAMPLE 17
Example 17 reports the result of dry-lime neutralizing the wastes from plant B using CaO which reacts spontaneously with iron chloride when a small amount of water is sprayed onto the solid mixture.
TABLE V__________________________________________________________________________Fe Mn V Cr-Total Cr.sup.VI Waste Insolu- Insolu- Insolu- Insolu- Insolu- From bilized bilized bilized bilized bilizedEx Plant mg/l % mg/l % mg/l % mg/l % mg/l %__________________________________________________________________________14 A 159 98.1 88.1 50.0 0.986 99.2 0.366 99.4 ND 10015 A 229 97.2 65.0 50.0 -- -- 0.53 99.1 0.1 10016 B 678 95.1 36.8 90.1 0.841 99.2 0.224 99.5 ND 10017 B 771 94.8 109.0 70.5 -- -- 8.40 82.3 2.1 --__________________________________________________________________________
As can be seen in Table V, chromium, chromium in the hexavalent state, vanadium and iron are all nearly completely reacted and insolubilized. Manganese is the only one which is only partially (50-90%) insolubilized.
EXAMPLE 18
Numerous CaCO 3 melt-neutralized iron chloride samples are tested in the laboratory for permeability under a two foot head of water. A sample of the permeability test data is presented in Table VI. Table VI also serves as a summary of the experimental findings for achieving water impermeability of the neutralized products. The following are the conclusions based on the test data.
The method of dampening the product before packing it into a permeability test tube does not produce impermeability with the melt-neutralized product.
Charging the molten, melt-neutralized sample into the permeability test tube can produce a self-sealing product under the conditions as follows:
The starting material has to contain >10% by weight FeCl 3 . Samples produced with pure FeCl 2 never did seal under any circumstances.
Samples produced from either pure FeCl 3 or FeCl 3 /FeCl 2 mixture sealed very well so long as the FeO y had been concentrated to about 20-90%, preferably 30% by weight. The concentration of FeO y can be achieved by either settling or centrifuging.
Both A and B plant samples, after neutralization and centrifuging, yielded self-sealing products.
Self-sealing property can also be achieved by first dehydrating the melt-neutalized product from tetra- to di-hydrate at 200° C. followed by wetting with H 2 O shortly before packing.
TABLE VI______________________________________Permeability Test of the CaCO.sub.3 Melt-Neutralized FeCl(Samples Packed When Still Molten)Run Reactants Product Time PermeationNo. Compound Gr-Mole Centrifuge* (Days) (lbs/ft.sup.2 -day)______________________________________36 Fe.sub.2 O.sub.3 -- -- 250 0CaCl.sub.2 2H.sub.2 O -- -- 042 FeCl.sub.2 0.15 No 128 38.4CaCO.sub.3 0.1540 FeCl.sub.2 0.15 Yes 134 31.2CaCO.sub.3 0.1543 FeCl.sub.3 0.15 No (CaCl.sub.2 was washedCaCO.sub.3 0.225 out of the 6" column in 20 days)44 FeCl.sub.3 0.15 Yes 127 0CaCO.sub.3 0.225 12735 FeCl.sub.3 0.075 No 250 2.1FeCl.sub.2 0.075 250CaCO.sub.3 0.188 25045 FeCl.sub.3 0.075 Yes 126 0FeCl.sub.2 0.075CaCO.sub.3 0.18848 A** 25.0 gr Yes 119 0CaCO.sub.3 15.0 gr49 B** 25.0 gr Yes 119 0CaCO.sub.3 15.0 gr______________________________________ Reaction conditions: 150° C., 60 min., 750 ml/min. O.sub.2 flow, CaCl.sub.2 .4H.sub.2 O, melt100 grmole. *After 10 minutes of centrifuging and the removal of supernatant molten salt, the remaining solids comprise approximately 20-40% iron oxides and 60-80% CaCl.sub.2 XH.sub.2 O. **A and B are TiO.sub.2 chlorinator chloride solid waste from two different sources. | A process for treating iron chloride wastes such as those obtained when chlorinating titanium ore is disclosed. The process involves reacting the iron chlorides with limestone in molten CaCl 2 .xH 2 O, where x equals 3-6 and separating the resulting iron oxide from the molten CaCl 2 .xH 2 O. | 8 |
BACKGROUND
In construction projects, rigid members, such as piles, sheet piles, poles, caissons, or other vertically oriented piles (hereinafter referred to as “piles”) must sometimes be inserted into and/or withdrawn from the earth. Piles may be made out of wood, steel, reinforced and/or prestressed concrete, or other materials. Piles may have a square, rectangular, circular, “H” or other cross-section when viewed through a horizontal cross-section.
Pile insertion and extraction techniques typically involve applying a static force in conjunction with a dynamic, often vibrating force, both forces typically applied at or near the top of a pile. In pile insertion contexts, the static force is commonly provided by the weight of the pile and pile driving equipment while the dynamic force may be provided by i) a diesel, steam, or hydraulic drop hammer which raises a weight and drops it onto the upper end of the pile, ii) a hydraulic, gear, or roller-drive system which presses-in or crowds the pile into the earth, and/or iii) a vibratory system which, for example, may use a pair of balanced, counter-rotating eccentric weights (often obtaining power through a hydraulic connection to a remote power system) to vibrate the pile, which liquefies the earth in contact with the pile and allows the static force to push the pile into the earth (or withdraw it from the earth, in the case of extraction and application of a static lifting force).
Existing pile driving equipment typically includes a caisson-clamp attached to the top of the pile. An example of an existing clamp is shown in FIG. 1 . FIG. 1 shows a caisson-beam 1001 and two caisson-clamps 1017 and 1013 . The clamps 1017 / 1013 each comprise an adjustment mechanism 1005 , a fixed jaw face 1011 , an adjustable jaw face 1009 , a pile guide 1007 , and caisson-beam track 1015 . In use, the distance between two such caisson-clamps is adjusted by sliding the clamps along the caisson-beam through the caisson-beam tracks. The distance between the caisson-clamps is first roughly selected to allow the fixed jaw face 1011 and adjustable jaw face 1009 to be lowered onto a pile. The adjustable jaw face 1009 may have a roughly flat face, as shown in the detail view in FIG. 1 , while the fixed jaw face 1011 may have a convex curve, generally with a tighter arc angle than the interior of the pile into which the caisson-clamps are to be lowered. The adjustable jaw face 1009 may be tightened (via the adjustment mechanism 1005 ) against the outside of the pile, causing the clamp to adjust its position relative to the pile 1000 and causing the fixed jaw face 1011 to tighten against the inside of the pile 1000 . The top of the pile 1000 is then pinched at two locations 1019 and 1021 by the jaw faces. Wedges 1020 may then be tightened to secure the position of the caisson-clamps 1013 / 1017 on the caisson-beam 1001 .
As shown in FIG. 1 , two caisson-clamps are shown at the approximate center of a caisson-beam, with the caisson-clamps having a left- and right-sided orientation as viewed in the figure (so that the adjustable jaw side of both clamps is on the exterior of the pile). Two caisson-clamps are also shown at opposite ends of the caisson-beam, caisson-clamps 1013 and 1017 , both of which clamps are shown with a left-sided orientation. In use, caisson-clamp 1017 would be removed from the caisson-beam, rotated 180 degrees, and re-inserted onto the caisson-beam with a right-sided orientation.
The existing prior-art caisson-clamps require placement and replacement of four jaw faces and often require clamps and/or jaw faces sized to specific piles or narrow ranges of piles. Existing caisson-clamps often require that the pile be machined, welded, cut, ground, or otherwise modified prior to and/or after insertion or extraction, procedures which take time, expertise, and which may add cost, time, and complexity to a pile insertion and/or extraction procedure as well as to utilization of the pile after the insertion and/or extraction procedure. The pile used in prior-art systems must be hollow to accommodate the caisson-clamps or must be modified to accommodate the caisson-clamps. Needed is a pile clamp which addresses these shortcomings.
SUMMARY OF THE INVENTION
Disclosed is a two-part caisson-clamp, wherein each half of the caisson-clamp contains only one jaw face. The two half caisson-clamps together pinch the top of a pile between them. The jaw faces may have a concave curve to secure the pile between them. The pile extends up between the two caisson-clamps to contact the caisson-beam. Horizontal forces on the two caisson-clamps, which would otherwise drive the two caisson-clamps apart, are resisted by mechanical stop(s). A mandril may be inserted into the pile to reinforce the top of the pile relative to the forces applied and transferred by the half-caisson clamps.
DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts a prior art set of caisson-clamps in an elevation view and a plan view of a prior art set of caisson-clamps clamped to a pile.
FIG. 2 depicts an elevation view of an embodiment of a caisson-clamp according to this disclosure.
FIG. 3.A depicts an elevation view of an embodiment of a mechanical stop according to this disclosure.
FIG. 3.B depicts an elevation view of an embodiment of a mechanical stop according to this disclosure.
FIG. 4 depicts an elevation view of an embodiment of a caisson-clamp as clamped to 4″ and 6″ piles, according to this disclosure.
FIG. 5 depicts an elevation view of an embodiment of a caisson-clamp as clamped to 8″ and 10″ piles, according to this disclosure.
FIG. 6 depicts elevation and plan views of an embodiment of a pile jaw to be attached to a moveable jaw holder.
FIG. 7 depicts elevation and plan views of an embodiment of a pile jaw to be attached to a fixed jaw holder.
FIG. 8 depicts an elevation view of a mandril.
FIG. 9 depicts an elevation view of an embodiment of a mechanical stop.
FIG. 10 depicts an elevation view of an embodiment of a mechanical stop.
DETAILED DESCRIPTION
The following description of the drawings and detailed description refers to the accompanying drawings. The reference numbers generally begin with a numeral which identifies the figure, followed by another numeral which identifies the feature. The same feature number in different drawings generally identify the same or similar elements and/or components. The following detailed description is for the purpose of illustrating embodiments of the invention only, and other embodiments are possible without deviating from the spirit and scope of the invention, which is limited only by the appended claims. Certain of the figures are discussed in this specification using certain terms. The following discussion uses these terms and related terms as examples and not as limitations. The components depicted in certain of the figures represent functional groups; it should be understood that such functional groupings need not exist as discrete hardware devices and that the functions described as occurring within, comprising, or being provided by a grouping may be provided within or by common or separate physical devices. The functions within and comprising any of the function groupings may be regrouped in other combinations and certain of the components may be omitted or added without deviating from the spirit of the disclosed invention. Certain of the groupings depict components which are included together in the illustration for the sake of convenience. Certain of the figures depict components in isolation; the components from different figures may be combined and/or regrouped. As used herein, “releasable,” “releasably” and similar shall mean being able to repeatedly connect/disconnect (or engage/disengage) through the use of hands, feet, or human appendage with or without use of a tool (including power tools), and without the need for removal of material or application of a high temperature (greater than approximately 150 degrees Fahrenheit). Examples of “releasable” components include nuts and bolts, screws and a threaded receptacle, friction locking cams or chocks or wedges (female and male), hydraulic pistons and straps and tensioning levers. Not considered “releasable” are components attached to another component by chemical bonding or welding or which are removed from another component through use of a saw, drill, grinding tool, other material removal tool, or high intensity heat source (such as a welder or high-temperature cutting tool).
FIG. 2 depicts an elevation view of an embodiment of a caisson-clamp according to this disclosure. A caisson-beam 2001 is shown with two attached half-caisson clamps 2030 and 2032 . Half-caisson clamp 2030 comprises a caisson-beam track 2015 , a wedge 2016 , moveable jaw holder connecting bolts 2036 , and moveable jaw holder comprising a piston 2037 , a connecting rod 2038 , a guide fin 2035 , and a moveable pile jaw face 2041 . Details of an embodiment of a moveable pile jaw face 2041 are shown in FIG. 6 .
The caisson-beam track 2015 is an example of means to connect the half caisson-beam clamp to the caisson-beam. Alternative means to secure the half caisson-beam clamps along the length of the caisson-beam are possible; examples include a caisson-beam comprising an opening (or other geometry) into which the caisson-beam clamp may be inserted (or otherwise may be coupled with). The moveable jaw holder and components thereof are examples of means for a moveable jaw holder; the piston 2037 may be powered by a hydraulic power system attached to hoses on or in the vicinity of the piston 2037 ; the moveable jaw holder may, for example, provide a horizontal movement range of 2¼″; a jack screw or similar is an example of an alternative to the components for the moveable jaw holder.
The wedge 2016 may comprise components such as bolts attached to at least one threaded chock in a set of metal chocks, which chocks are in a wedge relationship (at least two of the chocks having overlapping sides with an angle greater or less than horizontal); such that when the bolt(s) are turned to tighten the wedge 2016 , the threaded chock(s) slides along the other, forcing both chocks outward, generally perpendicular to their non-horizontal overlapping side, against the interior of the caisson-beam track 2015 and against the caisson-beam 2001 , thereby wedging the half-caisson clamp against the caisson-beam. The wedge 2016 holds the half-caisson clamp in a relationship with the caisson-beam, but is not expected to secure the half-caisson clamp against horizontal forces experienced during use. The wedge 2016 may be powered by a human-powered tool, such as a wrench, or by a power tool, or by a hydraulic power source.
Half-caisson clamp 2032 comprises a caisson-beam track 2015 , a wedge 2016 , and a fixed jaw holder comprising a fixed jaw face 2039 , fixed jaw face attachment bolts 2042 , and fixed jaw holder attachment bolts 2043 and 2045 . Details of an embodiment of a fixed pile jaw face 2039 are shown in FIG. 7 .
Also shown in FIG. 2 is a mechanical stop 2031 comprising a plate with holes drilled in it as well as holes drilled in the caisson-beam 2033 . A detailed plan view of the plate-based mechanical stop and caisson-beam are shown in FIGS. 3.A and 3 .B., while an alternative is shown in FIG. 9 . Discussing FIGS. 2 , 3 , and 9 , the illustrated mechanical stop is an example of means to secure the half-caisson clamps against the horizontal forces experienced during use. With respect to FIG. 2 , the holes in the mechanical stop 2031 as well as in the caisson-beam 2033 are chosen to allow a pile to be inserted between the half-caisson clamps taking into consideration factors such as i) that piles tend to have standard diameters, typically, for example, between 4″ and 12″; ii) taking into consideration the horizontal offset created by the width of the half-caisson clamp and the width of the mechanical stop; and iii) taking into consideration the horizontal movement range of the moveable jaw holder (approximately 2¼″).
As shown in FIG. 3.A as an example, the set of holes 3032 .A (in the mechanical stop 3031 ) and 3033 .A (in the caisson-beam 3001 ) and the set of holes 3032 .G (in the mechanical stop 3031 ) and 3033 .E (in the caisson-beam 3001 ) line up and may receive bolts, thereby securing the mechanical stop 3031 to the caisson-beam 3001 , which secured mechanical stop 3031 may secure a half-caisson clamp against horizontal forces experienced during use. As shown in FIG. 3.B as an example, the set of holes 3032 .D (in the mechanical stop 3031 ) and 3033 .B (in the caisson-beam 3001 ) and the set of holes 3032 .G (in the mechanical stop 3031 ) and 3033 .D (in the caisson-beam 3001 ) line up and may receive bolts, thereby securing the mechanical stop 3031 to the caisson-beam 3001 , which secured mechanical stop 3031 may secure a half-caisson clamp against horizontal forces experienced during use. The holes and relative hole-spacing in FIGS. 3.A and 3 .B are shown as examples.
FIG. 9 depicts an alternative mechanical stop in which the caisson-beam 9001 (shown as a partial view) has holes 9065 .A, 9065 .B, 9065 .C, 9065 .D, and 9065 .E. In this example, half-caisson clamp 9030 (also shown as a partial view) has hole 9067 . When, as shown in FIG. 9 , hole 9067 is lined up with one of the holes in the caisson-beam, hole 9065 .D, a bolt, rod, pin or similar may be passed through the lined up holes, thereby releasably securing the half-caisson clamp 9030 against horizontal forces. The bolt, rod, pin, or similar may be secured with a nut, with a cotter pin, or similar. The holes in FIG. 9 are shown with a horizontally oriented central axis; it would be appreciated that a vertically oriented central axis may be used, in which case the holes may pass through the bottom portion of the caisson-beam or another portion of the caisson-beam with a suitable orientation.
FIG. 10 depicts an alternative mechanical stop in which the half-caisson clamps 10030 and 10032 are secured by mechanical stop 10067 , comprising a bolt, rod, or similar. The mechanical stop 10067 may pass through a hole, channel, grove, or notch in the half-caisson clamps provided for this purpose. The ends of the mechanical stop 10067 may comprise one or more nuts, bolt-heads, or similar. Alternative mechanical stops not shown in the drawings include a belt, U-shaped bracket, or similar going around or attaching to one half-caisson clamp and going around or attaching to the other half-caisson clamp and/or the caisson-beam.
To clamp a different sized pile between the half-caisson clamps, the piston 2037 (if extended) may be withdrawn, the mechanical stop 2 / 3031 (if attached) may be unbolted from the caisson-beam 2 / 3001 , the wedges 2016 may be loosened (if required), the half-caisson clamps 2030 and 2032 may be relocated along the caisson-beam 2001 , the wedges 2016 may be tightened, the mechanical stops 2 / 3031 may be bolted to a new position, the new pile may be inserted into the space between the half-caisson clamps 2030 and 2032 , and the piston 2037 may extended to clamp the pile between the moveable pile jaw face 2041 and the fixed pile jaw face 2039 . One or more of these steps may be performed in another order.
FIG. 4 depicts an elevation view of an embodiment of a caisson-clamp as clamped to 4″ and 6″ piles, according to this disclosure.
FIG. 5 depicts an elevation view of an embodiment of a caisson-clamp as clamped to 8″ and 10″ piles, according to this disclosure.
FIG. 6 depicts elevation and plan views of an embodiment of a pile jaw to be attached to a moveable jaw holder, moveable pile jaw face 6041 . The depicted moveable pile jaw face 6041 has a concave portion 6053 to receive a pile. Shown is a moveable pile jaw face bracket 6051 , drilled to receive a bolt, rod, or similar to secure the moveable pile jaw face 6041 to the connecting rod 2038 .
FIG. 7 depicts elevation and plan views of an embodiment of a fixed jaw face 7039 to be attached to a fixed jaw holder. The fixed jaw face 7039 is depicted as having holes 7053 to receive fixed jaw face attachment bolts 2042 . The fixed jaw face 7039 has a concave portion 7057 to receive a pile.
The arc radius of the pile jaw face may be selected to approximate and/or be slightly larger than the arc radius of the pile to which the system is to be clamped.
Unlike the prior art, in which the jaw faces are flat or convex and in which two sets of jaw faces are required in each caisson-clamp, one set on each side of the pile (see 1021 and 1019 —a total of four jaw faces), the present invention utilizes two jaw faces, one per caisson-clamp, both of which jaw faces are concave. Unlike the prior art—in which the pile contacts the top of the caisson-clamps, in which the pile must be modified or reinforced to be driven into or extracted from the ground—in the demonstrated system, the pile contacts the caisson-beam, the pile does not need to be modified or reinforced, resulting in less damage to both the half-caisson clamps, the jaw faces, and the pile. Horizontal forces experienced by the half caisson-clamps during use are resisted by a mechanical stop.
FIG. 8 depicts an elevation view of a mandril 8061 . The mandril 8061 may have a hole 8063 to receive a bolt or similar to facilitate utilization of the mandril. The mandril 8061 may optionally be inserted into the pile to reinforce the pile against deforming forces which may be experienced during insertion or extraction of the pile. A mandril may not be used with the prior art. | Disclosed is a two-part caisson-clamp, wherein each half of the caisson-clamp contains only one jaw face. The two half caisson-clamps together pinch the top of a pile between them. The jaw faces may have a concave curve to secure the pile between them. The pile extends up between the two caisson-clamps to contact the caisson-beam. Horizontal forces on the two caisson-clamps, which would otherwise drive the two caisson-clamps apart, are resisted by mechanical stop(s). A mandril may be inserted into the pile to reinforce the top of the pile relative to the forces applied and transferred by the half-caisson clamps. | 4 |
FIELD OF INVENTION
[0001] The present invention relates tents, and in particular, relates to various features and accessories for vehicle roof-top tents.
BACKGROUND OF THE INVENTION
[0002] Camping has been a popular recreation for many years. Although camper vans and motor homes are commonly used by campers, they are expensive and they do not allow the campers to enjoy a close experience with nature to the extent that canvas and fabric tents do. However, canvas and fabric tents are typically placed on the ground, exposing them to problems with dampness, puddles, mud, rocky or uneven ground, insects, small mammals and other pests. Larger mammals such as bears, are downright dangerous for campers in tents placed on the ground. As a result, many attempts have been made to offer tents which are elevated, being mounted for example, on the tops of cars, SUVs and vans, or in the beds of trucks.
[0003] But the current offerings of vehicle-mounted tents still have many undesirable features such as weight, bulkiness, slow and/or complicated set-up, lack of aesthetic or convenient features, and many loose parts to be stored.
[0004] There is therefore a need for an improved vehicle-mounted tent and accessories.
SUMMARY OF THE INVENTION
[0005] It is an object of the invention to provide an improved vehicle-mounted tent and accessories.
[0006] According to one aspect of the present invention there is provided a vehicle roof-mounted tent comprising a base including: a fixed portion for mounting on the roof of the vehicle and a pivoting portion connected to the fixed portion, the pivoting portion being arranged to pivot away from the vehicle. The tent also comprises a main tent portion, generally of tent fabric, including a pivoting frame, the main tent portion being positioned over the fixed and pivotal portions of the base; and a canopy portion, generally of tent fabric, extending beyond the end of the pivoting portion of the base.
[0007] According to another aspect of the present invention there is provided a tent for mounting on the roof of a vehicle comprising: a base including a fixed portion for mounting on the roof of the vehicle and a pivoting portion connected to the fixed portion, the pivoting portion being arranged to pivot away from the vehicle. The tent also comprises a main tent portion of tent fabric, including: a pivoting frame; a door; and at least one window on a roof surface to serve as a skylight; the main tent portion being positioned over the fixed and pivotal portions of the base; a canopy portion of tent fabric, extending beyond the end of the pivoting portion of the base; a rain fly, comprising a PVC window positioned above the window on the roof surface of the main tent, the rain fly being positioned over the main tent portion and the canopy portion; and an access ladder pivotally connected to the end of the pivoting portion of the base.
[0008] As explained herein after, the claimed inventions provide many advantages over tents in the prior art. For example, the roof-top design frees up space inside your vehicle, and height provides a defense against wildlife and ground-related elements. Other advantageous aspects of the claimed inventions include a superior curved frame, removable shoe/utility bags, a roll-up window awning, large semicircular windows, a canopy PVC window, aluminum honeycomb tent base, an advantageous stowing arrangement for the canopy pole, bungee cord pockets, dual PVC skylights and a quick release mounting for the vehicle roof rack.
[0009] Other systems, methods, features and advantages of the invention will be, or will become, apparent to one with skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description, be within the scope of the invention, and be protected by the following claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] These and other features of the invention will become more apparent from the following description in which reference is made to the appended drawings wherein:
[0011] FIG. 1 shows a front perspective view of a tent in accordance with an embodiment of the present invention, having dual sky lights, in the deployed position on the roof of a vehicle, with the rain fly installed and the front awning deployed.
[0012] FIG. 2 shows a front view of the arrangement of FIG. 1 , in accordance with an embodiment of the present invention.
[0013] FIG. 3 shows a perspective view of the arrangement of FIG. 1 , in accordance with an embodiment of the present invention, from the rear, canopy side and below.
[0014] FIG. 4 shows a perspective view of the interior frame and base portions of a tent in accordance with an embodiment of the present invention.
[0015] FIG. 5 shows a detailed view of one of the pairs of brackets in accordance with an embodiment of the present invention.
[0016] FIGS. 6 and 7 show perspective views of a socket to support the canopy pole, in accordance with an embodiment of the present invention.
[0017] FIG. 8 shows a top perspective view of the tent with the pivoting portion of the base in the stowed position, the ladder in the contracted and stowed position, and the canopy pole in a stowed position, in accordance with an embodiment of the present invention.
[0018] FIG. 9 shows a rear perspective view of a tent in accordance with an embodiment of the present invention, having no sky lights, in the deployed position on the roof of a vehicle, with the rain fly installed and the rear awning stowed.
[0019] FIG. 10 shows a front perspective view of a tent in accordance with an embodiment of the present invention, having dual sky lights, in the deployed position, without the rain fly installed, and with the front awning in a stowed position.
[0020] FIGS. 11 a , 11 b and 11 c shows details of the quick-release mounting system in accordance with an embodiment of the present invention, FIG. 11 a showing the installed arrangement, FIG. 11 b showing the slides, threaded rods, plate and hand screws, and FIG. 11 c showing a hand screw in isolation.
[0021] FIGS. 12 a and 12 b show the details of the shoe/utility bags in accordance with an embodiment of the present invention.
[0022] FIGS. 13 a and 13 b show a top view of the pivoting base portion in a stowed position, with the utility pocket in a stowed position, and the ladder not yet installed in accordance with a further embodiment of the present invention.
[0023] FIG. 14 shows a top view of the pivoting base portion in a stowed position, with the ladder and its support brackets installed, and with the canopy pole in a stowed position, in accordance with a further embodiment of the present invention.
DETAILED DESCRIPTION
[0024] One or more currently preferred embodiments have been described by way of example. It will be apparent to persons skilled in the art that a number of variations and modifications can be made without departing from the scope of the invention as defined in the claims.
[0025] The preferred embodiment of the tent features a rugged, lightweight aluminum honeycomb base and dual skylights that allow for extra natural light even while the fly is on. Oversized awning windows can be rolled up for unrestricted views. Other unique features include utility storage bags and a hi-tech Diamond Ripstop rain fly. The tent can be set up and taken down in minutes, and comes with a built-in, cloth covered, high density foam mattress that can stay inside the tent during travel. The new curved design reduces weight, improves water shedding and improves aerodynamics.
[0026] As shown in FIGS. 1, 2 and 3 , the preferred tent 10 is not symmetrical when viewed from the exterior, consisting of a main portion 12 and an extended canopy portion 14 . The main portion 12 of the tent 10 has a base 16 which rests on and is clamped to a conventional rack 46 on the roof-top of a vehicle 18 , but also cantilevers out from the vehicle 18 somewhat, as shown in FIG. 3 . The extended canopy portion 14 provides additional shelter outside the vehicle 18 , as well as providing some protection for the accessory/shoe bags 20 and access ladder 22 from the elements.
[0027] As shown in FIG. 4 , the main portion 12 of the tent 10 is supported by a system of three frame poles 24 which are pivotally connected to the base 16 . The base 16 consists of two portions, which are hinged together with a pair of brackets 30 . One portion of the base 16 is fixed to the vehicle while in use (i.e. ‘the fixed portion of the base 26 ’), while the other portion of the base 16 (i.e. ‘the pivoting portion of the base 28 ’) pivots between a stowed position in which it lies over the fixed portion of the base 26 , and a deployed position in which it cantilevers out from the vehicle 18 . The pair of brackets 30 have flange-like members which stand off from the surface of the fixed 26 and pivoting 28 portions of the base 16 , provide a pivot point that is raised from the surface of the fixed 26 and pivoting portions 28 of the base 16 . In this way, the fixed 26 and pivoting 28 portions of the base 16 are spaced apart from one another in the stowed position, leaving room for the mattress 32 and the three frame poles 24 . In the preferred embodiment the fixed 26 and pivoting 28 portions of the base 16 will be spaced apart by about 8½″, although other dimensions could also be used. The three frame poles 24 are connected to the pair of brackets 30 on the base 16 , so that they pivot as the tent 10 is assembled or stowed. The pivot points for the three frame poles 24 are spaced apart on the brackets 30 , so that they do not interfere with one another.
[0028] A detail of one of the pair of brackets 30 is shown in FIG. 5 . As shown, each of the brackets 30 consists of two parts, each part having a foot 34 which is screwed to the U-channel of the base 16 , and an upright portion 36 having two holes. Each of the three frame poles 24 terminates in a clevis or yoke 38 that is attached to the frame pole 24 with a screw. The devises or yokes 38 allow the three frame poles 24 to pivot with respect to the upright portions 36 of the brackets 30 , being attached with a bolt and a nylon nut 40 or locknut arrangement. Note that the middle bolt 42 passes through two upright portions 36 of the bracket 30 as well as through the clevis or yoke 38 of the middle frame pole, so that the two parts of the bracket 30 can pivot with respect to one another.
[0029] The fixed 26 and pivoting 28 portions of the base 16 are preferably fabricated from 23 mm thick aluminum honeycomb, with a U-shaped channel 44 fixed about the perimeter. Other thicknesses of aluminum honeycomb could be used, or other materials which have sufficient strength to provide the desired cantilever distance. For example, the base 16 could be fabricated from an aluminum frame filled with polyurethane foam, covered on both sides with a 0.4 mm aluminum sheet. The aluminum honeycomb base described herein has dimensions of 310 cm length×143 cm width. As a result, the preferred embodiment of the tent as described herein has the following dimensions:
tent dimensions open: 310 cm length×143 cm width×126 cm height (i.e. this is the sleeping are, not including the canopy); tent dimensions closed: 125 cm length×143 cm width×30 cm height; mattress: 240 cm length×140 cm width×6 cm height; total pack size: 150 cm length×125 cm width×30 cm height; and weight: 97 lbs.
[0035] This arrangement fits on a vehicle with a roof rack 46 wider than 37 inches, and can be adjusted to fit roof racks 46 smaller than 37 inches with minor modifications.
[0036] The U-shaped channel 44 fixed about the perimeter of the base 16 has a groove 48 on the underside (see FIGS. 7 and 12A ), which is used to hold the travel cover 50 and to hold the tent fabric in the conventional manner. But as will be explained hereinafter, this groove 48 is also used to support the removable shoe/utility bags 20 .
[0037] The frame arrangement in the main portion 12 of the tent 10 is generally symmetrical. The three pivoting frame poles 24 may have slightly different sizes so that they nest together, or they may be the same size so that they lay on top of one another in the stowed position. The three pivoting frame poles 24 are preferably ¾″ diameter aluminum, which is light and sufficiently strong for this application. Steel poles would be less expensive, but would be heavier than aluminum. Smaller diameter or light gauge aluminum could be used, but it would be less durable. Fibreglass or other materials may also be used as known to one skilled in the art. Because the three pivoting frame poles 24 have a small outside diameter, it is not necessary for them to nest together in order to provide a low-profile in the stowed position. Thus, it is preferred that they all be the same size.
[0038] The system of three pivoting frame poles 24 are connected together by fabric straps 52 . At one end, the fabric straps 52 are attached to the outside edge 54 of the fixed portion of the base, while at the other end, they are connected to the outside edge 56 of the pivoting portion of the base. The fabric straps 52 are also frictionally engaged at specific positions on the three pivoting frame poles 24 so that the tent 10 has the desired shape in the assembled state. Thus, when the two base portions 26 , 28 are pivoted into the deployed position, the fabric straps 52 will draw the three pivoting frame poles 24 with them, pivoting them into evenly spaced arrangement about the pair of brackets 30 on the base 16 . Conversely, when the two base portions 26 , 28 are pivoted into the stowed position, the fabric straps 52 will relax and allow the three pivoting frame poles 24 to pivot back into the stowed position. The two fabric straps 52 shown in FIG. 4 are simply sewn into a loop at each point in which they cross the three pivoting frame poles 24 , so the fabric straps 52 are in frictional engagement with the three pivoting frame poles 24 . The fabric straps 52 could be fixed to the three pivoting frame poles 24 , for example, using a single screw through the fabric straps 52 , but this is generally not necessary.
[0039] The extended canopy 14 has an additional frame member, the canopy pole 58 , which is connected to the pivoting portion of the base 28 by way of a pair of sockets 60 which pivot in yokes or devises 62 (see FIGS. 6 and 7 ), fixed to the outside edge of the pivoting portion of the base 28 (see FIG. 3 ). The canopy pole 58 is removed completely when the tent 10 is disassembled and can be stowed on the top of the base 16 as shown in FIG. 8 . In the preferred arrangement, the canopy pole 58 slides through the four loops 64 on the sides of the base 16 , and is fixed in position with a single loop 66 of Velcro. When the tent 10 is assembled, the ends of the canopy pole 58 are fitted into the sockets 60 , and the canopy pole 58 is rotated into position, supporting the tent fabric over the extended canopy 14 . The extended canopy 14 is also deployed by way of a pair of guy lines 68 which are fixed to the ground with conventional stakes or pegs per FIGS. 2 and 3 . The canopy pole 58 is preferably fabricated from ¾″ diameter aluminum, like the three pivoting frame poles 24 .
[0040] All of the three pivoting frame poles 24 and the canopy pole 58 have curved profiles. Combining these curved profiles with the profile along the perpendicular axis of the tent 10 (i.e. the long axis of the tent), provides a curved aerodynamic design in all dimensions. This results in less noise inside the tent 10 on a windy day, along with less likelihood of damage. As well, it allows rain and other precipitation to roll off of the tent 10 more easily than in designs with flatter, horizontal surfaces. Preferably, the tent 10 should have the curvature as shown in the drawings, but the precise curvature is a trade-off between the amount of space inside the tent 10 , and the degree of aerodynamics and precipitation runoff that would be provided. In other words, having less curvature (i.e. a larger curvature radius) would provide more room inside the tent 10 , but poorer aerodynamics and reduced ability to shed precipitation.
[0041] The tent 10 itself is fabricated from water resistant 280 g Poly Cotton with flame retardant, PU (polyurethane water-proofing) and mold/mildew resistant coating. The rain fly 70 is fabricated from 420 denier waterproof Diamond Ripstop Polyester with flame retardant, PU and mold/mildew resistant coating. The travel cover 50 is fabricated from 2000 denier PVC coated durable polyester. The precise dimensions of the tent 10 , rain fly 70 and travel cover 50 follow directly from the dimensions of the base 16 and frame.
[0042] As shown in FIGS. 9 and 10 the tent 10 preferable has large windows 72 on both sides, and on the end of the tent 74 over of the fixed portion of the base. The windows 72 , 74 themselves are fabricated from “no-see-um mesh”, that is, extra-fine gauge netting which keeps out even very small bugs. Such netting is available in very sheer form which maintains a high level of visibility. The windows 72 , 74 are fully zippered in that the mesh is held to the tent fabric by zippers, as are the window covers. The windows 72 , 74 are also provided with a cover of tent fabric which can be unzipped and secured above with a loop and bone system.
[0043] The windows 72 , 74 are larger than those typically used, both in terms of height and width. The larger size provides for more light inside the tent 10 , better ventilation and better viewing for campers. The larger window size for the side windows 72 is facilitated in part by the use of the generally semi-circular shape; typical windows in the prior art are quite square or rectangular. The windows 72 , 74 are also equipped with awnings, which consist of sheets of fabric double-sewed to the tent above each window 72 , 74 . While awnings are available on prior art tents, it was found that the existing awnings were not effective with the larger semi-circular side windows 72 of the invention. The existing awnings were not shaped properly to be fitted across the entirety of the arcuate upper profile of the windows, resulting in a bunching of loose material when they were deployed. In order to obtain awnings 76 that properly fit the arcuate upper profile of the side windows 72 , so they could be connected all the way to the horizontal edge of the side windows 72 , awnings were roughly installed and then the superfluous material was removed. These new rounded awnings 76 are double-sewn to the tent fabric, and are extend out from the tent 10 using conventional curved steel rods 78 as shown in FIGS. 1 and 3 . The awnings 76 can be rolled-up or furled, being held with a typical loop, and bone system.
[0044] As shown in FIGS. 1 and 10 the tent 10 preferably has dual skylights 80 on the ‘roof’ of the tent 10 , with PVC windows 82 in corresponding locations on the rain fly 70 . This provides additional light into the tent 10 during the day, as well as a view of the sky at night. The PVC windows 82 are sheets of frost-proof PVC, which has been double-sewn into the fabric of the rain fly 70 . The skylights 80 in the tent 10 itself may either be a similar arrangement (i.e. PVC windows that have been double-sewn into the tent fabric) or may be the same arrangement as the side and end windows 72 , 74 (i.e. a window of “no-see-um” mesh with a flap of tent fabric, both of which are zippered onto the tent fabric). Other than the skylights and the curvature/dimensions of the rain fly 70 , the rain fly 70 is of generally conventional design being extended from the tent 10 with steel fly poles and/or guy lines. Note that the extended canopy 14 also has a PVC window 84 fabricated in the same way as the rain fly skylights 82 , using PVC which has been double-sewn into the fabric of the tent 10 (see FIG. 3 ).
[0045] Quick release hand screws 86 as shown in FIGS. 11 a , 11 b and 11 c are provided to facilitate easy installation and removal of the tent 10 from the roof rack 46 of a vehicle 18 . Two U-shaped aluminum slide channels 88 are provided across the bottom of the fixed portion 26 of the base 16 . These U-shaped slide channels 88 are configured with the open side down, allowing slide plates 90 to slide back and forth so their positions can be adjusted to accommodate the particular roof rack 46 on the vehicle 18 . Each slide plate 90 has a threaded rod 92 extending from it, the threaded rod 92 comprising a carriage bolt or being tack-welded to the slide plate 90 (for example). Each hand screw 86 is of a knurled polymer construction and has an imbedded nut 94 which mates with the threaded rod 92 . As shown in FIG. 11 a , the hand screws 86 are used to sandwich an arm of the vehicle roof rack 46 between a plate 96 and the U-shaped slide channels 88 . Four of such mounting arrangements would be used with the typical tent 10 , although a different number of such assemblies could also be used, such as six. Other variations on this design could also be used such as adding locknuts or lockwashers, using steel materials instead of aluminum, and adding neoprene or rubber pads to reduce scratching or damage to components.
[0046] Removable shoe/utility storage bags 20 are provided as shown in FIGS. 12 a and 12 b . The removable shoe/utility storage bags 20 are suspended from the pivoting portion of the base 28 as shown in FIG. 3 , so the user can store his/her shoes before entering the tent 10 . The removable shoe/utility storage bags 20 have two pockets: a large primary pocket 100 which is fabricated from rain fly fabric, and a smaller pocket 102 on the lower portion of the front which is formed from “no-see-um” material. The large primary pocket 100 can be closed with a Velcro strap 104 sewn into two portions of the removable shoe/utility storage bags 20 . A piece of Velcro is also secured to the base 16 (not shown) so that the removable shoe/utility storage bags 20 can be secured during disassembly, or can be positioned out of the way during use. The removable shoe/utility storage bags 20 include a rubber rod 106 which is sewn into the top edge (see FIGS. 6 and 7 ). This rubber rod 106 is sized to mate with the groove 48 in the bottom edge of the U-channel 44 . With this arrangement the user can slide the removable shoe/utility storage bags 20 sideways out of the groove 48 so that they can be removed completely.
[0047] The access ladder 22 preferably hinges to the underside of the pivoting portion of the base 28 using a pair of brackets 108 , as shown in FIGS. 3 and 14 . Thus, in the stowed position, the access ladder 22 rests on top of the pivoting portion of the base 28 as shown in FIG. 8 . The access ladder 22 is of aluminum construction and is extendible. When the user wishes to unfold the tent 10 from the stowed position, he/she simply pulls on the bottom rung of the access ladder 22 , and the access ladder 22 and pivoting portion of the base 28 will unfold to the deployed position. The access ladder 22 also has two adjustable pins 110 , one on each rail (see FIG. 14 ). When the access ladder 22 is pulled out to the deployed position, these pins 110 may be set so that the access ladder 22 has the proper angle for access, and so that it bears part of the weight of the cantilevered pivoting portion of the base 28 .
[0048] The access ladder 22 is also hinged to the underside of the pivoting portion of the base 28 so that it will not interfere with the door of the tent 10 (not shown). The door is fabricated with “no see um” mesh and tent fabric, both of which are zippered to the tent fabric. The door is positioned between the main portion of the tent 12 and the outside edge 56 of the pivoting portion of the base 28 . The door material may be rolled up and held to the roof of the tent 10 using a loop and bone system.
[0049] The tent 10 is also provided with a large rectangular utility pocket 112 as shown in FIGS. 13 a and 13 b . This utility pocket 112 is fabricated from two layers of “no-see-um” fabric, and is held in position with four bungee cords 114 or other elastic means, and some manner of removable connectors or carabiners, preferably plastic hooks with fabric loops secured to the U-channel of the base 16 . The utility pocket 112 is used to secure additional parts, accessories or other camping gear in a secure position during travel.
[0050] Finally, the tent 10 is also preferably provided with the following accessories:
2 inch thick, high density foam mattress; removable cotton mattress cover; Unisex emergency urinal; and D-ring 116 for hanging lighting (see FIG. 4 ).
[0055] While particular embodiments of the present invention have been shown and described, it is clear that changes and modifications may be made to such embodiments without departing from the true scope and spirit of the invention.
[0056] All citations are hereby incorporated by reference. | The present invention relates tents, and in particular, relates to various features and accessories for vehicle roof-top tents. The claimed inventions provide many advantages over tents in the prior art. For example, the roof-top design frees up space inside your vehicle, and height acts as a secondary safety defense against wildlife and ground-related elements. Other advantageous aspects of the claimed inventions include a superior curved frame, removable shoe bags, a roll up window awning, semicircular windows, a canopy PVC window, an aluminum honeycomb tent base, an advantageous stowing arrangement for the canopy pole, bungee cord pockets, dual PVC skylights and a quick release mounting for the vehicle roof rack. Other systems, methods, features and advantages of the invention are also described and presented in the figures and detailed description. | 4 |
BACKGROUND OF THE INVENTION
This invention relates to a fireplace enclosure, in general, and, more particularly, to an assembly that includes glass doors with a screen placed in front of the doors, with both the doors and screen covering the fireplace opening.
During the operation of a fireplace, hot gases rising from the fire will draw large amounts of heated air out of a room, and discharge the heated air up the chimney of the fireplace. Normally, during the active combustion of wood in a fireplace, the loss of heated air from the room is generally compensated by the heat convected and radiated out of the fireplace by the burning wood, and into the room. Accordingly, during active combustion, there tends not to be any great heat loss caused by the fire, and, for aesthetic reasons, it is preferred to leave the fireplace open rather than sealing the fireplace with glass doors.
After the fire has completely died out, it is common to close the damper of the fireplace chimney in order to prevent the loss of heat from the room up the chimney. However, it is not possible to close the damper until the fire has completely died out. Thus, during the period between active combustion and the fire's being completely extinguished, there is a period of time where the damper must remain open and substantial heat loss occurs from the room up the chimney. In addition to unwanted heat loss up the chimney, there is also the substantial danger of a down draft, which might result in forcing ashes out of the fireplace and into the room.
In order to obviate the problem of heat loss up the chimney, when a fire has died down, but is not totally extinguished, various mechanisms have been developed for sealing the fireplace opening. The most popular of these mechanisms is glass doors, which are mounted in the fireplace opening. The doors are pivotable in a frame mounted in the opening, and they can be opened during active combustion of the fire. However, when the glass doors are open, it is necessary that a screen be provided to prevent any of the ashes from flying out of the fire and into the room. The screen is generally mounted interiorly of the glass doors, and is suspended from a traverse rod. The screen can be opened, in the nature of a drapery, in order to place wood in the fireplace and light the fire, and can be closed when the fire is in active combustion. After the fire has died down, in order to prevent heat loss up the chimney, the glass doors are closed.
An alternative to the use of permanently installed glass doors is disclosed in Applicant's prior U.S. Pat. No. 4,971,032. In that patent, a foldable shield is disclosed, which is removable during active combustion of the fire. A free-standing fireplace screen is placed in front of the active fire, and when the active fire has died out, the shield is placed over the opening, and held in place by the frame of the free-standing screen.
The free-standing screens are placed on the hearth, in front of the fire, and serve the function of preventing any ashes from flying into the room. The screens usually have three or four panels, which are hinged together to permit them to be folded into a flat condition and removed so that the fireplace can be filled with wood and the fire ignited. Thereafter, the screen is returned to its position in front of the active fire. Designs for the free-standing screens, in both the three and four panel configurations, are shown in prior U.S. Pat. Nos. Des. 286,322 and Des. 288,712. Applicant is a co-inventor in both of these patents.
One of the problems with the permanent glass doors, which are now in common usage, is that the screen curtain behind the glass doors presents a hazard for young children. If they should be in the room and inadvertently fall against the screen curtain, they will not be prevented from falling into the fire. Although it is possible to have free-standing screens in front of the glass doors, to prevent the hazard of a child's falling into the fire, the free-standing screens must be physically removed and folded in order to place wood in the fireplace and start the fire.
One of the features of this invention is that a combination of glass doors and a screen in front of the glass doors is provided. However, rather than having the screen as a free-standing screen, it is mounted in place in front of the glass doors, and it has doors which are pivotably openable. This provides all of the advantages of the glass doors and the free-standing screen, without the disadvantage of having to remove the screen and fold it, during the placement of wood in the fireplace and the starting of the fire.
In another aspect of this invention, a safety latch is provided to maintain the screen in its closed position, thereby preventing a small child from getting close to the fire. The screen cannot be pivoted from its closed position, unless the latch is released. The latch is positioned in such a way that a small child will be unable to reach it, or if the child could reach it, the child would not have sufficient dexterity to open the latch.
In yet another aspect of this invention, a removable arch insert is provided to give the frame surrounding the fireplace doors an arcuate appearance at the top. Presently, whenever an arch shape is desired for the frame on fireplace doors, the arch is formed as an integral part of the frame. This can prove to be quite costly, since the glass in the fireplace doors must be cut with an arcuate upper edge, rather than using rectangular pieces of glass of standard dimensions. Various shapes can be provided for the arch insert, and the inserts can easily be changed. This permits the owner of the fireplace enclosure to vary the appearance of the enclosure, at minimal cost.
OBJECTS OF THE INVENTION
Accordingly, it is a general object of this invention to provide a novel fireplace enclosure.
It is another object of this invention to provide a fireplace enclosure consisting of glass doors and a fireplace screen rigidly supported exteriorly of the glass doors.
It is a further object of this invention to provide a fireplace screen supported in a fixed position in front of a fireplace, with at least one pivotable panel in the central portion thereof.
It is yet another object of this invention to provide a fireplace enclosure with a removable arch mounted in the frame thereof.
SUMMARY OF THE INVENTION
These and other objects of the invention are accomplished by providing a fireplace enclosure comprising a plurality of glass panels and a plurality of screen panels, with the screen panels being positioned exteriorly of the glass panels. The glass panels are maintained within a frame which is integrally connected to the screen panels. At least one of the screen panels is pivotable to an open position, which permits access to the glass doors, and into the fireplace. The glass doors are also movable relative to the frame, to permit access to the fireplace. A latching mechanism maintains the screen panels in a closed position, which prevents ready access to the fireplace.
DESCRIPTION OF THE DRAWINGS
Other objects and many of the attendant advantages of this invention will become readily appreciated as the same becomes better understood by reference to the following detailed description, when considered in connection with the accompanying drawings, wherein:
FIG. 1 is a front elevational view of the fireplace enclosure of this invention, in its closed condition;
FIG. 2 is an exploded perspective view showing the elements of the fireplace enclosure;
FIG. 3 is a front elevational view, partially broken away and partially in section, showing the latching mechanism of the screen assembly of this invention;
FIG. 4 is a sectional view taken along the line 4--4 of FIG. 3;
FIG. 5 is a sectional view taken along the line 5--5 of FIG. 3;
FIG. 6 is a sectional view taken along the line 6--6 of FIG. 3;
FIG. 7 is an enlarged sectional view taken along the line 7--7 of FIG. 1;
FIG. 8 is an enlarged sectional view taken along the line 8--8 of FIG. 2;
FIG. 9 is an enlarged sectional view taken along the line 9--9 of FIG. 2;
FIG. 10 is an exploded perspective view showing the elements for securing the screen to the frame for the glass panels; and,
FIG. 11 is an exploded perspective view showing the arch and frame for the glass panels.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now in greater detail to the various figures of the drawings, wherein like reference characters refer to like parts, a fireplace enclosure embodying the present invention is generally shown at 20 in FIG. 1. As seen in FIG. 2, enclosure 20 basically comprises a frame 22, having a plurality of glass doors or panels 24, a screen assembly 26, a support frame 28 and an arch 30.
Frame 22 is a conventional frame used for fireplace doors, and includes vertical legs 32 and a top member 34. The legs and top member are hollow, and can be formed from a decorative metal, such as brass. The outer glass panels 24 are pivotally secured to legs 32, and the inner glass panels 24 are hinged to their adjacent outer panels. Handles 36 are mounted on the tops of inner panels 24.
The glass doors 24 are aligned, as shown in full line in FIG. 2, when the opening to the fireplace is to be closed. The doors are maintained in the aligned position by any conventional means, such as spring clips or magnetic plates. When it is desired to gain access to the fireplace, such as when filling the fireplace and igniting the fire, or when the fire is in active combustion, the doors 24 are pivoted around their respective hinges, as indicated at 24' in FIG. 2. The opening and closing of the doors is conventional in the art, as is the general structure of the enclosure containing the doors.
With the doors in their aligned position, closing the fireplace, the fire can still burn. In order to enable sufficient air to enter the fireplace, to support combustion, metal grills 38 are provided at the top and bottom of frame 22. The grills have openings, through which air from the room passes. Frame 22 includes bars 40 positioned at the bottom of the top grill 38 and at the top of the bottom grill 38.
Referring to FIG. it is seen that a pair of spring clips 42 is secured to the inner surface of upper bar 40. When it is desired to have an arch in the upper surface of the door frame, arch plate 30 is slid between the spring clips 42 and the upper bar 40, as indicated at 30' in FIG. 11. The arch 30 is formed from a flat sheet of metal, which can be the same metal as the door frame. Thus, if the door frame is formed from brass, the arch plate 30 can also be formed from brass, to give a unitary appearance to the frame. With the frame 22 in place, the arch plate 30 can easily be slid into place from the exterior of the fireplace, when the doors 24 are open. The plate 30 can be formed in any desired shape, and can inexpensively provide an arch at the top of the frame, without the necessity of designing a custom-shaped frame. The arch is always visible through the glass doors 24.
The glass doors can be formed from any heat-resistant glass, as is conventional in the art. Tempered safety glass is preferred. The handles 36 facilitate the opening and closing of the glass doors.
Referring again to FIG. 2, it is seen that support frame 28 is in the shape of a trapezoid, and includes a rear leg 44, a front leg 46 that is parallel to rear leg 44, and side legs 50. Legs 44, 46 and 50 lie in a horizontal plane. Rear leg 44 is U-shaped, and open at the top, and legs 46 and 50 are L-shaped (see also FIG. 7). Small U-shaped channels 52 are mounted on legs 50, adjacent rear leg 44 (see also FIG. 9). Mounting assemblies 54 are secured at the intersections of legs 46 and 50 (see also FIG. 7). Mounted in the center of leg 46 is a small L-shaped bracket 56 (see also FIG. 4).
In assembling the enclosure of this invention, the frame 28 is placed on the hearth in front of the fireplace. Frame 22 is then inserted in U-shaped leg 44 of frame 28. The frame 22 can be dimensioned to fit within the fireplace opening, or to be slightly greater than the fireplace opening, so that it can be mounted against the face of the wall adjacent the opening. The frame 22 is then secured in place, utilizing any conventional method of securement for frames used with fireplaces, such as bolting the frame in place.
The screen 26 is supported on frame 28, and is secured to frame 22. The screen comprises a pair of side panels 58 and a pair of center panels 60. Each side panel includes a pair of vertical tubular members 62 and an arcuate tubular member 64 connecting the two members 62. A decorative handle 66 is secured to the top of each arcuate member 64. A horizontal tubular member 68 connects the bottoms of members 62.
Center screen panels 60 are similar in structure, size and appearance to end panels 58. The center panels include vertical tubular members 70, arcuate tubular member 72 and a lower horizontal tubular member 74. A wire screen 76 is mounted in each set of tubular members. Decorative balls 78 are secured on the tops of the outermost tubular members 68 and finials 80 are positioned between adjacent pairs of panels 58 and 60. The tubular members, decorative balls and finials of the screen panels are preferably formed from a decorative metal, such as brass or chrome-plated steel.
The end screen panels 58 are rigidly mounted in frame 28, and are secured to frame 22. The manner of securement is best seen in FIG. 10. As seen in FIG. 10, the threaded end 82 of a shaft 96 (FIG. 9) mounted within tubular member 62 projects through an opening in cap 84 of the tubular member. A clip 86, having an opening 88, is placed over threaded end 82. The clip is secured in place by decorative ball 78, which is threadedly secured on end 82.
The clip 86 includes a pair of legs 90 separated by slot 92. The legs 90 are placed against the side edge of top member 34 of frame 22, and a screw 94 is passed through slot 92, and is threadedly secured in top member 34. This secures the side panels 58 to the frame 22.
Referring now to FIG. 9, shaft 96, the top of which is threaded, as shown at 82 in FIG. 10, is received in U-shaped channel 52. A shaft 98 is welded to, and projects horizontally from, shaft 96. Shaft 96 is mounted within decorative tubular member 62. A vertical shaft similar to shaft 96 is welded to the other end of shaft 98, and the two vertical shafts are joined by an arcuate shaft, having the same shape as top tubular member 64. Wire screen 76 is secured on the framework formed by the vertical shafts, the horizontal shaft 98 and the arcuate top shaft. The framework is covered by the tubular members. The tubular members are slotted to permit the screen to pass therethrough. However, the tubular members give the screen panels their decorative appearance, such as that shown in FIGS. 1 and 2.
The manner of securing the screen assembly 26 to the frame 28 is best seen in FIGS. 2, 7 and 8. As seen in FIGS. 7 and 8, the mounting assembly 54 comprises a plate 100 that is welded at the intersection of legs 46 and 50. There are a pair of plates, with one being positioned at each intersection. The plates are welded to the top of the horizontal portion of each leg.
A bolt 102 (FIGS. 4 and 7) is threadedly secured in plate 100. The bolt serves the function of leveling the support frame 28 on the hearth. Thus, when the hearth is a stone hearth, its top surface is not smooth, and the bolts 102 compensate for any irregularities in the surface.
A horizontal bar 104 (FIGS. 7 and 8) is mounted on the upper surface of plate 100, and a vertically extending bar 106 is welded on plate 100, and secures horizontal bar 104 in place. A nut 108 (FIGS. 4, 7 and 8) is welded to the top of plate 100.
A rod 110 (see FIG. 2) is threadedly secured in nut 108, and extends vertically upwardly therefrom. A plate 112 (FIGS. 2 and 7) is positioned at the top of rod 110. Plate 112 includes an elongated slot 114 adjacent one end thereof. A pin 116 is mounted in the underside of plate 112, and is positioned adjacent the end opposite slot 114.
A shaft 118 projects vertically upward, and is parallel to shaft 96 (FIG. 9) of screen panel 58. Shaft 228 is welded to shaft 98, and forms the other vertical shaft for forming the frame to hold wire screen 76. The slot in decorative tube 68, through which the screen 76 passes, is shown at 120 in FIG. 7. Similar slots are provided in the other decorative tube members, for the same purpose.
A tab 122 is welded to shaft 118 (FIGS. 7 and 8). As seen in FIG. 8, the bottom of shaft 118 is received in a circular opening formed in plate 104. Tubular member 62 surrounds shaft 118, and is slotted to accommodate the screen 76 and its supporting frame. A slot is also provided in tubular member 62 to accommodate tab 122.
In assembling the enclosure of this invention, the screen assembly 26 is secured to the frame 28 by first inserting the rods 110 in their respective nuts 108, and threadedly securing them in place. The screen assembly 26 is then placed on the frame 28 and the pin of plate 112 is inserted in an opening in tab 122. The plate 112 is placed on the top of rod 110 (FIG. 8) and is threadedly secured in place by bolt 124 and associated washer 126. As seen in FIG. 7, the top of bolt 124 includes a hexagonal recess 128, to receive a wrench for tightening the bolt in place. With the bolt secured in place on the top of each rod 110, the screen assembly is rigidly linked to the frame 28. Through the use of clips 86 (FIG. 10) and associated screws 94, the screen assembly is also rigidly connected to the frame for the glass doors. Accordingly, the frame 28, glass door frame 22 and screen assembly 26 form an integral unit. If the frame 22 is to be mounted within the fireplace opening, the screws 94 are inserted through the clip prior to the mounting of the door frame. Alternatively, if the door frame will be mounted against the front wall adjacent the fireplace opening, then the screws 94 can be inserted after the door frame 22 is secured in place.
As will be described in further detail hereinafter, each pair of adjacent screen panels has a square rod 130 (FIG. 7) positioned therebetween. The rod 130 positioned between a side panel 58 and a center panel 60 is received in an opening in plate 104. A vertical shaft 132 of screen panel 60 is shown in cross section in FIG. 7. Shaft 132 is similar to shaft 96 (FIG. 9) and forms part of the framework for holding the screen in screen panel 60. The screen in each of the panels is held in place by identical framing.
The screen panels 60 are maintained in the position shown in FIGS. 1 and 2 whenever the fire is actively burning or whenever the fireplace is not in use. When access is required to the fireplace, such as for cleaning, igniting the fire or adding wood, the panels 60 are swung outwardly, around their left and right edges, respectively, in the direction of the arrows shown at 134 in FIG. 2. The mechanism for maintaining the screen panels in the position shown in FIGS. 1 and 2, and for permitting the panels to be swung outwardly in the direction of arrows 134, is shown in FIGS. 3, 4, 5 and 6.
The securing mechanism includes aforementioned L-shaped bracket 56 (FIG. 4). The bracket is maintained in place by a bar 136 (FIGS. 4 and 5) that is welded to the vertical portion of front leg 46. A clip 138 is mounted on the vertical portion of L-shaped bracket 56. The clip includes a rear leg 140, a bridging section 142, a front leg 144 and a flange 146. The clip is secured to bracket 56 by rivet 148. The clip is formed from spring steel, and frictionally and resiliently engages the bottom of left screen panel 60, as viewed in FIG. 1, as will be explained with reference to FIG. 5.
Referring to FIGS. 3 and 5, it is seen that left screen panel 60 includes a vertically extending shaft 150. Secured on the bottom of shaft 150, as by welding, is a plate 152. Plate 152 includes an opening through which square rod 154, which is similar to square rod 130 (FIG. 7), passes. The end of plate 152, opposite shaft 150, is notched to form a hook 156.
Referring now to FIG. 3, it is seen that right screen section 60 includes a vertical shaft 158 and a horizontal shaft 160 connected thereto. Shafts 158 and 160 form a part of the frame for securing the wire screen 76 in place, as previously described. The shafts holding the screen in place are covered by the decorative tubular members 70, 72 and 74. Square rod 154 is positioned between screen sections 60, and has a threaded upper end 162. Finial 80 is threadedly secured on square rod 154.
The top of shaft 150 passes through the decorative cap 84 on tubular member 70 and has a flange 164 (FIGS. 3 and 6). Flange 164 has a square opening therein, through which square rod 154 passes.
A cover 166 (see also FIG. 1) is positioned beneath finial 80. Covers having similar outer appearances are positioned beneath the other finials 80. The covers are formed from a decorative metal, such as brass, and are formed from the same metal as the tubular members of the screen panels. Cover 166 is secured to square rod 154 by pin 168. As seen in FIGS. 3 and 4, the cover 166 has a recess in its undersurface to permit it to overlie and receive flange 164. There is a second recess which permits the end cap 170 on shaft 158 to be received within the cover. The end cap is also formed from a decorative metal, which is the same as the cap 84 and the tubular members of the screen panel.
A lock 172 is mounted against the bottom of cover 166 by screw 174. Lock 172 includes a plate 176 and a dependent flange 178. A slot 180 is formed in plate 176, and the lock 172 is movable along the slot. The lock is held in place by the head of screw 174, which is larger than the width of the slot. A pin 182 is secured in square rod 154, and projects outwardly therefrom.
The engagement of the bottom of square rod 154 in the channel formed by bracket 56 and bar 136 is shown in FIG. 4. Any attempt to pivot the screen sections outwardly, in the direction of arrows 134 (FIG. 2) is prevented by the engagement of the rod with bar 136. The rod 154 is movable vertically upward, to lift its bottom above the upper edge of bar 136. The vertical movement of the rod is accomplished by lifting finial 80, which is threadedly secured to the rod. When the finial is lifted, it will also lift cover 166, which is secured to rod 154 by pin 168. However, upward movement is prevented by the engagement of the upper face of plate 176 With flange 164. Thus, left screen panel 60 is immovable vertically and, accordingly, vertical contact with the underside of flange 164 prevents any further upward movement. So long as rod 154 cannot move upwardly, neither panel 60 can be pivoted. Thus, since plate 152 is secured to shaft 150 (FIG. 5), and since the rod 154 passes through the plate, left panel 60 is immovable. Similarly, any attempt to pivot right panel 60 is prevented by the engagement of shaft 158 with hook 156 (FIG. 5).
When it is desired to pivot the screen panels 60 outwardly, flange 178 is pulled to the right, from the position shown in FIG. 4. This permits the plate 176 to move to the right, along slot 80. This frees the lock formed by the abutment of plate 176 against the underside of flange 164. At this point, the finial 80 can be raised, which will raise rod 154 along with it. The upward movement of the rod 154 is stopped by the abutment of pin 182 against the underside of flange 164, as shown in phantom at 182' in FIG. 4. The upward position of finial 80 is indicated at 80' in FIG. 4, and the upward position of cover 166 is indicated at 166'. Similarly, lock 172 is raised along with cover 166, and its retracted and upper position is indicated at 172' in FIG. 4.
With the finial in its raised position, the bottom of rod 154 is at a position that is higher than the upper edge of bar 136. At this point, the left screen panel can be pivoted outwardly, in the direction of arrow 134 to any desired open position. The pivoting takes place around shaft 132 (FIG. 7). In this connection, the lower edge of the screen panels is positioned above the upper edge of leg 46. In the pivoting of the left screen panel 60, the finial 80 and its associated cover 166 and rod 154, move with the left panel.
With the left panel moved out of the way, the hook 156 (FIG. 5) no longer engages the bottom of rod 158 Accordingly, right screen panel 60 is now free to rotate in the direction of arrow 134. The rotation is about a shaft identical to shaft 132, but being placed on the right side of the right panel 60.
The rotation of the left screen panel 60 around its associated shaft 132 will now be described in further detail, it being understood that there is identical structure for the counterpart shaft of right screen 60. The bottom of shaft 132 is rotatable in a socket formed in horizontal bar 104 (FIG. 7). The top of shaft 132 is rotatable in a socket formed in cover 166 under finial 80 (FIG. 1). In this connection, the outer finials 80 are supported on a square rod 130 (FIG. 7), which is secured in bar 104. A cover 166 is placed over the top of the bar and the finial 80 is threadedly secured over the cover, in the nature of the structure shown in FIG. 3. The cover 166 has two sockets, with one socket receiving the top of shaft 118 and the other socket receiving the top of shaft 132 (FIG. 7). Accordingly, screen panels 58 and 60 are rotatable relative to the square rod 130, which is rigidly fixed in place. Having the panels 58 rotatable relative to panels 60 permits the folding of the panels 58 onto panels 60, for shipment and storage. When the enclosure is assembled, the panels 58 are no longer rotatable, since they are held in place relative to the frame 28 by the securement of the clips 86 to frame 22 (FIG. 10).
When the panels 60 are pivoted outwardly, access can be gained to the fireplace, after the glass panels are pivoted to the position shown at 24' in FIG. 2. When it is no longer necessary to have access to the fireplace, the screen panels 60 are rotated back to the positions shown in FIGS. 1 and 2. In rotating the panels back to their closed positions, the right hand panel 60 is first rotated in a direction opposite the direction of arrow 134 in FIG. 2, to a position just prior to contacting the vertical leg of bracket 56 (FIGS. 4 and 5). Thereafter, the left panel 60 is rotated in a direction opposite that shown by arrow 134, until its bottom plate 152 abuts the vertical leg 144 of clip 138 (FIG. 4). Since the clip is formed from a spring metal, the flange 146 frictionally and resiliently engages plate 152, and holds it in place. At the same time, the hooked end 156 of plate 152 engages shaft 158, and holds it in place. Accordingly, the right screen panel 60 is no longer rotatable outwardly, since rotation is prevented by the hook 156.
With the screen panels 60 in place, the finials 80 are pushed downwardly, thereby having the right recess in the underside of cover 166 engage the top of shaft 158 (FIG. 3). Thereafter, the lock 172 is moved inwardly, to the position shown in full line in FIG. 4, and this prevents the raising of the finial and its associated rod 154. This securely locks the screen panels in a closed position.
Although the enclosure of this invention has been described as being used with, and secured to, a glass fireplace door, it is to be understood that the invention can be used without having the glass door, or without being secured to the glass door. In this connection, if it is desired to have a rigidly secured fireplace screen, rather than having one which must be lifted and folded for placement away from the fireplace, when access to the fireplace is needed, this can be accomplished by utilizing the frame 28 and the screen panels. When used in this manner, the screen panels 58 can be secured to the wall surrounding the fireplace opening or the wall within the fireplace opening, through the use of the clips 86 and screws 94, which are screwed into the wall, rather than the frame for the glass panels. Alternatively, the outermost ends of the panels 58 can be secured to rods similar to rods 110, using a connection similar to that obtained by tabs 122, to obtain a rigid securement.
One of the advantages of the enclosure of this invention is the fact that the screen panels are held rigidly in place, which prevents any access to the fire by a child. In the prior art, where glass doors are used, and are open when there is an active fire, the screen which is used to prevent sparks from flying into the room is in the nature of a drape or curtain positioned behind the frame for the glass panels. A young child could inadvertently fall into the fire if he tripped while playing near the fireplace. The rigid screen structure of this invention prevents that from happening. The screen panels are held rigidly in place, and cannot be knocked over by a child's falling into them. Since the lock 172 is placed on the rear side of the panels, a person would have to be relatively tall to be able to reach over and gain access to the lock, and thereafter open it. A young child would not have sufficient height or dexterity to accomplish this and, accordingly, the enclosure of this invention provides a far safer structure than was previously available.
Without further elaboration, the foregoing will so fully illustrate this invention that others may, by applying current or future knowledge, readily adapt the same for use under various conditions of service. | A fireplace enclosure comprising a plurality of glass panels and a plurality of screen panels, with the screen panels being positioned exteriorly of the glass panels. The glass panels are maintained within a frame which is integrally connected to the screen panels. At least one of the screen panels is pivotable to an open position, which permits access to the glass doors, and into the fireplace. The glass doors are also movable relative to the frame, to permit access to the fireplace. A latching mechanism maintains the screen panels in a closed position, which prevents ready access to the fireplace. A removable arch plate is releasably secured to the interior of the frame for the glass panels, and provides a decorative arch, which is seen through the glass panels. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is a continuation application of and claims priority under 35 U.S.C. §120 to U.S. patent application Ser. No. 10/564,586 (US 2006/0163507) filed 13 Jan. 2006 now U.S. Pat. No. 8,074,966, which claims priority to PCT/EP2004/007949 filed 16 Jul. 2004 and to German Application No. 203 11 032.3 filed 17 Jul. 2003, all of which are incorporated herein by reference in their entirety for all purposes.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable.
BACKGROUND OF THE INVENTION
The invention relates to a drive device for the adjustment of an actuating element of a throttle, valve, connecting device (coiled connector) or a dosage feed device or similar item of equipment, in particular in the mining of mineral oil or natural gas, with at least one spindle drive movably connected to the actuating element and a gear unit arranged between the spindle drive and at least one motor.
Such a drive device is known from DE 200 18 561. The prior device is used for the adjustment of a shut-off element as actuating element in a blow-out valve arrangement (blow-out preventer, BOP), whereby a connecting channel in the BOP can be closed by the shut-off element. The shut-off element is movably connected to the spindle drive. Through this spindle drive a rotational movement produced by the motor is converted into a linear movement for the adjustment of the actuating element. In addition, a worm gear is arranged as a further gear unit between the motor and the spindle drive.
This drive device and especially due to the application of the worm gear is characterised characterised by a self-locking mechanism and also otherwise can be well employed for the adjustment of various actuating elements. Such a drive device exhibits substantial advantages over other devices without worm gear. However, generally the efficiency is restricted to less than 50% and also the self-locking mechanism is only produced at a high transmission ratio. In addition, relatively high axial forces sometimes occur with worm gears.
SUMMARY OF THE PREFERRED EMBODIMENTS
The object of the invention is to improve a drive device of the type mentioned at the beginning such that with a simple and compact construction an increase in the efficiency for reduction of the dissipated losses is possible, at the same time especially avoiding high axial forces and needing only a low number of components.
This object is solved by the features of Claim 1 .
Through the application of an especially self-locking spur gear as part of the gear unit a very compact construction is produced and also the efficiency is increased to over 50% through the use of such a spur gear. In addition, at least only reduced axial forces occur due to the appropriate arrangement of the spur gear.
The spur gear here in this respect is assigned to the motor and is appropriately movably connected to it, whereby the gear unit furthermore exhibits a reduction gear which is assigned to the spindle drive and is movably connected to it. One such reduction gear is especially a so-called harmonic drive. Due to this further reduction gear the rotational speed of the motor can be reduced so far in a simple manner that even extremely slight adjustments to the corresponding actuating element are possible and accurately controllable. Due to the arrangement of spindle drive, reduction gear, spur gear and motor, a short, compact construction is also produced, requiring little space.
To obtain a spindle drive which features high loadability with a long service life and simultaneously very good mechanical properties, such a spindle drive can be a roller or ball screw drive with spindle nut and threaded spindle. In particular a suitable roller screw drive can be regarded as advantageous when applied in the mining of mineral oil or natural gas at inaccessible places, because it operates essentially free of maintenance.
Depending on the actuating element, its adjustment by different parts of the spindle drive spindle drive is of advantage. For example, the spindle nut can be supported rotationally, but axially immovable in the device housing. In this way the threaded spindle is moved accordingly in an axial or linear direction when the spindle nut rotates and can consequently with an appropriate connection to the actuating element also move the actuating element linearly. It is also possible to support the spindle nut rotationally rigidly, but axially movable in the device housing. In this respect the threaded spindle can rotate, but is arranged axially immovable. Through the appropriate coupling of the spindle nut and the actuating element, the movement of the spindle nut is then transferred to the actuating element.
A simple assignment of spindle drive and reduction gear can be seen when the spindle nut or threaded spindle is rotationally rigidly joined to the reduction gear. Accordingly, the rotation of the reduction gear on its output side is transferred to the spindle nut or threaded spindle. This can also occur by an essentially direct connection to the spindle nut or to the threaded spindle from the side of the reduction gear.
If the reduction gear is a so-called harmonic drive, it generally exhibits three components. The first component is a flexible, cup-shaped toothed sleeve. The second component is a fixed ring element and the third a wave generator. The toothed sleeve is in partial engagement with its outer teeth engaging suitable inner teeth on the ring element. The wave generator is arranged inside the toothed sleeve and through its rotation the flexible toothed sleeve is extended so far at two opposite points that its outer teeth engage the inner teeth of the ring element. Generally, the toothed sleeve exhibits two teeth less than the ring element so that with one rotation the relative movement between the toothed sleeve and the ring element amounts to two teeth. Such a harmonic drive is capable of extreme loads and requires little maintenance.
The transfer of the rotational movement of the harmonic drive to the spindle drive can for example occur in that the toothed sleeve is rotationally rigidly joined to the spindle nut or the threaded spindle.
There is the possibility of directly connecting the toothed sleeve and an appropriate part of the spindle drive. However, to design the drive device in a more variable manner and where applicable to construct it in a modular way, a rotationally supported but axially immovable connecting sleeve can be arranged between the toothed sleeve and the spindle drive. This connecting sleeve can be used at one end for the connection to the spindle nut or to the threaded spindle and at the other end for connection to the toothed sleeve.
In order to obtain a secure connection between the threaded spindle and the toothed sleeve or connecting sleeve, the threaded spindle can be rotationally rigidly inserted with one drive end in a retention hole of the connecting sleeve. Various possibilities are conceivable to fix the drive end in the retention hole. One possibility, which also permits the transfer of large forces, is the formation of splines between the threaded spindle and the inner side of the retention hole.
With a simple embodiment the spur gear can be helically toothed.
In order to retain the advantages of the spur gear, such as high efficiency, low reduction, simple construction, parallel axes, etc. and to also simply realise the self-locking or self-braking, the spur gear is formed as a double helical gear. Such a double helical gear exhibits double helical teeth and an approximate screw-shaped appearance. The self-braking effect can be varied depending on the helix angle of the double helical gear and its various helical gears. This applies analogously to the self-braking, whereby self-braking is in principle regarded as being on the drive side and self-locking on the driven side and with appropriate direction of rotation. Particularly, for devices in the mining of mineral oil and natural gas such self-braking and self-locking gears are of advantage, because separate holding/braking devices can be omitted.
Such helically toothed spur gears or also double helical gears feature small dimensions, a long service life, high reliability in operation and stable transmission. Furthermore, due to the parallel arrangement of the individual helical gears, a compact construction is produced. The gears can be easily adapted to different application conditions and also feature low noise levels.
An appropriate spur gear exhibits at least two helical gear wheels. According to the invention, the reduction gear and in particular its wave generator can be movably connected to a first spiral toothed gear wheel and the motor to a second spiral toothed gear wheel of the spur gear. It is again pointed out that efficiency for such spur gears and in particular for double helical gears is greater than 65% and can even amount to 80% or more. In addition, with such gears a linear contact of the tooth faces arises instead of a point contact as with a worm gear.
In order to transfer the drive power of the motor on the shortest and easiest path into the spur gear, the second spiral toothed gear wheel can be arranged on a drive shaft of the motor.
In order to construct the drive device redundantly or to design it also for higher powers, two or more motors can be assigned to the drive shaft. Here, there is the possibility that generally the actuating element can be adjusted by the operation of only one motor, so that the other motor or motors are only employed when that one motor fails. Similarly, there is the possibility of attaining an appropriate drive power through the application of a large number of relatively small motors.
There is also the possibility that two or more drive shafts each with at least one motor are supported essentially parallel to the threaded spindle in the device housing. This also provides redundancy or an increase in the power of the drive device. Of course, here two or more motors on each of the drive shafts are also possible. If motors on different drive shafts are employed simultaneously, then they are synchronised, whereby the synchronisation can occur electronically as well as mechanically, for example, directly between the drive shafts. Preferably two drive shafts can be arranged diametrically opposed in the device housing. However, arrangements are also possible in which the drive shafts are arranged offset from one another by certain angles in the circumferential direction of the device housing. Examples of such angles are 45°, 90°, 270° and also other intermediate values between 0° and 360°. This applies analogously to the arrangement of more than two drive shafts.
In order to connect each of the drive shafts directly to the spur gear, a second spiral toothed gear wheel, which engages the first spiral toothed gear wheel of the spur gear, can be arranged on each drive shaft.
In order to design a drive device independently of complicated feeds for compressed air or any other pressure medium, the motor can be an electric motor. Consequently, there is the possibility of electrifying the complete drive device as well as its control and monitoring system. One example of such an electric motor is a servomotor or an asynchronous motor.
With regard to the spur gear there is, of course, also the possibility that the various second spiral toothed gear wheels engage in each case different first spiral toothed gear wheels, whereby these first spiral toothed gear wheels, for example, can all be appropriately connected to the spindle drive. It has already been pointed out that the teeth of the spur gear can be so-called helical teeth, exhibiting a certain helix angle. Due to the helical orientation of the teeth, there is the possibility of reducing the normal number of teeth significantly. According to the invention, a helix angle for example of the first and/or the second spiral toothed gear wheel can be in the range from 50° to about 90° and particularly in the range from 65° to 85°. With an appropriately high helix angle the number of teeth can be reduced to one.
In contrast, in particular, to a worm gear in which self-locking is only provided for transmission ratios down to a certain smallest transmission ratio, with a spur gear transmission ratios lower than 25 and lower than 1 can be realised without having to dispense with a self-locking or self-braking mechanism. For the simple construction of the spur gear the first and second spiral toothed gear wheels exhibit 1 to 10, preferably 1 to 7 and especially preferred 1 to 4 teeth, whereby reduction ratios in the range 1 to 5 up to 1 to 100 on the drive device according to the invention are generally sought.
In order to proceed further with the modular construction of the drive device according to the invention and at the same time to be able to simply fit and remove certain parts, the connecting sleeve can be releasably connected at its end facing away from the spindle drive to the toothed sleeve.
When the spindle nut is the axially movable part of the spindle drive, there is the possibility of coupling the actuating element directly to the threaded nut, so that the actuating element can also be moved linearly. Another possibility is to provide another gear, which converts the linear movement of the spindle nut into a rotational movement, between the actuating element and the spindle nut. This can occur, for example, in a simple manner in that at least one engaging element protrudes from the threaded spindle or the spindle nut essentially radially outwards and engages in slots of a fixed sleeve and a rotating sleeve, whereby a first slot extends essentially in the axial direction and a second slot extends at an acute angle to the first slot. If, for example, the first slot is in the fixed sleeve, the rotating sleeve rotates when the corresponding part of the spindle drive is moved in the axial direction by the appropriate engagement of the engaging element in both slots. In this way the conversion of the linear movement into the rotational movement is determined by the slope of the corresponding second slot in the rotating sleeve. Here it is possible, for example, that the corresponding alignment of the slots changes so that in a first slot section only a slight rotation of the rotating sleeve occurs relative to the fixed sleeve. Consequently, an extremely fine rotation of the actuating element is possible, as is for example of advantage for throttles and the corresponding throttle elements. Once the throttle has then opened partially, the angle between the two slots can increase quickly so that the throttle is then completely opened very quickly. Further possibilities of the orientation of the two slots relative to one another are obvious.
As already stated, it can be favourable in this respect if the actuating element can be rotated together with the rotating sleeve.
There are various possibilities of monitoring the movement of the actuating element and of applying the monitored movement for the control of the drive device and therefore of the actuating element. With one embodiment a position sensor can be assigned to the axially movable part of the spindle drive. Of course, assignment of a position sensor and a rotating part of the spindle drive are also possible. In addition, an appropriate position sensor can also be assigned to another part of the drive device, from the movement of which the displacement of the actuating element can be determined.
In order to be able to accommodate a suitable position sensor in the device housing without this position sensor being disturbed by the other parts of the drive device, the position sensor can exhibit an essentially flat code carrier which is offset radially outwards with respect to the threaded spindle and arranged parallel to it. The code carrier also moves in the axial direction corresponding to the movement of the threaded spindle or spindle nut, so that this axial movement is directly acquired and the corresponding conclusions about the displacement of the actuating element can be drawn from it.
With a simple embodiment a dog can be arranged between the axially moving part of the spindle drive, in particular the engaging element and the code carrier. As previously explained, the engaging element is used for engaging the pair of slots so that with appropriate movement of the code carrier, conclusions can be drawn about the rotation of the rotating sleeve and therefore also about the displacement of the actuating element.
At this point it should be noted that such a code carrier of the position sensor can exhibit an appropriate position-specific pattern which passes by an appropriate scanning device of the position sensor when the code carrier moves. Through this passage of the pattern, accurate conclusions can be drawn about the displacement of the code carrier and therefore about the movement of the corresponding part of the spindle drive or of the actuating element.
For the further preferred design of the drive device and for increasing its variability a distance sleeve can be arranged in a motor hole of the device housing on a side, facing away from the second spiral toothed gear wheel, of the at least one motor. This distance sleeve can be removed where applicable to accommodate a second, third or more motors in the corresponding motor hole. Furthermore, the distance sleeve can also be used as further support for the drive shaft.
In order to adapt as applicable and, with regard to the motorization, to vary the drive device in a simple way to various circumstances and possibly also to various actuating elements, the device housing can be of modular construction. In this way there is the possibility that, for example, the gear unit, spindle drive and motors are accommodated in one part of the device housing, whereas in another part the actuating element is arranged. It may also be conceived as favourable that only the connecting sleeve, gear unit and motors are arranged in one housing part, whereas the spindle drive is arranged in another part of the housing and the actuating element is arranged in a further housing part. Of course, each of the housing parts exhibits an appropriate opening for the connection of the particularly moving devices arranged in each of the housing parts.
In addition, the device housing can be provided with various, diagonally running surfaces on its outer side which enable easy insertion by remote control of the complete drive device in, for example, a so-called tree on the sea bed.
Furthermore, due to the modular construction of the device housing, easy disassembly is provided, for example, to replace or maintain parts.
With the sideward parallel offset code carrier, in order to guide it in a simple manner within the device housing, the code carrier can be guided in a guide sleeve in the axial direction.
It is conceivable that with an embodiment of the drive device according to the invention the threaded spindle and the spindle nut are rotationally supported together in the device housing, but are axially immovable. In this way, for example, the rotation of the threaded spindle is converted directly into a rotation of the actuating element. The threaded nut is used in this connection as a support for the threaded spindle without it being axially displaced. Essentially here, only a corresponding rotation of the threaded nut occurs synchronously to the threaded spindle.
There is the possibility of displacing a valve element for more or less closing or opening the valve directly with a corresponding end of the threaded spindle. In this case however the modular character of the drive device is restricted, because the corresponding end of the threaded spindle is matched to the special valve element or similar component. It would be more convenient if the threaded spindle was releasably connected at its end facing away from the spindle nut to a sliding rod of the actuating element. In this way the sliding rod can be formed in the same way, also for different devices, only at its end facing the threaded spindle. Consequently, sliding rods assigned to different actuating elements can be connected to a threaded spindle with the same construction in each case.
If there is adequate space available and in particular when the threaded spindle is axially movable, the code carrier of the position sensor can at least be inserted with one end section into an inner hole of the threaded spindle and be releasably connected there for common movement of the code carrier and threaded spindle in the axial direction. In this respect the code carrier is accordingly also brought out through the following connecting sleeve, reduction gear and the spur gear so that an appropriate scanning of the code carrier only takes place outside of the gear unit. Consequently, the corresponding position sensor is easier to contact electrically and, where applicable, easier to replace.
There is also the possibility that the spindle nut and connecting sleeve are connected together releasably. In this way the rotation of the connecting sleeve is directly transferred to the spindle nut, whereby the spindle nut is here immovable in the axial direction due to the corresponding support of the connecting sleeve.
BRIEF DESCRIPTION OF THE DRAWINGS
Advantageous embodiments of the invention are explained in more detail in the following based on the figures enclosed in the drawings.
The following are shown:
FIG. 1 a longitudinal section through a first embodiment of a drive device;
FIG. 2 a section along the line II-II in FIG. 1 ;
FIG. 3 an enlarged view of a detail “X” in FIG. 1 ;
FIG. 4 a longitudinal section through a second embodiment of a drive device according to the invention;
FIG. 5 a section along the line V-V in FIG. 4 ;
FIG. 6 a longitudinal section through a third embodiment of the drive device according to the invention, and
FIG. 7 a longitudinal section through another embodiment of the drive device according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
With all embodiments according to the invention, the same reference symbols refer in each case to the same parts and are sometimes only discussed in connection with one of the figures. In part, reference symbols used in one or some of the figures are omitted in the other figures for reasons of clarity.
In all embodiments the arrangement of the various parts of the drive device 1 is common. These parts comprise in particular an appropriate actuating element 2 for the corresponding device, such as valve, throttle, dosage feed device or similar equipment, which are particularly employed in the mining of mineral oil and natural gas. Apart from the actuating element 2 which is formed differently according to the device, each drive device 1 exhibits a spindle drive 3 , a gear unit 6 movably connected to it and consisting of a reduction gear 7 and spur gear 9 as well as the motor or motors 4 , 5 driving the spur gear.
With the embodiment according to FIG. 1 , the actuating element 2 exhibits a sliding rod 40 which is connected at one of its ends to a holed sleeve 43 . At the free end of the holed sleeve 43 a number of holes 49 are formed in the sleeve, through which depending on the position of the holed sleeve 43 in the axial direction 38 more or less fluid flows from the inlet end 45 to the outlet end 46 according to the fluid flow 50 . In the illustrated position of the holed sleeve 43 all the holes 49 are closed so that no flow occurs through the outlet end 46 .
To prevent the holed sleeve 43 from rotating, it is rotationally rigidly connected to a circulation body 44 by means of a keyed shaft 47 . The circulation body is arranged in the device housing 42 . The various parts of the drive device 1 , such as the spindle drive 3 , gear unit 6 and motors 4 , 5 , are arranged inside the circulation body 44 .
The spindle drive 3 is formed as a recirculating roller spindle drive with an appropriate threaded spindle 11 and spindle nut 10 . The threaded spindle 11 is connected with its end 39 pointing away from the spindle nut 10 to the sliding rod 40 .
The spindle nut 10 is releasably attached to a connecting sleeve 15 by means of a number of threaded bolts, whereby the spindle nut 10 can rotate by means of a suitable rotational support of the connecting sleeve 15 , but is immovable in the axial direction.
The connecting sleeve 15 exhibits a retention hole 17 , refer also to FIG. 4 , in which the spindle nut 10 is partially inserted. In this retention hole 17 the threaded spindle 11 is also inserted depending on the axial displacement, whereby its drive end 16 located in the retention hole 17 is provided with an internal hole in which a code carrier 33 of a position sensor 32 is inserted. The code carrier 33 can be moved in the axial direction 38 together with the threaded spindle 11 .
A reduction gear 7 is connected as part of the gear unit 6 for the rotation of the connecting sleeve 15 to an end of the connecting sleeve 15 pointing away from the spindle nut 10 . The reduction gear 7 is formed as a so-called harmonic drive 8 . This exhibits a flexible toothed sleeve 12 which is at its closed end rotationally rigidly connected to the connecting sleeve 15 . The toothed sleeve 12 exhibits at its open end outer teeth which partially engage inner teeth of a fixed ring element 13 as another part of the harmonic drive 8 . Inside the toothed sleeve 12 a wave generator 14 is also arranged as part of the harmonic drive 8 in the region of the ring element 13 .
The harmonic drive 8 operates in a known manner in that the flexible toothed sleeve 12 is extended at two opposite points by the wave generator 14 such that its outer teeth engage the inner teeth of the ring element 13 . Generally, the toothed sleeve exhibits two teeth less than the ring element so that for one rotation the relative movement between the toothed sleeve and the ring element amounts to two teeth. The corresponding wave generator 14 is according to the invention rotationally rigidly connected to a first spiral toothed gear wheel 20 of a spur gear 9 as another part of the gear unit 6 . The first spiral toothed gear wheel 20 engages at least a second spiral toothed gear wheel 21 , whereby in a further embodiment the corresponding helical teeth 24 , refer also to FIG. 3 , of the spiral toothed gear wheels 20 , 21 can be formed such that a double helical gear 23 is produced. Such a helically toothed spur gear 9 is self-braking and self-locking. The helical teeth of the various spiral toothed gear wheels are formed by appropriate teeth which are arranged at an appropriate helix angle 25 , again refer to FIG. 3 .
For the first and/or second spiral toothed gear wheel the helix angle is 50° to approximately 90° and preferably 65° to 85°. Due to the spur gear a transmission ratio in the range between i=25 and i<1 is produced. Accordingly, the spiral toothed gear wheels exhibit 1 to 10, preferably 1 to 7 and especially preferred 1 to 4 teeth.
With the embodiments according to the figures, a second spiral toothed gear wheel 21 in each case externally engages the first spiral toothed gear wheel 20 . Of course two, three or more second spiral toothed gear wheels 21 can be arranged along the circumference of the first spiral toothed gear wheel 20 and can engage the first spiral toothed gear wheel 20 .
With the embodiment according to FIG. 1 the second spiral toothed gear wheel 21 is arranged on a drive shaft 22 which is offset radially outwards and extends parallel to the threaded spindle 11 . Transfer of the drive force from two electric motors 4 , 5 occurs on the drive shaft 22 .
There is the possibility that according to the arrangement of further second spiral toothed gear wheels also further drive shafts 22 can be accordingly arranged with motors 4 , 5 . These are then analogously distributed along the circumference of the first spiral toothed gear wheel 20 , whereby the corresponding drive shafts 22 are in each case arranged parallel to one another.
With the embodiment according to the invention of the drive device 1 the drive shaft 22 extends with its end facing away from the second spiral toothed gear wheel 21 to a distance sleeve 35 , whereby an appropriate end of the drive shaft 22 is rotationally supported in the distance sleeve 35 . There is the possibility of omitting this distance sleeve 35 , in that for example the drive shaft 22 is extended and is provided with further motors 4 , 5 in the region of the distance sleeve 35 .
The code carrier 33 of the position sensor 32 is passed through the first spiral toothed gear wheel 20 and the reduction gear 7 . The code carrier is inserted, with its end facing the threaded spindle 11 , in the same and fixed there. The code carrier 33 exhibits a position-specific pattern on its outer side, the said pattern being able to be scanned by a suitable scanning or sensor device of the position sensor 32 . This scanning produces an exact position determination of the code carrier 33 with displacement in the axial direction 38 , the said position displacement being convertible into a corresponding position displacement of the threaded spindle 11 , the sliding rod 40 and therefore the holed sleeve 43 . Consequently, the relevant position of the holed sleeve 43 and accordingly the arrangement of the holes 49 can be determined by the position sensor 32 , whereby the corresponding throttling of the actuating element 2 is determined with regard to the fluid flow 50 .
For the electrical supply of both the motors 4 , 5 and the position sensor 32 an electrical connection device 52 in the form of an electrical connector 48 is brought externally to the device housing 42 and attached there. The appropriate electrical supply cables are routed into the interior of the drive device 1 where they are connected to the appropriate units.
It is again pointed out that the corresponding parts of the drive device 1 —refer to the actuating element 2 , spindle drive 3 , motors 4 , 5 and gear unit 6 —are essentially similarly constructed and combined for all embodiments of the drive device. With the following embodiments only the differences to the embodiment according to FIG. 1 are explained.
In FIG. 2 a section along the line II-II from FIG. 1 is illustrated, whereby FIG. 1 corresponds to an appropriate section along the line I-I in FIG. 2 .
The circulation body 44 is circular shaped in cross-section, whereby the corresponding electrical connection devices or electrical connectors 48 are arranged at three equally spaced points in the circumferential direction. Centrally in the circulation body 44 the first spiral toothed gear wheel 20 is arranged which engages the second spiral toothed gear wheel 21 . Centrally in the first spiral toothed gear wheel 20 a sleeve-shaped end 68 of the position sensor 32 is inserted, refer also to FIG. 1 , whereby the code carrier 33 is located inside this sleeve-shaped end 68 .
Opposite the second spiral toothed gear wheel 21 an empty cavity 51 is arranged which can be used for the accommodation of a further second spiral toothed gear wheel 21 with appropriate drive shaft 22 and motors 4 , 5 and, where applicable, distance sleeve 35 . Further such empty cavities can be arranged at other points in the circumferential direction of the first spiral toothed gear wheel 20 .
In FIG. 3 an enlarged illustration of the detail “X” from FIG. 1 is shown, whereby this illustration corresponds to a side view from the radial direction of the second spiral toothed gear wheel 21 . This exhibits double arranged helical teeth 24 so that a double helical gear 23 is formed. An appropriate helix angle 25 for the helical teeth is between 50° and about 90° and preferably between 65° and 85°.
Analogously to the second spiral toothed gear wheel 21 , the first spiral toothed gear wheel 20 is formed with such a double helical tooth arrangement. There is also the possibility of only using one helical tooth arrangement.
FIG. 4 illustrates a section in the axial direction through a second embodiment of a drive device 1 .
The arrangement of the gear unit 6 and the motors 4 , 5 corresponds to that of FIG. 1 , refer to the explanations there.
A difference to the embodiment according to FIG. 1 is that the threaded spindle 11 is rotationally rigidly connected as part of the spindle drive 3 to the connecting sleeve 15 by means of splines 19 , but is fixed in the axial direction 38 . Accordingly, the drive end 16 of the threaded spindle 11 is inserted into the retention hole 17 of the connecting sleeve 15 and held rotationally rigidly on its inner side 18 by means of the splines 19 .
Along the threaded spindle 11 , the spindle nut 10 can be moved in the axial direction, whereby it is however arranged rotationally rigidly. The rotational rigidity is produced especially in that engaging elements 27 protrude radially outwards from the spindle nut 10 , the engaging elements engaging in diametrically opposite slots 28 of a fixed sleeve 30 . The slots 28 extend in the axial direction 38 and ensure the rotational rigidity of the spindle nut 10 due to the guidance of the engaging elements 27 . The appropriate engaging element 27 does not only engage the slot 28 of the fixed sleeve 30 , but also appropriate slots 29 of a rotating sleeve 31 . The slots 29 of the rotating sleeve 31 run diagonally to the slots 28 of the fixed sleeve 30 . In this respect the diagonal orientation in the longitudinal direction of the slots can vary so that for example first only a slight angle is present between the slots 28 , 29 so that only a slight relative rotation between the rotating sleeve 31 and the fixed sleeve 30 is produced even with a longer displacement of the spindle nut 10 in the axial direction 38 . Following that, the angle can enlarge so that then also with just a slight movement of the spindle nut 10 , a comparatively substantially large relative rotation between the rotating sleeve 31 and the fixed sleeve 30 occurs. Of course, different conversions of the appropriate axial movements of the spindle nut 10 into a rotational movement of the rotating sleeve 31 relative to the fixed sleeve 30 are possible by means of appropriate orientation of the slots 28 , 29 relative to one another.
The rotation of the rotating sleeve 31 is transferred by means of its attachment with appropriate threaded bolts to an intermediate ring 26 . This ring is connected rotationally rigidly by means of inserted pins to a rotary coupling sleeve 58 which in turn is rotationally rigidly connected to a first perforated screen 55 by means of appropriate inserted pins. By rotating the first perforated screen 55 relative to a second, stationary perforated screen 54 , an aperture opening of varying size is produced by the overlapping of appropriate openings in both perforated screens 54 , 55 . If the corresponding openings do not overlap, then no flow occurs through the perforated screen arrangement in the direction of flow 50 .
For determining the position of the spindle nut 10 and therefore also for the monitoring of the rotation of the first perforated screen 55 , the engaging element 27 exhibits at least on one side of the spindle nut 10 a dog 34 which protrudes further radially outwards. This dog 34 is connected to an essentially flat and rod-shaped code carrier 33 . Corresponding to FIG. 1 , this forms part of a position sensor 32 . Differing from the embodiment according to FIG. 1 , the position sensor 32 and code carrier 33 are offset radially outwards and arranged parallel to the threaded spindle 11 . Through the associated movement of the code carrier 33 with spindle nut 10 , an accurate position determination of the spindle nut 10 is provided by appropriate scanning of a position-specific pattern arranged on the code carrier. The position of the spindle nut 10 can be converted into an accurate rotated position of the first perforated screen 55 relative to the second perforated screen 54 .
Analogously as with the embodiment according to FIG. 1 , the spindle drive 3 according to FIG. 4 is a recirculating roller spindle drive and the spur gear 9 can be formed as a double helical gear 23 . Similarly analogously to the first embodiment, there is the possibility of arranging several drive shafts 22 with corresponding drive motors 4 , 5 and assigned second spiral toothed gear wheels 21 in the circumferential direction of the first spiral toothed gear wheel 20 .
FIG. 5 corresponds to a section along the line V-V from FIG. 4 , whereby FIG. 4 corresponds to a section along the line IV-IV according to FIG. 5 .
Essentially FIG. 5 corresponds to FIG. 2 , whereby however the second spiral toothed gear wheel 21 is not arranged to the side of the first spiral toothed gear wheel 20 , refer to FIG. 2 , but instead below it. The position sensor 32 is arranged diametrically opposed. There is the possibility of arranging further appropriate empty cavities 51 , refer to FIG. 2 , along the circumferential direction of the first spiral toothed gear wheel 20 for the accommodation of further drive shafts 22 and corresponding second spiral toothed gear wheels 21 .
Inside the first spiral toothed gear wheel 20 there is in accordance with the other arrangement of the position sensor 32 with the code carrier 33 no such code carrier 33 arranged, refer here instead to FIG. 2 .
FIG. 6 shows another embodiment of a drive device 1 according to the invention, which is essentially constructed analogously to the drive device 1 according to FIG. 1 . The differences essentially relate to the other application of the drive device 1 , i.e. the combination with another actuating element 2 , whereby similarly the corresponding parts of the drive device 1 are not integrated in a circulation body 44 according to FIG. 1 .
Instead the actuating element according to FIG. 6 exhibits a sliding rod 14 which is rotationally rigidly connected at its end facing away from the threaded spindle 11 to a pot holder 62 . The pot holder 62 is open at one end and a closing pot 61 is inserted in this open end. In the upper half according to FIG. 6 the closing pot is, as a maximum, pushed on to an appropriate holed sleeve 43 with holes 49 as a further part of the actuating element 2 . In the lower half according to FIG. 6 the closing pot 61 is pulled off the holed sleeve 43 as far as possible so that all the holes 49 let fluid pass according to the fluid flow 50 .
In order to prevent rotation of the pot holder 62 relative to the device housing 42 a keyed shaft 47 is arranged between them analogous to FIG. 1 .
It should be pointed out that with FIG. 6 also the same position sensor 32 as with FIG. 1 is used. This applies analogously also to the corresponding code carrier 33 and its arrangement within the drive device or its mounting on the threaded spindle 11 .
With regard to FIG. 6 is should be noted that here in particular the oblique roller bearings 63 of the connecting sleeve 15 have reference symbols which are however also used analogously with the other embodiments.
Furthermore, it should be noted that the device housing 42 , as also with the other embodiments, is of modular construction and with the steps on the outer surface, in particular with embodiments 4 and 6 , is used for the automatic insertion of the corresponding drive device 1 with the actuating element 2 in a so-called tree in the mining of mineral oil and natural gas. The arrangement is simplified by the various steps and diagonal surfaces on the outside of the device housing 42 so that insertion can also occur using a remotely controlled robot or similar equipment.
With the last embodiment according to FIG. 7 the arrangement of the corresponding parts of the drive device 1 in turn corresponds to that in FIG. 1 , refer particularly to the arrangement of the connecting sleeve 15 of the gear unit 6 and the motors 4 , 5 . Also with FIG. 7 a circulation body 44 is used about which the fluid flows according to the fluid flow 50 from the inlet end 45 in the direction of the outlet end 46 . In contrast to the embodiment according to FIG. 1 , another type of throttle element is used which is formed from two perforated screens 54 , 55 , refer here also to FIG. 4 . The first perforated screen 55 is supported rotationally and the second perforated screen 54 is supported rotationally rigidly inside the device housing 42 . The rotation of the first perforated screen 55 is transferred directly by rotation of the threaded spindle 11 of the spindle drive 3 . The threaded spindle 11 is employed analogously to the embodiment according to FIG. 4 in an appropriate retention hole 17 of the connecting sleeve 15 and is rotationally rigidly and axially immovably held there by splines 19 .
In contrast to the previous embodiments, with the embodiment according to FIG. 7 no displacement of a part of the spindle drive 3 occurs in the axial direction, because the spindle nut 10 can also rotate, but is supported immovably in the axial direction within the circulation body 44 . The corresponding support occurs by means of a bearing 66 arranged between two retention rings 64 , 65 .
The electrical supply of the corresponding units of the drive device 1 according to FIG. 7 occurs analogously to FIG. 1 . One difference between the embodiments according to FIGS. 1 and 7 arises in the application of a different position sensor 32 which according to FIG. 7 is a torsion spring 67 as the relevant rotary position of the connecting sleeve 15 and is therefore the element detecting the threaded spindle 11 . The corresponding torsion of the spring leads to different extended and compressed regions along the coil of the spring, which results in different resistance changes on electrical wires arranged in these regions. These resistance changes are converted into a corresponding torsion of the spring and hence into a corresponding rotated angle of the connecting sleeve 15 , of the threaded spindle 11 and finally of the first perforated screen 55 .
In the following the functioning principle of the drive device 1 according to the invention is explained based for example on FIG. 1 .
On actuating the motors 4 , 5 accordingly a rotation of the drive shaft 22 occurs and hence of the second spiral toothed gear wheel 23 of the helical spur gear 9 . The rotation of the second spiral toothed gear wheel 23 is transferred by engagement of the helical teeth to the first spiral toothed gear wheel 20 .
Through the helically toothed spur gear self-locking or self-braking is provided as well as a high efficiency with low dissipation losses. The corresponding tooth faces of the teeth 24 of the first and of each of the second spiral toothed gear wheels are in linear contact. Due to the parallel arrangement of the corresponding spiral toothed gear wheels essentially no axial forces occur and overall a simple construction arises. Furthermore, such a gear has relatively low noise levels, is compact in construction and exhibits a long service life.
As already explained, several of the second spiral toothed gear wheels 23 can be arranged in the circumferential direction of the first spiral toothed gear wheel 20 with corresponding drive shafts 22 and motors 4 , 5 .
The rotation of the first spiral toothed gear wheel 20 is transferred to the harmonic drive where it is further reduced. A drive of the connecting sleeve 15 occurs by means of the flexible toothed sleeve 12 and depending on the embodiment rotation of the spindle nut 10 or of the threaded spindle 11 occurs through the connecting sleeve. Due to the rotation of the corresponding part of the spindle drive 3 formed as a recirculating roller spindle drive a displacement or rotation of the relevant actuating element 2 occurs, whereby in addition a further gear unit comprising the fixed sleeve and the rotating sleeve 30 , 31 can be arranged between the spindle drive 3 and the actuating element 2 .
The actuating elements of the various embodiments are formed differently and generally exhibit a suitable sliding rod and flow control elements connected to it, such as perforated screens 54 , 55 or holed sleeves 43 . It should however be noted that drive devices according to the invention can also be used for other devices such as throttles, i.e. for example also for valves, dosage feed devices or similar equipment. | A driving device for adjusting an activating element of a throttle, of a valve, of a connecting device, of a metering device or the like in particular in the field of oil and gas exploration with at least one rotary gear movably connected to the activating element and a gear arranged between the rotary gear and at least one motor. To improve such a drive device in that the structure is simple and compact and efficiency is increased wherein simultaneously high axial forces are avoided and only a small number of assembly parts are necessary, the gear unit comprises a reduction gear assigned to the rotary gear in particular the so called harmonic drive gear, and a spare gear assigned to the motor which is in particular self locking. | 8 |
RELATED APPLICATIONS
This is a National Phase Application based on International Patent Application Serial Number PCT/US2007/017049, filed Jul. 30, 2007; which claims the filing benefit of U.S. Provisional Application Serial No. 60/834,193 filed Jul. 29, 2006 and U.S. Provisional Application Ser. No. 60/877,475 filed Dec. 27, 2006. The contents of each of these applications are incorporated herein by reference.
TECHNICAL FIELD
The present invention relates to an industrial high-speed door assembly, and more specifically, to facilitating the realignment of a door panel that has been displaced from its normal operative configuration.
RELATED APPLICATIONS
This application is related to and relies upon, the priority of U.S. Provisional Application Nos. 60/834193 filed Jul. 29, 2006,and 60/877,475 Dec. 27, 2006.
BACKGROUND OF THE INVENTION
High-speed industrial doors, which are capable of being rolled up on a shaft or drum to open, have long been used in the storing and staging areas of commercial buildings such as factories and warehouses. Materials handling machinery, such as conveyors and lift trucks are commonly used to transport items to, from, and between storage areas and staging areas such as loading docks. In such applications, as well as others known in the art, the industrial doors are often required to open quickly, such as opening at a rate of approximately 48 inches per second up to 100 inches per second or greater. This speed enhances productivity, cost savings, and safety, especially where cold storage and distribution is involved. Additionally, specific environmental or security requirements may need door speed and sealing integrity to be maintained in either the storing or staging area or both, e.g., temperature, cleanliness, etc.
Conventional high-speed roll-up door assemblies include a pair of vertically oriented assemblies installed proximate the vertical sides of an opening defining the passageway for people and commercial vehicles and are sometimes called “side columns”, or “guide assemblies”. The side columns are have structures which guide the flexible door panel during opening and closing. These “guides” provide surfaces which engage a vertical marginal edge portion of the moving door panel therein. The guide assemblies are installed on only one side of the opening and do not extend into the width of the opening so as to maximize the clear path of travel for freight-moving vehicles traversing the passage, and to avoid damage to the assemblies from collisions. The flexible door panel, often including its accompanying parts, e.g., a relatively rigid bottom bar, guide retention means such as rollers, knobs, etc., is thus made wider than the width of the opening such that a vertical margin of the door panel on each side of the opening near the vertical side edges thereof, extends into and is thus guided or retained within the guides.
Even though the door panel is moved vertically at a relatively fast rate, there are times when the door panel—or a portion of the door assembly itself—is impacted by a vehicle and dislodged from at least one of the guides. The door assembly cannot operate properly until the displaced door panel is reconfigured to be within the door assembly's guides so as to be in its normal operating configuration.
Reconfiguring or “repairing” the door's guiding function after an impact has been the subject of the design of others including the applicants of this application. However, the prior art has only limited or no solutions for restoring or “repairing” of an automatic high speed roll up door when it is dislodged in a direction which places the panel inside of, or through, the opening of the passage. In this case, with a conventional roll-up door, the wider door panel will be pushed through the narrower opening distorting its normal shape so as to comply with the width of the opening of the passage. As a result, the door panel and its associated structures as well as the side columns and the wall portions constituting the opening, are more susceptible to damage both because of the dislodging and the gesticulations required to repair the door to its operational state. These difficulties can result in commercial losses due to lost productivity, thermal losses, and loss of environmental integrity on one or both sides of the door. Repairing the door may also tend to damage the door panel or guide assemblies. The repair from such a dislodgement is routinely accomplished through human operator effort, and is not automated. The door panel must be moved back to the other side of the opening before being realigned and reinserted within the guides. Returning the door panel to the door-assembly side of the opening can be difficult—perhaps even requiring disassembly of portions of the door assembly—and may incur additional time, and further expose the door panel to more damage.
It is known in U.S. Pat. Nos. 5,141,043 and 5,319,015 to provide a “self-repairable” industrial door assembly having side uprights each including a slideway having a guide wall on either side of the plane of a door panel or curtain. Lateral portions of the curtain slide within the slideways and are adapted to escape from the slideways in the event of an abnormal or atypical transverse force. However, these doors work well only if the dislodgement of the door panel in the direction of the side of the opening where the guide assemblies are installed. If the door is displaced in the opposite direction, the stiff (relative to repairing) door panel material is forced to deform from its unbuckled state to fir within the opening. Automated or easy repair on such an instance can again be costly and/or can put undue wear on the door panel and guide assemblies.
Applicant is aware of low speed doors used in U.S. car washes which have loose or relatively wide stationary guides installed on the inside a door opening and have relatively non-stiff, light weight material comprising the door panel. These doors can repair themselves with some degree of success when dislodged in either direction. However, the low speed and reduced weight and stiffness of these doors are unacceptable for applications like freezer and warehouse applications because of the commercial demands for security, wind load, insulating ability, and high speed. Also, the flexibility of these light weight panels reduces potential damage while problems in waiting for repair are less critical in the car wash application. There is also far less criticality to maximizing the door opening width. In the meantime automobile traffic guided through a car wash, especially by its owner, does not experience the high speed and high rate of freight-vehicle traffic that high speed industrial door assemblies are required to manage or the higher rate of collisions between door and vehicle.
The present invention is provided to address these and other considerations.
SUMMARY OF THE INVENTION
In the broadest aspect of the invention, the door panel is sized to better fit between the opposites sides of an opening in a wall to which a door assembly is mounted to facilitate enhanced manual, and preferably automated self-repair, of a door panel when it is dislodged from its vertical guides, such as by impact with a vehicle into a passageway defined in part by the opening. A door so sized can more easily be retracted (to an open position) for re-feeding into its guides than one which, as is conventional, is sized to be wider than the opening for guiding.
To accommodate this sizing of the panel, guides for the panel are sized and configured to extend into the passageway generally defined by the opening. To reduce or eliminate the problems associated with this configuration one or more the following novel techniques for a high speed door is contemplated.
The goals of the invention can be achieved by at least a portion of the panel guides which extend into the passageway can be constructed to effectively minimize reduction of the passageway by allowing workers to effectively treat the opening as being equal to the passageway by reducing damage to the guides if hit. In some embodiments, this is accomplished constructing at least the portion of at least one of the guides which) protrudes into the passageway: (1) of a resilient and/or tough material (e.g. Buna N rubber) such that the guide portions can withstand a hit and return resiliently or mechanically to their pre-contact position for guiding; or (2) in a way which allows at least one of the guides to collapse when hit and return afterwards for guiding by virtue of either its shape and configuration alone or shape, configuration, and material properties.
The objects of the invention can also be achieved by constructing one or both of the guides (or at least a vertically lower portion of same which is most commonly hit) in a way where—upon activation of the door for opening, or at least during initial opening of the door, the guide(s) is automatically moved outwardly away from the passageway to define a larger passageway during opening. This accomplishes accommodation of guiding the narrower door panel and reduces the likelihood of the guide(s) being hit and the likelihood of the panel being dislodged from the guides in a way which requires repairing. It is contemplated that this latter method and configurations may be carried out by various motive devices such as: solenoids moving at least the lower portion of a guide(s) or tripping a spring or other device upon activation which will move it; or linear variable displacement transducers; or motor-driven gear drives; or the like. According to one embodiment of the invention described more fully below, as a result of door activation and movement of the door panel upwardly, a counterweight used to assist in raising the door panel, is configured to interact with a guide assembly to retract it during opening to prevent the guide from protruding into the passageway during traverse of same by a vehicle.
Accordingly, one embodiment of the present invention is directed to a high-speed door assembly capable of vertically moving a flexible door panel to permit and prohibit access through an opening having a width defined by opposed sides. The high-speed door assembly is adapted for displacement of its door panel from its operative path of travel upon receiving an atypical dislodging force and includes a first guide operatively mounted proximate the opening and having opposed surfaces between which a portion of the door panel is guided during movement of the door panel and wherein at least a portion of the opposed surfaces extends into the opening. The high-speed door assembly also includes a second guide operatively mounted proximate the opening and having opposed surfaces between which a portion of the door panel is guided during movement of the door panel and wherein at least a portion of the opposed surfaces extends into a passageway defined by the opening.
Another aspect of the present invention includes that at least one of the guides is collapsible wherein a portion thereof is flexible and capable of retracting upon impact thereto; and subsequently being capable of substantially returning to its initial operative configuration.
A further aspect of the present invention includes at least one of the opposed surfaces of either guide including a realignment ramp attached thereto and proximate the top of the opening. The realignment ramp may be movable and projects upward and at an angle away from the path of travel so as to facilitate operative alignment of the door panel within the path of travel subsequent to the displacement of the door panel there from.
In yet another aspect of the present invention, the high-speed door assembly includes a motor for vertically moving the door panel to permit and prohibit access through the opening. A sensor for detecting atypical movement of the door is operatively coupled to the motor such that the motor is capable of reacting to the event, to stop panel movement, reverse it, slow its speed, go into a “repair mode”, or combinations of these.
Yet another aspect of the present invention is directed to a high-speed door assembly operatively mounted proximate an opening with a width of the opening defined by opposed sides. The high-speed door assembly vertically moves a door panel to permit and prohibit access through the opening and includes a first guide operatively mounted proximate the opening and having opposed guide surfaces. A portion of the door panel moves through the first guide's opposed surfaces during opening and closing, and at least a portion of the opposed surfaces extends into the opening. A second guide is operatively mounted proximate the opening and has opposed surfaces between which a portion of the door panel is guided during opening and closing, wherein at least a portion of the second guide's opposed surfaces extends into the opening. A guide moving assembly is operatively connected to at least one of the first or second guides, where, in conjunction with movement of the door panel, at least a portion of one or both of the guides is movable between a first position and a second position.
In another aspect of the present invention including the guide moving assembly, an actuator is utilized with a track wherein at least one of the guides is operatively connected thereto. The actuator and track cooperate to move the guide between the first and second position. Preferably, in one of the first or second positions, one of the guides extends into the opening, and in the other of the first or second positions, at least a portion of one of the guide does not significantly extend into the opening.
In another embodiment of the invention, a counter-weight is operatively attached to the door panel and a drive means to facilitate movement of the door panel. A chute including a path of movement for the counter-weight is proximate the opening and is operatively connected to at least one of the guides, which is preferably pivotably mounted near the opening. A deflection member is attached to the guide and positioned within the path of movement of the counter-weight. As the counter-weight contacts the deflection member in a first direction, the guide will move from its first position to its second position; and, upon contact of the counter-weight with the deflection member in a second direction, the guide will move from its second position and return to its first position.
In another embodiment of the invention, a method is provided for realigning a dislodged door panel of a high-speed door assembly. The method includes detecting displacement of the door panel from its typical operative path of travel, and, in response to the detection of the displaced door panel, reducing the speed of travel of the door panel.
In another embodiment, at least one of the guides of a high-speed door assembly is movably mounted so that it can receive contact from an outside force, e.g., lift truck, without incurring inoperative or disabling damage, or requiring manual repair. The movably mounted guide is biased into a normal operative position and upon receiving an impact sufficient to displace it from its normal operative position, will subsequently return to it normal operative configuration.
It is to be understood that the aspects and objects of the present invention described above may be combinable and that other advantages and aspects of the present invention will become apparent upon reading the following description of the drawings and detailed description of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a front view of one embodiment of the present invention;
FIG. 2 is a partial cross-section view of the present invention shown in FIG. 1 and taken along line 2 - 2 ;
FIG. 3 is a partial top view of the present invention shown in FIG. 1 ;
FIG. 4 is a partial top view of another embodiment of the present invention;
FIG. 5 is a partial side view of another embodiment of the present invention;
FIGS. 6A and 6B are partial top views of another embodiment of the present invention depicting a movable guide;
FIGS. 7A and 7B are partial front views of the present invention shown in FIGS. 6A and 6B ;
FIGS. 8A-8D are partial front views of another embodiment of the present invention depicting a movable guide;
FIG. 9 is a partial front view of the present invention shown in FIGS. 8A-8D ; and,
FIGS. 10A-10C is a partial front view of another embodiment of the present invention depicting a movable guide utilizing a gravity or shape based bias mechanism.
DETAILED DESCRIPTION
While the present invention is susceptible of embodiment in many different forms, there is shown in the drawings and will herein be described in detail preferred embodiments of the invention with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the broad aspect of the invention to the embodiments illustrated.
FIGS. 1 , 2 and 3 generally disclose a high-speed door assembly 10 that rolls and unrolls a door panel 12 to permit and prohibit access through a passageway 14 . The passageway 14 includes an opening 16 having a width W defined by opposed sides of the wall forming the opening 16 . The passageway extends perpendicular to and beyond the opening. To permit access through the passageway 14 , the door panel 12 is vertically displaced up and down by rolling up and unrolling on a drum (although in other embodiments, the door panel may be accumulated overhead by other means such as a track, rail, and the like. Preferably, the door panel 12 is a continuous piece of material, e.g., a flexible sheet or panel, but may be comprised of two or more segments, sheets or panels.
A drive means 18 , e.g., an electric motor, is operatively connected to the door panel 12 and is mounted above the passageway 14 to move the door panel vertically up and down. The drive means 18 may also include a controller 19 and a sensor 20 in a rigid bottom bar 21 at the lower edge of the panel 12 as is known in the art. The controller 19 is responsive to the sensor 20 and has a plurality of operating modes in which to control the operation of the drive means 18 to move the door panel 12 at an opening speed of approximately 0-100 inches/second or more. The drive means 18 is responsive to the controller 19 which is preferably mounted to either one of the sides of the opening 16 .
The high-speed door assembly 10 is adapted for displacement of its door panel 12 from its operative path of travel upon receiving a force for example from a collision with a fork-lift vehicle, which causes movement atypical to its normal mode of operation and may also dislodge the door from its assembly. The sensor 20 is capable of detecting either atypical alignment of the door panel 12 with its guide(s) 22 , 23 or the atypical force applied to the door (for example when such as a pneumatic sensor, a strain gauge, or an accelerometer is employed as a sensor). The controller 19 responsive to the sensor 20 sending a signal indicating detection of an atypical force or misalignment of the door panel 12 with its guides, 22 , 23 may be programmed to stop vertical movement of the door panel 12 , reverse the direction of travel from down to up, or decrease the speed of travel of the door panel. Preferably, if the panel was moving downward, the controller 19 either stops the panel then reverses its direction and speed, or just reverses its direction and speed to roll the panel 12 up to a point where the bottom edge, in this case the bottom bar 21 can be aligned either by gravity or some manual urging back into alignment with its guides 22 , 23 . At that point, the controller may permit continued operation of the door panel 12 or may optionally wait for a diagnostic test which can be partially or totally manual or automated.
FIGS. 3 and 4 disclose one side of the vertical guide assembly ( 22 ) with reference numbers provided (without a separate drawing) of the identical (left-hand, right-hand) configuration of the two opposed guide assemblies 22 , 23 . Hence, FIG. 3 discloses a first guide 22 ( 23 ) operatively mounted on one side of the wall to which the door panel assembly is mounted and near the opening 16 . FIG. 3 discloses guide surfaces 24 , 26 and 25 , 27 between which opposite vertical margins of the door panel 12 are guided during opening and closing. At least a portion of the opposed surfaces 24 , 25 ; 26 , 27 extend into the passageway 14 . The first guide 22 is spaced apart from and aligned with the second guide 23 to define a planar (or horizontal or vertical) plane defining a path of travel 28 ( FIG. 5 ) for the door panel 12 such that a portion of the door panel—near the sides of the door panel—is guided within the first 22 and second 23 guides. To a large extent, the path of travel 28 is in a plane that is substantially parallel with the opening 16 and substantially perpendicular to the passageway 14 .
Referring now to FIG. 4 , one embodiment of the present invention provides that a portion of at least one of the first 22 or second 23 guides are resilient or collapsible so as to respond to an impact on them by initially retracting from the passageway 14 then rebounding to substantially their initial configuration. This may be accomplished by the guides 22 , 23 being made of a flexible material, e.g., rubber, having an inherent resiliency or of bended metal wherein due to its shape has formed a resilient spring as shown in FIG. 4 . It is further contemplated that a bias means 30 can be utilized with the guide 22 , 23 to achieve an amount dynamic response to facilitate temporary flexing or retracting upon impact and then subsequently substantially return to an operable configuration for opening and closing. Mechanical bias mechanisms, e.g., mechanical or chemical (polymer) springs or gravity can comprise or be operatively connected to the guide.
FIGS. 10A-10C , disclose a gravity-based bias mechanism 31 wherein the guides 22 , 23 essentially suspend proximate the opening 16 . The guides include a slanted slot 33 wherein a pin 35 is located therein. Upon receiving an impact, the guide 22 , 23 will flex on impact. Due to the geometrical configuration of the gravity or shape based bias mechanism 31 , the guide 22 , 23 will slide slightly upward along the pin 35 and then eventually return to its original position.
Another aspect of the present invention is shown in FIG. 5 , wherein at least one—preferably both—of the guides 22 , 23 of the high-speed door assembly 10 includes a realignment ramp 32 attached thereto and proximate the top of the opening 16 . The realignment ramp 32 projects upward and at an angle away from the path of travel 28 so as to facilitate operative alignment of the door panel 12 within the path of travel subsequent to displacement of the door panel from the guides 22 , 23 .
Displacement of the door panel 12 can result from contact of a sufficient force F A , F B upon the door panel to dislodge it from at least one of the guides 22 , 23 . The dislodging force can approach from either side A, B of the opening 16 . Upon displacement of the door panel 12 from guide(s) 22 , 23 , the drive means 18 preferably halts movement of the door panel for a predetermined amount of time and then reinitiates movement of the door panel such that the dislodged door panel will eventually approach the top of the opening 16 wherein the bottom portion of the door panel will slip over and past the realignment ramp 32 and return within the guides 22 , 23 for subsequent operation.
Upon receiving a sufficient force F B on the side B of the opening 16 where the high-speed door assembly 10 is mounted, the door panel 12 will dislodge from at least one of the guides 22 , 23 . Because the guides 22 , 23 extend into the opening 16 , the width of the door panel is less than or equal to the width W of the opening. As such, the door panel 12 is permitted to more freely move through the opening 16 and is primarily prevented from returning through the opening by the guides 22 , 23 extending therein—as opposed to the structure, e.g., wall, defining the sides of the opening. Upon detection of the displaced door panel 12 , the sensor 20 will send a signal to the controller 19 . The controller 19 will change the operating mode of the drive means 18 and the door panel will eventually be moved up toward the top of the opening 16 and pass by the realignment ramp 32 to return within the guide and on plane within the path of travel 28 .
The realignment ramp 32 is movable so that the entire door panel 12 will eventually be pulled past the movable realignment ramp and return between the guides 22 , 23 . Various embodiments of the movable realignment ramp 32 are envisioned by the present invention, including, and not limited to: being operatively attached to one of the surfaces 24 , 25 , 26 , 27 of the guides 22 , 23 ; being integral with one of the surfaces of the guides; and being biased—inherently via physical composition or shape, or mechanically, e.g., spring, coil, and the like.
In a preferred embodiment, each guide 22 , 23 will include a pair the realignment ramps 32 to facilitate normal operative configuration of the door panel 12 independent of the side of the opening 16 on which the door panel is displaced.
As shown thus far, due primarily to the configuration of the guides 22 , 23 extending within the opening 16 , the “self-repairable” high-speed door assembly 10 of the present invention is capable of quick and easy reconfiguration regardless of the direction of the dislodging force. And although the extension of a portion of the guides 22 , 23 appears to lessen the width W of the opening 16 , the movable guide described herein is capable of collapsing and/or retracting and thus effectively providing a width substantially as wide as the opening.
Alternatively, another aspect of the present invention is shown in FIGS. 6A , 6 B, 7 A, and 7 B and is directed to a guide moving assembly 34 that is operatively connected to at least one of the guides 22 , 23 . In conjunction with raising and lowering of the door panel 12 , a portion of one of the guides is movable between a first position and a second position. In the first position, the guide(s) extends into the opening 16 , (see FIGS. 6A and 7 A) and in the second position, at least a portion of the guide(s) does not extend into the opening (see FIGS. 6B and 7B ); and vice versa. The guide moving assembly 34 includes an actuator 36 operatively connected to the guide(s) 22 , 23 . Preferably, the actuator 36 cooperates with a track 38 —single or multiple rail—upon which the guide 22 , 23 is operatively connected. The actuator 36 cooperates with the track 38 to move the guide 22 , 23 between the first and second positions. Upon detection of an approaching vehicle intending to travel through the opening 16 , the actuator 36 will move at least a portion of the guide(s) 22 , 23 from its initial position so as not to extend into the opening. Thus, as the door panel 12 is being moved upward to permit access through the opening 16 , at least a portion of the guide(s) 22 , 23 will be moved and retracted from substantially extending into the opening to expose its full width W for passage of the vehicle there through. Subsequent to the passage of the vehicle through the opening 16 and in conjunction with the downward movement of the door panel 12 to prohibit access through the opening, the actuator 36 will return the guide(s) 22 , 23 to its initial position as the door panel 12 is lowered.
It is to be understood that various types of actuators known to one of ordinary skill in the art can be utilized with the present invention, including, and not limited to: a motor and cooperating cam, an air cylinder, and an electric solenoid.
Another embodiment of an alternate guide moving assembly is shown in FIGS. 8A through 8D ; 9 A, and 9 B and includes a counter-weight 40 operatively attached to the door panel—preferably via the drive means 18 . This embodiment moves a lower portion of the guides which are most commonly hit by traffic out of the passageway 14 beginning upon initial movement of the door panel 12 upwardly and replaces the guides for guiding upon closing of the door panel 12 .
The counter-weight 40 is a source of potential energy utilized to facilitate the upward movement of the door panel 12 along its path of travel 28 . The guide 22 , 23 is preferably pivotably mounted near the opening 16 and operatively attached to a chute 42 . Although the guide 22 , 23 extends into the opening, the chute 42 does not. The chute 42 includes a path for the counter-weight 40 to travel. A deflection member 44 is attached to the guide 22 , 23 and in line with the counter-weight's path within the chute 42 . Upon opening the door panel 12 , the counter-weight 40 will eventually contact the deflection member 44 wherein the guide 22 , 23 will be subsequently moved from its first position. Upon closing of the door panel 12 , cooperation of the counter-weight 40 with the deflection member 44 will eventually move the guide 22 , 23 from its second—retracted—position and return it to its first position.
Due to the pivotable mounting of the guide 22 , 23 near the opening 16 , it is apparent that although a portion of the guide will be retracted to expose the full width W of the opening, a portion of the guide may remain or further extend into the opening. When permitting access through the opening 16 , it is preferable to move the pivotable guide(s) 22 , 23 such that the full width W of the opening 16 is exposed to a height of at least approximately 4 feet to accommodate unencumbered passage of transport vehicles through the opening. In consideration of the interrelated and/or cooperating components of the high-speed door assembly 10 of the present invention—e.g., height and width of opening 16 and door panel 12 ; degree of pivot for the guide 22 , 23 ; shape or geometry of the counter-weight 40 and the cooperating deflection member 44 —it is further apparent that without undue experimentation, the door assembly of the present invention can be configured by one of ordinary skill to attain the desired operating characteristics of the high-speed door assembly.
The movable characteristics of the guides 22 , 23 described herein, whether the guide is collapsible, retractable, or pivotable, provide the high-speed door assembly 10 of the present invention with ability for adaptation as a separator between differing environments, e.g., cold/warm storage, humidity, clean rooms. It is contemplated by the present invention that the guides 22 , 23 can be extruded of an engineered material, e.g., plastic, fiberglass, foam, and combinations thereof, that lend themselves to use in such environments, wherein lower costs due to repair or replacement will be achieved. For example, energy costs related to insufficient insulation or the prevention/reduction of accumulated frost on the guide 22 , 23 can be reduced by the implementation of guides including specifically engineered material(s) suited for such purposes.
It is to be understood that additional embodiments of the high-speed door assembly described herein may be contemplated by one of ordinary skill in the art and that the scope of the present invention is not limited to the embodiments disclosed. While specific embodiments of the present invention have been illustrated and described, numerous modifications come to mind without significantly departing from the spirit of the invention, and the scope of protection is only limited by the scope of the accompanying claims. | The present invention is directed to an industrial high-speed door assembly having a reduced door panel width and having guides for guiding the door which extend into a passageway but are resilient, tough, or resiliently collapsible, to either withstand impacts from vehicle collisions or moveable during opening of the door to avoid collisions while returning for guidance upon closing the door. | 4 |
FIELD OF INVENTION
The present invention relates generally to video surveillance. More particularly, the present invention relates to systems and methods of creating coherent video data streams of an object moving between areas covered by multiple video data stream collecting devices.
BACKGROUND
Intelligent security has become a widespread and necessary reality of modern day civilization. One aspect of known intelligent security is video surveillance. Video surveillance is being increasingly used and accordingly, the number of cameras or other collection devices has also increased.
In known video surveillance systems, several cameras or other collection devices are often used to monitor a given location. For example, one video surveillance camera can be used to monitor an entry way to a particular building. Separate video surveillance cameras can be used to monitor each room in the building, and another video surveillance camera can be used to monitor the exit door of the building.
When a person, object, or group moves around the premises and from room to room of the building, it is difficult to create a single coherent video data stream of that person, object, or group. Traditionally, creating such a video data stream would require manually notating the different cameras capturing the person and then creating clips at different start and stop times from the various cameras. Then, a person would have to manually combine the various clips into a coherent video data stream. This is a time consuming, tedious, and convoluted process.
For example, in a forensics operation, often an evidentiary video data stream of a person, object, or group is desired to show the movement of that person, object, or group around a particular city, building, room, etc. As explained above, known solutions only provided for the manual creation of the evidentiary video data stream. The time, expense, man hours, and complexity associated with the manual creation of a coherent video data stream showing an object as it moves through a particular area has led many users to desire an automated or guided system and method for creating such a coherent data stream.
Accordingly, there is a continuing, ongoing need for an automated or interactive system and method for creating a coherent video stream showing an object as it moves through a particular area. Preferably, the coherent video data stream can be created from video data streams from more than one camera capturing the object as it moves between areas that are covered by the different cameras.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A and 1B are flow diagrams of a method of creating a coherent video data stream in accordance with the present invention;
FIG. 2 is a block diagram of a system for carrying out the method of FIGS. 1A and 1B in accordance with the present invention;
FIG. 3 is an interactive window displayed on a viewing screen of a graphical user interface for creating a coherent video data stream of an object as it moves through a particular area in accordance with the present invention;
FIG. 4 is an interactive window displayed on a viewing screen of a graphical user interface for creating a coherent video data stream of an object as it moves through a particular area and for marking time lines associated with video data streams in accordance with the present invention; and
FIG. 5 is an interactive window displayed on a viewing screen of a graphical user interface for creating a coherent video data stream of an object as it moves through a particular area and for exporting the coherent video data stream in accordance with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
While this invention is susceptible of an embodiment in many different forms, there are shown in the drawings and will be described herein in detail specific embodiments thereof with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention. It is not intended to limit the invention to the specific illustrated embodiments.
Embodiments of the present invention include automated or interactive systems and methods for creating coherent video data streams of an object as it moves through a particular area. Preferably, a coherent video data stream can be created from video data streams from more than one camera capturing the object as it moves between areas that are covered by the different cameras. Sources of the video data streams can be real-time live image sequences or pre-stored sequences without limitation.
In accordance with the systems and methods of the present invention, multiple cameras or other information collecting devices can be located in a particular area. Such an area can include a city, a building, a room, or the like all without limitation.
The cameras or other information collecting devices can be dispersed throughout the area so that each camera covers a different region within the area. For example, if the area is a city, each camera in the area can cover one block of the city. In this way, the entire city is captured by the cameras in the area. However, each individual camera only captures a portion of the area.
When a particular person, object, or group moves throughout the area, it will be captured by at least one of the cameras in the area at all times. However, each individual camera will only capture the person, object, or group when it is in the particular region covered by that camera.
Systems and methods in accordance with the present invention enable a user to simultaneously review video data streams from cameras in the area to create a coherent video data stream or clip sequentially showing the person, object, or group as it moves throughout the area. That is, the coherent video data stream can include data streams from each camera showing the person, object, or group in that region. The data streams from different sources can be chronologically ordered so that the complete and coherent video data stream shows the person, object, or group at all times and in a coherent, sequential manner as it moves throughout the area.
Systems and methods in accordance with the present invention can be automated or interactive. The present invention provides an easy-to-operate method to create and provide a coherent video data stream with minimal human error. Coherent video data streams in accordance with the present invention could be used in a variety of applications, including, for example, forensic operations, evidence production, and the like all without limitation.
FIGS. 1A and 1B illustrate a flow diagram of an exemplary method 100 of creating a coherent video data stream in accordance with the present invention. In the method 100 , a user can select the possible cameras or other data collection devices that it suspects might have captured the person, object, or group of interest as in 110 . The selected cameras can monitor areas or regions in which the user believes the person, object, or group of interest might have travelled. For example, the user can select cameras that monitor a particular city, building, room or the like. Then, the method 100 can synchronize the selected cameras as in 120 so that the user can view data streams or image sequences from the selected cameras for the same period of time, such as, for example, the same hour, day, or week. The data streams can be analog or digital and can be pre-stored or real-time streaming video without limitation.
From the group of selected cameras, a user can select a certain number of cameras of interest as in 130 . Video outputs from the selected cameras of interest can be viewed simultaneously on a viewing screen by the user as in 140 . That is, the video data streams from each of the selected cameras can run concurrently, and the user can review the video data streams from the selected cameras at the same time. The number of cameras selected as cameras of interest at one time can be, for example, four, or any number that can be appropriately displayed on a viewing screen showing the video from the selected cameras.
As the user reviews the video data streams from the selected cameras of interest, the user can determine whether the object of interest is depicted in any of the video data streams from the selected cameras of interest as in 150 . If the object of interest is not in any of the video data streams, then the method 100 can determine if the end of the video data stream has been reached as in 160 . If the end has been reached, then the method can proceed to determine whether there are any more cameras of interest as in 230 . However, if the end of the video has not been reached, a user can continue to review the vide data streams from the selected cameras of interest as in 140 .
If the object of interest is depicted in any of the video data streams from the selected cameras of interest, then the user can mark the video data stream in which the object of interest is depicted. Alternatively, the user can mark a time line associated with the video data stream depicting the object of interest or a viewing screen displaying the video data stream.
When the object of interest is depicted in a video data stream, the method 100 can first determine to which camera the video data stream corresponds as in 180 . For example, if the video data stream depicting the object of interest corresponds to a first camera in the group of selected cameras of interest, then the user can mark or identify the first video data stream, associated time line, or associated viewing screen with a selected symbol, for example, an IN marking, as in 190 . The IN marking can correspond to the time when the object of interest is first depicted in the first video data stream (i.e. an entrance time). When the object of interest no longer appears in the first video data stream (i.e. an exit time), the user can mark the first video data stream, associated time line, or associated viewing screen with another selected symbol, such as an OUT marking, for example, as in 200 . Similarly, if the video data stream depicting the object of interest corresponds to a second camera in the group of selected cameras of interest, then the user can appropriately mark the second video data stream, associated time line, or associated viewing screen.
After a video data stream, associated time line, or associated viewing screen has been marked at the time when the object of interest begins to be depicted (i.e. the entrance time) and at the time when the object of interest is no longer depicted (i.e. the exit time), then the method 100 can determine if the end of the video has been reached as in 210 . If the end of the video has not been reached, then a user can continue to review video data streams from the selected cameras of interest as in 140 .
However, if the method 100 determines that the end of the video has been reached for the selected group of cameras, then the method 100 can determine whether there are any more cameras of interest as in 230 . If there are more cameras of interest, then the method 100 can proceed to select more cameras of interest as in 130 . However, if there are no more cameras of interest, then the method 100 can prepare a coherent video data stream to be exported as in 250 .
The coherent vide data stream that is prepared by the method 100 can include the data stream clips corresponding to the selected periods of interest from each of the digital video streams. The periods of interest can relate to the portions of the video data streams between the entrance and exit times. That is, the periods of interest can cover times when the object of interest is depicted in a particular data stream. The data stream clips of the selected periods of interest can be arranged so that the coherent video data stream is chronological. That is, the coherent video data stream can be synchronized by time. In embodiments of the present invention, the original camera names or numbers, the user marking the periods of interest, and the names of the export files, for example, can be automatically traced and tracked so that the exported coherent video data stream includes this information as embedded data, for example.
The user can digitally sign a file to be exported as in 220 and name the file to be exported as in 230 . Then, the method 100 can export the file containing the coherent video data stream as in 240 to a drive, disk, or other storage device, for example, a hard disk drive, Blu-ray disk, digital video disc (DVD), or compact disc (CD). If the method 100 determines that it is exporting the file to a disk, for example, as in 290 , then the method 100 can determine the number of disks required to appropriately store the entire file as in 300 and prompt a user to insert that many disks as in 310 . Finally, the method 100 can write the export file containing the coherent video data stream to the selected storage device.
As described above, when an object of interest is depicted on a video data stream from a camera, a user can mark that video data stream, associated time line, or associated viewing screen at entrance and exit times. In embodiments of the claimed invention, when a user marks a video data stream, associated time line, or associated viewing screen with IN at an entrance time, the user will be given the option to mark the video data stream, associated time line, or associated viewing screen from the last time any video data stream, associated time line, or associated viewing screen in the selected group was marked OUT. That is, a user will be given an option to mark IN from the previous mark OUT. In such embodiments, the coherent video data stream that is created from the selected periods of interest will include video for all relevant time and will not include more than one video data stream for any particular time. That is, the coherent video data stream will not omit or duplicate any relevant periods of time.
In further embodiments, the method 100 can provide a default overlap period that can be, for example, 30 seconds. A user can change the overlap period to be greater or less than the default overlap period.
The method shown in FIGS. 1A and 1B and others in accordance with the present invention can be implemented with a programmable processor and associated control circuitry. As seen in FIG. 2 , control circuitry 10 can include a programmable processor 12 and associated software 14 as would be understood by those of ordinary skill in the art. Video data streams from a plurality of cameras or other data collection or storage devices can be input into the programmable processor 12 and associated control circuitry 10 . An associated user interface 16 can be in communication with the processor 12 and associated circuitry 10 . A viewing screen 19 of the user interface 16 , as would be known by those of skill in the art, can display an interactive window. In embodiments of the present invention, the user interface 16 can be a multi-dimensional graphical user interface.
FIGS. 3-5 are block diagrams of exemplary interactive windows 20 displayed on a viewing screen 19 of a graphical user interface 16 for creating a coherent video data stream of an object as it moves through a particular area. Those of skill in the art will understand that the features of the interactive windows 20 in FIGS. 3-5 may be displayed by additional or alternate windows. Alternatively, the features of the interactive windows 20 of FIGS. 3-5 can be displayed on a console interface without graphics.
Using the exemplary interactive windows of FIGS. 3-5 , a user can review video data streams from a plurality of selected cameras and mark portions of each of the video data streams, associated time lines, or associated viewing screens. For example, as seen in FIG. 3 , a user can select a plurality of cameras, cameras 1 - 4 , for review. Each of the cameras can capture a different area, and the user can review the video data streams from each camera for the presence of an object of interest.
Once the cameras are synchronized, the video data streams from each of the cameras can be displayed in different viewing panes, for example, 21 , 22 , 23 , and 24 , of the window 20 . A user can simultaneously view each of the video data streams and mark or identify a particular data stream, associated time line, or associated viewing screen when a person, object, or group of interest appears on that data stream.
For example, when a user observes a person of interest depicted on a viewing pane associated with a particular video data stream, the user can externally trigger the viewing pane to display a menu. For example, the user could click or press the viewing pane using a mouse or other controller, or the user could click or press an appropriate key on an associated keyboard. The user could then select an IN marking at the time when the person of interest is first depicted on the viewing pane. Similarly, when the person of interest no longer is depicted on the associated viewing screen, the user can externally trigger the viewing pane to display a menu, and the user can select an OUT marking. In such embodiments, the IN and OUT markings can be associated with frame times from the camera corresponding to the particular data stream displayed in the selected viewing pane.
The window 20 can also include a time line viewing pane 25 , which can include time lines, 26 , 27 , 28 , and 29 for each of the cameras displaying video in the viewing panes 21 , 22 , 23 , and 24 , respectively. When a user observes the person of interest, for example, in a video data stream, the user can mark the corresponding time line with an IN marking at the time when the person of interest is first depicted in the data stream. When the person of interest no longer is depicted in the video data stream, the user can mark the corresponding time line with an OUT marking. That is, the user can mark the appropriate time line with IN and OUT markings at the exact entrance and exit times of the person of interest in a corresponding video data stream.
As seen in FIG. 4 , each time line 26 , 27 , 28 , and 29 , can be marked with a selected period of interest, 30 , 33 , 36 , and 39 , respectively. It is to be understood that any time line can be marked with more than one period of interest if, for example, the object of interest is depicted on the video corresponding to that time line more than once. Further, it is to be understood that the selected periods of interest can be of varying lengths of time. The length of time for any selected period of interest corresponds to the length of time that the object of interest is depicted on of the corresponding video data stream.
In FIG. 4 , each time line 26 , 27 , 28 , and 29 has been marked IN at times represented at 31 , 34 , 37 , and 40 , respectively. Each time line has also been marked OUT at times represented as 32 , 35 , 38 , and 41 , respectively. The selected periods of interest 30 , 33 , 36 , and 39 correspond to the span between each IN marking 31 , 34 , 37 , and 40 , respectively, and each OUT marking 32 , 35 , 38 , and 41 , respectively.
As explained above, in embodiments of the claimed invention, when a user marks a video data stream, associated time line, or associated viewing screen with an IN marking, the user will be given the option to mark the video data stream, associated time line, or associated viewing screen from the last time any video data stream, associated time line, or associated viewing screen in the selected group was marked OUT. That is, a user will be given an option to mark IN from the previous mark OUT. As can be seen in FIG. 4 , in such embodiments, no selected period of time will overlap with any other selected period of time for selected cameras of interest.
Referring now to FIG. 5 , when the end of the video from the selected cameras of interest has been reached, and no additional cameras of interest are selected, a user can begin the preparation of an export file by clicking on or pressing an Export Clip button 42 . The coherent video data stream created by systems and methods of the present invention can be loaded in the export file, and the export file can be written to an appropriate storage device.
Software 14 , which can implement the exemplary method of FIGS. 1A and 1B , can be stored on a computer readable medium, for example, a disk or solid state memory, and can be executed by the processor 12 . The disk and associated software can be removably coupled to the processor 12 . Alternatively, the software 14 can be downloaded to the medium via a computer network.
From the foregoing, it will be observed that numerous variations and modifications may be effected without departing from the spirit and scope of the invention. It is to be understood that no limitation with respect to the specific system or method illustrated herein is intended or should be inferred. It is, of course, intended to cover by the appended claims all such modifications as fall within the spirit and scope of the claims. | A system for and a method of creating a coherent video data stream of an object moving between a plurality of areas covered by a plurality of data collecting devices is provided. The method includes selecting a plurality of data collecting devices from the plurality of data collecting devices, synchronizing video data streams from the selected plurality of data collecting devices, substantially simultaneously reviewing the video data streams from the selected plurality of data collecting devices, specifying periods of interest for the video data streams from the selected plurality of data collecting devices, and sequentially combining portions of the video data streams into the coherent video data stream, the portions corresponding to the specified periods of interest. | 7 |
This application is a division of application No. 08/132,246, filed Oct. 6, 1993.
FIELD OF THE INVENTION
This invention relates to polymers of maleic acid and amines.
DESCRIPTION OF RELATED ART
It is well known that polymers of ammonia and maleic acid can be prepared by thermal condensation of one or more equivalents of ammonia with maleic acid, malic acid, fumaric acid or the mono- or diamides of maleic acid, malic acid or fumaric acid.
U.S. Pat. No. 4,839,461 discloses a method for making polyaspartic acid from maleic acid and ammonia by reacting these constituents in a 1:1-1.5 molar ratio by raising the temperature to 120°-140° C. over a period of 4-6 hours and maintaining it for 0-2 hours.
Dessaigne (Comp. rend. 31,432-434 [1850]) prepared condensation products which gave aspartic acid on treatment with nitric or hydrochloric acid by dry distillation of the acid ammonium salts of malic fumaric or maleic acid at unspecified times and temperatures.
U.S. Pat. No. 3,846,380 discloses that polysuccinimide may be made by heat condensation of the following starting materials, aspartic acid; ammonium salts of aspartic acid, malic acid, maleic acid and fumaric acid; and mono- and diamides of aspartic acid, malic acid, maleic acid and fumaric acid.
U.S. Pat. No. 4,696,981 discloses the formation of anhydropolysuccinic acid by the microwave radiation of ammonium salts of malic acid via the formation of ammonium maleate.
Jpn. Kokai 60,203,636 [C.A. 104, 207690m, 1986] discloses a method for the synthesis of copolymers of aspartic acid by heating amides, ammonium salts or monoamide-ammonium salts of malic acid, maleic acid or/and fumaric acid with one or more amino acids at 180° C. for four hours.
A method of preparation of polyaspartate, useful for inhibition of incrustations due to materials causing hardness in water and of value in detergent formulations, in which maleic acid or fumaric acid are reacted in a molar ratio of 1:1-2.1 at temperatures greater than 190° C., followed by conversion of the polymer formed in this reaction to a salt of polyaspartic acid by basic hydrolysis is disclosed by U.S. patent application 08/007,376, filed May 14, 1992, by Louis L. Wood.
A method for obtaining higher molecular weight copolymers of polyaspartic acid, suitable for the inhibition of scale deposition, by reacting maleic acid and ammonia in a stoichlometric excess, with a diamine or a triamine, at 120°-350° C., preferably 180°-300° C., and then converting the copolymer of polysuccinimide formed to a salt of a copolymer of polyaspartic acid by hydrolysis with a hydroxide is disclosed in U.S. patent application Ser. No. 07/968,506, filed Oct. 10, 1992 by Louis L. Wood.
Copolymers of polyamino acids formed by reaction of polysuccinimide with alkyl, alkenyl, aromatic amines or alkyl and alkenyl polyamines are useful as inhibitors of mineral scale deposition are disclosed in U.S. patent application Ser. No. 07/968,319, filed Oct. 29, 1992 by Louis L. Wood and Gary J. Calton.
U.S. patent application Ser. No. 07/994,922, filed Dec. 22, 1992, by Louis L. Wood and Gary J. Calton, discloses copolymers of polyaspartic acid which are suitable for the inhibition of scale deposition which are obtained by reacting maleic acid, an additional polycarboxylic acid and ammonia in a stoichiometric excess, at 120°-350° C., preferably 180°-300° C., to provide copolymers of polysuccinimide. In a second embodiment, a polyamine was added to the reaction mix. These intermediate polysuccinimide copolymers could then be converted to the salts of copolymers of polyaspartic acid by hydrolysis with a hydroxide.
U.S. patent application Ser. No. 08/031,856, filed Mar. 16, 1993 by Louis L Wood, discloses a method for preparing copolymers of polyamino acids by reaction of an alcohol with maleic anhydride to form the half ester followed by addition of ammonia, ammonia and an amine, or ammonia and a polyamine. The mixture is then heated to 120°-350° C. to form polysuccinimide or a derivative thereof. The resulting polysuccinimide may be hydrolyzed to form its salt or reacted further to provide a derivative of polyaspartic acid.
It is also well known that maleic polymers can be obtained through radical polymerization as disclosed in U.S. Pat. No. 5,064,563 and references cited therein.
SUMMARY OF THE INVENTION
We have found that useful polymers and salts thereof can be prepared by thermal condensation, at temperatures above 120° C., but preferably above 160° C. and more preferably above 190° C. for a time sufficient to remove the water of condensation, of less than one equivalent of an amine having the formula NHR'R" where R' and R" can be the same or different and where R' and R" independently represent hydrogen or an alkyl, a carboxy alkyl, an hydroxyalkyl, an alkenyl, an alkyl amine, or an alkyloxy amine, with a monomer selected from the group of monomers consisting of maleic acid, malic acid, fumaric acid or maleic anhydride. Such polymers are easily formed when the amine is present at 0.05 equivalent of amine per mole of monomer to less than 1 equivalent of amine per mole of monomer. A preferred range of amine is 0.25 to less than 1 equivalent of amine per mole of monomer. An especially preferred range of amine is 0.5 to less than 1 equivalent of amine per mole of monomer. Amines such as ammonia or those having at least one primary or secondary amine are useful in formation of the polymers. Molecules having additional amine groups consisting of at least one or more primary or secondary amines are of value in extending the molecular weight of the polymer. Illustrative of the types of amines which might be used are alkyl amines having 1-36 carbons, polyoxyalkyleneamines, polyoxyalkylenediamines, polyoxyalkylenetriamines, alkyl diamines such as ethylene diamine or hexanediamine, alkyltriamines such as diethylene triamine or melamine, or amino acids such as lysine and arginine. Permutations and combinations of the various amines provide polymers, all of which have useful properties, to a greater or lesser degree, as described below. The process for synthesis of the polymers comprises polymerizing (1) one of the members of the group consisting of maleic acid, malic acid, and fumaric acid and (2) less than one equivalent of ammonia, at a temperature greater than about 120° C., to produce said polymer; polymerizing (1) one of the members of the group consisting of maleic acid, malic acid, and fumaric acid, (2) less than one equivalent of ammonia and (3) an amine, at a temperature greater than about 120° C., to produce said polymer; polymerizing (1) one of the members of the group consisting of maleic acid, malic acid, and fumaric acid, (2) less than one equivalent of ammonia, and (3) a carboxylic acid, at a temperature greater than about 120° C., to produce said polymer; or polymerizing (1) one of the members of the group consisting of maleic acid, malic acid, and fumaric acid, (2) less than one equivalent of ammonia, (3) an amine and (4) a carboxylic acid, at a temperature greater than about 120° C., to produce said polymer. The polymer may be hydrolyzed to form a salt having high carboxyl functionality by further reacting said polymer with a salt of an alkali, an alkaline earth metal or ammonia which is capable of hydrolyzing said polymer. Among those salts capable are the oxides, carbonates or other weak acid salts, such as those of organic adds, and hydroxides of the alkali or alkaline earth elements, or ammonium hydroxide. Each of these hydrolysates provides a salt of the polymer wherein the counter-ion of the salt is an ion of an alkali, an alkaline earth metal or ammonia. Other carboxylic acids may be incorporated providing a variation in the hydrophobic/hydrophilic ratio and varying the interatomic distance between carboxylic acid functionalities. Illustrative examples of such acids are monocarboxylic acids such as alkyl carboxylic acids containing 1-36 carbons, for example stearic, oleic, N-methyl-N-lauric, and palmitic acids, amino acids such as alanine, lysine and polycarboxylic acids such as adipic acid, citric acid, fumaric acid, malic acid, malonic acid, succinic acid, glutaric acid, oxalic acid, pimelic acid, itaconic acid, nonanedioic acid, dodecanedioic acid, octanedioic acid, isophthalic acid, terphthalic acid, phthalic acid or polycarboxylic acids, such as aspartic acid or glutamic acid. The molecular weight of these polymers, with or without the inclusion of alternate carboxylic acids, may be extended by substituting a polyamine for a portion of the ammonia used.
The polymer formed may then be hydrolyzed to give a water soluble polycarboxylic acid salt. The alkaline hydrolysis is carried out for a suitable time at a temperature in the range of 0° to 50° C., and if necessary, with cooling. The reaction is generally complete after several minutes, but it may take several hours, in some cases, before it goes to completion. The alkali hydroxides or carbonates of alkali metals and alkaline earth metals, for example, NaOH, KOH, LiOH, RbOH, CsOH, Li 2 CO 3 , Na 2 CO 3 , Rb 2 CO 3 , Cs 2 CO 3 , Ba(OH) 2 , etc., may be employed as well as the salts of the alkali or alkaline earth metals with a weak Lewis acid, where the pH of the salt in aqueous solution is above 5.5. illustrative examples of these salts are the sodium salts of carbonic acid, acetic acid, formic acid and the like. The concentration of alkali employed can be varied widely depending upon the number of hydrophobic groups in the material to be hydrolyzed, but the preferred concentration is in the range of 0.1 to 10N. The hydrolysis product may provide both alpha and beta carboxyl groups to the amines. This ratio may vary due to the strength of the hydrolyzing agent; however all of the hydrolyzing agents tested have given excellent activities in the testing carried out.
At the present time, the structure of the polymers is unknown, and although not wishing to be held to any theory, the lack of an equivalent amount of an amine in the reaction with maleic acid would appear to preclude the formation of a strict polyamide, as has been suggested to occur by a number of authors concerning the thermal polymerization of maleic acid with more than one equivalent of an amine. Studies of the mechanism of the antonic polymerization of maleic anhydride catalyzed by triphenyl phosphine and tributyl phosphine, showed the formation of succinic anhydride units and cyclopentanone units or ketoolefinic units. Such units, along with their nitrogen containing analogs may well present in the polymer of the present invention, most probably randomly interspersed in the polymer chain.
The polymers of the present invention provide properties which are different from their counterparts prepared with one or more equivalents of amine. The polymers also provide materials which are distinctly advantageous in their lighter color. The economic advantage due to reduced quantities of ammonia provides an economic incentive for their use.
The polymers are valuable intermediates which may be reacted further, for instance, after the manner of Jacquest, et al, U.S. Pat. No. 4,363,797, Fujimoto et al, U.S. Pat. No. 3,846,380 or Wood, U.S. patent application Ser. No. 08/031,856, filed Oct. 6, 1993, issued as U.S. Pat. No. 5,442,038 on Aug. 15, 1995.
The salts of these polymers are valuable as solubilizing agents, dispersing agents, emulsifying agents, rust-proofing agents, fiber-treating agents, level dyeing agents and retarding agents, inhibitors of metal scale deposition and inhibitors of corrosion of ferrous metals. As dispersing agents, they are useful in suspending paints, coal, day, pigments and paper fibers, to provide even suspensions, pumpable fluids and to prevent settling of sediments, for instance. The inhibition of metal scale deposition by these polymer salts may occur by prevention of nucleation of salts such as those of calcium, strontium, barium and magnesium in waters as well as by prevention of crystal growth by the addition effective amount of a the salt of the polymers. The use of said polymer salts in water treatment may also be desirable as a result of disruption of the crystal pattern of the metal salt, making a scale which is more easily removed. Thus, the incorporation of these salts or polymers into water treatment composition, which include a scale deposition inhibition effective amount of the salt, or polymer which may be hydrolyzed in situ, provides an effective water treatment composition. These polymer salts are useful when incorporated into laundry and dishwashing detergents as suspending agents or to prevent metal salt deposition on clothing, glassware or metal objects. The salts may be incorporated in oral health care products to prevent the accumulation of tartar on the teeth or on porcelain objects used in the mouth. Zinc salts are very useful in oral health care. They are especially useful in dentrifice compositions for inhibition of tartar deposition in effective amount of the salts of the polymers in combination with an orally acceptable dentrifice composition compatible with said salt, and more especially in the form of an oral hygiene formulation such as mouthwashes, rinses, irrigating solutions, abrasive gel dentrifices, nonabrasive gel dentrifices, denture cleansers, coated dental floss, interdental stimulator coatings, chewing gums, lozenges, breath fresheners, foams and sprays. They are useful in treating cloth and fibers as warp sizing compounds.
The addition of the polymer itself to the detergent formulation may be desirable where the pH of the detergent is sufficient to cause hydrolysis of the polymer yielding the salt in situ.
One object of this invention is to provide novel compositions useful as solubilizing agents, dispersing agents, emulsifying agents, rust-proofing agents, fiber-treating agents, level dyeing agents and retarding agents, inhibitors of scale deposition, inhibitors of corrosion of ferrous metals, inhibitors of scale formation in hard water, boiler water, cooling water, oil well waters, agricultural sprays and irrigation water and as builders and dispersants in detergent formulations.
Another object is to provide a method of producing these novel polymers.
Yet another object is to provide compositions suitable for incorporation in oral health care products for the inhibition of dental calculus.
A final object is to provide methods for preventing scale formation which are effective, low in cost, and environmentally benign.
DETAILED DESCRIPTION OF THE EMBODIMENTS
EXAMPLE 1
A solution of 39.2 g (0.4 moles) of maleic anhydride in 40 ml of water were stirred at 25°-75° C. for 45 min to give a white slurry of maleic acid. To this slurry was added 42 g of 30% aqueous ammonium hydroxide (0.36 moles NH 3 , 90% of theoretical required) with stirring and cooling. The resultant clear solution was then tumbled at 180°-200° C. (salt bath temperature) for 10 min to give a tan solid. The solids were pulverized and tumbled for 10 min at 200°-22° C. Once again the solids were pulverized and then tumbled at 225°-240° C. for 10 min. Finally, the solids were pulverized and tumbled for 10 min at 230°-240° C. to give 39.3 g of tan powder which was insoluble in water.
EXAMPLE 2
The procedure of Example 1 was repeated using 35 g of 30% aqueous ammonium hydroxide (0.3 moles NH 3 , 75% of theoretical required) to give 39.3 g of pink-tan powder which was insoluble in water.
EXAMPLE 3
The procedure of Example 1 was repeated using 23.5 g of 30% aqueous ammonium hydroxide (0.2 moles NH 3 , 50% of theoretical required) to give 37.8 g of pink-tan powder which was insoluble in water.
EXAMPLE 4
The procedure of Example 1 was repeated using 11.6 g of 30% aqueous ammonium hydroxide (0.1 moles NH 3 , 25% of theoretical required) to give 36.3 g of pink-tan powder which was soluble in water.
EXAMPLE 5
Four gram portions of the solids from Examples 1-4 were each dissolved 9.0 g of water containing 1.25 g of NaOH to give clear red*brown solutions, pH 7.5-8.5, estimated to contain 36-37% solids. Gel permeation chromatography (GPC) was run on a 1 cm×18 cm, Sephadex G-50 column in a mobile phase of 0.02M sodium phosphate buffer, pH 7.0, running at 0.5 ml/min, with detection in the UV at 240 nm. Table 1 shows the results which were obtained.
TABLE 1______________________________________Sample Residence time (min)______________________________________Example 1 21.5Example 2 21.0Example 3 23.0Example 4 31.0______________________________________
EXAMPLE 6
Preparation of a maleic polymer with a polyamine
To a solution of 4.6 g (0.025 moles) of lysine in 40 g of water containing 1.0 g of NaOH was added 39.2 g (0.4 moles) of maleic anhydride while stirring at 70°-75° C. for 10 min to give a pale yellow slurry of maleic acid. To this slurry was added 5.0 g (0.29 moles) of anhydrous ammonia with stirring and cooling. This solution was then treated with heat as in Example 1 to give 44.0 g of pink-tan powder which was insoluble in water.
A 4.0 g portion of the powder was dissolved in a solution of 9.0 g of water containing 1.3 g of NaOH to give a clear red-brown solution, estimated to contain 36% solids. Addition of 0.55 g of 30% H 2 O 2 gave a clear yellow solution after 16 hrs at 25° C. Chromatography of this solution as in Example 5 gave a peak centered at 13 min.
To prepare a 100% ammonia sample for comparison purposes, this experiment was carded out in the proportions above except that 1 equivalent of ammonia was used (noted as 6a in the results).
EXAMPLE 7
Calcium sulfate inhibition assay
The material to be tested as an inhibitor of calcium sulfate scale formation was added in the quantities indicated to a solution of 10 ml of calcium chloride solutions 17.3 g of CaCl 2 dihydrate in 800 g of water containing 33 g of NaCl). To this solution was then added 10 ml of sulfate solution (16.8 g of Na 2 SO 4 and 33 g NaCl in 800 ml of water). The mixture was then sealed and maintained at 65° C. for 16 hours. Finally the mixture was filtered through Whatman #2 paper and dried at 65° C. for 8 hours, after which the weight of precipitate was determined. The results in Table 2 were obtained.
TABLE 2______________________________________ percent of CaSO.sub.4 Inhibtion of PrecipitationSample from equivalence 1.25 ppm 2.5 ppmExample Number of ammonia 0 ppm (mg ppt) (mg ppt)______________________________________blank 79.51 90 23 102 75 4.5 13 50 48 04 25 51 35a 100 37 196 75 49 28 6a 100 52 14polyaspartic acid 38 10______________________________________ .sup.a prepared by the method of Example 1 using 1 equivalent of ammonia
EXAMPLE 8
Inhibition of calcium carbonate precipitation by the calcium drift assay
In this assay a supersaturated solution of calcium carbonate is formed by adding 29.1 ml of 0.55M NaCl and 0.01M KCl to 0.3 ml of 1.0M CaCl 2 , 5 microliter of sample (100 mg of the aqueous solution in 10 ml of water) and 0.6 ml of 0.5M NaHCO 3 . The reaction is initiated by adjusting the pH to 8.55-8.65 by titration with 0.5N NaOH. At three minutes, 10 mg of CaCO 3 is added and the pH is recorded. The decrease in pH is directly correlated to the amount of CaCO 3 that precipitates. The additive concentration in the final test solution is 2.7 ppm.
TABLE 3______________________________________Sample percent of CaCO.sub.3from equivalence DriftExample Number of NH.sub.3 (pH units)______________________________________blank 1.051 90 0.602 75 0.633 50 0.534 25 1.05a 100 0.88 6a 100 0.60polyaspartate 0.442000 mol. wt. polyacrylate 0.374500 mol. wt. polyacrylate 0.20______________________________________ .sup.a prepared by the method of Example 1 using 1 equivalent of ammonia
EXAMPLE 9
Dispersant activity
Kaolin dispersion was run by placing the sample (final concentration of 20 ppm) in a 12×100 mm test tube containing 5 ml of deionized water and adding 40,000 ppm kaolin clay. The height of the suspended solids was measured and compared to a control in which no dispersant had been added. A higher value indicates better dispersancy. Table 4 gives the results.
TABLE 4______________________________________Sample percent of Kaolin clayfrom equivalence helght (mm)Example Number of NH.sub.3 suspension settled______________________________________blank 0 151 902 75 47 3.53 50 48 2.54 25 48 2.5a 100 50 3 6a 100polyaspartate2000 mol. wt. polyacrylate 48 24500 mol. wt. polyacrylate 48 3______________________________________ .sup.a prepared by the method of Example 1 using 1 equivalent of ammonia
EXAMPLE 10
pH drift assay for calcium phosphate
A solution which is supersaturated with calcium phosphate was prepared by adding 0.1 ml of previously prepared aqueous solutions of 1.32M CaCl 2 dihydrate and 0.90M NaH 2 PO 4 to 29.8 ml of distilled water, resulting in 4.4 mM Ca 2+ and 3.0 mM dissolved inorganic phosphorus. The reaction vessel is maintained at 25° C. There is considerable irregularity in the time necessary to begin precipitation. Calcium phosphate begins to crystalize within a few minutes of initiation (first drop in pH) and is transformed to hydroxyapatite, Ca 10 (PO 4 ) 6 (OH) 2 , with a consequent downward pH drift (second drop in pH). The reaction ceases when the reactants are depleted and the pH ceases its downward drift. The samples prepared in Examples 1-4 and 6 were tested and the results (the average of two separate runs) are given in Table 5.
TABLE 5______________________________________Sample from percent of InductionExample equivalence periodNumber of ammonia (min)______________________________________blank 17.5 100 34.51 90 30.52 75 413 50 344 25 29.5a 100 26.56 75 34.5 6a 100 27polyaspartic acid 37______________________________________ .sup.a prepared by the method of Example 1 using 1 equivalent of ammonia
EXAMPLE 11
Maleic anhydride with 99% of a theoretical equivalent of NH 3
Maleic anhydride, 39.2 g (0.4 moles) dissolved in 40 g of water was added to 43.1 g of aqueous NH 4 OH (6.7 g NH 3 , 0.394 moles) and tumbled at 180°-195° C. for 8 min to give a clear pink melt. It heated to 185°-200° C. for 10 min to give a pink foam. The pulverized foam was heated for 10 min at 200°-235° C. to give a pink powder and then heated at 235°-2450° C. for 10 min to give 38.5 g of a pink tan powder. The material was hydrolyzed with aqueous NaOH. The GPC gave a peak at 23 min. In the CaSO 4 assay of Example 7, the blank was 83 mg while the sample at 2.5 ppm gave a precipitate of 11 mg and at 1.25 ppm it gave a precipitate of 41 mg. In the Kaolin dispersion test of Example 9, at 20 ppm the height of suspended solids was 48 mm whereas the blank was 0 mm.
EXAMPLE 12
Maleic anhydride with 5% of a theoretical equivalent of NH 3
Maleic anhydride, 39.2 g (0.4 moles) dissolved in 40 g of water was added to 4.3 g of aqueous NH 4 OH(0.34 g NH 3 , 0.02 moles) and tumbled at 180°-195° C. for 12 min to give a tan melt. It was then heated to 200°-2250° C. for 10 min to give a tan melt. The melt was heated for 10 min at 220°-230° C. to give 18.1 g of brown solid. The material was hydrolyzed with aqueous NaOH. In the CaSO 4 assay of Example 7, the blank was 80 mg while the sample at 2.5 ppm gave a precipitate of 50 mg and at 1.25 ppm it gave a precipitate of 78 mg.
EXAMPLE 13
Preparation of a maleic polymer with a polyamine
To a solution of 1.9 g (0.025 moles) of ethylene diamine in 40 g of water containing 1.0 g of NaOH was added 39.2 g (0.4 moles) of maleic anhydride while stirring at 70°-25° C. for 10 min to give a white slurry of maleic acid. To this slurry was added 21.7 g of water containing 1.7 g (0.1 moles) of ammonia with stirring and cooling. This solution was then heated for 15 min at 170°-200° C. to give a tan melt. The melt was heated at 200°-2250° C. for 10 min to give 36.5 g of a tan melt. It was further heated at 225°-235° C. for 10 min to give 35.4 g of tan melt which was not soluble in water.
The powder was dissolved in a solution of 9.0 g of water containing 1.3 g of NaOH to give a clear red-brown solution, estimated to contain 36% solids. In the CaSO 4 assay of Example 7, the blank was 80 mg while the sample at 2.5 ppm gave a precipitate of 22 mg and at 1.25 ppm it gave a precipitate of 66 mg. The GPC showed a peak at 29.5 min with a broad shoulder at 21-25 min.
EXAMPLE 14
Preparation of a maleic polymer with maleamic acid
A solution of 9.8 g (0.1 mole) maleic anhydride in 40 g of water was stirred 45 min at 75°-250° C. To this solution was added 34.5 g (0.3 mole) of maleamic acid. The slurry was tumbled at 180°-195° C. for 10 min. All of the solids dissolved to give 39.9 g of a viscous red-tan syrup. Upon further heating for six 10 rain periods at 180°-245° C., a tan powder, insoluble in water, was obtained. A 3.9 g portion was dissolved in 10 g of water containing 1.6 g of NaOH. The GPC showed a peak at 22.5 min. In the CaSO 4 assay of Example 7, the blank was 86 mg while the sample at 2.5 ppm gave a precipitate of 11 mg.
EXAMPLE 15
Preparation of a maleic polymer with diethylene triamine and oleic acid
A mixture of 2.0 g (0.0175 moles) of diethylene triamine and 1.13 (0.0195 moles) of oleic acid was heated with stirring for 10 min at 190°-210° C. The resulting oil was dissolved in 50 g of methanol. To this solution of 9.8 g (0.1 mole) maleic anhydride in 40 g of water was stirred 45 min at 75°-25° C. To this solution was added 39.0 g (0.4 mole) of maleic anhydride. The reactants were stirred 45 min, following which 4.3 g (0.25 mole) of ammonia in 20 g of water was added (75% of an equivalent). The slurry was tumbled at 170°-1850° C. for 10 min. Upon further heating for four 10 min periods at 190°-245° C., 42.3 g of a tan powder, insoluble in water, was obtained. A 4.0 g portion was dissolved in 10 g of water containing 1.6 g of NaOH. The GPC showed two broad peaks at 14 and 24 min. In the CaSO 4 assay of Example 7, the blank was 86 mg while the sample at 2.5 ppm gave a precipitate of 8 mg. In the Kaolin dispersion test of Example 9, at 20 ppm the height of suspended solids was 48 mm whereas the blank was 0 mm.
EXAMPLE 16
Preparation of a maleic polymer with oleyl amine
To a solution of 2.67 g (0.01 mole) oleyl amine in 50 g of methanol was added 39.2 g (0.4 mole) maleic anhydride with stirring for 45 min at 25° C., following which 5.0 g (0.29 mole) of ammonia in 20 g of water was added (75% of an equivalent). The slurry was tumbled at 170°-195° C. for 10 min. Upon further heating for four 10 min periods at 200°-2350° C., 41.4 g of a brittle glass, insoluble in water, was obtained. The material was dissolved in 100 g of water containing 16 g of NaOH. To this solution was added 5.5 g of 30% H 2 O 2 . After 16 hrs at 25° C., the solution was a clear yellow color. The GPC showed a peak at 14 min. In the CaSO 4 assay of Example 7, the blank was 86 mg while the sample at 2.5 ppm gave a precipitate of 9 mg.
It will be apparent to those skilled in the art that the examples and embodiments described herein are by way of illustration and not of limitation, and that other examples may be utilized without departing from the spirit and scope of the present invention, as set forth in the appended claims. | Polymers of maleic acid may be prepared by thermally polymerizing malic acid, maleic acid or fumaric acid with less than one equivalent of ammonia. The polymers are modified by the incorporation of amines, carboxylic acids or combinations thereof. The polymers formed are excellent inhibitors of alkaline earth salt deposition, dispersants, tartar control additives, detergent additives, and water treatment agents. | 2 |
BACKGROUND OF THE INVENTION
This invention relates to a titanium-clad steel with a high bonding strength and to a method for its manufacture.
Titanium-clad steel has been manufactured by the explosive cladding method, which is advantageous in that the formation of intermetallic compounds is markedly suppressed since the bonding area is not heated to high temperatures, bonding being achieved by heavy working. However, the explosive cladding method has drawbacks regarding noise, productivity, and manufacturing costs.
As a method to eliminate these drawbacks, a rolling method for manufacturing a titanium-clad steel has been developed. In carrying out the rolling method, important factors are (i) an insert to be placed between the steel base metal and Ti cladding, (ii) conditions for assembling with welding as well as for evacuating the assembly, and (iii) heating temperatures for rolling.
Among these factors, it is most important to select an insert particularly suitable for avoiding the formation of brittle intermetallic compounds in the bonding area.
Titanium easily forms intermetallic compounds with various other elements. There are only a few elements such as Mo, Nb, and V that do not form any intermetallic compounds with titanium. However, it is rather difficult to use such materials as an insert, since they are expensive and usually not available in the form of a thin plate. In addition, if they are used as an insert, they are easily broken during rolling.
The purpose of using an insert for manufacturing titanium-cladding steel is to pfevent the formation of intermetallic compounds as well as a brittle titanium carbide layer caused by diffusion of carbon from the base metal steel to the Ti cladding in the bonding area between the titanium or titanium alloy and the base metal steel.
In the prior art, in order to prevent the formation of titanium carbides in the bonding area it has been proposed to use a nickel insert (Japanese Patent Application No. 146763/1985), and a pure iron or ultra-low carbon steel insert (Japanese Patent Application Laid-Open Specification No. 122681/1981), and to carry out decarburization of the base metal steel on the titanium-facing side prior to cladding (Japanese Patent Application Laid-Open Specification No. 220292/1984).
The diffusion rate of nickel in titanium is large and the transformation of Ti from alpha-phase to beta-phase due to the diffusion of Ni into Ti during heating and rolling, further accelerates the diffusion of nickel into the Ti cladding. Therefore, the temperature range which can be employed is very restricted. Thus, a nickel insert is less desirable than ferrous inserts. However, the formation of intermetallic compounds is unavoidable even if a ferrous insert is used. Once formed, such intermetallic compounds grow during spinning, welding, strain-releasing annealing, and other processes which follow cladding, resulting in a deterioration in bonding properties.
Thus, in order to achieve stable and improved bonding properties, it is necessary to develop an insert with which there is no formation of intermetallic compounds in the boundary area between the Ti cladding and the insert, or which can delay the formation and growth of such intermetallic compounds.
SUMMARY OF THE INVENTION
The purpose of this invention is to provide a titanium-clad steel which is less expensive and is substantially free from intermetallic compounds in the bonding area between the Ti cladding and the base metal steel and a method for the manufacture thereof.
More specifically, the purpose of this invention is to provide a titanium-clad steel exhibiting a shear strength of 14 kgf/mm 2 or more as defined in JIS G 3603 (Ti-clad steels) even after being reheated to high temperatures, and a method for the manufacture thereof.
The inventor of this invention has noted that (i) niobium and vanadium do not form intermetallic compounds with titanium, (ii) Fe-V and Fe-Nb alloys can be worked more easily than Fe-Mo alloys and the former alloys can be rolled to form a thin plate, which is useful as an insert, and (iii) these metals are carbide-formers and effective to prevent the formation of Ti-carbides caused by diffusion of carbon from the base metal.
With the above in mind, the inventor has conducted a series of experiments and found that a ferrous insert containing Nb and V in an amount of 3% or more markedly inhibits the formation of intermetallic compounds of Ti and Fe and that these intermetallic compounds are not formed when the content of Nb and V is increased. This is because V and Nb are stabilizers for the beta-phase of Ti and broaden the beta-phase range due tb a diffusive dissolution of these elements into Ti to suppress the formation of intermetallic compounds between Fe and Ti.
Thus, according to this invention a ferrous alloy containing Nb and V is used as an insert.
Therefore, in one aspect, this invention is a titanium-clad steel with improved bonding properties, characterized by comprising a Ti-cladding, a base metal steel, and an insert between them, the insert being made of a ferrous alloy consisting essentially of, in % by weight, 0.05% or less of carbon, 3 to 20% by weight of at least one of niobium (Nb) and vanadium (V), and a balance of iron.
According to this invention, it is possible to provide a titanium-clad steel exhibiting stable and improved bonding properties. However, when it is heated for an extended period of time at a temperature over 600° C. or 650° C. during working or servicing, carbon from the base metal steel and Nb and V of the insert react to form a layer of carbides such as NbC and VC, which deteriorates the bonding properties.
The inventor of this invention has found that the provision of a nickel layer between the insert and the base metal can successfully prevent the diffusion of carbon from the base metal while producing no adverse effects on the insert of the ferrous alloy.
Thus, in another form, this invention is titanium-clad steel with improved bonding properties, characterized by comprising a Ti-cladding, a base metal steel, an insert on the Ti-cladding, and an intermediate layer on the base metal steel, the insert being made of a ferrous alloy consisting essentially of, in % by weight, 0.05% or less of carbon, 3 to 20% by weight of at least one of niobium (Nb) and vanadium (V), and a balance of iron, the intermediate layer being made of nickel (Ni) or a nickel alloy.
The inventor of this invention has also found that austenitic alloys with a fcc crystal structure such as austenitic stainless steels are very effective to successfully prevent diffusion of carbon from the base metal steel, and that the diffusion of carbon is determined by the crystal structure of the matrix phase, and the diffusion rate of carbon in the closed-packed structure is small, i.e., 0.1 mm for 100 hours at 600° C.
Thus, in a preferred embodiment, this invention is a titanium-clad steel with improved bonding properties, characterized by comprising a Ti-cladding, a base metal steel, an insert on the Ti-cladding, and an intermediate layer on the base metal steel, the insert being made of a ferrous alloy consisting essentially of, in % by weight, 0.1% or less of carbon, 1 to 20% by weight of at least one of niobium (Nb) and vanadium (V), and a balance of iron, the intermediate layer being made of Fe-Ni-Cr austenitic alloy containing the amounts of Ni and Cr as defined by the following formulas, in % by weight;
Cr≦18%, Ni≧-0.78 Cr %+26
Cr>18%, Ni≧1.13 (Cr %-18)+12
wherein, Cr %+Ni %≦100
In a still another aspect, this invention is a method of manufacturing a Ti-clad steel with improved bonding properties, which comprises a Ti cladding and a base metal steel, the method comprising preparing a cladding assembly of the Ti-cladding, the base steel, and an insert placed between them, the insert being made of a ferrous alloy containing, in % by weight, 3 to 20% of at least one of Nb and V, and a balance of iron, heating the cladding assembly or the bonding area at a temperature of 680° to 900° C., and preferably 700° to 870° C., and effecting bonding under pressure.
In a preferred embodiment, an intermediate plate of nickel or nickel alloy may be placed between the insert and the base metal steel.
The intermediate plate may also be replaced by the before-defined Fe-Ni-Cr austenitic alloy.
The preparation of the cladding assembly comprises sealing the assembly of the Ti-cladding, the insert, the intermediate layer, if used, and the base metal steel, degassing, and evacuating the assembly.
The Ti cladding may include pure titanium and titanium alloys. The base metal steel is not restricted to a specific one, but preferably it is selected from carbon steels and low-alloy high-strength steels.
The insert may be a powder layer, powder coating layer, or electroplated layer placed on the base metal.
The austenitic alloy may contain 0.1% by weight or less of carbon, and it may contain Mn, Si, Mo, Ti, Nb, and other alloying elements in a total amount of 5% by weight or less.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagramatic sectional view of a cladding assembly of this invention;
FIG. 2 and FIG. 3 are graphs showing the test results of the working examples of this invention;
FIG. 4 and FIG. 5 are graphs showing relationships between the growth of intermetallic compounds and heating time for Nb- and V-bearing inserts, respectively; and
FIG. 6 is a graph showing the Ni and Cr content of alloys used as an intermediate member.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
This invention will now be described in conjunction with the attached drawings.
FIG. 1 shows a diagramatic sectional view of a cladding assembly 1 prior to bonding. The assembly 1 comprises Ti cladding 2 and a base metal steel 3, an insert 4 of a ferrous alloy placed between them, and if necessary, an intermediate member 5 of a nickel or an austenitic alloy. The thickness of the insert is preferably 0.5 mm or more, and usually 1 mm or more. The thickness of the intermediate member is generally greater than 50 μm, and preferably greater than 100 μm, but is thinner than the insert. A cover 6 is disposed over the whole of the assembly, and is seal-welded to the base metal steel. The inside thereof is degassed and evacuated, preferably to 10 -1 Torr or less. The evacuation is carried out in order to suppress oxidation of each of the bonding surfaces. When a predetermined level of vacuum is achieved, the whole of the assembly or at least the bonding area thereof is heated to 680° to 900° C., and preferably 700° to 870° C., and is hot rolled to effect cladding. After the rolling, the cover 6 is removed to obtain a Ti-clad steel.
Each of the steps mentioned above is known in the art as a rolling method to achieve cladding except for the above-specified heating conditions.
The reasons for the restrictions on the composition of the insert employed in this invention will be described in more detail.
First, the carbon content is defined as 0.05% or less in order to have V and Nb as active as possible. For this purpose, the lower the carbon content the better. When the carbon content is over 0.05%, Nb and V easily react with carbon to form carbides thereof, causing cracks during cold rolling which is employed to prepare an insert in the form of a thin plate. The upper limit on the carbon content is therefore set at 0.05%, since a satisfactory level of the shear strength can be obtained even when the content of carbon is restricted to 0.05% or less. In case the Fe-Ni-Cr alloy is used as the intermediate member between the insert and the base metal, the upper limit of carbon may be 0.1%.
Regarding the content of Nb and V, the total amount thereof is restricted to 3.0% or more. In case the Fe-Ni-Cr alloy is employed in place of the nickel plate as the intermediate member, the lower limit of a total amount of Nb and V may be 1.0%. It is not always necessary to specify an upper limit thereon, ut in view of the material costs, the upper limit thereof is restricted to 20%. Preferably, the total amount of Nb and/or V is 5-15%.
Such a ferrous alloy insert may be placed on the base metal steel in the form of a thin plate or a foil. The insert may be formed by means of powder coating.
In a preferred embodiment of this invention, an additional insert, i.e., the intermediate member may be employed in order to further improve the bonding properties. The intermediate member may be a nickel plate or nickel alloy plate. The nickel plate may be of industrial-grade pure nickel. The purity and the content of impurities do not have any substantial effects. The nickel alloy may include commercial nickel alloys such as Permalloy (50% Ni - 50% Fe)--tradename--and invar alloys (36% Ni - 64% Fe).
The nickel intermediate member may be in the form of a foil. This layer may also be formed by means of electroplating or powder coating.
Since one of the purposes of providing the intermediate member is to prevent the carbon of the base metal from diffusing and permeating into the ferrous alloy insert when reheating after rolling, the thickness of the intermediate member is expressed in terms of thickness after rolling. If it is expressed in this way, a thickness of 5 μm or more is enough.
On the other hand, regarding the intermediate member of Fe-Ni-Cr alloys which may be used in place of the nickel intermediate member between the insert and the base metal steel, the crystal structure is to have an austenitic phase (fcc phase) in order to prevent diffusion of carbon from the base metal steel. As long as it has an austenitic phase, there is no limit regarding the intermediate member.
Fe-Ni-Cr alloys which comprise an austenitic phase (fcc phase) are austenitic alloys containing the amounts of Ni and Cr defined by the following formulas, in % by weight;
Cr≦18%, Ni≧-0.78Cr %+26
Cr>18%, Ni≧1.13(Cr %-18)+12
wherein, Cr %+Ni %≦100.
The austenitic alloy intermediate member may be in the form of a foil. This layer may also be formed by means of electroplating or powder coating.
FIG. 6 is a graph showing the Ni and Cr content of alloys used as an intermediate. The hatched area in the graph indicates an austenitic alloy, and the other area indicates ferrite or ferrite+austenite dual-phase alloys. The reference numerals in the graph refer to the alloy numbers of Table 3 to be detailed hereinafter.
The presence of Fe does not have any substantial effects on the formation of an austenitic phase, and the Fe content does not have any upper limit. However, the Ni content should be as low as possible because Ni is expensive. The remainder is iron with incidental impurities. Therefore, it is desirable that the Fe content be as high as possible. When the austenitic alloy contains more than 0.1% of carbon, the diffusion of carbon sometimes occurs so much that Ti carbides form, producing a decrease in bonding strength. Thus, it is desirable that the carbon content be restricted to 0.1% or less. In addition, when the total amount of other alloying elements such as Si, Mn, Mo, Ti, and Nb is more than 5% by weight, the austenitic phase becomes unstable. Thus, the total content of these elements, if present, is restricted to 5% by weight or less.
There is no specific restriction on the thickness of the intermediate member. The thickness is determined in view of reheating temperatures and reheating time after rolling. In most cases, a thickness of 5 μm or more after cladding by rolling is enough. The upper limit may be determined based on the circumstances.
A cladding assembly is heated to a predetermined temperature and then is subjected to bonding under pressure. In the case of this invention, the bonding area or the whole of the cladding assembly is heated to 680° to 900° C., preferably 700° to 870° C., and then is subjected to bonding under pressure. When the assembly is not heated to 680° C. or higher, and preferably 700° C. or higher, the interdiffusion is not thorough, and a more powerful rolling apparatus is necessary to carry out rolling. In contrast, when the assembly is heated to a temperature higher than 900° C., transformation of the Ti cladding into beta-phase takes place or the formation of beta-phase is accelerated. As a result, the diffusion rate of Ti becomes too great, accelerating the formation of intermetallic compounds, so that the bonding strength does not satisfy specifications. Therefore, in this invention, the upper limit on the heating temperature is defined as 900° C. and preferably 870° C.
A typical means of carring out bonding under pressure is rolling. It may also be performed by forging and the like, which are suitable methods for carrying out bonding of small-sized articles.
This invention will be further detailed with reference to working examples, which are presented merely for illustrative purposes.
EXAMPLE 1
A plate of low-alloy high-strength steel of 50 kgf/mm 2 grade, 90 mm thick, was machined to give a flat surface and degreased. This plate was the base metal. A Ti-plate (JIS first grade), 10 mm thick, was used as the Ti cladding. These members were assembled by means of welding to give the cladding assembly shown in FIG. 1. In this example, the intermediate member 5 was deleted. As the insert 4, a lot of materials shown in Table 1 were employed in the form of a sheet 1 mm thick. The inside of the cladding assembly was evacuated to a pressure of 3×10 -1 Torr, and then was closed. After heating, bonding under pressure was carried out to provide a 20-mm thick Ti-clad steel.
The thus-manufactured Ti-clad steels were then subjected to the shearing tensile test defined in JIS G 0601 to evaluate the bonding properties.
When the heating temperature was within the range of 700°-800° C., the shear strength was over 14 kgf/mm 2 for each of the specimens. In order to evaluate a change in the shear strength after reheating, the shear strength after reheating at 850° C. for 10 hours was determined. For the steel of this invention, the shear strength was 14 kgf/mm 2 or more, showing improvement in bonding properties. The test results are summarized in Table 1 and the relationships between the shear strength of the as-rolled specimens and that of the specimens after being reheated are shown in FIGS. 2 and 3, respectively.
The relationships between the content of Nb and V of the ferrous alloy insert and the growth of intermetallic compounds were evaluated.
FIGS. 4 and 5 show graphs of the thickness (μm) of intermetallic compounds with iron in the boundary of the base metal steel, which are plotted with respect to the heating time (second) at 850° C. when the contents of Nb and V are varied.
In these cases, when the content of Nb and V is 3% or more, there is no longer a significant degree of formation of intermetallic compounds. When the content goes over 20%, the effect thereof saturates.
EXAMPLE 2
In this example, Example 1 was repeated except that the intermediate member 5 of industrial-grade pure nickel was used in the form of a foil 100 μm thick.
In this example, too, when the heating temperature was within the range of 700°-800° C., the shear strength was over 14 kgf/mm 2 for each of the specimens. In order to evaluate a change in the shear strength after reheating, the shear strength after reheating at 850° C. for 10 hours, 30 hours, and 100 hours was determined. For steels of this invention, the shear strength was 14 kgf/mm 2 or more even after being reheated at 850° C. for 100 hours, showing a remarkable improvement in bonding properties. The test results are summarized in Table 2.
EXAMPLE 3
In this example, Example 2 was repeated except that a Fe-Ni-Cr alloy in a foil 100 μm thick was used in place of the Ni member as the intermediate member.
In order to evaluate the bonding properties after reheating, the test pieces were heated to 850° C. for 100 hours, and the change in shearing strength was determined.
The alloying compositions of austenitic alloys of the intermediates employed in this example are shown in Table 3.
The test results are summarized in Table 4.
As is apparent from the test results shown in Table 4, according to this invention, the shear strength of the as-rolled steel was 20 kgf/mm 2 or more for each of the test samples. In addition, after heating at 850° C. for 100 hours, the shear strength defined in JIS specifications is 14 kgf/mm 2 or higher, e.g., 20 kgf/mm 2 or higher. Thus, according to this invention bonding properties have been improved remarkably.
As is apparent from the foregoing, this invention can provide a Ti-clad steel in which intermetallic compounds are not found in the bonding area, and which exhibits improved properties including a high level of bonding strength even after reheating at high temperatures. Thus, this invention is very advantageous from a practical viewpoint.
TABLE 1______________________________________Ferrous Alloy Heating Shear StrengthInsert Tempera- (kgf/mm.sup.2)Run (% by weight) ture As- Re-No. C Nb V (°C.) Rolled heated Remarks______________________________________1 0.02 3.1 -- 800 20 18 Invention2 0.02 3.1 -- 650 8 2 Compara- tive3 0.04 10 -- 850 25 20 Invention4 0.03 20 -- 830 27 25 Invention5 0.03 20 -- 950 9 3 Compara- tive6 0.02 0.5 -- 820 18 6 Compara- tive7 0.03 -- 0.3 830 19 4 Compara- tive8 0.03 -- 3.2 850 22 18 Invention9 0.01 -- 5 800 25 19 Invention10 0.03 -- 11 750 28 25 Invention11 0.01 -- 19 700 25 24 Invention12 0.03 5 10 750 24 20 Invention13 0.02 0.2 0.1 800 19 6 Compara- tive______________________________________
TABLE 2__________________________________________________________________________Ferrous Alloy Heating Shear Strength (kgf/mm.sup.2) Insert Inter- Tempera- Time Elapsed AfterRun (% by weight) mediate ture Heating at 850° C. (hr)No. C Nb V Member (°C.) As-Rolled 10 30 100 Remarks__________________________________________________________________________ 1 0.02 3.5 -- Present 800 22 20 20 18 Invention 2 0.02 3.5 -- None* 800 22 20 14 10 Comparative 3 0.02 3.5 -- Present 650* 10 2 3 1 Comparative 4 0.04 10 -- Present 850 25 25 20 18 Invention 5 0.04 10 -- None* 850 25 23 18 13 Comparative 6 0.03 20 -- Present 830 27 27 25 20 Invention 7 0.03 20 -- None* 830 27 25 20 13 Comparative 8 0.03 20 -- Present 950* 13 10 8 5 Comparative 9 0.02 0.5* -- Present 820 20 18 12 5 Comparative10 0.03 -- 0.3* Present 800 18 15 5 2 Comparative11 0.03 -- 4.5 Present 750 28 25 20 16 Invention12 0.03 -- 4.5 None* 750 28 20 14 7 Comparative13 0.03 -- 4.5 Present 600* 8 5 2 2 Comparative14 0.03 -- 11 Present 800 28 25 25 20 Invention15 0.03 -- 11 None* 800 28 20 14 10 Comparative16 0.03 -- 19 Present 700 30 28 25 25 Invention17 0.01 5 10 Present 700 27 27 26 20 Invention18 0.02 5 10 None* 750 28 21 17 10 Comparative19 0.02 0.3 0.5 Present 820 20 18 13 8 Comparative__________________________________________________________________________ None: *indicates outside the range of the invention.
TABLE 3______________________________________AlloyNo. C Cr Ni Others______________________________________1 0.08 5.0 80.02 0.04 19.9 55.3 Mn = 1.53 0.10 40.2 50.2 Si = 2.54 0.02 20.3 25.7 Mo = 1.05* 0.02 39.8 30.46* 0.10 4.8 10.57* 0.08 50.3 0.248* 0.05 35.2 20.2______________________________________ Note: *indicates outside the range of the invention.
TABLE 4__________________________________________________________________________Ferrous Alloy Fe--Ni--Cr Shear StrengthInsert Alloy (kgf/mm.sup.2)Run (% by weight) (Alloy No. 100 hours AfterNo. C Nb V of Table 3) As-Rolled Heating at 850° C. Remarks__________________________________________________________________________1 0.09 3.5 -- 1 25 20 Invention2 0.03 5.2 -- 6* 28 11 Comparative3 0.10 10.3 -- 2 30 23 Invention4 0.09 12.5 -- 8* 31 10 Comparative5 0.05 20.0 -- 3 35 25 Invention6 0.03 19.5 -- 7* 33 12 Comparative7 0.10 -- 4.5 4 26 18 Invention8 0.02 -- 4.6 5* 26 7 Comparative9 0.03 -- 11.2 1 30 20 Invention10 0.08 -- 13.0 6* 31 10 Comparative11 0.03 -- 19.0 2 34 24 Invention12 0.09 -- 19.5 8* 35 11 Comparative13 0.02 2.0 1.5 3 24 18 Invention14 0.01 2.0 2.0 7* 25 6 Comparative15 0.07 10.0 2.0 4 31 23 Invention16 0.03 11.0 2.5 5* 32 12 Comparative__________________________________________________________________________ Note: *indicates outside the range of the invention. | A titanium-clad steel with improved bonding properties and a method for the manufacture thereof are disclosed. The titanium-clad steel is characterized by comprising a Ti-cladding, a base metal steel, and an insert between them, the insert being made of an alloy consisting essentially of, in % by weight, 0.05% or less of carbon, 3 to 20% by weight of at least one of niobium (Nb) and vanadium (V), and a balance of iron. | 8 |
BACKGROUND OF THE INVENTION
The present invention relates to an arithmetic circuit for performing arithmetic, logical, and other general operations and, more particularly, to a stack-type arithmetic circuit for performing operations by using a stack.
A conventional stack-type arithmetic circuit of this type pops necessary data from a stack to perform an operation, and pushes back an operation result to the stack. That is, data to be operated is stored in only the stack. An up/down counter is used as a stack pointer for accessing the stack.
The operation speed of the above conventional stack-type arithmetic circuit, however, is lower than that of an arithmetic circuit (to be referred to as a register-type arithmetic circuit hereinafter) which holds data to be operated in a register and stores an operation result in the register In addition, this register-type arithmetic circuit can execute an instruction in one cycle, while the stack-type arithmetic circuit cannot execute an instruction in one cycle since the stack must be accessed Furthermore, since the structure of an up/down pointer used as a stack pointer is complicated, switching between counting directions requires a long time.
SUMMARY OF THE INVENTION
It is a first object of the present invention to provide a stack-type arithmetic circuit capable of increasing an operation speed above that of a conventional arithmetic circuit.
It is a second object of the present invention to provide a stack-type arithmetic circuit capable of completing an operation in one cycle of a stack.
It is a third object of the present invention to provide a stack-type arithmetic circuit capable of forcibly interrupting all instructions currently being executed in accordance with an external signal.
In order to achieve the above objects of the present invention, there is provided a stack-type arithmetic circuit which has a stack structure for holding data to be operated, performs an operation by an arithmetic unit by using the data to be operated on the stack in accordance with an operation instruction, and stores an operation result again in the stack, comprising a first register, having input and output terminals connected to an external bus via buffers, respectively, for holding the latest value pushed by the stack, a second register, having input and output terminals connected to the output and input terminals of the first register, respectively, for holding an immediately preceding value of the latest value, and a memory for holding remaining data in the stack be operated, wherein outputs from the first and second registers are supplied to the arithmetic unit, and an output result from the arithmetic unit is returned to the first register.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram showing an embodiment of the present invention; and
FIGS. 2A to 2J are timing charts showing an operation of the circuit shown in FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
An embodiment of the present invention will be described in detail below with reference to the accompanying drawings.
FIG. 1 shows an arithmetic circuit according to the embodiment of the present invention. Referring to FIG. 1, reference numerals 1a to 1f denote buffers; 2a to 2c, 2-input/1-output data selectors; 3, a memory (STACK); 4, a register (MSTR) for holding the most significant data of a logical stack; 5, a register (SSTR) for holding the second significant data of the logical stack; 6, a down counter (SP) which receives an output from an adder (to be described below) as a new down counter value and is updated at the leading edge of a clock at the end of each of execution cycles T1, T2, . . . , shown in FIG. 2A; 7, an adder (INC) for adding "1" to an output value from the down counter (SP); 8, an arithmetic unit for actually performing an operation; and 9a to 9j, signal lines.
The register (MSTR) 4 and the register (SSTR) 5 are updated to input values at the leading edge of a clock shown in FIG. 2B at the end of each of execution cycles T1, T2, T3, . . . , shown in FIG. 2A. The memory (STACK) 3 is similarly updated to a value of an address represented by an address from the buffer 1f. FIGS. 2A to 2J are timing charts showing an operation of the arithmetic circuit, in which FIG. 2C shows an operation instruction to be executed; FIG. 2D, data on the signal line 9a; FIG. 2e, data in the register (MSTR) 4; FIG. 2f, data in the register (SSTR) 5; FIG. 2g, data on the signal line 9g; FIG. 2H, data in the down counter (SP) 6; FIG. 21, an output from the adder (INC) 7; and FIG. 2J, data on the signal line 9j.
An operation of the arithmetic circuit having the above arrangement will be described below with reference to FIGS. 2A to 2J. In order to externally push data to the logical stack, external data is inputted to the register (MSTR) 4 via signal line 9a - buffer 1- signal line 9b - selector 2a. Data in the register (MSTR) 4 is inputted to the register (SSTR) 5 via signal line 9c - selector 2b. Data in the register (SSTR) 5 is inputted to the memory (STACK) 3 via signal line 9e - buffer 1e - signal line 9g. At this time, the value of the down counter (SP) 6 is incremented by "1" by the adder (INC) 7 and this result is supplied from the selector 2c to the memory (STACK) 3 as its address via the buffer 1f. Even if interruption of a PUSH instruction is externally forced while the instruction is being executed, the instruction can be interrupted if it is before the leading edge of a clock. In this case, even if the value of the memory (STACK) 3 is already updated, data in the memory (STACK) 3 can be held unless the down counter (SP) 6 is updated. In order to pop data from the stack 3 to external equipment, the most significant data of the logical stack is outputted to external equipment via register (MSTR) 4- signal line 9c - buffer 1b - signal line 9a. The second significant data in the logical (STACK) 3 is selected via register (SSTR) 5- signal line 9e - data selector 2a and input to the register (MSTR) 4. Data to be input to the register (SSTR) 5 is selected via memory (STACK) 3- signal line 9g - buffer 1d - data selector 2b and input to the register (SSTR) 5. At this time, the value of the down counter (SP) 6 is selected by the selector 2 c and inputted from the buffer 1f to the stack 3 as its address. The register (MSTR) 4 and the register (SSTR) 5 are updated and the value of the down counter (SP) 6 is decremented at the leading edge of a clock at the end of each of the execution cycles T1, T2, . . . In this case, if interruption of the instruction is externally forced, the instruction can be interrupted by interrupting updating of the register (MSTR) 4, the register (SSTR) 5, and the down counter (SP) 6. In order to perform a binary operation using the most significant data and the second significant data of the stack 3 as data to be operated, data to be operated is input from the register (MSTR) 4 to the arithmetic unit 8 via the signal line 9c and is also input from the register (SSTR) 5 to the arithmetic unit 8 via the signal line 9e, and the arithmetic unit 8 executes the operation. The operation result is input to the register (MSTR) 4 via signal line 9d - buffer 1c - selector 2a. Data to be set in the register (SSTR) 5 is supplied from the memory (STACK) 3 as in the pop operation. At this time, the value of the down counter (SP) 6 is similarly supplied to the memory (STACK) 3 as its address. The register (MSTR) 4 and the register (SSTR) 5 are updated and the value of the down counter (SP) 6 is decremented at the leading edge of the clock at the end of each execution cycle. As in the case of the pop operation, the operation instruction can be interrupted by interrupting updating of the register (MSTR) 4, the register (SSTR) 5, and the down counter (SP) 6. In order to perform a unitary operation using the most significant data of the logical stack as data to be operated, data to be operated is supplied to the arithmetic unit 8 via register (MSTR) 4- signal line 9c, and the arithmetic unit 8 executes the operation. The operation result is input to the register (MSTR) 4 via signal line 9d - buffer 1c - data selector 2a. The register (MSTR) 4 is updated at the leading edge of the clock (see FIG. 2B) at the end of each execution cycle shown in FIG. 2A. In this case, the operation instruction can be interrupted by interrupting updating of the register (MSTR) 4.
A calculation of equation C=NOT (A) AND (B) will be described below as an example. In an operation instruction shown in FIG. 2C, if a PUSH instruction is executed in the execution cycle T1, data "A" on the signal line 9a connected to an external data bus shown in FIG. 2D is read by the register (MSTR) 4 via buffer 1a - signal line 9b - data selector 2a, as shown in FIG. 2E. At this time, a value X of the register (MSTR) 4 is transferred to the register (SSTR) 5 via signal line 9c - data selector 2b, as shown in FIG. 2F. The value of the adder (INC) 7 is set in the down counter (SP) 6, as shown in FIG. 2H. When a NOT instruction shown in FIG. 2C is executed in the execution cycle T2, negation "A" of the data "A" is set in the register (MSTR) 4, while the other values are kept unchanged. When a PUSH instruction shown in FIG. 2C is executed in the execution cycle T3, data B on the signal line 9a shown in FIG. 2D is read by the register (MSTR) 4 via buffer 1a - signal line 9b - data selector 2a, as shown in FIG. 2E. The other operation is the same as in the execution cycle T1. When an AND instruction shown in FIG. 2C is executed in the execution cycle T4, an AND result of NOT (A) AND (B) is set in the register (MSTR) 4, and the previous data X is returned from the memory (STACK) 3 to the register (SSTR) 5. For this reason, the value of the down counter (SP) 6 is decremented as shown in FIG. 2H. When a POP instruction shown in FIG. 2C is executed in the execution cycle T5, the operation result in the register (MSTR) 4 is output to the external data bus via signal line 9c - buffer 1b - signal line 9a, as shown in FIG. 2D. The value X is returned from the register (SSTR) 5 to the register (MSTR) 4, and the value Y is returned from the memory (STACK) 3 to the register (SSTR) 5. The value of the down counter (SP) 6 is decremented.
As has been described in detail above, according to the arithmetic circuit of the present invention, the register for holding data to be operated is additionally used together with the stack pointer and the adder, thereby simultaneously executing access of the stack and an operation. In addition, since an operation can be completed in one cycle of a clock, an operation speed can be increased. Furthermore, since updating of the registers and the counter is performed at the end of each execution cycle, all instructions currently being executed can be forcibly interrupted by an external signal. | A stack-type arithmetic circuit includes a first register, a second register, and a stack. The first register has input and output terminals connected to an external bus via buffers, respectively, and holds the latest value pushed by the arithmetic circuit. The second register has input and output terminals connected to the output and input terminals of the first register, respectively, and holds an immediately preceding value of the latest value. The stack holds remaining data to be operated. Outputs from the first and second registers are supplied to an arithmetic unit, and an output result from the arithmetic unit is returned to the first register. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation application of U.S. patent application Ser. No. 11/667,324, filed May 8, 2007, which was the National Stage of International Application No. PCT/US2005/009511, filed Mar. 22, 2005, which claims the benefit of U.S. Provisional Application No. 60/559,600, filed Apr. 5, 2004, all of which are incorporated herein by reference in their entireties.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to propping agents, and more particularly to propping agents that are labeled to enable detection of the presence of the propping agent.
[0004] 2. Description of the Related Art
[0005] One of the problems encountered in attempting to maximize recovery of hydrocarbons such as crude oil and natural gas from underground formations is the entrapment of hydrocarbons within low permeability formations. In fact, wells often contain large amounts of the hydrocarbon entrapped in such low permeability rock formations. The entrapped hydrocarbon, of course, does not flow readily to the well bore.
[0006] Thus, subterranean formations that contain entrapped hydrocarbons are often “fractured” to enhance the recovery of the entrapped hydrocarbon from the formations. Fracturing typically involves the injection of viscosified aqueous or hydrocarbon fluids into the well bore at a rate and pressure in excess of the formation stresses, thereby causing rock fatigue and opening or inducing new fractures in the formation. Fractures are natural or induced fissures or channels in the formation matrix. The injected fluids usually contain a proppant material, commonly referred to as a “propping agent” or simply a “proppant.” Proppants are particulate solids such as sand or ceramic particles, which may or may not be coated with another material such as resin. After the exerted injection pressure has been relieved, the fractures, which would otherwise tend to close, are propped open by propping agent left behind in the fracture. More conductive channels are thus provided to allow the oil or gas to flow to the well bore after the injection pressure is relieved.
[0007] Frequently, however, a substantial portion of the proppant does not remain in the fractures, but flows back to the well bore. Such proppant flowback not only results in inefficiency due to the failure of the proppant that has flowed back to serve its purpose of propping open the fractures, but also can cause serious wear in the production equipment. In wells that contain more than one zone to which proppant has been delivered it can be very difficult to determine which of the zones may be the source of the proppant flowback problem. Therefore, the proppant flowback problem is particularly troublesome in such wells.
[0008] Some techniques have been developed which provide a means to identify the zone or zones that are the source of the proppant flowback. Generally, such techniques involve tagging the proppants with a tracer or marker that can be detected by some standard method. According to such techniques, the proppant delivered to each zone is tagged with a tracer distinct from the tracers associated with the other zones. By detecting which tracer is present in the proppant that has flowed back from the formation, it can then be determined the zone from which the proppant flowed.
[0009] However, none of the techniques so far developed are entirely satisfactory. For example, radioactive tracers have been used, but radioactive materials can have a short shelf-life and may be difficult to handle and can be hazardous to the environment. U.S. Pat. No. 6,691,780 discloses a technique for tagging proppants with non-radioactive materials, but that technique employs a tag within a resin coating over the proppant. Thus, the technique is limited to resin-coated proppants and is susceptible to loss of the tags if the coating is lost by friction, heat or other means.
[0010] As a result, superior tagged proppants, and methods of producing them, that avoid the aforementioned problems are still needed. In particular, it is desired that the tagged proppant be non-radioactive and be tagged in a way that is not susceptible to loss of the tracer by friction and the like. Moreover, because the proppants must be suspended in the carrier fluid and must withstand substantial forces to prop open fractures, and because the purpose of the proppants is to increase flow-through or “conductivity” of fluids, the tagged proppant should maintain the strength and density of the untagged proppant, and should provide at least a similar conductivity (that is, fluid flow-through) as does the untagged proppant.
SUMMARY OF THE INVENTION
[0011] Briefly, therefore, the present invention is directed to a novel proppant composition comprising a non-radioactive, detectable tracer at least partially embedded in a ceramic composition.
[0012] The present invention is also directed to a novel method for producing a particle comprising a non-radioactive, detectable material and a ceramic material, the method comprising agglomeration of granules of the ceramic material and granules of the non-radioactive, detectable material to produce the particle by compression.
[0013] The present invention is also directed to a novel method for producing a substantially resin-free particle that need not be resin-coated, but may be (if so desired) at least partially coated with resin, comprising agglomeration of granules of the ceramic material and granules of the non-radioactive, detectable material to produce the substantially resin-free particle comprising the non-radioactive, detectable material at least partially embedded in the ceramic material. If a coating is desired, the substantially resin-free particle thus formed may then at least partially coated with a coating material.
[0014] The present invention is also directed to a novel method for tracking the backflow of proppants in a fractured subterranean formation into which a plurality of such tagged proppant composition particles have been introduced. According to the method, a sample of the backflow is analyzed by detecting for presence of the tracer in the sample.
[0015] Among the several advantages found to be achieved by the present invention, therefore, may be noted the provision of a tag that is integral with the ceramic material rather than associated with the ceramic material by means of a coating; the provision of a proppant that bears such a tag; the provision of such proppant that maintains desirable strength, density and conductivity despite the presence of the tag; the provision of a method for preparing such tagged proppants; and the provision of a method for tracking particulate flowback with such proppants.
[0016] Further features and advantages of the present invention, as well as the structure and operation of various embodiments of the present invention, are described in detail below with reference to the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a graph of the conductivity for an untagged proppant compared to that of the proppant tagged with a tracer “A” and that of the proppant tagged with a tracer “B,” wherein tracer “A” is lanthanum oxide and wherein tracer “B” is cerium oxide.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] In accordance with the present invention, it has been discovered that, surprisingly, a non-radioactive tracer may be embedded in a ceramic proppant without diminishing the strength or conductivity of the proppant or undesirably altering its density. In fact, the proppants can even be tagged according to the methods of this invention to allow different versions of the tagged proppant with identical strengths and densities to be distinguished. Moreover, because the tag is embedded in the ceramic, it is not prone to wearing or flaking off of the proppant due to friction, heat or other causes typically encountered by the proppant. And, because the tracers of the subject invention do not break down like radioactive tracers, they are not hazardous and have virtually unlimited shelf-lives.
[0019] While particles comprising or derived from bauxite (low grade or “true” bauxite), kaolin or other particles comprising one or more clays, alumina, silica and mixtures of any of the foregoing have been found particularly suitable for tagging according to the preparation techniques of the present invention, it is believed that any ceramic proppant may be tagged according to the preparation techniques of this invention. Many ceramic materials suitable for proppants are well known. For example, Lunghofer U.S. Pat. No. 5, 120,455, Fitzgibbon U.S. Pat. Nos. 4,427,068 and 4,879,181, and patents cited in each of the foregoing patents, identify a variety of proppants and proppant materials, and are incorporated herein by reference. The proppant materials themselves will be referred to herein as “ceramic compositions” in contrast and distinction to the tracer that is applied thereto.
[0020] It is believed that the tagged proppant of this invention made be prepared by any standard pelletizing or tabletting technique well known in the proppant manufacture, pelletizing and tabletting arts for agglomerating a powder into a proppant, pellet or tablet, but wherein the powder is a mixture of ceramic composition and tracer, as discussed below, and the resulting particle, pellet or tablet is of appropriate size, shape, strength and density as is well known for suitable proppants. Thus, for example, the tagged proppant may be prepared by continuous spray atomization, spray fluidization, spray drying, or compression. An example of a compression technique is that has been formed to the yield excellent tagged proppants is described in U.S. Pat. No. 4,879,181 for untagged proppants, except that alternative ceramic compositions, as noted above, besides the calcined clay, alumina, bauxite and mixtures thereof may be employed as the ceramic composition in the starting ingredients and a non-radioactive, detectable tracer is mixed with the ceramic starting ingredients, and it is this resulting mixture that is milled, homogenized and pelletized by compression.
[0021] The tracer may be any non-radioactive material that is detectable in the proppant, particularly detection by methods that can determine the chemical compositions of samples. For instance, the tracer material may be one that is detectable by inductively-coupled plasma (ICP), X-ray fluorescence, or proton-induced X-ray emission (PIXE). However, other methods that can detect the presence of the tracer, such as the chemical analysis, may be used. Techniques for detecting the presence of certain materials by such methods are well known. Thus, U.S. Pat. No. 6,691,780 describes a method to detect the presence of a tagged proppant by ICP. While the proppant of U.S. Pat. No. 6,691,780 is tagged with a tracer-containing resin coating, the ICP detection technique of that patent is applicable to the tagged proppants of the present invention as well. According to the ICP method of U.S. Pat. No. 6,691,780:
an aqueous sample is nebulized within an ICP spectrophotometer and the resulting aerosol is transported to an argon plasma torch located within the ICP spectrophotometer. The ICP spectrophotomer measures the intensities of element-specific atomic emissions produced when the solution components enter the high-temperature plasma. An on-board computer within the ICP spectrophotomer accesses a standard calibration curve to translate the measured intensities into elemental concentrations. ICP spectrophotometers for use according to the ICP method are generally commercially available from the Thermo ARL business unit of Thermo Electron Corporation, Agilent Technologies and several other companies.
[0023] As explained below, other detection techniques, and so tracers, such as noted in U.S. Pat. No. 6,691,780 may be applicable as well, so long as the detection is not dependent on the tracer being exposed in an external coating rather than embedded within the ceramic.
[0024] It is also preferred that the material employed as a tracer not be one that is otherwise present in the ceramic composition or at least is present in the composition in a concentration less than about 1,000 ppm based on weight. This is desirable to avoid false concentration measurements resulting from interference from the material present in the ceramic composition and, in the case of multi-zone formations, to avoid false measurements resulting from the presence of the material from proppants flowing back from other zones. Generally, it is believed that the tracer may be any substance, particularly a solid, that is detectable by chemical analysis at a concentration in the proppant (especially when the proppant is present in the sample to be tested at the lowest concentration at which the proppant desired to be detected) that does not degrade the physical properties of the proppant with respect to density, strength and conductivity.
[0025] Based on such considerations, ceramic forms of certain metals have been found to be especially good tracer materials. Examples of such preferred metals include the lanthanide series of rare earth metals, strontium, barium, gallium, germanium, and combinations thereof, particularly, lanthanum, cerium, strontium, barium, gallium, germanium, tantalium, zirconium, vanadium, chromium, manganese, and combinations thereof, especially lanthanum, cerium, and combinations thereof. Although the metals may be employed in elemental form, some metals in their metallic form are hazardous and it is contemplated that more commonly compounds containing the metals, such as the ceramic forms (oxides, hydroxides and carbonates) of the metals will be used. Thus, references herein to the metals themselves shall be taken in their broadest sense and so include the molecular, ionic, and mineralogical forms of the metals. Of course, for multi-zone applications where it is desirable to distinguish the zones from which proppant has flowed back, it is desirable for the tracers to be not just detectable, but detectable in a way that one type can be distinguished from the others used for other zones.
[0026] Moreover, combinations of types of tracers are particularly useful for application to subterranean formations in which the number of zones in the formation exceeds the number of different available types of tracers. In such situations, a plurality of different types of tracers may be combined to produce a distinct tracer defined by the combination. By way of illustration, if sixteen different types of tracers are available, four of the types of tracers may be designated, say, A-D, while the remaining eleven may be designated, say, 1-12. By pairing the tracer types, forty-eight different tracers in the form of tracer combinations A1, A2, . . . B1, B2, and so forth can be used to distinguish forty-eight different zones. As is now apparent, by combining the tracer types in different ways, many different zones may be distinguished with a limited number of types of tracers.
[0027] Certain techniques can be employed to avoid confusion that might otherwise arise from mixing tracers. For example, if the backflow contains tracers A1, A2, B1 and B2, it may be difficult from the detection of tracer types A, B, 1 and 2 to determine how much of the tracer type A is from the zone associated with Al and how much is associated with A2. The presence of additional amounts of tracer types 1 and 2 from the tracers B1 and B2 might interfere or complicate the ability to distinguish between A1 and A2 base on the amounts of tracer types 1 and 2 detected. However, the tracer combinations may be assigned to disparate zones that would be unlikely to intermingle backflows, thereby avoiding such overlaps.
[0028] The amount of tracer that is desirable to mix with the ceramic composition depends on a variety of circumstances. Nevertheless, the concentration of the tracer in the proppant should be sufficient so that its presence in the backflow will be detectable by the selected detection method when the amount of proppant in the backflow is at a level at which detection of its presence is desired. It also is desired that the concentration of the tracer in the proppant not be substantially above that level, as the use of more tracer can result in higher cost and, in some circumstances, might degrade the desirable qualities of the proppant. Generally, tracer concentrations of at least about 0.03% by weight are desired for convenient detection by conventional detection techniques, while in some situations tracer concentrations in excess of 0.15%, and especially in excess of 0.2%, by weight have been found to change the firing temperature significantly and may even degrade the properties of lightweight proppants. Thus, generally, it has been found that tracer concentrations of from about 0.005 to about 0.5, preferably about 0.01 to about 0.3, more preferably from about 0.03 to about 0.2, even more preferably from about 0.03 to about 0.15, such as from about 0.05 to about 0.15, typically about 0.13, percent by weight, based on the weight of the ceramic composition, are particularly useful. In situations in which a combination of tracer types is used, each type should be in a concentration sufficient to be detectable at the level of proppant desired to be detected. Generally, in such situations, each type of tracer should be present in a concentration of at least about 0.005 percent, preferably at least about 0.01 percent, more preferably at least about 0.02, and even more preferably at least about 0.03 percent by weight based on the weight of the ceramic composition. In any event, however, the minimum concentration depends on the sensitivity of the method of chemical analysis and so it is possible that concentrations even lower than 0.01 percent may be used with some analytical techniques. For example, neutron activation analysis (NAA) is reported to be able to have detection limits of 1-5 ppm (or 0.0001-0.0005 wt %) for La 2 O 3 and CeO 2 , which would allow detection (and so concentration levels) in the range of 0.001 wt %.
[0029] As noted above, the tagged proppant may be prepared in the manner described in U.S. Pat. No. 4,879,181 for untagged proppants, except that, in the present invention, the tracer is included as part of the starting proppant ingredients. Therefore, it is contemplated that tagged proppants according to the subject invention will be prepared typically by agglomeration of granules of the ceramic material and granules of the non-radioactive, detectable material to produce the particle, whether by compression or some other agglomeration means. For example, a mixture of fine grains of the ceramic composition and of the tracer can be compressed together to form a proppant particle. Thus, briefly but in more detail, the tagged proppant may be prepared as follows.
[0030] Starting materials for the ceramic composition (such as calcined clay and alumina, bauxite, or mixtures thereof or other ingredients as discussed above as suitable proppant materials), may be added to a high intensity mixer, such as a ball mill, in a predetermined ratio with the tracer in a concentration as discussed above. The additives to the mixer then may be milled to a fine powder, which is then stirred to form a dry homogeneous particulate mixture. For example, the powder may be stirred with a stirring or mixing device that is obtainable from Eirich Machines, Inc., known as an Eirich Mixer. Similar mixing equipment is available from other manufacturers. While the mixture is being stirred, sufficient water to cause formation of composite, spherical pellets from the ceramic powder mixture may be added. The resulting pellets may be dried and the dried pellets then fired at sintering temperature for a period sufficient to enable recovery of sintered, spherical pellets having an apparent specific gravity of, for instance, between 2.70 and 3.60 and a bulk density of, for instance, from about 1.0 to about 2.0 grams per cubic centimeter. The specific time and temperature to be employed is, of course, dependent on the starting ingredients and is determined empirically according to the results of physical testing of pellets after firing. The resulting pellets may be screened to produce proppants within a size range of, for example, about 40 mesh to about 20 mesh, from about 16 mesh to about 20 mesh, from about 30 mesh to about 50 mesh, from about 30 mesh to about 60 mesh, or from about 16 mesh to about 30 mesh. More specific details of this process are discussed in U.S. Pat. No. 4,879,181.
[0031] Other known methods of preparing proppants may be modified similarly to prepare the tagged proppants of the subject invention. Thus, for example, it is believed that alternative methods of preparation may be according to similarly modified processes described in U.S. Pat. No. 4,440,866 and referred to in U.S. Pat. No. 5,120,455. These patents, including the patents referred to in U.S. Pat. No. 5,120,455, are incorporated herein by reference.
[0032] The resulting tagged proppant, therefore, comprises a non-radioactive, detectable tracer at least partially embedded in a ceramic composition. The tagged proppant may be prepared from a mixture of powdered ceramic composition and powdered tracer and so comprises not a discrete tracer-containing coating over a tracer-free ceramic particle, but a mixture—an agglomeration—of the ceramic composition and the tracer. In fact, at least some of the tracer is at least partially—and may be completely surrounded by ceramic composition. Thus, the tracer does not tend to rub off of the proppant. And surprisingly, it has been found that tagging the proppants according to the method of the present invention does not degrade the strength, density or conductivity of the proppants. Moreover, because the tracer of the proppant particle is thus in contact with the ceramic composition, in fact, adhered directly to the ceramic composition, it need not be applied by coating the particle with a resin containing the tracer. Although the proppant composition may be substantially or completely free of resin, it may also be coated partially or completely with a coating material such as resin if so desired, and the coating may be substantially or completely free of the tracer. As discussed above, the tracer may comprise a plurality of distinct types of tracers, generally distinct types of tracer metals.
[0033] The tagged proppant of the present invention may be used in place of prior art proppants, and particularly in place of prior art tagged compositions to determine whether and how much proppant is flowing back from one or a plurality of zones within a subterranean formation. In fact, the fact that the tagged proppants of the present invention are not radioactive, are strong, need not bear a resin-coating, and so forth, may permit employment of such proppants in situations in which conventional proppants are not useful or practical. Moreover, in the case of multiple zones, it is possible, with the tagged proppants of the present invention, to identify which zone or zones are associated the flowback.
[0034] In short, a subterranean formation having one or multiple zones may be treated and backflow from the zone(s) tracked by introducing tagged proppant into a well bore in the formation, for example, by way of a fracturing fluid to fracture the well by standard techniques except for the replacement of convention (tagged or untagged) proppants with the tagged proppants of the present invention. In the case of a multi-zone formation, a plurality of types of tagged proppants, each type of proppant tagged with a tracer distinguishable from tracers of the other types of tagged proppants, may be employed by directing each of the types of proppants to a different zone. As explained above, a plurality of tracers may be a plurality of combinations of types of tracers. Flowback from one or more of the zones may then be analyzed, such as by collecting at least a portion of the flowback, and the proppants (and so zones) associated with the flowback identified by detecting the tracer(s) therein.
[0035] The following examples describe the preferred embodiments of the invention. Other embodiments within the scope of the claims herein will be apparent to one skilled in the art from consideration of the specification or practice of the invention as disclosed herein. It is intended that the specification together with the examples, be considered exemplary only, with the scope and spirit of the invention being indicated by the claims which follow the examples. Percentages identified in the examples are based on weight.
EXAMPLE 1
[0036] Tests were carried out to investigate whether low addition levels of tracers to a bauxite-based proppant would change the final physical properties required of a high strength proppant. Two different markers (lanthanum oxide and cerium oxide) were lab tested. Batches of the untagged proppant were made in the lab with and without marker additions. Testing of the resulting bulk density, apparent specific gravity, crush at 15 kpsi (103.5 MPa), and conductivity showed no degradation in physical properties for batches with either of the two marker additions compared to the batch without a marker addition.
EXAMPLE 2
[0037] Because lab produced proppant samples can have improved properties due to the increased control of the process that is possible in a lab setting with high precision lab equipment, control batches of the proppant of Example 1, above, without any tracer additions were made along with batches with tracer additions to give a more direct comparison of properties of the proppant.
[0038] One batch of the bauxite-based raw material was ground in the lab without any tracers. Additional batches were blended with a tracer and then milled in the lab to make a homogeneous blend. Each batch was made into pellets and sintered in a lab kiln. Each batch of sintered pellets was sized to the following sieve distribution:
[0000] U.S. % Mesh Retained +16 0 −16 +20 3.6 −20 +25 34.7 −25 +30 47.0 −30 +35 14.0 −35 +40 0.7 −40 +50 0 −50 0
Density, strength, and conductivity testing was performed on each batch according to API specifications. Specific gravity was measured using a Micromeritics Helium Pycnometer.
The following table shows the density and crush strength for the proppant with tracer A (lanthanum oxide) for two different trials at a concentration level of 0.03% and the proppant with tracer B (cerium oxide) at a concentration level of 0.03%.
[0000] Control Tracer A Tracer A Tracer B Batch 0.03% 0.03% 0.03% Specific 3.64 3.65 3.64 3.65 Gravity B.D. 1.99 2.02 2.02 1.99 (g/cc) A.S.G. 3.65 3.67 3.66 3.67 Crush @ 2.4 2.9 2.2 3.0 15 kpsi (103 MPa) (%)
The conductivities of all four batches of the proppant are shown in FIG. 1 . The density and crush strength data and conductivity data are within the experimental error for each test and consequently demonstrate that there is no measurable degradation in the properties of the proppant when either tracer A or tracer B are added in a concentrations of 0.03%.
EXAMPLE 3
[0039] Samples were sent to two outside labs for X-Ray Fluorescence (XRF) and Inductively Coupled Plasma (ICP) analysis. Redundant samples were sent to each lab and all samples were identified only with a generic, sequential identification number (for XRF 001 . . . 015 and for ICP 001 . . . 010). XRF & ICP on the control batches measured the background concentration (in wt %) of tracers A and B as described in Example 2, above. XRF and ICP analyses of the batches with tracer A or B, measured the total concentration (in wt %) of tracers A and B.
[0040] For the tagged batches with markers A or B added at a concentration level of 0.03 wt %, the resulting chemistry measured via XRF was:
Background concentration of tracer A in six control batch samples: 0.00% ±0.01 Total measured concentration of tracer A in five marked batch samples: 0.02%±0.01 Background concentration of tracer B in six control batch samples: 0.01% ±0.01 Total measured concentration of tracer B in three marked batch samples: 0.04%±0.01
[0045] For the tagged batches with tracers A or B added at a concentration level of 0.03%, the resulting chemistry measured via ICP was:
Background concentration of tracer A in four control batch samples: 0.003% ±0.001 Total measured concentration of tracer A in four marked batch samples: 0.032% ±0.001 Background concentration of tracer B in four control batch samples: 0.030% ±0.010 Total measured concentration of tracer B in two marked batch samples: 0.051% ±0.001
[0050] Both XRF and ICP analysis was able to detected the presence of the tracers within at least 0.01%.
[0051] All references cited in this specification, including without limitation all journal articles, brochures, manuals, periodicals, texts, manuscripts, website publications, and any and all other publications, are hereby incorporated by reference. The discussion of the references herein is intended merely to summarize the assertions made by their authors and no admission is made that any reference constitutes prior art. Applicants reserve the right to challenge the accuracy and pertinence of the cited references.
[0052] In view of the above, it will be seen that the several advantages of the invention are achieved and other advantageous results are obtained.
[0053] As various changes could be made in the above methods and compositions without departing from the scope of the invention, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.
EXAMPLE 4
[0054] Each of several samples of ground Comalco Bauxite were blended with no (control) or a particular rare earth additive or other ceramic additive not found in the bauxite in appreciable quantities in a Lab Eirich mixer for ten minutes. The blends were then jet milled to reduce particle size to a powder and to mix the components intimately. The powders were pelletized to green pellets and sieved to the −16 to +40 sieve range. Two samples of pellets formed from each blend were sent to a lab for analysis by inductively coupled plasma (ICP). On other green pellets from each blend, three boats of each were sieved to the −16 to +40 sieve range, fired to peak temperature (about 1500° C.) at 960° C/hr. with a hold of about thirty minutes.
[0055] The ICP analysis showed that the presence of the taggant of concentration higher than that inherently present (that is, the background level of the taggant in untreated proppant as represented by the control) could be detected. In the following table, the first number in the column labeled “Background Level of the Taggant Composition” is the concentration (in wgt. %) of the taggant composition measured in the untreated control for samples in the form of green pellet samples and the second number is for samples in the form of dust. The first number in the column labeled “Measured Level of Taggant” is the concentration (in wgt. %) of the taggant composition measured in the proppant to which the taggant has been added is for samples in the form of green pellet samples and the second number is for samples in the form of dust. The column labeled “Difference” is the difference between the average concentration of taggant measured for taggant composition and the average background concentration of the taggant composition measured in control samples. For each tagged proppant, 0.1% taggant was added, except for ZrSiO 4 , in which case, 0.25% was added.
[0000]
Background Level of
Measured Level
Taggant
Taggant Composition
of Taggant
Difference
ZrSiO 4
0.18, 0.20
0.36, 0.36
0.15
ZnO
0.001, 0.001
0.092, 0.091
0.085
SrO(CO 2 )
0.002, 0.002
0.10, 0.11
0.10
Nd 2 O 5
0.002, 0.002
0.12, 0.11
0.11
Pr 6 O 11
0.002, 0.002
0.10, 0.099
0.98
MnO
0.015, 0.018
0.10, 0.097
0.083
CuO
0.002, 0.001
0.10, 0.098
0.097
Cr 2 O 3
0.002, 0.042
0.15, 0.15
0.12
NiO
0.001, 0.001
0.95, 0.10
0.096
V 2 O 5
0.014, 0.009
0.12, 0.13
0.12
Co 3 O 4
0.004, 0.003
0.13, 0.14
0.13
Sb 2 O 3
0.002, 0.002
0.086, 0.092
0.087
[0056] Similar tests were conducted on other samples comparing % added La 2 O 3 with the results of the % La 2 O 3 measured, compared to controls in which no La 2 O 3 was added, as follows:
[0000] % La 2 O 3 Measured % La 2 O 3 Added In Control In Tagged Proppant 0.15 0.004 0.11 0.15 0.004 0.12 0.03 under 0.005 0.02 0.15 under 0.005 0.018 0.03 — 0.017 0.15 — 0.018 0.03 under 0.005 0.02 0.15 under 0.005 0.018 0.15 — 0.024 0.15 — 0.024 0.15 — 0.11 0.15 — 0.10
The tests were repeated for CeO 2 , with the following results:
[0000] % La 2 O 3 Measured % La 2 O 3 Added In Control In Tagged Proppant 0.03 0.010 0.041 0.03 0.019 0.039 0.03 — 0.041 0.15 — 0.13 0.03 — 0.12
Further tests were carried out using X-Ray Fluorescence (XRF) with the following measured La 2 O 3 concentrations for no additive and for 0.03% and 0.15% La 2 O 3 and CeO 2 added:
La 2 O 3 :
[0057]
[0000]
Control
0.03% La 2 O 3 Added
0.15% La 2 O 3 Added
Under 0.005
0.020
0.11
Under 0.005
0.018
0.10
Under 0.005
0.017
Under 0.005
0.018
Under 0.005
0.020
Under 0.005
0.018
Under 0.005
0.024
Under 0.005
0.024
CeO 2 :
[0058]
[0000] Control 0.03% CeO 2 Added 0.15% CeO 2 Added 0.008 0.010 0.13 0.008 0.039 0.12 0.011 0.041
Further tests were carried out using ICP with the following measured concentrations for no additive and for 0.03% and 0.15% La 2 O 3 and CeO 2 added:
La 2 O 3 :
[0059]
[0000]
Control
0.03% La 2 O 3 Added
0.15% La 2 O 3 Added
0.003
0.032
0.14
0.003
0.032
0.14
0.003
0.032
0.003
0.032
0.003
0.027
0.003
0.030
CeO 2 :
[0060]
[0000]
Control
0.03% CeO 2 Added
0.15% CeO 2 Added
0.028
0.051
0.16
0.030
0.050
0.16
[0061] The resulting pellets also were analyzed for bulk density by the standard ANSI test, apparent specific gravity by the standard API test, specific gravity by Helium Picnometer, and crush strength at 15 ksi (103 MPa) by the standard API test. The following results were obtained, where the measured content of the taggant was determined by ICP:
[0000]
Short Term Conductivity (Darcy-ft)
Bulk
2 ksi
4 ksi
6 ksi
8 ksi
10 ksi
12 ksi
Measured Content of Taggant
Taggant
Density
Crushed
Specific Gravity
(13.8
(27.6
(41.4
(55.2
(69
(82.8
In
Added
(gm/cc)
(%)
Apparent
Actual
MPa)
MPa)
MPa)
MPa)
MPa)
MPa)
Control
In Taggant Proppant
Control
1.99
2.4
3.65
3.6422
9.26
7.93
7.05
6.25
5.58
4.96
N/A
N/A
0.03% CeO 2
1.99
3.0
3.67
3.653
9.53
7.78
6.84
6.15
5.25
4.88
0.026
0.0505
0.15% CeO 2
2.01
3.42
3.60
3.6564
9.17
8.04
7.22
6.10
5.33
4.75
0.15% CeO 2
2.01
3.82
3.60
3.6564
0.15% CeO 2
2.01
4.22
3.61
3.6667
0.15% CeO 2
2.04
5.16
3.64
3.6581
0.15% CeO 2
2.04
2.18
3.63
3.6667
10.74
9.07
7.74
6.92
6.30
5.47
0.026
0.160
0.15% CeO 2
2.02
4.35
3.64
3.6453
0.15% CeO 2
2.02
3.61
3.61
3.6352
0.03% La 2 O 3
2.02
2.9
3.67
3.6488
9.91
8.61
7.43
6.67
6.10
5.31
0.003
0.031
0.15% La 2 O 3
2.05
2.96
3.60
3.6638
8.77
6.83
5.91
5.45
4.82
4.38
0.15% La 2 O 3
2.05
3.75
3.55
3.6678
0.15% La 2 O 3
2.06
3.93
3.64
3.6588
0.15% La 2 O 3
2.03
3.00
3.64
3.6577
10.42
7.80
6.85
6.27
5.44
4.77
0.003
0.140
0.15% La 2 O 3
2.06
3.38
3.66
3.6547
0.15% La 2 O 3
2.06
2.75
3.64
3.6446
Control
2.04
3.77
3.64
3.6486
Control
2.00
2.83
3.60
3.6365
Control
1.97
3.09
3.59
3.6251
8.90
7.66
6.73
6.07
5.48
4.92
N/A
N/A
0.10% ZnO
2.04
3.77
3.64
3.6603
9.60
8.19
7.35
6.65
5.91
5.33
0.007
0.092
0.10% ZnO
2.01
3.82
3.60
3.6538
0.25% ZrSiO 4
2.04
4.17
3.65
3.6619
0.25% ZrSiO 4
2.02
3.61
3.67
3.6587
9.40
8.08
7.38
6.54
5.74
5.24
0.21
0.36
0.25% ZrSiO 4
2.02
3.81
3.64
3.6551
0.10% SrO(CO 2 )
2.05
2.96
3.65
3.6488
8.61
7.30
6.64
5.90
5.40
4.68
0.002
0.105
0.10% SrO(CO 2 )
2.02
3.41
3.61
3.6471
0.10% Nd 2 O 3
2.01
3.82
3.63
3.6689
9.08
7.73
6.67
5.94
5.13
4.59
0.002
0.115
0.10% Nd 2 O 3
2.02
4.0
3.65
3.6639
0.10% Pr 6 O 11
2.04
3.17
3.65
3.6591
8.78
7.72
6.82
6.04
5.48
4.64
0.002
0.100
0.10% Pr 6 O 11
2.03
3.59
3.64
3.6577
0.10% MnO 2
2.04
2.40
3.64
3.6534
0.10% MnO 2
2.03
2.19
3.64
3.6458
9.46
8.21
7.31
6.48
5.81
5.41
0.016
0.099
0.10% Red CuO 2
2.03
1.99
3.64
3.6644
9.65
8.72
7.58
6.85
6.35
5.67
0.002
0.099
0.10% Red CuO 2
2.04
2.38
3.64
3.6574
0.10% Cr 2 O 3
2.06
2.95
3.65
3.6623
9.28
7.97
7.26
6.54
5.86
5.34
0.034
0.15
0.10% Cr 2 O 3
2.05
2.96
3.63
3.6643
0.10% Cr 2 O 3
2.03
3.78
3.63
3.653
Control
1.96
3.63
3.59
3.6047
9.33
8.14
7.29
6.49
5.68
5.07
N/A
N/A
Control
1.95
3.94
3.56
3.5946
0.10% Ni 2 O 3
2.02
1.60
3.64
3.6522
10.26
8.64
7.57
7.04
6.05
5.48
0.002
0.096
0.10% Ni 2 O 3
2.02
3.60
3.60
3.6487
0.10% Ni 2 O 3
2.01
2.21
3.56
3.6440
0.10% V 2 O 5
2.00
2.73
3.64
3.6474
0.10% V 2 O 5
1.99
2.77
3.61
3.636
0.10% V 2 O 5
1.99
2.42
3.60
3.6315
8.85
7.70
6.85
6.06
5.44
4.76
0.009
0.116
0.10% Co 2 O 3
2.06
2.55
3.59
3.6548
0.10% Co 2 O 3
2.04
2.42
3.61
3.6436
Co 3 O 4
0.10% Co 2 O 3
2.03
2.06
3.57
3.6402
9.78
8.26
7.55
6.73
6.13
5.36
0.004
0.131
0.10% Sb 2 O 3
2.02
3
3.65
3.6503
9.11
7.67
6.95
6.26
5.69
5.10
0.002
0.087
0.10% Sb 2 O 3
1.98
3.1
3.56
3.6325
0.10% Sb 2 O 3
1.98
3.67
3.56
3.6325
EXAMPLE 5
[0062] The process of Example 4 was repeated, but with kaolin-based pellets instead of bauxite-based pellets. The results were as follows:
[0000]
Short Term Conductivity (Darcy-ft)
Bulk
2 ksi
4 ksi
6 ksi
8 ksi
10 ksi
12 ksi
Measured Content of Taggant
Taggant
Density
Crushed
Specific Gravity
(13.8
(27.6
(41.4
(55.2
(69
(82.8
In
Added
(gm/cc)
(%)
Apparent
Actual
MPa)
MPa)
MPa)
MPa)
MPa)
MPa)
Control
In Taggant Proppant
Control
1.53
7.90
2.75
2.7649
Control
1.56
5.70
2.79
2.7899
8.71
7.04
5.61
4.17
3.01
2.12
0.004
N/A
Control
1.55
7.83
2.80
2.7868
0.15% La 2 O 3
1.54
8.92
2.77
2.7794
0.15% La 2 O 3
1.57
6.96
2.78
2.7807
9.65
7.95
6.29
4.48
3.26
2.22
0.004
0.115
0.15% La 2 O 3
1.55
7.45
2.78
2.7842
0.15% La 2 O 3
1.55
10.23
2.79
2.7704 | A proppant particle comprising a sintered proppant composition that comprises a non-radioactive, detectable tracer uniformly distributed throughout a ceramic composition, wherein the tracer is one or more tracer metal oxides and the tracer metals are selected from a group consisting of lanthanides, strontium, barium, gallium, germanium, tantalum, vanadium, and manganese. | 4 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application No. PCT/EP2015/070585, filed Sep. 09, 2015, which claims the benefit of German patent application No. 10 2014 224 432.3, filed Nov. 28, 2014, all of which are hereby incorporated by reference herein.
TECHNICAL FIELD
[0002] The invention relates to a permanent-magnet synchronous machine having a rotor and stator and to a motor vehicle system.
BACKGROUND
[0003] A motor vehicle system, for example a braking or steering system, which is suitable for automatic operation requires a redundant power supply, i.e. a power supply delivered by two on-board networks, such that the operation of a system or a plurality of systems can be maintained, even in case of faults or outages (functional security). Internal redundancy in respect of actuator technology and power electronics is also required.
[0004] From DE 19960611 A1, an electromechanical braking system is known, having a generic brushless DC motor for two independent on-board networks with an identical voltage level of 2×12 V, in which the stator winding is sub-divided into at least two separate windings with respectively equal numbers of turns, such that each part of the stator winding can be connected to one of said on-board networks via a respective power electronics circuit. By this subdivision of the stator winding according to the number of independent on-board networks in a vehicle, a plurality of mutually-independent half-motors are formed such that, in case of the failure of one of the two on-board systems, a half-motor can continue to operate using the other on-board network, with reduced output power.
[0005] In a brushless DC motor of this type according to DE 19960611 A1, subdivision of the stator winding is achieved by means of taps on the continuous winding. However, the voltage supplies are required to operate at different levels. As a result of the lack of mechanical separation of the coil windings associated with the two on-board networks, however, potential faults affecting the control thereof cannot be excluded, such that genuine redundancy is not achieved.
[0006] The divided stator windings provided for the two on-board networks are configured as separate windings, which are mutually overwound or interwound, wherein, for each of these separate windings, an output stage is provided, with six circuit-breakers. By overwinding or interwinding, however, a short-circuit associated with the contact of wires, which would affect both half-motors and compromise the availability thereof, cannot be ruled out. To date, it has consistently been required that, insofar as possible, both half-motors should perform identically and, accordingly, are operated using two output stages of identical design and substantially identical controllers. Moreover, for future applications, on-board systems with higher rated voltages than the customarily-applied 12 V or 14 V are envisaged for which, in many cases, no redundancy is to be provided.
[0007] The background description provided herein is for the purpose of generally presenting the context of the disclosure. Work of the presently named inventors, to the extent it is described in this background section, as well as aspects of the description that may not otherwise qualify as prior art at the time of filing, are neither expressly nor impliedly admitted as prior art against the present disclosure.
SUMMARY
[0008] Thus, a permanent-magnet synchronous machine and a motor vehicle system with improved functional security, specifically for use with non-redundant on-board vehicle networks of higher rated voltages is provided.
[0009] A permanent-magnet synchronous machine comprises a rotor and a stator for holding at least one first stator winding and a second stator winding which is electrically insulated from said first stator winding. The second stator winding has a smaller conductor cross-section and a larger number of turns than the first stator winding, wherein the first stator winding is provided for motor operation with a first operating voltage, and the second stator winding is provided for motor operation at a second operating voltage with a higher rated voltage than a rated voltage of the first operating voltage.
[0010] An improved functional security is thus achieved, specifically in applications involving on-board vehicle networks of higher rated voltage and non-redundant design. In normal duty, the synchronous motor according to the invention is supplied by both on-board networks such that, in the event of the failure or malfunction of the two on-board networks, the synchronous machine can be operated using the remaining intact on-board network.
[0011] For the first and second stator winding, a dedicated converter is provided for the respective control thereof which, in a known manner, can be configured with six power semiconductors. Accordingly, these converters for the control of the stator windings are not of identical design, but are adapted in accordance with the relevant voltage, specifically with respect to current-carrying capacity, wherein, for example in the case of a lower voltage—in accordance with the torque to be generated by the respective half-motor—the transmission of a higher current must be possible. The power semiconductors are designed correspondingly. Accordingly, the term half-motor is not to be understood restrictively in the sense of exactly one half (50%), as the division can be executed in consideration, for example, of safety requirements in the event of an outage or a malfunction.
[0012] Preferably, the connection of the first stator winding differs from that of the second stator winding, specifically in that the first stator winding (of lower rated voltage) is star-connected and the second stator winding (of higher rated voltage) is delta-connected. This results in a smaller difference in conductor diameter and, on the motor side with the higher voltage, the number of turns is smaller, thereby resulting in a saving in manufacturing time.
[0013] According to one embodiment, the stator of the permanent-magnet synchronous machine comprises a plurality of stator poles, separated by slots, for the accommodation of the at least first and second stator windings, wherein the first stator winding is arranged on a first group of stator poles, and the second stator winding is arranged on a group of stator poles which is separate from the first group.
[0014] Each stator pole either has a winding configured as a first stator winding or a winding configured as a second stator winding, wherein electrical insulation, and thus redundancy, is further improved in a simpler manner.
[0015] The number of stator poles in the first group has a specific ratio to the number of stator poles in the second group, which is dependent upon the number of stator poles. Thus, for example, an even number of stator poles on the stator can be divided in half, such that both the first group and the second group comprise an equal number of stator poles. A different ratio of division can be selected, for example 3/4 to 1/4, in the case of a stator with 12 slots and an 8-pole rotor, or 2/3 to 1/3 in the case of a stator with 9 slots and a 6-pole rotor. The synchronous motor can thus be adapted to the performance capability of the two on-board networks.
[0016] According to one configuration, the stator with its first and second stator windings is configured such that the stator poles of the first and second group are arranged in a consecutive sequence, wherein the first group of stator poles and the second group of stator poles preferably constitute one half of the stator poles of the stator respectively.
[0017] According to a further configuration, it is proposed that the stator poles of the first group and the stator poles of the second group are arranged in an alternating manner. The exceptionally quiet running of the synchronous motor at both operating voltages can thus be achieved.
[0018] Finally, according to a further configuration, it is proposed that two, or a multiple of two adjoining stator poles in the first group and the second group are arranged in an alternating manner. Thus, for example, two adjoining stator poles accommodate a winding of the first stator winding, the consecutive two adjoining stator poles accommodate a winding of the second stator winding, etc. This results in the symmetrical loading of the synchronous motor, with a simultaneous reduction in localized saturation, specifically if said synchronous motor is to be operated at one on-board network voltage only.
[0019] The invention moreover relates to a motor vehicle system, to which at least one permanent-magnet synchronous machine is assigned, and having at least two independent voltage supplies with a first and second operating voltage, wherein the first operating voltage for the supply of a first stator winding of the permanent-magnet synchronous machine has a lower rated voltage than a second operating voltage for the supply of a second stator winding of the permanent-magnet synchronous machine.
[0020] The rated voltage of the first operating voltage is preferably double that of the rated voltage of the second operating voltage. Specifically, the rated voltage of the first operating voltage is of the order of 48 V, and the rated voltage of the second operating voltage is of the order of 12 V.
[0021] Other objects, features and characteristics of the present invention, as well as the methods of operation and the functions of the related elements of the structure, the combination of parts and economics of manufacture will become more apparent upon consideration of the following detailed description and appended claims with reference to the accompanying drawings, all of which form a part of this specification. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the disclosure, are intended for purposes of illustration only and are not intended to limit the scope of the disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] The invention is clarified and described in greater detail hereinafter with reference to the attached figures, wherein:
[0023] FIG. 1 shows a schematic circuit diagram of the drive circuit of a permanent-magnet synchronous machine with two on-board network voltages of different rated voltage and with divided stator windings;
[0024] FIG. 2 shows a cross-sectional representation of a permanent-magnet synchronous machine according to the invention;
[0025] FIG. 3 shows a winding diagram of the stator of the synchronous motor according to FIG. 1 ;
[0026] FIG. 4 shows a cross-sectional representation of a further permanent-magnet synchronous machine;
[0027] FIG. 5 shows a cross-sectional representation of a further permanent-magnet synchronous machine;
[0028] FIG. 6 shows a cross-sectional representation of a further permanent-magnet synchronous machine; and
[0029] FIG. 7 shows a cross-sectional representation of a further permanent-magnet synchronous machine.
DETAILED DESCRIPTION
[0030] FIG. 1 shows a schematic circuit diagram of the drive circuit of a permanent-magnet synchronous machine 1 which, in motor operation, is supplied with energy by means of two separate on-board networks in a vehicle, or by an on-board network having a rated voltage of 12 V and a second on-board network having a rated voltage of 48 V. Control is executed in an exemplary manner by means of the converters 4 a and 4 b, which deliver control signals via at least one unrepresented control unit. The stator winding of the permanent-magnet synchronous machine 1 is divided into a first stator winding SW 1 and a second stator winding SW 2 , wherein a first half-motor HM 1 and a second half-motor HM 2 are constituted, both of which are configured for the generation of a torque on the rotor 2 ( FIG. 2 ) of the synchronous machine. The stator winding SW 1 is star-connected, and the stator winding SW 2 is delta-connected. The two stator windings SW 1 and SW 2 of the half-motors HM 1 and HM 2 can also both be delta-connected, or can both be star-connected. Each of the U-, V- and W-terminals of the half-motors HM 1 and HM 2 are connected respectively to one of the two half-bridges comprised of two semiconductor switches (not represented) in the converters 4 a or 4 b, such that each half-motor HM 1 and HM 2 is controlled by 6 power semiconductors.
[0031] The stator winding SW 2 for the higher on-board network voltage has a reduced conductor cross-section, in comparison with the stator winding SW 1 for the lower on-board network voltage. The space factor of the stator windings in both half-motors HM 1 and HM 2 is essentially equal. Motor control for the two half-motors HM 1 and HM 2 is executed independently, with appropriately-adapted setpoint torques in each case.
[0032] FIG. 2 shows a cross-sectional representation of the permanent-magnet synchronous machine 1 . The latter comprises a stator 2 with 12 stator poles P 1 to P 12 , separated by slots, and a 10-pole rotor 2 . The stator winding of the stator 2 is divided into a first stator winding SW 1 arranged on a first group SP 1 of stator poles P 1 to P 6 , with the windings Wu 11 , Wu 12 , Wv 11 , Wv 12 , Ww 11 , Ww 12 , and a second stator winding SW 2 arranged on a second group SP 2 of stator poles P 7 to P 12 , which is separate from the first group, with the windings Wu 21 , Wu 22 , Wv 21 , Wv 22 , Ww 21 , Ww 22 . On each of these stator poles P 1 to P 12 respectively, only one winding of the first stator winding SW 1 or of the second stator winding SW 2 is arranged. The first group SP 1 of stator poles P 1 to P 6 and the second group SP 2 of stator poles P 7 to P 12 are respectively arranged in a consecutive sequence, such that the stator 2 is divided in half by the first and second groups of stator poles SP 1 and SP 2 , as represented in FIG. 2 by the line D. Accordingly, by each of these groups SP 1 and SP 2 of stator poles, in combination with the respective windings of the first stator winding SW 1 or SW 2 , the first half-motor HM 1 and the second half-motor HM 2 are constituted.
[0033] The stator windings Wu 11 , Wu 12 , Wv 11 , Wv 12 , Ww 11 , Ww 12 and Wu 21 , Wu 22 , Wv 21 , Wv 22 , Ww 21 , Ww 22 associated with each half-motor HM 1 and HM 2 are connected to the 12 V on-board network or to the 48 V on-board network by means of the respective converter 4 a or 4 b. The associated winding diagram of the stator 2 for phase U of the half-motor HM 1 and the half-motor HM 2 are represented in FIG. 3 .
[0034] According to FIG. 3 , the winding Wu 11 of the stator pole P 1 and the winding Wu 12 of the stator pole P 2 of phase U are each formed of 10 turns, wherein the winding Wu 11 is supplied with the on-board network voltage U 1 of the 12 V on-board network, and the winding Wu 12 is routed to a star point CT 1 on the 12 V on-board network. The windings Wv 11 and Wv 12 for phase V and the windings Ww 11 and Ww 12 for phase W are correspondingly wound and connected for the half-motor HM 1 .
[0035] As the half-motor HM 2 is operated on the 48 V on-board network, the windings Wu 21 and Wu 22 have 40 turns respectively. The winding Wu 21 is wound on the stator pole P 7 and, in the case of star-connection, is connected to a star point CT 2 on the 48 V on-board system. The winding Wu 22 is wound onto the directly consecutive stator pole P 8 , and is connected to the on-board network voltage U 2 of the 48 V on-board network. For the half-motor HM 2 , the windings Wv 21 and Wv 22 for phase V and the windings Ww 21 and Ww 22 for phase W are wound and connected in a corresponding manner.
[0036] A halved division of the stator poles in a stator 2 with 12 slots is also possible in the case of an 8-pole rotor 3 . Thus, a first stator winding SW 1 with the windings Wu 11 , Wv 11 , Ww 11 , Wu 12 , Wv 12 and Ww 12 is wound onto the stator poles P 1 to P 6 in the sequence described, and a second stator winding SW 2 with the windings Wu 21 , Wv 21 , Ww 21 , Wu 22 , Wv 22 and Ww 22 is arranged on a second group of stator poles P 7 to P 12 , which is separate from the first group, in the sequence described.
[0037] FIG. 4 represents a permanent-magnet synchronous machine 1 having a stator 2 and a rotor 3 wherein, in accordance with the synchronous motor 1 in FIG. 2 , the stator 2 is configured with 12 stator poles P 1 to P 12 , and the rotor 3 with 10 magnet poles. However, the synchronous motor 1 according to FIG. 2 is not divided into two halves by the first and second stator windings.
[0038] According to FIG. 4 , the windings Wu 11 , Wu 12 , Wv 11 , Wv 12 , Ww 11 , Ww 12 of the first stator winding SW 1 , connected to the 12 V on-board network, and the windings Wu 21 , Wu 22 , Wv 21 , Wv 22 , Ww 21 , Ww 22 of the second stator winding SW 2 , connected to the 48 V on-board network, are wound onto the stator poles P 1 to P 12 in an alternating manner. Accordingly, winding Wu 11 is arranged on stator pole P 1 , winding Wu 21 on stator pole P 2 , winding Wu 12 on stator pole P 3 , winding Wu 22 on stator pole P 4 , winding Wv 11 on stator pole P 5 , winding Wv 21 on stator pole P 6 , winding Wv 12 on stator pole P 7 , etc. The stator poles P 1 , P 3 , P 5 etc. thus constitute a first group SP 1 of stator poles, and the stator poles P 2 , P 4 , P 6 etc. constitute a second group SP 2 of stator poles, which is separate from the latter.
[0039] Again, in this embodiment of a permanent-magnet synchronous machine 1 , the windings Wu 11 , Wu 12 , Wv 11 , Wv 12 , Ww 11 , Ww 12 of the first stator winding SW 1 and the windings Wu 21 , Wu 22 , Wv 21 , Wv 22 , Ww 21 , Ww 22 of the second stator winding SW 2 are star-connected, and are respectively connected to the 12 V on-board network or to the 48 V on-board network via a converter 4 a, 4 b comprised of 6 power semiconductors. Delta connection, rather than star connection, is also possible.
[0040] Again, the stator winding of the permanent-magnet synchronous machine 1 according to FIG. 5 is not divided, such that the stator 2 is divided into two halves by the first and second stator windings. In this case, the division of the stator winding is configured such that two windings Wu 11 , Wu 12 , Wv 11 , Wv 12 , Ww 11 , Ww 12 of the first stator winding SW 1 alternate with two windings Wu 21 , Wu 22 , Wv 21 , Wv 22 , Ww 21 , Ww 22 of the second stator winding SW 2 . Thus, according to FIG. 5 , the windings Wu 11 , Wu 12 of the first stator winding SW 1 are arranged on the adjoining stator poles P 1 and P 2 , the windings Wu 21 , Wu 22 of the second stator winding SW 2 are arranged on the next adjoining stator poles P 3 and P 4 , further windings Wv 11 , Wv 12 of the first stator winding SW 1 are arranged on the next adjoining stator poles P 5 and P 6 , etc. The stator poles P 1 , P 2 , P 5 , P 6 etc. thus constitute a first group SP 1 of stator poles, and the stator poles P 3 , P 4 , P 7 , P 8 etc. constitute a second group SP 2 of stator poles, which is separate from the latter.
[0041] In this embodiment, the windings Wu 11 , Wu 12 , Wv 11 , Wv 12 , Ww 11 , Ww 12 of the first stator winding SW 1 are likewise star-connected, and connected to the 12 V on-board network via a converter 4 a with 6 circuit-breakers. The windings Wu 21 , Wu 22 , Wv 21 , Wv 22 , Ww 21 , Ww 22 of the second stator windings SW 2 are also star-connected, and connected to the 48 V on-board network via a further converter 4 b with 6 circuit-breakers. Alternatively, delta connection is also possible in each case.
[0042] The synchronous machine according to FIG. 5 has symmetrical loading of the motor, and limited localized saturation, in the event of the unavailability of one of the two on-board networks or of one of the two output stages.
[0043] In the synchronous motors according to FIGS. 2, 4 and 5 , the symmetrical division of the stator windings of the stator 2 has been applied. The application of an asymmetrical division—as represented in FIG. 6 —is also possible. Thus, the stator 2 according to FIG. 6 , having stator poles P 1 to P 12 and a 10-pole rotor 3 , on the grounds of its 4-way symmetry, can be divided by a ratio of 3/4 to 1/4. A first stator winding SW 1 with the windings Wu 11 , Wu 12 , Wu 13 , Wv 11 , Wv 12 , Wv 13 , Ww 11 , Ww 12 and Ww 13 is connected to the 48 V on-board network; a second stator winding SW 2 with the windings Wu 2 , Wv 2 and Ww 2 is connected to the 12 V on-board network.
[0044] The division of the 12 stator poles P 1 to P 12 can be seen in FIG. 6 . Thus, stator pole P 1 , P 2 or P 3 carries the winding Wu 11 , Wu 12 or Wu 13 of the first stator winding SW 1 , stator pole P 4 carries the winding Wu 2 of the second stator winding SW 2 , stator pole P 5 , P 6 or P 7 carries the stator winding Wv 11 , Wv 12 or Wv 13 of the first stator winding SW 1 , stator pole P 8 again carries the stator winding Wv 2 of the second stator winding SW 2 , etc. The stator poles P 1 , P 2 , P 3 , P 5 , P 6 , P 7 , P 9 , P 10 and P 11 thus constitute a first group SP 1 of stator poles, and the stator poles P 4 , P 8 and P 12 constitute a second group SP 2 of stator poles, which is separate from the latter.
[0045] Again, in this embodiment of a synchronous motor 1 according to the invention, the windings Wu 11 , Wu 12 , Wu 13 , Wv 11 , Wv 12 , Wv 13 , Ww 11 , Ww 12 and Ww 13 of the first stator winding SW 1 are star-connected, in an identical manner to the three windings Wu 2 , Wv 2 and Ww of the second stator winding SW 2 , and are respectively controlled by an associated converter 4 a, 4 b comprising 6 power semiconductors. The two stator windings SW 1 and SW 2 can also be delta-connected, or can be connected in a different manner, such that one stator winding is star-connected and the other stator winding is delta-connected.
[0046] A division of a stator 2 having 12 slots in a ratio of 3/4 to 1/4 is also possible in the case of a 8-pole rotor 3 . Thus, a first stator winding SW 1 with the windings Wu 11 , Wv 11 , and Ww 11 is wound onto the consecutive stator poles P 1 to P 3 in the sequence described, and a second stator winding SW 2 with the windings Wu 21 , Wv 21 , Ww 21 , Wu 22 , Wv 22 , Ww 22 , Wu 23 , Wv 23 and Ww 23 is arranged on a second group of stator poles P 4 to P 12 , which is separate from the first group, in the sequence described.
[0047] In the permanent-magnet synchronous machine 1 according to FIG. 7 , an asymmetrical division of the stator poles between a first stator winding SW 1 and a second stator winding SW in a ratio of 1/3 to 2/3 is likewise applied. This synchronous motor 1 comprises a 6-pole rotor and a stator with 9 slots. Thus, a first stator winding SW 1 with the windings Wu 11 , Wv 11 and Ww 11 is wound onto the consecutive stator poles P 1 , P 2 and P 3 in the sequence described, thus constituting a first group SP 1 of stator poles. A second stator winding SW 2 with the windings Wu 21 , Wv 21 , Ww 21 , Wu 22 , Wv 22 and Ww 22 is wound onto the consecutive stator poles P 3 to P 12 , thus constituting a second group SP 2 of stator poles.
[0048] Various options are available for the connection of the two stator windings SW 1 and SW 2 .
[0049] Thus, the first stator winding with the windings Wu 11 , Wv 11 and Ww 11 is star-connected or delta-connected. A star connection is employed for the second stator winding SW 2 , wherein the windings of one phase, i.e. the windings Wu 21 and Wv 21 , the windings Ww 21 and Wu 22 , and the windings Wv 22 and Ww 22 are connected in series or in parallel.
[0050] While the best modes for carrying out the invention have been described in detail the true scope of the disclosure should not be so limited, since those familiar with the art to which this invention relates will recognize various alternative designs and embodiments for practicing the invention within the scope of the appended claims. | A permanent-magnet synchronous machine comprises a rotor and a stator for holding at least one first stator winding and a second stator winding which is electrically insulated from said first stator winding. The second stator winding has a smaller conductor cross section and a larger number of turns than the first stator winding, wherein a first operating voltage is provided for motor operation of the first stator winding and a second operating voltage is provided for motor operation of the second stator winding. The second operating voltage has a higher rated voltage than a rated voltage of the first operating voltage. | 7 |
BACKGROUND OF THE INVENTION
This invention generally relates to explosive compositions and more particularly to explosive compositions containing guanidinium picrate.
Guanidinium picrate has been known to be an explosive composition for many years. Thus, in U.S. Pat. 1,558,565 guanidinium picrate is disclosed as being used an an explosive fill in a bomb. However, this compound has an unusually low heat of detonation so that it has not been used to any great extent. In fact, there are many explosives available today which have much greater heats of detonation and which release considerably more explosive energy upon detonation.
However, it has only recently been discovered that guanidinium picrate possesses certain properties which now make its use for certain applications advantageous. Thus, its extremely low sensitivity to impact, its low cost of production and excellent thermal stability can make the use of guanidinium picrate highly desirable for certain applications despite its low heat of detonation.
SUMMARY OF THE INVENTION
Accordingly, one object of this invention is to provide an explosive composition.
Another object of this invention is to provide an explosive composition that uses a relatively low cost material.
A further object of this invention is to provide an explosive composition which has good thermal stability.
A still further object of this invention is to provide an explosive composition which has relatively low sensitivity to impact.
These and other objects of this invention are accomplished by providing an explosive composition comprising a mass of explosive material completely encompassed or surrounded by a layer of guanidinium picrate.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The explosive composition of this invention comprises an explosive mass completely encompassed or surrounded by a layer of guanidinium picrate. The guanidinium picrate comprises the outer layer of explosive since using it in this manner enables one to take advantage of certain of its properties and make it a useful explosive despite the low heat of detonation. Thus, the fact that guanidinium picrate is very insensitive to impact, (it survived the drop of the standard weight from 320 cm (the test machine limit) without detonation) means that the shock sensitivity of any explosive matter which is more sensitive than guanidinium picrate can be decreased by surrounding said explosive matter with a layer of guanidinium picrate. Similarly, the fact that guanidinium picrate has excellent thermal stability (less than 0.1cc of gas per gm per hr at 260° C and 4.0 at 300° C in the vacuum stability test) would increase the thermal stability of any composition which is less thermally stable if guanidinium picrate surrounds it. Thus, guanidinium picrate used as the outer layer of an explosive composition, such as in a bomb, would by virtue of its own excellent thermal stability and insulating ability reduce the hazard of accidental initiation by fires, aerodynamic heating or impact.
The general nature of the invention having been set forth, the following example is presented as a specific illustration thereof. It will be understood that the invention is not limited to this specific example but is susceptible to various modifications that will be recognized by one of ordinary skill in the art.
EXAMPLE
PREPARATION OF GUANIDINIUM PICRATE (I)
A mixture of picric acid in a solution of 350 ml of water and 50 ml of 28% NH 4 OH was heated to 60° C until the picric acid was dissolved. Then a solution of 20.0 grams of guanidinium carbonate in 100 ml of water was added to the hot picric acid solution, immediately forming a precipitate. The precipitate was collected on a fine sintered glass funnel and washed with methanol. The precipitate was then suspended in 3000 ml of water. The mixture was heated to 90° C to redissolve the precipitate and the resulting solution was filtered while still hot. The filtrate was cooled slowly overnight. Massive, thick, yellow-orange, needle-like crystals were formed. The crystals were washed first with methanol and then with diethyl ether. Finally, the crystals were dried at 110° C. The yield was 19.0 grams of guanidinium picrate (I) which decomposed at 325° C with very little prediscoloration.
Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims the invention may be practiced otherwise than as specifically described herein: | An explosive composition with enhanced thermal stability and decreased imt sensitivity comprising an explosive material completely surrounded by a layer of guanidinium picrate. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority to U.S. Provisional Application Ser. No. 60/842,083, filed on Sep. 5, 2006, which is hereby incorporated by reference herein in its entirety.
FIELD OF THE INVENTION
This invention relates to methods of inferring a network topology, and in particular to methods of merging anonymous routers when carrying out an end-to-end network topology process.
BACKGROUND OF THE INVENTION
With the rapid growth of the Internet overlay networks have been increasingly used to deploy network services. Examples of such services include application-layer multicast (ALM) services, peer-to-peer to file sharing and overlay path routing services. However, to provide such services to a high standard it is important to know the topology of the underlying network. For example, in the case of ALM services it has been shown that topology-aware ALM can achieve substantially lower end-to-end delay, low physical link stress and high-tree bandwidth.
Various methods have been proposed to infer the topology of an underlying network. In particular, traceroute-like tools are often used to extract router-level path information between a pair of hosts. Traceroute is a widely used and well-defined measurement tool in the Internet. The specification of traceroute is defined in G. Malkin, “Traceroute Using an IP Option”, IETF RFC 1393 (January 1993), available at filing from http://www.ietforg/rfc/rfc1393.txt?number=1393. Traceroute is implemented using ICMP (Internet Control Message Protocol) messages that are sent from a source to a destination. The source transmits to a destination an IP datagram with a certain TTL (time-to-live) value and each router that handles the datagram is required to decrement the TTL value by one. When a router receives an IP datagram whose TTL is 1, the datagram is thrown away and the router returns an ICMP “time exceeded” error message back to the source. This error message includes the router name, router IP address and round-trip-time (RTT) to the source. The source therefore sends out to the destination a succession of IP datagrams with increasing TTL values and each datagram can identify one router in the path. In addition, if the datagram arrives at the destination with an unused port number (usually larger than 30,000) the destination's host UDP module generates an ICMP “port unreachable” error message that is returned to the source. Using these return messages the router-level path can be identified.
However, some routers process ICMP messages differently from each other. Some do not return ICMP error messages at all and consequently such routers appear as unknown and are conventionally indicated by the symbol “*” in the traceroute results. Other routers may return ICMP error messages only when their workload is light such that on some occasions the router appears in the traceroute results as a normal router, while on other occasions the router is unknown. Other routers may simply discard the ICMP messages and therefore all subsequent routers in the path appear as unknown. In this application routers that do not return ICMP messages at all are referred to as “type-1 routers”, routers that return ICMP messages only when their loading is light are referred to as “type-2 routers”, and routers that simply discard ICMP messages are referred to as “type-3 routers”.
Traceroute results therefore provide details of router with known IP addresses and these are conventionally called known routers. Unknown routers without an explicit IP address are referred to as anonymous routers.
FIG. 1 shows in Table I an example of typical traceroute results obtained from three experimental trials conducted from a server at The Hong Kong University of Science and Technology with www.sohu.com as the destination. The names, IP addresses and round-trip delays (including transmission delay, propagation delay, router processing delay and queuing delay) of the intermediate routers are all shown, but it will be seen that the third router is an anonymous router about which no information is known other than its presence in the path.
Topologies can be inferred from such traceroute results. To infer an underlying topology from traceroute results each occurrence of an anonymous router can be considered to be unique (ie each anonymous router corresponds to a different router) however this leads to high inflation of anonymous routers in the resulting inferred topology. This can be seen from the example of FIG. 2( a ) that shows an example of an actual path topology. Here hosts are labeled as 1, 2, 3 and 4. R 1 is a known router while * 1 and * 2 are anonymous routers of the type that never return time exceeded error messages. FIG. 2( b ) shows the topology that is inferred with pair-wise traceroutes among the four-hosts assuming the paths are symmetric. It will be seen that the two actual anonymous routers become nine anonymous routers in the inferred topology.
Various proposals have therefore been made in the past to reduce this problem by merging anonymous routers in inferred topologies while meeting a number of consistency requirements, including: (a) trace preservation, the inferred topology should agree with all the traceroute paths; and (b) distance preservation, the length of the shortest paths between two nodes in the inferred topology should not be shorter than the traceroute results. Such prior proposals have however been found to be very complex to implement and require very high computational complexity.
SUMMARY OF THE INVENTION
According to the present invention there is provided a method of inferring a network topology from traceroute results, comprising the steps of (a) estimating router co-ordinates, and (b) merging anonymous routers.
In preferred embodiments of the invention step (a) comprises collecting and analyzing round-trip delays from the traceroute results, and using the Isomap algorithm to embed routers in a high-dimensional Euclidean space. The round-trip delays may be defined in terms of round-trip time (and preferably anonymous routers are assumed to be evenly distributed between known neighbors) or round-trip delays may be defined in terms of hop numbers.
In the context of this specification the term “Isomap” refers to the tool developed by Stanford University, described in J. B. Tenenbaum et al., “A global geometric framework for nonlinear dimensionally reduction”, Science , Vol. 290, pp. 2319-2323 (December 2000), which is hereby incorporated by reference herein in its entirety, and found at filing at http://isomap.stanford.edu.
Preferably prior to estimating router co-ordinates a preliminary router merging is performed in which two anonymous routers or one anonymous router and one known router are merged if they share the same neighbors.
In one embodiment of the invention in step (b) two anonymous routers are merged if they are separated by a predefined distance. Alternatively two anonymous routers may be merged if they share one known neighbor and are within a predefined distance.
According to another aspect of the present invention there is provided a method of inferring a network topology from traceroute results, comprising merging pairs of anonymous routers that share at least one known neighbor and do not appear in the same traceroute path. This method may be repeated iteratively until no further pairs of anonymous routers can be merged.
According to the present invention there is further provided a method of providing an application layer service on an underlying network, including inferring a network topology from traceroute results by means of a method comprising the steps of (a) estimating router co-ordinates, and (b) merging anonymous routers.
According to the present invention there is still further provided a method of providing an application layer service on an underlying network, including inferring a network topology from traceroute results, comprising merging pairs of anonymous routers that share at least one known neighbor and do not appear in the same traceroute path.
BRIEF DESCRIPTION OF THE DRAWINGS
Some examples of the invention will now be described by way of example and with reference to the accompanying drawings, in which:
FIG. 1 shows a table with example traceroute results,
FIGS. 2( a ) and ( b ) show examples of (a) an actual topology and for comparison (b) a corresponding topology inferred according to prior art techniques,
FIGS. 3( a ) and ( b ) show examples of (a) an actual topology and for comparison (b) an inferred topology,
FIG. 4 shows a table with example delay information from traceroute results,
FIG. 5 shows a table with an example of a distance matrix in one embodiment of the invention,
FIG. 6 shows a table with an example of a distance matrix in another embodiment of the invention,
FIG. 7 plots simulated example results of the invention on generated topologies, and
FIG. 8 plots simulated example results of the invention on real Internet topologies.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Before describing in detail some embodiments of the invention, first it will be shown that traditional approaches that keep the distance and trace consistencies have high computational complexities and are not practical for even a medium-sized network with hundreds of routers. To reduce the complexity, in embodiments of the present invention these constraints are relaxed and two fast algorithms are proposed.
As anonymous routers greatly inflate the topology, the following problem is considered: Given a group of N hosts and a set of traceroute results among them, how can an inferred topology be constructed by reducing the number of anonymous routers?
As described before, there exist three types of anonymous routers and there are dealt with separately. First of all, the arc method is used to deal with routers that discard ICMP messages (i.e., type-3). See, A. Broido et al., “Internet topology: Connectivity of IP graphs”, in Proc. SPIE ITCom ' 01 (August 2001), which is hereby incorporated by reference herein in its entirety. Suppose a traceroute path from host A to host B contains a type-3 router * x . All the routers following * x in the traceroute path must be “*”. Denote the router directly before * x as X. First check whether traceroute from B to A has been conducted. If not, add an arc to directly connect X and B. Otherwise, the traceroute path from B to A must also contain a type-3 router * y . Similarly, denote the router directly before * y as Y and add an arc to connect X and Y.
After introducing the arcs, the remaining anonymous routers in the resultant topology are of either type-1 or type-2. If it is assumed that each of the remaining anonymous routers is a unique one, the inferred topology is consistent with traceroutes but suffers high inflation of routers and links. It is therefore necessary to merge the anonymous routers.
To keep the distance and trace consistencies as in B. Yao et al., “Topology inference in the presence of anonymous routers”, in Proc. IEEE INFOCOM ' 03, pp. 353-363 (April 2003), which is hereby incorporated by reference herein in its entirety, it is necessary to check whether two anonymous routers are mergeable. To do that, all the inter-host shortest paths in the topology after merging are computed and compared with traceroute results one by one. Suppose N is the number of hosts, n k is the number of known routers, and n i is the number of anonymous routers in the initially inferred topology. Computing single-source shortest paths in a graph with V vertices by the Dijkstra algorithm takes O(V 2 ) time, i.e., O((N+n k +n i ) 2 ) in our topology. See, T. H. Cormen et al., “Introduction to Algorithms”, MIT Press (2001), which is hereby incorporated by reference herein in its entirety. To compute all the inter-host shortest paths, the complexity is O(N(N+n k +n i ) 2 ). There are a total of O(N 2 ) paths to be compared, thus the total complexity of checking one pair of anonymous routers is O(N(N+n k +n i ) 2 +N 2 )=O(N(N+n k +n i ) 2 ). Furthermore, it has been shown that the mergeable relationship is not transitive. That is, if * 1 is mergeable with * 2 , and * 2 is mergeable with * 3 , it does not mean that * 1 is mergeable with * 3 . An additional check between * 1 and * 3 is necessary. (See, Yao et al.) In summary, given n i anonymous routers in the topology, at least O(n i ) pairs of anonymous routers need to be compared (in the worst case O(n i 2 )pairs), leading to a total of at least O(N(N+n k +n i ) 2 n i ) complexity. Simulations and Internet measurements indicate that n k and n i are usually much larger than N, leading to a high check complexity. In view of this level of complexity, in order to handle large networks a possible option is to relax the consistency constraints by allowing some inconsistent merging, and in embodiments of the invention two algorithms are proposed to merge anonymous routers that reduce the calculational complexity.
In embodiments of the invention the Isomap algorithm will be used. Isomap estimates point coordinates in a multi-dimensional space given the distances between them and Isomap can be used to estimate router coordinates based on traceroute results. In this way, multiple occurrences of the same anonymous router may result in similar coordinates and can then be merged. (See, J. B. Tenenbaum et al.)
Multidimensional scaling (MDS) and principal component analysis (PCA) have been widely applied to capture the inter-correlation of high-dimensional data in low-dimensional space. PCA finds a low-dimensional embedding of data points that best preserves their variance as measured in the high-dimensional input space. Classical MDS finds an embedding that preserves the inter-point distances, which is equivalent to PCA when the distances are Euclidean. However, MDS requires the distances between all pairs of points as input. If the missing distances are simply replaced by infinity values, the accuracy of results would be seriously affected. Note that it is impossible to obtain pair-wise router distances from traceroutes, therefore MDS is not so useful here.
Isomap allows an incomplete distance matrix as input to estimate point coordinates in a multi-dimensional space. Isomap is in fact a generalized MDS method. It views the problem of high dimensionality to low dimensionality transformation as a graph problem. The Isomap algorithm consists of three steps: (1) Given a distance matrix, Isomap first constructs a neighborhood graph on top of the points. Namely, each point needs to select some points as its neighbors and adds edges to them. The neighbors can be the points within a certain distance range or a certain number of closest points. All the points hence form a connected graph; (2) Isomap then computes pair-wise shortest path distances in the neighborhood graph by the Floyd-Warshall algorithm or Dijkstra algorithm. The distance between any two points (in the neighborhood graph) is then known and a complete distance matrix is available; (3) In the final step, Isomap applies MDS to the complete distance matrix to estimate point coordinates.
In a traceroute result, the network distance between the source and an intermediate known router is available and can be expressed in terms of delays (RTT) or hops. Delay-based embedding is often more accurate than hop-based embedding, as in Costa et al., below, leading to more accurate merging. Regarding delay based embedding, see the following, each of which is incorporated herein by reference in its entirety: T. S. E. Ng et al., “Predicting Internet network distance with coordinates-based approaches”, in Proc. IEEE INFOCOM ' 02, pp. 170-179 (June 2002); H. Lim et al., “Constructing Internet coordinate system based on delay measurements”, in Proc. ACM SIGCOMM IWC ' 03, pp. 129-142 (October 2003); M. Costa et al., “PIC: Practical Internet coordinates for distance estimation”, in Proc. ICDCS ' 04 (March 2004); F. Dabek et al., “Vivaldi: A decentralized network coordinate system”, in Proc. ACM SIGCOMM ' 04, pp. 15-26 (August 2004); and B. Wong et al., “Meridian: a lightweight network location service without virtual coordinates”, in Proc. ACM SIGCOMM ' 05, pp. 85-96 (August 2005). This is because the RTT between two hosts often correlates with their geographic distance, which is approximately in a 2-dimensional Euclidean space. However, delay-based embedding has the following drawbacks: (a) The link delay may not be accurate and stable, especially in heavy-loaded networks; (b) The delays associated with anonymous routers are not available from traceroutes. Therefore, their estimated coordinates are inaccurate even if the embedding of known routers and hosts is fully accurate. In the following, the delay-based Isomap merging algorithm is called the Isomap-delay algorithm, and the hop-based Isomap merging algorithm is called the Isomap-hop algorithm. In embodiments of the invention either may be chosen and they are described in the following, but before either merging algorithm is applied some initial pruning may be performed.
Initial Pruning
Check the neighbors of anonymous routers. If two anonymous routers or one anonymous router and one known router share the same neighbors (known routers or hosts), merge them directly (To check whether an anonymous router is mergeable to some known router, it is only necessary to compare the anonymous router with its neighbors' neighbors). For example, in FIG. 2( b ), * 1 and * 2 lie between host 1 and router R 1 and they can be merged into one router. The justification for such pruning is that this merging preserves both the distance and the trace consistencies. Furthermore, in the Internet, the path segment between a pair of routers two hops away is usually stable. Therefore, this pruning works in most cases.
Following this initial pruning the distance matrix is then constructed.
Construction of Distance Matrix
The operations in the Isomap-delay and Isomap-hop algorithms must be distinguished.
Isomap-delay algorithm: Collect and analyze round-trip delays from traceroute results. In a traceroute path, the delay between any two known nodes (known routers or hosts) is either directly available or can be computed. However, the delays associated with anonymous routers are not available. Suppose A and B are two valid IP addresses in a traceroute, sandwiched by a list of anonymous routers b 1 , . . . , b n , in that order. We assume that these anonymous routers are evenly distributed between A and B, and accordingly compute delay(b i , b j ) as (j−i)/(n+1)×delay(A,B), where delay(X 1 , X 2 ) is the delay between X 1 and X 2 .
Suppose the total number of nodes in the inferred topology (including known and anonymous routers, and hosts) is n t . We build a n t ×n t distance matrix G as
G ( i , j ) = { 0 , if i = j ; min ( d ( i , j ) , d ( j , i ) ) , if both d ( i , j ) and d ( j , i ) exist ; d ( i , j ) , if only d ( i , j ) exists ; d ( j , i ) , if only d ( j , i ) exists ; ∞ , otherwise ;
where d(i, j) is the minimum delay from i to j in traceroute results.
Isomap-hop algorithm: Collect network connectivity information from traceroute results, and build a symmetric n t ×n t distance matrix G′ as
G ′ ( i , j ) = { 0 , if i = j ; 1 , if i and j are directly connected in at least one path ; ∞ , otherwise ;
Coordinate Estimation
Apply Isomap to G or G′ to compute the coordinates of routers and hosts. It has been shown that Internet coordinates can be approximately modeled by multi-dimensional Euclidean space. (See, Ng et al., Lim et al., Costa et al., and Dabek et al.) We hence use 5-dimensional Euclidean space in this embodiment.
Router Merging
Compute the distance between any pair of anonymous routers according to their coordinates. Merge anonymous routers as follows:
(1) Merge two anonymous routers within distance Δ 1 . (2) Merge two anonymous routers that share one same neighbor (known routers or hosts) and are within distance Δ 2 . (3) Do not merge two anonymous routers that appear in the same path.
Δ 1 and Δ 2 are two pre-defined thresholds. Clearly, a large threshold increases incorrect merging, while a small one decreases correct merging.
An example of such router merging will now be illustrated with reference to FIG. 3 . FIG. 3( a ) shows the actual underlay topology, which contains three hosts labeled as 1 , 2 and 3 , three known routers labeled as R 1 , R 2 and R 3 , and one type-1 anonymous router. The labels along lines indicate the delays of links in the unit of ms. With pair-wise traceroutes (i.e. path 1 → 2 , 1 → 3 , and 2 → 3 ), we obtain an inferred topology as shown in FIG. 3( b ).
Using the Isomap-delay algorithm, the delay information as shown in Table II in FIG. 4 is obtained. The third column “Delay Measured in Traceroute” shows the delays directly returned by traceroutes. The fourth column shows the delays among known routers and hosts which are computed according to router sequences in paths and the directly measured delays. The fifth column shows the delays associated with anonymous routers by assuming these anonymous routers are evenly distributed between their known neighbors.
We then construct the distance matrix G as Table III in FIG. 5 shows. Isomap takes this distance matrix as input and estimates the coordinates of * 1 , * 2 , and * 3 in 5-dimensional space as (2.36, 2.02, 0, 0, 0), (−3.58, 1.20, 0, 0, 0), (0.75, −2.19, 0, 0, 0), respectively. As a result, the distances between * 1 and * 2 , * 1 and * 3 , * 2 and * 3 are computed as 6.00 ms, 4.51 ms and 5.50 ms, respectively. If Δ 1 is set to 10 ms, we can merge all the three anonymous routers.
Using the Isomap-hop algorithm we construct a distance matrix G′ as in Table IV in FIG. 6 . Applying Isomap to G′, we obtain the coordinates of * 1 , * 2 and * 3 as (0.65, −1.53, −0.75, 0.05, 0.10), (0.90, 1.02, 0.75, 0.05, −0.06) and (−1.55, 0.51, 0.75, −0.10, −0.04), respectively. The distances between * 1 and * 2 , * 1 and * 3 , * 2 and * 3 are 2.74, 2.64 and 2.74, respectively. With a suitable choice for Δ 1 and Δ 2 , we may merge two or three of them.
The complexity of the algorithms can be considered, given that the time and space complexities of Isomap are O(M 3 ) and O(M 2 ), respectively, where M is the number of input points. First the time complexity is analyzed. In the pruning procedure, we compare all O(n i 2 ) pairs of anonymous routers. Each anonymous router has only two neighbors since each anonymous router is assumed to be a unique one. Therefore, the comparison of one pair takes O(1) time. To handle type-2 routers, we compare each anonymous router with its neighbors' neighbors. In the worst case, we need to compare O(n i n k ) pairs of routers. Each comparison takes O(1) time since each anonymous router has two neighbors (if a known router has multiple neighbors, a hashing function can be used to organize its neighbors). As a result, the whole pruning procedure takes O(n i 2 +n i n k ) time. The construction of the distance matrix needs to process a total of O(N 2 ) paths. We assume that the number of routers in a path does not exceed a certain constant, therefore the complexity of constructing the distance matrix is O(N 2 ). The Isomap step takes O((N+n k +n i ) 3 ) time. Afterwards, it takes O(n i 2 ) time to compute the distances between anonymous routers and merge them. In total, the overall complexity is O(n i 2 +n i n k +N 2 +(N+n k +n i ) 3 +n i 2 )=O((N+n k +n i ) 3 ).
The space complexity is analyzed as follows. The initially inferred topology contains (N+n k +n i ) nodes. The links among known routers and hosts take up at most O((N+n k ) 2 ) storage space. The links associated with anonymous routers can be stored in O(n i ) space, because each anonymous router has two neighbors and two adjacent links. So the initially inferred topology can be stored in O((N+n k ) 2 +n i ) space. The distance matrix, Isomap and the coordinates need at most O((N+n k +n i ) 2 ), O((N+n k +n i ) 2 ) and O(N+n k +n i ) spaces, respectively. Therefore, the total space complexity is O((N+n k +n i ) 2 ).
Complexity can be reduced by using a simpler algorithm, the neighbor matching algorithm, which trades off some accuracy for lower complexity. In this algorithm pairs of anonymous routers are merged if they share at least one neighbor (known router or host) and do not appear in the same traceroute path. All the anonymous router pairs are compared and the procedure repeated until no more pairs can be merged. For example, in FIG. 3( b ), we merge * 1 and * 2 302 because they have the same neighbor R 1 . Denote this new router as * 12 , which keeps all the links previously adjacent to * 1 or * 2 . We proceed to merge * 12 and * 3 304 since they share the same neighbors: R 2 and R 3 . In this way, we finally merge all the anonymous routers together. Clearly, this approach may over-merge anonymous routers.
The time complexity of the neighbor matching algorithm is roughly analyzed in terms of the total number of router pairs compared. In the first iteration, we compare all O(n i 2 ) anonymous router pairs and possibly merge some of them. Suppose we merge k 1 pairs of routers in this iteration. In the second iteration, we only need to compare these k 1 newly generated routers with each other and with other routers, i.e. O(k 1 ×k 1 +k 1 ×(n i −k 1 −1))=O(k 1 ×n i ) pairs. Suppose there are a total of t iterations before the algorithm stops, and in each iteration, k 1 , k 2 , . . . , k t pairs are merged, in that sequence. The total number of pairs that need to be compared is then
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Regarding the space complexity, observe that each merging decreases the number of routers in the topology by one and also decreases the number of links. The maximum storage space is then required for the initially inferred topology, which is O((N+n k ) 2 +n i ).
Simulations may be performed to evaluate the merging algorithms of embodiments of the present invention on Internet-like topologies and a real Internet topology.
1) Simulation Setup: The following metrics are defined to enable an evaluation of the performance of the merging algorithms.
Router ratio: defined as the total number of routers in an inferred topology divided by the number of routers in the actual topology.
Link ratio: defined as the total number of links in an inferred topology divided by the number of links in the actual topology.
Anonymous router ratio: defined as the number of anonymous routers in an inferred topology divided by the number of anonymous routers in the actual topology.
Error merging ratio: defined as the number of incorrect merging in topology inference divided by the total number of merging.
Graph distance: defined as the minimum number of primitive operations (i.e., vertex insertion, vertex deletion and vertex update) that need to be applied to an inferred topology to make it isomorphic with the actual topology. (See, A. N. Papadopoulos et al., “Structure-based similarity search with graph histograms”, in Proc. DEXA ' 99, pp. 174-178 (September 1999), which is hereby incorporated by reference herein in its entirety.) This indicates the degree of similarity between two graphs. The smaller the graph distance, the more similar the two graphs are.
Hop gap: the hop gap between a pair of hosts A and B is defined as (1-Hop(A,B) in the inferred topology/Hop(A,B) in the actual topology). We are interested in the average hop gap among all pairs of hosts.
The ideal and expected inference result is the actual topology, whose router ratio, link ratio and anonymous router ratio are all 1.0, and error merging ratio, graph distance and hop gap are all 0. Given a set of pair-wise traceroutes, the initially inferred topology without any merging has perfect error merging ratio and hop gap but large router/link/anonymous router ratios and graph distance. Isomap merging can reduce router/link/anonymous router ratios and graph distance, but it increases error merging ratio and hop gap. The neighbor matching algorithm further reduces router/link/anonymous router ratios and increases the error merging ratio and hop gap.
Two types of network topologies are used to conduct simulations. Generated topologies: we generate 5 Transit-Stub topologies with Georgia Tech's network topology generator. (See, E. Zegura et al., “How to model an internetwork”, in Proc. IEEE INFOCOM ' 96, pp. 594-602 (March 1996), which is hereby incorporated by reference herein its entirety.) Each topology is a two-layer hierarchy of transit networks (with 8 transit domains, each with 16 randomly-distributed routers) and stub networks (with 256 domains, each with 12 randomly-distributed routers). Each topology contains 3200 routers and about 20000 links. A host is connected to a router with 1 ms delay, while the delays of core links are given by the topology generator. Real Internet topology: we also use a router-level Internet topology from “Internet maps”, found at http://www.isi.edu/scan/mercator/maps.html, which is hereby incorporated by reference herein its entirety, obtained by the Mercator project and Lucent Bell Lab in November 1999. This topology contains 284,805 routers and 860,683 links. However, it only keeps connectivity information and does not record router-level delays.
Pair-wise traceroutes are conducted in the simulations and shortest-path routing is used to identify a path between a pair of hosts. As discussed above, type-2 anonymous routers can be easily detected while type-3 anonymous routers cannot be well managed using end-to-end measurements. The simulations therefore focus on type-1 anonymous routers. Simulations on the topologies are conducted as follows. For the generated topologies, a number of routers (25-200) are selected randomly and one host is attached to each of them. Some routers are randomly set to be anonymous. Five simulations are conducted on each topology and the results are averaged. For the real Internet topology, 100 hosts are randomly attached to routers and anonymous routers are randomly set as above. Twenty-five simulations are performed and the results are averaged. In the simulations, good results are obtained if Δ 1 and Δ 2 in the Isomap-delay algorithm are set to 10 ms and 30 ms, respectively. In the Isomap-hop algorithm, it is good to set them to 0.05 and 0.2, respectively.
FIG. 7 shows the performance of the merging algorithms on the generated GT-ITM topologies. Group size indicates the total number of hosts in a session. We randomly set 5% routers to be type-1 anonymous routers. The lines labeled “Init” and “Pruning” indicate results on the initially inferred topology and the topology after pruning, respectively. In FIG. 7( a ), we clearly see that there is high router inflation. Router ratio without merging increases with the group size. Simple pruning can significantly reduce the inflation, but the residual router ratio is still rather high. The three merging algorithms further reduce the router ratio to close to 1. Note that in all the three algorithms, the router ratio only increases slowly with the group size which shows that these algorithms are efficient even in a large-scale network. Among them, neighbor matching merges the most anonymous routers while Isomap-hop merges the least. In fact, some of the values of neighbor matching are less than 1, which shows that it is too aggressive in merging and tends to over-merge routers. FIGS. 7( b ) and ( c ) show the link ratio and anonymous router ratio, respectively. A
Again it can be seen that there is very high inflation, especially for the anonymous router ratio. In FIG. 7( c ), with the merging algorithms, anonymous router ratios are reduced to a low value (less than 4). This shows significant improvement as compared to the topology with only pruning.
FIG. 7( d ) shows the error merging ratios of the three merging algorithms. Note that the error merging ratio for pruning is always 0 in the simulations and hence only the results based on the final inference topologies are shown. This is because shortest path routing is used and the path between any two routers is unique. As shown, neighbor matching has the largest merging error, while Isomap-hop has the smallest. Clearly, neighbor matching aggressively merges anonymous routers and often makes incorrect decisions. Isomap-hop merges the least anonymous routers, leading to the smallest merging error. As for Isomap merging, error merging ratios are less than 8%. This means that most of the merging decisions (more than 92%) are correct.
FIG. 8( e ) shows the similarity distance between the inferred topology and the actual topology. In the graph, the similarity distance between the actual topology and a topology generated by randomly adding a certain percentage of links is also shown. As the group size increases, the similarity distances all increase, mainly due to higher inflation. Among all the three inferred topologies, Isomap-delay is the most similar to the actual topology, followed by Isomap-hop and then neighbor matching. Isomap-delay achieves a topology very close to the actual one (similar to the topology with about 5% additional links). Isomap-hop also performs similarly to the one with 10% additional links.
FIG. 8( f ) shows the average hop gap of the three topologies. Isomap-delay performs the best while neighbor matching performs the worst. All of them achieve a relatively low average hop gap (less than 40%). It is not expected that the performance of most overlay applications would be sensitive to such a discrepancy.
In summary, the simplest neighbor matching algorithm tends to over-merge routers and hence introduces the highest error. Isomap-delay achieves better performance by its higher complexity. It also performs better than Isomap-hop for most of the metrics considered. This is because Isomap works the best on Euclidean distances among points, but Isomap-hop only uses 0/1 hop values, which introduces error in the fitting of routers to a high-dimensional space. However, in some other networks where delay information is not stable and accurate, Isomap-hop is more useful and applicable.
Due to the lack of round-trip time among routers, the Isomap-delay algorithm is not evaluated on the real Internet topology. Instead, the performance of the other two algorithms is evaluated with a different number of anonymous routers. Their performance is shown in FIG. 8 . Clearly, the conclusions are qualitatively the same as that of the generated topologies. The anonymous routers significantly inflate the network. Simple pruning can efficiently reduce the inflation. Isomap-hop and neighbor matching algorithms make further reductions. Neighbor matching merges more anonymous routers than Isomap-hop, but it also makes more mistakes by showing larger error merging ratio, similarity distance and average hop gap.
Comparing FIGS. 7( d ) and 8 ( d ), it can be seen that the error merging ratios on the real Internet topology are larger than those on the generated topologies. One reason is that the total number of routers in the real Internet topology is much larger than that in the generated topologies. Note that routers have been randomly selected to attach hosts and shortest path routing has been used to identify inter-host paths. With a huge amount of routers in the real Internet topology, the shortest paths have few overlaps. This is different from the case on the generated topologies, where routers in the core are more frequently visited than others. This also explains why the “Init” and “Pruning” curves in FIGS. 8( a ), ( b ) and ( c ) have much smaller inflation ratios than that in FIG. 7 .
In FIGS. 8( e ) and ( f ), the similarity distance and average hop gap almost linearly increase with the percentage of anonymous routers. When the percentage of anonymous routers is large (say, larger than 7%), the merging error is also large. In that case, application-layer inference may not be sufficient to obtain a highly accurate topology, and more information about anonymous routers is desired.
The algorithms described above have a number of practical applications. The inferred topology can be applied in many overlay network services. A typical example is a peer-to-peer streaming service. With an inferred topology, the streaming service can reduce end-to-end delay and bandwidth consumption and thus provide better streaming quality. The stage at which the topology inference is carried out may depend on the specific application. In some applications peers may dynamically join and leave and in order to obtain the latest topology information continuous (or periodic) topology inference is required. In other cases, for example when peers and networks are relatively stable, the topology inference may be carried out only once.
While several aspects of the present invention have been described and depicted herein, alternative aspects may be effected by those skilled in the art to accomplish the same objectives. Accordingly, it is intended by the appended claims to cover all such alternative aspects as fall within the true spirit and scope of the invention. | Algorithms are described that facilitate the inference of a network topology by estimating router co-ordinates and merging anonymous routers. The algorithms have practical applications in the inference of a network topology as part of the provision of a network service that is based on the underlying topology and where knowledge of the actual topology allows improved performance. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of International application PCT/AU2008/001874 filed Dec. 19, 2008, which, claims priority to AU2008905097 filed Sep. 30, 2008 and AU2008905201 filed Oct. 5, 2008. This application is also a continuation-in-part of U.S. application Ser. No. 11/995,585 filed Jan. 14, 2008, which is incorporated in its entirety by reference herein, which is a U.S. national phase of International application PCT/AU2006/000981 filed Jul. 13, 2006, claiming priority to AU 2005903707 filed Jul. 13, 2005.
TECHNICAL FIELD
[0002] The invention described herein relates to a combined light fitting and ceiling fan having blades that are compactly folded when the fan is not in use and that move outwardly when the fan is started. More particularly the invention relates to improved fan blades for such an appliance.
BACKGROUND
[0003] Ceiling fans have long been recognized and used as an inexpensive way to provide movement of air within rooms of buildings. They can be simple to use and install, safe, and inexpensive to buy and run when compared to such alternatives as for example refrigerated and evaporative air conditioning units. They can often provide a surprisingly effective alternative to air conditioning as the air movement they generate can evaporate skin perspiration with a resulting cooling effect.
[0004] It is known to combine ceiling fans with lighting means, as firstly it is a common requirement to provide ceiling mounted light sources, and secondly it is convenient to provide a single power supply to operate a combined fan and light fitting.
[0005] Less commonly, it has also been known to provide a combined light fitting and ceiling fan with some form of folding or retracting blade arrangement. Le Velle has described three versions. U.S. Pat. No. 1,445,402 discloses a light fitting and ceiling fan in which blades move outwards under centrifugal force when the fan is switched on, and are retracted by springs when the fan is switched off. U.S. Pat. Nos. 1,458,348 and 2,079,942 disclose improved versions, in which (unlike the early version of U.S. Pat. No. 1,445,402) the inward and outward movements of the blades are synchronized. Synchronizing blade movement is important for preserving satisfactory balance of the rotating parts of the fan. More recently, a combined light fitting and ceiling fan has been disclosed by Villella (see international patent publication WO 2007/006096) with a concealed and simple blade movement synchronizing arrangement that lends itself to modern design.
[0006] A problem in the design of a combined light fitting and ceiling fan is to provide blades that when in use can provide useful air moving performance without requiring excessive power and that when not in use can fold into a reasonably compact overall form. The present invention addresses this problem.
[0007] References above and elsewhere in this specification to certain patents are not intended as or to be taken as admitting that anything therein forms a part of the common general knowledge in the art in any place.
SUMMARY
[0008] A combined ceiling fan and light fitting will in this specification be referred to as a fan/light for convenience and brevity.
[0009] The invention relates to fan/lights having a plurality of fan blades that move outwardly to operating positions during fan operation and inwardly to stowed positions when fan operation ceases. Movement of the fan blades outwardly may be by action of centrifugal force when the blades are rotated about a fan axis by a motor. Retraction of the fan blades to their stowed positions may be by action of resilient means, for example one or more springs.
[0010] The blades are adapted and arranged when in their operating positions to move air downward as they rotate, and when in their stowed positions to lie within a defined radius from the fan axis, such as the radius of a translucent enclosure of circular form (when seen in plan view) for light emitting devices such as incandescent lamps. Each blade when stowed may overlap at least one other blade.
[0011] Preferred forms and relative positionings of blades are disclosed that are believed to provide a useful balance between the requirements of reasonable air movement and compact stowage of the blades when not in use. These forms are particularly characterized by certain distributions of incidence, blade chord (distance measured from leading edge to trailing edge) and dihedral. They are preferably of aerofoil cross section with such camber that lower blade surfaces are concave and upper blade surfaces convex.
[0012] More specifically, the invention provides in a first aspect a combined ceiling fan and light fitting having a plurality of fan blades, wherein:
[0013] each blade is pivotally mounted so as to be pivotable about an upright pivot axis of the blade between a stowed position and a deployed position;
[0014] each blade when in its stowed position lies within a specified radius from an upright fan rotation axis and above a light fitting portion and has an air moving portion that in the deployed position of the blade extends beyond said specified radius; and
[0015] each blade is generally elongate and arcuate when seen in plan view and in its stowed position extends peripherally within said specified radius between its pivot axis and a tip end of the blade and partially overlies a neighbouring one of the blades in its own stowed position;
[0016] the combined ceiling fan and light fitting characterized in that:
[0017] (a) each blade initially rises in height above a datum height with increasing distance along the blade from its pivot axis end so that the blade when in its stowed position overlies the pivot axis end of the neighbouring blade in its own stowed position and
[0018] (b) with increasing distance from a pivot-axis end of the air moving portion towards the tip end of the blade the leading edge of the air moving portion first increases in height above the said datum height and then turns downwardly whereby to limit the height of the tip end above the datum height.
[0019] The term “neighbouring blade” here means a blade that is first found by moving peripherally forward (i.e. in the direction of fan rotation) from one blade.
[0020] The phrase “turns downwardly” here does not necessarily mean that with increasing distance toward the tip end from such turning down the blade begins to actually descend. Rather it means that the blade increases in height at a lesser rate than before the turning down, which may still be positive although that is not to preclude a zero or negative rate of height increase.
[0021] Thus, the leading edge of the air moving portion of each blade may have a peak height above the datum height at a position between the pivot-axis end of the air moving portion and the tip end of the blade.
[0022] Further, the height above the datum height of the leading edge of the air moving portion may decline from said peak height with increasing distance along the leading edge toward the tip end of the blade.
[0023] The “specified radius” may be approximately a radius of a light fitting portion that is comprised in the combined ceiling fan and light fitting and located below the blade and that is of circular shape when seen in plan view.
[0024] The “datum height” may, purely for example, be the height of an upper surface of a horizontal platelike member to which each of the blades is pivotably mounted as in the case of the construction described by Villella.
[0025] The air moving portion of each blade may have a trailing edge that when seen in plan view is approximately a circular arc which when the blade is in its stowed position said is substantially centred on the fan rotation axis. This arrangement allows effectively use of the available space above a light fitting portion that is round when seen in plan view.
[0026] Preferably, for each blade when in its stowed position the radial distance between the leading and trailing edges of the air moving portion reduces progressively (i.e. the blade tapers as seen in plan view) from a maximum value partway along the length of the air moving portion towards the blade tip end.
[0027] More preferably, when all blades are in their stowed positions there is for each blade a first point on the leading edge of its air moving portion where the blade overlies its neighbouring blade which first point when seen in a notional radial plane including the fan rotation axis lies at a greater radius than a second point in the same notional plane that is on the leading edge of the overlain neighbouring blade.
[0028] Still more preferably, the said first point may be at a height above the datum height not exceeding the height of the said second point.
[0029] These arrangements can enhance the compactness of stowage of the blades.
[0030] It is preferred that the air moving portion of each blade has in the deployed position of the blade a maximum angle of incidence to the horizontal at a position partway along the air moving portion the angle of incidence decreasing with increasing distance from that position of maximum incidence towards the tip end of the blade.
[0031] Preferably also, the air moving portion has a positive angle of incidence to the horizontal at its pivot-axis end.
[0032] The position partway along the air moving portion of each blade at which its incidence to the horizontal is a maximum when the blade is in its deployed position may be radially inboard of a position at which the blade chord measured along an arc centred on the fan rotation axis is at a maximum value. It is thought (but not asserted) that this feature may smooth the distribution of downward thrust on the air along the blade, so reducing induced drag on the blade.
[0033] Although adaptable to other numbers of blades, for example three or five, the number of blades is preferably four with the blades' pivot axes being spaced 90 degrees apart from each other peripherally.
[0034] That section of each blade between its pivot axis and its tip end when the blade is in its stowed position may subtend an angle of about 160 to 170 degrees at the fan rotation axis. Values in this range allow reasonable blade areas within the available stowage space above the light fitting portion, but without at any point requiring the stacking of more than two blades. This assists in obtaining compact blade stowage.
[0035] Preferably, each blade pivots through an angle of about 180 degrees to move from its stowed position to its deployed position. This gives a satisfactory blade-swept area for a given blade size.
[0036] Preferably, the air moving section of each blade is upwardly cambered (i.e. Concave downwards) between its leading and trailing edges when seen in cross-section on a cylindrical surface centred on the fan rotation axis and intersecting the air moving section at a radius between the specified radius and the blade tip end.
[0037] It is also preferred for efficient air moving that the air moving section of each blade has a rounded leading edge and a sharp trailing edge over at least part of its along-blade length when seen in cross-section on a cylindrical surface centred on the fan rotation axis and intersecting the air moving section at a radius between the specified radius and the blade tip end.
[0038] The minimum height difference between each blade and its neighbouring blade when the blades are in their stowed positions may advantageously occur approximately where the blade overlies its neighbouring blade. If an overlying blade sags slightly, as may be the case with blades moulded from certain plastics if left unused for some time, this arrangement has been found to support the outer part of the blade reasonably well once contact between a blade and its underlying neighbour has been made.
[0039] The invention provides in another aspect a combined ceiling fan and light fitting having a plurality of elongate and arcuate planform blades that can move pivotally about upright axes between firstly stowed positions above a light fitting enclosure and secondly deployed positions in which the blades extend outwardly beyond the light fitting, characterized in that leading edges of the blades when in their deployed positions firstly rise with increasing radius beyond the light fitting enclosure first and thereafter are cranked downwardly.
[0040] In this aspect, when the blades are in their stowed positions each blade overlies a part of its neighbouring blade which part is received in a gap above the light fitting enclosure and below the underside of the overlying blade said gap existing by virtue of the cranked shape of the overlying blade.
[0041] Each blade may be pivotally mounted to a rotating platelike member with said gap lying above said platelike member.
[0042] In a third aspect the invention provides a combined ceiling fan and light fitting having air moving blades that in use exhibit gullwing dihedral. It is thought that such a dihedral form may be advantageous in itself even apart from its ability to enable compact stowage of retracting blades. “Gullwing dihedral” is to be taken as meaning that a lifting blade or wing rises between its root end and a point or region along its length toward its tip end and then either falls, remains level or rises more slowly.
[0043] In a further aspect the invention provides a combined ceiling fan and light fitting having a plurality of fan blades, wherein:
[0044] each blade is pivotally mounted so as to be pivotable about an upright pivot axis of the blade between a stowed position and a deployed position;
[0045] each blade when in its stowed position lies within a specified radius from an upright fan rotation axis and above a light fitting portion and has an air moving portion that in the deployed position of the blade extends beyond said specified radius; and
[0046] each blade is generally elongate and arcuate when seen in plan view with concave and convex sides and in its stowed position extends peripherally within said specified radius between its pivot axis and a tip end of the blade,
[0047] characterized in that:
[0048] (a) each blade when deployed is so positioned that a concave side of the blade faces forward in the blade's direction of rotation and so that a radially outer portion of the blade's length extends both outwardly and forwardly;
[0049] there is a first position partway along the air moving portion of the blade at which the blade's chord as measured in a peripheral direction has a maximum value and a second position partway along the air moving portion of the blade at which the blade has a maximum positive angle of incidence to the horizontal; and
[0050] (c) the first position is at a greater radius than the second position.
[0051] That is, the distributions of incidence and chord disclosed herein are believed advantageous in themselves apart from the issue of blade stowage.
[0052] The invention further provides a blade adapted for use in fan/lights as disclosed.
[0053] It is explicitly intended that the specific four-blade embodiment described in detail below be taken to be a claimable aspect of the invention both as to the proportions of the blades and their relative positions when in their stowed and operating positions.
[0054] The invention is preferably applied in fan/lights having certain features of the construction described in International Patent Publication WO 2007/006096 (based on International Patent Application No. PCT/AU2006/000981 by Joe Villella).
[0055] In a still further aspect of the invention there is further provided a fan/light comprising a plurality of retractable fan blades, wherein:
[0056] each said blade is pivotally mounted to a fan member that is rotatable about an upright fan rotation axis so that said blade is pivotable between a retracted position and an operating position about an upright blade pivot axis of said fan member;
[0057] each said blade has an elongate and generally arcuate air moving blade portion that when said blade is in the retracted position of said blade lies within a space bounded by:
[0058] (a) an inner cylindrical surface coaxial with said fan rotation axis and touching an inner edge of said blade portion;
[0059] (b) an outer cylindrical surface coaxial with said fan rotation axis and touching an outer edge of said blade portion;
[0060] (c) a first radial plane containing said fan rotation axis and said blade pivot axis; and
[0061] a second radial plane containing said fan rotation axis and that touches a tip of the blade,
[0062] so that associated with every point on said blade portion is an angle theta being an angle between said first radial plane and a radial plane containing the fan rotation axis and that point; and
[0063] within a continuous section of the blade portion that lies between said first and second radial planes, said inner edge increases in height above a datum height with increasing theta, and a radial projection of said inner edge onto a cylindrical surface coaxial with said fan rotation axis is concave downwards.
[0064] Preferably, within said continuous section of said blade said inner edge increases in height above said datum height with increasing theta until a maximum value of the inner edge height is first reached at a point thereon whose value of theta is less than the value of theta at the blade tip.
[0065] Within said continuous section and for theta values greater than the smallest value at which said inner edge has its maximum height above said datum height, the height of said inner edge may decrease with increasing theta. This particular embodiment corresponds to the preferred embodiment described in detail herein.
[0066] In such a fan/light the other preferred features proportions and relative positioning of the blades as described herein may also be applied, including as to the blade trailing edge shape.
[0067] Further features, preferences and inventive concepts are disclosed in the following detailed description and appended claims.
[0068] In this specification, including in the appended claims, the word “comprise” (and derivatives such as “comprising”, “comprises” and “comprised”) when used in relation to a set of integers, elements or steps is not to be taken as precluding the possibility that other integers elements or steps are present or able to be included.
BRIEF DESCRIPTION OF THE DRAWINGS
[0069] In order that the invention may be better understood there will now be described, non-limitingly, preferred embodiments of the invention as shown in the attached Figures, of which:
[0070] FIG. 1 is a perspective view from above of a fan/light with retractable fan blades according to the invention, shown with its blades deployed to their operating positions;
[0071] FIG. 2 is a perspective view from below of the fan/light shown in FIG. 1 with its blades deployed to their operating positions;
[0072] FIG. 3 is a perspective from above of the fan/light shown in FIG. 1 , now with its fan blades shown in their folded, non-operating positions;
[0073] FIG. 4 is a perspective view from below of the fan/light shown in FIG. 1 , with its fan blades shown in their folded, non-operating positions;
[0074] FIG. 5 is a plan view of the fan/light of FIG. 1 , with its fan blades shown deployed to their operating positions;
[0075] FIG. 6 is a plan view of the fan/light of FIG. 1 , with its fan blades shown in their folded, non-operating positions;
[0076] FIG. 7 is a side view of the fan/light of FIG. 1 , with its fan blades shown deployed to their operating positions;
[0077] FIG. 8 is a side view of the fan/light of FIG. 1 , with its fan blades shown in their folded, non-operating positions;
[0078] FIG. 9 is a perspective view from below of a subassembly of a fan/light with retractable fan blades described in International Patent Publication No. WO 2007/006096 by Villella;
[0079] FIG. 10 is a schematic plan view of the fan/light shown in FIG. 1 showing one blade in both deployed and retracted positions and the other blades in retracted positions and chain-dotted lines only;
[0080] FIG. 11 is a schematic plan view of the fan/light shown in FIG. 1 with all blades shown in chain-dotted lines in retracted positions and one blade also shown in its deployed position the view further showing positions of a set of cylindrical surfaces intersecting, and located at radially spaced stations along, the extended blade;
[0081] FIG. 12 is a set of sections (labeled a- 1 ) on radial planes as defined in FIG. 10 of refracted blades of the fan/light shown schematically in FIG. 10 ;
[0082] FIG. 13 is a graph of heights above a datum height of inner and outer edges of a blade of the fan/light shown in FIG. 1 , as a function of circumferential position when the blade is in a refracted position;
[0083] FIG. 14 is a graph of radial distance between inner and outer edges of a blade of the fan/light shown in FIG. 1 , as a function of circumferential position when the blade is in a retracted position;
[0084] FIG. 15 is a graph of heights above a datum height of inner and outer edges of all blades of the fan/light shown in FIG. 1 , as a function of circumferential position when the blades are in their retracted positions;
[0085] FIG. 16 is a set of cross-sections of the extended blade shown in FIG. 11 taken on planes tangential to the arcs shown therein an numbered 1 to 8 ;
[0086] FIG. 17 is a graph of an angle of incidence to the horizontal of the extended fan blade shown in FIG. 11 as a function of radial position on the blade; and
[0087] FIG. 18 is a graph of the chord of the extended blade shown in FIG. 11 as a function of radial position on the blade.
DETAILED DESCRIPTION
[0088] As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.
[0089] FIGS. 1 to 8 show a fan/light 10 according to the invention. Fan/light 10 has a non-rotating bowl-like translucent enclosure 12 in which is mounted at least one electric lamp (not shown), and is supported from a ceiling by a tubular support 13 in known manner. Fan/light 10 also has fan blades 1 , 2 , 3 and 4 that are rotatable by an electric motor (not shown) about an upright axis 15 coaxial with tubular support 13 . The electric motor and the lamp are operable separately or together from a source of electric power that is supplied through the tubular support 13 . The motor is of a known type, widely used in ceiling fans, that has a rotating external casing (not shown) with a central cavity in which is received the tubular support 13 . Enclosure 12 is circular in plan view, centered on axis 15 .
[0090] Blades 1 - 4 each extend outwardly to the operating positions shown in FIGS. 1 , 2 , 5 and 7 when the motor is switched on, and retract (fold) into positions shown in FIGS. 3 , 4 , 6 and 8 when the motor is switched off. The sense of rotation is as shown by arrow 7 . Each one of blades 1 - 4 is pivotally supported on a blade support plate 14 that supports and rotates with blades 1 - 4 , is disc-shaped, is coaxial with the rotation axis 15 of the motor and is secured to the motor's casing. A decorative dust cover 18 is secured on the support 4 above the blades 1 - 4 when they are in the folded positions shown in FIGS. 3 , 4 , 6 and 8 .
[0091] Pivoting of blades 1 - 4 on blade support plate 14 is respectively about axes 21 , 22 , 23 and 24 parallel to the axis 15 of rotation of the motor. When the motor is switched on, blades 1 - 4 pivot outwardly under the influence of centrifugal force, pivoting around their respective pivot axes 21 - 24 , until the operating positions shown in FIGS. 1 , 2 , 5 and 7 are reached. When the motor is switched off, blades 1 - 4 are retracted to their stowed positions as shown in FIGS. 3 , 4 , 6 and 8 , again pivoting about their respective axes 21 - 24 .
[0092] In international patent No. publication WO 2007/006096 (based on International Patent Application No. PCT/AU2006/000981 by Villella), which is incorporated herein in its entirety by reference, there is described a fan/light generally in accordance with the above principles and arrangement, albeit with three blades instead of the four blades 1 - 4 of fan/light 10 . The present invention in its preferred embodiment is made in accordance with the principles and arrangement set out in Villella's disclosure save for the use of the four blades 1 - 4 instead of three.
[0093] In particular, synchronization of the pivoting movement of blades 1 - 4 and their refraction, may be by means of a simple adaptation to four blades of the approach disclosed by Villella, now briefly described. FIG. 9 (similar to FIG. 7 of Villella's publication) shows a subassembly 30 of Villella's fan/light comprising a motor 34 , blade support plate 36 and three blades 31 , 32 and 33 . (Note: The item numbers used herein to describe subassembly 30 are not the same as those used in the cited Villella publication.) Blade support plate 36 is ring shaped and secured to motor 34 (of the rotating casing type previously mentioned) so as to rotate therewith in its own plane.
[0094] Secured below blade support plate 36 is a sun gear 38 . (The term “sun gear” is here used as it is in the art of so-called planetary gearing systems, where it refers to a gear that meshes with a number of “planetary” gears arrayed around its periphery.) Sun gear 38 is coaxial with the motor 34 when support plate 36 is mounted to motor 34 , and is able to rotate about its axis relative to support plate 36 . Meshing with sun gear 38 are planetary gears 41 , 42 and 43 , each of which rotates as its associated one of blades 31 - 33 pivots between its stowed and operating positions. Each of gears 41 - 43 is secured to a short shaft (not visible) that passes downwardly from its associated one of blades 31 - 33 and can rotate within support plate 36 . The gears 41 - 43 are equispaced around the periphery of sun gear 38 and are themselves all at the same radius as each other from the rotation axis 35 of motor 34 . The effect of this arrangement is that provided blades 31 - 33 are identical and identically positioned in their working positions relative to support plate 36 , they will be kept synchronized always when they pivot between their operating and retracted positions.
[0095] To retract blades 31 - 33 when motor 34 is switched off, coil springs 44 are provided. One end of each spring is secured to a formation 46 depending from support plate 36 and the other end is secured to a formation 48 depending from sun gear 38 . Coil springs 44 are arranged to be in tension when blades 31 - 33 are in their retracted position and are extended as centrifugal force urges blades 31 - 33 out when motor 34 is started. When motor 34 is stopped, springs 44 urge sun gear 38 to rotate relative to support plate 34 so as to retract the blades 31 - 33 .
[0096] For further information on, and options relating to, this arrangement for blade synchronization and retraction, refer can be made to the cited publication of Villella.
[0097] The way to adapt this arrangement to the four blades 1 - 4 of the embodiment of the present invention here described will be readily apparent to persons skilled in the art. There would be provided four planetary gears (not shown, but equivalent to gears 41 - 43 ) instead of three, equispaced around the sun gear (not shown, but equivalent to sun gear 38 ) and each associated with one blade.
[0098] In the following description, it will be assumed that blades 1 - 4 are pivotally mounted to support plate 14 essentially similar to support plate 36 and synchronized and refracted in the same way as blades 31 - 33 of subassembly 30 . However, it is emphasized that the aerodynamic design of blades 1 - 4 and the way that they “nest” together when refracted are by no means limited to this particular fan/light construction. The configuration and arrangement of blades 1 - 4 could be applied to fan/lights of other constructions and to fans requiring retractable blades and without any lighting capability.
[0099] The blades 1 - 4 and their arrangement in fan/light 10 will now be described. Blades 1 - 4 are intended to provide fan/light 10 with a useful balance between satisfactory air-moving performance, compactness when the blades are in their stowed (i.e. refracted or folded) position, together with a diameter of the translucent enclosure 12 that is large enough to provide a reasonably diffuse lighting effect. The blades 1 - 4 are intended to lie substantially above the translucent enclosure 12 when retracted. In the embodiment shown and described herein, the enclosure 12 has a diameter that is about 39% of the overall diameter of fan/light 10 with its blades 1 - 4 extended for operation. The diameter of the hub of a conventional ceiling fan or fan/light without retractable blades is typically smaller than 39% of the overall diameter over the blades. The larger the diameter of enclosure 12 for a given overall diameter, the easier it is to meet the requirement of compact folding, with blades 1 - 4 above enclosure 12 , but the more difficult it is to provide satisfactory air moving performance at normal fan rotational speeds. A range of from about 36% to about 42% for the above ratio is believed to be possible by straightforward adaptation of the blade shapes as described herein, but a figure in the region of 38% to 40% is preferred.
[0100] The geometry of blades 1 - 4 will be described below by reference to quantities and sections defined in FIGS. 10 and 11 . In the schematic plan view of FIG. 10 , enclosure 12 is represented simply by its circular outer peripheral edge 26 . Blades 1 - 4 are all shown in outline in their retracted positions, blade 1 in solid lines and the others in chain-dotted lines, and blade 1 is also shown in solid lines in its deployed position. Blades 1 - 4 are substantially identical to each other and are generally scimitar-shaped, i.e. of arcuate form so as to lie, when retracted, within the enclosure peripheral edge 26 and around the motor (not shown but centred on axis 15 ). The pivot axes 21 - 24 are adjacent to root ends 51 - 54 respectively ( FIG. 11 ) of blades 1 - 4 and in their refracted position the blades 1 - 4 extend clockwise to tips (free ends) 61 - 64 respectively. Item numbers with the postscript “a” are for blade 1 in its deployed position and item numbers with the postscript “b” are for blade 1 in its retracted position.
[0101] Blades 1 - 4 of fan/light 10 are shown (by arrow 7 ) as rotating clockwise when seen from above. It is to be understood however, that counter-clockwise rotation could equally well be chosen, in which case the term “counter-clockwise” would be applicable where in the present description “clockwise” now appears, including in the definitions given below of the terms “next blade” and “previous blade”. (Note that for counter-clockwise rotation, the blades would be made of opposite hand to blades 1 - 4 , as it is preferred that each blade's leading edge be its concave one.)
[0102] In relation to any given one of blades 1 - 4 , the term “next blade” refers to the blade whose pivot axis is 90 degrees in the rotation direction (here clockwise) from the pivot axis of the given blade, and the term “previous blade” refers to the blade whose pivot axis is 90 degrees in a counter-direction opposite to the rotation direction (i.e. counter-clockwise here) from the pivot axis of the given blade. Thus, in relation to blade 1 , the next blade is blade 2 and the previous blade is blade 4 . The blade shape will be described mainly by reference to blade 1 for convenience, noting that blades 1 - 4 are substantially identical.
[0103] To show how blades 1 - 4 are arranged relative to each other in nesting fashion when refracted, it will be convenient to use sectional views on radial planes, i.e. planes that include the fan axis 15 . Such a plane 42 is shown in FIG. 10 and is shown to be at an angle θ (theta) to a similar plane 44 that includes both axis 15 and axis 21 of blade 1 .
[0104] For discussion of the blade shape from the point of view of aerodynamic characteristics when in the deployed position, it will be useful to consider blade sections taken on surfaces that are cylindrical, coaxial with fan axis 15 , and located at stations radially spaced apart along a blade. Arcs numbered 1 to 8 in FIG. 11 indicate such stations on blade 1 . Stations 1 and 8 are respectively at radii of 39% and 97% of the overall fan radius (i.e. substantially at the edge of enclosure 12 ) with stations 2 - 7 radially equispaced between stations 1 and 8 .
[0105] Each of blades 1 - 4 pivots through 180 degrees between its retracted and operating positions. From axis 21 to tip 61 , representative blade 1 when retracted extends from theta=0 degrees to theta=approximately 168 degrees. The angle 168 degrees is chosen to be close to, but below, 180 degrees so as to provide a blade 1 whose tip 61 is well clear of enclosure peripheral edge 26 when blade 1 is deployed, but with no more than two of blades 1 - 4 overlapping each other at any point when the blades are retracted. This is important in keeping the overall height of the group of blades 1 - 4 , when retracted, to a compactly small value. Note that if tip 61 where at theta=180 degrees, all three of blades 1 , 2 and 3 would overlap at theta=180 degrees.
[0106] As can be seen in FIGS. 1 , 5 and 7 , representative blade 1 has two distinct portions, namely a root-end portion 80 and a blade portion 82 which in the operating position extends outwardly of peripheral edge 26 of enclosure 12 and is aerodynamically shaped to facilitate air movement. Blade portion 82 is supported cantilever-fashion from blade portion 80 which is pivotably secured to blade support plate 14 . In the preferred embodiment, portions 80 and 82 are formed as a single part, for example by injection molding in a suitable plastics material.
[0107] Root end portion 80 comprises a plate 84 that lies above and, approximately parallel to support plate upper surface 46 . A hole 86 in plate 84 permits a stub shaft (not shown) to pass through it and through to the underside of support plate 14 to be secured there to a planet gear (not shown) of the blade synchronization mechanism as described previously. Root end portion 80 further comprises a blade end plate formation 88 whose function is to provide a suitably strong connection between portions 80 and 82 with blade portion 82 inclined at an angle of incidence to plate 84 (see below).
[0108] FIG. 12 shows a set of 12 radial sections (i.e. on planes 42 ) of representative blade 1 and its next and previous blades 2 and 4 in their retracted positions, each section being labeled with its correct value of theta for blade 1 . Radii from fan axis 15 increase to the right in sections (a) to ( 1 ). In each section, blade support plate 14 is shown, with its outer edge 90 at the same lateral position on each page to facilitate comparison between the sections. Outer edge 90 lies radially just within but is close to the enclosure peripheral edge 26 (not shown in FIG. 12 ).
[0109] Sections (a) to (c) of FIG. 12 show how portion 80 of blade 1 transitions to the cantilevered air-moving portion 82 .
[0110] As can be best seen in FIG. 10 , outer edge 94 of portion 82 of representative blade 1 is very close to a circular arc except near the rounded tip 61 , that arc being centred on fan axis 15 when blade 1 is retracted and having a radius very close to the radius of enclosure peripheral edge 26 . Accordingly outer edge 94 of portion 82 of blade 1 lies at almost exactly the same radius as the outer edges of next and previous blades 2 and 4 , except near tip 61 , as shown in sections (d) to ( 1 ) of FIG. 12 .
[0111] FIG. 10 and sections (a) to (f) of FIG. 12 show that previous blade 4 overlies representative blade 1 between theta=0 degrees and slightly less than theta=90 degrees, but without contact between blades 1 and 4 . Between theta=90 degrees and theta=165 degrees (sections (g) to (l)) blade 1 itself overlies next blade 2 , without contact between blades 1 and 2 .
[0112] FIG. 13 is a graph showing the heights of inner edge 92 and outer edge 94 of representative blade 1 above surface 46 of support plate 14 as a function of angle theta Inner edge 92 is higher than outer edge 94 for a given value of theta, consistently with blade 1 having an angle of incidence to the horizontal so as to move air downward when deployed (see below). Absolute height figures are used in FIG. 13 , for a fan/light 10 having an overall swept diameter with blades 1 - 4 deployed of 1200 mm.
[0113] FIG. 14 is a graph showing the radial distance between inner edge 92 and outer edge 94 of representative blade 1 when in its retracted position as a function of angle theta. Absolute radial distances are used in FIG. 13 , for a fan/light 10 having an overall swept diameter with blades 1 - 4 deployed of 1200 mm. The curve between data points has not been extended to the data point for theta=165 degrees because that point is affected by rounding of tip 61 .
[0114] FIG. 15 is a graph showing the same data as FIG. 13 , but now for all of blades 1 - 4 , in their respective peripheral angle (theta) positions. The initials “LE” and “TE” are used for inner and outer edges 92 and 94 respectively in FIG. 15 , because the inner edge of a blade is its leading edge and the outer edge is its trailing edge, when in the deployed position. Note that the blade pivot axes 21 , 22 , 23 and 24 are at angles theta of 0 degrees, 90 degrees, 180 degrees and 270 degrees, respectively.
[0115] FIG. 12-15 together illustrate how blades 1 - 4 in their retracted positions “nest” compactly together without any two blades contacting each other. It has been found that the arrangement shown can also give satisfactory air moving performance.
[0116] As illustrated by the edge heights in FIGS. 13 and 15 , representative blade 1 rises smoothly from its pivot axis 21 (at theta=0 degrees) to a point (at about theta=90 degrees) where it must overlap and clear the next blade 2 . However, instead of continuing further upward at the same rate towards its tip 61 , blade 1 ceases to rise any higher, as shown by the leveling off and then decreasing of the height of inner edge 92 with increasing theta. This arrangement limits the overall height 96 ( FIG. 12 ) above support plate 14 of the group of blades 1 - 4 when retracted. The maximum value of height 96 occurs for representative blade 1 at about theta=105 degrees.
[0117] It will be noted in FIGS. 13 and 15 that, after remaining approximately constant between about theta=90 degrees and theta=120 degrees, outer edge height 94 increases again beyond about theta=120 degrees. As can be seen from sections (j) to (l) in FIG. 12 , and from the slight protrusion of blade 1 shown in FIG. 4 , this optional feature means that some slight sacrifice of compactness in the blade nesting arrangement is incurred (although without any increase in overall height 96 ), it is believed to be aerodynamically desirable, as set out later herein, and so is preferred.
[0118] FIG. 13 can be interpreted as a partial picture of blade 1 as it would appear if projected on an imaginary cylindrical surface coaxial with fan axis, with that surface then being laid flat. It is apparent that blade 1 in such a picture resembles a gull wing, or an aircraft wing with a particular form of varying dihedral, firstly rising with increasing distance from its root end and from a certain point rising no further or at a lesser rate towards its tip end.
[0119] FIG. 15 shows that the inner edge height 92 of representative blade 1 becomes lower than the leading edge height of its next blade 2 for values of theta greater than about 150 degrees. This can be seen in sections (k) and (l) of FIG. 12 . It does not mean that there is contact between blades 1 and 2 because the reduction in radial width of blade 1 means that inner edge 92 of blade 1 is radially outward of the corresponding edge of blade 2 .
[0120] In addition to folding neatly, the blades 1 - 4 must move air downwards reasonably efficiently when deployed and rotating about fan axis 15 , so the shapes of blades 1 - 4 as they affect air movement will now be discussed. The arcs in FIG. 11 that are numbered 1 - 8 represent a set of spaced apart cylindrical surfaces coaxial with axis 15 and radially spaced apart. Although the downward air flow through fan/light 10 will not in general be precisely axial (i.e. parallel to axis 15 ) and therefore occur on such surfaces, a reasonable way to discuss blade shape is by reference to the intersections with the cylindrical surfaces 1 - 8 of representative blade 1 when in its deployed position.
[0121] It is also helpful in the following discussion of the representative blade 1 when it is deployed to make mention of values of the angle theta that was used above in describing its geometry when retracted. Theta is in effect a measure of position along the scimitar-shaped blade 1 . In FIG. 11 , there is shown a non-physical point 101 that if blade 1 were to be retracted would fall on axis 15 , and that when blade 1 is deployed is displaced by 180 degrees from axis 15 about the blade pivot axis 21 . The value of angle theta corresponding to a particular feature on deployed blade 1 can be found using the schematic plan view of FIG. 11 by constructing firstly a line joining point 101 to the feature in question and secondly a line 102 joining point 101 and passing through axes 21 , 15 and 23 . Theta is the angle between these two lines.
[0122] FIG. 16 shows cross sectional views of blade 1 taken on chords 100 (see FIG. 10 ) that are tangent to the cylindrical surfaces of stations 1 to 8 . These are close approximations to the shapes of the cylindrical surfaces of intersection between stations 1 to 8 and blade 1 , as those surfaces would appear if laid flat. In the sections of FIG. 16 , blade 1 moves right to left, so the leading edge 92 and trailing edge 94 are positioned as shown. Although trailing edge 94 is of course not straight in reality, the views in FIG. 16 are so positioned that the trailing edge 94 in all sections is vertically aligned to facilitate comparisons among them.
[0123] FIG. 17 is a graph showing alpha (α), the angle of incidence to the horizontal of representative blade 1 at stations 2 to 8 , the meaning of alpha being illustrated in the section for station 7 in FIG. 16 . The values of alpha plotted in FIG. 17 are not taken from the approximate sections of FIG. 16 , but are estimates of the values that would be obtained in the manner shown if the sections of FIG. 16 were laid-flat developments of the true surfaces of intersection between the cylindrical surfaces numbered 2 to 8 and blade 1 .
[0124] FIG. 18 is a graph showing values of the true chord (i.e. distance measured directly from leading edge 92 to trailing edge 94 ) of blade 1 at intersections with the cylindrical surfaces numbered 1 to 8 . The chord values are not taken from the approximate sections of FIG. 16 , but are estimates of the values that would be obtained if the true surfaces of intersection between blade 1 and the cylindrical surfaces numbered 1 to 8 were obtained and laid flat.
[0125] It has been found that fan/light 10 with blades 1 - 4 having the geometry shown does move air reasonably satisfactorily despite the comparatively large ratio of the diameter of enclosure 12 to the overall diameter swept by the deployed blades 1 - 4 and the scimitar-like shape (in plan view) of the blades.
[0126] Generally, the blades 1 - 4 thrust air downward (and themselves experience a corresponding reactive lifting force) as they rotate. The effectiveness of a blade in this (for a given speed of rotation) is believed to be dependent on, at least, its aerofoil-type cross sectional shape, its incidence to the horizontal, its size (for example its chord as measured from leading edge to trailing edge), the distribution of these along the blade's length (span) and its shape as seen in plan view.
[0127] As seen in the cross-sections of representative blade 1 in FIG. 16 , blades 1 - 4 have an aerofoil-type cross-sectional shape, being cambered so that their lower faces are concave and their upper faces are convex. Their leading edges (eg leading edge 92 of representative blade 1 ) are rounded and their trailing edges (eg edge 94 of representative blade 1 ) are sharp. Generally, blades 1 - 4 are preferred to have cambered aerofoil sections.
[0128] Representative blade 1 has positive incidence to the horizontal (and is of cambered aerofoil cross-section) near its pivot end where, when deployed, it crosses the enclosure peripheral edge 26 , and this is believed to be one factor in its air-moving performance. This positive incidence (alpha greater than zero) is apparent in the section numbered 1 in FIG. 16 .
[0129] It is thought desirable that the lift distribution (and the consequent distribution of air moving effect) along the length of a blade should be generally smoothly varying and in particular that there should be no strong concentration of the effect close to the outer (tip) end. Such a concentration is thought to produce a tendency for high pressure air below the tip area to “leak” upward over the tip end ( 61 in representative blade 1 ) to the area above the tip area, merely agitating the air locally (and wasting power) rather than moving it bodily downward. Therefore, the distribution of incidence angle alpha shown in FIG. 17 shows that the peak blade incidence of about 20 degrees is at about the radius of station 3 (see FIG. 11 ) and smoothly decreases with increasing radius to about 10 degrees at station 8 . (Station 3 corresponds very approximately to theta=60 degrees.)
[0130] The incidence distribution shown in FIG. 17 is due in part to the optional upsweeping of the blade trailing edge beyond about theta=120 degrees that was discussed above. Although a slightly more compact nesting of blades 1 - 4 is achievable if this upsweeping is not incorporated, it does appear to be beneficial to the blades' performance due to its effect on the incidence distribution achieved.
[0131] A further way to influence the lift distribution along the blade is by control of its width (chord) distribution. If one imagines a scimitar shaped blade of constant width along its length (for example for all values of the theta) deployed in the way shown for blades 1 - 4 in FIG. 11 , an effect of the scimitar shape would be that the blade chord, as measured in the circumferential direction with the blade deployed, would be highest at the blade tip and root end and lower therebetween. To offset this effect and so limit the tendency to concentrate the lifting effect at the tip and root ends, blades 1 - 4 are not of constant width. Referring to FIG. 14 , the blade width as seen in plan view) is greatest at about theta=90 degrees and progressively reduces towards the tip end ( 61 for representative blade 1 ). As can be seen in FIG. 11 , theta=90 degrees corresponds approximately to station 5 . This reduction serves the dual purposes of compact nesting of the blades when retracted (as discussed above) and obtaining the desired blade lift distribution.
[0132] FIG. 18 shows the blade chord increasing from a minimum in the region of stations 2 and 3 before falling away at station 8 due to tip rounding. However, the rate of increase in chord with radius is less than it would be if the blade width did not vary with angle theta in the way described herein. See also FIG. 16 , where the alignment of the sections numbered 1 to 8 on the page allows the distribution of chord with radius to be seen.
[0133] As mentioned above the blades may be made conveniently by injection molding in suitable plastics materials. As unobtrusiveness is a desired feature of fan/lights according to the invention, one way of enhancing this is to provide that the blades be formed from a transparent or at least translucent material. This feature is believed to be inventive in itself.
[0134] Although the blade stowage arrangement and method described herein provides for stowage of the blades without contact between blades, the described stowage positions of the blades are such that slight sagging of one blade so as to contact another may not cause failure to deploy. It will be noted in FIG. 12 that the sectional view showing the smallest clearance between blade 1 and its next blade 2 is section (g), corresponding to theta=90 degrees. This is thought to be a suitable position for minimum clearance and so for first contact between blades 1 and 2 to occur if after a period of stowage without fan use, blade 1 should sag slightly. It is thought that after such contact between blades 1 and 2 , the tendency to further sagging would be limited and the moment arm about axis 21 of any friction force due to blade contact less than for contact between tip 61 of blade 1 and the underlying blade 2 , thus, limiting the possibility of a failure of blade 1 to deploy on fan startup.
[0135] The possibility of blades that are comparatively thin (so that they may sag over time if not used) also means that the blades when in use may flex upwardly toward their tip ends. This can it is believed advantageously direct air slightly more outwardly as well as downwardly than if the blades were rigid.
[0136] The particular shape of the translucent lower section 9 of enclosure 2 is by no means the only possible one. Even a shape that is not of the circular shape in plan, as shown in the FIGS. 1 to 7 could be used as an alternative aesthetic choice.
[0137] A further invention will now be disclosed. In fan/lights such as those described by Villella in his aforementioned PCT application, the “sun gear” may comprise a single member to which toothed segments are secured for engagement with the “planet gears”, instead of a complete gear. This possibility, which it has been found can reduce manufacturing costs arises because suitable sun and planet gear proportions can be chosen which do not require the sun gear to rotate far enough during deployment and refraction for any one tooth thereof to encounter more than one planet gear.
[0138] It will be readily apparent to persons skilled in the art that many other variations and choices can be made to the fan/light described above without exceeding the scope of the invention as stated
[0139] While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. Additionally, the features of various implementing embodiments may be combined to form further embodiments of the invention. | There is provided a combined ceiling fan and light fitting ( 10 ) having blades ( 1 - 4 ) that when the ceiling fan is not in use retract and are stowed above an enclosure ( 12 ) containing a light emitting device and that when the fan is in use are extended under centrifugal force. The blades are formed in such a way as to both stow compactly above the enclosure and provide reasonable aerodynamic performance. Each blade partially overlies a neighbouring blade when in its stowed position and the blades are so formed as to permit such stacking while limiting the overall height of the assemblage of stowed blades. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a process for the preparation of a blocked mercaptosilane, from a metal salt of a polysulfane-containing organosilicon compound and an acyl halide or carbonyl dihalide, wherein the metal salt of the polysulfane-containing organosilicon compound is formed by reacting a polysulfane-containing organosilicon and an alkali metal, alkaline earth metal or a strong base derived from an alkali metal or alkaline earth metal. This invention also relates to the use of said blocked mercaptosilane as a coupling agent in rubber mixtures.
2. Description of Related Art
Sulfur-containing organosilicon compounds are useful as essential components in the production of silica-filled tires. A silica-filled tire provides for enhanced performance in automotive applications, specifically, improved abrasion resistance, rolling resistance and wet-skidding properties. There are a broad range of sulfur-containing organosilicon compounds that are used as coupling agents in silica-filled tires. Mercapto-containing organosilicon compounds offer superior coupling at reduced loading, however, their chemical reactivity with organic polymers results in unacceptably high viscosities during processing and premature curing. Blocked mercaptosilanes have been shown to maintain the benefits of mercapto-containing organosilicon compounds without displaying the aforenoted problems. The blocked mercapto-containing organosilicon compounds, in particular, thiocarboxylic-containing silicon compounds, can be prepared by reacting a mercapto-containing silicon compound with an acid halide. The byproduct of this reaction, hydrogen chloride, reacts with the organosilicon compound degrading the desired product, and generating chlorosilanes. These reactions with hydrogen chloride are very fast and cannot be prevented by conventional mechanical means, i.e., temperature or pressure, due to the high solubility of the hydrogen chloride in the product. Neutralization of the above noted chlorosilanes can be done using a base such as sodium alkoxide, or propylene oxide, but degradation of the product and/or an undesirable mixture is obtained making this approach undesirable.
Another process used previously, is to neutralize the hydrogen chloride, in situ, using an acid acceptor, i.e., tertiary amine, see U.S. Provisional Patent Application No. 60/423,577 filed Nov. 4, 2002; but this requires a stoichiometric amount of the amine that reduces batch yield and affords a large amount of an undesirable salt that must subsequently be removed, see U.S. Pat. No. 6,229,036. As is already known, tertiary amine salts are difficult to remove due to their solubility, and conventional filtration methods are mechanically intensive and often lead to poor yields. Furthermore, further processing of the filter cake adds additional costs, such as the disposing of the tertiary amine and the hydrogen chloride salt in itself, which poses significant environmental issues.
As has been shown, the reaction of a metal salt of a mercapto-containing organosilicon compound and an acid halide generates the desired blocked mercaptosilane and a metal halide salt, see U.S. Pat. No. 6,414,061 the contents of which are incorporated herein by reference; but in addition to the previously mentioned difficulties, mercapto-containing organosilicon compounds are expensive making their widespread use prohibitive. Therefore, there is an interest in developing a blocked mercaptosilane using a process that is inexpensive and does not provide for the chemical and environmental concerns noted above. There are a number of known methods to cleave a sulfur-sulfur bond, i.e., the use of bases such as amines, phosphines, metal cyanides, metal hydrides and alkali metals, however, phosphines and metal hydrides are expensive and metal cyanides offer a host of safety concerns.
SUMMARY OF THE INVENTION
Polysulfane-containing silicon compounds are inexpensive and widely available, in addition to their affordability, the metal halide byproduct does not react with the product blocked mercaptosilane nor do polysulfane-containing silicon compounds have the environmental concerns of a tertiary amine halide salt. Alkali metals are both safe and inexpensive. The reaction of an alkali metal with a polysulfane-containing organosilicon compound to generate the metal salt of the polysulfane-containing organosilicon compound, affords the desired acid acceptor, in situ, that can be used to produce the desired blocked mercaptosilane compound and a metal halide salt.
Additionally, the use of an aqueous wash of the product thereby minimizes the aforementioned costs and difficulties of removing the metal salt. Removing the metal halide salt by means of either filtration or by use of a centrifuge requires intensive mechanical unit operations and capital investment, whereas an aqueous wash requires neither but results in a two-phase system where one phase contains the blocked mercaptosilane and the second phase contains an aqueous solution of the metal halide. The primary hazard with this method is the potential for hydrolysis of the blocked mercaptosilane and for organofunctional silanes. However, through the presence of metal halide the ionic character of the aqueous phase is increased and thereby minimizes any hydrolysis reaction, see U.S. Pat. No. 6,294,683.
It is an object of the invention to provide a process for preparing a blocked mercaptosilane for use as a coupling agent, which process minimizes the production of byproducts that react with the blocked mercaptosilane, does not require neutralization or filtering and is commercially affordable.
In keeping with this and other objects of the invention there is provided a process for the manufacture of a blocked mercaptosilane comprising:
(a) reacting at least one polysulfane-containing organosilicon compound of the general formula:
(R 1 3 SiG) 2 S n
in which each R 1 is independently methoxy, ethoxy or alkyl of from 1 to about 6 carbon atoms, provided, that at least one R 1 group is methoxy or ethoxy, G is an alkylene group of from 1 to about 12 carbon atoms and n is from 2 to about 8, with at least one alkali metal, alkaline earth metal or a basic derivative of an alkali metal or alkaline earth metal to provide the corresponding metal salt of the polysulfane-containing organosilicon compound and;
(b) reacting the metal salt of the polysulfane-containing organosilicon compound with an acyl halide or carbonyl dihalide to provide a blocked mercaptosilane.
In contrast to the process described in aforementioned U.S. Pat. No. 6,414,061 the process of this invention makes it possible to produce a blocked mercaptosilane from readily available polysulfane-containing organosilicon compounds. This results in a high purity blocked mercaptosilane that does not require neutralization or filtering to remove the byproduct metal halide that is formed upon reaction of the metal salt of the polysulfane-containing organosilicon compound with the acyl halide or carbonyl dihalide.
A further object of this invention is to provide a process that involves the use of an aqueous wash of the final product solution, which unlike the distillation step required in aforementioned U.S. Pat. No. 6,414,061, is a more expedient and efficient way to separate the product blocked mercaptosilane from the metal halide byproduct.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the process of this invention, a polysulfane-containing organosilicon compound of the formula (R 1 3 SiG) 2 S n in which R 1 , G and n have the aforestated meanings, and an alkali metal, alkaline earth metal or a strong base derived from the alkali metal or alkaline earth metal, can be considered to react to form a metal salt of the polysulfane-containing organosilicon compound in accordance with the reaction (illustrated for an alkali metal such as sodium):
Metal+(R 1 3 SiG) 2 S n →(R 1 3 SiG) 2 S-Metal
The metal salt of the polysulfane-containing organosilicon compound and a reactive halide such as an acyl halide or carbonyl dihalide, e.g., of the formula R 2 C(O)X in which R 2 and X have the aforestated meanings, can then be considered to react to form the product blocked mercaptosilane and a metal halide byproduct in accordance with the reaction:
(R 1 3 SiG) 2 S-Metal+R 2 C(O)X→R 2 C(O)SGSiR 1 3 +Metal-X
Useful polysulfane-containing organosilicon compounds include, for example, bis[(triethoxysilyl)propyl]polysulfane, bis[(methyldiethoxysilyl)propyl]polysulfane, bis[(triethoxysilyl)isobutyl]polysulfane, bis[(methyldiethoxysilyl)isobutyl]polysulfane, bis[(trimethoxysilyl)propyl]polysulfane, bis[(methyldimethoxysilyl)propyl]polysulfane, bis[(trimethoxysilyl)isobutyl]polysulfane, and bis[(methyldimethoxysilyl)isobutyl]polysulfane.
The polysulfane-containing organosilicon compound is reacted with an alkali metal, alkaline earth metal or a strong base derived from an alkali metal or alkaline earth metal. Useful alkali metals, alkaline earth metals and basic metal derivatives include, for example, lithium, sodium, potassium, magnesium, calcium, lithium hydride, sodium hydride, potassium hydride, magnesium hydride, calcium hydride, sodium methoxide, sodium ethoxide, potassium methoxide, potassium ethoxide, and mixtures thereof.
The resulting polysulfane-containing organosilicon compound metal salt is combined with an acyl halide or carbonyl dihalide, e.g., of the general formula R 2 C(O)X supra in which R 2 is halogen or alkyl, alkenyl, aryl, alkaryl or aralkyl of up to about 18 carbon atoms and X is halogen, to produce a blocked mercaptosilane. Useful acyl halides include acetyl chloride, propanoyl chloride, butanoyl chloride, pentanoyl chloride, hexanoyl chloride, heptanoyl chloride, octanoyl chloride, 2-ethylhexanoyl chloride, lauroyl chloride, oleoyl chloride, octyl chloroformate, adipoyl chloride, phenylacetyl chloride, benzoyl chloride, terephthaloyl chloride, and phenyl chloroformate. Useful carbonyl dihalides include carbonyl dichloride (phosgene), diphosgene, triphosgene, thiophosgene, and oxalyl chloride.
The blocked mercaptosilane product obtained by the foregoing process conforms to the general formula R 2 C(O)SGSiR 1 3 wherein, R 1 , R 2 , and G have the aforesaid meanings. Specific blocked mercaptosilanes include, for example, 2-triethoxysilyl-1-ethyl thioacetate; 2-trimethoxysilyl-1-ethyl thioacetate; 2-(methyldimethoxysilyl)-1-ethyl thioacetate; 3-trimethoxysilyl-1-propyl thioacetate; triethoxysilylmethyl thioacetate; trimethoxysilylmethyl thioacetate; triisopropoxysilylmethyl thioacetate; methyldiethoxysilylmethyl thioacetate; methyldimethoxysilylmethyl thioacetate; methyldiisopropoxysilylmethyl thioacetate; dimethylethoxysilylmethyl thioacetate; dimethylmethoxysilylmethyl thioacetate; dimethylisopropoxysilylmethyl thioacetate; 2-triisopropoxysilyl-1-ethyl thioacetate; 2-(methyldiethoxysilyl)-1-ethyl thioacetate; 2-(methyldiisopropoxysilyl)-1-ethyl thioacetate; 2-(dimethylethoxysilyl)-1-ethyl thioacetate; 2-(dimethylmethoxysilyl)-1-ethyl thioacetate; 2-(dimethylisopropoxysilyl)-1-ethyl thioacetate; 3-triethoxysilyl-1-propyl thioacetate; 3-triisopropoxysilyl-1-propyl thioacetate; 3-methyldiethoxysilyl-1-propyl thioacetate; 3-methyldimethoxysilyl-1-propyl thioacetate; 3-methyldiisopropoxysilyl-1-propyl thioacetate; 1-(2-triethoxysilyl-1-ethyl)-4-thioacetylcyclohexane; 1-(2-triethoxysilyl-1-ethyl)-3-thioacetylcyclohexane; 2-triethoxysilyl-5-thioacetylnorbornene; 2-triethoxysilyl-4-thioacetylnorbornene; 2-(2-triethoxysilyl-1-ethyl)-5-thioacetylnorbornene; 2-(2-triethoxysilyl-1-ethyl)-4-thioacetylnorbornene; 6-triethoxysilyl-1-hexyl thioacetate; 1-triethoxysilyl-5-hexyl thioacetate; 8-triethoxysilyl-1-octyl thioacetate; 1-triethoxysilyl-7-octyl thioacetate; 6-triethoxysilyl-1-hexyl thioacetate; 1-triethoxysilyl-5-octyl thioacetate; 8-trimethoxysilyl-1-octyl thioacetate; 1-trimethoxysilyl-7-octyl thioacetate; 10-triethoxysilyl-1-decyl thioacetate; 1-triethoxysilyl-9-decyl thioacetate; 1-triethoxysilyl-2-butyl thioacetate; 1-triethoxysilyl-3-butyl thioacetate; 1-triethoxysilyl-3-methyl-2-butyl thioacetate; 1-triethoxysilyl-3-methyl-3-butyl thioacetate; 3-trimethoxysilyl-1-propyl thiooctanoate; 3-triethoxysilyl-1-propyl thiopalmitate; 3-triethoxysilyl-1-propyl thiooctanoate; 3-triethoxysilyl-1-propyl thiobenzoate; 3-triethoxysilyl-1-propyl thio-2-ethylhexanoate; 3-methyldiacetoxysilyl-1-propyl thioacetate; 3-triacetoxysilyl-1-propyl thioacetate; and 2-methyldiacetoxysilyl-1-ethyl thioacetate.
The reaction of the polysulfane-containing organosilicon compound with alkali metal, alkaline earth metal, or basic derivatives of alkali metal or alkaline earth metal is carried out in mole equivalents of from about 1:1 to about 1:10, and preferably from about 1:2.0 to about 1:2.5. The reaction of the polysulfane-containing organosilicon compound metal salt with acyl halide can be carried out in the range of 1.25:1 to about 1:1 or with a carbonyl dihalide in the range of from about 2.25:1 to about 2:1 mole equivalents.
The reaction between the polysulfane-containing organosilicon compound and the alkali metal, alkaline earth metal or basic metal derivative is conducted at a range of from about ambient temperature to about the melting temperature of the metal or metal derivative used. It is preferably conducted at a temperature wherein the metal used is in a liquid state to increase its surface area such as, for example, from about 25° to about 150° C. and preferably in the range of from about 80° to about 120° C. The subsequent reaction of the metal salt of the polysulfane-containing organosilicon compound and acyl halide or carbonyl dihalide can be carried out at a temperature of from about ambient temperature to about the boiling point of the solvent used; and preferably the temperature is from about 10° to about 50° C. The aqueous wash of the product blocked mercaptosilane and metal halide is conducted in a range of from about 4° to about 100° C. and preferably from about 10° to about 50° C. In addition, the entire process or any step therein, may be conducted at ambient, elevated or reduced pressure.
The entire process of this invention or any step therein, can be conducted in a solvent. Useful solvents can be, for example, any aromatic compound, such as, toluene, benzene, xylene, and any hydrocarbon solvent, such as, hexane, heptane, isooctane and octane.
The following examples are illustrative of the process of this invention.
All operations were performed under a nitrogen atmosphere. Silquest® A-1589 (bis(triethoxysilylpropyl)disulfane), Silquest® A-15304 “more purified disulfide then Silquest® A-1589” (bis(triethoxysilylpropyl) disulfane), Silquest® A-1289 (bis(triethoxysilylpropyl)tetrasufsulfane), toluene, and sodium were used as received without further purification. Deionized water was used as obtained. All GC data is expressed in weight mass % (wt/wt) and obtained from the GC Lab using a Hewlett-Packard 5890 Series II gas chromatograph. The following abbreviations and tradenames (with their descriptions) appear in the examples:
Abbreviation
Description
CPTES
Chloropropyltriethoxysilane
MPTES
Mercaptopropyltriethoxysilane
Blocked Mercaptosilane
3-(Octanoylthio)-1-propyltriethoxysilane
S 1 -BTESPS
Bis(triethoxysilyl)propyl sulfane
S 2 -BTESPS
Bis(triethoxysilyl)propyldisulfane
S 3 -BTESPS
Bis(triethoxysilyl)propyltrisulfane
2Si
Disiloxane of S-thiocarboxylate mercaptosilane
Eluted Heavies
Sum of 2Si and all components that eluted after
the 2Si.
Solvent ® 140
Mixture of non-aromatic hydrocarbons in the
range of C 12 -C 14 with an average molecular
weight of 140
COMPARATIVE EXAMPLE 1
At ambient temperature 515.20 g of toluene was treated with 25.00 g of sodium (1.076 moles) and warmed to ˜105° C. The molten sodium-toluene suspension was treated with 265.21 g of MPTES (1.079 moles) over the course of 30 minutes resulting in the evolution of hydrogen. After the MPTES addition was completed, the resulting clear, colorless solution was cooled to ˜45° C. and treated with 164.75 g of octanoyl chloride (0.982 moles). The addition of octanoyl chloride resulted in an exothermic reaction and the generation of salts. The octanoyl chloride was added over the course of one hour while the reaction temperature slowly increased to 62° C. Once the reaction cooled to 50° C., 215.0 g of deionized water was added resulting in the salts dissolving and the formation of two layers. The aqueous layer was removed, and toluene was removed, in vacuo, recovering 504.72 g of toluene (98% recovery). Recovered was 387.59 g of blocked mercaptosilane as a clear, colorless liquid with the following GC composition (98% efficiency):
Blocked
Eluted
Toluene
Ethyl Octanoate
CPTES
MPTES
Mercaptosilane
S 1 -BTESPS
2Si
Heavies
0.45
0.74
0.01
4.67
89.74
0.85
1.71
3.49
COMPARATIVE EXAMPLE 2
At ambient temperature, a 50 L reactor was charged with 45.0 lbs of toluene (20.4 kg) followed by the addition of 2.4 lbs of sodium (1015 g, 43.7 moles). This suspension was warmed to ˜105° C. and the resulting molten sodium was treated with 24.3 lbs of MPTES (11.0 kg, 44.8 moles) over the course of one hour and 22 minutes resulting in the evolution of hydrogen. After the MPTES addition was completed, the clear solution was cooled to ambient temperature and then treated with 15.5 lbs of octanoyl chloride (7.0 kg, 42.8 moles) over the course of one hour and 35 minutes with the reaction temperature reaching 58° C. The resulting mixture was cooled to 32° C. and then 19.0 lbs of deionized water (8.6 kg) was added resulting in the salts dissolving to give two layers. The aqueous layer was removed, recovering 25.4 lbs of aqueous wastes (11.5 kg) and the toluene was removed in vacuo recovering 46.1 lbs of toluene (20.9 kg, 102% recovery). The product was filtered through a Kuno filter using a 5 micron filter pad, recovering 31.0 lbs of blocked mercaptosilane (14.0 kg) as a clear, yellow liquid with the following GC analysis (85% efficiency):
Blocked
Eluted
Toluene
Ethyl Octanoate
CPTES
MPTES
Mercaptosilane
S 1 -BTESPS
2Si
Heavies
0.69
3.80
0.01
6.40
82.04
0.71
2.28
2.97
EXAMPLE 1
At ambient temperature, 526.82 g of toluene was treated with 29.28 g of sodium (1.261 moles) and warmed to 110° C. The molten sodium-toluene suspension was treated with 299.15 g of Silquest® A-1589 (0.590 moles) over the course of 45 minutes. The Silquest® A-1589 addition was exothermic and a dark red-purple, opaque solution formed. After the Silqueste® A-1589 addition was completed, the reaction mixture was cooled to ˜45° C. and 189.26 g of octanoyl chloride (1.152 moles) was added over the course of one hour resulting in a viscous salt suspension with the reaction reaching 60° C. At ˜45° C., the reaction was treated with 278.42 g of water resulting in the salts dissolving to give a clear, yellow-orange toluene layer and a dark, opaque aqueous layer which was removed. 382.62 g of aqueous waste was recovered. The toluene was stripped in vacuo recovering 576.93 g of toluene (106% recovery, contained water). 373.53 g of blocked mercaptosilane was recovered as a clear, dark orange liquid with the following GC analysis (87% efficiency):
Ethyl
Blocked
Eluted
Toluene
Octanoate
CPTES
MPTES
Mercaptosilane
S 1 -BTESPS
S 2 -BTESPS
S 3 -BTESPS
2Si
Heavies
1.41
0.76
0.01
0.43
80.36
6.80
4.97
0.01
2.90
4.06
EXAMPLE 2
At ambient temperature, a 50 L reactor was charged with 46.0 lbs of toluene (20.9 kg) followed by the addition of 2.3 lbs of sodium (164 g, 45.8 moles) and warmed to ˜110° C. The molten sodium was treated with 22.7 lbs of Silquest® A-1589 (10.3kg) over the course of 69 minutes resulting in an exothermic reaction. After the Silquest® A-1589 addition was completed, the resulting dark suspension was cooled to ˜38° C. and then treated with 13.8 lbs of octanoyl chloride (6.3 kg, 38.1 moles) over the course of two hours with the reaction temperature reaching 48° C. The resulting suspension was cooled to ambient temperature and then treated with 22.0 lbs of deionized water (10.0 kg). A 5° C. exotherm was observed and the salts dissolved resulting in two layers. The dark opaque aqueous layer was removed recovering 31.4 lbs of aqueous wastes (14.2 kg). The toluene was stripped recovering 43.9 lbs (19.9 kg, 95% recovery). The product was filtered through a Kuno filter using a 5 micron filter pad recovering 31.0 lbs of blocked mercaptosilane (14.1 kg) as a clear, yellow liquid with the following GC analysis (92% efficiency):
Ethyl
Blocked
Eluted
Toluene
Octanoate
CPTES
MPTES
Mercaptosilane
S 1 -BTESPS
S 2 -BTESPS
S 3 -BTESPS
2Si
Heavies
0.80
0.99
0.01
1.00
79.01
7.08
5.72
0.16
2.36
4.02
EXAMPLE 3
At ambient temperature, 509.88 g of toluene was treated with 30.04 g of sodium, (1.299 moles) and warmed to ˜110° C. The molten sodium-toluene suspension was treated with 300.97 g of Silquest® Y-15304 (0.590 moles) over the course of 45 minutes. The Silquest® Y-15304 addition was exothermic and a dark red-purple, opaque solution formed. After the Silquest® Y-15304 addition was completed, the reaction mixture was cooled to ˜45° C. and 196.01 g of octanoyl chloride (1.169 moles) was added over the course of one hour resulting in a viscous salt suspension with the reaction reaching 60° C. ˜At 45° C., the reaction was treated with 270.72 g of water resulting in the salts dissolving to give a clear, yellow-orange toluene layer and a dark, opaque aqueous layer which was removed. 330.89 g of aqueous waste was recovered. The toluene was stripped in vacuo recovering 382.98 g of toluene (75% recovery). 433.06 g of blocked mercaptosilane was recovered as a clear, dark yellow liquid with the following GC analysis (95% efficiency):
Ethyl
Blocked
Eluted
Toluene
Octanoate
CPTES
MPTES
Mercaptosilane
S 1 -BTESPS
S 2 -BTESPS
S 3 -BTESPS
2Si
Heavies
0.04
0.46
0.01
0.15
84.47
2.15
5.41
1.52
3.02
4.91
EXAMPLE 4
At ambient temperature, a 50 L reactor was charged with 45.0 lbs of toluene (20.4 kg) and 2.34 lbs of sodium (1061 g, 45.7 moles) and warmed to 110° C. The molten sodium was treated with 22.8 lbs of Silquest® Y-15304 (10.3 kg) over the course of 69 minutes resulting in an exothermic reaction. After the Silquest® Y-15304 addition was completed, the resulting dark opaque suspension was cooled to 35° C. and 13.6 lbs of octanoyl chloride (6.2 kg, 37.6 moles) was added over the course of one hour and 49 minutes resulting in an exothermic reaction with the reaction temperature reaching ˜50° C. After the octanoyl chloride addition was completed, the resulting suspension was treated with 22.2 lbs of deionized water (10.1 kg) resulting in the salts dissolving to give two layers. The resulting dark aqueous layer was removed recovering 30.3 lbs (13.7 kg). The toluene was removed in vacuo recovering 45.7 lbs (20.7 kg, 102% recovery). The product was filtered through a Kuno filter using a 5 micron filter pad recovering 30.6 lbs of blocked mercaptosilane (13.9 kg) as a clear, dark yellow liquid with the following GC analysis (92% efficiency):
Ethyl
Blocked
Eluted
Toluene
Octanoate
CPTES
MPTES
Mercaptosilane
S 1 -BTESPS
S 2 -BTESPS
S 3 -BTESPS
2Si
Heavies
0.61
0.82
0.01
2.72
82.04
2.57
6.57
0.14
2.38
3.37
EXAMPLE 5
At ambient temperature, 160 g of Solvent® 140 was treated with 11 g of sodium (0.478 moles) and warmed to ˜110° C. The molten sodium-Solvent® 140 suspension was treated with 63 g of Silquest® A-1289 (0.117 moles) over the course of 45 minutes. The Silquest® A-1289 addition was exothermic and a dark red-purple, opaque solution formed. After the Silquest® A-1289 addition was completed, the reaction mixture was cooled to ˜45° C. and 76 g of octanoyl chloride (0.468 moles) was added over the course of one hour resulting in a viscous salt suspension with the reaction temperature reaching 104° C. At ˜45° C., the reaction was treated with 175 g of water resulting in the salts dissolving to give a clear yellow-orange Solvent® 140 layer and a dark, opaque aqueous later which was removed. 236 g of aqueous waste was recovered. The toluene was stripped in vacuo recovering 155 g of Solvent® 140 (97% recovery). 110 g of blocked mercaptosilane was recovered as a clear, dark yellow liquid with the following GC analysis (89% efficiency):
Ethyl
Blocked
Eluted
Toluene
Octanoate
CPTES
MPTES
Mercaptosilane
S 1 -BTESPS
S 2 -BTESPS
S 3 -BTESPS
2Si
Heavies
0.70
2.20
0.01
2.66
64.75
0.90
23.31
2.18
—
— | A process for the manufacture of a blocked mercaptosilane comprising:
reacting at least one polysulfane-containing organosilicon compound of the general formula:
(R 1 3 SiG) 2 S n
(a) in which each R 1 is independently methoxy, ethoxy or alkyl of from 1 to about 6 carbon atoms, provided, that at least one R 1 group is methoxy or ethoxy, G is an alkylene group of from 1 to about 12 carbon atoms and n is from 2 to about 8, with at least one alkali metal, alkaline earth metal or a basic derivative of an alkali metal or alkaline earth metal to provide the corresponding metal salt of the polysulfane-containing organosilicon compound and;
(b) reacting the metal salt of the polysulfane-containing organosilicon compound with an acyl halide or carbonyl dihalide to provide a blocked mercaptosilane. | 2 |
FIELD OF THE INVENTION
The technology described herein relates generally to systems for cargo organization in vehicles. More specifically, the technology described herein relates to a slidable, retractable, and foldable cargo floor organizer and multiple-compartment interior cargo tray area with a rotatable and extensible retention net frame and associated cargo retention net for the rear cargo floor area of a vehicle. The system provides for the secure containment of cargo in the rear cargo floor area of a vehicle.
BACKGROUND OF THE INVENTION
The vehicle cargo systems now in general use for the rear floor cargo area are used to prevent cargo items from moving around freely or sustaining damage during transit. A variety of rear floor cargo organization and retaining systems and methods have been described previously and are known in the related art. None of these systems or methods, however, is designed to solve the particular problem addressed by the technology described herein, and none is capable of being modified to do so. For example, U.S. Pat. No. 5,772,370, issued to Moore on Jun. 30, 1998, discloses a net-type cargo restraining system for motor vehicles of the type having a cargo floor with a front area, and a hinged exterior door which opens from outside the vehicle to provide access to the cargo floor. Also, for example, U.S. Pat. No. 6,439,633, issued to Nemoto on Aug. 27, 2002, discloses a luggage holding apparatus for a vehicle used in coordination with removable floor panels covering the rear cargo area of the vehicle. Neither Moore nor Nemoto disclose a system for a slidable, retractable, and foldable cargo floor organizer with a rotatable and extensible retention net frame and associated cargo retention net for the rear cargo floor area of a vehicle. Additionally, neither Moore nor Nemoto disclose a system providing multiple storage compartments. Therefore, a need still exists for such a system as the one described herein.
BRIEF SUMMARY OF THE INVENTION
In various exemplary embodiments, the technology described herein provides a slidable, retractable, and foldable cargo floor organizer and multiple-compartment interior cargo tray area with a rotatable and extensible retention net frame and associated cargo retention net for the rear cargo floor area of a vehicle. The system provides for the secure containment of cargo in the rear cargo floor area of a vehicle.
In one exemplary embodiment, the technology described herein provides a cargo organization and retention net system for securely holding cargo in place, in combination with a vehicle having a rear cargo area. The cargo organization and retention net system includes an interior cargo tray having a plurality of partitions and compartments and a cargo retention net frame attachably disposed to the interior cargo tray area. The interior cargo tray area having multiple partitions includes a plastic washable surface area. The cargo retention net frame is extensible and pivotable from the interior cargo tray. The cargo organization and retention net system also includes a cargo retention net, the cargo retention net being disposed about the retention net frame. The cargo retention net also is extensible from the cargo retention net frame and extends as the cargo retention net frame extends. The cargo organization and retention net system also includes a rear cargo area top lid, wherein the rear cargo area top lid is hingedly attached to the cargo organization and retention net system, and the rear cargo area is retractable. The cargo organization and retention net system includes a separator flap, wherein the separator flap is hingedly attached to the cargo organization and retention net system and is both retractable and foldable. When the rear cargo area top lid and the separator flap are both retracted, the interior cargo tray area having multiple partitions is accessible. The cargo organization and retention net system also includes a plurality of retention net frame pivot points, which are hingedly attached to the interior cargo tray, and about which the retention net frame pivots and is raised or lowered, as desired, to hold a cargo item securely in place.
In another exemplary embodiment, the cargo organization and retention net system also includes a ratchet tension locking mechanism integrally located within the retention net frame pivot points. The cargo retention net frame and the cargo retention net are held in place while pivoted, and while in a closed position, by the ratchet tension locking mechanism integrally located within the retention net frame pivot points.
In another exemplary embodiment, the cargo organization and retention net system includes a release latch, whereby the cargo organization system is grasped by a user and either is lifted upward or pulled outward. When the cargo organization system is lifted upward, a rear cargo storage area beneath the floor level is made available. When the cargo organization system is pulled outward, the interior cargo tray area is made more accessible to a user.
In yet another exemplary embodiment, the cargo organization and retention net system also includes a pair of slidable tracks, mounted one at each of the left and right sides of the underside of the interior cargo tray area, and whereby the interior cargo tray area is outwardly extensible, sliding along the slidable tracks. The cargo organization and retention net system also includes a pair of track pivot points, the track pivot points being mounted at the rear of the interior cargo tray area and on the underneath side, whereby the cargo organization and retention net system is liftable upwardly and pivotable about the pair of track pivot points. The cargo organization and retention net system also includes a pair of track latches, the pair of track latches being mounted at the forward section of the interior cargo tray area and on the underneath side, the track latches securely holding the slidable track in place, and whereby the cargo organization and retention net system remains stationary and securely in place.
In yet another exemplary embodiment, the cargo organization and retention net system provides that the interior cargo tray having multiple partitions further includes a plurality of place-holder grooves, the grooves providing support for the separator flap when it is located in a raised position.
In yet another exemplary embodiment, the cargo organization and retention net system provides that when the rear cargo area top lid and the separator flap are located in a closed, downward position, the cargo retention net frame and cargo retention net are located above the closed rear cargo area top lid and the closed separator flap.
In yet another exemplary embodiment, the cargo organization and retention net system provides a tension mechanism, the tension mechanism being located within the cargo retention net frame. The cargo retention net frame is disposed about the interior cargo tray, wherein the cargo retention net frame is extensible and remains in place by the tension mechanism while not being extended or retracted.
Advantageously, the cargo organization and retention net system for securely holding cargo in place overcomes many of the deficiencies known in the art pertaining to vehicle cargo systems. The technology described herein provides an easy-to-use, retractable, and adjustable net frame retention system for securely holding vehicle cargo in place. The technology described herein additionally provides a cargo organization system that is washable and resists the wear and damage known in carpet panel cargo lid systems, and the like. Furthermore, the technology described herein further provides a retractable and foldable rear cargo area lid that, when in the open position for loading the cargo area, prevents items from falling behind the rear seats.
There has thus been outlined, rather broadly, the features of the technology described herein in order that the detailed description that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are additional features of the technology described herein that will be described and which will form the subject matter of the claims. In this respect, before explaining at least one embodiment of the technology described herein 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 technology described herein 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 are for the purpose of description and should not be regarded as limiting.
As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods, and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the technology described herein.
Additional aspects and advantages of the technology described herein will be apparent from the following detailed description of an exemplary embodiment which is illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The technology described herein is illustrated and described with reference to the various drawings, in which like reference numbers denote like method steps and/or system components, respectively, and in which:
FIG. 1 is a perspective view of a rear cargo floor organizer according to an embodiment of the invention, illustrating, in particular, the latch release, the top lid, and the separator flap;
FIG. 2 is a perspective view of the rear cargo floor organizer of FIG. 1 , shown with the top lid and separator flap, both in a retracted position, illustrating, in particular, the interior rear cargo tray area, the retention net system, including a retention net frame, retention net, and retention net frame pivot points, and showing the retention net frame in an unextended position;
FIG. 3 is a perspective view of the rear cargo floor organizer of FIGS. 1 and 2 , shown with the top lid and separator flap both in a retracted position, illustrating, in particular, the retention net system, including a retention net frame, retention net, and retention net frame pivot points, and showing the retention net frame in an extended, telescoped position;
FIG. 4 is a perspective view of a rear cargo floor organizer according to an embodiment of the invention, illustrating, in particular, stowed cargo securely retained underneath the retention net system, and further illustrating the secure retention of the cargo in place under the retention net and the tension-locked retention net frame;
FIG. 5 is a perspective view of a rear cargo floor organizer according to an embodiment of the invention, illustrating, in particular, use of the retention net system on top of the separator flap and the top lid, both of which are located in a closed position;
FIG. 6 is a perspective view of a rear cargo floor organizer according to an embodiment of the invention, showing the rear cargo floor organizer in an unlatched and raised position, and further illustrating, in particular, the slidable tracks, track pivots, latch release cable, and the rear floor cargo area available upon opening the rear cargo floor organizer;
FIG. 7 is a perspective view of a rear cargo floor organizer shown in the rear cargo area of a vehicle and illustrating the use of the retention net system on top of the closed separator flap and top lid;
FIG. 8 is a perspective view of a rear cargo floor organizer shown with the retention net, top lid, and separator flap all removed to illustrate, in particular, the interior cargo tray area and its multiple partitions and storage areas;
FIG. 9 is a perspective view of a rear cargo floor organizer according to an embodiment of the invention, illustrating, in particular, the latch release, top lid in a raised position, separator flap in a raised position, slidable tracks, track pivots, and track latches;
FIG. 10 is the perspective view of the rear cargo floor organizer of FIG. 8 , further illustrating the rear cargo floor organizer, and in particular the interior cargo tray area, in a forward position, outwardly extended, after being pulled out along the slidable tracks;
FIG. 11 is a perspective view of the rear cargo floor organizer in an unlatched and raised position, further illustrating the disengagement and detachment of the slidable tracks from the track latches and pivot of the rear cargo floor organizer about the hack pivots;
FIG. 12 is a perspective view of a rear cargo floor organizer, illustrating, in particular, use of the retention net frame on top of the separator flap and top lid, both of which are located in a closed position;
FIG. 13 is a perspective view of the rear cargo floor organizer with the retention net, top lid, and separator flap all removed, further illustrating the retention net frame in an extended, telescoped position and the interior cargo tray area with its multiple partitions and multiple storage areas; and
FIG. 14 is a perspective view of a rear cargo floor organizer, illustrating the retention net frame in a raised position, pivoted about the retention net system pivot points, and shown located stationary in position as a result of the tension-locked retention net frame.
DETAILED DESCRIPTION OF THE INVENTION
Before describing the disclosed embodiments of the technology described herein in detail, it is to be understood that the technology is not limited in its application to the details of the particular arrangement shown here since the technology is capable of other embodiments. Also, the terminology used herein is for the purpose of description and not of limitation.
Referring now to FIG. 1 , a rear cargo floor organizer 100 is shown. The rear cargo floor organizer 100 is shown with a top lid 102 and a separator flap 104 , each having a substantially rectangular shape. The top lid 102 and the separator flap 104 are hingedly connected to the rear portion of the rear cargo floor organizer 100 and are both retractable. The top lid 102 is shown open, flipped up in a backward direction. The separator flap 104 , which is foldable for purposes of retraction, is shown in a closed position. In an open position, the top lid 102 prevents cargo items from falling behind the vehicle passenger rear seats (not shown) when sliding the rear cargo floor organizer 100 out for access. Additionally, the rear cargo floor organizer 100 includes a latch release 106 . The latch release 106 enables a user to selectively grasp and lift (as shown in FIG. 6 ) or grasp and pull out (as shown in FIG. 10 ) the rear cargo floor organizer 100 . The rear cargo floor organizer 100 is located just inside the back door or liftgate of a vehicle. The liftgate, for example, is located in an open position (not shown) and is thus disconnected from the liftgate latch 400 . A portion of the retention net frame 202 is visible in FIG. 1 . The remainder of the retention net frame 202 is located under the separator flap 104 . Optionally, in an alternative embodiment, the retention net frame 202 is fully covered by the separator flap 104 . The top lid 102 and the separator flap 104 both provide ease of use in vehicle cargo storage. Additionally, unlike traditional vehicle carpet floor systems, both the top lid 102 and the separator flap 104 are easily cleaned and washed since they are manufactured of washable materials.
Referring now to FIG. 2 , the rear cargo floor organizer 100 of FIG. 1 is shown with the top lid 102 (not shown, located behind the separator flap 104 ) and the separator flap 104 , both in a retracted position, thus exposing and illustrating the retention net system 200 and the interior cargo tray 108 , recessed and available with various partitions. The separator flap 104 includes a horizontal fold, such that as it is retracted, it also folds essentially in half. The cargo retention net system 200 includes a cargo retention net frame 202 and a cargo retention net 204 . The cargo retention net frame 202 is hingedly secured to the rear cargo floor organizer 100 and the cargo retention net 204 is securely attached to the cargo retention net frame 202 . The cargo retention net frame 202 is lifted upward, pivoting about the pivot points 206 . In one embodiment, the cargo retention net 204 is extended and placed over cargo items to securely hold them in place between the retention net 204 and the interior cargo tray 108 . The cargo retention net system 200 includes the cargo retention net frame 202 in an unextended position and unraised in relation to the pivot points 206 . A latch release 106 is available for a user to selectively lift or pull out the rear cargo floor organizer 100 . The liftgate is located in an open position (not shown) and is thus disconnected from the liftgate latch 400 .
Referring now to FIG. 3 , the rear cargo floor organizer 100 is illustrated with the retention net system 200 in an extended position, extended outwardly from the pivot points 206 . The cargo retention net frame 202 is illustrated in an extended position, highlighting the telescopic capabilities of the frame. The cargo retention net 204 is wrapped securely about the cargo retention net frame 202 . The cargo retention net 204 also is shown in an expanded, stretched state, having moved with the cargo retention net frame 202 as it was extended. The cargo retention net system 200 is extended by pulling the retention net frame 202 in the direction away from the retention net frame pivot points 206 . The cargo retention net frame 202 , for example, is either raised in an upward direction, pivoted about the pivot points 206 , before being extended and placed over cargo, or it is extended while stowed in the rear cargo floor organizer 100 . The top lid 102 (not shown, located behind the separator flap 104 ) and the separator flap 104 are both located in a retracted position. A latch release 106 is available for a user to selectively lift or pull out the rear cargo floor organizer 100 . The liftgate is located in an open position (not shown) and is thus disconnected from the lift gate latch 400 .
Referring now to FIG. 4 , the rear cargo floor organizer 100 is shown with the cargo retention net system 200 in an extended position securing stowed cargo 500 . The cargo retention net frame 202 is illustrated in an extended position, highlighting the telescopic capabilities of the frame. The cargo retention net 204 also is shown in an expanded, stretched state, having moved with the cargo retention net frame 202 as it was extended. The cargo retention net system 200 is extended by pulling the cargo retention net frame 202 in the direction away from the cargo retention net frame pivot points 206 . The cargo retention net frame 202 , for example, is either grasped-and-raised in an upward direction, pivoted about the pivot points 206 , before being extended and placed over cargo 500 , or it is grasped-and-extended while stowed in the rear cargo floor organizer 100 . The cargo retention net frame 202 remains stationary in place either in a downward position, securely holding stowed cargo 500 , or in a raised, ready-to-load position. The cargo retention net frame 202 is held in place by the ratchet-like tension locking mechanism in the cargo retention net frame system 200 that holds the cargo retention net frame 204 in place at a desired angle to the pivot points 206 . The top lid 102 (not shown, located behind the separator flap 104 ) and the separator flap 104 are both located in a retracted position. A latch release 106 is available for a user to selectively lift or pull out the rear cargo floor organizer 100 . The liftgate is located in an open position (not shown) and is thus disconnected from the liftgate latch 400 .
Referring now to FIG. 5 , the rear cargo floor organizer 100 is shown with the cargo retention net system 200 located in a position on top of the separator flap 104 . The top lid 102 and the separator flap 104 are hingedly connected to the rear portion of the rear cargo floor organizer 100 and are both retractable. The top lid 102 and the separator flap 104 both are located in a closed, downward position. The cargo retention net frame 202 and the cargo retention net 204 both are illustrated in a partially extended position, neither fully extended nor fully retracted, again highlighting the telescopic capabilities of the frame. The cargo retention net system 200 is extended by pulling the retention net frame 202 in the direction away from the retention net frame pivot points 206 . The cargo retention net system 200 is retracted by pushing the cargo retention net frame 202 in the direction toward the cargo retention net frame pivot points 206 . While used in this manner, the rear cargo floor organizer 100 provides secure storage above the top lid 102 and the separator flap under the cargo retention net 204 , below the top lid 102 and the separator flap 104 in the interior cargo tray area 108 (not shown, but as illustrated previously in FIG. 2 ), and below the entire rear cargo floor organizer 100 once it has been selectively grasped and lifted up by a user grasping latch release 106 and lifting. The rear floor cargo area 404 storage area located underneath the entire rear cargo floor organizer 100 is illustrated in FIG. 6 . The liftgate is located in an open position (not shown) and is thus disconnected from the lift gate latch 400 .
Referring now to FIG. 6 , the rear cargo floor organizer 100 is shown in an unlatched and raised position, exposing the rear floor cargo area 404 . Items are stowed in the rear floor cargo area 404 . The rear cargo floor organizer 100 is shown as it is located once it has been selectively grasped and lifted up by a user grasping latch release 106 and lifting. The underside mechanisms of the release latch 106 are shown. Once the latch release 106 is grasped by a user, the latch release cable 110 disengages any locks, levers, or the like holding the rear cargo floor organizer 100 in place in its closed position. The rear cargo floor organizer 100 , in this raised position, is shown with the track pivots 302 , about which the rear cargo floor organizer 100 is lifted and retracted. The track pivots 302 are hingedly connected to the back rear corners of the rear cargo floor organizer 100 and enable the opening of the rear cargo floor organizer 100 . The rear cargo floor organizer 100 also is illustrated with a slidable track 300 on each side. A slidable track 300 is mounted on each of the left and right sides of the underside of the rear cargo floor organizer 100 . When not used for sliding the rear cargo floor organizer 100 out toward the user (as shown in FIG. 10 ), the slidable tracks 300 provide structural support to the rear cargo floor organizer 100 .
Referring now to FIG. 7 , the rear cargo floor organizer 100 is shown in the rear cargo area of a vehicle, illustrating, in particular, the use of the cargo retention net system 200 on top of the closed separator flap 104 and top lid 102 . The top lid 102 and the separator flap both are located in a closed, downward position. The cargo retention net frame 202 and the cargo retention net 204 both are illustrated in a partially extended position, neither fully extended nor fully retracted, highlighting the telescopic capabilities of the frame. The liftgate is located in an open position (not shown) and is thus disconnected from the liftgate latch 400 just inside the vehicle from the rear bumper 402 of the vehicle.
Referring now to FIG. 8 , the rear cargo floor organizer 100 is shown with the cargo retention net, top lid, and separator flap all removed ( 204 , 102 , 104 , respectively, in FIG. 7 ) to illustrate, in particular, the interior cargo tray area 108 . The interior cargo tray area 108 is recessed and includes multiple partitions to further support and retain cargo items and preventing unwanted shifting of cargo items during transit or otherwise. When the rear cargo floor organizer 100 is used with the top lid 102 and separator flap 104 in a retracted position, larger cargo items may be stored on the interior cargo tray area 108 . The interior cargo tray area 108 is an easy-to-use, washable compartment that is covered by the top lid 102 and separator flap 104 when not in use. The cargo retention net system 200 is shown with its cargo retention net frame 202 in an unextended position. The cargo retention net frame 202 is lifted upward, pivoting about the pivot points 206 . The rear cargo floor organizer 100 includes a slidable track 300 on the left and right undersides. The slidable track 300 is connected to a track pivot 302 , about which the rear cargo floor organizer 100 is lifted upward at an angle to the track pivot 302 . A latch release 106 is available for a user to selectively lift or pull out the rear cargo floor organizer 100 . When not lifted upward the rear cargo floor organizer 100 is held firmly in place by the track latches 304 in which the slidable track is detachably mounted.
Referring now to FIG. 9 , the rear cargo floor organizer 100 is shown with the top lid 102 and the separator flap 104 retracted. The separator flap 104 is also shown in a folded position. The separator flap 104 uses grooves 105 located with the interior cargo bay area 108 to hold the separator flap 104 , once it has been folded, in placed while loading cargo items. The rear cargo floor organizer 100 is illustrated with the cargo retention net system 200 . The cargo retention net frame 202 is illustrated in an extended position, highlighting the telescopic capabilities of the frame. A latch release 106 is available for a user to selectively lift or pull out the rear cargo floor organizer 100 . The rear cargo floor organizer 100 includes a slidable track 300 on the left and right undersides of the interior cargo tray area 108 . The slidable track 300 is mounted to a track pivot 302 , about which the rear cargo floor organizer 100 is lifted upward at an angle to the track pivot 302 . When not filled upward, the rear cargo floor organizer 100 is held firmly in place by the track latches 304 in which the slidable track is detachably mounted.
Referring now to FIG. 10 , the rear cargo floor organizer 100 is shown with the interior cargo tray area 108 , in a forward position, outwardly extended, after being pulled out, by a user, along the slidable tracks 300 . A user grasps the latch release 106 and selectively lifts upward or pulls outward the interior cargo tray area 108 . As illustrated here, a user has grasped the latch release 106 and pulled the interior cargo tray area 108 outward. The slidable track 300 is connected to a track pivot 302 , about which the rear cargo floor organizer 100 is lifted upward at an angle to the track pivot 302 . When not lifted upward the rear cargo floor organizer 100 is held firmly in place by the track latches 304 in which the slidable track is detachably mounted. The retention net system 200 is shown with its retention net frame 202 in an unextended position.
Referring now to FIG. 11 , the rear cargo floor organizer 100 is shown in a lifted, upright position. A user grasps the latch release 106 and selectively lifts upward or pulls outward the interior cargo tray area 108 . As illustrated here, a user has grasped the latch release 106 and lifted the rear cargo floor organizer 100 upwardly, thus making available the rear floor cargo area 404 (as shown in FIG. 6 ). The slidable track 300 is connected to a track pivot 302 , about which the rear cargo floor organizer 100 is detached from the track latches 304 and lifted upward at an angle to the track pivot 302 . The track latches 304 are mounted to the vehicle floor to securely hold the rear cargo floor organizer 100 in place when in a closed position. When not lifted upward, the rear cargo floor organizer 100 is held firmly in place by the track latches 304 in which the slidable track is detachably mounted.
Referring now to FIG. 12 , the rear cargo floor organizer 100 is shown with the cargo retention net system 200 and the cargo retention net frame 202 on top of the separator flap 104 and top lid 102 , both of which are located in a closed position. The top lid 102 and the separator flap both are located in a closed, downward position. The cargo retention net frame 202 is illustrated in a partially extended position. While used in this manner, the rear cargo floor organizer 100 provides secure storage above the top lid 102 and the separator flap 104 . The slidable track 300 is connected to a track pivot 302 , about which the rear cargo floor organizer 100 is lifted upward at an angle to the track pivot 302 . When not lifted upward the rear cargo floor organizer 100 is held firmly in place by the track latches 304 in which the slidable track is detachably mounted. The rear cargo floor organizer 100 may be lifted even while the retention net system 200 is located on top of the separator flap 104 and top lid 102 . A latch release 106 is available for a user to selectively lift or pull out the rear cargo floor organizer 100 .
Referring now to FIG. 13 , the rear cargo floor organizer 100 is shown with the interior cargo tray area 108 . A user grasps the latch release 106 and selectively lifts upward or pulls outward the interior cargo tray area 108 . The slidable track 300 is connected to a track pivot 302 , about which the rear cargo floor organizer 100 is lifted upward at an angle to the track pivot 302 . When not lilted upward the rear cargo floor organizer 100 is held firmly in place by the track latches 304 in which the slidable track is detachably mounted. The retention net system 200 is shown with its retention net frame 202 in a partially extended position.
Referring now to FIG. 14 , the rear cargo floor organizer 100 is shown with the interior cargo tray area 108 and cargo retention net system 200 . A user grasps the latch release 106 and selectively lifts upward or pulls outward the interior cargo tray area 108 . The slidable track 300 is connected to a track pivot 302 , about which the rear cargo floor organizer 100 is lifted upward at an angle to the track pivot 302 . When not lifted upward the rear cargo floor organizer 100 is held firmly in place by the track latches 304 in which the slidable track is detachably mounted. The cargo retention net system 200 is shown with its retention net frame 202 in an unextended, yet upright, position. The cargo retention net frame 202 is lifted upward, pivoting about the pivot points 206 . The cargo retention net system 200 is extended by pulling the retention net frame 202 in the direction away from the retention net frame pivot points 206 . The cargo retention net system is retracted by pushing the retention net frame 202 in the direction toward the retention net frame pivot points 206 . The cargo retention net frame 202 is held in place by the ratchet-like tension locking mechanism in the cargo retention net frame system 200 that holds the cargo retention net frame 204 in place at a desired angle to the pivot points 206 .
Although the present invention has been illustrated and described herein with reference to preferred embodiments and specific examples thereof, it will be readily apparent to those of ordinary skill in the art that other embodiments and examples may perform similar functions and/or achieve like results. All such equivalent embodiments and examples are within the spirit and scope of the present invention and are intended to be covered by the following claims. | The technology described herein provides a slidable, retractable, and foldable cargo floor organizer with a rotatable and extensible retention net frame and associated cargo retention net for the rear cargo floor area of a vehicle. The system additionally provides an interior cargo tray having multiple partitions. The system includes a cargo retention net frame disposed about the interior cargo tray, wherein the cargo retention net frame is extensible, and a cargo retention net, the cargo retention net being disposed about the retention net frame, and wherein the cargo retention net is extensible and extends as the cargo retention net frame extends. The system provides for the secure containment of cargo in the rear cargo floor area of a vehicle. | 1 |
RELATED APPLICATION
This application claims the priority of provisional application No. 60/347,260, filed Nov. 8, 2001.
BACKGROUND
1. Field of Invention
The present disclosure relates to swimming pools, and, more particularly, to a track assembly with apparatus for forming deck edging for swimming pools.
2. Background
Swimming pools are commonly covered to prevent debris from entering the pool, to preserve chemical treatments in the water and to heat the pool in the case of a solar cover. An automatic pool cover provides convenience for a user by allowing the cover to be easily extended over the pool during periods of non-use, and retracted during periods of use. Typically, automatic pool covers utilize a track assembly built into the walls for guiding the leading edge bar of the cover as it traverses the pool. Such track assemblies are difficult to install and add clutter to the pool sides that may be unsightly and awkward to use.
In forming the coping and edging around the perimeter of pools it is useful to employ a mechanism in or attached to the pool walls that will provide uniformity in the coping and that can be easily installed and removed. Current forms are typically made of disposable materials, such as styrofoam, wood forms or other such materials. Such forms were often attached to the pool by two-sided tape or other temporary means. Often they were damaged during removal, so that new forms had to be used for each installation.
For pools with automatic vinyl covers, it is useful to have a mechanism in the pool walls that secures the bead of the vinyl liner to prevent wear and to maintain suitable appearance and structure. It is desirable that such a mechanism is simple, easy to install and firmly secures the edge or bead of the vinyl liner to the pool walls.
In addition, it is sometimes desirable to secure fiber optic lights or other decorative items in or around the pool walls. Using separate securing mechanisms for these purposes adds to the expense and installation time involved with pool construction.
Accordingly, a multiple purpose assembly for pool walls is needed that can perform one or more of the foregoing functions while minimizing the time and expense of installation. Such an assembly should be relatively simple and unobtrusive and should be flexible to accommodate various needs of different types of pool construction. Preferably, the assembly may include coping and edging forms that are easy to affix, provide uniformity in the forming function and are reusable to minimize cost.
SUMMARY
The present disclosure provides a multiple purpose encapsulation member that is able to carry out the functions described above. The encapsulation member includes an element for guiding a pool cover edge as it is retracted and extended. The member may further include an element for securing a form piece to be used in forming the edge of the pool decking. The form may be removably secured to the member, enabling it to be reused and for different forms to be utilized with a common encapsulation member. In addition, the member may provide an element for securing a bead on the end of a vinyl liner. Further the member has an element for securing fiber optic light tubing or other decorative elements.
In one implementation apparatus is provided for constructing edging around the perimeter of a swimming pool having a decking and a retractable pool cover wherein an elongated guide connector is attached to a wall of the swimming pool for mating to a guide member for the pool cover. The apparatus comprises a form member shaped to form the edging, and a form mating structure on the form member for removably mating the form member to the elongated guide connector. For purposes of this application, the term “mating” shall mean in contact, in an adjoining relationship, fit together, joined, or connected.
In another implementation, apparatus is provided for attaching to a wall of a swimming pool having a decking and a retractable pool cover, and disposed to accommodate a guide member for the edge of the pool cover as the cover extends and retracts. The apparatus comprises an elongated track member attached to the wall of the swimming pool to accommodate the guide member, and a form element for forming an edge of the decking for the pool, the form element being removably mated to the track member.
In another implementation, a method is provided for constructing edging around the perimeter of a swimming pool having a decking and a retractable pool cover, comprising connecting an elongated guide connector to a wall of the swimming pool, and removably mating to the elongated guide connector a form member shaped to form the edging.
BRIEF DESCRIPTION OF THE DRAWINGS
The above-mentioned and other features and advantages of this disclosure, and the manner of attaining them, will become more apparent and the disclosure will be better understood by reference to the following description of an implementation of the disclosure taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is a plan view of a pool showing the location of the encapsulation assembly in the pool walls, according to the present disclosure;
FIG. 2 is a perspective view of an implementation of a encapsulation extrusion, according to the present disclosure;
FIG. 3 is a perspective view of another implementation an encapsulation extrusion, according to the present disclosure;
FIG. 4A is a perspective view of an implementation showing a cover guide extrusion according to the present disclosure;
FIG. 4B is a perspective view of an implementation showing a guide support spacer extrusion according to the present disclosure;
FIG. 5 is a perspective view of an implementation of a clip-on coping extrusion, according to the present disclosure;
FIG. 6 is a perspective view of one implementation of the encapsulation assembly, according to the present disclosure;
FIG. 7 is a perspective view of the implementation of FIG. 6 showing a vinyl liner and a pool cover, according to the present disclosure;
FIG. 8 is a perspective view of the implementation of FIG. 6 showing a portion of a deck and a guide cover, according to the present disclosure;
FIG. 9 is a perspective view of an implementation of a concrete form extrusion, according to the present disclosure;
FIG. 10 is a side view of the implementation of FIG. 9 , in mating position with the encapsulation extrusion of FIG. 3 , according to the present disclosure;
FIG. 11 is a perspective view of the implementation of FIG. 10 showing the deck and other members, according to the present disclosure;
FIG. 12 is a perspective view of the implementation of FIG. 9 , alternately mated with the encapsulation extrusion of FIG. 2 , according to the present disclosure;
FIG. 13 is a side view of the implementation of FIG. 3 showing the encapsulation extrusion disposed in a pool wall with masonry, according to the present disclosure;
FIG. 14 is a perspective view of another implementation showing an encapsulation extrusion for concrete pool walls, according to the present disclosure; and
FIG. 15 is a perspective view showing a cover for the encapsulation extrusion implementation shown in FIG. 14 ; and
FIG. 16 is a side view of the implementation of FIG. 14 showing the encapsulation extrusion disposed in a pool wall with masonry, according to the present disclosure.
Corresponding reference characters indicate corresponding parts throughout the several views. The exemplification set out herein illustrates one implementation of the disclosure, in one form, and such exemplification is not to be construed as limiting the scope of the disclosure in any manner.
DETAILED DESCRIPTION
Referring now to the drawings, and more particularly to FIG. 1 , an implementation of a rectangular swimming pool 10 is shown having a pool deck 12 and walls 14 surrounding the pool. An automatic pool cover 16 extends from a pool cover mechanism 18 in a cover assembly box 20 disposed at one end of the pool 10 . A leading edge bar 22 at the front edge of the pool cover 16 rides in a track encapsulation assembly 24 along the interior walls of the pool.
Deck 12 is generally horizontal and is preferably constructed from concrete. Coping 14 connects to deck 12 in a substantially coplanar fashion along the edge of deck 12 facing the interior of swimming pool 10 . Encapsulation track assembly 24 may include structure to retain vinyl lining, coping forms and structure for fiber optic lighting running along the length of the pool.
FIG. 2 shows an implementation of an encapsulation extrusion 30 according to the present disclosure. Extrusion 30 has an elongated slot 32 running along the bottom thereof to provide a cavity for securing the vinyl liner bead (not shown). A three-sided rectangular elongated cavity 34 formed by a bottom wall 35 , a side wall 36 and a top wall 37 , runs the length of extrusion 30 for receiving a cover guide extrusion, discussed below.
A bottom side 38 of top wall 37 includes protruding channels 39 and 40 that form grooves 41 and 42 for guiding the cover guide extrusion. Opposing elongated notches 43 and 44 are disposed in the bottom side 38 of top wall 37 and the top side 45 of bottom wall 35 , respectively for securing a track cover, described below.
The top side 46 of top wall 37 includes an elongated lip 48 for securing a coping extrusion. Extending from the bottom of side wall 36 is an elongated L-shaped securing flange 50 running the length of the encapsulation extrusion. An elongated lip 52 extends from the end of flange 50 at approximately a right angle thereto. A small elongated groove (not shown) may be included to extend longitudinally along top side 46 .
Referring now to FIG. 3 , an alternate implementation is shown of an encapsulation extrusion 54 that is essentially identical to the implementation shown in FIG. 2 , except for the addition of an elongated cavity 56 for securing fiber optic lighting. Cavity 56 is formed by a side wall 58 extending vertically between the bottom wall 35 and a top wall 31 forming elongated slot 32 . Wall 58 may be shaped as desired to accommodate the fiber optic tubing. Retaining lips 57 and 59 extend towards each other in the front of cavity 56 to retain the tubing.
FIG. 4A shows an implementation of a cover guide extrusion 60 , sized and shaped to fit inside the cavity 34 of the encapsulation extrusions 30 illustrated in FIG. 2 or 54 illustrated in FIG. 3 . An elongated cavity 62 is formed in the cover guide extrusion 60 having an open side 64 for receiving the edge of a pool cover (not shown). The top wall 66 of cover guide extrusion 60 is shaped with elongated channels 67 and protrusions 68 that are adapted to engage the grooves 41 and 42 and the protruding channels 39 and 40 respectively (depicted in FIGS. 2 and 3 ) so that the cover guide extrusion is mated in cavity 34 with the encapsulation extrusions 30 or 54 .
FIG. 4B discloses a guide support spacer extrusion 80 for wedging into the cavity 34 of the encapsulation extrusion 30 above or below the cover guide extrusion 60 , to secure extrusion 60 tightly in the cavity 34 . Spacer extrusion 80 may include elongated protrusions 82 to provide additional security.
FIG. 5 discloses an elongated clip-on coping extrusion 70 for mating to the top wall 37 of the encapsulation extrusion 30 . Extrusion 70 includes a flat member 72 having a lip 74 at one end and a slot 76 at the other end. A curved elongated member 78 is shaped to form the pool coping (not shown). Member 78 may be formed in any shape to provide the appearance desired for the coping. A lip 79 extends downward to secure the coping extrusion 70 to the top of encapsulation extrusions 30 or 54 , shown in FIGS. 2 and 3 . A snap hook extrusion 73 extends longitudinally along the undersurface of member 72 for further securing the coping extrusion 70 , as disclosed below. Looking now at FIG. 6 , the elements separately shown in FIGS. 3-5 are shown functional connection with each other to form an encapsulation assembly 84 . Coping extrusion 70 is mated to encapsulation extrusion 54 by sliding lip 48 into slot 76 and by sliding lip 74 onto the end of top wall 37 , as shown. Coping extrusion 70 is further secured by mating snap hook extrusion 73 into groove 47 . Cover guide extrusion 60 is wedged in cavity 34 of encapsulation extrusion 54 by spacer extrusion 80 . A fiber optic tube 86 is secured in cavity 56 .
FIG. 7 shows the same assembly 84 including a vinyl liner 89 in contact with a side wall 88 and having a beaded edge 90 secured within cavity 62 of the encapsulation extrusion 30 . A pool cover 92 is secured to assembly 84 by an elongated tubing 94 connected to the edge of cover 92 and secured in cavity 62 . Preferably tubing 94 is smaller than the dimensions of the cavity 62 so that it can move freely along the cavity 62 as the pool cover is extended or retracted. Lips 63 and 65 at the front of cavity 62 retain tubing 94 in cavity 62 . Support spacer extrusion 80 is pushed into the cavity 34 below the cover guide extrusion 60 .
FIG. 8 shows another implementation of an encapsulation assembly 100 in which the encapsulated extrusion 30 of FIG. 2 is mated with the coping extrusion 70 of FIG. 5 . Assembly 100 is embedded in an edge of a pool deck 102 . Curved coping member 78 shapes the edge of the pool deck 104 to the configuration of member 78 .
In this implementation, a cover guide is not used, either because a pool cover is not deployed or because the encapsulation assembly is disposed on a back wall of the pool where a pool cover guide extrusion is not needed. In such instances, cavity 108 may be capped by a cover 106 for cosmetic and safety purposes. Cover 106 is secured by small flanges 109 and 110 that extend into cavity 108 . Tiny lips 11 land 113 at the end of flanges 109 and 110 mate with corresponding grooves, such as grooves 43 and 44 as shown in FIG. 2 . Looking now at FIG. 9 , a concrete form 110 is shown that can be attached to the encapsulation extrusions 30 or 54 , shown in FIGS. 2 and 3 . Form 110 is a generally L-shaped member having a bottom wall 112 and a side wall 114 . Bottom wall 112 includes channel 116 and protrusion 117 that are formed to mate with corresponding protrusion 39 and channel 42 in the bottom side 38 of top wall 37 , as shown in FIG. 3 . Side wall 114 has a curvature 118 designed to shape the edge of the concrete decking of the pool. A channel 120 is formed along the back side of wall 114 for holding an alignment piece for aligning form 116 with adjacent form members. Opposing lip members 122 and 123 are formed to retain the alignment piece.
FIG. 10 shows the manner in which the concrete form 110 mates to the encapsulation extrusion 54 . Bottom wall 112 extends into the cavity 34 of extrusion 54 so that channel 116 and protrusion 117 mate with the corresponding protrusion 39 and channel 42 of the bottom part 38 of top wall 37 of extrusion 54 .
FIG. 11 shows the concrete form 110 and encapsulation extrusion 54 completely mated. A concrete deck 122 is formed adjacent thereto, with the shape of side wall 114 of form 110 determining the curvature of the deck edging 124 . A spacer 126 is inserted into cavity 34 of encapsulation extrusion 54 to maintain the shape of the cavity during formation of the deck. Spacer 126 may be of any shape and material sufficient to maintain concrete form 110 snugly abutting the lower surface of encapsulation extrusion 54 . After the deck is formed, concrete form 110 is removed from cavity 34 , together with filler piece 126 so that the pool cover guide extrusion 60 can be inserted, as shown in FIG. 6 .
FIG. 12 show concrete form 110 mated with the encapsulation extrusion 30 shown in FIG. 2 . FIGS. 11 and 12 together make it apparent that concrete form 110 will readily mate with both of the encapsulation extrusions 30 and 54 shown in FIGS. 2 and 3 .
FIG. 13 shows the encapsulation extrusion 54 of FIG. 3 inset on the top of a pool wall 130 . Flange 50 and lip 52 extend into the mortar 132 above the wall 130 to secure the extrusion 54 . In this arrangement, masonry 134 is formed above extrusion 54 made of any appropriate material, such as brick, in any desirable shape to form an edge to the pool. In this situation, concrete form 110 or coping form 70 would not be required.
FIG. 14 shows an encapsulation extrusion 140 for use with gunite concrete pools rather than vinyl lined pools. In this implementation of the encapsulation extrusion no vinyl bead retention slot 32 or fiber optic cavity 56 are needed, as shown in the implementation of FIG. 3 . Extrusion 140 has a bottom wall 142 , a side wall 144 and a top wall 146 which form a cavity 152 , similar to the shape of the other encapsulation extrusions shown in FIGS. 2 and 3 . Also, a flange 143 with lip 145 extends from the intersection of bottom wall 142 and side wall 144 , for securing the encapsulation extrusion 140 in an appropriate medium, such as mortar.
FIG. 14 includes channels 148 , 149 and protrusions 150 , 151 to mate with the cover guide extrusion 60 shown in FIG. 4A . When the cover guide extrusion 60 is not used, such as in the absence of a pool cover or along the wall of the pool opposite the pool cover assembly, an encapsulation gap cover 159 can be applied to cover cavity 152 , as shown in FIG. 15 . This arrangement is similar to the members shown in FIG. 8 . Cover 159 includes flanges 154 and 155 each having tiny lips 156 and 157 that are designed to snap into elongated grooves 158 a,b.
FIG. 16 discloses the encapsulation extrusion 140 shown in FIG. 14 inset on the top of a pool wall 160 , similar to the implementation shown in FIG. 13 . Flange 143 and lip 145 extend into mortar 162 to secure the extrusion 140 . Masonry 164 of any appropriate design and shape rest on top of the top wall 146 of extrusion 140 .
As can be seen, the encapsulated track assembly of the present disclosure can take several different shapes, depending on the type of pool and the functions required, including securing the vinyl liner, holding fiber optic lighting, positioning form extrusions to form deck coping or edging and guiding pool cover edge members as the cover is retracted and extended. This This multiple purpose system is simple, easy to construct and install and relatively inexpensive.
The encapsulated track assembly provides a simple means to insert a form for the decking into the assembly and then remove it for future use after the decking is formed. The concrete forms are reusable and are readily mated with the encapsulation assembly. Numerous additional advantages are apparent from the disclosure provided herein.
Although the above implementations are representative of the present disclosure, other implementations will be apparent to those skilled in the art from a consideration of this specification and the appended claims, or from a practice of the implementations of the disclosed disclosure. It is intended that the specification and implementations therein be considered as exemplary only, with the present disclosure being defined by the claims and their equivalents. | An apparatus is provided for constructing edging around the perimeter of a swimming pool having a decking and a retractable pool cover, wherein an elongated guide connector is attached to a wall of the swimming pool for connecting to a guide member for the pool cover, that includes a form member shaped to form the edging, and a form mating structure on the form member for removably mating the form member to the elongated guide connector. | 8 |
This invention relates to improvements in the tear characteristics of certain adhesive tapes, particularly industrial tapes of the type known as duct tapes. Such tapes commonly comprise a pliable film base, such as polyethylene; a reinforcing open-meshed fabric; and an adhesive mass which anchors the fabric to the film, coating the fabric surface.
BACKGROUND OF THE INVENTION
It is customary for tapes of this nature to have a reinforcing fabric of spun cotton, rayon, or synthetic yarns, which provide strength to the tape in processing and in use. Such a fabric, when woven, normally varies in count from 32 to 44 warp yarns and 20 to 36 filling yarns per square inch, with the yarns 30's singles, of spun cotton.
Such fabrics have more than adequate strength for the reinforcement of such tapes, and for the sake of economy attempts have been made to utilize gauze fabrics of lower count, such as 24×20 or 20×12. However, in applications involving the use of the tape, it is customary to tear the tape across the warp yarns by hand, particularly when a number of repeated applications are made as in sealing the joints in industrial ductwork. When tapes containing a low-count gauze, are thus used, they almost invariably tear in a ragged and frayed manner, with dangling threads and the likelihood of deformation of the film backing.
Attempts have been made to improve the tear characteristics of tapes comprising low-count fabrics by using stronger yarns in the filling, such as high-twist spun yarns, continuous filament synthetic yarns, or even monofilament yarns, all with a marked lack of success.
It is with improvements in the tear properties of such tapes that the present invention is concerned, and it is an object of the invention to provide an adhesive tape incorporating a low-count fabric which when torn crosswise by hand will tear in a smooth and even manner.
SUMMARY OF THE INVENTION
It has now been found that so-called texturized or "false-twist" yarns in the filling of low-count fabrics, such as 24×20 or 20×12, will have a dramatic and unexpected effect on the tear characteristics of adhesive tapes incorporating such fabrics.
Texturized, or false-twist yarns, are continuous filament yarns which have been given increased bulk and loft by the introduction, of numerous loops, curls, and coils along the length of the individual filaments by aerodynamic or twist-set-untwist processes. Such yarns, commonly using nylon or polyester filaments, are a standard article of commerce. Due to the numerous irregularities induced along the individual filament lengths, such yarns are inherently elastic to some degree. Representative products and processes describing such yarns are set forth in U.S. Pat. Nos. 2783609 and 2869967, among others.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention may be more fully understood with reference to the following description and drawings, in which:
FIGS. 1 and 2 are representations of the characteristically irregular torn ends of adhesive tapes using low-count fabrics of 24×20 or 20×12 count wherein the filling yarns in the fabric are spun yarns or non-texturized continuous filament yarns.
FIG. 3 is a similar representation of the torn end of an adhesive tape wherein the fabric component is a 20×12 woven gauze with texturized yarns in the filling of the fabric.
FIG. 4 is a highly magnified cross-sectional view of a section of a texturized yarn 16 as used in the fabric employed in the adhesive tapes of the invention, consisting of convoluted filaments 17.
FIG. 5 is a highly magnified cross-sectional view of a segment of a three-component adhesive tape in which a spun yarn or a non-texturized continuous filament yarn is employed in the filling of the fabric.
FIG. 6 is a similar view of an adhesive tape in which texturized yarns are employed in the filling of the fabric.
FIG. 7 is a highly magnified view of a segment of a woven fabric suitable for use in this invention.
FIG. 8 is a similarly magnified view of a nonwoven fabric suitable for use in this invention.
DESCRIPTION OF THE INVENTION
Referring now to FIG. 6, the adhesive tapes 20 of this invention comprise a pliable backing substrate 10, commonly a layer of polyolefine film; a layer of adhesive 12; and a reinforcing fabric such as a low-count woven gauze or a yarn-reinforced nonwoven fabric. In FIG. 5, 14 represents the cross-section of a filling yarn in a prior art fabric in which a non-texturized continuous filament yarn is employed in the filling of the fabric. In FIG. 6, 16 represents a similar cross section of a filling yarn in fabric of this invention in which a texturized yarn is employed in the filling.
FIGS. 1 and 2 are elevation views of prior art three-component adhesive tapes, with hand-torn edges 26 and 28 respectively, wherein a low-count woven 20×12 fabric with spun yarns or non-texturized continous filament filling yarns employed in the filling of the fabric. Depending on the specific nature of the adhesive, which affects the degree of union between fabric and base, the tear may be of the so-called "step ladder" variety as at 26 in FIG. 1, or of the variety shown at 28 in FIG. 2, where the yarns 30 of the fabric have pulled away from the base 10. Either type of tear is undesirable, interfering with a smooth, even, rapid application of such tapes.
By contrast, FIG. 3 is a view of the hand torn edge 32 of a tape 20 of this invention, employing texturized yarns in the filling of a woven 20×12 fabric.
A possible explanation of the efficiency of texturized yarns in effecting this result may lie in the randomly kinked, coiled, and curled nature of the filaments of such yarns. Microscopic studies of tapes made using non-texturized continuous filament or spun yarns versus texturized yarns in the filling of such fabrics reveals that the latter afford approximately twice the filling yarn coverage, which is a measure of the degree of adhesion between individual filaments, adhesive mass, and the pliable base. As an example, considering FIGS. 5 and 6 again, a tape made using non-texturized continuous filament yarns in the filling of a 20×12 fabric revealed that the width of the 220 denier continuous filament yarn averaged 0.33 mm., as shown at 14 in FIG. 5. An otherwise identical tape, using 200 denier texturized polyester yarn in the filling or lateral direction (FIG. 6) revealed that the width of the filling yarns averaged 0.65 mm., as shown at 16 in this figure, thus doubling the area of mass-to-yarn contact.
An additional advantage of the use of texturized yarns in accordance with this invention lies in the fact that since such yarns flatten out and spread more than non-texturized yarns, less adhesive mass is needed to unite the base, the fabric, and the mass into an integral tape, as shown by comparison of the relative thicknesses of adhesive mass 13 in prior art tapes, FIG. 5, and the adhesive mass 12 of the tapes of this invention, FIG. 6. Since the function of the adhesive mass is to present a smooth even surface to the article to which it is to be applied, sufficient mass is used to cover the reinforcing fabric and anchor it securely to the backing. In this respect, the spreading characteristic of the texturized yarn 16 allows as thinner film of adhesive mass to be used, resulting in a thinner, more pliable tape as well as economics in adhesive mass reduction.
The following example is illustrative only and does not limit the scope of the invention.
SPECIFIC EMBODIMENT OF THE INVENTION
A gauze fabric was constructed using 20 yarns per inch of 30's cotton in the warp, 12 false-twist polyester yarns, 200 denier 96 filament, per inch of filling. In a calendering operation, this gauze was superimposed on a 4 mil thick low density polyethylene film and combined with a 6 mil thick layer of adhesive mass. The adhesive mass was composed of 40% rubber, 30% fillers, 28% tackifier resins, and 2% process aids. Calendering was by means of a 3 roll calendar with the top roll heated to 400 degrees F., center roll 200 degrees F., bottom roll 210 degrees F. Processing speed was 35 yards per minute.
When torn by hand, the tear properties imparted by this 20×12 fabric were comparable to the tear shown in FIG. 3, an even tear hitherto achieved only by the use of fabrics of 44×28 count, 30's cotton yarns, or 32×28 count, with spun yarns of 50% polyester, 50% cotton, or by fabrics of similar higher count.
OTHER EMBODIMENTS OF THE INVENTION
The tape construction of this invention may utilize a wide variety of adhesive masses; hot melts, acrylics, natural and synthetic rubbers, etc. Although the mass is customarily of pressure sensitive nature, the invention is equally applicable to masses of a heat-or solvent-activated mass.
It is also applicable to the use of various pliable bases, with polyethylene film of 4 to 6 mil thickness being preferred. The film may be preformed or film extrusion, fabric lamination, and adhesive application may be combined in a single operation.
Similarly, in place of woven fabrics as reinforcement, nonwoven fabrics or similar pliable but relatively non-extensible fibrous bases may be employed.
FIG. 7 is a magnified view of a suitable woven fabric, consisting of regular warp yarns 17 of spun cotton and filling yarns 16 of a texturized type, as characterized above.
FIG. 8 is a magnified view of a suitable nonwoven fabric, consisting of an unwoven array of textile length fibers, having adherent thereto a set of texturized yarns 16 arranged laterally of the fabric, corresponding to the filling in a woven fabric. In such yarn-reinforced fibrous bases, the fibrous array should be of a random or isotropic nature, so that the fiber orientation does not interfere with the clean hand-tear nature of the tape. | The tear properties of flexible adhesive tapes comprising a pliable base and a low-count open meshed fabric adhered thereto by a layer of adhesive are improved by the use of so-called texturized or false-twist yarns in the filling of the fabric. | 2 |
FIELD OF THE INVENTION
This invention relates in general to light curtain systems for detecting the movement or intrusion of objects into a protected zone. More particularly, the invention relates to light curtain systems which detect the intrusion of objects in a work place area or in association with an industrial machine.
BACKGROUND OF THE INVENTION
Photosensitive detector systems, commonly known as light curtains, are employed in a variety of industrial applications to sense the intrusion of objects in or around a prescribed area. Light curtains typically are employed for operator protection around machinery such as punch presses, brakes, molding machines, presses, automatic assembly equipment, coil winding machinery, robot operation, casting operations and the like. Conventional light curtain systems employ invisible pulsed infrared light beams which project across the area to be protected. Unintended intrusion of the light beams by an object, such as the operator's hand, are sensed by the circuit to trigger a warning signal, shut the machinery down, or otherwise safeguard the area.
There is a critical requirement to provide a light curtain system which cannot fail unblocked, i.e. in an unsafe mode. Thus, certain governmental regulations concerning industry workers prohibit the use of machinery having a design in which a part can fail unsafe. Conventional light curtain systems have design limitations which can permit them to fail unblocked, making them unsafe for certain applications.
Another problem with conventional light curtain systems is their high degree of complexity and cost. Certain of these systems, such as the Weber U.S. Pat. No. 4,266,124, provide a system which attempts to achieve self-checking operation by using one set of circuits to select individual light receivers and a separate set of additional circuits to verify that the correct receivers are selected. This results in a relatively more complex and costly design.
Conventional light curtain designs employ a light receiver circuit with a series of phototransistors which respond to light signals. Each phototransistor typically is coupled with a single operational amplifier to provide a fast and sensitive circuit, but which on the other hand is relatively complex, expensive and failure prone.
Conventional light curtain systems also typically employ analog circuits to sequentially select the photodetector channels. These circuits produce a relatively unsafe system in that intruding objects may not be properly detected if an incorrect channel is selected such as from a part failure. The system thus would not be intrinsically safe.
OBJECTS OF THE INVENTION
Accordingly, it is a principal object of the present invention to provide an improved light curtain system and method of operation which is intrinsically self-checking in its mode of operation and which employs a relatively simple and inexpensive circuit design.
Another object of the invention is to provide a light curtain system and method of operation of the type described which employs a self-checking safety logic circuit to ensure operation.
Another object is to provide a light curtain system and method of operation which includes a digital logic circuit to verify proper selection of channels during light scanning to ensure self-checking operation.
SUMMARY OF THE INVENTION
The invention in summary provides a light curtain system and method of operation for detecting the intrusion of objects into a zone or area by means of a light transmitter and light receiver, the operation of which are coordinated by control means incorporating a digital logic verification circuit. The control means selects phototransistors to sense the light in a given channel responsive to the light transmitter strobing a light beam which is exclusively addressed for the given channel. The logic verification circuit verifies that the light transmitter is correctly strobing a light beam for the given channel in predetermined timed relationship with selection of the phototransistor in the light receiver. A relay circuit is provided for generating a signal responsive to the light receiver not properly sensing the light beam in a channel at the time the light transmitter is verified as correctly strobing for that channel.
In the preferred embodiment of the invention, the light receiver includes a circuit in which the phototransistors act as switches to select the channels responsive to the control circuit. In the receiver circuit a single amplifier is used in combination with a plurality of phototransistors to amplify the signal for a number of channels.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and additional objects and features of the invention will appear from the following specification in which the several embodiments have been set forth in conjunction with the accompanying drawings wherein:
FIG. 1 is a fragmentary perspective view showing the light transmitting and light receiving components of a light curtain system incorporating the invention;
FIG. 2 is a block diagram illustrating the major components of the electrical control system for the light curtain of FIG. 2;
FIG. 3 is a schematic block diagram of the transmitter circuit means;
FIG. 4 is a more detailed schematic diagram of the transmitter circuit means;
FIG. 5 is a schematic block diagram showing the concatenation of multiple receiver circuits;
FIG. 6 is a more detailed schematic diagram of the receiver circuit;
FIG. 7 is a more detailed schematic diagram of components of the receiver circuit showing selection of a phototransistor;
FIG. 8 is a schematic diagram of the components of FIG. 7 showing de-selection of the phototransistor;
FIG. 9 is a detailed schematic diagram of components of the receiver circuit showing one phototransistor selected and another phototransistor de-selected;
FIG. 10 is a detailed schematic diagram of components of the receiver circuit showing the combination of multiple amplifiers on a single analog output line;
FIG. 11 is a more detailed schematic block diagram of the logic circuit of FIG. 2;
FIG. 12 is a more detailed schematic diagram of the relay operate/check circuit of FIG. 2;
FIG. 13 is a more detailed schematic diagram of the shift register verification logic circuit of FIG. 11;
FIG. 14 is a more detailed schematic diagram of the amplifier/interface circuit of FIG. 2;
FIG. 15 is a schematic block diagram of the power supply circuit of FIG. 2;
FIG. 16 is a detailed schematic diagram of receiver circuit components in an embodiment providing faster overdrive and select recovery functions.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the drawings FIG. 1 illustrates generally at 10 components of a light curtain system incorporating one embodiment of the invention. The light curtain system includes light transmitting means 12 and light receiving means 14 which are operated by the control system shown generally in the block circuit diagram of FIG. 2. The light transmitting means is comprised of a plurality of light sources, preferably light-emitting diodes (LEDs), which emit pulses of infrared light responsive to the control circuit. The LEDs are mounted on a housing positioned in series along a plane, which typically is a vertical plane. The LEDs are focused by collimating lenses 17 into light beams 15 which project along predetermined paths or channels across the zone or area of the work place which is to be protected.
Light receiving means 14 is comprised of a plurality of phototransistors (PTs) which typically are mounted in series in a housing which is located in the zone across from the housing of the LEDs. Preferably the number of light receiving PTs is equal to the number of light transmitting LEDs, with each PT associated with the LED of a respective channel. At the work place the housings of the light transmitting and light receiving means are installed so that the PTs are substantially in optical alignment with the light beams from the LEDs. While operation of the invention will be described by the use of infrared light, it is understood that the invention contemplates the use of other radiant energy, for example near-infrared or visible light. It is also understood that the invention contemplates that a plurality of light transmitting modules and/or a plurality of light receiving modules may be combined in tandem to protect a relatively large zone or area.
FIG. 2 illustrates the major components of the control circuit in block diagram form. The control circuit includes a power supply 16, logic circuit 18, relay operate/check circuit 20, relay output circuit 22, transmitter circuit 24 which is connected to the logic circuit through an interface circuit 26, and receiver circuit 28 which is connected to the logic circuit through amplifier/interface circuit 30. The lines 32 represent the paths of the light beams which project across the protected zone from the transmitter LEDs to the receiver PTs.
FIG. 3 illustrates details of transmitter circuit 12 showing a plurality of transmitter blocks 34, 36, 38 concatenated together. Each transmitter block in turn is comprised of a plurality, typically eight, of LEDs 40-47, as shown in FIG. 4 for the first transmitter block 34. In FIG. 3 the total number of transmitter blocks concatenated together would be determined by the size of the zone which is to be protected. The inputs into the transmitter circuit include a clock signal line 48, data-in line 50, LED power control line 52 and data-out line 53 from the last transmitter in the concatenation, all of which are combined in a cable leading from interface circuit 26 into the logic circuit 18.
In each transmitter block, as illustrated in FIG. 4, the LEDs 40-47 are connected in parallel with LED power control line 52. Eight power drivers 55 are provided in the transmitter block, one for each LED. The power drivers are conventional solid state devices which selectively activate their associated LEDs responsive to control signals from a shift register 56, which will be described in detail hereafter. The shift register receives binary data in through line 50 and receives the clock signal through line 48. A data-out line 57 transfers data to the shift register of the next transmitter block in the concatenation, except for the shift register of the last block which loops the data back to the logic circuit via line 53.
FIG. 5 is a block diagram illustrating the concatenation of multiple receiver blocks 58, 60, 62. As shown in FIG. 6, the typical receiver block 58 is comprised of PT sensors 64, 65 corresponding to the number of LEDs in the transmitter block with which it is associated. In the above example, eight PTs are arrayed in each receiver block. The number of receiver blocks in the concatenation will vary in accordance with the number of transmitter blocks, as required by the size of the zone or area to be protected. The data-in signal from the logic circuit is routed through amplifier/interface circuit 30 via line 66 into first receiver block 58. The clock signals from the logic circuit are routed through the amplifier/interface circuit via line 68 into the receiver blocks. The output signals from the receiver blocks are connected with the cathodes of diodes 70 which have their anodes connected to a line 72 that provides the analog output signal back to the logic circuit. The data-out signal from the last receiver 62 is directed through line 74 into amplifier/interface circuit and back to logic circuit 18.
FIG. 6 shows the circuit components for the typical receiver block 58 of FIG. 5. This circuit includes a shift register (SR) 76 having eight terminals, each of which is connected with the collector of a respective one of the eight phototransistors 64, 65. A single amplifier circuit 80 is provided for each receiver block. In the circuit 80 the output terminal of an operational amplifier 82 is connected in parallel through resistors 84 85 with the bases of the PTs. Terminal 86 of the op amp is normally maintained at +2.5 volts. Feedback from the emitters of the PTs is directed into op amp terminal 88.
FIG. 7 is a schematic circuit illustrating operation of the phototransistor amplifier combination when the single PT 64 is selected and is also struck by the light beam. The PT is selected by application of a +5 volt signal from shift register 76 through line 90 to the transistor collector. The light input supplies a part of the base current to the PT so that the amplifier does not have to supply as much current through resistor 84. The amplifier output voltage then drops proportional to the light input, thereby providing a light detection signal.
FIG. 8 illustrates the mode of operation of the single PT 64 when it is de-selected by means of a signal from shift register 76 grounding the collector of the transistor. In this mode the PT functions in the manner of a virtual pair of diodes, represented as D c and D e within the broken line circle 92 of the diagram. This grounding of the collector eliminates the photosensitivity of the transistor and drops its base voltage V B to approximately 0.6 volts. With all of the PTs de-selected in this manner, amplifier 82 tries to maintain the voltage across resistor 94 by going as positive as it can. The virtual diode Dc keeps V B at approximately 0.6 volts so that virtual diode D e is reverse-biased and there is no feedback. The amplifier output then goes to the positive power supply rail. The de-selected PTs therefore act as if disconnected from the circuit.
FIG. 9 illustrates schematically the mode of operation in which one PT 64 is de-selected and at least one additional PT 65 is selected. The PT 64, represented by the virtual pair of diodes within dashed line circle 92, is de-selected by the signal from shift register 76 grounding its collector. At the same time PT 65 is selected by a +5 volt signal from the shift register. PT 65 is then the only source of feedback to resistor 94 so that the output of amplifier 82 reflects only the light which strikes PT 65. When the collector of PT 65 is grounded and the +5 volt signal is applied to the collector of PT 64, then PT 64 will supply the feedback and PT 65 will be disabled.
The amplifier/PT circuits which comprise the receiver blocks of FIGS. 5 and 6 can be concatenated with additional receiver blocks into longer chains using single diodes 70, 71, and 73 by means of the circuit of FIG. 10. Assuming that all of the PTs for a single amplifier 82 are de-selected, and that the positive input of the amplifier is at 2.5 volts, then the negative input does not receive current because all of the PTs are in the off mode so that the negative input of amplifier 82 goes to 0 volts. The output of the amplifier thus goes to +15 volts which is the positive supply rail. Assuming that PT 64 is then selected by applying the +5 volt signal to its collector, amplifier 82 feeds back through the PT so that its output is at approximately 3 volts or less. Since the saturated amplifiers are at +15 volts then diodes 71 and 73 are off and only the unsaturated amplifier's diode 70 is on. Therefore the combined output of the concatenated receiver blocks will be proportional to the lowest of all of the diode cathode inputs so that the combined circuit will output only the selected amplifier/PT. In this way a number of the multiple PT receivers can be multiplexed onto a single analog line.
The major subcomponents of the logic circuit 18 are illustrated in the block diagram of FIG. 11. The following principal functions are performed by the logic circuit: a) it amplifies the data-out signals coming in from the light receivers, b) it sequences the light transmitters with the light receivers, c) it supplies reference voltages to other subcircuits, and d) it verifies the shift register logic. The circuit includes a clock sequence generator 96 which produces timing signals used in the system. The clock speed can be in the range of 2 μs to 1000 μs depending upon the application. A clock speed of 100 μs is suitable for the preferred embodiment. The data-in signals from the receivers are amplified in circuit 98, the output of which is directed into comparator 100. The individual outputs from each receiver are compared against a voltage threshold provided at 102. The output from the comparator is analyzed by decision circuit 104. The decision circuit generates relay drive signals 106, 108 when the signal from a given receiver exceeds the threshold, indicating that the PT of a particular channel has received light. The relay drive signals are fed into a one-shot output circuit 110 and then into a redundant relay driver circuit 112. The relay driver circuit supplies the output relays 114, 116, shown in FIG. 12, with signals so that the relays remain energized as long as every channel has the correct output indicating that it is receiving light and is working.
The relay operate/check circuit 20 is shown in detail at FIG. 12 and includes a plurality, shown as two, of the output relays 114, 116 connected with lines 120, 122 through which the drive signals are received from relay driver 112. Each relay includes two sets of contacts. One set of contacts 124 and 126 for each relay are shown in FIG. 12 and the other set, not shown, are employed by the user for the appropriate end use application, e.g. triggering an alarm, energizing a light bulb or controlling machinery. The circuit operates to verify that the relay contacts agree with each other, agree with their respective drive signals, and that both drive signals agree. If any of these conditions are not met for more than ten milliseconds, the switch 128 is opened which disables the output relays, thereby putting them in a safe state. A flipflop stores the failed state condition until a reset button, which is a part of verification circuit 132, is pushed, or until power is restored. If the failure persists then the circuit again opens switch 128. An auxiliary output is comprised of relay 130 and its drive circuit, which is a part of verification circuit 132, which operate to close an externally available contact pair 134 for triggering the alarm or the like in the event that any of the failures have been detected. This relay is only reset when the entire verification circuit is reset.
Decision circuit 104 operates to verify that the selected channel is not detecting light until the associated LED is turned on, and that it is detecting light when the LED flashes on. If either of these conditions are not met, the one-shot output circuit 110 is triggered and the output relays are de-energized to the "detect object" condition.
Shift register verification logic circuit 136 of the logic circuit of FIG. 11 is shown in detail in FIG. 13. This circuit 136 receives the data-out signals, which are binary coded information, from both the receiver data line 138 and transmitter data line 140, and also receives timing signals on line 142 from the clock sequence generator. At each clock signal the verification logic determines if the correct sequence of data bits is coming out of the individual shift registers from both of the transmitter and receiver lines. If at any time the actual data-out signals from the transmitters or receivers do not agree with the clock sequence data, then the verification circuit sends a shutdown signal through line 144 (FIG. 11) into redundant relay driver 112 which signals the relays into the shutdown mode.
In the verification logic circuit of FIG. 13 the user installs jumpers across the appropriate jumper contacts 146 in accordance with the desired number of channels installed in the system. This in turn establishes the number of stages that are in the shift registers between data-in and data-out. This permits the logic circuit to make an appropriate comparison between the data-out information from the shift registers.
The data-out line 140 from the transmitter circuit leads into one contact of exclusive OR gate 148, and the data-out line 138 from the receiver circuit is connected with one contact of a second exclusive OR gate 150. The exclusive OR gates compare the sequence generator data stream to the actual data stream coming in on line 152 from the shift registers of the transmitter and receiver. The outputs from these exclusive OR gates continue through OR gate 154 and AND gate 156, the output of which leads into a one-shot monostable multivibrator 158. When the signals disagree, multivibrator 158 is triggered to disable the relays. Line 142 is used to clear and reset the logic so that minor timing variations do not trigger the circuit.
During operation, both the transmitter and receiver shift registers inject a "one" bit at the start of each scanning cycle of the light curtain, and the activated transmitter/receiver channel is determined by the point in the shift register where this "one" bit is located. When the shift register shifts this "one" bit through the complete cycle, it appears at the data-out line of the shift register. The verification logic circuit checks to make sure that this "one" bit comes out exactly after the correct number of shifts, and that no "one" bit comes out of the shift register at any other time. If the shift register, or any wiring, fails, the circuit will either put out a "one" bit at the wrong time or put out a "0" when the "one" should come out. In either event the relays are opened and the system shuts down.
FIG. 14 illustrates components of the amplifier/interface circuit 30 which conditions the signals for going over a long cable. The amplifier/interface circuit includes a pull-up resistor 160 which applies a positive signal to the anodes of all of the diodes 70, 71, 73 of the output multiplexing circuit described in connection with FIG. 10. The pull-up resistor makes the cathode of the appropriate diode the most negative so that the circuit will output only from the selected PT.
Amplifier/interface circuit 30 functions to buffer the analog line, to increase the signal strength sufficient to travel over a long cable, and removes all steady-state signals from the PT amplifiers which result from such conditions as ambient light, Vbe drop, the +2.5 volt amplifier offset, diode drop and the like. This DC component is removed from each channel during a cycle before the channel's signal is interrogated by the remainder of the circuit. This is accomplished by closing the DC restore switch circuit, which is comprised of the components enclosed by the dashed line 162, during a period when no LED light is arriving at a selected PT. The DC restore switch is closed by a signal from logic circuit 18.
The components of power supply circuit 16 are illustrated in FIG. 15. The 60 Hz main line connects with a transformer 164 which is coupled with IC voltage regulator 166. The LED variable voltage regulator 168 supplies voltage to the +LED power control line 170. A monitor circuit 172 functions as a current and voltage over-limit detector which provides a relay shutdown signal through line 174 to the logic circuit if the voltage or current go too high. This circuit thereby insures that the system is in a safe mode if there is any type of power failure.
FIG. 16 shows an alternate embodiment of an individual PT receiver array 176 which provides a faster overdrive and select recovery capability. The base of PT 178 is connected with the output of an amplifier 180, and a diode 182 is connected between the plus and minus inputs of the amplifier. This circuit configuration increases the speed at which the PT can be selected. When a PT goes out of the de-select mode and into the selected mode then a discrete time is required for its photosensitivity to recover. When the PT is selected by the logic circuit it causes very high emitter currents which sweep the charge rapidly out of the device. When selected the PT then peaks at very high currents in a relatively short time.
In the method of operation of the invention with the control circuits powered up logic circuit 18 operates the LED transmitter circuit 24 and PT receiver circuit 28 for scanning of the light channels in sequence across the zone to be protected. The LEDS are activated in sequence to strobe light exclusively addressed for a given channel. The PTs are selected by the logic circuit to detect light at the time in the cycle which corresponds to the appropriate channel being strobed.
The PTs are selected by the logic circuit applying a +5 volt signal to the collector. When light which is emitted from the LED transmitter of the same channel strikes the selected PT, then less current is supplied to the base by the amplifier loop because the light provides a portion of the base current. The loop then holds the collector current constant to produce the light detection signal.
Each PT is de-selected when the logic circuit grounds its collector. The de-selected PT no longer operates as a transistor but rather as a virtual diode pair in series as illustrated by FIGS. 8 and 9. The grounding of the collector forward biases the virtual diode on the base-collector junction, thereby eliminating the device's photosensitivity and dragging the base to approximately 0.6 volts from ground. With the amplifier input at 2.5 volts the virtual diode on the base-emitter junction is reversed-biased and off, carrying substantially no current. This condition effectively disconnects the PT from the inverting input of the amplifier. If any other PT is enabled by being selected, then all of the de-selected PTs are completely out of the circuit so that the amplifier output reflects only the light which strikes a PT that is selected.
The single amplifier for each receiver block, e.g. amplifier 82 of FIG. 6, provides the analog output signal through diode 70. The signal is directed through amplifier/interface circuit 30 and into logic circuit 18. The analog signals from the PT receivers are processed in the logic circuit through amplifier circuit 98, comparator circuit 100 and decision circuit 104. When these circuits determine that light is present in the proper channel at the proper time in the cycle, the relay drive signals signal one-shot output circuit and redundant relay driver 112. At the same time the receiver data-out signals, transmitter data-out signals and timing signals are processed by shift register verification logic circuit 144. If this circuit determines that the actual data-out signals from the transmitter and receiver shift register agree with the signals from the clock sequence generator, then no shutdown signal is generated and the system continues into the next cycle of light sequencing through the channels. If the verification logic senses a disagreement between the transmitter/receiver data-out signals and the clock sequence generator signals, a shutdown signal is directed into relay driver 112 to safe out the relays. The relays in turn activate the appropriate alarm or shut down the machinery which is being safeguarded.
While the foregoing embodiments are at present considered to be preferred it is understood that numerous variations and modifications may be made therein by those skilled in the art as fall within the true spirit and scope of the invention. | A light curtain system and method of operation which detects the intrusion of objects into a protected zone. The system is characterized in having an inherent self-checking mode of operation by logic circuits which analyze data signals from both the LED light transmitters and phototransistor receiver circuits. A shutdown signal is generated if the logic circuit determines that light is not received in a selected channel at the time that the LED is strobing light exclusively for that channel. The system further provides a relatively simple and inexpensive method of selecting and amplifying the LED transmitters and PT receivers. In the circuit each PT acts as a switch which selects itself, and a single amplifier is employed for a plurality of the channels. The circuit further provides for the concatenation of groups of amplifier/PT circuits into a longer chain using a single diode. | 5 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to German Application 101 64 100.1 entitled DEVICE FOR THE FEEDING OF POULTRY, FATTENED POULTRY IN PARTICULAR, AND ESPECIALLY BROILERS, which was filed on Dec. 24, 2001.
BACKGROUND OF THE INVENTION
[0002] The invention relates to a device for the feeding of free-range poultry kept in coops, fattening poultry in particular, and especially broilers, with at least one feed delivery pipe held above the floor of the coop in a raisable and lowerable manner. The feed delivery pipe has a series of branch apertures, of which each is allocated to a bowl device suspended on the delivery pipe, which features a downpipe descending from the branch aperture and a feed bowl located beneath the delivery pipe. Bowl cupolas are formed from grid bard running in spoke fashion, whereby the downpipe consists of an inner cylinder departing from the branch aperture and an outer cylinder surrounding the inner cylinder, to which the feed bowl is suspended by means of the grid bars of its bowl cupola in such a way that it comes to rest when the feed delivery pipe is lowered, coming to rest in particular on the floor of the coop. The outer cylinder is guided in relation to the inner cylinder so as to be rotatable as well as capable of being raised and lowered, and is provided with at least one raising stop delimiting the raising and lowering travel.
[0003] A device of the generic type referred to is shown in EP 0 105 571 B1.
[0004] When the feed bowl of the known device comes to rest with the lowering of the feed pipe, apertures in the downpipe can be cleared. As a result of this, depending on the individual position of the apertures in relation to the feed bowl, it is possible to allocate different discharge cones and discharge heights to the feed passing via the downpipe into the feed bowl. In order, for example, to provide chicks with improved eating conditions, a higher discharge height and therefore a high feed level to the bowl is necessary, which can be achieved by clearing further apertures in the downpipe with the known device. In accordance with the growth of the chicks, the feed level in the bowl can also be set lower because growing animals can easily reach areas located lower in the feed bowls than chicks are capable of for the purpose of acquiring feed.
[0005] Devices installed in a coop should be as free of maintenance as possible. Accordingly, the most uniform refill of the feed is desired, while still remaining free of interruption, in predetermined metering volumes in each case into each individual feed bowl. With the known device, however, interruptions may arise in that feed emerges irregularly from the downpipe into the feed bowls, as a result, for example, of the corresponding outlet apertures becoming closed in the casing surface of the downpipe. This is the case in particular with feed which is prone to form bridges, for example with feed with poor sprinkle behavior.
[0006] In addition to this, the outer pipe is capable of rotating in relation to the inner pipe, as a result of which the cross-section of an additional outlet aperture in the downpipe is reduced, because an aperture in the outer cylinder is no longer congruent, or only partially, with the aperture allocated to it in the inner cylinder.
[0007] Feed bowls should be cleaned at regular intervals. This is effected by spraying with water, at least after a fattening period, before the coop is occupied by new chicks. During the spraying process, it is advantageous for the feed bowl to be capable of rotation about the longitudinal axis of the fall pipe deriving from the feed pipe, because in this situation practically all inner areas of the feed bowl run past a sharp water jet directed from one side into the feed bowl. While the possibility of the feed bowl to rotate on the inner cylinder of the downpipe is still advantageous for cleaning, it is nevertheless disadvantageous, for the reasons described heretofore, for keeping clear the additional apertures in the downpipe. A further disadvantage of the free rotation of the feed bowl lies in the fact that a predetermined distance interval between the feed bowl and the free end of the downpipe, on which the feed level desired in each case is dependent, may be unintentionally wrongly adjusted due to the rotational movement during cleaning.
SUMMARY OF THE INVENTION
[0008] The invention is based on the problem of avoiding these disadvantages by means of a device for the feeding of poultry, as described in the Background of the Invention.
[0009] With the device according to the invention, both the outer cylinder and the inner cylinder consist in each case of cylinder sections adjacent to one another and coaxial to one another, whereby the face periphery areas of the cylinder sections, turned towards one another, are connected to one another by means of bridging elements, which bridge a gap area which corresponds to the distance interval between the cylinder sections.
[0010] It has been shown that, during a fattening period, with an initial feed level for chicks and another feed level for broilers, in the final analysis therefore with only two feed level positions in the feed bowl, adequate fattening results can be achieved, so that, with a subdivision of the inner cylinder and the outer cylinder into two cylinder sections in each case, a simple design is provided that has adequate operational reliability.
[0011] The gap interval between two cylinder sections of the inner cylinder or the outer cylinder respectively forms an additional aperture for the emergence of feed into the feed bowl, also referred to here as a “360° window,” which is located next to the lower free end of the downpipe formed from the inner cylinder and outer cylinder. Each gap interval between the cylinder sections forms a free circumferential aperture, which is only interrupted by the bridge elements. These, however, without any losses in strength or stability needing to be taken into account, can be kept so thin that their thickness, and therefore their cross-section, reduces the free aperture width of the 360° window formed in a virtually imperceptible manner. Even with unfavorable circumstances, it is therefore possible to arrive at a situation with hardly any bridging formations or blockages in the area pertaining as the 360° window of the additional apertures in the casing of the downpipe or its cylinder respectively.
[0012] On the actuation of the delivery device installed in the feed delivery pipe, e.g. a dragline or a spiral feed device, it is guaranteed with the device designed according to the invention that each feed bowl will also be reliably filled up to the predetermined feed level. The risk will hardly arise any longer of individual feed bowls remaining empty, in particular in the critical initial stage of the fattening period for chicks which are still small, due to blockages in the area of the additional apertures in the downpipe.
[0013] The feed delivery pipe, usually running vertical and therefore parallel to the floor of the coop, can be moved perpendicularly, for example by means of traction cables capable of being centrally actuated. With the known device, this actuation makes it possible for the feed bowl to be brought into positions in which it rests either on the floor of the coop or is raised off of it. In the same manner as with the known device, the setting of the feed bowl on the floor of the coop is used to displace the outer cylinder vertically to the inner cylinder, and, by means of this displacement travel, to open an additional feed discharge aperture, namely the 360° circumferential window, in the downpipe. With this means of effect, comparable to the prior art, with the device according to the invention in a further embodiment, however, a situation is reached in which the end-side cylinder section covers the gap area between the cylinder sections of the outer cylinder when the outer cylinder is moved by means of a raising of the feed delivery pipe into a position which is lowered in relation to the inner cylinder, in which the lifting stops of the inner and outer cylinder are in mutually opposed positions. It can be seen that the formation of the 360° window has the advantage that, even in the ground resting position, in which the window is cleared, possible rotation of the feed bowl in relation to the inner cylinder which may arise will not have any disadvantageous effect on the feed outflow through the 360° window.
[0014] In order to prevent the possibility of the outer pipe with the feed bowl falling away from the inner cylinder when the feed delivery pipe is raised, at least one lifting stop is provided for. With the device according to the invention, a recess in the inner surface of the cylinder plays a part in the formation of the lifting stop of the outer cylinder, as well as at least one contact shoulder for the recess, projecting radially from the inner cylinder. If the inner cylinder is raised, in that the feed delivery pipe is brought into a greater distance interval from the floor of the coop, the inner cylinder initially slides in the outer cylinder as far as the contact shoulder projecting from the inner cylinder, against which the step formed by the recess in the outer cylinder comes in contact, so that, with the further raising of the inner cylinder, the outer cylinder and therefore the feed bowl connected to it can be drawn along together. In this position, therefore, the parts of the inner cylinder and the outer cylinder participating in the formation of the lifting stops are in a mutually-opposed position, and the end-side cylinder section of the inner cylinder covers the gap area between the cylinder sections of the outer cylinder. The additional aperture in the feed downpipe, the “360° window,” is closed.
[0015] Each contact shoulder for the recess may be a projection arranged at random on the inner cylinder. For preference, each contact shoulder for the recess is a part of a radial projection of the inner cylinder, in the manner of a collar flange.
[0016] In order for the bridging elements which connect the cylinder sections only to reduce the free opening surfaces of the “360° window” by an insignificant amount, and nevertheless to connect the cylinder sections to one another in an adequately stable and secure manner, a special design and cross-sectional shape has been selected for the bridging elements. Each bridging element is a flat web, of which the web surface plan runs radially to the axis of the inner or outer cylinder in each case. The number of flat webs can be varied. Four webs for the inner cylinder and seven webs for the outer cylinder have proved their worth. To particular advantage, the bridging elements of the outer cylinder which pertain as flat webs feature the form of paddles or vanes projecting radially over the periphery of the outer cylinder into the feed bowl. The vanes at the outer cylinder control and maintain the uniform feed distribution into the feed plates, even if the entire feed bowl is intended to swing or move in pendulum fashion about the delivery pipe, and prevent the excessive scratching and pecking of the animals in the feed, which can result in feed losses.
[0017] It is intended that the feed should be discharged and distributed as uniformly as possible from the downpipe. In this situation, an overflow of the feed from the feed bowl due to an excessively high feed level is to be avoided just as too low a feed level, which impedes the feeding of the animals. For the correct metering of the feed into the bowl, it is determinant, as already mentioned, that a predetermined distribution cone be formed and maintained in the feed bowl, whereby the distribution cone can in turn be influenced by the distance interval between the feed outlet apertures present in the downpipe and the feed bowl. The distance between the feed bowl and the lower free end of the downpipe or from the “360° window” respectively therefore has a substantial influence on the feed level in the bowl, and it is in turn dependent on the feed level as to whether the feed consumption by the animals takes place in optimum fashion. The possibility of altering or adjusting the interval distance between the feed bowl and the lower free end or between the feed bowl and the “360° window” of the downpipe is advantageous, and with the device according to the invention is achieved in terms of design in that the outer surface of an upper cylinder section of the outer cylinder is designed as a threaded spindle and that the free ends of the grid bars of the bowl cupola are connected to a screw ring, which is screwed onto the area of the outer cylinder designed as a threaded spindle.
[0018] The pitch of the threaded spindle is selected for preference of such a type that, even at relatively low extension or angular movement of the feed bowl, a perceptible change is noticeable between the distance between the feed bowl and the feed delivery pipe, from which the downpipe with its apertures departs.
[0019] As described heretofore, the feed bowls begin to rotate about an upright axis when subjected to cleaning under a water jet. This rotation is even desirable. The rotary movement does have the disadvantage, however, that the feed level which has been set may as a result be unintentionally changed. After cleaning, all the feed bowls in the feed line in a coop would therefore have to be readjusted, which involves a considerable amount of work.
[0020] The undesirable automatic change of setting or rotation of the feed bowls is prevented with the device according to the invention in that it features at least one rotational stop, which prevents or at least delimits the rotational path of the outer cylinder in relation to the inner cylinder.
[0021] In this situation, the formation and arrangement are set in such a way that each rotational stop features at least one elevation arranged at a predetermined area of the outer surface of the inner cylinder, as well as at least one driver dog or projection located on the inner surface of the outer cylinder, into the rotational path of which, during the rotation of the outer cylinder about the inner cylinder, the elevation projects. If the feed bowl rotates, and therefore the outer cylinder on which the feed bowl is suspended, in relation to the inner cylinder, the projection strikes against the elevation at the latest after a predetermined rotational path has been covered, and prevents it from rotating back again.
[0022] The predetermined area of the outer surface of the inner cylinder, which is provided with the elevation for the rotational stop, is the upper head part, which is offset against the other part of the inner cylinder as a result of the reduced cylinder diameter. The feed bowl and its outer cylinder can therefore only rotate freely about the inner cylinder in that position in which it is suspended above the raising stops between the outer and inner cylinder on the inner cylinder. In the upper position, i.e., in a lowered position of the feed delivery pipe and therefore also of the inner cylinder in which the feed bowl rests, and, as a result, its outer cylinder is raised in relation to the inner cylinder, the projection is, by contrast, in the area of effect of the elevation located on the upper head part of the inner cylinder, said elevation projecting into the rotational path of the projection on the outer cylinder. The outer cylinder, and therefore the feed bowl, is therefore only capable of rotation in the upper position until the rotational movement is stopped by the rotational stop.
[0023] The device according to the invention is also characterized by the fact that the automatic, uncontrolled, and therefore undesirable rotation of the screw ring in relation to the outer cylinder is prevented, which would in consequence result in an incorrect setting of the feed level in the feed bowl, that the outer cylinder features, in its area designed as a threaded spindle, at least one spring-elastic engagement cam, preferably a spring elastic in the radial direction, which can engage in positive fit with cut-outs which are featured by the screw ring in its inner circumferential surface.
[0024] With the device according to the invention, it is of particular inventive significance that the rotational stop, in conjunction with the areas of the inner cylinder offset in respect of the diameter, serves the purpose of blocking the specified setting of the feed level, if required, against unintentional actuation by means of the engagement cams in the suspended position or, if appropriate, in the raised position of the bowl. This is achieved in that the engagement cams and the cut-outs are provided with run-on flanks aligned obliquely to the direction of rotation about the upright axis.
[0025] Because the engagement cams and the cut-outs are provided with run-on flanks aligned obliquely to the direction of rotation, the spring-elastic engagement cams are deflected with the appropriate application of force during rotation, and in a similar manner to a cam drive are deflected out of the cut-outs. After the deflection of the engagement cams from the cut-outs, the screw ring can be further rotated on the thread of the outer cylinder, whereby the feed stand position defining the feed level changes, as described heretofore. As soon as the engagement cams have reached an adjacent cut-out, they engage again into this cut-out, or the screw ring, under the repetition of the deflection movement, may rotate further.
[0026] This is only possible, however, in the upper position of the outer cylinder in relation to the inner cylinder, because, due to the offset outer surface of the inner cylinder with the reduced cylinder diameter, there is sufficient room behind the engagement cams into which they can be moved during rotation and raising out of the cut-outs. In the lower suspended position, the outer surface of the inner cylinder is supported from behind against the engagement cams because of their enlarged outer diameter at that point, with the result that clearance of the feed stand positions which have been set, and raising from the cut-outs, are not possible even with the greatest exertion of force.
[0027] In view of the fact that, during cleaning, the entire feed line is raised with the feed pipe, and, as a consequence, only the suspended position of the outer cylinder is provided, in this suspended position of the outer cylinder it is automatically guaranteed that the previously-set feed stand positions will be locked in place, and unintentional changing of the feed stand positions is therefore not possible. The feed bowl can however be rotated freely on the inner cylinder, in the suspended position of the outer cylinder, for the purpose of cleaning.
[0028] Only in the raised position of the feed bowl and the external cylinder connected to it is an adjustment of the feed stand position possible by the rotation of the screw ring on the threaded spindle part of the outer cylinder, because only in this position can the engagement cams be deflected out of the cut-outs of the screw ring with the aid of the rotary stops, acting in the manner of a driver dog.
[0029] To adjust the feed stand position which has been set, the unit consisting of the feed bowl, cupola and outer cylinder is therefore first to be raised. This unit can then be rotated about the upright axis in the direction of rotation of the desired change of the feed stand, until the point at which driver dogs present on the outer cylinder in the form of projections have reached the separation cylinder, and the outer cylinder is secured against a further rotation. In the continuation of the rotational movement, with increasing effect of force, the engagement cams release the feed stand positions, in order, after a predetermined path of rotation, to be able to engage again in the next feed stand position.
[0030] To improve the cleaning effect and facilitate cleaning work, in a further embodiment of the device according to the invention there is incorporated the measure that the feed bowl features a feed plate, which in the area of the plate edge features connecting elements to connect to the bowl cupola. The connecting elements may feature a folding joint and at least one locking or retention element. Instead of a connection with the bowl cupola, the feed plate also may be formed, in the area of its plate edge, of two plate edge sections, one of which is connected to the grid bars of the bowl cupola, and which are connected to each other by means of at least one folding joint and at least one locking or retaining element, e.g. clamps. Of particular advantage is an unhookable folding joint, so that a feed plate can be replaced if necessary.
[0031] The feed plate is designed to be conical in the center, so that feed falling into the feed plate from the unit of inner cylinder and outer cylinder forming the downpipe can slide outwards.
[0032] To improve feed consumption by the animals, a ring surface of the feed plate, which runs around the center of the plate located beneath the downpipe, is divided into feeding sections. Each feeding section consists of at least one plate, one field, or the like by way of a shape delimited by a depression or elevation.
[0033] To particular advantage, the number of feeding sections is equal to a multiple of the number of the bridging elements of the outer cylinder designed as paddles or vanes.
[0034] If, for example, seven cut-outs are arranged on the inner circumference of the screw ring, then this specifies seven feed stand positions, which can be adjusted by the rotation of the screw ring in relation to the outer cylinder. The outer cylinder itself features in its thread area at least one, and preferably two, engagement cams, which are located on the circumference of the outer cylinder in such a way that they can engage simultaneously in cut-outs of the screw ring arranged for each of them. With seven possible feed stand positions, it is possible to arrange seven bridging elements at the circumference of the outer cylinder, and to design these as paddles or vanes, so that they control and maintain the uniform distribution of the feed into the feed plate. In the case of the feed plate subdivided into 14 sections, there are then two fields or pockets of the feed plate in each case between two bridging elements of the outer cylinder present in the form of vanes or paddles, so that on the one hand it is easy for the animals to take the feed and, on the other, it is rendered more difficult for them to scatter feed sideways out of the feed bowl. Because of the seven feed stand positions selected in the threaded connection between the outer cylinder and screw ring and because of the hinge connection between the feed plate and bowl cupola, the seven paddles or vanes can come into unambiguous concordance in relation to the fields or pockets of the feed plate.
[0035] 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
[0036] An embodiment of the invention, from which further inventive features can be derived, is represented in the drawings. These show:
[0037] FIG. 1 is a view of the bowl device suspended on the feed delivery pipe, for the feeding of broilers.
[0038] FIG. 2 is a view of an outer cylinder.
[0039] FIG. 3 is a side view of the outer cylinder according to FIG. 2 , in a half-section.
[0040] FIG. 4 is a view of the inner cylinder, with upper pipe adapter for securing to the feed delivery pipe without a closing upper part.
[0041] FIG. 5 is a side view of the inner cylinder, in a half-section.
[0042] FIG. 6 is a side view of the device according to FIG. 1 , in a half-section with the feed delivery pipe raised, so that the feed bowl hangs freely above the floor of a coop.
[0043] FIG. 7 is the unit of a downpipe, formed from the inner cylinder and the outer cylinder guided on this, in a sectional view along the line VII-VII in FIG. 6 .
[0044] FIG. 8 is a side view of the device with the feed delivery pipe lowered, so that the feed bowl is resting on the floor of the coop.
[0045] FIG. 9 is a section through the downpipe of the device according to FIG. 8 , consisting of inner cylinder and outer cylinder, in a section along the line IX-IX in FIG. 8 .
[0046] FIG. 10 is a view of a feed bowl, in which, to make the feed plate clearer, the bowl cupola has been removed.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0047] The device for feeding free-range poultry for fattening kept in a coop, and broilers in particular, consists of at least one feed delivery pipe 1 , held above the floor of the coop in a lowerable manner, which runs along the entire length of the coop and, by means of a delivery worm element located inside it, or a cable or a chain with delivery disks, transports feed capable of scatter distribution to individual bowl devices 2 suspended on the feed delivery pipe 1 . The parts described can also be designated in their entirety as the feed line.
[0048] In FIG. 1 , only one part of the feed delivery pipe 1 is represented, with a bowl device 2 suspended in the area of a branch aperture in the feed delivery pipe 1 . The bowl device 2 comprises a downpipe 3 , departing from a branch aperture not further visible here, and a feed bowl 4 located beneath the downpipe 3 , with bowl cupolas 6 formed from grid bars 5 running in spoke fashion. In this situation, the downpipe 3 consists of an inner cylinder 7 , departing from the branch aperture not visible here, and an outer cylinder 8 , surrounding the inner cylinder 7 , on which the bowl 4 is suspended by means of the grid bars 5 of its bowl cupola 6 , in such a way that, when the feed delivery pipe 1 is lowered, it comes to rest, and in particular comes to rest on the floor 34 of the coop, not represented any further here. The outer cylinder 8 is guided in rotatable fashion at the inner cylinder 7 and in a raisable and lowerable manner, whereby at least one lifting stop is provided to delimit the lifting and lowering path, which will be described in greater detail hereinafter.
[0049] FIG. 2 shows a view of the outer cylinder 8 .
[0050] In FIG. 3 , a side view of the outer cylinder 8 according to FIG. 2 is shown, in a half-section.
[0051] FIGS. 2 and 3 are explained in greater detail hereinafter.
[0052] The outer cylinder 8 consists of adjacent cylinder sections 8 ′ and 8 ″, co-axial to each other. The cylinder sections 8 ′ and 8 ″ are connected to each other by means of bridging elements 9 , each of which is designed as a paddle or vane 10 , projecting over the periphery of the outer cylinder 8 into the feed bowl 4 . The bridging elements 9 bridge the gap area 11 , which corresponds to the distance between the cylinder sections 8 ′ and 8 ″ of the outer cylinder 8 , or in this case its upper cylinder section 8 ′, features a recess 13 , which is part of a lifting stop 14 . The outer surface of the upper cylinder section 8 ′ of the outer cylinder 8 is designed in the upper end part as a threaded spindle 15 , which has screw threads 16 .
[0053] The outer cylinder is made of suitable plastic material, with the result that the screw threads 16 and therefore the threaded spindle 15 can be shaped without problem during the manufacture of the outer cylinder 8 .
[0054] As FIG. 1 also shows, the free ends of the grid bars 5 of the bowl cupola 6 are connected to a screw ring 17 , which can be screwed onto the area designed as a threaded spindle 15 of the cylinder section 8 ′ of the outer cylinder 8 .
[0055] At the rotation of the feed bowl 4 , relative to the outer cylinder 8 , the threaded spindle 15 causes a movement of the feed bowl 4 in respect of the height, towards the lower end of the cylinder section 8 ″ with the vanes 10 of the outer cylinder 8 .
[0056] FIGS. 2 and 3 further show that a rotational stop delimiting the rotational path of outer cylinder 8 in relation to the inner cylinder 7 features a driver dog 19 , located in this case on the inner surface 18 of the outer cylinder 8 , into the rotation path of which he elevation 21 arranged on the outer surface 20 of the inner cylinder 7 projects during the rotation of the outer cylinder 8 about the inner cylinder 7 .
[0057] FIG. 4 shows a view of the inner cylinder 7 , which consists of cylinder sections 7 ′ and 7 ″, whereby the open gap area between the cylinder sections 7 ′ and 7 ″ is again bridged by bridging elements 23 in flat web form. In FIG. 4 , a part of the lifting stop 14 is visible, which at the inner cylinder 7 is designed as at least one abutment shoulder 24 for the recess 13 in the outer cylinder 8 , projecting radially from the inner cylinder 7 .
[0058] FIG. 4 shows that each abutment shoulder 24 for the recess 13 is a part of a radial projection 25 of the inner cylinder 7 , similar to a collar flange in shape. FIG. 4 also shows that the outer surface 20 of the inner cylinder 7 , in the upper area and therefore in the area of its head part, is offset by means of a reduced cylinder diameter in relation to the other part of the cylinder section 7 ′ of the inner cylinder 7 . The offsetting step is designated by 26 .
[0059] FIG. 2 further shows that, to provide securing against rotation of the structural unit consisting of the screw ring 17 ( FIG. 1 ) with bowl cupola 6 and the feed bowl 4 , there is provided at each outer cylinder 8 , in its area designed as a threaded spindle 15 , two spring-elastic engagement cams 27 . Each engagement cam 27 is connected by means of a spring-elastic tongue 28 to the outer cylinder 8 . In this situation, removal from the mold is effected in such a way that the tongues are wall parts of the outer cylinder, formed by insertion cuts, which are capable of springing from the outside inwards under radial pressure and can be moved back elastically into the initial position when the pressure is released. In the pressureless initial position, the tongues 28 are flush again with the wall of the outer cylinder 8 .
[0060] FIG. 5 shows a side view of the inner cylinder, whereby the right half of the inner cylinder is shown in a longitudinal section.
[0061] The same components are designated with the same reference numbers.
[0062] FIG. 4 in particular shows that the inner cylinder 7 in its upper free end is involved in the formation of a pipe adapter, in that a bowl half 29 of the pipe adapter is formed on the inner cylinder 7 . This bowl half can be supplemented to form the pipe adapter by the imposition of an upper part 30 , which is visible in FIG. 1 , which encompasses the feed pipe 1 in the area of a branch aperture, not further shown, in such a way that the branch aperture is flush with the fall aperture 31 in the upper bowl part 29 of the inner cylinder 7 . Feed emerging from the feed delivery pipe passes over the branch aperture and the fall aperture 31 into the inner cylinder, and can fall into the feed bowl via the gap area 22 or into the lower fall aperture 32 . The lower fall aperture 32 is circumscribed by the lower edges 33 of the cylinder section 7 ″.
[0063] FIG. 6 shows, in a side view, a bowl device 2 suspended on a feed delivery pipe 1 , whereby the right-hand side is shown in section. The same components are designated with the same reference numbers.
[0064] It can be seen from FIG. 6 that the inner cylinder 7 is designed in such a way that its end-side cylinder section 7 ″ covers the gap area 11 between the cylinder sections 8 and 8 ″ of the outer cylinder 8 , when the outer cylinder 8 is moved by a raising of the feed delivery pipe 1 into a position which is lowered in relation to the inner cylinder 7 , in which the parts forming the lifting stop 14 are in opposing positions. With this embodiment, it can be seen in FIG. 6 that the outer cylinder 8 , with the step surface formed by its recess 13 in the cylinder section 8 ′, is in contact on the abutment shoulder 24 of the radial projection 25 of the inner cylinder 7 . Feed material entering the inner cylinder 7 from the feed delivery pipe is represented here by dots, and trickles into the feed bowl 4 , whereby it trickles out of the lower fall aperture 32 of the inner cylinder 7 into the cylinder section 8 ″ of the outer cylinder 8 , and from there directly into the feed bowl 4 . This feed covers the conically-shaped floor of the feed bowl 4 , likewise made of plastic, in a flat dispersal, as can be seen here. Poultry running about on the floor 34 of the coop can reach the feed located in the depth of the feed bowl 4 .
[0065] The height of the dispersal cone of feed above the floor of the feed bowl 4 is adjustable. To regulate the feed level, or to adjust what is referred to as the feed stand position, the screw ring 17 , to which the grid bars 5 of the bowl cupola 6 are connected, is rotated about a height axis. Depending on the rotation path and pitch of the screw threads 16 , the position of the bowl is displaced in relation to the lower emergence edge 35 of the lower free end of the outer cylinder section 8 ″.
[0066] FIG. 7 is a sectional view along the line VII-VII in FIG. 6 . The same components are designated by the same reference numbers. FIG. 7 shows that the inner cylinder 7 , of which the cylinder section 7 ′ is visible here, is encompassed by the outer cylinder 8 , or by its cylinder section 8 ′, visible here. The outer cylinder, in the position represented here, is therefore freely rotatable about the inner cylinder 7 . In FIG. 7 , the driver dogs 19 can be seen which are arranged on the inner surface of the outer cylinder 8 .
[0067] The screw ring 17 features on its inner circumferential surface 36 cut-outs 37 . Engagement cams 27 , which are mounted on the spring-elastic tongues 28 , can engage with the cut-outs 37 , so that the screw ring 17 , with the engagement cams 27 engaged in the cut-outs 37 , cannot be rotated in relation to the outer cylinder 8 . The feed level, once set, can be maintained. In the event of rotational forces being imposed on the feed bowl or via its bowl cupola on the screw ring 17 , the unit consisting of the outer cylinder 8 , screw ring 17 , bowl cupola 6 and feed bowl 4 will rotate only in relation to the inner cylinder 7 . The inner cylinder 7 cannot rotate together because of its suspension on the feed delivery pipe 1 .
[0068] FIG. 8 shows a side view according to FIG. 6 , whereby the right half is in turn shown in section. The feed delivery pipe is lowered in the position shown in FIG. 8 , so that it runs at a slight distance above the floor 34 of the coop. The feed bowl 4 , in the position shown in FIG. 8 , rests on the floor 34 of the coop, as a result of which the unit formed by the outer cylinder with the bowl cupola 6 and the feed bowl 4 is raised in relation to the inner cylinder 7 . In this position, the recess 13 forming the lifting stop 14 and the abutment shoulder 24 of the inner cylinder 7 are no longer in mutually opposed positions. The outer cylinder 8 with its cylinder sections 8 ′ and 8 ″ are therefore raised in relation to the inner cylinder to such an extent that the gap area 11 between the cylinder sections 8 ′ and 8 ″ of the outer cylinder 8 is congruent with the gap area 22 between the cylinder sections 7 ′ and 7 ″ of the inner cylinder 7 . As a result of the congruent open gap areas 11 and 22 , which form a “360° window”, the feed can additionally pass to the lower fall aperture 32 into the feed bowl 4 , as is represented here by dots. The feed level in the feed bowl 4 is simultaneously higher, with the result that even young animals, such as chicks, can reach over the edge of the feed bowl 4 to the feed, which now stands higher in the feed bowl 4 .
[0069] FIG. 8 also indicates that the upper area of the cylinder section 8 ′ of the outer cylinder 8 , which is provided with screw threads 16 , onto which the threaded ring 17 is screwed, are now raised to such an extent that the driver dogs 19 , not visible here, can be brought into effective connection by means of an elevation 21 or 21 ′ of the inner cylinder 7 .
[0070] FIG. 9 again shows that the elevations 21 and 21 ′ on the outer surface 20 of the cylinder section 7 ′ of the inner cylinder 7 can come in contact with the driver dogs 19 , which project from the inner surface 18 of the cylinder section 8 ′ of the outer cylinder 8 . The driver dogs 19 of the fixed inner cylinder 7 prevent the further rotation of the outer cylinder 8 beyond the position of the elevation 21 and 21 ′. The outer cylinder 8 can therefore only be rotated through 180° in each case, and further rotation is accordingly stopped by the elevation 21 or 21 ′ respectively. If the outer cylinder is nevertheless rotated further, for example in order to change the level of the feed with the aid of the threads on the outer cylinder and with the aid of the screw ring 17 , then the engagement cams 27 , because of their oblique flanks 38 , will be pressed out of the cut-outs 37 in the screw ring, said cut-outs also being provided with oblique edges 39 . The engagement cams 27 are in this situation deflected inwards, and specifically against the elastic resetting force of the tongues 28 . With the corresponding further rotation into the next feed position, which is indicated here by numbers on the screw ring, the engagement cams 27 can engage again in the next cut-out 37 , as shown in FIG. 7 .
[0071] FIG. 10 shows the view of a bowl device, of which the bowl cupola has been left out for simplification of the internal arrangements of the feed bowl 4 . The same components are designated with the same reference numbers.
[0072] FIG. 10 shows in particular that the feed bowl 4 features a feed plate, which in the area of its plate edge 40 features connecting elements 41 and 42 for connection to the bowl cupola 6 , not visible here. The connecting elements 41 and 42 comprise a folding joint 43 and at least one locking or retention element 44 . A ring surface of the feed plate, which runs around the plate center located beneath the downpipe 3 , is subdivided into feeding sections, whereby each feeding section consists of at least one pocket, one field, or similar shaped area 45 , delimited by depression or elevation. The number of feeding sections is equal to a multiple of the number of the bridging elements 9 of the outer cylinder 8 , formed as paddles or vanes 10 , of which the cylinder sections 8 ′ and 8 ″ are visible here, with the gap area 11 located between them.
[0073] The above description is considered that of the preferred embodiment only. Modification 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 embodiment shown in the drawings and described above is 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. | A device for feeding poultry kept in a barn, comprises at least one food supply tube ( 1 ) which is held above the floor of the barn such as to be able to be lowered or raised, with a series of branch openings, each provided with a dish device ( 2 ) hanging on the supply tube, comprising a dropping tube extending from the branch opening and a feeding dish ( 4 ) arranged below, the dropping tube with a spoked arrangement of lattice bars ( 5 ) forming the cup of the dish. The dropping tube comprises an inner cylinder ( 7 ) leading off from the branch opening and an outer cylinder ( 8 ) surrounding the inner cylinder, from which the dish hangs by means of the lattice bars, such as to be placed on the floor of the barn in the lowered state of the food supply tube. The outer cylinder runs on the inner cylinder such as to rotate, be raised or lowered and at least one stop is provided for limiting the raising and lowering stoke. The outer and the inner cylinder each comprise adjacent cylindrical sections ( 8′, 8, 7′, 7 ) coaxial to each other, whereby front face regions of the cylinder sections turned to face other are connected to each other by means of bridging bodies (9, 23), which bridge a gap region corresponding to the separation between the cylinder sections. | 0 |
BACKGROUND OF THE INVENTION
[0001] The present disclosure relates to a heat exchanger for an aircraft and, in particular, to using a thermoelectric device to regulate the heat of fuel used to cool a controller of the aircraft.
[0002] An aircraft has a number of electronic controllers used to control an operation of the aircraft. One such controller manages the function of the aircraft engines and is commonly known as a Full Authority Digital Engine Control or FADEC. The FADEC is generally installed in an environment of the aircraft susceptible to both very high temperatures and very low temperatures. For example, the FADEC may be installed in the engine bay where large amounts of heat are generated during flight conditions. In these conditions, the FADEC requires a substantial amount of cooling to regulate its operating temperature. When the aircraft is not in flight, however, the engine bay may be extremely cold when ambient air temperature is low. At these conditions, the FADEC requires very little, if any, cooling.
[0003] The FADEC, like many aircraft controls, is composed of electronic components that require moderate and uniform temperatures for optimal operation. The large temperature swings experienced by the FADEC is not conducive to the best performance of these temperature sensitive components. While there are electronic components that are capable of performing at the extreme temperature conditions of the aircraft, these components are generally very expensive and have relatively low performance (memory, process, reliability, or speed) compared to most modern electronics.
[0004] A need therefore exists for an assembly and technique that maintains the electronics of an aircraft controller within their designed operating temperatures.
SUMMARY OF THE INVENTION
[0005] According to one embodiment, a heat exchange system for an aircraft control is disclosed. The system includes an aircraft controller for controlling an operation of an aircraft, a thermoelectric device having a low temperature side and a high temperature side, an inlet line that carries fluid through the low temperature side of the thermoelectric device and to the aircraft controller and an outlet line that carries the fluid away from the and aircraft controller through the high temperature side of the thermoelectric device. In this embodiment, heat is transferred away from the inlet line to the outlet line through the thermoelectric device when a predetermined condition is met.
[0006] According to another embodiment, an aircraft including any of the heat exchanger systems or heat exchange methods contained herein is disclosed.
[0007] According to yet another embodiment, a method of cooling a Full Authority Digital Engine Control (FADEC) of an aircraft is disclosed. The method includes: pumping fuel from a fuel tank via an input line to the FADEC through a low temperature side of a thermoelectric device; pumping the fuel from the FADEC via an output line through a high temperature side of the thermoelectric device back to the fuel tank; applying an electrical signal to the thermoelectric device to cause heat from fluid in the input line to be transferred to fluid in output line.
[0008] Additional features and advantages are realized through the techniques of the present disclosure. Other embodiments and aspects of the disclosure are described in detail herein. For a better understanding of the disclosure with the advantages and the features, refer to the description and to the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The subject matter which 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 features, and advantages of the invention are apparent from the following detailed description taken in conjunction with the accompanying drawings in which:
[0010] FIG. 1 shows a high level block diagram of heat exchange system where engine fuel is used as a cooling liquid to cool a FADEC;
[0011] FIG. 2 shows a more detailed depiction of an example of a thermoelectric device that may be utilized in one embodiment; and
[0012] FIG. 3 shows a more detailed version of a system according to one embodiment.
DETAILED DESCRIPTION OF THE INVENTION
[0013] Embodiments described herein to closed loop cooling system for a FADEC. The FADEC may be part of an aircraft and, as such, embodiments disclosed herein may be implanted on an aircraft. The system may utilize thermoelectric (TE) device positioned between the inbound and outbound fuel lines providing cooling fuel to the FADEC. In one embodiment, the TE device is superlattice device. The TE cooler, when powered, “pumps” heat from the inbound fuel line and provides that heat to the hot, outbound fuel line. According to one embodiment, the TE device is sized to handle fuel temperatures up to 190° F. at flow rates currently used for FADEC cooling. Closed loop control is achieved when fuel temperature sensing is applied to the inbound flow. When temperatures exceed inbound limits, a controller adjusts power provided to the TE device to effect cooling of the fuel to keep inbound fuel temperatures at the desired level.
[0014] FIG. 1 shows a high level block diagram of heat exchange system 100 where engine fuel is used as a cooling liquid to cool a FADEC. Most generally, the system includes a fuel tank 102 , one or more pump (shown as pump 103 ), a TE device 104 and electronics to be cooled 106 . In the following discussion the electronics may be referred to as a FADEC but is shall be understood that other electronics or even other non-electronic devices may be cooled in the manner disclosed herein. As such, while FADEC is used as a description, unless specifically required, the electronics to be cooled 106 are not limited to a FADEC.
[0015] Engine fuel is stored in a reservoir or fuel tank 102 . The tank 102 may be a primary fuel tank used for all engines or an individual tank used for a single engine. Further, the tank 102 may be a portion of a larger tank. A pump 103 is provided that can pump fuel out of the tank 102 . This pump 103 may be a single pump or may include more than one pump. Regardless of the configuration, the pump 103 causes fuel form the tank 102 to be provided through an input line 110 to the FADEC 106 . The input line 110 passes through a low temperature heat source side 120 (referred to as “low temperature side” hereinafter) of the TE device 104 before being provided to the FADEC 106 . The fuel in the input line 110 passes through, around or near the FADEC 106 such that heat from the FADEC 106 is transferred to the fuel. The fuel then returns to the fuel tank 102 via return line 112 . Before returning the fuel tank 102 via return line 112 , the fuel passes through the high temperature heat sink side 122 (referred to as “high temperature side”) hereinafter of the TE device 104 . In general, to the extent that the TE device removed heat from the fuel as it passed through the low temperature side 120 , that heat is at least partially transferred to the fuel in the return line 112 as it passes through the high temperature heat sink side 122 of the TE device 104 .
[0016] In operation, fuel enters the lower temperature side 120 of the TE device 104 at a first temperature T 1 . When operating, the energy (heat) is removed from the fuel by the TE device 104 such that it leaves the TE device at a second, lower temperature T 2 . The fuel then enters the FADEC 106 where it has heat transferred to it and leaves the FADEC at T 3 . It is assumed that in operation, T 3 is greater than T 2 .
[0017] As mentioned above, as the fuel in the return line 112 is passed through the high temperature side 122 of the TE device 104 , heat removed from the fuel at the low temperature side 120 is added to the fuel such that it exits the TE device 104 at an even higher temperature T 4 . That is, T 4 is greater than T 3 when the TE device is operating.
[0018] In one embodiment, the TE device 104 may be formed such that that application of a voltage and current causes heat in one location to be moved to another location. With reference to FIG. 2 , application of a voltage V and current to the low temperature side causes heat from to move from one side of the TE device to the other. The direction of the travel is based on the polarity of the voltage and the rate is based on the magnitude of the current. As shown, the direction of heat travel is against the temperature gradient.
[0019] As discussed above, and now with reference to FIG. 3 , at times the TE device 104 may not be operating to remove heat from the input line 110 . Such a case may exist when T 1 is sufficiently low to cool the FADEC 106 without having heat removed from it. To that end, in one embodiment, the system 100 may include a temperature sensor 304 that measures the temperature of the fuel in the input line 110 after it exits the TE device 104 . Of course, the position of the sensor could be moved such that it is upstream (e.g., closer to the tank 102 than the TE device 104 ) of the TE device 104 in one embodiment.
[0020] In such a system a sensor 302 is also provided that measures the temperature in or near the FADEC 106 . While shown in the FADEC itself, it shall be understood that the sensor need only be able to measure the temperature of the FADEC and does not have to necessarily be within it. Based on the two temperatures, a cooling controller 306 determines how much (if any) heat needs to be removed from the fuel such that T 2 is at a level that may effectively cool the FADEC 106 . In one embodiment, the TE device 104 may operate when the temperature of the fluid leaving it is over a predetermined level. In another embodiment, the operation of the TE device 104 may depend on a difference in the temperature measured by sensor 302 and that measured by the temperature sensor 304 . That is, the TE device may operate when a difference between a temperature of the fuel leaving the TE device 104 and a temperature of the FADEC 106 is below a limit difference.
[0021] Regardless, the amount of change needed will determine the voltage polarity and current level provided on line 308 to set the rate at which the TE device 104 removes heat from the input line 110 . The exact manner in which voltage and current is applied will depend on the type/configuration of the TE device 104 used.
[0022] The above description provides for a system 100 that works in a closed loop manner to control the cooling of a FADEC 106 . The “closed” refers to the means of controlling the temperature. For example, an open loop temperature control is one that sets temperature based on a table or some other condition that is fixed. As here, a closed loop system closes the control loop by measuring temperature and commanding a response (e.g., turning on the TE device).
[0023] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one more other features, integers, steps, operations, element components, and/or groups thereof.
[0024] While the invention has been described in detail in connection with only a limited number of embodiments, it should be readily understood that the invention is not limited to such disclosed embodiments. Rather, the invention can be modified to incorporate any number of variations, alterations, substitutions or equivalent arrangements not heretofore described, but which are commensurate with the spirit and scope of the invention.
[0025] Additionally, while various embodiments of the invention have been described, it is to be understood that aspects of the invention may include only some of the described embodiments. Accordingly, the invention is not to be seen as limited by the foregoing description, but is only limited by the scope of the appended claims. | A heat exchange system for an aircraft includes an aircraft controller for controlling an operation of an aircraft, a thermoelectric device having a low temperature side and a high temperature side, an inlet line that carries fluid through the low temperature side of the thermoelectric device and to the aircraft controller; and an outlet line that carrier the fluid away from the and aircraft controller through the high temperature side of the thermoelectric device. Heat is transferred away from the inlet line to the outlet line through the thermoelectric device when a predetermined condition is met. | 1 |
BACKGROUND OF THE INVENTION
The present invention relates to an automatic gate opener and, more particularly, to an automatic gate opening device that may be used at locations where commercial electricity is not economically available. By proper linkage and utilization of a hydraulic cylinder with a bidirectional gear pump, a gate may be opened and closed with appropriate electronic controls. The electronic controls may provide different types of sensors as well as a manual override for the opening and closing of the gate. Storage batteries can be used for providing the energy to operate the gate opening device and solar panels can be used for the recharging of the battery. By the appropriate electronic controls, this may be done automatically.
DESCRIPTION OF THE PRIOR ART
In ranch country, there may be a large number of acres fenced in with gates for roads going through the fenced acreage. Many times, commercial electricity is not available for the operation of the gates. If the roads are traveled fairly often, it is a tremendous inconvenience for individuals to have to stop to open and close the gates.
If a system for opening a gate is designed for operation off of a battery, it is very important that the system be highly efficient, or the battery will rapidly discharge and have to be recharged by commercial means.
Just as radio signals have been used to operate garage door openers, similar type radio signals have been used to operate gates. However, commercially available power is normally available and it is not critical for the system to be highly efficient.
Various types of gate or door opening devices have been designed in the past to utilize hydraulic cylinders and mechanical linkage. A typical such device is shown in U.S. Pat. No. 3,936,977 issued to Runft, et al., which has a double acting power cylinder. Pivotal interconnecting linkage is utilized to open a door depending upon the fluid operating the control piston inside of the cylinder.
Other types of gate opening devices have utilized a ram such as that shown in Vollmar (U.S. Pat. No. 3,500,585). The ram must be pivotally mounted and pivotally connected to the gate, plus have a motor to operate the ram. Such a system is not very efficient or practical for remote locations without commercially available power. In Vollmar, the entire motor pivots with the ram.
Further examples of typical prior art can be found in U.S. Pat. No. 3,645,042 issued to Bolli; U.S. Pat. No. 2,592,891 issued to Hall; and U.S. Pat. No. 4,231,190 issued to Tieben.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an automatic gate opening device.
It is another object of the present invention to provide an automatic gate opener that may be used at locations where commerical electricity is not economically available.
It is still another object of the present invention to provide a gate opener operated by a hydraulic cylinder controlled by a bidirectional gear pump with a cylinder rod operating pivotal linkage to open and close a gate, such pivotal linkage possibly including as many as six pivot points.
It is yet another object of the present invention to provide electronic controls for an automatic gate opener, which electronic controls provide a number of different options as far as available power that can be used, as well as different means for actuation and sensors to determine gate position.
It is another object of the present invention to provide a solar powered gate opener that may be used at remote locations, which gate opener is highly efficient.
The mechanical portion of the gate opener has a stationary base on which is pivotally mounted a hydraulic cylinder that may be operated in either direction by a bidirectional gear pump. The cylinder rod from the hydraulic cylinder connects to an opening rod with a center pivot linkage. The opening rod has one end pivotally connected to a stationary based. The oppose end of the opening rod is pivotally connected to the gate. The bidirectional gear pump may provide fluid to either end of the hydraulic cylinder, which hydraulic cylinder operates a piston contained therein for movement of the cylinder rod. Movement of the cylinder rod opens and closes the gate.
The control portion of the automatic gate opener operates the motor of the bidirectional gear pump. Sensors may be located on either end of the hydraulic cylinder to limit the amount of fluid supplied to the hydraulic cylinder, and hence control the position of the gate. Other sensors may be located in other positions to also determine the position of the gate. The gate may be opened or closed manually, by radio frequency signals or by automatic sensing devices. The particular type sensor to be used is left to the preference of the owner. A storage battery is used to provide energy for the automatic gate opener, which storage battery may be recharged either by a battery charger or by a solar device. Also, alternatively, energy may be received from commercially available electricity; however, the system is designed for use at locations that do not have commercially available electricity.
By the use of solid state switching, essentially no energy is being used when the gate is not being opened or closed. When the gate is being opened and closed, it is with the minimum amount of energy drain.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a pictorial overhead view of the mechanical portion of an automatic gate opener with the gate closed.
FIG. 2 is a pictorial overhead view of the mechanical portion of an automatic gate opener with the gate open.
FIG. 3 is a perspective view of the automatic gate opener as installed.
FIG. 4 is an elevational view of the active components of the automatic gate opener prior to installation with the housing of a control box being open.
FIG. 5 is a block diagram of electrical components of the automatic gate opener.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIGS. 1 and 2 of the drawings in combination, there are shown overhead illustrative views of a gate 10 pivotally mounted on pivot point 12 to fence 14. Fence 14 has an opening 16 that is closed by the gate 10 to prevent livestock or other animals from getting across the fence 14. The opposite end of the gate 10 from the pivot point 12 rests against stop 18 when closed.
Operating the gate 10 is an automatic gate opener 20 which is pictorially illustrated in FIGS. 1 and 2. The automatic gate opener 20 has a base support 22 that may consist of any suitable structure, such as a poured concrete block. Mounted on the base support 22 is a mounting bracket 24 and a mounting bracket 26. Pivotally connected to mounting bracket 26 by means of pivot support 28 and clamp 30 is a hydraulic cylinder 32.
Inside of hydraulic cylinder 32 is a piston (not shown) to which is connected cylinder rod 34. As the piston in hydraulic cylinder 32 moves back and forth, the cylinder rod 34 attached thereto also extends and retracts. One end of the cylinder rod 34 is pivotally connected by pivot pin 36 to opening rod 38. A first end of opening rod 38 is connected through pivot pin 40 to mounting bracket 24 on base support 22. It should be realized that the base support 22 with the mounting brackets 24 and 26 is not movable.
The opposite end of the opening rod 38 is connected by pivot pin 42 to gate 10.
A control box 44 contains the appropriate electronic controls and a hydraulic fluid device (as will be explained in more detail subsequently) to open and close the gate 10. Hydraulic lines 46 and 48 receive hydraulic fluid from the control box 44 upon receiving an appropriate contol signal. Assume that control box 44 received a signal to open gate 10, hydraulic fluid will be supplied through hydraulic line 46 to retract the cylinder rod 34 inside of the hydraulic cylinder 32 as pictorially illustrated in FIG. 2. Upon the piston inside of the hydraulic cylinder 32 reaching a predetermined location, sensor 50 will sense the position of the piston and send a signal back to control box 44 to stop the flow of hydraulic fluid through hydraulic line 46 to stop the movement of the gate 10. The sensor 50 will only be activated when the gate 10 is opened as shown in FIG. 2.
Thereafter, if the control box 44 receives a signal to close the gate 10, hydraulic fluid is received through hydraulic line 48 from the control box 44 thereby projecting the cylinder rod 34 from the hydraulic cylinder 32 to close the gate 10 as shown in FIG. 1. At the time that gate 10 is closed, a sensor 52, which again detects the position of the piston inside of the hydraulic cylinder 32, sends a signal to the control box 44 to stop the flow of hydraulic fluid through hydraulic line 48. This should occur simultaneously with the gate 10 being closed as shown in FIG. 1.
By using the type of pivotal linkage as illustrated in FIGS. 1 and 2, the minimum amount of energy necessary for opening and closing the gate 10 is expended. A center pivot point 54 of the opening rod 38 allows the force being used to open gate 10 to be applied as close to perpendicular to the gate 10 as possible. This prevents the hydraulic cylinder 32 from exerting any more force than is absolutely necessary against pivot point 12 and opening the gate 10. When the gate 10 is closed, opening rod 38 with pivot point 54 acts as a knee brace to hold the gate 10 closed.
Other than a manual switch for control box 44, other types of sensors may be utilized, such as magnetic vehicle sensors 56 and 58. On either side of the approach path for the gate 10, magnetic vehicle sensors 56 and 58 may send a signal to the control box 44 upon a vehicle moving thereacross. The magnetic vehicle sensors 56 and 58 send a signal to the control box 44 in response to a change in the magnetic flux created by a vehicle moving thereacross. Such a magnetic vehicle sensor 56 or 58 can provide an automatic control signal for control box 44 to open or close the gate 10. This is an optional feature and other types of controls may be used as will be explained in more detail subsequently.
A switch 60 may be mounted on stop 18 to send a signal to the control box 44 when the gate 10 is closed. Likewise, a switch 62 may be mounted on mounting bracket 26 to indicate when the gate 10 is open. The switches 60 and 62 stop the flow of hydraulic fluid from the control box 44 through hydraulic lines 48 and 46, respectively, when the gate 10 is closed or opened, respectively. It should be realized that switches 60 and 62 are redundant with sensors 52 and 50, respectively, and provide an alternate control. The internal workings of the control box 44 will be shown in more detail subsequently.
Referring to FIG. 3, there is shown a perspective view of the gate 10 closed with the automatic gate opener 20 being shown in more detail. In the configuration as shown in FIG. 3, the auxiliary controls of magnetic vehicle sensors 56 and 58 and switches 60 and 62 have not been included. A control cable 64, which contains the hydraulic lines 46 and 48, therein also send signals from sensors 50 and 52 to the control box 44. Also as illustrated in FIG. 3 and as will be explained in more detail subsequently, a solar panel 66 may be used to recharge a storage cell or battery as may be contained in control box 44 during daylight hours.
Referring now to FIG. 5, the electronic controls and hydraulic system as contained in control box 44 will be explained in more detail. The solar panel 66 is used to recharge the storage batteries 68 as contained inside of the control box 44. While many different types of storage batteries can be used, applicant has found that a 12 volt battery with 5 amp hours with 80 amp peak current capability to be particularly suited for the present application. Also, the storage battery 68 may be recharged by an convenient means, such as a battery charger 70, if solar power is not appropriate. Also, rather than using storage battery 68, standard 120 volt AC power can be used with an appropriate converter to change the voltage to a constant DC voltage.
The storage battery 68 supplies power for a sensor amplifier 72; latching, logic and timing circuit 74; and a motor 78 via a solid state motor switch 76.
Assume that a manual actuate button 80 is pushed sending a signal to sensor amplifier 72 to either open or close the gate 10. Sensor amplifier 72 will amplify the signal to the latching, logic and timing circuit 74 to indicate the gate 10 should be either opened or closed. The latching, logic and timing circuit 74 will operate solid state motor switch 76 thereby causing the motor 78 to turn in either the forward or reverse direction. Depending upon the direction the motor 78 is turning, a bidirectional gear pump 82 is likewise turned. Depending upon the direction the bidirectional gear pump 82 is turned, hydraulic fluid will flow under pressure through either hydraulic line 46 to open the gate 10, or under pressure through hydraulic line 48 to close gate 10. The pressurized fluid being received inside of hydraulic cylinder 32 will move the piston 84 either to the right or left. Movement of the piston 84 to the left will cause the cylinder rod 34 to be retracted therein to open the gate 10. Movement of the piston 84 to the right will cause the cylinder rod 34 to be extended from the hydraulic cylinder 32 thereby closing the gate 10. As previously explained, sensors 50 and 52 will detect the piston 84 when it moves contiguous therewith. Displaced hydraulic fluid flows back through either hydraulic line 46 or 48 to bidirectional gear pump 82.
The sensing by sensors 50 or 52 of the piston 84 will cause a signal to be sent to latching, logic and timing 74 to switch the solid state motor switch 76 thereby cutting OFF power to the motor 78. This stops the flow of hydraulic fluid through the bidirectional gear pump 82 to the hydraulic cylinder 32, which in turn stops the movement of the gate 10.
In addition to the manual actuate button 80 as previously described, an optional feature includes a radio actuate 86, which is simply a radio transmitter similar to those used for garage door openers. The sensor amplifier 72 may have to be modified to have a receiving device therein prior to sending a signal to the latching, logic and timing circuit 74. Thereafter upon receiving a signal from the radio actuate 86, a signal is generated and sent to the latching, logic and timing circuit 74.
As another optional feature, magnetic vehicle sensors 56 and 58 as previously described can be utilized to determine if a vehicle is approaching the entrance to the gate. In the same way as an automatic magnetic triggering device would trigger a traffic light, sensors 56 and 58 can open and close the gate 10 upon a vehicle approaching the gate 10. However, for security purposes, an individual may elect not to include the magnetic vehicle sensors 56 and 58 depending upon their particular circumstance.
It should be realized that various options could be utilized, including switches 60 and 62 as previously described in conjunction with FIGS. 1 and 2, which options have not been described. Many different types of sensors for opening and closing the gate 10 are entirely feasible. Also many different alternative sources of power may be used; however, applicant particularly envisions this automatic gate opening device to be used at remote locations where commerical power is not readily available.
While different types of devices are available for providing pressurized hydraulic fluid, applicants have found a bidirectional gear pump 82 to be particularly efficient and require less energy than many other types of hydraulic devices.
Referring now to FIG. 4, the component parts requiring energy or generating energy are shown. The solar panel 66 is connected through conduit 88 to the control box 44. The door 90 of the control box 44 is opened to show the internal component parts. Inside of the control box 44 is located the motor 78, which drives the bidirectional gear pump 82, located within a hydraulic fluid reservoir. A manual actuate 80 is provided by switch 96 to either open or close the gate 10. A manual ON-OFF power switch 98 is also provided.
Upon installation of the automatic gate opening device as previously described hereinabove, there is a total of six pivot points including pivot point 12, pivot pin 42, center pivot point 54, pivot pin 36, pivot support 28, and pivot pin 40. Each of these pivot points should pivot about a vertical axis with respect to a horizontal plane. However, because a gate may not be mounted entirely perpendicular, and because the pivot points of the automatic gate opener 20 may not all operate in the same horizontal plane, pivot pin 42, pivot support 28, and pivot pin 40 should be able to rotate at least to a limited degree about a horizontal axis. Therefore, the mounting supports for these pivot points should be of such a nature to allow such pivotal rotation about the horizontal axis. Applicants have particularly found that the use of a self-locking bolt 100, which provides a loose connection with the mounting structure, to be particularly suitable for allowing the limited rotational movement about a horizontal axis. This prevents possible binding upon opening and closing of the gate 10. Many different types of connectors to allow pivotal motion along two axes may also be used. (See FIGS. 1 and 2.)
Referring back to the block diagram as shown in FIG. 5, the sensor amplifier 72 is on a 24 hour standby so that if a sensor is actuated, the signal is immediately amplified and provided to the latching, logic and timing circuit 74. This allows the minimum amount of power drain to keep the sensors in a standby condition. The latching, logic and timing circuit 74 is normally OFF as well as the solid state motor switch 76. The latching, logic and timing circuit 74 and the solid state motor switch 76 are only energized when the gate 10 is being opened or closed. This type of standby sensor draws approximately 1 milliamp in the 24 hour standby mode whereas commercially available gate openers that are connected to commerically available power normally draw approximately 50 milliamps continuous power as a minimum.
It is also envisioned that the storage battery 68 would be of the lead-acid type, which can supply approximately 80 amps peak current for immediate response. By use of a bidirectional gear pump 82 and motor 78, solenoid switching is not necessary thereby keeping the power drain low. | The present invention is for an automatic gate opening device where commercial electricity is not economically available. A hydraulic cylinder operated by a bidirectional gear pump moves a cylinder rod which connects to an opening rod. The opening rod is pivotally connected to one end to the gate and on the other end to a stationary location. Due to pivotal connections and a pivotal linkage near the middle of the opening rod, the gate may be opened and closed by the hydraulic cylinder. The hydraulic cylinder is also pivotally mounted. Electronic controls may be operated by a number of different type sensors, including limit switches on the hydraulic cylinder, sensors for detecting the gate location, manual switches or other traditional vehicle approach sensors. Power is provided by a storage battery, which battery can be recharged during daylight hours at a solar panel or by a traditional battery charger. | 4 |
BACKGROUND OF THE INVENTION
The invention relates generally to radiation attenuation systems and more particularly to a modular radiation attenuation system designed to be temporarily assembled in any desired location and alignment and then filled with radiation attenuating fluid.
In nuclear power plants and in dealing with radiation wastes in general, it is desirable to be able to place a portable shielding system in place with a minimum of exposure to the workers in putting the attenuation system in place, have a maximum radiation attenuation in the system as well as ease in utilizing the system.
Each worker in a radiation emitting environment typically is attired in radiation protective clothing; however, additional shielding is desired when the workers have to be in a radiation area for any length of time. Further the amount of exposure to each worker should be as small as possible.
Attempts to reduce the radiation exposure, such as around a reactor head during refueling operations or in waste removal, have been made such as by placing lead shielding around the radiation source or providing a frame with balloon or bag type constructions which are then filled with water. Some attempts have also been made to provide large hollow shells which are then filled with a radiation attenuation fluid. These non-integrated systems have several disadvantages including exposure between the lead members or bags. These prior art units are cumbersome to work with, generally are not free standing and are not easily adaptable to the irregular work spaces which often exist in the radiation environment.
SUMMARY OF THE INVENTION
The above and other disadvantages of prior art radiation attenuation systems and techniques are overcome in accordance with the present invention by providing a self-supporting modular radiation attenuation system which easily can be assembled in any desired configuration between the radiation source and the work area. The system is formed from a plurality of radiation attenuation modules which are shaped to conform with adjacent modules when secured to one another in the desired alignment. The modules are formed from hollow containers which include entrance and exit ports for filling the containers with the radiation attenuation fluid such as water. Each module includes flexible strapping to secure it to the adjacent module when assembled in the desired alignment in relation to the radiation source. The system can include single or stackable modules.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial perspective view of one embodiment of the modular radiation attenuation system of the invention with portions broken away;
FIG. 2 is a top view of a portion of the attenuation system of FIG. 1;
FIG. 3 is a perspective view of a second embodiment of the modular radiation attenuation system of the invention;
FIG. 4 is a partial side section view of two modules of the system of FIG. 3 taken along the line 4--4 therein;
FIG. 5 is a partial side sectional view of one module port of the system of FIG. 3 taken along the line 5--5 therein;
FIG. 6 is a partial top sectional view of the system illustrating one embodiment of module securing means;
FIG. 7 is a partial top sectional view of the system illustrating the internal reinforcement portion of one module;
FIG. 8 is an exploded perspective view of one module embodiment of the radiation attenuation system of the invention;
FIG. 9 is an exploded partial perspective view of one stacking embodiment of the system modules;
FIG. 10 is an exploded partial perspective view of one strap securing plate of the shielding system;
FIG. 11 is an exploded partial perspective view of one coupling plate of the shielding system; and
FIG. 12 is a partial perspective view of another embodiment of the modular radiation attenuation system of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1 and 2, a modular radiation attenuation system embodying the invention is designated generally by the reference numeral 10. The modular radiation attenuation system or radiation attenuator 10 is shown assembled in an angular configuration and includes a plurality of modules 12. Each module 12 includes at least two ports 14 and 16 which are utilized to fill and empty the modules 12 with radiation attenuating fluid. Each module 12 includes a container body 18 shaped to conform to the body 18 of an adjacent module.
Each module 12 includes a pair of top straps 20 and a pair of bottom straps 22 which are secured to the adjacent module 12 to assemble the radiation attenuator 10. Once the modules 12 are assembled with their respective straps 20 and 22 in the desired alignment between the work space and the source of radiation, each of the containers 18 can be filled through the ports 14 and 16 which can be coupled together in a manifold type system with the filling and emptying done from a remote position.
One or more of the modules 12 can include a viewing port 24 which can be utilized by a worker to observe the radiation area on the opposite side of the radiation attenuator 10.
One or more of the modules also can include a semi-transparent strip 25 which can be monitored to make sure the system 10 is completely filled with fluid. Alternately, an external level indicating tube or device can be utilized. The fluid can contain a coloring agent to assist in visually determining the fluid level in the system. The modules 12 also can include an internal grid plate 26 which adds structural strength to the modules 12.
Each module 12 includes a substantially rounded convex portion 28 which terminates in an outwardly turned flange 30. A second concave portion 32 conforms to the shape of the rounded portion 28 of the adjacent module 12. The concave portion 32 includes a flange piece 34 which is welded or otherwise secured to the flange piece 30 to form an integral extending flange 36 on opposite sides of each module 12. The flange 36 may include a brace 38 where necessary or desired. If the radiation attenuator 10 is aligned in one or more bends or otherwise is aligned in other than a substantially straight line the braces 38 can be eliminated.
A second embodiment of attenuator 10' with stacked modules 12' is best illustrated in FIG. 3. The modules 12 (FIG. 1) can be six or eight feet tall and hence do not need to be stacked to protect the workers. The modules 12' may be smaller units which are stacked to form the radiation attenuator 10'. The modules 12' can include a single pair of straps 40. Braces 38' can be utilized as desired. The upper port 16' and the lower port 14' can be connected by a flexible tubing 42 to allow each pair of stacked modules 12' to be filled and emptied together. In a like manner each pair of the stacked modules 12' can be coupled together in a single manifold system where desired. Each module 12' is substantially identical and can be the top or bottom module.
To assist in stacking the modules 12' to one another a groove or indentation 44 can be formed in the top and bottom of each of the modules 12', as best illustrated in FIG. 4. The grooves 44 mate with one another when the modules 12' are stacked upon one another and can include a gasket 46 inserted therein to assist in aligning and securing the modules 12' to one another. The modules 12' also preferably are connected together by pairs of securing plates 48 (FIG. 3) which are connected to the stacked modules 12' through the respective flanges 36".
Referring now to FIG. 5, a top port 16' is illustrated which is formed in an indentation 50 in the container 18' to eliminate damage to the fitting 52 forming part of the port 16'. The port 16' includes an inner tube 54 which can be a J-type tube to ensure that the attenuation fluid 56, such as water, will fill the module 12' completely. The bottom pot also contains the J-type tube to completely empty the module.
Referring to FIG. 6, the securing of the modules 12' (or modules 12) is best illustrated. The straps 40 are secured through mounting plates 58 mounted by bolts 60. Alternately, an adjustable strap 40' can be bolted by a bolt 62 through a pair of mounting plates 64 securing the strap 40' to the flange 36'. The end of the strap 40' then is inserted through the mounting plate 58, tightened by a lever 66 and secured by a fastener 67 in a conventional manner.
The internal structure of one of the modules 12 (or 12') is illustrated in FIG. 7 which includes a reinforcing member 68. The triangular shaped member 68 has a center support rib 70 which runs the length of the module 12. The member 68 with the rib 70 maintains the concave shaped portion 32 so that the modules 12 or 12' can be secured in any alignment desired without a direct radiation path between adjacent modules 12 or 12'. The modules 12 or 12' can have a diameter D of about two feet which provides at least a ten fold reduction in transmitted radiation when filled with water.
Referring now to FIG. 8, a second embodiment of a non-stackable module 12" is illustrated. The container body 18" can include a handle 72 formed or secured to a top member 74 of the container 18". The top member 74 can be a cap type member which is inserted over the exposed ends of the body 18" in manufacturing the body to form the container 18". The top also includes an entrance port 76 and an exit port 78 which would replace the ports 14 and 16 illustrated in FIG. 1. The port 78 would be connected to a tube 80 which extends substantially to the bottom of the container 18" so that the container can be completely emptied of the attenuation fluid when desired.
To facilitate aligning the modules 12" in the modular radiation attenuation system a hub or pan 82 can be utilized to form the pattern for the system alignment prior to inserting the modules 12" in position. The hubs or pans 82 have a configuration conforming to that of the outside of the bottom of the container 18" and can be secured to the floor or one another to provide the proper alignment. In a like manner the hubs or pans 82 also can be utilized, with appropriate openings, on the tops of the modules 12" to aid in securing the modules 12" in their proper position.
The gasket 46 described in FIG. 4 is illustrated in FIG. 9. The gasket 46 can be an elastomeric type member which aids in aligning and securing the top module 12' when the system 10' is being assembled.
The modules 12 or 12' can include one or more of the strap mounting plates 58 (previously described) as illustrated in FIG. 10. The plates 58 are secured to the flange 36 by bolts 60. The plates 58 include an opening 84 through which the straps or other securing means are passed to secure the modules to one another in the assembled system.
The stacked modules 12' are secured to one another by the securing plates 48 best illustrated in FIG. 11. The plates 48 are secured to the respective top and bottom module flanges 36' by bolts 86. If the modules 12' are formed with the top and bottom caps 78 (similar to those illustrated in FIG. 8), then the plates 48 will be extended across the gap between the ends of the flanges 36".
FIG. 12 illustrates another embodiment of the radiation system 10". The system 10" includes a plurality of modules 88 which can be hollow block type containers. The modules 88 can then be stacked where desired. The containers 88 are most suited for use in a straight line to minimize the gaps between the modules 88.
Many modifications and variations of the present invention are possible in light of the above teachings. The modules can have numerous shapes such as triangular. The fitting 52 can be a flexible quick-disconnect fitting for easy connection between the stacked modules 12'. The attenuation system preferably is a rigid self supported structure made out of a fiberglass type material or other material which does not generate secondary emissions from exposure to radiation. The material can be fiberglass, plastic or any molded polyethylene light weight material which has sufficient strength and rigidity. The material preferably would be reinforced fiberglass which has the same attenuation characteristics as water, such as the type utilized in road trailer bodies. The flange 36 can be molded or made by gluing or riveting the flanges 30 and 34. The port 24 can be formed from plexiglass. The attenuation liquid can be water or can be other liquid such as boron and may include antifreeze or a heater to prevent the fluid from freezing if it is in a non-heated environment. It is, therefore, to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described. | A portable self-supporting modular radiation attenuation system formed from a plurality of modules secured to one another in any desired alignment to protect workers from radiation exposure. The modules are hollow containers shaped to mate with one another when secured thereto such as by strapping. The modules can be a single height or stacked and include ports for filling the modules with attenuation fluid when assembled and emptying them when they are to be removed. The modules mate with one another to eliminate radiation paths between the assembled modules. The modules can be formed from fiberglass and can include internal reinforcing to maintain the mating shapes. | 6 |
ACKNOWLEDGMENT OF GOVERNMENT SUPPORT
[0001] This invention was made with government support under Contract No. DE-AC52-06NA25396 awarded by the U.S. Department of Energy. The government has certain rights in the invention.
FIELD
[0002] The present application relates to antennas, and, more particularly, to a superluminal antenna for generating a polarization current that exceeds the speed of light.
BACKGROUND
[0003] Charged particles cannot travel faster than the speed of light, as is known by Einstein's Special Relativity theory. However, a pattern of electric polarization can travel faster than the speed of light by a coordinated motion of the charged particles.
[0004] Experiments performed at Oxford University and at Los Alamos National Laboratory established that polarization currents can travel faster than the speed of light. Two rows of closely-spaced electrodes were attached on opposite sides of a strip of dielectric alumina. At time t, a voltage was applied across the first pair of opposing electrodes to generate a polarization current in the dielectric alumina. A short time later, t+delta t, a voltage was applied to the second, adjacent pair of opposing electrodes, whilst the voltage applied to the first electrode pair was switched off, thus moving a polarization current along the dielectric. This process continued for multiple pairs of electrodes arranged along the dielectric. Given the sizes of the devices, superluminal speeds can be readily achieved using switching speeds in the MHz range. More subtle manipulation of the polarization current is possible by controlling magnitudes and timings of voltages applied to the electrodes, or by using carefully-phased oscillatory voltages. The superluminal polarization current emits electromagnetic radiation, so that such devices can be regarded as antennas. Each set of electrodes and the dielectric between them is an antenna element. Since the polarization current radiates, the dielectric between the electrodes is a radiator element of the antenna. Superluminal emission technology can be applied in a number of areas including radar, directed energy, communications applications, and ground-based astrophysics experiments.
[0005] It is desirable to build such a system using a modular approach with identical antenna elements closely spaced along a line or along a curve designed to give a desired, quasi-continuous trajectory in the dielectric for the polarization current.
[0006] Previously designed modular antenna elements had a coaxial cable connected to each antenna element. For each antenna element, the inner conductor of the coaxial cable was connected to the electrode on one side of the dielectric radiator element and the outer conductor (ground) to an electrode on the other side of the dielectric. The application of a voltage signal to such a connection establishes an electric field across the dielectric radiator element and hence creates the polarization. The connection to ground is straightforward due to the accessibility of the outer conductor. However, the inner conductor requires careful shaping to establish a smooth change in impedance. Moreover, a relative height of the outer conductor to the inner conductor proved difficult to replicate for each antenna element. Given the manufacturing tolerances, small variations in the relative heights of the conductors resulted in wide performance variations. In addition, a concentric conducting tube was provided around the coaxial cable to act as a quarter-wave stub. However, in the original embodiment it was found that the performance of the quarter-wave stub was very susceptible to slight variations in manufacturing tolerance, leading to large variations in performance from almost identical elements. This is clearly undesirable for antenna applications.
SUMMARY
[0007] A superluminal antenna element is disclosed that is operationally stable and easy to manufacture.
[0008] In one embodiment, the superluminal antenna element integrates a sleeve (or bazooka) balun and a triangular impedance transition to better match the impedance of the coaxial cable to the rest of the antenna element, preventing undesirable stray signals due to reflection. For example, a dielectric housing material can be used that has a cutout area. A cable can extend into the cutout area. A coaxial, cylindrical conductor connected to the screen of the cable and terminated below the conductive shielding element functions as a sleeve balun analogous to those used in conventional dipole antennas. A triangular impedance transition connects the central conductor of the coaxial cable to one side of the radiator element. The other side of the radiator element is connected by a planar conductor and/or conducting block to the screen of the coaxial cable.
[0009] By including a sleeve balun and by using the triangular impedance transition, improved impedance matching can be established between a cable (e.g., 50 Ohms impedance) and free space (e.g., 370 Ohms in the air, gas or vacuum above the radiator element). Not only does the impedance matching provide better performance (e.g. reduced leakage), but the current embodiment of the sleeve balun and impedance transition also allows the antenna element to be very consistent in its operation and replication, irrespective of slight variations in the manufacturing process.
[0010] The foregoing and other objects, features, and advantages of the invention will become more apparent from the following detailed description, which proceeds with reference to the accompanying figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is an exemplary superluminal antenna including multiple wedge-shaped superluminal antenna elements coupled together.
[0012] FIG. 2 is a dielectric housing material used to form an exemplary antenna element.
[0013] FIG. 3 shows the plated sidewalls within a cutout area of the dielectric housing material, the sleeve balun, triangular impedance transition and planar conductor coupling a coaxial cable to ground and signal sidewalls.
[0014] FIG. 4 shows an alternative embodiment of the conductive components within the antenna element with a simplified ground conductor.
[0015] FIG. 5 shows the current paths through the antenna element.
[0016] FIG. 6 shows the antenna element fully assembled including a radiator element and a sleeve balun through which the coaxial cable passes.
[0017] FIG. 7 shows a second embodiment of an antenna element, wherein the antenna element is rectangular shaped.
[0018] FIG. 8 is flowchart of a method for using a balun-type element in a superluminal antenna.
DETAILED DESCRIPTION
[0019] FIG. 1 shows a superluminal antenna 100 having a plurality of antenna elements, such as shown at 120 . Each antenna element has its own cable 140 coupled thereto for delivering the desired voltage signal to the antenna element. Each antenna element comprises a pair of electrodes, placed on either side of a dielectric material.
[0020] Individual amplifiers (not shown) are coupled to the antenna elements 120 via the cables and can be used to control the polarization currents by applying voltages to the electrodes at desired time intervals or phases. The application of voltage across a pair of electrodes creates a polarized region in between, which can be moved by switching voltages between the electrodes on and off, or by applying oscillatory voltages with appropriate phases. Superluminal speeds can readily be achieved using switching speeds or oscillatory voltages in the MHz-GHz frequency range. The dielectric between each pair of electrodes contains the polarization current that emits the desired radio waves, and thus functions as the radiator element of each antenna element.
[0021] The individual antenna elements allow for a modular approach, which is easier to manufacture than previous designs. Although the superluminal antenna 100 is shown as circular, other geometric shapes or configurations can be used. For example, a straight line, curved line or sinusoidal form can be used. Though desirable in many applications, a modular approach is not necessary, and larger blocks of antenna elements can be made using the same principles as described here. For example, radiator elements between antenna elements can be formed from a single monolithic unit or divided into groups of larger antennas.
[0022] FIG. 2 shows a base portion 200 of an antenna element. The base portion 200 is generally a dielectric housing material having a cutout area 210 and an aperture 225 for receiving a cable. The dielectric housing material can be formed from a wide variety of dielectrics, such as glass epoxy laminates (e.g., G10). Example permittivity values are between 4 and 5 , but other permittivity values can be used. The base portion is shown as wedge shaped, but other shapes can be used. The cutout area 210 has a main section 220 into which the cable passes, and a series of opposing steps 230 , 240 , the outer pair of which, 240 , are for mounting a radiator element made from any low loss-tangent dielectric with a reasonably high dielectric constant, such as alumina, as further described below. The cutout area can be a wide variety of shapes, depending on the particular application.
[0023] FIG. 3 shows the metal components of the antenna element that mount within the base portion 200 . The inner walls of the base portion 200 adjacent the cutout area are lined with a conductive material 320 , 370 (e.g., copper) for carrying transmission signal and ground to opposing ends of a dielectric radiator element in the fully assembled antenna element. The conductive material forms a ground conductor 320 and a signal conductor 370 electrically separated by a layer of non-conductive material 360 , such as Teflon. When in use, the dielectric radiator element 310 rests between the upper vertical boundaries of conductors 320 and 370 . The radiator element 310 can be made from any low loss-tangent dielectric with a reasonably high dielectric constant. The coaxial cable 350 enters the base of the unit, and is surrounded by the coaxial tube functioning as a sleeve balun 340 . The lower extremity of the sleeve balun 340 is connected to the screen of the coaxial cable 350 ; the upper extremity can be not connected. A conductive, triangular impedance transition 380 is coupled between the central conductor of cable 350 and the signal conductor layer 370 . At an end wherein the impedance matching element 380 couples to the signal conductor 370 , the impedance matching element is approximately the width of the signal conductor and then tapers at an opposite end to couple to the drive conductor in the cable. In applications where negligible leakage of radiation into the area below the antenna element is desired. a conductive block 390 may be attached to the screen of cable 350 , but may not make contact with, the upper part of the sleeve balun 340 . Additional isolation of the balun 340 can be provided by a circular gap 330 .
[0024] FIG. 4 shows an alternative compact embodiment that gives similar antenna performance. Here, the conductive block 390 is replaced by a conductive slab 450 that is connected directly to the ground conductor 460 , and covers (but does not touch) the end of the sleeve balun 430 . Electrical insulation between the ground conductor 460 and the signal conductor 470 is provided by a gap. The coaxial cable 440 , sleeve balun 430 and connection 410 between the cable's central conductor and the conductive impedance transition can be similar to the previously described embodiment.
[0025] As shown below, the impedance transition when used in conjunction with the sleeve balun 430 , 340 establishes better impedance matching from the coaxial line to the radiator element. This improvement makes the antenna element operationally stable and greatly increases reproducibility against slight variations in manufacturing. The cable can be a coaxial cable having multiple conductors for carrying a signal and ground. Additionally, the cable can include dielectric material positioned between the signal and ground conductors. The cable can be replaced with any desired signal conductor, such as a waveguide, traces on a printed circuit board, etc..
[0026] FIG. 5 shows a simplified section of the element to illustrate the electrical connection of the cable and sleeve balun to the signal and ground conductors; this differs from previous designs. The signal conductor 540 couples a drive line 530 from the coaxial cable to one side of the radiator element. A ground conductor 550 , encompassing the top of the conductive element (i.e., block or slab), couples the ground from screen 520 of the cable to the opposite side of the radiator element. The sleeve balun 510 is connected to a lower part of the screen of the coaxial cable. Consequently, by creating a sleeve balun, and by including the impedance transition, impedance matching is established between the coaxial cable (50 Ohms impedance) and free space (370 Ohms impedance in the air, gas or vacuum directly above the radiator element). Not only does the impedance matching provide better performance, but the sleeve balun and the impedance transition also allow the antenna element to be consistent in its operation and replication.
[0027] FIG. 6 shows an assembled antenna element 400 . A conductive block 410 is positioned within the cutout area and includes a hole therein through which the sleeve balun 340 containing the coaxial passes. As explained previously, the conductive block is an exemplary conducting element and can be replaced by alternative elements. A dielectric radiator element 420 is mounted within the cutout area so as to couple at one end to the signal conductor 370 and, at an opposite end, to ground conductor 320 . The radiator element can be made from any low loss-tangent dielectric with a reasonably high dielectric constant. The impedance transition and the sleeve balun 340 act to make the antenna element operationally stable and increase reproducibility against slight variations in manufacturing. The cable can be a coaxial cable having multiple conductors for carrying a signal and ground. Additionally, the cable can include dielectric material positioned between the signal and ground conductors. With suitable modifications to the balun geometry, the cable can be replaced with any desired signal conductor, such as a waveguide, traces on a printed circuit board, etc.
[0028] FIG. 7 shows a second embodiment of an antenna element wherein a base portion 500 is rectangular shaped. The rectangular-shaped base portion 500 can include protruding blocks 520 positioned at opposing ends of a radiator element 530 . The blocks 520 may improve the radiation pattern. Not all features of the antenna element will be described, as it is similar to the wedge-shaped embodiment.
[0029] FIG. 8 is a flowchart of a method for shielding a superluminal antenna element. In process block 910 , an array of superluminal antenna elements are provided. In process block 920 , varying voltage signals are provided, one for each element in the array. The voltage signals can be provided using a series of coaxial or other input cables, signal conductors, or waveguides. In process block 930 , a voltage signal is transmitted from each cable, signal conductor, or waveguide to its corresponding radiator element. The transmission is made via components that function as a sleeve balun and an impedance transition. In process block 940 , the transmitted voltage signals are used to induce a moving polarization current inside the dielectric volume formed by the array of radiator elements.
[0030] In view of the many possible embodiments to which the principles of the disclosed invention may be applied, it should be recognized that the illustrated embodiments are only preferred examples of the invention and should not be taken as limiting the scope of the invention. Rather, the scope of the invention is defined by the following claims. We therefore claim as our invention all that comes within the scope of these claims. | A superluminal antenna element integrates a balun element to better impedance match an input cable or waveguide to a dielectric radiator element, thus preventing stray reflections and consequent undesirable radiation. For example, a dielectric housing material can be used that has a cutout area. A cable can extend into the cutout area. A triangular conductor can function as an impedance transition. An additional cylindrical element functions as a sleeve balun to better impedance match the radiator element to the cable. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
Generally, the field of the present invention is adhesion bonding with semiconductors. More particularly, the present invention relates to the adhesion of metallic layers to p-type III-V compound semiconductors.
2. Background Art
In order to enhance the performance of semiconductors, advances have been made in types of materials used and methods for forming those materials. One such area of performance pertains to the formation and structure of metal and semiconductor contact. For semiconductor lasers, this contact should be ohmic, that is, the contact should exhibit linear I-V characteristics, and a low contact resistance is required. U.S. Pat. No. 5,429,986 describes a process for forming a low resistance ohmic contact electrode that has a layer of Pt interposed between a p-type GaAs layer and a Ti/Pt/Au layer wherein the interposed Pt layer has a thickness greater than 50 Å and less than 400 Å. The '986 also extrapolates that for thicknesses less than 50 Å, unsuitable contact resistances are obtained.
However, in addition to contact resistance, other characteristics are desirable for contacts formed on p-type semiconductors. For example, the time required to complete the formation of a contact through annealing can impact the overall cost of manufacturing devices utilizing the contacts. Additionally, the adhesion strength between contact metals and underlying semiconductor and insulating layers can allow subsequent fabrication steps without metal peeling and can determine the infant mortality rate and useful life of devices incorporating the contacts. Thus, reliability remains important and concomitant attributes such as robustness and versatility can extend the scope of use of products fabricated with ohmic contacts.
Thus, despite the considerable efforts that have been exerted for many years, there remains a long felt need for a p-metal that provides superior strength, reliability, and processing time without any attendant drawbacks.
SUMMARY OF THE INVENTION
According to one aspect of the present invention, an adhesive layer joining opposing device layers of a semiconductor device includes a thin layer of Pt having a thickness greater than or equal to 15 Å and less than or equal to 50 Å.
According to another aspect of the present invention, a metallization layer for a semiconductor device includes a first layer made of Pt and having a thickness greater than or equal to 15 Å and less than or equal to 50 Å, and a second layer formed on the first layer and made of a plurality of metallic sub-layers, such as Ti/Pt/Au.
According to another aspect of the present invention, a semiconductor device includes a semiconductor substrate including a top layer having a surface, an insulating layer formed on a first portion of the surface and not formed on a second portion of the surface, a metallization layer deposited on the insulating layer and the second portion of the surface, wherein the metallization layer includes a first layer made of Pt and having a thickness greater than or equal to 15 Å and less than or equal to 50 Å and a second layer made of a plurality of metallic sub-layers.
According to another aspect of the present invention, a method includes forming a p-type semiconductor layer, and forming a metallization layer on the p-type semiconductor layer wherein the metallization layer includes a thin Pt layer having a thickness less than or equal to 50 Å and greater than or equal to 15 Å and a plurality of metallic layers on the thin Pt layer.
The foregoing and other objects, features, and advantages will become more apparent from the following detailed description, which proceeds with reference to the accompanying figures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of a typical p-metal deposited on a p-type III-V compound semiconductor and forming an electrode.
FIG. 2 is a cross-sectional view of an exemplary embodiment of the present invention showing an additional Pt layer at the p-type semiconductor interface, said additional Pt layer being shown in greater detail in an expanded bubble.
FIG. 3 is a flow-chart diagram showing typical processing steps for making a device using exemplary methods of the present invention.
FIG. 4 is a chart showing the superior strength of an exemplary embodiment of the present invention.
FIG. 5 is a plan view image of an embodiment of the present invention after destructive testing.
FIG. 6 is a plan view image of the remains of typical p-metal deposited on a p-type semiconductor after destructive testing.
FIG. 7 is a plan view image of semiconductor devices after destructive testing.
FIG. 8 is a chart of the L-I-V curves of both a typical p-metal layer and a layer utilizing an embodiment of the present invention.
FIG. 9 is a chart of the L-I curves of catastrophic optical damage testing of both a typical p-metal layer and a layer utilizing an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIG. 1 , a semiconductor device structure 10 is shown that includes a semiconductor crystal 12 epitaxially grown and processed so as to form a mesa structure 14 from p-type semiconductor epi layers 16 . The semiconductor 12 typically includes several p-type semiconductor layers 16 having varying compositions, including a surface layer 20 made of, for example, GaAs. Other surface layers may be used depending on the device made. For example, InGaAs surface layers can be used for InP based semiconductor devices. The various epi layers 16 are typically grown on an n-type substrate 18 . The mesa structure 14 may be trapezoidal as shown in FIGS. 1 and 2 or it may have other shapes as suitable for different applications. A dielectric layer 22 , such as silicon oxide or silicon nitride, is deposited on top semiconductor surface 24 and is selectively removed above a portion 26 of the surface 24 of top layer 20 on the mesa 14 . A p-metal metallization layer 28 is applied to bare surface 26 of p-type layer 20 and surface 30 of silicon oxide layer 22 . Typically, the p-metal 28 has three layers 32 , 34 , 36 comprised of Ti, Pt, and Au, respectively; however other p-metal layer combinations can also be used. The metal/semiconductor structure 10 is annealed in order to form a secure mechanical and electrical connection between the metallization layer 28 and the semiconductor surface and silicon oxide layers 20 , 22 . The structure 10 may undergo additional processing steps and may then become suitable for use in various applications, such as semiconductor lasers.
Referring to FIG. 2 , in an exemplary embodiment of the present invention, a metal/semiconductor semiconductor device structure 38 is shown. Similar to structure 10 , structure 38 includes a multi-layer p-metal 40 , such as three layers 32 , 34 , and 36 made from Ti, Pt, and Au, respectively, a dielectric layer 22 such as silicon oxide or silicon nitride, as well as multiple semiconductor layers 16 epitaxially grown on an n-type substrate 18 . The structure 38 also includes an additional thin Pt layer 42 formed between p-metal 40 and surfaces 26 , of p-type semiconductor and silicon oxide layers 20 , 22 . Structure 38 may also take the form of a planar structure or depressed structure (not shown) as well. The layer 42 has a deposited thickness of 50 Å or less and causes the structure 38 to exhibit several superior characteristics over structures having layers of Pt with thicknesses larger than 50 Å or having no additional Pt layer ( FIG. 1 ). More particularly, Pt layers 42 having a thickness of about 15-25 Å exhibit highly desirable characteristics overall.
Referring now to FIG. 3 , typical processing steps for metal/semiconductor structures 10 , 38 are shown including steps for methods of the present invention. Using various semiconductor growth techniques, such as metalorganic chemical vapor deposition (MOCVD), several semiconductor layers 16 are epitaxially grown, as per step 50 , on a semiconductor substrate 18 . The surface of the semiconductor is etched, as per step 52 , through one or more layers 16 using suitable processing techniques such as lithography and acid-etching in order to form mesa structures 14 . Silicon oxide 22 is deposited, as per step 54 , on the surface 24 of the semiconductor to form an insulating barrier and then a contact portion 26 is exposed by removing the silicon oxide using lithography and acid etching or other suitable techniques. A metallization layer 40 is deposited, as per step 56 , on surfaces 26 , 30 of p-type and silicon oxide layers 20 , 22 using conventional techniques, such as electron beam evaporation. However, as opposed to using a series of three layers Ti/Pt/Au or other suitable combination, a thin layer of Pt 42 is deposited first and other p-metal layers, such as Ti/Pt/Au, are deposited subsequently.
After depositing the Pt/Ti/Pt/Au p-type metallization layer 40 , the metal/semiconductor structures are annealed, as per step 58 , in order to form a low resistance ohmic contact and secure the layer 40 to the exposed contact surface 26 and the surface 30 of the insulating silicon oxide layer 22 . In contradistinction to more commonly applied metallization layers requiring annealing times of approximately 20 minutes at a temperature of 400° C., the Pt/Ti/Pt/Au metallization layer 40 achieves superior adhesion and low resistance results when annealed at between 375 and 425° C. for only 1 minute. Thus, when warm-up and cool-down times of approximately five minutes each are included, the Pt/Ti/Pt/Au metallization layer 40 requires approximately two thirds less time in the annealing process than conventional Ti/Pt/Au metallization layers 28 . The substantial reduction in annealing time results in significantly improved manufacturing throughput.
One result of the annealing process step 58 is the formation of an ohmic contact at exposed mesa surface 26 . In order for the contact to be ohmic, the contact resistance must be low enough so as not to have a significant effect on the operation of the device and the I-V characteristics across the contact should be as linear and symmetric (positive and negative bias) as possible. After annealing the Pt/Ti/Pt/Au metallization layer, an ohmic contact is formed that exhibits linear and symmetric I-V characteristics and that exhibits contact resistances in a range between 0.7 and 2.7 μΩ-cm 2 . Such contact resistances are similar to those achieved for structures which do not have Pt layer 42 , and more importantly, the contact resistances achieved are much smaller compared to the resistances associated with other portions of the package, such as across the p-n junction or substrate.
The annealing process step 58 also results in an increased mechanical strength or adhesion between the metallization layer 40 and the layers of silicon oxide 22 and surface p-type semiconductor 20 . As can be seen in FIG. 4 , the die shear force strength curve 70 achieved by the metallization layer 40 using 20 Å samples is significantly higher, having approximately two times higher average strength, than the strength curve 72 of conventional layers 28 , such as Ti/Pt/Au, which omit thin Pt layer 42 . Additionally, the strength curve 70 for metallization layer 40 has a more Gaussian and symmetric shape, yielding more reliable strength behavior for semiconductor structures using layer 42 as well as devices that include those structures and processes that work with those structures.
Referring now to FIGS. 5-6 , images are shown of p-type GaAs after destructive testing which further indicate the improved adhesion strength characteristics introduced by additional Pt layer 42 . FIG. 5 shows a plan view of semiconductor mesa structures 14 separated by channels 74 . A line 76 is scribed across the structures 14 that have a p-metal 40 deposited thereon and annealed. Tape is placed over top surface 48 and aggressively peeled away to cause damage to the deposited layers 40 and semiconductor structure. After peeling the tape, dark regions 78 are revealed that are underlying damaged GaAs p-type semiconductor 20 . Thus, instead of the p-metal layer 40 failing at an interface between the p-type semiconductor 20 and the p-metal 40 , portions of the underlying p-type semiconductor 20 are removed. In contrast, FIG. 6 shows a plan view of similar semiconductor mesa structures 14 with deposited p-metal 28 omitting thin Pt layer 42 . Without layer 42 , some p-metal 28 is stripped away to reveal the interface (gray color) between the p-metal 28 and the underlying p-type semiconductor 20 , i.e., the surface 26 of the p-type semiconductor 20 . Consequently, the more conventional p-metal layer 28 is peeling from the semiconductor surface and failing before the stronger p-type semiconductor lattice 20 to which layer 28 should remain secured.
When the thickness of Pt layer 42 is greater than 50 Å, the adhesion between the p-metal 46 and SiO2 is adversely affected. Similar destructive tests were used for such thicker Pt layers and the result is shown in FIG. 7 . A line 76 was scribed across metalized mesa structures 14 (five shown) and top surface 48 was taped and peeled. Similar dark regions 78 reveal where p-metal was removed along with portions of underlying p-type semiconductor 20 in accordance with a preferred failure. However, also shown are gray regions 80 where the surface 30 of silicon oxide layer 22 was revealed. Hence, the Pt layer 42 thickness is up-limited by the adhesion between the Pt layer and silicon oxide.
After annealing processing step 58 , thick gold is coated, such as by plating, as per step 60 , over the metallization layer 40 typically to a thickness of a couple of μm. The structure 38 is lapped and polished, as per step 62 , on the bottom end (not shown) in preparation for subsequent processing steps. An n-metal is typically deposited, as per step 64 , on the underside 44 of the structure 10 , 38 and the devices are cleaved, and if it is a laser, its facet is usually coated, as per step 66 . The resulting devices may then be attached, as per step 68 , to an additional substrate for further processing. There are various applications for a finished semiconductor device, including as a semiconductor laser. Performance characteristics of laser diodes made from semiconductor structures 38 utilizing the Pt layer 42 in the metallization layer 40 match or are very close to the characteristics of devices without the Pt layer 42 . Shown in FIG. 8 are L-I-V curves 82 for laser diodes utilizing the Pt layer 42 as well as overlapping L-I-V curves 84 for laser diodes using a conventional Ti/Pt/Au layer 28 . The results of catastrophic optical damage testing are shown in FIG. 9 . As shown by comparison of curve 86 representing diode laser performance for devices using layer 42 and curve 88 representing diode laser performance for reference devices using a conventional metallization layer, minimal differences are observed. Thus, the overall performance of devices utilizing the Pt layer 42 demonstrate similar threshold current, slope, and burn-in stability as devices without the Pt layer.
However, devices such as laser diodes using layer 42 exhibit improved reliability over diodes that do not utilize layer 42 in Mil standard tests such as thermal cycling, shock, and vibration testing. After experiencing one hundred temperature cycles, vibration, and shock tests under Mil-Std-883, none of fifteen devices using Pt layer 42 shows degradation. For devices using conventional p-metal Ti/Pt/Au, one of fifteen failed after 38 temperature cycles, and five parts in fifteen showed increased thermal resistance. Moreover, with the addition of Pt layer 42 , the failure rate experienced during later device fabrication is substantially reduced, such as during cleaving and coating process step 66 and die bonding process step 68 .
It is thought that the present invention and many of the attendant advantages thereof will be understood from the foregoing description and it will be apparent that various changes may be made in the parts thereof without departing from the spirit and scope of the invention or sacrificing all of its material advantages, the forms hereinbefore described being merely exemplary embodiments thereof. | A metallization layer for a semiconductor device includes a first layer made of Pt and having a thickness greater than or equal to 15 Å and less than or equal to 50 Å, and a second layer formed on the first layer and made of a plurality of metallic sub-layers such as Ti/Pt/Au. A semiconductor device fabricated from the metallization layer includes a semiconductor substrate having a top layer and mesa structure and corresponding surface for securing an insulating layer and a corresponding exposed surface, and wherein the metallization layer is deposited over the insulating layer and exposed surface. Methods for forming the metallization layer are also disclosed. | 7 |
[0001] This application is related to provisional patent application Ser. No. 60/249,372 filed Nov. 17, 2000.
FIELD OF THE INVENTION
[0002] This invention relates to spout end devices. More specifically, this invention relates to laminar flow-type spout end devices having anti-microbial properties.
BACKGROUND OF THE INVENTION
[0003] A common problem in hospitals, well known to the people responsible for infectious disease control, is the proliferation of disease-causing bacteria. Bathroom faucets are potential sites for bacterial colonization in the hospital environment because of the presence of moisture and their proximity to patients with infectious diseases.
[0004] The part of the faucet most likely to harbor dangerous microbes is the spout end device because of its relatively large wetted surface area and its exposure to air and location closest to the point of use. Because of high risk of contamination by the ambient air, spout end devices of the aerator type with vast exposed surfaces are shunned in favor of laminar flow devices with less air-exposed surfaces. However, even after flow is stopped, a few drops of water invariably remain on its laminar-forming and other surfaces, susceptible to contamination by the ambient air.
[0005] Recognition of this potential health hazard has led to the establishment of procedures in hospitals designed to sterilize the water system using high temperature water or extra doses of chlorination. However, at best, these procedures are carried out only infrequently.
SUMMARY OF THE INVENTION
[0006] The invention is a laminar-flow end device for a water spout comprising a generally cylindrical plastic component through which water passes. The component is characterized in that the plastic is molded from ingredients including a thermoplastic resin and an anti-microbial agent. The invention thus provides for continuous retardation of bacterial growth in the spout end device.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] Further objects and features of the invention will be clear to those skilled in the art from a review of the following specification and drawings, all of which present a non-limiting form of the invention. In the drawings:
[0008] [0008]FIG. 1 is a side elevational view of an assembly embodying the invention, depicted in semi-lateral cross section; and
[0009] [0009]FIG. 2 is also a side elevational view of an assembly disposed in a discharge orifice, also in semi-lateral section.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0010] A laminar flow device is shown in an assembly in FIG. 1 and the assembly is generally designated 1 . It is disposed in a discharge housing 2 as is shown in FIG. 2. The discharge housing is connectable with the discharge end of a sanitary fitting (not shown).
[0011] The assembly 1 (FIG. 1) comprises essentially three elements: a laminar flow device 3 , including a perforated plate 20 having a depending skirt 20 a which blocks lateral entrance of air into the laminar flow device 3 , a flow-through volume controller 4 and a filter attachment 5 . The flow direction is designated by the arrow Pf 1 .
[0012] The laminar flow device 3 with its annular passages 22 and their radial spoke-like walls 24 serves to organize the water into a laminar stream. It may be a modified form of the type shown and disclosed earlier in U.S. Pat. Nos. 5,495,985 and 5,769,326 which issued Mar. 5, 1996 and Jun. 23, 1998 respectively to Dieter Wildfang GmbH. The teachings of both of these patents are incorporated herein by reference.
[0013] The flow-through volume controller element 4 serves as a largely water-pressure-independent limitation of flow-through performance. The attachment filter 5 lastly serves to keep solid particles accompanying the water away from the flow-through volume controller and the laminar flow device to ensure that they function properly and are not impaired.
[0014] Depending on the application, various combinations of elements are provided. As an example, flow-through volume controllers 4 having various flow-through rates can be selectively used. There is also the option of using the laminar flow device 3 with a directly placed attachment filter 5 if no flow-through volume controller 4 is needed.
[0015] To be able to attach mounting parts 3 , 4 , 5 optionally with each other, they themselves have snap-type connectors 6 that adapt in each case to each other (FIG. 1). Such connectors 6 are found on the laminar flow device 3 on its in-flow side end, on the flow-through volume controller 4 at both ends, and on the attachment filter 5 on its out-flow side end. The connectors 6 are described in detail in the aforementioned U.S. Pat. No. 5,769,326 and are not part of this invention.
[0016] Turning to the present invention, anti-microbial compounds exist in various forms, some employing inorganic ingredients such as silver, zinc oxide and titanium dioxide; others consisting of organic compounds such as chlorinated phenols. The common characteristic of these compounds when mixed into the plastic resin is that they create a surface condition on the finished plastic parts that retards the growth of bacteria.
[0017] Because spout end devices of most faucets are removable, anti-microbial spout end devices or components can be retrofitted into existing faucets, thereby supplementing the normal infectious disease control procedures in hospitals, for instance, and assisting in the prevention of disease.
[0018] In the process of making the component of the invention, the plastic selected, in powder form, is mixed with a suitable quantity of powder of the anti-microbial agent. Preferably, the proportions are such that the portion of the mixture which is the anti-microbial agent is no more than 5-10% of the total mixture. A larger portion may adversely affect the stability of the mixture.
[0019] The mixing should be sufficient to distribute the two powders intimately. The mixture is injected into a closed injection molding press. After setting, the mold is opened and the product ejected. Products made in accordance with the invention have the anti-microbial characteristics desired.
[0020] The anti-microbial agent preferred in the practice of the invention is the inorganic type. Specifically, an agent containing silver and zinc and a carrier of alumino-silicate is preferred and is available as “Agion” from Agion Technologies of Wakefield, Mass.
[0021] An organic anti-microbial agent may be a chlorinated phenol available under the trademark “Microban” from Microban Products Company of Charlotte N.C.
[0022] Preferably, the thermoplastic resin used with the agent in the practice of the invention is an acetal, such as “Delrin” or “Celcon”. Under the invention the mixture is used in the molding of parts 3 , 4 and 5 .
[0023] Variations in the invention are possible. Thus, while the invention has been shown in only one embodiment, it is not so limited but is of a scope defined by the following claim language which may be broadened by an extension of the right to exclude others from making, using or selling the invention as is appropriate under the doctrine of equivalents. | A water spout end device for producing laminar flow of the water emitted therefrom comprising a generally cylindrical housing containing a cylindrical plastic component formed with a plurality of annular passages divided by annular spoke-like walls and characterized in that the plastic component is molded from ingredients including an anti-microbial agent. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to firearms generally, and particularly relates to a breech-loading, repeating bolt action rifle.
2. Description of the Prior Art
A bolt action rifle is a firearm which is defined by the mechanism used to insert cartridges into the firing chamber. Most rifles have a magazine for the storage of cartridges from which cartridges are stripped under spring pressure, one at a time, for insertion into firing position. While being stripped, and once stripped, the cartridge round in a bolt action rifle is impelled forward by a structure called the bolt. The bolt is generally hand operated by the user.
A breech loading rifle is defined as a firearm in which a cartridge is loaded into the rear of the barrel.
The literature and history relating to breech loading bolt action rifles is both extensive and complex. The rifle models manufactured by Paul Mauser as the Mauser Model 1898 have achieved special fame and are described in an article "The Mauser Rifle Story" by Jon Sundra, Guns & Ammo, September, 1985, and by "The Bolt Action", by Stuart Otteson, Volume I, Wolfe Publishing Co. Inc., ISBN 0-935632-21-2, 1976.
U.S. Pat. No. 3,835, 566 to Bielfeldt et al. is descriptive of a bolt action rifle.
The Sundra article, on page 52, describes a problem called "double loading". Many bolt action designs allow that the cartridge is not under direct control by the bolt during insertion but rather the cartridge is merely pushed forward toward the firing chamber. If for any reason, such as panic, the operator fails to fully insert the cartridge by complete and proper travel of the bolt, it is possible to leave an unspent cartridge in the rifle and to reverse the bolt ("short stroking") to return to strip out a second cartridge from the magazine. When the bolt is used to insert the second cartridge, the point of the second cartridge encounters the rear of the first unejected cartridge and may detonate the first cartridge or may merely jam the loading mechanism.
The double loading problem was recognized by Paul Mauser and corrected in his design known as the Spanish Mauser 1891. This rifle provided for a bolt which rotated about its axis prior to movement longitudinally toward and away from the firing chamber. At the rearmost position of the bolt, the bolt face stops behind the magazine. The bolt has an undercut bolt head rim which receives the cartridge rim. A non-rotating extractor captures the cartridge after it jumps free of the magazine. Thus, if the bolt is drawn rearward at any time, it pulls the cartridge with it and ejects the cartridge normally from the rifle before a new cartridge is stripped from the magazine. This mechanism effectively prevents double loading malfunctions.
The Mauser 1891 design introduced a new problem in exchange for the elimination of double loading. The undercut to the face of the bolt leaves a portion of the cartridge unsupported during firing.
It is usual to manufacture cartridge cases of brass, a material which has insufficient strength to withstand the gas pressures generated by the detonation of the cartridge. The cartridge expands during detonation and bears against the stronger steel surfaces which surround it, generally that of the bolt face and the barrel. In the direction of the barrel axis, gas pressure is relieved by propelling the rifle bullet forward.
In the area of the undercut of the bolt face, a portion of the cartridge rim is not supported. That is, the cartridge must expand excessively to encounter support steel. This lack of support results in occasional cartridge rupture, producing a flux of brass particles and high pressure gas through the mechanism of the rifle and outward via available clearances.
Efforts to more effectively seal the breech involved decreasing the area of nonsupport by decreasing the bolt rim height or by milling projections from the rear of the barrel. This resulted in a decrease of feeding reliability and/or involved complex machining and difficult fitting of breech components. Because of the otherwise extreme reliability, the basic design of the Mauser rifle bolt and extractor were closely imitated by military bolt action rifles. Many commercial rifles, in contrast, use fully-enclosing bolt faces which combine with the barrel to fully enclose the cartridge during firing. These rifles do not preclude double loading.
An object of this invention is to provide a bolt action rifle design which simultaneously allows for controlled round feeding to prevent double loading and for a fully supported cartridge to help prevent and contain a cartridge rupture, resulting in increased reliability and safety.
SUMMARY OF THE INVENTION
The invention is a repeating bolt action rifle of the Mauser type having a non-rotating extractor attached to a non-rotating bolt. The bolt head rim is undercut allowing controlled round feeding as in Mauser pattern designs. In this invention the bolt does not rotate and therefore permits a mating projection to occupy the space left open by the bolt rim undercut. The projection supports the cartridge case during detonation and seals a portion of the breech in the event of cartridge rupture.
The projection is not integral to the barrel but rather is a separate ring-shaped part held in place between the barrel and the receiver, which ring has a flange projecting therefrom to mate with and fill the undercut of the bolt.
The bolt mechanism of the rifle is non-rotating to enable the projecting flange to mate with the undercut. An inner bolt sleeve slides axially along and within an outer bolt sleeve, extending and retracting a plurality of lugs at the forward end of the bolt dovetailed into the inner bolt sleeve, into and out of bracing contact between the receiver and the barrel to lock the firearm for firing when needed. A stud at the rear end of the inner bolt sleeve engages a spiral groove in a rotating bolt collar which is controlled by the operator via a bolt handle. Rotation of the bolt collar is converted to axial movement of the inner bolt sleeve by sliding of the stud in the spiral groove. The bolt mechanism also has a firing pin which is cocked by axial motion of the inner bolt sleeve, and a bolt collar lock to prevent bolt collar rotation with the bolt in its rear-most position.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial side elevation view of a bolt action rifle as modified by this invention, shown locked closed in a ready-to-fire position with a loaded cartridge;
FIG. 2 is a partial side elevation view of the invented bolt action rifle with the bolt handle in its fully raised position and with the locking lugs in the unlocked position;
FIG. 3 is a partial plan view of the rifle in the breech area, sectioned as indicated in FIG. 2, with the firing pin in a forward firing position;
FIG. 4 is an exploded perspective view of the bolt mechanism, a perspective view of the breech ring, and a perspective view of an end of the barrel;
FIG. 5 is a partial perspective view of the bolt with its locking lugs in the locked position;
FIG. 6 is a partial perspective view of the bolt with its locking lugs in the unlocked position;
FIG. 7 is a schematic of a forward end of an inner bolt sleeve having several components omitted for clarity, showing a typical locking lug;
FIG. 8 is a section of the bolt and receiver taken from FIG. 2 with the locking lugs in the unlocked position; and
FIG. 9 is a profile view of the outer surface of the bolt assembly with the bolt handle in the fully raised position.
DETAILED DESCRIPTION
While this description is intended to fully describe the invention, nevertheless the material in U.S. Pat. No. 3,835,566 to Bielfeldt et al, incorporated herein by reference, may aid in a full understanding.
In the claims, in the drawings and in this description, similar numerals denote similar features.
Referring to FIG. 1, the mechanism is shown to have a receiver 11 which is of roughly cylindrical shape bored out longitudinally to accept an axially slidable (along F and R) bolt assembly 12. Numeral 12 refers to the total bolt assembly. A barrel 13, shown in part, is attached by screw threads to a forward end of receiver 11. Generally speaking, receiver 11 is an enclosure which receives a cartridge and contains the mechanism, especially bolt assembly 12, which inserts the cartridge into the barrel for discharge. Barrel 13 is the component of the rifle which contains the explosively expanding gases which propel the bullet along and out barrel 13. A cartridge chamber 14 (see FIG. 4) is reamed out of the breech end of barrel 13. A cartridge 15 is shown inserted in cartridge chamber 14. A breech ring 18 is tightly captured between the breech end of barrel 13 and an inner shoulder 16 in receiver ring 17. Breech ring 18 is geometrically a thin cylinder with an annular circular hole therethrough the cylinder axis, sized to permit passage therethrough by cartridge 15. Projecting from the rear surface of breech ring 18 and integral with the body of breech ring 18 is a flange 19 which is sized and shaped to mate with and fill within the limits of engineering tolerances the entirety of bolt rim undercut 20 when bolt 12 is in its forward position. An outer surface of flange 19 is flush or coextensive with the surface of receiver ring 18 formed by the hole therethrough. (See FIGS. 1 and 4) Refer to FIG. 4 for a better view of breech ring 18 and refer to FIG. 5 for the best view of bolt rim undercut 20.
In FIG. 5, bolt head 21 at its forward surface forms bolt face 22 which is perforated at its center by firing pin hole 23. At the circumference of bolt face 22 is bolt rim 24 which surrounds cartridge 15 at extractor groove 25, seen in FIG. 1. At the bottom portion of bolt face 22 in FIG. 5, bolt rim 24 is cut away to leave a remainder of the circumference of bolt face 22 without bolt rim 24; this portion of the circumference is defined as the bolt rim undercut 20. Bolt rim undercut 20 serves to permit passage therethrough the undercut of the rim of cartridge 15, which slips under an extractor hook 26 in passage from magazine 27.
Refer to FIG. 3. Extractor 28 is mounted flush with the outside of bolt 12 in a recess close to the forward end of bolt 12. Extractor 28 is pivotally mounted with a pin 29 and is coil spring 30 loaded. An extractor hook 26 passes through an undercut 20 in bolt rim 24. Extractor hook 26 is wedge shaped, as shown in FIG. 5, so that if it were blown outward by a ruptured cartridge it would wedge against bolt rim 24 at its top and against breech ring flange 19 at the bottom, effectively sealing the breech. Extractor 28, bolt rim 24 and flange 19 are also supported by the inner surface of the receiver ring 17 wall.
Again referring to FIG. 3, opposite extractor 28 on bolt 12 is an ejector 31 which is of the plunger type. Ejector 31 is spring biased toward its retracted position along R. Ejector 31 is activated by being struck at its rear by bolt stop 32 when bolt 12 is moved almost completely rearward.
Bolt stop 32 is mounted in receiver 11 and rides in a longitudinal bolt guide groove 33 seen in FIGS. 3 and 9 on the outer surface of bolt body 12. Bolt stop 32 thus also acts as a bolt guide and ejector actuator. During the phase of bolt operation when bolt 12 is forward, bolt stop 32, seen in FIG. 3 rides in a circumferential groove 34 on the outer surface of collar 56, best seen in FIG. 9. Circumferential groove 34 curves forward to index with bolt guide groove 33. At the curved section are chambering and extraction camming surfaces 35.
As may be seen in FIGS. 1 and 2, close to the front end of bolt 12, mounted in outer bolt sleeve locking lug recesses 36 in outer bolt sleeve 37 are rotating locking lugs 38. It is probably best to provide three such lugs 38, mounted 120 degrees apart around the barrel, but the exact number and spacing can vary. Lugs 38 function to transfer the force of firing recoil from bolt head 21 to receiver 11. A surface 42 of each lug 38 bears against a surface 41 of the receiver 11 when lug 38 is pivoted out in the firing position to transfer the recoil forces. In FIGS. 1 and 5, locking lugs 38 are shown in an extended out, locked bolt 12 position. In FIGS. 2 and 6, locking lugs 38 are shown in a retracted inward, bolt released position. Lugs 38 are pivotally mounted in outer bolt sleeve 37 at a forward end of lug 38 which is shaped spherically to mate with spherical axial bearing surface 39. Lugs 38 are pivotal radially from an inward withdrawn position (of FIGS. 2 and 6) to an outward locking position (of FIGS. 1 and 5) within receiver locking lug recesses 40.
As shown in FIGS. 1, 2, 7, and 8, pivoting locking lugs 38 are held in place at the rear end by engagement with an inner bolt sleeve 43 dovetail cutout 53, and are held at a forward end by engagement with forward axial bearing surface 39 of bolt 12. Unlike prior designs, locking lugs 38 do not have retaining pins.
Refer to FIG. 4. Bolt assembly 12 comprises an outer bolt sleeve 37 with recesses 36 to receive rotating locking lugs 38. Outer bolt sleeve 37 is longitudinally bored to accept inner bolt sleeve 43. Inner bolt sleeve 43 is also longitudinally bored (hole 23) to receive firing pin 44.
Inner bolt sleeve 43 is non-rotating, but is axially shiftable relative to outer bolt sleeve 37. Inner bolt sleeve 43 is actuated to shift in directions R or F by a separate camming mechanism near the rear of bolt 12 operably connected to bolt handle 45.
As seen in FIGS. 1, 2, and 3, firing pin 44 is longitudinally shiftable within inner bolt sleeve 43. Rearward motion R of inner bolt sleeve 43 relative to outer bolt sleeve 37 causes a corresponding rearward movement of firing pin 44 due to abutment of cocking piece 46 against the rear edge of inner bolt sleeve 43. This abutment forces firing pin 44 into a retracted and cocked position. A separate firing pin retracting mechanism is not required.
Firing pin 44 is prevented from motion forward along F to a firing position until inner bolt sleeve 43 is in the forward locking position. This safety provision prevents discharge of the cartridge with the bolt unlocked.
Refer to FIG. 1. Firing pin 44 is threaded at its rear end to cocking piece 46. Cocking piece 46 engages a sear 47 at a sear notch 48.
Firing pin 44 is spring loaded by an inner mainspring 49 and an outer spring 50 which fits into rear bolt sleeve 51 and bears against the rear of cocking piece 46.
Referring to FIGS. 1 and 2, the axial movement of inner bolt sleeve 43 provides a telescopic type mechanism for actuating the forward mounted rotating locking lugs 38.
As best seen in FIGS. 1, 2, 5, 6, and 7, inclined cam surfaces in a dovetailed slot 53 at the forward end of inner bolt sleeve 43 engage projections 52 from the under surface of rotating locking lugs 38. These dovetailed slot cam surfaces 53 serve to extend locking lugs 38 to the locked position of FIGS. 1 and 5. Surfaces 53 also retract lugs 38, drawing them flush with the outer diameter of bolt 12, as shown in FIGS. 2 and 6, releasing bolt 12 to move rearward along R.
Refer to FIGS. 5, 6, 7, and 8. A dovetail cam system for the control of lugs 38 comprises a female longitudinal dovetail slot 53 which is wider at its base than at its top. Male projection 52 of lug 38 slides in slot 53. Since dovetail slot 53 is inclined as shown in FIGS. 1 and 7, axial motion of inner bolt sleeve 43 along R or F impels a radial rotation of the entire lug 38 about its end engaged in bearing surface 39.
Since slot 53 and projection 52 are dovetailed together, any significant motion between the two except longitudinal sliding is prevented. This provides positive mechanical control of locking lugs 38 via inner bolt sleeve 43.
The cam system described above does not bear the axial compression load of cartridge recoil during firing. This load is transferred to the receiver via lugs 38.
At the rearward end of inner bolt sleeve 43 are two radially extending studs 54 opposed 180 degrees from each other, as best seen in FIG. 4. These inner bolt sleeve studs 54 slide in two stud guide slots 55 milled longitudinally in the rear end of outer bolt sleeve 37. Inner bolt sleeve 43 and firing pin 44 are non-rotating and slide axially together rearward relative to outer bolt sleeve 37. This axial motion, along F and R, is mechanically impelled by up and down movement of bolt handle 45. Bolt handle 45 is attached to a cylindrically shaped bolt collar 56 which slides over the rear portion of outer bolt sleeve 37 and rotates around the axis of outer bolt sleeve 37.
Inner bolt sleeve studs 54, while riding in longitudinal stud guide slots 55, extend beyond the outer surface of outer bolt sleeve 37 as seen in FIG. 1.
Refer to FIG. 4. Inner bolt sleeve studs 54 fit in two bolt collar inner spiral grooves 57 milled into the inner surface of bolt collar 56. Inner bolt sleeve studs 54 slide in inner spiral grooves 57 in response to rotational motion of bolt collar 56.
Upward motion of bolt handle 45 causes counterclockwise (viewed from the rear along F) motion of bolt collar 56.
The left hand spiral of the bolt collar inner spiral grooves 57 urges rearward non-rotating motion of inner bolt sleeve studs 54, inner bolt sleeve 43, and firing pin 44 to the position shown in FIG. 2. Conversely, downward motion of bolt handle 45 urges forward motion of inner bolt sleeve 43 but not firing pin 44 since firing pin 44 is captured in normal operation at a rearward cocked position by a sear 47 seen in FIG. 1.
When inner bolt sleeve studs 54 are at an extreme rearward position, with continued rotation of bolt collar 56, studs 54 are held at the rear by holding notches 58 in inner spiral grooves 57 seen in FIG. 4.
Refer to FIG. 3. The root of bolt handle 45 fits in bolt handle slot 61 in receiver 11.
Refer to FIGS. 1 and 4. Rear bolt sleeve 51 is threaded to the rear of outer bolt sleeve 37. Rear bolt sleeve 51 supports bolt collar 56. Pivotally mounted in the underside of rear bolt sleeve 51 is a sear 47 which engages sear notch 48 of firing pin cocking piece 46 when cocking piece 46 is moved to an extreme rearward position. Sear 47 is mounted in bolt 12, and not in the receiver or trigger mechanism as might be usual or expected.
Sear 47 is held in its cocked position by trigger mechanism 59 when bolt 12 is closed.
When bolt collar 56 is rotated fully counterclockwise approximately 65 degrees, and bolt 12 is moved rearward, bolt collr 56 must be locked in this position or it will tend to rotate out of position. Bolt collar lock 62, shown in FIG. 3, is pivotally mounted in rear bolt sleeve 51 and is actuated by a bolt collar lock cam pin 64 mounted in a bolt collar lock groove 63 in a receiver bridge 65 by axial motion of bolt 12. Rearward motion of bolt 12 locks bolt collar 56 to rear bolt sleeve 51 and prevents rotational motion until bolt 12 is again almost completely forward.
Bolt collar lock 62 also serves as a disassembly mechanism. Bolt collar lock 62 also locks rear bolt sleeve 51 to outer bolt sleeve 37, preventing rotation of bolt 12 in receiver 11 during rotation of bolt handle 45. Rear bolt sleeve 51 is prevented from rotation by the interference fit of bolt collar lock 62 in groove 63 in receiver bridge 65.
Magazine box 27, shown in FIG. 1, contains the cartridges which are urged upward by a magazine spring 66, shown partially compressed, and follower 67. The cartridges are held in place under magazine feed lips 68.
OPERATION
Assume that magazine 27 contains cartridges and the firearm has just been discharged. The operational sequence of events which follows will aid in an understanding of the mechanical details of the rifle.
Beginning with bolt 12 in the closed and locked position as in FIG. 1, but with firing pin 44 forward as in FIG. 3, assume that the operator lifts bolt handle 45 upward through an arc of approximately 65 degrees to the position of FIGS. 2 and 8. This lifting motion rotates bolt collar 56 counterclockwise. Studs 54 projecting from inner bolt sleeve 43 slide axially in stud guide slots 55 in outer bolt sleeve 37. Studs 54 also slide in inner spiral grooves 57 in bolt collar 56. Studs 54 and inner bolt sleeve 43 are urged rearward in the direction R. As inner bolt sleeve 43 is forced rearward, dovetailed slot 53 engages projection 52 of locking lugs 38 and urges locking lugs 38 downward out of receiver locking lug recesses 40 to a position flush with the outer surface of outer bolt sleeve 37 as seen in FIGS. 2 and 6. Simultaneously, the rearward movement of inner bolt sleeve 43 retracts firing pin 44 against the pressure of inner and outer mainsprings 49 and 50. At the extreme rearward position, firing pin cocking piece 46 is engaged at sear notch 48 by sear 47 mounted in rear bolt sleeve 51 as shown in FIG. 2.
During the last phase of bolt collar 56 rotation, bolt collar 56 and thus the entire bolt 12, is cammed rearward a small distance by bolt stop 32 contact with extraction cam surface 35 as shown in FIG. 9. The discharged cartridge, held to bolt face 22 by extractor hook 26, is removed a small distance along R from chamber 14, releasing the cartridge in case it is somewhat jammed. Bolt assembly 12 is now unlocked as in FIGS. 2 and 6, and free to move rearward.
Assume that the operator now moves bolt handle 45 along R to its extreme rearward position.
During rearward motion of bolt assembly 12, bolt collar lock 62 engages bolt collar lock cam pin 64 in bolt collar lock groove 63 in receiver bridge 65. This locks bolt collar 56 in position during the time bolt 12 is not completely forward.
As bolt 12 is moved rearward, bolt stop 32 is engaged in bolt guide groove 33. This engagement prevents rotation of bolt assembly 12 in receiver 11 and guides bolt 12 smoothly forward and backward.
As bolt 12 moves rearward, extractor 28 pulls cartridge 15 with it. As bolt 12 nears its rearmost position, bolt stop 32 strikes ejector 31 causing ejector 31 to strike the base of cartridge 15, ejecting cartridge 15 out of the ejection port of receiver 11.
At this point, a fresh cartridge moves up from magazine 27 to engagement with magazine feed lips 68. The rim of the cartridge will contact bolt face 22 at rim undercut 20 when bolt 12 is pushed forward along F.
As bolt 12 is pushed forward along F by the operator, the cartridge is pushed longitudinally under magazine feed lips 68 until the cartridge is free of contact with lips 68 and leaps upward. At that moment, the cartridge slides under extractor hook 26 and is captured and placed under control of extractor 28. If bolt 12 is moved rearward at this point, for any reason, but especially if bolt 12 is moved rearward in error by a frightened operator, cartridge 15 will follow the bolt and will be ejected before a new cartridge could be received from magazine 27.
In normal operation, cartridge 15 will be fed into chamber 14 as bolt 12 is moved to its forward position. Bolt collar lock 62 would be cammed to its unlocking position as in FIG. 1, allowing bolt handle 45 to be lowered.
As bolt handle 45 is lowered from position U (up) to position D (down) in FIG. 8, there is a cam forward displacement of bolt collar 56 by contact of bolt stop 32 with chambering cam surface 35 at the circumferential groove 34 shown in FIG. 9. Also, inner bolt sleeve 43 moves forward through its mechanical linkage to bolt collar 56. Firing pin cocking piece 46, having been engaged by sear 47, remains at its rearward position until sear 47 is released by trigger mechanism 59.
The surfaces of dovetail cams 53 at the forward end of inner bolt sleeve 43 cam rotating locking lugs 38 outward into receiver locking lug recesses 40, into the position shown in FIGS. 1 and 5.
Movement of outer bolt sleeve 37 forward along F toward barrel 13 has accomplished insertion of flange 19 into bolt rim undercut 20. Flange 19 fills undercut 20 completely within engineering tolerance.
The firearm is now ready for firing. Movement of trigger piece 60 to the rear releases sear 47, releasing firing pin 44. Under spring pressure, firing pin 44 moves rapidly forward, to the position of FIG. 3, striking cartridge 15 and detonating it.
For interpretation of the claims, the terms cartridge, receiver, extractor, barrel, and bolt are intended to have the meaning usual and common in the art of bolt action firearms. The following definitions are not exclusive, but inclusive and illustrative, of the general understanding of these terms to be gained from the art widely known to persons of ordinary skill in the manufacture of firearms. A cartridge is a case of approximately cylindrical geometry having a bullet or projectile at one end and containing an explosive propellant. A barrel is an elongated member having a cavity therethrough for supporting the cartridge during detonation and for guiding the projectile. The receiver is a structure attached to the barrel which contains the bolt mechanism for inserting the cartridge into the barrel. The firing chamber is a cavity partially formed by abutment of the bolt against the barrel which cavity supports the case of the cartridge. The extractor is a device which seizes the cartridge and pulls it out of the firing chamber after firing.
Other terms used in the claims, especially controlled round feeding, double loading, and undercut, are defined in this specification as well as generally in widely available literature. | A bolt action rifle having a flange projecting from a ring captured between the barrel and the receiver, the flange mating with the undercut in the bolt needed to pass the cartridge during loading into the grip of the extractor to achieve controlled round feeding, the flange serving to support the cartridge during detonation in the area of the cartridge which otherwise would be unsupported.
The mating of the flange with the undercut of the bolt requires a non-rotating bolt. An inner bolt sleeve is provided, axial movement thereof serving to control rotating locking lugs at the front of the bolt which lock the bolt during detonation. | 5 |
BACKGROUND
[0001] It is believed that the use of kava (Piper methysticum Forst.) predates written history. The origination of the plant is attributed to the New Guinea/Indonesia area and it is believed that Polynesian explorers were responsible for its spread from island to island. Oceania (i.e., the Pacific island communities of Micronesia, Melanesia and Polynesia) is an area where islanders have been known for centuries to consume a drink, also called kava and derived from the root of kava, in ceremonies and celebrations due to its reported calming effect and ability to promote sociability. The root and the drink were apparently first described in the Western world by Captain James Cook as a result of his exploration of the South Seas in 1768. Many myths and anecdotal stories surround the use of kava, and these vary from culture to culture.
[0002] The extract of the kava root is known to contain a class of structurally related chemical compounds known as kavalactones. At least sixteen different members of this chemical class are known to be present. A relaxing action (i.e., calming effect, sleep inducing effect) of the extract is attributed to certain members of this class. Kavalactones possess low bioavailability; in fact, they are practically insoluble in water. Thus, bioavailability in oral administration settings is always an issue that must be addressed. The mechanism of activity of the kavalactones remains uncertain, and their effect on cytokines, such as the interleukins is unclear.
[0003] Cytokines such as interleukin-12 (IL-12) mediate the acute phase response to inflammatory stimuli, enhance the microbicidal functions of macrophages and other cells, and promote specific lymphocyte responses. See, e.g., Fearon and Locksley, Science 272:50 (1996). Recently, in vivo studies implicate the inhibition of IL-12 production in therapeutic effects against inflammatory disorders such as sepsis (Zisman et al., Eur. J. Immunol. 27:2994 (1997)), collagen induced arthritis (Malfait et al., Clin. Exp. Immunol. 111:377 (1998)), established colitis (U.S. Pat. No. 5,853,697), experimental autoimmune encephalomyelitis (Leonard et al., J. Exp. Med. 181:381 (1995)), experimental autoimmune uveoretinitis (Yokoi et al., Eur. J. Immunol. 27:641 (1997)), psoriasis (Turka et al., Mol. Med. 1:690 (1995)), and cyclophosphamide induced diabetes (Rothe et al., Diabetologia 40:641 (1997)). Thus, compounds having IL-12 inhibitory activity provide new approaches for therapeutic strategies to address these and other IL-12 mediated disease.
SUMMARY
[0004] The invention is based in part on the unexpected discovery that three kavalactones, dihydrokawain, dihydromethysticin, and kawain (structures shown below), exhibit IL-12 inhibitory activity.
[0005] As such, the compounds, compositions and methods of this invention are useful in treating IL-12-mediated disease or disease symptoms (e.g., IL-12 overproduction-related disorders) in a subject. IL-12 mediated disease or disease symptoms refers to disease or disease symptoms in which IL-12 activity is involved, such as those wherein IL-12 is involved in signaling, mediation, modulation, or regulation of the disease process. IL-12 overproduction-related disorders involve those where overproduction of IL-12 is a basis for the disorder.
[0006] In one aspect, the invention relates to a medicinal ointment including 1% to 90% (e.g., 1% to 40%, 1.5% to 30%, 2% to 25%) by weight an active kavalactone selected from the group consisting of dihydrokawain, dihydromethysticin, kawain, and a combination thereof, and a medicinally acceptable carrier. The term “active kavalactone” herein refers only to dihydrokawain, dihydromethysticin, kawain, or a combination of them.
[0007] In another aspect, the invention is a patch (see, for example, U.S. Pat. No. 5,186,938) including an active kavalactone-containing material layer. More specifically, the material layer, e.g., a pad or a pressure-sensitive adhesive, serves as a substrate for receiving 1% to 90% (e.g., 1% to 40%, 1.5% to 30%, 2% to 25%) by weight an active kavalactone selected from the group consisting of dihydrokawain, dihydromethysticin, kawain, and a combination thereof. The active kavalactone can be in the form of a composition having 1% to 90% (e.g., 1% to 40%, 1.5% to 30%, 2% to 25%) by weight an active kavalactone associated ) with the material layer (e.g., impregnated, embedded, or coated on the surface. A patch optionally has a protective layer intimately adhered to one side of the material layer, which is resistant to passage of the active kavalactone.
[0008] The invention also relates to a method for treating (e.g., curing, preventing, or ameliorating) an IL-12 overproduction-related disorder, including administering to a subject (e.g., human, dog, cat) in need thereof an effective amount of an active kavalactone selected from the group consisting of dihydrokawain, dihydromethysticin, kawain, and a combination thereof. The method of treating has an effect on the disease itself or on the symptom. The effect can be objective, that is, a measurable physical effect (e.g., greater range of motion, reduced swelling, reduced rash area), or subjective, that is, based on the feeling or perception of the subject (e.g., decreased irritation, decreased soreness, general feeling of relief). The disorder that can be treated by the method includes colitis, Crohn's disease, diabetes, encephalomyelitis, multiple sclerosis, oesteoarthritis, periodontitis, psoriasis, rheumatoid arthritis, sepsis, and uveoretinitis.
[0009] Another aspect of the invention relates to a packaged product including a container, a composition containing an active kavalactone disposed in the container, the kavalactone being selected from the group consisting of dihydrokawain, dihydromethysticin, kawain, and a combination thereof, and a label (e.g., sticker, product insert) with the container and having instructions for application of the active kavalactone for treating an IL-12 overproduction-related disorder.
[0010] Also within the invention are a composition herein for use in treating disease (e.g., IL-12 mediated diseases or disease symptoms (such as osteoarthritis), or other diseases (such as fibromylagia), and use of such a composition for the manufacture of a medicament for the treatment of the aforementioned diseases or disease symptoms.
[0011] The details of one or more aspects of the invention are set forth in the accompanying FIGURE and the description below. Other features, objects, and advantages of the invention will be apparent from the description and from the claims.
DESCRIPTION OF DRAWING
[0012] [0012]FIG. 1 illustrates the IL-12 inhibitory activity of six kavalactones.
DETAILED DESCRIPTION
[0013] This invention is based in part on the unexpected discovery that specific kavalactones inhibit production of IL-12, whose overproduction is implicated in a number of diseases and disease symptoms. The IL-12 inhibitory activity of six major kavalactones (e.g., desmethoxyyangonin, dihydrokawain, dihydromethysticin, kawain, methysticin, and yangonin) was measured using a cellular assay for determination of IL-12 cytokine inhibition. Among them, kawain, dihydrokawain, and dihydromethysticin were found to have much higher IL-12 inhibitory activity relative to the other kavalactones. These results are shown in FIG. 1. Thus, compositions containing one of the three active kavalactones, kawain, dihydrokawain, dihydromethysticin, or a combination thereof, are useful for treating disease or disease symptoms related to IL-12 overproduction.
[0014] Referring back to FIG. 1, six kavalactones were tested in an IL-12 inhibitory assay as follows: Lipopolysaccharide (LPS, Serratia marscencens ) was obtained from Sigma (St. Louis, Mo.). Human recombinant IFNg was purchased from Boehringer Mannheim (Mannheim, Germany). Human peripheral blood mononuclear cells were isolated by centrifugation using Ficall-Paque (Pharmacia Biotech, Uppsala, Sweden) and prepared in RPMI medium supplemented with 10% FCS and antibiotics in a 96-well plate with 1×106 cells/well. Human PBMC were primed with IFNγ (30 U/mL) for 16 h and then stimulated with 1 mg/mL of LPS in the presence of different concentrations of test compound. Cell-free supernatants were taken 20 h later for measurement of cytokines. Cell viability was assessed using the bioreduction of MTS [3-(4,5-dimethylthiazol-2-yl)-5-(3-carboxymethoxyphenyl)-2-(4-sulfophenyl)-2H-tetrazolium] (Promega, Madison, Wis.). Cell survival was estimated as the ratio of the absorbance in compound-treated groups versus compound-free control. Human IL-12 was assayed using ELISA kits (Endogen, Cambridge, Mass.), essentially according to the manufacturer's instructions. IL-12 inhibition can also be measured by other methods (e.g., in vivo, in vitro, animal models) of assaying for enzyme inhibition activity.
[0015] This invention is also based in part on another unexpected discovery: the active kavalactones, i.e., dihydrokawain, dihydromethysticin, and kawain, can be administered effectively in a transdermal fashion (e.g., as a medicinal ointment). Upon homogeneous formulation in an inert carrier, the active kavalactones can be effectively administered in the absence of permeation enhancers (e.g., dimethyl sulfoxide, 1-dodecyoazacycloheptan-2-one, sodium guaiazulene-3-sulfonate). Thus, compositions of the invention can be administered as an ointment thus avoiding bioavailability problems associated with oral administration (e.g., first pass effects, short half-life in blood, degradation, cytochrome P450 metabolism, gut metabolism, liver or kidney metabolism, or absorption). Such administration techniques allow for systemic or local administration of the dihydrokawain, dihydromethysticin, kawain, or a combination thereof. A medicinal ointment of the invention includes allows for one or more active kavalactones to reach subcutaneous levels, and provides an effect beyond that of a cosmetic or dermapharmaceutical, which affects activities at skin level (e.g., skin cell respiration, regeneration, and hydration).
[0016] An ointment composition of the invention can be formulated with one or more of the active kavalactones suspended or dissolved in a carrier, such as mineral oil, liquid petroleum, white petroleum, propylene glycol, polyoxyethylene polyoxypropylene compound, emulsifying wax, water, sorbitan monostearate, polysorbate 60, cetyl esters wax, cetyl alcohol, 2-octyldodecanol, and stearyl alcohol. An acceptable carrier can include water, a solvent, an emollient, a surfactant, a preservative, or a combination thereof. Water, when present, can be in an amount of 5 to 80% by weight. Other than water, the acceptable carrier can also contain a relatively volatile solvent such as a monohydric C1-C3 alkanol (e.g., methyl alcohol or ethyl alcohol) in an amount of 1 to 70% by weight, and an emollient such as those in the form of silicone oils and synthetic esters in an amount of 0.1 to 30% by weight. Other solvents that are acceptable carriers include any suitable for administration of dihydrokawain, dihydromethysticin, and kawain, for example, dimethyl sulfoxide, C1-C20 alcohols, glycols, and ethers. Anionic, nonionic, or cationic surfactants can also be included in the biological acceptable carrier. The concentration of total surfactants can be from 0.1 to 40% by weight. Examples of anionic surfactants include soap, alkyl ether sulfate and sulfonate, alkyl sulfate and sulfonate, alkylbenzene sulfonate, alkyl and dialkyl sulfosuccinate, C8-C20 acyl isethionate, acyl glutamate, C8-C20 alkyl ether phosphate, and a combination thereof. Examples of nonionic surfactants include C10-C20 fatty alcohol or acid hydrophobe condensed with from 2 to 100 moles of ethylene oxide or propylene oxide per mole of hydrophobe; C2-C10 alkyl phenol condensed with from 2 to 20 moles of alkylene oxide; mono and di-fatty acid ester of ethylene glycol; fatty acid monoglyceride; sorbitan, mono- and di-C8-C20 fatty acid; block co-polymer (ethylene oxide/propylene oxide); polyoxyethylene sorbitan, and a combination thereof. Preservatives can also be included in the biological acceptable carrier to prevent growth of potentially harmful microorganisms, and can be employed in an amount of 0.01 to 2% by weight. Examples of preservatives include alkyl ester of para-hydroxybenzoic acid, hydantoin derivative, propionate salt, and a variety of quaternary ammonium compounds. Each preservative should be selected based on its compatibility with other ingredients in the composition. An ointment of this invention can be applied to any particular surface area of the body (including gums).
[0017] Also within the scope of the invention is a method for treating an IL-12 overproduction-related disorder, including administering to a subject (e.g., human, dog, cat) in need thereof an effective amount of an active kavalactone selected from the group consisting of dihydrokawain, dihydromethysticin, kawain, and a combination thereof. The effective amount of active kavalactone is between 0.01 and 100 mg/kg body weight per day, alternatively between 0.5 and 75 mg/kg body weight per day of dihydrokawain, dihydromethysticin, kawain, or a combination thereof. The effective amount is useful in a monotherapy or in combination therapy for the treatment of IL-12 overproduction-related disease or disease symptoms. As the skilled artisan will appreciate, lower or higher doses than those recited above may be required. Effective amounts and treatment regimens for any particular subject (e.g., human, dog, cat) will depend upon a variety of factors, including the activity of the specific compound employed, the age, body weight, general health status, sex, diet, time of administration, rate of excretion, drug combination, the severity and course of the disease, condition or symptoms, the patient's disposition to the disease, condition or symptoms, and the judgment of the treating physician or veterinarian.
[0018] To practice the method of the present invention, an active kavalactone-containing composition can be administered orally, parenterally, by inhalation spray, topically, rectally, nasally, buccally, vaginally, perineurally, epidurally, by iontophoresis, or via an implanted reservoir. The term “parenteral” as used herein includes subcutaneous, intracutaneous, intravenous, intramuscular, intraarticular, intraarterial, intrasynovial, intrasternal, intrathecal, intralesional and intracranial injection or infusion techniques.
[0019] A sterile injectable preparation, for example, a sterile injectable aqueous or oleaginous suspension, can be formulated according to techniques known in the art using suitable dispersing or wetting agents (such as, for example, Tween 80) and suspending agents. The sterile injectable preparation can also be a sterile injectable solution or suspension in a non-toxic parenterally acceptable diluent or solvent, for example, as a solution in 1,3-butanediol. Among the acceptable vehicles and solvents that can be employed are mannitol, water, Ringer's solution and isotonic sodium chloride solution. In addition, sterile, fixed oils are conventionally employed as a solvent or suspending medium (e.g., synthetic mono- or diglycerides). Fatty acids, such as oleic acid and its glyceride derivatives are useful in the preparation of injectables, as are natural pharmaceutically-acceptable oils, such as olive oil or castor oil, especially in their polyoxyethylated versions. These oil solutions or suspensions can also contain a long-chain alcohol diluent or dispersant, or carboxymethyl cellulose or similar dispersing agents. Other commonly used surfactants such as Tweens or Spans or other similar emulsifying agents or bioavailability enhancers which are commonly used in the manufacture of pharmaceutically acceptable solid, liquid, or other dosage forms can also be used for the purposes of formulation.
[0020] A preparation for oral administration can be any orally acceptable dosage form including, but not limited to, capsules, tablets, emulsions and aqueous suspensions, dispersions and solutions. In the case of tablets for oral use, carriers which are commonly used include lactose and corn starch. Lubricating agents, such as magnesium stearate, are also typically added. For oral administration in a capsule form, useful diluents include lactose and dried corn starch. When aqueous suspensions or emulsions are administered orally, the active ingredient can be suspended or dissolved in an oily phase combined with emulsifying or suspending agents. If desired, certain sweetening, flavoring, or coloring agents can be added. A nasal aerosol or inhalation composition can be prepared according to techniques well-known in the art of pharmaceutical formulation and can be prepared as solutions in saline, employing benzyl alcohol or other suitable preservatives, absorption promoters to enhance bioavailability, fluorocarbons, and/or other solubilizing or dispersing agents known in the art. An active kavalactone-containing composition can also be administered in the form of a suppository or an implantable device. Implantable devices and related technology are known in the art and are useful as delivery systems where a continuous, or timed-release delivery of pure kavalactone compounds or compositions delineated herein is desired. Additionally, the implantable device delivery system is useful for targeting specific points of pure kavalactone compound or composition delivery (e.g., localized sites, or organs). See, Negrin C M, Delgado A, Llabres M and Evora C., Biomaterials 22 (6), 563 (2001). Timed-release technology involving alternate delivery methods can also be used in this invention. For example, timed-release formulations based on polymer technologies, sustained-release techniques and encapsulation techniques (e.g., polymeric, or liposomal) can also be used for delivery of the pure kavalactone compounds and compositions delineated herein. Topical-patches having pure dihydrokawain, dihydromethysticin, kawain or a combination thereof, or a composition thereof are also included in this invention.
[0021] Acceptable carriers that can be used to prepare active kavalactone-containing compositions of this invention include, but are not limited to, ion exchangers, alumina, aluminum stearate, lecithin, self-emulsifying drug delivery systems (such as d-α-tocopherol polyethyleneglycol 1000 succinate), surfactants used in pharmaceutical dosage forms (such as Tweens or other similar polymeric delivery matrices), buffer substances (such as phosphates), glycine, sorbic acid, potassium sorbate, partial glyceride mixtures of saturated vegetable fatty acids, water, salts or electrolytes (such as protamine sulfate), disodium hydrogen phosphate, potassium hydrogen phosphate, sodium chloride, zinc salts, colloidal silica, magnesium trisilicate, polyvinyl pyrrolidone, cellulose-based substances, polyethylene glycol, sodium carboxymethylcellulose, polyacrylates, waxes, polyethylene-polyoxypropylene-block polymers, polyethylene glycol and wool fat. Other solubilizing agents can also be advantageously used to enhance delivery of dihydrokawain, dihydromethysticin, kawain, or a combination thereof.
[0022] Also within the invention is a patch to deliver active kavalactone. A patch includes a material layer (e.g., polymeric, cloth, gauze, bandage) and 1% to 90% (e.g., 1% to 40%) by weight an active kavalactone selected from the group consisting of dihydrokawain, dihydromethysticin, kawain, and a combination thereof. One side of the material layer can have a protective layer adhered to it to resist passage of active kavalactone compositions. The patch can additionally include an adhesive to hold the patch in place on a subject. An adhesive is a composition, including those of either natural or synthetic origin, that when contacted with the skin of a subject, temporarily adheres to the skin. It can be water resistant. The adhesive can be placed on the patch to hold it in contact with the skin of the subject for an extended period of time. The adhesive can be made of a tackiness, or adhesive strength, such that it holds the device in place subject to incidental contact, however, upon an affirmative act (e.g., ripping, peeling, or other intentional removal) the adhesive gives way to the external pressure placed on the device or the adhesive itself, and allows for breaking of the adhesion contact. The adhesive can be pressure sensitive, that is, it can allow for positioning of the adhesive (and the device to be adhered to the skin) against the skin by the application of pressure (e.g., pushing, rubbing,) on the adhesive or device. Also included are peelable masks that can be formulated by placing the composition as a gel or paste on a protective layer made of a film-forming polymer (e.g., polyvinyl alcohol) and an adhesive promoting polymer (e.g., hydrophobic acrylate or methacrylate polymer, such as Pemulen TR2.RTM. from the B.F. Goodrich Company). Alternatively, a hydrogel composition (see, for example, U.S. Pat. No. 5,961,479 or U.S. Pat. No. 5,306,504) including any one or more of the active kavalactones can be used.
[0023] The invention also covers a pharmaceutical composition having a pure active kavalactone selected from the group consisting of dihydrokawain, dihydromethysticin, kawain, or a combination thereof. Such a composition is useful for treating IL-12 mediated disease or disease symptoms, or other diseases (such as fibromylagia). Also within this invention is a method of treating disease or disease symptoms, (including IL-12 mediated disease or disease symptoms) in a subject by administering to the subject a pure kavalactone-containing composition. The subject can be a human or an animal (e.g., dog, cat). The term “pure” refers to a level of 90% or higher. Pure active kavalactone can be derived from natural (e.g., root extract and purification) or synthetic (e.g., synthesis from natural or synthetic materials) means, or a combination thereof.
[0024] A crude extract of the kava roots (obtained using various extraction methods (e.g., simple solvent soak, supercritical fluid extraction)) can be used as the source of active kavalactones for the preparation of a composition of this invention. If desired, the active kavalactones can be further purified by column chromatography. They can also be synthesized from readily available starting materials by conventional chemical methods. See, for example, Kostermans, Reclk. Trav. Chim. Pays-Bas., 70, 79 (1951); Klohs et al., J. Org. Chem., 24, 1829 (1959); Spino, et al. Tetrahedron Lett., 37, 6503 (1996), and references cited in each. The active kavalactones present in a composition can be enriched by addition of those kavalactones (from either natural or synthetic sources). The three active kavalactones (e.g., dihydrokawain, dihydromethysticin, and kawain) contain one or more asymmetric centers and thus can occur as racemates and racemic mixtures, single enantiomers, individual diastereomers and diastereomeric mixtures. They can also occur in cis- or trans- or E- or Z-double bond isomeric forms. All such isomeric forms can be tested using IL-12 assays to determine their inhibitory activity.
[0025] In order that the invention described herein may be more readily understood, the following examples are set forth. It should be understood that these examples are for illustrative purposes only and are not to be construed as limiting this invention in any manner. All references cited herein are expressly incorporated by reference in their entirety.
EXAMPLE 1
[0026] Kawain is synthesized essentially as follows. N-Bromosuccinimide (1 eq.) is slowly added to a 2.3M solution of ethyl β-methoxycrotonate (1 eq.) in carbon tetrachloride. Upon allowing the reaction to equilibrate, the mixture is heated at reflux for ca. 4 h. The mixture is then cooled (0° C.) and filtered, followed by washing of the precipitate with cold CCl 4 . The combined filtrates are concentrated (in vacuo, rotovap) and the residue distilled to give the desired product, ethyl γ-bromo-β-methoxycrotonate, whose identity is confirmed by various means including proton nuclear magnetic resonance spectrometry and mass spectrometry.
[0027] A 0.5M solution of ethyl γ-bromo-β-methoxycrotonate (1 eq.) in benzene is poured into a flask containing zinc filings (1.2 eq.). Cinnamic aldehyde (1.2 eq.) is added. Upon gentle warming to initiate the reaction, the mixture is refluxed for ca. 1 hr. The mixture is cooled, poured into cooled saturated aqueous ammonium chloride, and the aqueous phase extracted three times with ethyl ether. The combined extracts are dried over sodium sulfate, filtered and concentrated in vacuo. The resulting residue is recrystallized (MeOH) to give to give the desired product whose identity is confirmed by various means including proton nuclear magnetic resonance spectrometry and mass spectrometry.
EXAMPLE 2
[0028] Dihydrokawain is synthesized essentially as follows. Methyl 3-hydroxy-5-phenylpentanoate (1 eq.) in tetrahydrofuran is added to a solution of the lithium enolate of t-butyl acetate (3 eq., from lithium diisopropylamine and t-butyl acetate) at −78° C. and allowed to slowly warm to 0° C. The mixture is quenched with 1N HCl solution and extracted with dichloromethane. The combined extracts are washed with aqueous sodium bicarbonate, brine, dried over sodium sulfate, filtered and concentrated in vacuo to give a residue. The residue can be purified (silica gel chromatography) or converted directly. The resulting β-diketone is hydrolyzed with subsequent lactonization essentially according to the procedure of Tabuchi et al. (trifluoroacetic acid, dichloromethane; J. Org. Chem. 59, 4749, (1994)) to give the desired product, whose identity is confirmed by various means including proton nuclear magnetic resonance spectrometry and mass spectrometry.
EXAMPLE 3
[0029] Dihydromethysticin is synthesized essentially as follows. 10% Palladium on carbon (0.03 wt. eq.) is added to a 1M solution of methysticin (1 eq.) in tetrahydrofuran. The mixture is subjected to hydrogenation using a Parr apparatus at ca. 35 p.s.i. The mixture is filtered and the combined filtrates are concentrated (in vacuo, rotovap) to give a solid. The solid material is recrystallized ( i PrOH) to give the desired product, whose identity is confirmed by various means including proton nuclear magnetic resonance spectrometry and mass spectrometry.
EXAMPLE 4
[0030] A crude EtOH extract of kava-kava (100 g) containing about 40 g of kavalactones (PureWorld botanicals, NJ) was suspended into a mixture of water (300 mL) and ethyl acetate (200 mL). After removal of insoluble residues, the organic layer was separated from the aqueous layer. The aqueous layer was further extracted with ethyl acetate (200 mL×2) to produce organic extracts. All organic extracts were combined to obtain an organic solution, which was washed with a saturated NaCl solution (200 mL×2), dried over anhydrous NaSO 4 , and dried. The resulting dark brown oil (45 g) was purified by column chromatography with 800 g of Kieselgel 60 (230-400 mesh ASTM, EM Science, Germany), n-hexane/ethyl acetate (2:1) being the eluting solvent. Pale yellow kavalactone fractions were collected and dried to produce a partially crystallized amorphous oil (36 g). The total content of the kavalactones in the product thus obtained was about 93% by weight. Each of the three kavalactones, dihydrokawain, dihydromethysticin, and kawain, was identified by high pressure liquid chromatography.
EXAMPLE 5
[0031] A crude EtOH extract of kava-kava (100 mL) containing about 15 g of kavalactones (PureWorld botanicals, NJ) was concentrated under reduced pressure to remove excess EtOH. The concentrated extract (60 mL) was purified by column chromatography with 500 g of Florisil (200mesh, Aldrich), n-hexane/ethyl acetate (2:1) being the eluting solvent. Yellow kavalactone fractions were collected and dried to produce a pale yellow amorphous oil (13 g). The total content of the kavalactones in the product thus obtained was about 95% by weight.
EXAMPLE 6
[0032] A light yellow kava-kava extract (10 g) containing about 5 g of kavalactones (extracted by Phasex Corp., MA) obtained by a supercritical fluid extraction method (V.J. Krukonis, ACS Symposium Series 289 (1984), pp 155-175) was purified by column chromatography with 300 g Aluminum Oxide, Neutral (J. T. Barker, NJ), with n-hexane/ethyl acetate (2:1) being the eluting solvent. Pale yellow kavalactone fractions were collected and dried to produce a partially crystallized amorphous oil (4.2 g). The total content of the kavalactones in the product thus obtained was about 95% by weight.
EXAMPLE 7
[0033] Composition of a kavalactones-containing cream of this invention:
chemical name wt. % kavalactones 10 glycerin 1 propylene glycol 1 polyglycerylmethacrylate 1 hydroxyethylcellulose 0.5 magnesium aluminum silicate 0.5 imidazolidinyl urea 0.5 disodium EDTA 0.05 petrolatum 2 isopropyl palmitate 5 dimethicone 0.5 cetyl alcohol 0.5 isostearic acid 3 PEG-40 stearate 1 PEG-100 stearate 1 sorbitan stearate 1 glycolic acid 7 ammonium hydroxide pH adjusted to 4.4 deionized water qs to 100%
EXAMPLE 8
[0034] Composition of another kavalactones-containing cream of this invention:
chemical name wt. % kavalactones 10 Isostearyl Isononanoate 2.5 propylene glycol 1 hydroxyethylcellulose 0.5 magnesium aluminum silicate 0.75 cocoa butter 1.2 petrolatum 2 isopropyl palmitate 5 dimethicone 0.5 stearic acid 3 isostearic acid 1.5 glycerol stearate 1.5 PEG-40 stearate 1 PEG-100 stearate 1 cetyl/stearyl alcohol 2.5 glycerin 2.5 glycolic acid 10 propylparaben 0.1 ammonium hydroxide pH adjusted to 3.8 deionized water qs to 100%
EXAMPLE 9
[0035] Composition of another kavalactones-containing cream of this invention:
chemical name wt. % beeswax 24.5 kavalactones 5 vegetable oil (jojoba oil) 70 propylparaben 0.5
EXAMPLE 10
[0036] Composition of a cream, to which various amounts of kavalactones can be added:
ingredient wt (%) petrolatum 2 stearyl alcohol 0.5 isopropyl myristate 5 sorbitan monooleate 5 polyoxyl 40 stearate 5 propylene glycol 5 methylparaben 0.3 ammonium hydroxide pH adjusted to 4.4 deionized water qs to 100%
EXAMPLE 11
[0037] Composition of a kavalactones-containing jelly of this invention:
chemical name wt. % white petrolatum, USP 90 kavalactones 10
EXAMPLE 12
[0038] Composition of an oil-in-water emulsion, to which various amounts of kavalactones can be added:
chemical name wt. % xanthan gum 0.2 disodium EDTA 0.1 sodium PCA 0.5 diazodinyl urea 0.3 titanium dioxide 1 stearic acid 3 cyclomethicone 0.3 cetyl alcohol 0.5 glyceryl stearate 0.5 PEG-100 stearate 0.5 steareth-2 0.2 lecithin 0.5 tocopherol 0.2 octyl methoxycinnamate 6 glucono-1,5-lactone 6 glycolic acid 3 malic acid 2 lactic acid 2 green tea extract 1 triethanolamine pH adjusted to 3.8 deionized water qs to 100%
EXAMPLE 13
[0039] A patient with rheumatoid arthritis (left leg, joint) was unresponsive to several oral medications. A composition containing 5 g of cream (as described in Example 10) and 500 mg of kavalactones (as extract prepared according to Example 4) was administrated to the joint three times a day. Substantial relief of the rheumatoid arthritis symptoms was achieved 30 min after topically applying the kavalactones-containing cream to the joint.
EXAMPLE 14
[0040] A patient suffered from chronic lower back problems, which could not be relieved by oral drugs (such as aspirin and ibuprofen). Substantial relief of the symptoms (e.g., relief from burning sensation in the affected area, general relief to resume daily activity (e.g., walking) was achieved 10 min after applying the kavalactones-containing cream described in Example 13 to the back.
EXAMPLE 15
[0041] A patient suffers from fibromylagia symptoms in the left knee. Ten minutes after applying the kavalactones-containing cream described in Example 13 to the knee, the patient felt relief from discomfort.
EXAMPLE 16
[0042] A patient suffers from periodontitis (molars). Ten minutes after applying a kavalactones-containing jelly described in Example 11 (using kavalactone extract prepared according to Example 4) to the gum area, the symptoms were ameliorated, including reduced redness of the affected area and relief from discomfort.
Other Embodiments
[0043] While a number of embodiments of this invention have been described, it is apparent that they can be altered to provide other embodiments that utilize the products and processes of this invention. Therefore, it will be appreciated that the scope of this invention is to be defined by the claims rather than by the specific embodiments that have been represented by way of example. Accordingly, other embodiments are within the scope of the following claims. | This invention relates to compositions having health enhancing qualities, and more particularly to compositions having kavalactones, as well as use and preparation of the compositions. | 0 |
BACKGROUND
[0001] 1. Technical Field
[0002] The present disclosure relates to an apparatus for treating an open wound, and, more specifically, relates to a wound dressing for use in a subatmospheric pressure wound therapy procedure.
[0003] 2. Description of Related Art
[0004] Wound closure involves the migration of epithelial and subcutaneous tissue adjacent the wound towards the center of the wound until the wound closes. Unfortunately, closure is difficult with large wounds or wounds that have become infected. In such wounds, a zone of stasis (i.e. an area in which localized swelling of tissue restricts the flow of blood to the tissues) forms near the surface of the wound. Without sufficient blood flow, the epithelial and subcutaneous tissues surrounding the wound not only receive diminished oxygen and nutrients, but, are also less able to successfully fight microbial infection and, thus, are less able to close the wound naturally. Such wounds have presented difficulties to medical personnel for many years.
[0005] Wound dressings have been used in the medical industry to protect and/or facilitate healing of open wounds. One popular technique has been to use negative pressure therapy, which is also known as suction or vacuum therapy. A variety of negative pressure devices have been developed to allow excess wound fluids, i.e., exudates, to be removed while at the same time isolating the wound to protect the wound and, consequently, reduce recovery time. Various wound dressings have been employed to promote the healing of open wounds.
SUMMARY
[0006] Accordingly, the present disclosure is directed to further improvements in subatmospheric pressure wound therapy. In one preferred embodiment, a wound dressing apparatus includes an outer member dimensioned for positioning relative to a wound bed and defining an internal reservoir, a port associated with the outer member and in communication with the internal reservoir for applying subatmospheric pressure to the internal reservoir to facilitate treatment of the wound bed and removal of fluid therefrom, an inner member at least partially positionable within the wound bed and confined within the outer member, and an adhesive agent in contact with a peripheral section of the outer member to facilitate attachment of the peripheral section to the periwound tissue. The adhesive agent is preferably substantially devoid of contact with the inner member such that the integrity of the inner member is not affected or degraded, due to its otherwise contact with the inner member. In one embodiment, a layer of adhesive material is disposed on the peripheral section of the outer member.
[0007] A release member may be mounted to the layer of the adhesive material in at least partial superposed relation with the outer member. The release member is removable to expose the adhesive material. The layer of the adhesive material may be disposed on a major portion of one surface of the outer member. In another embodiment, the release member may define a plurality of release sections. The release sections may be selectively separable to expose a predetermined area of the layer of the adhesive material for attachment to the periwound tissue.
[0008] A supplemental member may be positioned over the inner member, to prevent contact of the adhesive layer with the inner member. The supplemental member may include a layer of gauze.
[0009] The adhesive agent may be a liquid agent applicable to the peripheral section of the outer member or applicable to the periwound tissue prior to attachment thereof to the periwound tissue. The adhesive agent may be thermally activated, adapted to be activated through application of ultraviolet energy, or adapted to be activated upon exposure to an exothermic catalyst.
[0010] In another embodiment, a pad member has the adhesive agent on one surface thereof. The pad member is dimensioned to be positioned about the peripheral section of the outer member to at least partially overlap and adhere to each of the peripheral section and the periwound tissue to thereby secure the outer member to the periwound tissue.
[0011] The inner member may include a material selected from the group consisting of foams, beads, nonwoven composite fabrics, hydrogels, cellulosic fabrics, super absorbent polymers, and combinations thereof. The inner member further may include at least one of a medicament, an anti-infective agent, an antimicrobial, polyhexamethylene biguanide (hereinafter, “PHMB”), antibiotics, analgesics, healing factors, vitamins, growth factors, debridement agents and nutrients.
[0012] A subatmospheric pressure source may be in fluid communication with the port. The subatmospheric pressure source supplies subatmospheric pressure to the internal reservoir.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] Various embodiments of the subject wound dressing are described herein with reference to the drawings wherein:
[0014] FIG. 1 is a side cross-sectional view of the wound dressing apparatus in accordance with the principles of the present disclosure positioned about a wound bed illustrating the outer member, inner member, adhesive member and the wound liner;
[0015] FIG. 2 is a view similar to the view of FIG. 1 illustrating the wound dressing subjected to subatmospheric pressure;
[0016] FIG. 3 is a plan view of an outer member in accordance with an alternate embodiment of the wound dressing;
[0017] FIG. 4 is a side cross-sectioned similar to the view of FIG. 2 illustrating the wound dressing of FIG. 3 positioned about the wound bed;
[0018] FIG. 5 is a side cross-sectional view similar to the view of FIG. 2 illustrating another embodiment of the wound dressing apparatus; and
[0019] FIG. 6 is a side cross-sectioned view similar to the view of FIG. 2 illustrating another embodiment of the wound dressing apparatus.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] The composite wound dressing of the present disclosure promotes healing of a wound via the use of a subatmospheric pressure reservoir. The subatmospheric pressure reservoir subjects the wound to subatmospheric pressure or a vacuum to effectively draw wound fluid, including liquid, exudates from the wound bed with continuous, or non-continuous, application of a subatmospheric pressure source or pump. Hence, subatmospheric pressure can be applied once, or in varying intervals, depending on the nature and severity of the wound until the composite wound dressing is saturated with exudate or the wound is healed. If the wound dressing is saturated with exudate and the wound is not healed, the composite wound dressing can be replaced and the process of applying subatmospheric pressure can be repeated.
[0021] Referring now to FIGS. 1-2 , the composite wound dressing apparatus 100 in accordance with a preferred embodiment of the present disclosure is illustrated in the form of an article with multiple layers arranged in juxtaposed or superposed relation. The multiple layers include, but, are not limited to a wound liner 102 , an inner member 104 an adhesive agent or member 106 , and an outer member 108 which includes and/or defines the internal subatmospheric pressure reservoir 110 .
[0022] The wound liner 102 is in direct contact with the wound bed “w”. The wound liner 102 is typically porous allowing passage of subatmospheric pressure to the wound bed. In one preferred embodiment, the base layer includes a “non-adherent” material. “Non-adherent” as used herein refers to a material that does not adhere to tissues in and around the wound bed. “Porous” as used herein refers to a material which contains numerous small perforations or pores which allow wound fluids to pass through the material to the dressing layers above. The passage of wound fluid through the porous material may be unidirectional such that wound exudate does not flow back to the wound bed. This direction flow feature could be in the form of directional apertures imparted into the material layer, a lamination of materials of different absorption to the wound liner 102 or specific material selection that encourages directional flow. Exemplary materials used as the wound liner 102 include a contact layer sold under the trademark XEROFLOW® by Kendall Corp., a division of TycoHealthcare. In the alternative, wound dressing apparatus 100 may be devoid of the wound liner 102 .
[0023] In addition, agents such as hydrogels, adhesives and medicaments could be bonded or coated to the wound liner 102 to reduce bioburden in the wound, promote healing and reduce pain associated with dressing changes or removal. Medicaments include, for example, antimicrobial agents, growth factors, antibiotics, analgesics, debridement agents and the like. Furthermore, when an analgesic is used, the analgesic could include a mechanism that would allow the release of that agent prior to dressing removal or change. Exemplary triggers of a release mechanism could be temperature change, moisture, ph, pressure and the like.
[0024] Inner member 104 may serve as an absorbent/packing layer. In this capacity, inner member 104 is intended to absorb and capture wound fluid and exudates. Exemplary absorbent materials include foams, nonwoven composite fabrics, fibers, hydrogels, cellulosic fabrics, alginates, super absorbent polymers, hydrophilic and hydrophobic beads, and combinations thereof. Typically, the inner member 104 can absorb up to about 100 cubic centimeters (cc) or more of wound fluid. The absorbent material may include the antimicrobial dressing sold under the trademark KERLIX® by Kendall Corp., a division of TycoHealthcare. In one embodiment, the inner member 104 could be preformed or shaped to conform to varying shapes of the wound bed. Those skilled in the art will recognize that the inner member 104 can be formed in any suitable shape. The inner member 104 may include multiple layers.
[0025] Additionally, the inner member 104 could be treated with medicaments. Medicaments include, for example, an anti-infective agent such as an antiseptic or other suitable antimicrobial or combination of antimicrobials, polyhexamethylene biguanide (hereinafter, “PHMB”), antibiotics, analgesics, healing factors such as vitamins, growth factors, nutrients and the like, as well as a flushing agent such as isotonic saline solution.
[0026] With continued reference to FIGS. 1-2 , the adhesive member 106 at least encompasses the perimeter of the wound dressing 100 to surround the wound bed to provide a seal around the perimeter of the wound bed “w”. For instance, the sealing mechanism may be any adhesive bonded to a layer that surrounds the wound bed “w” or an adhesive applied directly to the skin. The adhesive must provide acceptable adhesion to the periwound tissue “t” surrounding the wound bed “w” skin, e.g., the periwound area, and be acceptable for use on skin without contact deterioration (for example, the adhesive should preferably be non-irritating and non-sensitizing.) Typical adhesives can include acrylics, silicone, urethanes, hydrogels, rubber-based hydrogels and the like. The adhesive may be semi-permeable to permit the contacted skin to transmit moisture or may be impermeable. Additionally, the adhesive could be activated or de-activated by an external stimulus such as heat, light or a given fluid solution or chemical reaction. Adhesives include, for example, the dressing sold under the trademark ULTEC® Hydrocolloid or hydrogel sold under the trademarks of Curagel® or Aqua Flo® dressing by Kendall Corp., a division of TycoHealthcare.
[0027] In one embodiment, the adhesive member 106 is a layer of adhesive material, i.e., incorporated within or a component of the outer member 108 . Releasable contact liners may be incorporated within the outer member 108 to protect the adhesive member 106 prior to use as will be discussed. The adhesive member 106 may also be in the form of an entire layer proximal to the inner member 104 , or, may be annular or “donut shaped” as shown. Preferably, the adhesive member 106 is not bonded to the inner member 104 . In one embodiment, the adhesive member 106 is a component of the periphery of the outer member 108 . The adhesive member 106 is secured to the outskirts of the wound liner 102 and at least bonded to the periwound tissue “t” to be in overlapping relation with the tissue “t”. Alternatively, the adhesive member 106 may be positioned on the peripheral portion of the outer member 108 and secured to the tissue “t” about the wound bed “w”, and not bonded to the wound liner 102 . As a further alternative, the adhesive member 106 may be a liquid substance applied to the peripheral portion of the outer member 108 or the periwound tissue “t” prior to application of the wound dressing apparatus 100 . Preferably, the adhesive member 106 is substantially devoid of contact with the inner member 104 . With this relation, the adhesive member 106 will not affect the integrity of the inner member 104 nor come into contact with the healing tissue within the wound bed “w”.
[0028] The outer member 108 typically seals the top of the wound dressing 100 and helps maintain the appropriate subatmospheric pressure level within the wound dressing 100 . In one preferred embodiment, the outer member 108 includes the flexible transparent dressing manufactured under the trademark POLYSKIN® II by Kendall Corp., a division of TycoHealthcare. POLYSKIN® II is a transparent, semi-permeable material which permits moisture and oxygen exchange with the wound site, and provides a barrier to microbes and fluid containment. In another approach, the outer member 110 may be impermeable. As a further alternative, the outer member 108 may include a resilient, e.g., elastomeric, material in the shape, e.g., of a dome.
[0029] The outer member 108 defines a sealed or enclosed subatmospheric pressure reservoir 110 . The subatmospheric pressure reservoir 110 is preferably maintained at an appropriate subatmospheric pressure level for a predetermined period of time sufficient to initiate or complete healing of the wound bed “w”, i.e., to draw wound fluid and exudate away from the wound bed “w” while subjecting the wound to subatmospheric pressure. The subatmospheric pressure may be re-applied as needed to maintain a therapeutic effect. The subatmospheric pressure may be continuous or intermittent as desired.
[0030] As best seen in FIG. 1 , the subatmospheric pressure reservoir 110 is defined within the dome of the outer member 108 . As shown in FIG. 2 , once subatmospheric pressure is applied via the subatmospheric pressure source 112 , the dome of the outer member 108 is drawn downwardly toward the inner member 104 with the subatmospheric pressure or subatmospheric reservoir 110 created beneath the outer member 108 . Typically, the outer member 108 includes a subatmospheric pressure port or connector 114 in fluid communication with the subatmospheric pressure reservoir 110 . Preferably, the subatmospheric pressure port 114 includes a one-way valve (shown schematically as reference numeral 116 ) which provides unidirectional flow of suction and may provide a means for allowing connection of the composite wound dressing 100 to the subatmospheric pressure source 112 . The one way valve 116 may be incorporated within the subatmospheric pressure port 114 or, alternatively, be “in line” with the subatmospheric pressure source 112 . A flexible tubing 118 is connected to the subatmospheric pressure port 114 and the subatmospheric pressure source 112 . The tubing 118 provides suction to the wound from the subatmospheric pressure source 112 and enables the wound fluid or exudates to be transferred from the wound dressing 100 . The tubing 118 may be fabricated from PVC, silicone based material or other flexible materials (polymers). The tubing 118 may optionally include a connection to a collection canister 120 for wound drainage and debris. Hence, the subatmospheric pressure source 112 can draw wound fluid through the composite wound dressing 100 and tubing 118 into the canister 120 . In a preferred embodiment of the present disclosure, the canister 120 is portable so that the patient will have the freedom to move about rather than being confined to a fixed location. The canister 120 may also house an absorbent material to absorb wound fluid and exudate.
[0031] The subatmospheric pressure source 112 may apply subatmospheric pressure to the wound by means such as a manual pump as disclosed in commonly assigned U.S. Pat. No. 5,549,584 to Gross, the entire contents of which are hereby incorporated herein by reference. In the alternative, the subatmospheric pressure source 112 may include an automated pump. Typically, the subatmospheric pressure level is applied to achieve a range between about 20 mmHg to about 500 mmHg, more preferably, about 40 mmHg and about 125 mmHg. The automated pump may be a wall suction apparatus such as those available in an acute or sub-acute care facility. The automated pump may be in the form of a portable pump. The portable pump may include a small or miniature pump that maintains or draws adequate and therapeutic subatmospheric pressure levels. In a preferred embodiment, the pump is a portable, lightweight, battery operated, suction pump which attaches to the distal end of the tubing. Typically, the subatmospheric pressure source 112 has regulation means 122 to apply the optimal subatmospheric pressure for healing the wound. The regulation means 122 may include one or more pressure sensors 124 , 126 . One pressure sensor 124 may be utilized to detect the pressure within the subatmospheric reservoir 110 , and with the appropriate circuitry or logic associated with the regulations means 122 , may adjust (e.g., increase or decrease), delay, halt, and/or commence the operation of the subatmospheric pressure source 112 to achieve a subatmospheric pressure objective adjacent the wound. The pressure sensor 124 may be remote from the wound and in fluid communication with the subatmospheric reservoir 110 through the tubing 118 , or alternatively, may be positioned directly within the subatmospheric reservoir 110 and/or the wound dressing 100 and in electrical communication with the regulation means 122 through wiring or conduit extending through the tubing 118 . It is further envisioned that the pressure sensor 124 may be capable of sending remote, e.g., wireless signals, from the wound site to the regulation means 122 through a transmitter 128 to control operation of the subatmospheric pressure source 112 .
[0032] The pressure sensor 126 is envisioned to detect a change in pressure, e.g., an increase in negative pressure indicating that the canister 120 is full or near a full condition. In this embodiment, a filter 130 is disposed between the canister 120 and the subatmospheric pressure source 112 . Once the canister 120 becomes full and the exudates communicates with the filter 130 , the filter 130 becomes clogged or blocked and the subatmospheric pressure is substantially increased as detected by the pressure sensor 126 . As a result, the subatmospheric pressure source 112 is switched to an off condition to permit subsequent emptying or disposal of the canister 120 .
[0033] Tubing connector 114 , one-way valve 116 or tubing 118 may incorporate vent (schematically identified as numeral 132 ) to permit the clinician to manually vent to the atmosphere when a clog is connected, or to clear the lines of fluid. Vent 132 may be a valve which opens and closes or a perforated filter which may control leak rate so that the exudates may be able to be deposited into canister 120 .
[0034] Furthermore, the subatmospheric pressure source 112 would preferably contain a mechanism to detect a leak in the system if the optimal subatmospheric pressure is not achieved. Preferably, the subatmospheric pressure source 112 would also contain an indicator (not shown) to indicate when the optimal subatmospheric pressure is achieved. In the alternative, a hand pump in the form of a squeeze bulb or a foot pump may serve as the subatmospheric pressure source 112 .
[0035] Preferably, a pump is used as the subatmospheric pressure source 112 . Typical pumps include diaphragm or voice coil activated styles that can deliver variable subatmospheric pressure up to 18 liters/minute.
[0036] FIGS. 3-4 illustrate an alternate embodiment of the wound dressing apparatus 200 of the present disclosure. In accordance with this embodiment, outer member 202 includes a plurality of releasable liner sections 204 which cover the adhesive agent or member 206 disposed on the lower surface of the outer member 202 . The releasable liner sections 204 are independently separable from the outer member 202 about the perforated lines or score lines 208 to selectively expose the adhesive member 206 to generally correspond to the size of the wound bed. In one embodiment, the outer member 202 includes a plurality of concentric annular or circular releasable liner sections 204 . Thus, the clinician may remove the outer liner sections 204 as desired to expose the adhesive member 206 for securement of the outer member 202 to the periwound tissue “t”. The inner releasable liner sections 204 may be retained on the outer member 202 as desired to ensure that the adhesive member 206 will not come into contact with the inner member 210 as shown in FIG. 4 .
[0037] FIG. 5 illustrates an alternate embodiment of the wound dressing apparatus 300 . Wound dressing apparatus 300 may incorporate a supplemental member 302 positionable between the inner member 304 and the adhesive member 306 which may or may not be a component of the outer member 308 . The supplemental member 302 , thus, is in contact with the adhesive member 306 thereby preventing exposure of the inner member 304 to the adhesive member 306 . In one embodiment, the supplemental member 302 may be a gauze material such as the aforementioned KERLIX® and the inner member 304 may include a foam material.
[0038] FIG. 6 illustrates an alternative embodiment of the wound dressing apparatus 400 . In accordance with this embodiment, the adhesive member 402 is an annular or ring like member which is positionable onto the upper surface of the outer member 404 . The adhesive member 402 may include a base member 406 having a layer of adhesive 408 disposed on the base member 406 . A releasable liner may be positioned on the adhesive member 402 to protect the adhesive during transport. In use, the releasable liner may be removed to expose the adhesive member 402 . Thereafter, the adhesive member 402 is mounted to the outer surface of the outer member 404 and arranged to overlap the outer member 404 and the periwound tissue “t’ thus securing the outer member 404 to the patient. In one embodiment, the adhesive member 402 , i.e., the layer of adhesive material 408 , is thermally activated with the application of a thermal energy source as shown schematically by arrows 410 . In one aspect, the adhesive member 402 is activated by ultraviolet light. Alternatively, the adhesive member 402 is adapted to be activated upon exposure to an exothermic catalyst.
[0039] It is further contemplated that the wound dressing apparatus may incorporate external means or applications to stimulate tissue growth and/or healing. For example, an ultrasonic transducer may be incorporated into the wound dressing apparatus to impart mechanical energy for the treatment of the tissue such as, for instance, directing thermal or vibratory energy on the wound area to stimulate healing and/or further encouraging exudates removal by subatmospheric pressure and/or introducing various drugs into the human body through the skin. Other sensor types are also contemplated for incorporation into the wound dressing apparatus including oxygen, chemical, microbial and/or temperature sensors. The detection of oxygen adjacent the wound area would assist the clinician in determining the status of wound healing. The presence of an elevated temperature may be indicative of an infection.
[0040] While the disclosure has been illustrated and described, it is not intended to be limited to the details shown, since various modifications and substitutions can be made without departing in any way from the spirit of the present disclosure. Accordingly, further modifications and equivalents of the invention herein disclosed can occur to persons skilled in the art using no more than routine experimentation, and all such modifications and equivalents are believed to be within the spirit and scope of the disclosure as defined by the following claims. | A wound dressing apparatus for use in subatmospheric pressure therapy includes an outer member dimensioned for positioning relative to a wound bed and defining an internal reservoir, a port associated with the outer member and in communication with the internal reservoir for applying subatmospheric pressure to the internal reservoir to facilitate treatment of the wound bed and removal of fluid therefrom, an inner member at least partially positionable within the wound bed and confined within the outer member, and an adhesive agent in contact with a peripheral section of the outer member to facilitate attachment of the peripheral section to the periwound tissue. The adhesive agent is preferably substantially devoid of contact with the inner member. In one embodiment, a layer of adhesive material is disposed on the peripheral section of the outer member. | 0 |
FIELD OF THE INVENTION
[0001] This invention relates to the design, and automation thereof, of high-performance digital integrated circuits. The invention is particularly directed to the problem of obtaining timing closure of entire integrated circuits or functional units of an integrated circuit by optimizing or tuning individual macros that constitute the functional unit or integrated circuit.
RELATED APPLICATIONS
[0002] D. J. Hathaway, L. K. Lange, C. Visweswariah and P. M. Williams, “Method of Design Marking for Partial Macro Tuning,” filed ______ under U.S. Ser. No. ______ (0081).
[0003] E. K. Cho, D. J. Hathaway, M. Hsu, L. K. Lange, G. A. Northrop, C. Visweswariah, C. Washburn, P. M. Williams, J. Zhou, “A circuit tuning methodology whereby synthesized random logic macros are tuned in a continuous design space and the optional insertion of low threshold voltage devices,” filed ______ under U.S. Ser. No. ______ (0206).
[0004] These co-pending applications and the present application are owned by one and the same assignee, International Business Machines Corporation of Armonk, N.Y.
[0005] The descriptions set forth in these co-pending applications are hereby incorporated into the present application by this reference.
[0006] Trademarks: IBM® is a registered trademark of International Business Machines Corporation, Armonk, N.Y., U.S.A. Other names may be registered trademarks or product names of International Business Machines Corporation or other companies.
BACKGROUND
[0007] Achieving timing closure of high-performance digital integrated circuits (or functional units of a high-performance digital integrated circuit) implies obtaining sufficient timing performance from the design. This may mean, for example, being able to operate the clock fast enough to obtain the required performance while guaranteeing functional correctness. Achieving timing closure is an important, iterative and time-consuming step in the design of any digital integrated circuit. Particularly in microprocessor designs, timing requirements, logic requirements and technology parameters are often changed late in the design cycle, making automated design closure techniques extremely valuable.
[0008] Prior-art methods are illustrated in FIG. 1 (flow 100 ). Because the overall design is too large and complex to optimize at once, prior-art methods typically divide the design into partitions called macros, and assign to each individual macro a timing and area budget by a process of apportionment (box 110 ). Then each macro is designed or the design is refined with the goal of meeting its budget, either by a process of automated synthesis or by means of custom design techniques (box 120 ). The optimization at this stage takes many forms such as logic re-structuring, buffer insertion, transistor sizing and use of low threshold voltage devices. The resulting design is timed, typically by means of static timing analysis (box 130 ). If every macro meets its budget, it is obvious that timing closure is achieved and the design is complete (box 150 ). More typically, the apportionment process is imperfect and involves some conjecture and guesswork. Hence, several macros will not meet their budgets, and overall timing closure is not achieved, as detected by box 140 . In this case, the apportionment process is repeated (box 110 ), individual macros are then redesigned and/or re-optimized (box 120 ), and the resulting overall design is timed (box 130 ), and this process iteratively repeated until timing closure is obtained (box 150 ), as depicted in FIG. 1. The main difficulty in prior-art techniques is that the application of automatic optimization techniques on individual macros interferes with the achievement of overall timing closure. This problem is illustrated in FIG. 2. Consider the simple case of macro A (box 200 ) feeding macro B (box 210 ). A short path of delay 200 time units of macro A feeds a long path of delay 600 time units of macro B. A different long path of delay 600 time units of macro A feeds a different short path of delay 200 time units of macro B, as shown in FIG. 2. Assume that all output signals are required to be available by time 700 . In this case, the initial design is missing timing closure by 100 time units, or, in other words, the initial design has a slack of −100 time units. Slack is defined as the algebraic difference between required arrival time (RAT) and actual arrival time (AT). One particular prior-art apportionment technique will assign this negative slack of 100 time units to each of the two macros, giving the optimization procedures applied to each macro the opportunity to see and correct the entire negative slack of the global path. Using this apportionment method, the required arrival times will be 100 and 500 at the upper and lower outputs of macro A, respectively, and 700 at both the upper and lower outputs of macro B, and the arrival times will be zero at both the upper and lower inputs of macro A, and 200 and 600 at the upper and lower inputs of macro B, respectively, as shown in the Figure.
[0009] Suppose the short paths cannot be improved, but there is room for improvement in the long paths. It is clear from this example that improving the two long paths from 600 to 500 units will achieve overall timing closure. Unfortunately, prior-art methods will never achieve timing closure in this case, since the redesign and re-optimization of individual macros typically target the worst slack, and because the short paths cannot be improved, the redesign and re-optimization techniques have no incentive to improve the delay of the long paths.
[0010] Another prior-art apportionment method, one iteration of which is illustrated in FIG. 3, would divide the negative slack according to the fraction of the global path delay suffered in each macro, and in the example of FIG. 2, would assign −25 time units of the upper path slack to macro A, −75 of the upper path slack to macro B, −75 of the lower path slack to macro A, and −25 of the lower path slack to macro B. Using this apportionment method, the required arrival times will be 175 and 525 at the upper and lower outputs of macro A, respectively, and 700 and 700 at both the upper and lower outputs of the second macro B, and the arrival times will be zero at both the upper and lower inputs of macro A, and 175 and 525 at the upper and lower inputs of macro B, respectively. The situation after one iteration is depicted in FIG. 3.
[0011] Suppose now that each of the delays through each of the macros can be decreased by 50 units by optimization. Again, prior-art methods will never achieve timing closure under this apportionment scheme, since the redesign and re-optimization of individual macros typically target the worst slack, and because the long paths cannot be improved beyond 550, the redesign and re-optimization techniques have no incentive to improve the delay of the short paths, and upon successive iterations through loop of FIG. 1, the delays and targets will be adjusted by decreasing amounts, and will asmyptotically approach but not reach timing closure.
[0012] With this second prior-art apportionment method, if the long paths in each macro can be improved by 100 units each, and the short paths cannot be improved at all, it is clear that although an easy solution exists for global timing closure, the iteration of FIG. 1 will not converge to the solution in reasonable time. The reason is that the short path's stubborn negative slack at each iteration of FIG. 1 will limit the improvement that is targeted for the long path of each macro.
[0013] Irrespective of the apportionment method employed, the crux of the problem is that prior-art optimization techniques target only paths with the worst slack and therefore do not improve sub-critical slacks even though such actions would help achieve timing closure from a global vantage point. Improving sub-critical paths also makes it easier downstream in the methodology to focus design efforts in limited areas of the circuit to obtain timing convergence. Thus the formulation of the objective function during individual macro optimization has the unwanted consequence of preventing or impeding overall timing convergence.
[0014] It is to be appreciated that this simple example merely illustrates the problem. With a large number of macros and a large number of interconnections between them, the problem is exacerbated and achievement of timing closure becomes an extremely hard problem, leading to costly redesign efforts and increased time-to-market of the product.
SUMMARY OF THE INVENTION
[0015] This invention relates to an improved method for achieving timing closure. During the design iterations, focusing solely on the most critical (or limiting) slack inhibits overall timing closure. Instead, this invention reformulates the objective of the redesign and re-optimization phase so that there is an incentive during automatic optimization to improve not only the arrival time of the most critical signals, but other sub-critical signals as well. Instead of the prior-art focus on the most critical signal or signals, the inventive method creates an incentive to optimize the arrival time of every output signal, the incentive being proportional to the criticality of the signal. Thus once the most critical signals cannot be further improved, sub-critical signals are improved, leading to more efficient and effective overall timing closure.
[0016] These and other improvements are set forth in the following detailed description. For a better understanding of the invention with advantages and features, please refer to the detailed description and to the drawings.
DESCRIPTION OF THE DRAWINGS
[0017] [0017]FIG. 1 illustrates a typical prior-art iterative procedure for achieving timing closure of a high-performance digital integrated circuit or functional unit of a high-performance digital integrated circuit.
[0018] [0018]FIG. 2 illustrates an example situation in which prior-art optimization techniques will lead to inefficient achievement of timing closure, or not achieve timing closure at all.
[0019] [0019]FIG. 3 illustrated the same example situation as FIG. 2, but with application of one iteration of a second prior-art apportionment scheme; again, prior-art optimization techniques will not achieve timing closure.
[0020] [0020]FIG. 4 illustrates the dependence of the penalty contributed by a signal on its criticality, using the preferred objective function reformulation.
[0021] [0021]FIG. 5 illustrate the dependence of the logarithm of the penalty contributed by a signal on its criticality, using the preferred objective function reformulation.
[0022] [0022]FIG. 6 illustrates an example slack histogram showing the slack histogram before optimization, after optimization with prior-art formulation of the objective function and after optimization with the inventive objective function reformulation.
[0023] Our detailed description below explains the preferred embodiments of out invention, together with advantages and features, by way of example with reference to the drawings.
DETAILED DESCRIPTION OF THE INVENTION
[0024] The heart of the invention is the reformulation of the objective function of any optimization that is performed by automatic means to improve individual macros. The reformulation makes the overall timing closure loop more effective and efficient. Traditional circuit optimization tools such as EinsTuner formulate the optimization problem in one of two ways, as described below. A description of EinsTuner is available in A. R. Conn, I. M. Elfadel, W. W. Molzen, Jr., P. R. O'Brien, P. N. Strenski, C. Visweswariah and C. B. Whan, “Gradient-based optimization of custom circuits using a static-timing formulation,” Proceedings of the 1999 Design Automation Conference, June 1999, pages 452-459. The description below assumes a simple combinational circuit to illustrate the detailed description of the invention. It is to be understood that the formulation can easily be extended to situations containing sequential elements including all types of latches and possibly multiple clocks by one of skill in the art.
[0025] It is to be noted that the reformulation of the objective function is being demonstrated by means of the example of transistor sizing by a formal, mathematical optimizer. However, the inventive method is applicable to any type of circuit change such as logic restructuring, buffering or use of low threshold voltage devices, and to any optimization method such as heuristic optimization, linear programming, nonlinear programming, branch-and-bound, dynamic programming or simulated annealing, provided the method of optimization makes use of an objective (or “cost” or “merit”) function that is to be minimized. The inventive method simply reformulates that objective function.
[0026] The first traditional formulation is delay minimization in which the problem is formulated as follows:
min z
s.t. z≧AT i −RAT i ,i= 1,2 , . . . ,n
[0027] where z is an auxiliary optimization variable representing the negative slack of the circuit, n is the number of primary output signals of the combinational circuit, AT i and RAT i are the arrival time and required arrival time of the i th primary output signal. It is to be understood that many other constraints like area and slew constraints are required to render the results of the optimization practical, but the simplistic formulation above serves to illustrate a point. At optimality, z is larger than the negative of the worst slack among all the primary outputs, and has the smallest possible value, hence the circuit has the smallest possible negative slack, or equivalently, the largest possible positive slack. It is clear that such a formulation will lead to a large number of equally critical paths, as explained in the above-mentioned Design Automation reference. Further, it is clear that if there is a limiting signal whose slack cannot be further improved, optimization based on this prior-art formulation has no incentive to improve any signal with a slack worse than the limiting signal's slack.
[0028] The second traditional formulation is area minimization, in which the problem is formulated as follows:
min area
s.t. AT i ≦RAT i −desired — slack, i= 1,2 , . . . ,n
[0029] where the area of the circuit is minimized subject to timing constraints, and desired_slack represents an (algebraic) additional slack required by the user. Using desired_slack merely provides a notational convenience, since the required arrival times could be modified to reflect the additional desired slack. Note that a positive required_slack value makes the problem more difficult to solve. It is clear that even in this second formulation, a large number of equally critical paths will result, especially since area is “stolen” from sub-critical paths to speed up critical paths. Further, once a primary output signal achieves its timing requirement, there is no further incentive to improve its timing.
[0030] Thus, both traditional optimization formulations described above do not solve the problem of encouraging the optimizer to pay attention to sub-critical paths. Instead, this invention proposes a new formulation of the objective function as follows:
∑ i = 1 n f ( - slack i ) = ∑ i = 1 n ( f ( - RAT i - AT i - desired_slack ) )
[0031] where f is a penalty function and slack i is the effective slack of the i th primary output, taking desired_slack into account. Thus the negative slack of each and every primary output is represented in the objective function. The key decision to be made is the choice of the function f, since it is desired that the signals that are most critical contribute the most to the objective function, thus giving the optimizer the most incentive to improve the timing of such signals. At the same time, if those signals cannot be improved any more, it is desired that sub-critical signals also have substantial contribution to the objective function, thus incenting the optimizer to improve their timing properties as well. Clearly, f should be a decreasing function of its argument. If applied in a formal mathematical continuous optimizer, f should preferably be a smooth, continuous and continuously differentiable function.
[0032] In a preferred version of this invention, the choice of f is as follows:
f ( x ) = exp ( 3 + 5 x worst_starting _slack )
[0033] At the start of the optimization, the limiting primary output will have a slack equal to the worst_starting_slack (usually a negative number), and hence the contribution of this signal to the objective function is exp(8). As the optimization progresses, if a primary output signal achieves its timing requirement, the effective slack is 0, hence the contribution to the objective function is exp(3). If the timing of this signal further improves, the contribution to the objective function gets smaller, and the rate of decrease in the contribution to the objective function per unit of timing improvement also decreases. In the meanwhile, even if a signal does not achieve its timing requirements, there is sufficient incentive on sub-critical signals to improve their timing characteristics, since every signal contributes a term to the objective function. That term gets smaller as timing requirements are closer to being met. FIG. 5 shows the variation of f with its argument (negative of the effective slack), and FIG. 6 shows the same data on a logarithmic scale.
[0034] Applying this method to the simple example of FIG. 2, we see that even though the “short path” cannot be improved in the two individual macros being tuned, there is sufficient incentive to improve the long paths even though they are non-limiting paths, and the overall loop moves towards timing closure.
[0035] Typical results obtained by using this invention on a sample individual macro are shown in the slack histogram of FIG. 6. In a slack histogram, the horizontal axis represents slack, and the vertical axis value of a point on the curve represents the number of paths with that slack or better. It is clear that traditional optimization has no incentive to improve sub-critical paths. The inventive method not only improves the limiting slack of the macro, it also improves the timing characteristics of each and every signal with an incentive proportional to its respective criticality.
[0036] One reason to reformulate the objective function is to obtain more “separation,” where separation is the difference between the slack of a sub-critical path and the overall slack of the macro. This separation has beneficial properties in obtaining global timing convergence, as taught by this invention. It is to be noted that another reason to obtain separation is to be relatively immune to downstream changes in the design, modeling or manufacturing of the circuit, as disclosed in X. Bai, D. J. Hathaway, P. N. Strenski, and C. Visweswariah, “Parameter-Variation Tolerant Method for Circuit Design Optimization,” Docket FIS920020034US1, filed May 30, 2002. In that invention, penalty terms were added to the traditional objective function to obtain separation in order to be tolerant to downstream changes or modeling uncertainties. In contrast, the objective function in this invention is reformulated to obtain separation while simultaneously incenting the optimizer to work hardest on the most critical path(s) in order to enhance timing convergence at the functional-unit or chip-level. The uncertainty-awareness and all the benefits thereof that are obtained by increased separation are preserved by the present invention.
[0037] The commercial application of our invention can be applied to any type of formal or heuristic optimization which requires the formulation of an objective function; it can be applied to any type of circuitry that is amenable to static timing analysis; it can be extended to application having master-slave latches, transparent latches, multi-cycle clocks, multi-frequency clocks and dynamic circuits.
[0038] While the preferred embodiment 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. | Disclosed is a method for enhanced efficiency and effectiveness in achieving timing closure of large, complex, high-performance digital integrated circuits. Circuit macros are re-optimized and re-tuned in the timing closure loop by means of a reformulated objective function that allows the optimizer to improve the slack of all signals rather than just the most critical one(s). The incentive to improve the timing of a sub-critical signal is a diminishing function of the criticality of the signal. Thus all signals are improved during the optimization, with the highest incentive to improve on the most critical signals, leading to faster and more effective overall timing closure. | 6 |
This Application is a divisional of U.S. patent application Ser. No. 10/630,327 filed Jul. 30, 2003, now U.S. Pat. No. 6,845,576 entitled MATERIALS MOVING BLADE which is a Continuation-in-Part of U.S. Design patent application 29/171,447, filed Nov. 21, 2002 now U.S. Pat. No. D 478,097 entitled; SNOW MOVING APPARATUS and application No. 29/185,854, filed Jul. 3, 2003 now U.S. Pat. No. D 519,128 also entitled; SNOW MOVING APPARATUS.
FIELD OF THE INVENTION
The present invention relates to a materials pushing or moving blade for use with heavy equipment vehicles, for example, a bulldozer or loader and more specifically to a method and apparatus for moving snow, specifically a snow moving blade having a reinforcing gusset for strengthening the extended sidewalls of the snow moving blade.
BACKGROUND OF THE INVENTION
In general, heavy equipment, for example, a bulldozer, loader, etc., for moving materials, e.g., earth, snow, refuse, etc., are provided with a main blade which is attached to a hydraulically articulated blade adjustment device on the vehicle. A general materials moving blade is a substantially planar, rectangular piece of steel which may have a substantially vertically oriented curve or bend along its length to facilitate materials handling and moving. It is also known that these blades may be divided into horizontally adjacent blade segments for materials handling purposes as well. The blades are also often provided with a replaceable or reinforced lower edge to replace or prevent damage to the blade from the ground surface over which the blade is pushed, pulled or carried by the machinery.
For purposes of snow removal, such above described blades are provided with a substantially longer longitudinal length than conventional earth moving blades due to the generally lighter and more consistent nature of snow relative to other materials. The longer length facilitates the clearing of large swaths of, for example, roads, parking lots, loading docks etc., of commercial and industrial centers during the winter months.
In order to contain the snow within the span or longitudinal length of the blade, sidewalls are often attached to the ends of the blade extending substantially perpendicularly out from the blade, i.e., parallel to the direction of travel of the equipment. This ensures that as much snow as possible is maintained in front of the blade, i.e., snow does not spill off the ends of the main blade. The sidewalls are usually a single, relatively thin piece of steel to keep the blade as light weight as possible
A problem that arises with such apparatus is the lack of strength in the connection or joint between each sidewall attached at opposing ends of the blade. The substantially perpendicular welded joint attaching each sidewall to the blade, as is usual in the art, provides attachment but only minimal support for the relatively thin sidewall which extends a desired distance out in front of the main blade. Without any support other than the joint with the main blade, the thin sidewalls can be easily damaged, and are particularly susceptible to being bent outwards by sufficient snow loads within the confines of the box blade, especially as the machine pushes the blade with a load.
In order to overcome this problem of stability and to better secure the sidewalls to the main blade and prevent such damage, a support bar, tube, or a multiplicity of such bars or tubes are often welded between each sidewall and main blade. The support(s) are generally horizontal to the ground, i.e., perpendicular relative to but spaced from the substantially vertical joint between the sidewall and main blade. The support thus forms a triangular-type brace between the front surface of the main blade and the inner side of the sidewall to provide further rigidity and support to the sidewall.
These previously known supports present several problems, including a space between the support and the joint in which objects could be caught up or entangled. Also, such a horizontal support tends to form a shelf or trap for snow, ice or other debris which cannot become loosened without the operator intervening. In snow plowing, snow may build up in and around these supports and in order to remove such build up of snow, the operator must strike the blade upon the ground surface to loosen the snow or must physically remove the buildup by exiting from the cab and scraping the snow out, all of which may cause damage and time delays with respect to snow removing.
OBJECT AND SUMMARY OF THE INVENTION
Wherefore, it is an object of the present invention to overcome the above mentioned shortcomings and drawbacks associated with the prior art.
Another object of the present invention is to provide a materials moving blade having sidewalls which are strengthened relative to the main blade by a conic section gusset.
A further object of the invention is to provide the gusset with a substantially larger base portion adjacent the connected ends of the main blade and sidewall to a substantially smaller apex portion adjacent the extended free end of the sidewall.
Yet another object of the present invention is to provide a gusset for strengthening a joint between substantially perpendicular members of a heavy equipment blade which easily sheds materials being plowed, for example, snow, ice and/or earth where the materials being moved or plowed contact only a contiguous forward facing surface to facilitate disengagement of the material from the blade or bucket.
A still further object of the present invention is to provide an easy to manufacture and economical support gusset to provide increased strength and stability of the material mover with the least amount of additional weight to the blade or bucket.
The present invention also relates to a materials moving blade for attachment to a vehicle comprising a main blade ( 2 ) defined by a first and second ends, a top edge ( 18 ), a bottom edge ( 20 ) and a front and back surfaces ( 4 , 6 ); a first sidewall ( 26 ) and a second sidewall ( 28 ) attached to and extending substantially perpendicular from the respective first and second ends of the main blade ( 2 ); a first support gusset extending from a larger base portion connected to the front surface ( 4 ) of the main blade ( 2 ) to a smaller apex portion connected to the first sidewall ( 26 ); a second support gusset extending from a larger base portion connected to the front surface ( 4 ) of the main blade ( 2 ) to a smaller apex portion connected to the second sidewall ( 28 ).
The present invention also relates to a materials moving box blade ( 1 ) comprising a main blade ( 2 ) defined by a first and second ends, a top edge ( 18 ), a bottom edge ( 20 ) and a front and back surfaces ( 4 , 6 ); a first sidewall ( 26 ) and a second sidewall ( 28 ) attached to and extending substantially perpendicular from the respective first and second ends of the main blade ( 2 ); a first support gusset extending from a larger base portion connected to the front surface ( 4 ) of the main blade ( 2 ) to a smaller apex portion connected to the first sidewall ( 26 ); a second support gusset extending from a larger base portion connected to the front surface ( 4 ) of the main blade ( 2 ) to a smaller apex portion connected to the second sidewall ( 28 ).
The present invention also relates to a method of strengthening a materials moving box blade ( 1 ), the method comprising the steps of providing a main blade ( 2 ) defined by a first and second ends, a top edge ( 18 ), a bottom edge ( 20 ) and a front and back surfaces ( 4 , 6 ); attaching a first sidewall ( 26 ) and a second sidewall ( 28 ) to and extending substantially perpendicular from the respective first and second ends of the main blade ( 2 ); attaching a first support gusset extending from a larger base portion connected to the front surface ( 4 ) of the main blade ( 2 ) to a smaller apex portion connected to the first sidewall ( 26 ); attaching a second support gusset extending from a larger base portion connected to the front surface ( 4 ) of the main blade ( 2 ) to a smaller apex portion connected to the second sidewall ( 28 ).
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described, by way of example, with reference to the accompanying drawings in which:
FIG. 1 is a front perspective view of the materials moving apparatus;
FIG. 2 is a rear perspective view of the materials moving apparatus;
FIG. 3 is a front elevational view of the materials moving apparatus;
FIG. 4 is a rear elevational view of the materials moving apparatus;
FIG. 5 is a bottom plan view of the materials moving apparatus;
FIG. 6 is a top plan view of the materials moving apparatus;
FIG. 7 is a left side view of the materials moving apparatus;
FIG. 8 is a right side view of the materials moving apparatus;
FIG. 9 is a front perspective view of the materials moving apparatus; and
FIG. 10 is a front perspective view of an embodiment of the materials moving apparatus.
DETAILED DESCRIPTION OF THE INVENTION
In conjunction with FIGS. 1 and 2 , a brief description concerning the various components of the present invention will now be provided. As can be seen in this embodiment, the present invention provides a box blade 1 having main blade 2 extending along a longitudinal axis A for a longitudinal length L. The main blade 2 may be planar, i.e., flat, relative to the longitudinal axis A or curved and/or bent at an angle substantially about the longitudinal axis A running the longitudinal length L of the blade 1 to facilitate retention of materials being moved by the blade 1 .
The main blade 2 has a front surface 4 for engaging material and a back surface 6 generally for supporting mounting hardware. The main blade 2 may be provided as either a single sheet of metal or, as shown in conjunction with FIG. 2 , the main blade 2 may be a double walled design having a spaced apart front and rear wall 8 , 10 , respectively. A double walled design may include the front and rear walls 8 , 10 having a substantially different curvature, bend or orientation about the longitudinal axis A, for example, the front wall 8 may be curved as in FIG. 1 , and the back wall 10 may have a bend 7 as shown in FIG. 2 . Also due to the space between the front and back walls 8 , 10 , the double walled design can also help stop damage to the hydraulics or any vehicle connection devices attached to the rear wall 10 of the main blade 2 where the front wall 8 is damaged by an object. In any event, whether the main blade 2 is single or double walled, the main blade 2 is defined having the front surface 4 and the back surface 6 .
Observing FIGS. 3 and 4 , besides the front and back surfaces 4 , 6 , the main blade 2 has opposing first and second side ends 14 , 16 , a top edge 18 and a bottom edge 20 . The bottom edge 20 is normally in contact or very close to the ground during cutting and pushing operations, especially during snow clearing operations, although it may be raised above the ground in certain situations for transport and providing necessary clearance for certain objects on the ground, curbs, reflectors, etc. The bottom edge 20 of the main blade 2 is often provided with attachment points or bolt holes 22 (as shown) to facilitate the attachment of a replaceable edge 24 which can be fastened to the bottom edge 20 , for example, by rivets or bolts. Such a replaceable edge 24 is important for protecting the main blade 2 from wear against the ground as well as minimizing damage from objects which the blade may encounter.
As is well known in the colder latitudes of the world, heavy earth moving equipment vehicles, e.g., graders, scrapers, loaders, etc., are often used to facilitate the removal of snow, for example, at airports, large commercial parking and vehicle loading lots, etc. The heavy equipment is usually provided with the box blade 1 as shown in FIGS. 1-4 and designed specifically for snow removal. The box blade 1 is used in place of or attached to the main regular bucket or blade of the heavy equipment. In addition to the above described main blade 2 , box blades 1 are provided with an opposing first and second side walls 26 , 28 to better entrap the snow and facilitate the removal thereof.
The first sidewall 26 and the second sidewall 28 are attached to the respective first and second ends 14 , 16 of the main blade 2 . The first and second sidewalls 26 , 28 are, in general, welded or connected in some manner, as known in the art, to the respective first and second ends 14 , 16 of the main blade 2 and are generally formed of a single planar piece of material for purposes of conserving weight. The intersection between each connected sidewall 26 , 28 and the respective side edges 14 , 16 of the main blade 2 defines a substantially vertical connection joint 30 running perpendicular to the longitudinal axis A of the main blade 2 . The box blade 1 is formed by providing the first and second sidewalls 26 , 28 with a height h defined by a sidewall top and bottom edges 31 , 33 and a length l defined between the front and rear sidewall edges 32 , 34 . These edges may define overall a substantially square or rectangular end wall, although other shapes could be contemplated as well.
For purposes of discussion, the following description relates to only the first connection joint 30 between the first side edge 14 of the main blade 2 and the first sidewall 26 , as each opposing sidewall is joined in the same manner and with the same components and structures, only a description of one side is believed necessary. The first sidewall 26 is connected near or adjacent its rear edge to the respective first side edge 14 of the main blade 2 , along the connection joint 30 . From the connection joint 30 , the sidewall 26 extends substantially perpendicularly with respect to the main blade 2 , and radially from the longitudinal axis A, along its length l to space the front sidewall edge 32 at a substantial distance relative to the rear sidewall edge 34 from the longitudinal axis A of the blade.
As seen in FIGS. 5-8 , the bottom edge 31 of the sidewall may be provided with a skid foot, or a plurality of skid feet 36 , in order to protect the sidewall bottom edge 31 and facilitate the passage of the box blade 1 itself across a ground surface without damage. The skid feet 36 may be either welded or bolted to the bottom edge 31 of the first and second sidewalls 26 , 28 in order to facilitate replacement in the event of damage or breakage.
With the sidewalls 26 , 28 attached to each end 14 , 16 of the main blade 2 , the above described arrangement essentially defines a 3-sided box structure having a forward facing opening O to push and contain the materials being moved, thus the term “box blade” as is known in the art. With respect to such box blades, as is readily apparent to one of ordinary skill in the art, the farther the front sidewall edge 32 extends from the respective connection joint 30 with the main blade 2 , the more flexible the first and second sidewalls 26 , 28 become due to the increasing weight of the sidewall as it extends farther from the connection joint 30 thus creating a greater moment arm about the connection joint 30 .
Turning to FIG. 9 , in order to maintain the integrity of the box blade 1 , specifically the rigidity of the main blade 2 , and especially the first and second sidewalls 26 , 28 , relative thereto, a strengthening gusset 40 is incorporated with each connection joint 30 and between the sidewall and the main blade 2 to stabilize each sidewall relative to the main blade 2 .
Each gusset 40 is formed as a substantially conic section, i.e., a partial cone, having a base portion 42 attached to and extending radially from the front surface 4 of the main blade 2 to an apex portion 44 spaced therefrom and attached on the inner surface of the sidewalls 26 , 28 . The apex portion 44 may extend substantially the length of the inner surface of the sidewall to be situated substantially near the front edge 32 or forward edge of the respective sidewall.
The conic section gusset 40 is provided with a contiguous outer surface 46 and an outer supporting edge 48 which is joined to the respective front surface 4 of the main blade 2 and the inner surface of the sidewall 26 . The attachment between the main blade 2 , the sidewall 26 and the gusset 40 is complete, i.e., it defines a contiguous, usually welded gusset seam attaching the entire outer edge 48 of the conic section gusset to the box blade 1 . Thus, the gusset 40 , in conjunction with the sidewall 26 and main blade 2 , presents an uninterrupted or unbroken face to any material being pushed or moved
In the present embodiment, the contiguous outer surface 46 of the conic section gusset 40 is formed by a first and second substantially planar surfaces 50 , 52 aligned at an angle with respect to one another. The first and second planar surfaces 50 , 52 are angled with respect to one another along a bend 54 which extends substantially the length of the conic section from the base portion 42 connected to the main blade 2 to the apex portion 44 connected to the first sidewall 26 .
In another embodiment as seen in FIG. 10 , the cone may have a substantially hemispherical or semi-hemispherical surface 56 having a radius of curvature, for instance, a semi-circular section. It is to be understood that the conic section gusset 40 may also be formed with a plurality of adjacent surfaces to effectively produce the conic section provided with a respective number of angles to effect a number of differently surfaced conic sections. Generally, the conic section gusset 40 is integrally formed from a single piece of material, for example, steel, although it could be made of several separate sections joined together to form the gusset 40 . In any event, each adjacent surface of a multi-surface conic section gusset is provided with a wider base portion 42 and a narrower apex portion 44 joined to the respective main blade 2 and sidewall 26 as described above.
The use of such a conical shape is particularly important in that the gusset 40 may be formed from a single piece of material which may be bent or curved into the desired surface shape and then welded or connected to the main blade 2 along the outer edge 48 . This provides not only a structurally strong gusset 40 and unbroken material moving face, but also provides ease of manufacture and application of the gusset 40 to the main blade 2 and first sidewall 26 .
It is well known to those in the mechanical field that in order to reduce the moment of an arm about an axis, the weight or mass of the arm can be reduced. It is an important aspect of the present invention that as the gusset 40 extends from the main blade 2 and the longitudinal axis A, the cone gusset 40 has the larger base portion 42 decreasing to the more narrow apex portion 44 as it extends radially away from the main blade 2 and consequently the longitudinal axis A. With the first and second sidewalls 26 , 28 extending perpendicular to the axis, this decreased mass of the apex portion 44 of the cone gusset is particularly helpful in lowering the moment of the first and second sidewalls 26 , 28 and the gusset 40 about the horizontal axis.
In the above described embodiment of the present invention, the cone gusset 40 , which also extends radially and substantially perpendicular relative to the longitudinal axis A of the main blade 2 , depends downward from the base portion 42 located higher up relative to the ground surface, to the apex portion 44 situated closer to the ground G and attached adjacent the lower edge 31 and front edge 32 of the sidewall 26 . Such a downward depending gusset 40 inherently also aligns the contiguous surfaces 50 and 52 of the conic section gusset 40 not only inward relative to the box blade 1 , but also radially downward towards the ground which facilitates the shedding of snow and/or earth or other material from the gusset 40 .
Since certain changes may be made in the above described improved materials moving apparatus without departing from the spirit and scope of the invention herein involved, it is intended that all of the subject matter of the above description or shown in the accompanying drawings shall be interpreted merely as examples illustrating the inventive concept herein and shall not be construed as limiting the invention. | A materials pushing or moving blade for use with heavy equipment vehicles, for example, a bulldozer or loader, and more specifically to a method and apparatus for moving snow, specifically a snow moving blade having a reinforcing gusset for strengthening the extended sidewalls of the snow moving blade. | 4 |
CROSS REFERENCE TO RELATED APPLICATIONS AND PATENT
This application is related to copending U.S. application Ser. No. 07/132,790, filed Dec. 10, 1987, entitled "TREATMENT OF COTTON", now U.S. Pat. No. 4,888,856, granted Dec. 26, 1989 and which application is a divisional application to U.S. application Ser. No. 06/833,987, filed Feb. 26, 1986, entitled "TREATMENT OF COTTON", now U.S. Pat. No. 4,796,334, granted Jan. 10, 1989, which is related also to copending U.S. application Ser. No. 07/207,252, filed Jun. 15, 1988, entitled "TREATMENT OF COTTON", and which application is a continuation application to the aforementioned parent application, namely U.S. application No. 06/833,987. This application is also related to the commonly assigned U.S. application Ser. Nos. 07/359,495, filed May 31, 1989, and entitled "METHOD OF AND APPARATUS FOR TREATING COTTON CONTAMINATED WITH HONEYDEW", and Ser. No. 07/359,494, filed May 31, 1989, and entitled "METHOD OF AND APPARATUS FOR REDUCING THE STICKINESS OF COTTON FLOCKS",
BACKGROUND OF THE INVENTION
The present invention broadly relates to a method of and apparatus for treating cotton flocks at an early stage of cotton processing and, more specifically, pertains to a new and improved method of reducing the stickiness or tackiness of the fibers of cotton flocks contaminated with honeydew. The present invention also relates to a new and improved apparatus for reducing the stickiness of the fibers of honeydew-contaminated cotton flocks.
Generally speaking, the present invention relates to a new and improved method of the type hereinbefore described and which method entails heating the honeydew-contaminated cotton flocks.
It is known that cotton flocks of certain provenances or origins are contaminated or coated to varying degrees with sugar-containing secretions from insects. These secretions containing sugar are generally known as honeydew. A large number of proposals have been made as to how honeydew can be made to caramelize by heating cotton flock samples for the purpose of determining the degree of honeydew contamination from the resulting change in the color of the cotton flocks. This is namely very important because in the event of considerable contamination, the cotton flocks become sticky or tacky and tend to stick or adhere to various parts of the yarn production plant or to form laps or coils at rolls or rollers or other rotatable members, this being very undesirable since it results in frequent interruption of the yarn manufacturing process and in an inferior yarn.
A method of the aforementioned type is already disclosed in European Patent Application No. 86.102352.1, published Oct. 8, 1986 under European Patent Publication No. 196,449. The object of this known method is to convert any contaminating honeydew into a non-sticky or non-tacky and brittle state or condition by supplying heat for a short period of time and preferably without causing any discoloration or change in the color of the cotton flocks, so that the brittle sugar deposits can be crushed and removed in the course of subsequent processing.
A number of devices or apparatuses for performing this prior art method have been proposed in the abovementioned European Patent Application No. 86.102352.1, published under European Patent Publication No. 196,449. One device or apparatus is intended to heat the fiber flocks before the actual opening of the raw cotton bales, i.e. directly at the start of the yarn manufacturing process. On the other hand, other devices or apparatuses are intended for treating fiber slivers between the card and drafting arrangement or during drafting.
In spinning mills, in which the cotton spun is heavily contaminated with honeydew, efforts are made to keep the ambient air moisture or humidity very low, and experience has shown that this results in reduction of the frequency of interruptions in the yarn manufacturing process. However, the very low air humidity is undesirable as such, since the cotton fibers suffer mechanical damage during yarn manufacture such that the yarn quality is not at an optimum although the best types of cotton in terms of quality originate from provenances where the honeydew contamination is quite considerable. Also, very dry air causes problems with regard to electrostatic charges which result, for example, in undesirable accumulations of fly fibers. Furthermore, in the case of a very low air humidity, the operating staff or personnel finds the climatic conditions inside the spinning mill unpleasant.
As a result of such difficulties many yarn manufacturers first wash the cotton flocks in order to remove the honeydew deposits. However, washing is not only expensive, but also results in reduction or deterioration of yarn quality.
Since only some types of cotton or deliveries of cotton are contaminated with honeydew, the installation of special continuous treatment plants, for instance in accordance with the disclosure of the aforesaid European Patent Application No. 86.102352.1, published under European Patent Publication No. 196,449, is in many cases undesirable, particularly since there is frequently no space at all for any subsequent installation.
SUMMARY OF THE INVENTION
Therefore, with the foregoing in mind, it is a primary object of the present invention to provide a new and improved method of, and apparatus for, reducing the stickiness or tackiness of the fibers of cotton flocks contaminated with honeydew, and which method and apparatus do not exhibit the aforementioned drawbacks and shortcomings of the prior art.
Another and more specific object of the present invention aims at providing a new and improved method of reducing the stickiness or tackiness of the fibers of cotton flocks contaminated with honeydew, and which method does not require extensive preparatory operations and permits using the simplest possible means requiring a minimum of space, so that by means of the inventive method cotton bales or at least large parts thereof are pretreated, at least hours or preferably days or even weeks prior to the actual yarn manufacturing process, such that interruptions of the yarn manufacturing process due to honeydew contamination are largely avoided without the cotton fibers being exposed to mechanical damage and without the subsequent yarn processing having to take place in the presence of very low air humidity.
Now to implement these and still further objects of the invention, which will become more readily apparent as the description proceeds, the method of the present invention of reducing the stickiness or tackiness of the fibers of cotton flocks contaminated with honeydew is manifested, among other things, by the steps of heating the cotton flocks while still in bale form in a high-frequency field, i.e. electrical or electromagnetic field and bringing the honeydew to an elevated temperature, thus substantially evaporating the water contained in the honeydew contamination. The step of heating the cotton flocks entails a temperature increase of the cotton flocks to reach a temperature in the region of the temperature of ebullition or boiling point of water. The term "high-frequency" as used in this disclosure is intended to also encompass microwave frequencies.
Although it is generally known that cotton fibers very rapidly absorb ambient humidity, it has surprisingly been found that after the pretreatment of the cotton bales according to the new and improved method of the present invention, the stickiness or tackiness of the honeydew contamination is essentially reduced. Furthermore, it has surprisingly been found that the contaminations thus treated only slowly re-absorb moisture from the air or from the fibers to which they adhere, so that it is readily possible to pretreat the bales even more than a week prior to their use for yarn manufacture without the risk of increased stickiness or tackiness during actual yarn manufacture. This behavior is attributed to a change of the condition or state of the honeydew contamination as a result of the heat treatment. This change of properties occurs particularly when the cotton flocks undergo appropriate heating.
Preferably, the high-frequency field is produced by field generating elements arranged at opposite sides of the bale or bale portion. This ensures that a good depth of penetration of the energy is achieved so that the treatment of entire bales is rendered possible.
The high-frequency field may be a high-frequency electrical field which is generated between the plates of a capacitor, such plates constituting field generating elements. A problem can arise here inasmuch as the capacitance of the capacitor varies during evaporation of water, so that the resonant or oscillatory circuit formed by the electrical components associated with the capacitor and intended to oscillate at a very accurately set frequency, the permissible frequencies being regulated by law, tends to drift away from resonance. In other high-frequency installations this phenomenon is counteracted by varying the spacing of the capacitor plates.
This is basically possible with respect to the inventive method. However, there is a preferred arrangement in which an additional capacitor is connected in parallel to the capacitor formed by the aforesaid capacitor plates between which the cotton bale is located, adjustment being effected by a change alteration of the adjustable additional capacitor. According to the invention, there is thus rendered possible a very rapid and accurate adjustment or adaptation of the resonant frequency of the load circuit.
In a preferred variant of the inventive method, the high-frequency field is the electromagnetic field of a microwave generator or of a plurality of microwave generators jointly heating the cotton bale. Although this may be somewhat surprising at first, since it would be initially assumed for technical reasons and considerations that the penetration depth of microwaves or microwave energy into a densely compressed cotton bale would be relatively limited. However, it has been found that this penetration depth rapidly increases with increasing temperature within the cotton bale, so that very uniform heating of the entire cotton bale is possible. This uniform heating particularly occurs when the field generating elements are disposed laterally of the cotton bale and means are provided in order to repeatedly reflect the microwave radiation to and fro through the cotton bale. This arrangement also beneficially influences the escape of water vapor occurring during heating, such water vapor ascending and being extractable from the top of the associated oven or furnace.
A characteristic of heating by means of microwaves, i.e. microwaves energy, also resides in the fact that these microwaves appear to selectively act on the honeydew contaminations so that the latter reach a temperature somewhat higher than the temperature of the cotton itself. This ensures that the moisture is very rapidly expelled from the honeydew contamination and that the required change of state or condition or structure of the honeydew contamination occurs without the cotton flocks themselves having to be heated to a temperature at which a fire hazard would occur. The selective action on the honeydew contaminations also enables the treatment times to be shortened and the required amount of energy to be reduced. This, in turn, is for the benefit of the method in terms of economy of operation and constructional expenditure.
A particular feature of the method according to the invention is characterized in that the gases or air used to cool the microwave generator or each microwave generator, subsequent to flowing through the or each microwave generator, are injected into the microwave oven containing the cotton bale or bales and flow through the microwave oven to achieve an additional drying of each of the cotton bales and/or carry away escaping water vapor or steam. In this manner, the flow of gas or air used for cooling is utilized for a two-fold purpose in that the heat carried away from the microwave generators is not lost, in that it is beneficially used to extract moisture.
It has been found according to the inventive method that the treatment time can be readily selected in the range of 5 minutes to 90 minutes, depending on the moisture of the cotton bales, it being advantageous to use power in the range of 0.02 to 0.08 kilowatts per kilogram bale weight. Thus with average power and average moisture it is possible to treat a cotton bale in less than 30 minutes, so that a single microwave oven would be able to handle or cope with the entire daily production of a medium-sized cotton spinning mill. With such a treatment time there is also sufficient time available to ensure that produced water vapor or steam escapes from the cotton bale. The treatment is preferably continued until the residual moisture in the cotton is on average in the range of 4% to 1% water.
A further particularly preferred feature of the inventive method is characterized in that the microwave generator power during the pretreatment is reduced by an open loop control system or a closed loop control system in accordance with a predetermined or measured course of moisture reduction. This method results in very protective treatment of the cotton and in substantial energy saving, particularly because the cotton can steam out during reduced energy supply times, thus also reducing the risk of local overheating of the cotton.
As alluded to above, the invention is not only concerned with the aforementioned method aspects, but also relates to a new and improved construction of apparatus for carrying out the inventive method.
To achieve the aforementioned measures, the inventive apparatus, in its more specific aspects, is manifested, among other things, by the features that the apparatus comprises an oven or furnace for accommodating cotton bales, field generating elements or means arranged at opposite sides of the cotton bales for heating the latter inside the oven, and means for generating an airflow through the oven.
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 throughout the various figures of the drawings, there have been generally used the same reference characters to denote the same or analogous components and wherein:
FIG. 1 is a schematic cross-section through a first exemplary embodiment of the apparatus constructed according to the invention and in which a cotton bale is heated by means of microwaves or microwave energy; and
FIG. 2 is a schematic cross-section through a second exemplary embodiment of the apparatus constructed according to the invention and in which cotton bales can be heated by means of high-frequency energy.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Describing now the drawings, it is to be understood that to simplify the showing thereof, only enough of the structure of the apparatus for realizing the inventive method of reducing the stickiness or tackiness of the fibers of honeydew-contaminated cotton flocks in bale form has been illustrated therein as is needed to enable one skilled in the art to readily understand the underlying principles and concepts of this invention. Turning attention now specifically to FIG. 1 of the drawings, the exemplary embodiment of apparatus illustrated therein by way of example and not limitation will be seen to comprise a microwave oven or furnace 11 shown in a sectional view taken through a substantially vertical plane. This microwave oven 11 is specially designed to treat cotton bales 12 in accordance with the inventive method and one or more cotton bales 12 can be treated therein. The microwave oven 11 itself comprises a base or bottom 13, a left side wall 14 and a right side wall 15, a top or upper side 16 which is formed as a chimney, tapered upwards and merges into a connecting pipe or stud 17. The microwave oven 11 also possesses a back or rear wall 18 which for the sake of clarity is shown only in broken lines in FIG. 1, and a door hinged on one of the side walls 14 and 15 to enable the cotton bale or bales 12 to be introduced into the microwave oven 11. The hinged door is not particularly shown in the drawing. If desired the back or rear wall 18 can also be constructed as a door so that the cotton bales 12 can be introduced through the front and taken out at the rear.
In a top plan view or a horizontal sectional view the microwave oven 11 is of substantially square or rectangular configuration and its dimensions are adapted to those of a conventional cotton bale 12, but can be selected to be somewhat smaller if, and this is basically possible, only a fraction of a cotton bale 12, for instance half a cotton bale 12, is to be treated in one operation. Within the microwave oven 11 the cotton bale 12 stands with its layers 12' extending substantially horizontal on a platform 19 which is constructed as a grid through which there can pass microwaves, so that the bottom or lower side 21 of the cotton bale 12 is somewhat higher than the base or bottom 13 of the microwave oven 11. The platform 19 stands on individual legs 22 or the like between which there are suitable openings not particularly shown in the drawings. The interior or inner space of the microwave oven 11 should be larger than the space occupied by the cotton bale 12 and/or have a guide to prevent the cotton bale 12 from jamming in the microwave oven 11 if the cotton bale 12 expands and becomes larger due to the heat treatment.
The middle or center part of the base or bottom 13 is constructed as a course-mesh screen or perforate plate 23 which is non-previous to microwaves or microwave energy so that air 24 coming from below can flow through this screen or perforate plate 23 and through the aforesaid openings provided between the individual legs 22. The top of the platform 19 is also constructed as a screen or perforate plate to enable the air 24 to have access to the cotton bale 12 and also to enable water vapor or steam escaping from the cotton bale 12 to pass through the platform 19.
Individual microwave generators 25 are arranged laterally of the microwave oven 11 although the drawing only shows four such microwave generators 25, namely two on the left side and two on the right side. The microwave generators 25 are arranged one above the other in two substantially horizontal planes. Although not shown in the drawing, further microwave generators 25 can be arranged in planes behind or in front of the plane of the drawing of FIG. 1, for example, to provide a total of twelve such microwave generators 25. A radiation outlet 26 of each microwave generator 25 projects through an associated waveguide into one of the side walls 14 and 15 of the microwave oven 11 and is directed towards the interior thereof. In this manner, radiation lobes or beams 27 of substantially funnel-divergent shape are formed, during operation, by the associated microwave generators 25, the arrangement being such as to give the maximum possible energy density in the cotton bale 12.
A plurality of wave agitators or wavers 28 are mounted at the side walls 14 and 15 of the microwave oven 11, each wave agitator 28 consisting basically of a circular metallic rotor mounted on a rotational axle or spindle 29 and driven to perform slow rotary movements, for example, ten revolutions per minute. The purpose of these wave agitators 28 is initially to reflect the radiation passing through the cotton bale 12 back and forth, so that each radiation lobe or beam 27 repeatedly passes through the cotton bale 12 before being completely absorbed. Reflection of microwaves, which reflection occurs at each metal or metallic surface, results in the energy density in the cotton bale 12 being rendered uniform to some extent. The operation of the wave agitators or wavers 28 serves to provide further uniformity of the energy density within the cotton bale 12.
The individual microwave generators 25 have to be cooled during operation, for which purpose air is pumped through these microwave generators 25 by any suitable pumping means 58. In the present example this air, after cooling the microwave generators 25, is injected or blown into collecting headers or pipes 30 which lead to an air chamber 45 located beneath the coarse-mesh screen or perforate plate 23 of the microwave oven 11. In this manner the heated-up air passes into the microwave oven 11 and ensures further heating of the cotton bale 12 and the removal of water vapor escaping as a result of the heat treatment of the cotton bale 12, such water vapor initially ascending to the connecting pipe or stud 17 and then being suction-extracted by a blower or fan, generally indicated by reference numeral 50.
The microwave generators 25 each preferably have a maximum power output of about 1.2 kilowatts, and this means that with a total of twelve microwave generators 25 it is possible that a cotton bale 12 weighing approximately 220 kilograms and having an original 6% water content can be dried in about 14 minutes to have a residual moisture of 4% water. If even dryer cotton is required, for instance cotton with a residual moisture of 1%, the treatment time is extended to about 35 minutes.
It is actually not the residual moisture in the cotton itself that is important. What is important is that the moisture of the honeydew deposits or contaminants, which moisture may initially be much higher than the average moisture in the cotton bale 12, is itself reduced, this being particularly favorably achievable by means of microwaves, since microwave energy is preferentially absorbed by the water contained in honeydew. It can therefore be stated that drying of cotton to a residual mositrue of 2% to 4% is sufficient to expel the excess water from the honeydew and, as assumed, bring about a change of state or condition or structure thereof, so that the tendency of these deposits to re-absorb water is substantially reduced.
Fire monitoring devices, i.e. signalling fire detectors, as schematically conveniently indicated in FIG. 1 by reference numeral 52, are installed at individual locations in the microwave oven 11 itself to detect any fire and immediately stop the supply of energy to the microwave generators 25. If required the signals of these signalling fire detectors 52 can be used to inject a quenching gas into the microwave oven 11 n order to immediately extinguish any developing fire. A particular advantage of microwave heating is that the energy supply can be immediately stopped and that the microwave oven 11 is immediately cool after the microwave generators 25 have been switched off, so that the risk of any fire outbreak by additional absorbed heat is extremely small.
A further possibility of pretreating entire cotton bales 12 or fractions thereof in accordance with the invention is schematically illustrated in FIG. 2. An oven 31 of this embodiment is of similar configuration to the microwave oven 11 in FIG. 1 but, instead of using microwave generators 25, two substantially rectangular capacitor plates 32 and 33 are provided within this oven 31, the plate 32 being arranged substantially in parallel with the left side wall 14 of the oven 31 and the plate 33 substantially in parallel with the right side wall 15 of the oven 31.
A high-grade dielectric is used between the two substantially rectangular capacitor plates 32 and 33 and the associated side walls 14 and 15 of the oven 31. In this embodiment the cottom bale 12 likewise rests on a platform 35 of grid-like construction and an air current or flow 43 is generated from below in the upward direction to remove water vapor occuring during treatment. This air current or flow 43 can be produced by means of a blower or fan, generally indicated by reference numeral 54 in FIG. 2, connected to a connecting pipe or stud 34 via a line or conduit. A high-frequency electrical alternating field forms between the two capacitor plates 32 and 33, with the result that the cotton which represents a high-loss dielectric, is heated. In this manner, the maximum heat absorption is in the zone of high water content, for example, in the honeydew.
The high-frequency electrical alternating field is generated by a high-frequency generator 36 which feeds electrical energy to a working or operating circuit comprising an inductance 37 and the capacitor formed by the capacitor plates 32 and 33 between which there is located the cotton bale 12 serving as a dielectric. The frequency of the power supply and therefore of the high-frequency electrical alternating field must be maintained within close limits in view of regulations set by law in a number of countries, such regulations concerning limitation of stray radiation from industrial high-frequency installations. The working or operating frequency usually selected will be the industrial frequency of 27.12 MHz±0.6% or, in rare cases 13.56 MHz±0.05%.
Since the energy transmission from the high-frequency generator 36 to the working or operating circuit can be at a maximum only if the resistance of the working or operating circuit is adapted to that of the high-frequency generator 36, and since the resistance of the working or operating circuit varies according to the nature and moisture content of the actually provided cotton bales 12, it is necessary to match or adapt, during the heating process, the working or operating circuit to the high-frequency generator 36.
This is achieved, according to the invention, in that an additional capacitor 38 is connected in parallel with the load circuit and is adjusted by a controller or control unit 39 via a motor 40 and a transmission 41 or equivalent structure in order to keep constant at all times the resonant or oscillatory frequency of the load circuit.
The actual value fed to the controller or control unit 39 is the anode current of the high-frequency generator 36 or a value equivalent or corresponding thereto, and the controller or control unit 39 compares this actual value or equivalent value with a predetermined desired or reference value. In the event of any deviation, a signal is applied to the motor 40 which adjusts the additional capacitor 38 via the transmission 41 until the desired or reference value of the anode current is restored.
In operation, the cotton bale 12 is heated by the high-frequency electrical field between the two substantially rectangular capacitor plates 32 and 33 such that the moisture is expelled from the honeydew and the latter is brought to the desired or required state or condition.
Also in this exemplary embodiment of the inventive apparatus the inner space of the oven 31 should be greater than the cotton bale 12 or have a suitable guide. Here again it is advantageous to guide the waste heat of the high-frequency generator 36 through the oven 31 in the form of a heated air current or flow. Suitable fire monitoring devices or fire detectors 52 are here likewise shown in FIG. 2.
If the cotton bale 12 to be pretreated is held together by metal strapping or bands, such metal strapping or bands should be removed and replaced by suitable plastic strapping or bands prior to introducing the cotton bale 12 into the oven 31.
While there are shown and described present preferred embodiments of the invention it is to be distinctly understood that the invention is not limited thereto, but maybe otherwise variously embodied and practiced within the scope of the following claims, ACCORDINGLY, | The invention relates to a method of and an apparatus for reducing the stickiness or tackiness of the fibers of honeydew-contaminated cotton flocks by heating the same. For this purpose, the cotton flocks while still in bale form are heated in a high-frequency electrical or electromagnetic field until the honeydew is brought to an elevated temperature and the water contained in the honeydew contamination is substantially evaporated, the temperature preferably being such that the cotton flocks reach a temperature in the region of the temperature of ebullition or boiling point of water. | 3 |
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
The invention disclosed herein was conceived and developed in part during work on Award Number DE-AR0000340, titled “Micro-Synchrophasors for Distribution Systems,” from the Advanced Research Projects Agency-Energy (ARPA-E) of the U.S. Department of Energy.
CROSS-REFERENCE TO RELATED APPLICATIONS
Application Ser. No. 14/808,439, “Method and Apparatus for Precision Phasor Measurements Through a Medium-voltage Distribution Transformer”
REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTING COMPACT DISK APPENDIX
Not Applicable
BACKGROUND OF THE INVENTION
The present invention is in the technical field of measurement of electric parameters.
More particularly, the present invention is in the technical field of voltage and current phasor measurements on an alternating current (a.c.) power distribution grid, and employing those phasor measurements to detect a cyber attack on remotely-operable elements of that power distribution grid.
Electric power distribution grids, including substations, are commonly used to move a.c. power from high-voltage transmission lines towards a set of loads, and sometimes to move power from distributed generation resources.
These electric power distribution grids, including substations, contain elements such as switches, bus connecting elements, interrupting elements, and transformer tap changing elements. To improve energy efficiency and grid reliability, these elements are often configured for remote operation, for example by an operator at a Distribution Grid Control Center.
Such a remote operation generally takes place through a communication network. Often, the remotely-operable element can report its present state. For example, a distribution grid control center might be able to ask a remotely-operable switch to report if it is “on” or “off”, and a distribution control center could instruct such a remotely-operable switch to change its state from “off” to “on”.
Such automated systems can be subject to cyber attack, an event in which unauthorized individuals or organizations attempt to take control of remotely-operated elements in a distribution grid, or attempt to cause remotely-operated elements to incorrectly report their state, or both.
In our Department of Energy ARPA-E Project DE-AR0000340, titled “Micro-Synchrophasors for Distribution Systems,” we have been investigating the application of synchrophasor measurements to medium-voltage distribution grids, as opposed to the traditional application to high-voltage transmission grids. Due to smaller inductances and shorter distances on distribution grids compared to transmission grids, the phase angle changes during interesting phenomena on distribution grids are much smaller. We have determined that, for distribution grid applications, a angular resolution for voltage phasors and current phasors of ±0.015° could be useful.
Such voltage phasor and current phasor measurements can be used to detect cyber attacks on distribution systems.
SUMMARY OF THE INVENTION
The present invention is a method and apparatus for detecting cyber attacks on remotely-operable elements on a distribution grid by periodically comparing a first state estimation of the distribution grid based on commands to and reports from the remotely-operable elements, with a contemporaneous second state estimation of the distribution grid based on precise phasor measurements performed on the distribution grid. A difference between the two contemporaneous state estimations indicates that the distribution grid may be under cyber attack.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an illustration of the present invention.
FIG. 2 is a view of an exemplary instrument used in the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Turning our attention to FIG. 1 , we see an illustrative example: a one-line schematic representation of a 3-phase high-voltage transmission line 1 , well known in the art, that provides alternating current power to a substation 2 , which is equipped in this illustrative example with two transformers 3 , 4 . The medium-voltage secondaries of the two transformers 3 , 4 are connected through remotely-operable elements 5 , 6 , which are switches in the present example, to two substation buses 7 , 8 . The two substation buses can be tied together through a remotely-operable element 9 , which, in the present example is a normally-open switch.
Medium-voltage a.c. power leaves the substation through other remotely-operable elements 10 , 11 , 12 and travels in the usual ways, well known in the art, in this illustrative example through distribution feeders 20 , 21 , 22 , 23 , 24 , 25 , 26 , 27 , in some cases passing through additional remotely-operable elements 13 , 14 , 15 to ultimately reach loads 31 , 32 , 33 , 34 , 35 . The exact nature of the loads 31 , 32 , 33 , 34 , 35 are not important to the present invention.
Continuing to examine FIG. 1 , we see a Distribution Grid Control Center 40 with connections 41 to the remotely-operable elements 5 , 6 , 9 , 10 , 11 , 12 , 13 , 14 , 15 by any typical electric power grid communication system, known to those familiar with the art.
Examining the illustration of the connections 41 to the remotely-operable elements, we see that the arrows are bi-directional, indicating that the Distribution Grid Control Center 40 can both instruct the remotely-operable elements 5 , 6 , 9 , 10 , 11 , 12 , 13 , 14 , 15 to change to a different state, e.g. change from “off” to “on”, and the remotely-operable elements 5 , 6 , 9 , 10 , 11 , 12 , 13 , 14 , 15 may in some cases also report their state to the Distribution Grid Control Center 40 , both types of communications taking place through the connections 41 .
The exact nature of the connections 41 is unimportant to the present invention except that the connections 41 may be subject to a disruptive cyber attack. Such a disruptive cyber attack could, for example, cause one or more of the remotely-operable elements 5 , 6 , 9 , 10 , 11 , 12 , 13 , 14 , 15 to transition to an undesired state; or it could, for example, cause one or more of the remotely-operable elements 5 , 6 , 9 , 10 , 11 , 12 , 13 , 14 , 15 to inaccurately report its state, e.g. report that it is “off” when it is in fact “on”.
Continuing to examine FIG. 1 , we see three instruments 50 , 51 , 52 (referred to by those familiar with the art as micro-phasor-measurement-unit(s), abbreviated μPMU) for measuring micro-synchrophasors that specifically measure time-synchronized magnitude and phase angle of voltages and, in some cases, currents on the distribution feeders 20 , 23 , 26 . It will be recognized by those familiar with the art that the location in the distribution grid that has been selected for these μPMU's 50 , 51 , 52 in FIG. 1 is simply illustrative of the present invention, and that other placements incorporating more or fewer μPMU's could be selected.
The μPMU's 50 , 51 , 52 report their time-synchronized magnitudes and phase angles through communication channels 53 , the precise nature of which is not important to the present invention except that it is unlikely to be subject to the attack at the same time and in the same way as the other connections 41 , to a Phasor Data Concentrator 60 of a type well-known in the art, which calculates various phasor and power flow parameters such as phase angle differences, the exact list and nature of which is not critical to the present invention. These phasor and power flow parameters are passed to a Phasor-based State Estimator 61 , which has algorithms, the nature of which do not limit the present invention, that employ the values of the phasor and power flow parameters to form an estimate of the state of this distribution grid.
By the “state” of this distribution grid, we mean the present state of all of the elements in this distribution grid, including the remotely-operable elements 5 , 6 , 9 , 10 , 11 , 12 , 13 , 14 , 15 . Returning our attention to the Distribution Grid Control Center 40 , we see that, based on the information it receives from remotely-operable elements 5 , 6 , 9 , 10 , 11 , 12 , 13 , 14 , 15 through their connections 41 , it periodically prepares State Estimation A 43 and communicates it through communication channel 42 , the nature of which is not critical to the present invention. A second State Estimate B 62 , contemporaneous with State Estimate A 43 , is prepared by the Phasor-based State Estimator 61 and communicated through a connection 63 .
A State Estimation comparison block 44 , the details of which are not critical to the present invention, compares State Estimation A 43 with State Estimation B 62 . The State Estimation comparison block 44 may, for example, simply compare the estimated states prepared in State Estimation A 43 and State Estimation B 62 ; or it may also include an evaluation of confidence in the estimations prepared by State Estimation A 43 and State Estimation B 62 , or use other algorithms to conclude whether the two State Estimations are sufficiently equal.
If the algorithm comparison block 44 determines that the two State Estimations 43 , 62 are not equal, it concludes that the distribution grid may be under a cyber attack. It could, for example, use a communication channel 45 to activate an alarm 46 in the Distribution Grid Control Center. It will be apparent to one of ordinary skill that the above description, which assumes a single-phase system, can be readily extended to three-phase systems.
Turning our attention now to FIG. 3 , we see an illustration of a Micro Synchrophasor Instrument 31 which implements one possible embodiment of the present invention. (The hand 37 in the illustration is shown to visually indicate approximate scale, and does not play any part in the present invention.) This Micro Synchrophasor Instrument 31 is one embodiment of the uPMU instrument 52 shown in FIG. 1 .
The Micro Synchrophasor Instrument 31 incorporates a display 33 and communications means 36 . The display 33 is not an essential element to the present invention. The Micro Synchrophasor Instrument 31 also incorporates voltage inputs 35 for measuring voltage phasors, current inputs 34 for optionally measuring the current phasors, and computing means 32 for converting raw voltage measurements and optional raw current measurements into phasor measurements.
While the foregoing written description of the invention enables one of ordinary skill to make and use what is considered presently to be the best mode thereof, those of ordinary skill will understand and appreciate the existence of variations, combinations, and equivalents of the specific embodiment, method, and examples herein. The invention should therefore not be limited by the above described embodiment, method, and examples, but by all embodiments and methods within the scope and spirit of the invention. | A method and apparatus for detecting cyber attacks on remotely-operable elements of an alternating current distribution grid. Two state estimates of the distribution grid are prepared, one of which uses micro-synchrophasors. A difference between the two state estimates indicates a possible cyber attack. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to diagnostic systems for vehicles and to methods for planning a vehicle diagnosis.
2. Description of the Related Art
From published German patent application document DE 10 2009 045 376 A1, a method is known for diagnosing the dynamic behavior of an exhaust gas sensor. The disclosed diagnostic method is part of an on-board diagnosis, or OBD, that monitors all systems that influence the exhaust gas in a vehicle during driving operation. Errors that occur can be stored in a storage device and can be read out via standardized interfaces when there is a technical check of the vehicle. In addition, errors that occur can be indicated to the driver of the vehicle via a warning light.
BRIEF SUMMARY OF THE INVENTION
According to a first aspect of the present invention, a method is provided for the temporal planning of a vehicle diagnosis in a vehicle, having the following steps:
estimation of an operating characteristic of the vehicle on a route that is to be traveled by the vehicle; and planning of the vehicle diagnosis based on a probability that the estimated operating characteristic of the vehicle corresponds to an operating characteristic suitable for the vehicle diagnosis.
Here, an operating characteristic is to be understood as the temporal course of one or more operating variables of the vehicle. These operating variables can be for example the load torque of the vehicle, a torque outputted by the internal combustion engine, a wheel rotational speed, a crankshaft rotational speed, the radiator temperature, or any other operating variable in the vehicle on the basis of which inferences can be made concerning the load state of the vehicle. Here, planning is understood to mean, inter alia, a temporal and/or spatial determination of vehicle diagnoses, including operating range changes for creating conditions required for vehicle diagnoses, and the exclusion of vehicle diagnoses.
The indicated method is based on the consideration that during vehicle diagnosis the vehicle should follow a particular operating characteristic so that the vehicle can react with an expected behavior during the vehicle diagnosis. In order for example to check the effectiveness of the lambda probe in a vehicle, the vehicle should follow an operating characteristic in which an incomplete combustion would take place without the lambda probe. In order to achieve this operating characteristic with the vehicle, waiting could take place until the corresponding operating characteristic was achieved by the vehicle on its own, for example if the driver excessively accelerates the vehicle. However, if after a longer period of operation an operating characteristic suitable for the vehicle diagnosis does not arise, the vehicle could be forced into the operating characteristic suitable for carrying out the vehicle diagnosis; however, this would result in correspondingly increased energy consumption and thus correspondingly increased fuel consumption, which is not only economically counterproductive but also damaging to the environment.
In contrast, the idea of the present invention is to estimate the operating characteristic of the vehicle in the future. Through the estimation of when and whether the vehicle will move from pure driving operation to an operating characteristic suitable for the vehicle diagnosis, it is possible to avoid unnecessarily forcing the vehicle to assume a corresponding operating characteristic with increased energy consumption, thus saving fuel and reducing environmental damage.
In a development, the operating characteristic suitable for the vehicle diagnosis is a function of a state of the vehicle that has to fulfill specified conditions for the vehicle diagnosis. The state can be for example an internal state of the vehicle that is influenced by the operating characteristic of the vehicle itself, such as the torque provided by the internal combustion engine, specified by the driver through his behavior. This torque of the internal combustion engine presupposes a specific operating characteristic that in turn can be suitable for the vehicle diagnosis. Further states of the vehicle influenced by the operating characteristic would include operating time and/or no-load time of the vehicle, vehicle speed, and/or engine rotational speed of the vehicle. However, the state can also be an external state to which the vehicle is exposed, such as ambient temperature, air pressure around the vehicle, and/or a particular load state resulting for example when driving uphill, driving downhill, or driving on a flat plane. The vehicle also reacts to these external states with a particular driving characteristic that can be suitable for carrying out the vehicle diagnosis.
The internal and external states can be determined adaptively or predictively in order to estimate the operating characteristic of the vehicle. While an adaptive determination includes an active recognition of the internal and/or external states that are to be expected, for example in a navigation system, and/or includes a vehicle log in the vehicle, a predictive recognition of the internal and/or external states that are to be expected includes an estimation based on concrete boundary conditions that can be acquired for example by a sensor.
The operating characteristic suitable for the vehicle diagnosis can be based on specified minimum times in which the vehicle will have to have been in a specified internal state and/or will have to have been exposed to a specified external state. In this way, it can be ensured that the internal and/or state that forms the basis of the operating characteristic is static and will not change. For example, the temperature of an internal combustion engine of the vehicle changes in the start phase and remains constant only after the internal combustion engine has warmed up to operating temperature. During this warming phase, it would not be suitable to examine the lambda probe in order to determine whether it is operating correctly.
The operating characteristic suitable for the vehicle diagnosis can however also be defined on the basis of a temporal development that is to be expected of the internal and/or external states of the vehicle forming the basis of the operating characteristic. In this way, during the vehicle diagnosis particular operating state points can be initiated that are necessary for a successful vehicle diagnosis.
In a preferred development, the temporal development of the internal and/or external states of the vehicle includes a temporally independent time segment. This preferred development is based on the consideration that as a rule the vehicle diagnosis is carried out based on a control loop that brings a certain degree of disturbance into the vehicle that then has to be regulated out through the systems in the vehicle that are to be examined. Here the disturbance is part of the operating characteristic suitable for the vehicle diagnosis. Such a control loop as a rule entails a dead time, as a result of the regulation path, during which waiting takes place through the temporally independent time segment. By taking into account whether the estimated operating characteristic of the vehicle corresponds to an operating characteristic suitable for the vehicle diagnosis having a corresponding temporally independent development, during the planning of the vehicle diagnosis it can be taken into account whether the vehicle is at all capable during normal operation of producing a step response, based on the introduced disturbance, from which information can be reliably derived about the error-free behavior, or possible malfunctioning, of the vehicle.
In a particularly preferred development, the probability that the estimated operating characteristic of the vehicle corresponds to an operating characteristic suitable for the vehicle diagnosis includes a probability as to whether the operating characteristic suitable for the vehicle diagnosis can be forced to come about using auxiliary aggregates in the vehicle. In this way, during the planning of the vehicle diagnosis a larger degree of freedom in design can be achieved, because smaller expected deviations in the operating characteristic of the vehicle suitable for the vehicle diagnosis can be compensated via these auxiliary aggregates. In principle, all auxiliary aggregates in the vehicle can be used that are suitable for influencing the operating characteristic of the vehicle. Thus, in order to compel the operating characteristic suitable for the vehicle diagnosis in an electrical on-board network, additional electrical consumers, such as a climate control system, can be connected in order to bring about a particular increased load state, or, in a hybrid vehicle, an electric motor can be connected to the internal combustion engine in order to bring about, with the internal combustion engine, a particular reduced load state.
In a further development, the indicated method includes the step of preventing the vehicle diagnosis when the probability that the estimated operating characteristic of the vehicle corresponds to the operating characteristic suitable for the vehicle diagnosis is below a specified threshold value. In this way, during the planning of the vehicle diagnosis for the vehicle all unsuitable path segments on a foreseeable route are deleted ahead of time for which it is clear from the outset that the vehicle diagnosis will not be able to be completed, and therefore will fail.
In an alternative development of the present invention, the indicated method includes the step of reading out the route to be traveled from a navigation device, and estimation of the operating characteristic of the vehicle based on information provided by the navigation device concerning the route to be traveled. This information provided by the navigation device can originate for example from environmental data or traffic data, such as that distributed for example via the Traffic Message Channel service. Thus, for example given a foreseeable traffic jam on a street traveled by the vehicle, vehicle diagnoses can be avoided that would presuppose a high-speed operation of the internal combustion engine of the vehicle. It is also possible to request from the navigation device altitude data, climate data, or any other data concerning the route to be traveled that can be provided by the navigation device.
In another alternative development, the indicated method includes the steps of writing a vehicle log based on a route traveled by the vehicle before traveling the route to be traveled, and estimating the operating characteristic of the vehicle on the route to be traveled by the vehicle based on the written vehicle log. Using the vehicle log, for example route-dependent load data of the internal combustion engine of the vehicle can be noted and used for planning the vehicle diagnosis. If, due to a particular driving behavior of the driver, for example because he commutes daily between his residence and his place of work, it turns out that after a particular number of kilometers traveled a particular load state is always achieved, e.g. because the driver has to stop at a traffic light, this can effectively be used in the planning of the vehicle diagnosis in the vehicle.
In yet another development, the indicated method includes the step of estimation of the operating characteristic of the vehicle based on a near-field sensor attached on the vehicle. With the near-field sensor, obstacles immediately in front of the vehicle that exclude the vehicle diagnosis, or external states suitable for the vehicle diagnosis, can be acquired and used in the planning of the vehicle diagnosis. Thus, a near-field sensor fashioned as a camera can, for example, predict an imminent acceleration on the basis of a sign indicating that the vehicle is leaving a city area, or can predict an imminent braking event based on a slow-moving vehicle. Path segments already released for a vehicle diagnosis can also be retroactively blocked using a near-field sensor, if the near-field sensor detects corresponding circumstances that prevent the vehicle diagnosis, such as a tractor on the roadway traveling slowly in front of the home vehicle.
In an alternative development, the indicated method includes the steps of acquisition of a behavior of a driver of the vehicle and estimation of the operating characteristic of the vehicle based on the behavior of the driver. Thus, for example it can be recognized whether a driver is driving with a comparatively high torque, or is braking strongly over comparatively short stretches. In connection with the above-named collected information, it is then possible to plan a suitable vehicle diagnosis for example shortly before coming to a traffic light, because it can be expected that the driver will brake strongly before this traffic light or will accelerate strongly after the traffic light.
According to a further aspect, a device is provided that is set up to carry out the indicated method. The indicated device can be arbitrarily expanded in order to be capable of carrying out one of the indicated methods as recited in the subclaims.
In a development of the present invention, the indicated device has a storage device and a processor. The indicated method is stored in the storage device in the form of a computer program, and the processor is provided for carrying out the method when the computer program is loaded into the processor from the storage device.
According to a further aspect of the present invention, a vehicle has a device as indicated.
The present invention also relates to a computer program having program code means for carrying out all steps of one of the indicated methods when the computer program is executed on a computer or on one of the indicated devices.
The present invention also relates to a computer program product that contains a program code that is stored on a computer-readable data carrier and that carries out one of the indicated methods when it is executed on a data processing device.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a schematic representation of a vehicle traveling on a roadway.
FIG. 2 shows a schematic representation of an example of a vehicle diagnostic system.
FIG. 3 shows an example of a temporal speed curve of the vehicle traveling on a roadway.
FIG. 4 shows a first example of a temporal mixture setting curve of the vehicle traveling on a roadway, shown opposite a part of the temporal speed curve of FIG. 3 .
FIG. 5 shows a second temporal mixture setting curve of the vehicle traveling on a street, shown opposite a part of the temporal speed curve of FIG. 3 .
DETAILED DESCRIPTION OF THE INVENTION
In the Figures, elements having identical or comparable functions are provided with identical reference characters, and are described only once.
Reference is made to FIG. 1 , which shows a schematic representation of a vehicle 4 traveling on a roadway 2 .
Vehicle 4 moves along a route 6 on roadway 2 . At an assumed first point in time, vehicle 4 is located at a position on roadway 2 at which vehicle 4 is shown in solid lines in FIG. 1 . In addition, vehicle 4 is shown in FIG. 1 with dotted lines at a second and at a third position at which, seen from the first point in time, it will be situated at a second and third point in time in the future.
In order to ensure error-free operation of vehicle 2 , so-called on-board tests, or OBD tests, are prescribed by law in order to timely recognize an exhaust-gas-related malfunctioning of vehicle 2 and to prevent environmental damage due to the malfunctioning of vehicle 2 . Such OBD tests are defined for example by the California Air Resources Board, or CARB. A function required by CARB for the documentation of vehicle diagnoses that are carried out is the Diagnostic In-Use Monitor Performance Ratio, or DIUMPR, whose specification is known to those skilled in the art.
The OBD tests of exhaust gas-related components in vehicle 2 have to be carried out on the basis of test cycles. During the execution of an OBD test, vehicle 2 has to follow a required operating characteristic, for example with regard to a torque of the internal combustion engine. Based on the required operating characteristic, it can be monitored whether the exhaust gas-related components of vehicle 2 react in an error-free way or not. However, during actual driving operation the operating characteristic of vehicle 2 is as a rule always different than the required operating characteristic, so that if the required operating characteristic of vehicle 2 is not maintained during a corresponding OBD test, the test is broken off and an attempt is made to repeat the OBD test the next time vehicle 2 achieves the required operating characteristic.
FIG. 2 shows a schematic representation of an example of a vehicle diagnostic system 8 suitable for carrying out an OBD test.
Vehicle diagnostic system 8 monitors an internal combustion engine 10 made up of an engine block 12 and an air supply duct 14 that supplies combustion air to engine block 12 , the air quantity in air supply duct 14 being capable of being determined using an air supply measurement device 16 . The exhaust gas of internal combustion engine 10 is conducted through an exhaust gas cleaning installation having as main component an exhaust gas duct 18 in which there are situated, in the direction of flow of the exhaust gas, a first exhaust gas sensor 20 before a catalytic converter 22 and a second exhaust gas sensor 24 after catalytic converter 22 .
The two exhaust gas sensors 20 , 24 are connected to control device 26 , called an engine electronics system, that calculates the mixture from the data of exhaust gas sensors 20 , 24 and the data of air supply measuring device 16 , and controls a fuel metering device 28 for the metering of fuel. Coupled to control device 26 , or integrated therein, is a diagnostic device 30 with which the signals of exhaust gas sensors 20 , 24 can be evaluated. Diagnostic device 30 can additionally be connected to a display/storage unit 32 on which the evaluation results from diagnostic device 30 can be represented or stored.
Using first exhaust gas sensor 20 situated in exhaust gas duct 18 behind engine block 12 , with the aid of control device 26 a lambda value can be set that is suitable for the exhaust gas cleaning system in order to achieve an optimal cleaning effect. Second exhaust gas sensor 24 , situated in exhaust gas duct 18 behind catalytic converter 22 , can also be evaluated in control device 26 , and is used, in a known method, to determine the oxygen storage capacity of the exhaust gas cleaning system.
In the present embodiment, only one internal combustion engine 10 is shown, having only one exhaust gas duct 18 . The indicated method for planning a vehicle diagnosis in a vehicle however also extends to vehicles having internal combustion engines 10 that have multi-bank exhaust gas systems in which the cylinders are combined into a plurality of groups and the exhaust gas of the various cylinder groups is conducted into separate exhaust gas ducts 18 , in each of which there is installed at least one exhaust gas sensor.
For the normal operation of internal combustion engine 10 , in control device 26 there is provided a linear lambda regulation algorithm. First exhaust gas sensor 20 , fashioned as a broadband lambda probe, determines the oxygen content in the exhaust gas and forms a corresponding output signal that is supplied to control device 26 . This device forms therefrom the regulator manipulated quantities for fuel metering device 28 and for throttle devices, present in air supply duct 14 , for setting the supplied quantity of air so that internal combustion engine 10 is operated with a specified lambda value, i.e. a specified air-fuel ratio. For an optimized exhaust gas post-treatment in catalytic converter 22 , realized as a three-way catalytic converter, operation at a λ of 1 is provided. Constantly operating first exhaust gas sensor 20 , in connection with a linear lambda regulation algorithm implemented in the control device, enables the continuous adjustment of the regulator manipulated quantities without a superposed periodic oscillation.
When a two-point regulating algorithm is used as linear lambda regulating algorithm, the λ in the exhaust gas oscillates between two specified boundary values. When the λ reaches a lower boundary value, assigned to a rich air-fuel mixture, the two-point regulation algorithm sets the regulator manipulated quantities for fuel metering device 28 and the throttle devices in such a way that a modification of the air-fuel ratio takes place to a leaner setting, i.e. an excess of air. If in this way the λ reaches the upper boundary value, assigned to a lean air-fuel mixture, then the two-point regulating algorithm sets the regulator manipulated quantities for fuel metering device 28 and the throttle devices in such a way that a modification of the air-fuel ratio takes place to a rich setting, i.e. an excess of fuel. The speed with which the change between the lean and rich setting takes place is a function of the selected regulating parameters, the regulation path, and the dynamic behavior of first exhaust gas sensor 20 . Accordingly, for given regulating parameters and a given regulation path, the period duration of the λ oscillation is a measure of the dynamic behavior of first exhaust gas sensor 20 , and can correspondingly be used to diagnose the dynamic behavior of first exhaust gas sensor 20 .
For vehicle diagnosis, in the depicted vehicle diagnostic system 8 , for example in diagnostic device 30 , a regulating algorithm is implemented with which the dynamic behavior of a regulation path in internal combustion engine 10 can be monitored, including exhaust gas sensors 20 , 24 as measurement elements, the engine block as actuating element, and control device 26 as regulator.
In an OBD test that tests the dynamic characteristic of first exhaust gas sensor 20 , through diagnostic device 30 the fuel mixture could be deliberately made excessively rich in order to test whether first exhaust gas sensor 20 acquires this excessive richness, and whether the regulation loop including first exhaust gas sensor 20 reacts to this excessive richness within specified time limits. If, however, a slight enrichment of the fuel mixture is necessary due to the operating characteristic of vehicle 2 , then the regulating loop including first exhaust gas sensor 20 will indeed react to the excessive richness, but not within the specified time limits. The OBD test will fail, and will have to be repeated.
In the case of too-frequent repetition of this OBD test, excessive consumption of fuel may occur that is due solely to this OBD test. Other OBD tests that alter the fuel mixture can be used for example in the diagnosis of catalytic converter 22 and in the diagnosis of the dynamic behavior of exhaust gas sensor 24 after catalytic converter 22 . In addition to the increased fuel consumption, such OBD tests can also be damaging to the environment, because if they are carried out too often such active manipulations of the fuel mixture make the exhaust gas worse, which over time causes a worsened exhaust gas balance.
In order to avoid the above-named overconsumption of fuel and unnecessary environmental damage, the present embodiment proposes to investigate route 6 shown in FIG. 1 and to estimate on which path segments 32 vehicle 2 could have an operating characteristic suitable for a particular OBD test. Alternatively or in addition, individual path segments 32 can however also be recognized as unsuitable for particular OBD tests, whereupon the start of the corresponding OBD test is forbidden on these path segments 32 .
The investigation of route 6 can take place adaptively, for example based on the recognition of whether this route 6 was already traveled. For this purpose, for example in a storage device 34 of vehicle 2 a table can be stored in which for example the steering angle of the vehicle is shown opposite a traveled path. If comparison of the path of current route 6 with the steering angle and vehicle speed correlates to the comparison stored in storage device 34 , it can be inferred that the route has already been traveled. In addition, in storage device 34 driver profiles can be stored from which the driving behavior of the driver can be derived from the route.
Alternatively or in addition, the investigation of route 6 can also predictively, using a navigation system 36 or a near-field sensor 38 from which environmental and traffic data about route 6 can be derived. Here as well, the driving behavior of the driver can also be included in the investigation of route 6 . For example, navigation system 36 could recognize traffic jams on route 6 . On the basis of these recognized traffic jams, OBD tests could then be planned that would be carried out when vehicle 2 was at a standstill or in stop-and-go operation. In addition, OBD tests could also be avoided that could not be carried out in a traffic jam. Alternatively or in addition, near-field sensor 38 could be used to scan the environment around vehicle 2 . For this purpose, near-field sensor 38 could for example be a camera having a connected image evaluation system. If for example a slow-moving vehicle in front of vehicle 2 is recognized, then for example an imminent braking process can be inferred that can be included in the planning of the vehicle diagnosis of vehicle 2 .
Through the investigation of route 6 , possible OBD tests over route 6 can be recognized, planned, and included in the operating strategy e.g. of internal combustion 10 in hybrid and in conventional drive designs. In this way, frequently interrupted OBD tests can be avoided, and the influence of the OBD tests on the selection of the operating point of the internal combustion engine in classical and hybrid drivetrain designs can be timely taken into account, which in the present embodiment results in a saving of fuel and/or improved exhaust gas characteristics. In this way, the execution of the OBD test and of the DIUMPR can be improved.
On the basis of FIGS. 3 to 5 , as an example the planning of some OBD tests is explained on the basis of a speed curve of vehicle 2 on route 6 .
FIG. 3 shows, as an example of the operating characteristic of vehicle 2 , a temporal expected speed curve 40 of vehicle 2 on route 6 . Speed curve 40 can be predictively estimated and/or adaptively determined in the manner described above.
From speed curve 40 , as expected operating characteristic of vehicle 2 first an initial standing phase 42 is recognized after the start of vehicle 2 . After initial standing phase 42 , vehicle 2 accelerates, in an acceleration phase 44 , to an average travel speed that is not further referenced. This can for example be the acceleration after leaving the parking spot of vehicle 2 in a garage or parking lot. After acceleration phase 44 , in a driving phase 46 the average speed is maintained over a period of time that can be foreseen via the predictive or adaptive determination of the speed curve 40 , until vehicle 2 , during a braking phase 46 , is again braked to a standstill, for example because it is expected that the vehicle will have to stop at a traffic light. There then again follows a standing phase 42 , correspondingly followed by an acceleration phase 44 , a driving phase 46 , and a braking phase 48 . This sequence is repeated more or less regularly; in FIG. 3 , for clarity the individual phases are not all referenced.
FIG. 4 shows a first example of a temporal mixture setting curve 52 of vehicle 2 traveling on route 6 , shown opposite a part 50 of temporal speed curve 40 from FIG. 3 .
In first standing phase 42 , a first mixture setting 54 can be planned in order to heat the catalytic converter. In addition, during first driving phase 46 a second mixture setting 56 can be planned for the diagnosis of first exhaust gas sensor 20 , and in second driving phase 46 a third mixture setting 58 can be planned for the diagnosis of catalytic converter 22 , and in braking phase 48 following the second driving phase a fourth mixture setting 60 for thrust and clearing the catalytic converter can be planned, because in these phases the operating conditions of vehicle 2 are sufficiently stationary for the execution of the corresponding OBD test.
FIG. 5 shows a second example of a temporal mixture setting curve 62 of vehicle 2 traveling on route 6 , shown opposite a part 50 of temporal speed curve 40 of FIG. 3 .
In FIG. 5 , it can be seen that in third and fourth driving phase 46 , following second driving phase 46 , the operating conditions of vehicle 2 are probably not sufficiently stationary for a long enough time to completely carry out a corresponding OBD test for diagnosing catalytic converter 22 , so that here a corresponding mixture setting 64 , 66 is correspondingly to be forbidden by the planning. | A method for planning a vehicle diagnosis in a vehicle includes: estimation of an operating characteristic of the vehicle on a route to be traveled by the vehicle; and planning of the vehicle diagnosis based on a probability that the estimated operating characteristic of the vehicle will correspond to an operating characteristic suitable for the vehicle diagnosis. | 8 |
BACKGROUND OF THE INVENTION
The invention relates to an accelerator pedal unit comprising an accelerator pedal, an actuator and a control shaft via which the actuator can transmit a restoring torque to the accelerator pedal.
An accelerator pedal unit is already known from the German patent publication DE 10 2009 021 585 A1, comprising an accelerator pedal, an actuator and a control shaft, by means of which a restoring torque can be transmitted to the accelerator pedal. The accelerator pedal unit can generate an additional restoring force which acts on the accelerator pedal, for example in order to regulate or limit the speed of a vehicle or to function as a warning device in the event of speeding. Disadvantageously, the actuator and the accelerator pedal are rigidly coupled to each other. As a result, brief losses of torque of the actuator, for example losses of torque of a brushed DC electric motor (torque ripple), are transmitted to the accelerator pedal with no change in their relative magnitude and are noticeable to the driver in a disruptive manner. A further disadvantage is that the additional restoring force generated by the actuator is subject to uncontrollable fluctuations due to different effects. Firstly, an undesirable increase in the restoring force can occur due to inertia forces as a result of coupled co-movement of the actuator during a quick actuation of the accelerator pedal. Secondly, the mechanical gearing mechanism path is afflicted with friction, so that the force actually transmitted to the accelerator pedal is dependent on temperature. Moreover, the relationship between the generated engine torque and the current applied to the actuator is subject to unpredictable fluctuations which are dependent on temperature and material and component tolerances.
SUMMARY OF THE INVENTION
The accelerator pedal unit according to the invention has in contrast the advantage that the actuator is mechanically decoupled from the accelerator pedal by the torque of the control shaft being transmitted via a damping element to said accelerator pedal. From a mechanical perspective, a spring or damping element is thus disposed between the control shaft and the accelerator pedal. Torque fluctuations of the actuator which occur are damped to a great extent by the damping element, so that said fluctuations are unnoticeable to the driver.
According to one advantageous embodiment, the damping element is designed as a helical spring, torsion spring, flexible spring or rubber spring.
It is particularly advantageous if a control lever for transmitting the torque is provided on the control shaft, wherein the damping element is connected at one end to the control lever and at the other end to the control shaft.
It is furthermore advantageous for the control lever to be rotatably mounted on the control shaft because the restoring torque is transmitted in this way exclusively via the dampening element.
It is very advantageous for the damping element to be attached with the end thereof associated with the control shaft to a shoulder connected to said control shaft because the damping element can be attached particularly easily to said control shaft in this way.
It is also advantageous for the damping element to extend around the control shaft with at least one winding because the damping element can thereby be disposed in a very space saving manner.
It is furthermore advantageous for the control lever to comprise a rotatably mounted rolling element because the torque can be transmitted with little friction from the control lever to the accelerator pedal in this way.
In addition, it is advantageous for the control lever to act on a surface of the accelerator pedal which is provided with a coating because the torque can be transmitted in this way form the control lever to the accelerator pedal in a practically frictionless and low-noise manner.
It is advantageous for a positioning spring to be provided which is attached with the one end thereof to a rotationally fixed housing section and acts with the other end on the control lever. The positioning spring ensures a bracing of a gearing mechanism disposed between the actuator and the accelerator pedal independently of the effective direction thereof; thus enabling the tooth flanks of the teeth of the gearing mechanism to fit tightly against each other. In so doing, there is little noise during the operation of the gearing mechanism.
In addition, it is advantageous for the positioning spring to be designed in such a manner that said spring pushes the control lever towards the accelerator pedal or in the opposite direction into a stop position that is spaced apart from the accelerator pedal. According to the first alternative, the positioning spring acts as a restoring spring against the spring force of the damping element. According to the second alternative, the positioning spring acts in the direction of the damping element and ensures that the control lever is constantly in contact with the accelerator pedal, whereby the actuator can very quickly introduce a force into the accelerator pedal.
It is furthermore advantageous for the damping element and the positioning spring to each be provided on a bearing bushing that is rotationally mounted on the control shaft. In this way, it is ensured that the springs are well guided and cannot break out in an undefined manner when subjected to a mechanical load.
BRIEF DESCRIPTION OF THE DRAWINGS
An exemplary embodiment of the invention is depicted in a simplified manner in the drawings and is explained in detail in the following description. In the drawings:
FIG. 1 shows an accelerator pedal unit according to the invention in a three dimensional view.
FIG. 2 shows a top view of the inventive accelerator pedal unit according to FIG. 1 .
DETAILED DESCRIPTION
FIG. 1 shows an accelerator pedal according to the invention in a three dimensional view.
The accelerator pedal unit according to the invention comprises a rotatably mounted accelerator pedal 1 , an actuator 2 and a control shaft 3 via which the actuator 2 can transmit a restoring torque to the accelerator pedal 1 . In this way, the accelerator pedal unit can take on functions, such as, for example, actively limiting the speed of a vehicle or indicating that the speed limit is being exceeded.
The accelerator pedal 1 is mounted so as to be rotatable about a rotational axis 4 and has a first lever arm 5 which can be actuated by foot and a second lever arm 6 which can be actuated by means of the actuator 2 . The first lever arm 5 and the second lever arm 6 lie on opposite sides in relation to the rotational axis 4 . The actuator 2 is, for example, a direct current motor, DC motor or brushless motor.
The control shaft 3 is rotatably mounted, for example in at least one pivot bearing.
Provision is made according to the invention for the torque of the control shaft 3 to be transmitted via a damping element 10 to the accelerator pedal 1 . In this way, the control shaft 3 exerts a predefined restoring force on the accelerator pedal 1 when current is passed through the actuator 2 . The damping element 10 is designed as a helical spring according to the exemplary embodiment, can, however, also be a torsion spring, flexible spring or rubber spring. When designed as a helical spring, the damping element 10 extends around control shaft 3 with at least one winding and is therefore disposed and supported on the control shaft 3 . According to the exemplary embodiment, the damping element 10 has a spring stiffness in a range between 30 Nmm/degree and 80 Nmm/degree. In the case of a helical spring, the damping element 10 extends helically or in a thread-like manner around the control shaft.
A control lever 11 which transmits the torque to the accelerator pedal 1 is provided on the control shaft 3 , wherein the damping element 10 is connected at one end to the control lever 11 and at the other end to the control shaft 3 . According to the exemplary embodiment, the damping element 10 is connected to the control shaft 3 at the other end. The control lever 11 is arranged on the control shaft 3 in a rotatably mounted manner, for example by the control shaft 3 protruding through an opening in the control lever. In this way, it is ensured that the torque is transmitted exclusively via the damping element 10 and not directly from the control shaft 3 to the accelerator pedal 1 .
The damping element 10 is inserted with the end thereof associated with the control lever 11 , for example, into an opening of the control lever 11 or is hooked into a receiving area. With the end thereof associated with the control shaft 3 , the damping element 10 is, for example, attached to a shoulder 12 that is connected to the control shaft 3 in a rotationally fixed manner or, respectively, to a control arm 12 that is connected to said control shaft 3 in a rotationally fixed manner. According to the exemplary embodiment, the shoulder or, respectively, the control arm 12 is a separate, disk-shaped or plate-shaped component which is attached on the control shaft 3 in a rotationally fixed manner, for example in a positive locking and force-fitting manner. Of course, the shoulder can, however, also be connected to the control shaft 3 in a materially bonded manner. The shoulder 12 can also be omitted, and the dampening element 10 can be directly attached to the control shaft 3 . The damping element 10 is, for example, inserted into an opening 13 of the shoulder 12 with the end thereof facing said shoulder 12 or is hooked into a receiving area. A rotatably mounted rolling element 16 can be provided on the control lever 11 , said rolling element acting on a surface of the second lever arm 6 of the accelerator pedal 1 . The surface 17 can be provided with a predefined coating in order to reduce the friction between said surface 17 of the accelerator pedal 1 and the rolling element 16 of the control lever 11 .
A positioning spring 20 can be provided which is attached with the one end thereof to a rotationally fixed housing section 21 and acts with the other end thereof on the control lever 11 . The positioning spring 20 is arranged, for example, like the damping element 10 on the control shaft 3 and is designed, for example, as a helical spring or as a spiral spring. The positioning spring 20 extends helically or in a thread-like manner around the control shaft 3 in the case of a helical spring and spirally in the case of a spiral spring. The spiral spring requires very little installation space in the axial direction with respect to the control shaft 3 . An unspecified noise and/or vibration dampening element can be provided on the positioning spring 20 which fits snugly against said positioning spring 20 .
The housing section 21 is, for example, formed by a so-called bearing bracket with which the accelerator pedal unit is attached to a vehicle. The positioning spring 20 can be designed in such a manner that said spring pushes the control lever 11 either towards the accelerator pedal 1 or in the opposite direction into a stop position that is spaced apart from said accelerator pedal 1 . According to the first alternative, the positioning spring 20 acts as a restoring spring against the spring force of the damping element 10 . According to the second alternative, the positioning spring 10 acts in the direction of the damping element 10 and ensures that the control lever 11 is constantly in contact with the accelerator pedal 1 , whereby the actuator 2 can very quickly introduce a force into the accelerator pedal 1 . In both cases, the positioning spring 20 is installed with an elastic preload. The positioning spring 20 is, for example, inserted with the one end thereof into an opening of the housing section 21 and, for example, loosely rests under preload with the other end thereof against the control lever 11 .
The damping element 10 and the positioning spring 20 can each be disposed on a bearing bushing 22 that is rotatably mounted on the control shaft 3 . The bearing bushing of the positioning spring 20 can also be integrally formed with the control lever 11 . The bearing bushing 22 can also in each case be omitted and the diameter of the control shaft 3 can be designed in such a manner that said control shaft 3 itself takes on the guidance and support of the springs 10 , 20 .
In addition, a gearing mechanism 24 can be provided between the actuator 2 and the control shaft 3 , said gearing mechanism transmitting the rotational movement of the actuator 2 with a predefined speed reduction. The positioning spring ensures a bracing of the gearing mechanism 24 independently of the effective direction thereof; thus preventing a tooth flank change in the gearing mechanism 24 . In so doing, there is little noise during the operation of the gearing mechanism.
The gearing mechanism 24 is, for example, a spur gear unit or a worm gear, wherein the worm gear can be of self-locking or non-self-locking design. The damping element is designed in such a manner that the accelerator pedal 1 can still be moved at least by 5 degrees in the event of a blockage of the gearing mechanism. This enables an emergency operation of the vehicle. The damping element 10 is thus not allowed to go solid within these at least 5 degrees. When the accelerator pedal is actuated while the gearing mechanism 24 is blocked, a torque is exerted by the accelerator pedal 1 on the damping element 10 so that said element is deformed.
FIG. 2 shows a view from above onto the inventive accelerator pedal unit according to FIG. 1 .
In the accelerator pedal unit according to FIG. 2 , the parts which remain the same or act the same with respect to the accelerator pedal unit according to FIG. 1 are denoted with the same reference signs.
The actuator 2 and the gearing mechanism 24 are disposed according to the exemplary embodiment on the side of the housing section 21 that faces away from the accelerator pedal 1 , wherein the control shaft 3 protrudes via a through-hole through the housing section 21 . Provision is, for example, made for the control shaft 3 to be rotationally mounted in the through-hole. | An accelerator pedal unit is known comprising an accelerator pedal, an actuator, and a control shaft via which the actuator can transmit a restoring torque to the accelerator pedal. The accelerator pedal unit can generate an additional restoring force which acts on the accelerator pedal, for example in order to regulate or limit the speed of a vehicle or to function as a warning device in the event of speeding. In the accelerator pedal unit according to the invention, the actuator is mechanically decoupled from the accelerator pedal. According to the invention, the torque of the control shaft ( 3 ) is transmitted to the accelerator pedal ( 1 ) via a damping element ( 10 ). | 8 |
FIELD OF THE INVENTION
The present invention pertains to harnesses and saddles for horses and other beasts of burden.
BACKGROUND OF THE INVENTION
To date, the common means of securing a saddle or other load bearing attachment to a horse or other beast of burden is to utilize straps secured tightly around the animal usually placed just behind the animal's front legs and around the entire chest of the animal. These straps are made of leather or some strong fabric or other material and are secured and tightened using metal buckles or fittings of an appropriate type or some other form of fastening hardware. This requires the rider or some other horse handler to physically manipulate these straps and buckles to get them as tight as that person's strength allows. Many times that strength is not sufficient to the task and the saddle is so loose on the horse that it slides sideways putting the user in severe jeopardy of falling off the horse.
This problem is often exacerbated by the horse inhaling a large amount of air while being saddled to purposely prevent the saddle from being strapped on tight enough to be safe. After holding that air in until the saddle has been tightened, the horse exhales it and the saddle immediately gets much looser on its body. To further confound the problem, modern saddles are mere copies of saddle concepts that have been used for millenniums and are lacking in many aspects of rider comfort and safety. Studies show that between 60 to 85 percent of all injuries due to human contact with horses are due to the rider being ejected from the horse's back accidentally.
Yet another problem is the position on the horse's back which is taken by saddles made to the current, universally popular design. At the point on the horse's back where all saddles of the current design are positioned there is no physical prominence of the horse's anatomy that provides a positive bearing surface to anchor the saddle in a central, upright position. Therefore, many riders are injured and some even killed when the saddle they are riding on spins or rotates around the round midsection of the horse's body where almost all saddles are positioned when in use.
SUMMARY OF THE INVENTION
It is an object of the present invention to produce a harness and saddle assembly capable of being tightened so it holds properly in place on the horse even when tightened by a weak person because of the novel design of a secondary tightening device that is employed after the first tightening adjustment has been accomplished.
It is a further object of the present invention to produce a harness and grab saddle assembly including the art explained in my U.S. Pat. No. 5,423,164 to provide a complete saddle system which will weigh far less than currently designed saddles yet allow the rider to so secure themselves to the horse that they are more safely mounted than any current saddle systems are capable of doing.
It is a further object of this invention to present a complete saddle concept that will replace and obsolete all current saddle designs and their attendant accessories and inherent dangers.
It is a further object of this invention to provide a saddle design that prevents most accidents caused by the rotation of the saddle when mounted on a horse.
It is a further object of this invention to provide a viable saddle design that has minimal weight.
It is a further object of this invention to provide a saddle design which removes any rigid saddle framework from underneath the rider so there is no harmful, rigid frame positioned between the rider and the horse to gouge the horse's back by being driven down into the horse's back by the action of the rider's weight bouncing on top of the saddle.
It is a further object of this invention to provide a design for a saddle device that can help hold a rider in place in the saddle so most accidental ejection accidents are prevented.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an end view of the harness's preferred embodiment;
FIG. 2 is a bottom view of the harness shown in FIG. 1;
FIG. 3 is an end view of the harness with a winch;
FIG. 4 is a bottom view of the harness shown in FIG. 3;
FIG. 5 is an end view of harness with an extended air cushion;
FIG. 6 is a bottom view of the harness shown in FIG. 5;
FIG. 7 is an side view of the harness's cover,
FIG. 8 is a view of a horse wearing the Grab Saddle System;
FIG. 9 is a view of a horse with an alternate Grab Saddle System;
FIG. 10 is a side view of the Grab Saddle;
FIG. 11 is the same view as in FIG. 10 with cover flaps open;
FIG. 12 is a cross sectional view of Item 55 a;
FIG. 13 is a cross sectional view of Item 55 ;
FIG. 14 is an end view of Grab Saddle with cover flaps open;
FIG. 15 is a view of a horse with an alternate Grab Saddle System.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings wherein like reference characters indicate like parts in the several views, there is shown in FIG. 1 an end view from the rear of the harness portion of the system assembly. Item 10 is one of several mounting bolts shown which hold wood slabs 11 onto steel straps 13 and between them is sandwiched the perforated leather straps 14 . Item 17 indicates one perforation of many made in item 14 . Item 12 is an inflatable air bladder that receives its pressurized air through air tube 16 from hand pump 15 . Air tube 16 also houses a manual pressure relief valve which is operated by the user when it is time to remove the Grab Saddle Assembly from the horse. Item 12 may be, for instance, a bicycle tire containing a bicycle tire inner tube which assembly can be attached to the wooden slab 11 by the use of glue or wood screws or some other mechanical mounting method or device. Items 14 which are the perforated leather straps are shown attached to item 19 by the use of buckles 18 which serve to join the two items into a length adjustable assembly. This assembly of straps 14 and 19 provides a strap assembly harness that encircles the chest of the horse as is the current custom for attaching a saddle to a horse or other beast of burden and holding it in place while the animal is being ridden. The tightening of straps 14 and 19 using buckle 18 to secure that tightening provides the initial tightening of the saddle around the horse or other beast of burden. After the initial hand tightening of this harness assembly made up of items 14 , 18 and 19 around the horse, the inflation of said air tube 12 accomplishes the invented secondary tightening of the harness. This happens because the pressurized gas expands the dimensions of item 12 on top of the horse after the user or rider has first pulled the girth straps 14 and 19 as tight as possible by hand and buckled or tied them off so they hold that initially adjusted dimension. It can be seen that item 12 can only inflate to its maximum dimension and after that it will not become any larger therefor it can only tighten up around the horse's body by a fixed amount so the horse is in no danger of being squeezed too tightly by the saddle girth 19 and saddle straps 14 .
FIG. 2 is a bottom view of the harness assembly's underside which side contacts the horse's back as described by view A—A which is indicated in FIG. 1 . It displays the circular shape of item 12 which is the secondary tightening device employed in this FIGS. 1 and 2 embodiment. As explained later, this is only one of many mechanical methods that can be employed to accomplish the invented secondary tightening of the harness as described in this patent. This circular shape indicates a bicycle tire and tube although this item 12 air chamber could be any shape or a specially designed shape and still function properly given it were a proper size and placed in the proper position. This tire and tube are connected for air pressure to the other end of the air hose emanating from an air pump item 15 . This pump can be either manual or power driven or the pressurized gas supply can come from a pre pressurized gas pressure reservoir which has not been shown.
FIG. 3 is a view the same as FIG. 1 but showing another mechanical means of accomplishing the invented secondary tightening of the harness method of securing a load carrying device to a beast of burden. It shows the utilization of a winch 22 and winch handle 23 which allows the user to manually turn the winch to tighten the harness straps items 14 and 19 . The lines 26 are wound around the winch 22 as it turns and said lines are attached at their other ends to glide blocks 11 a on either side of the animal, said glide blocks slide against and are guided by the locator bolts 10 which project through slots 25 in the glide blocks 11 a. Glide blocks 11 a also slide upon and are supported by slide plates 20 . This back and forth sliding of the glide blocks alternately tightens and loosens the straps 14 which are attached to glide blocks 11 a and which in turn likewise effects their attached girth strap 19 .
FIG. 4 is a view B-B which is the same as FIG. 2 's view A—A but showing the embodiment for the invented secondary tightening of the harness system as described in FIG. 3 . It must be noted that there are many such mechanisms like those described in FIGS. 1 and 3 that are known and can function to effect the invented secondary tightening of the harness herein disclosed and not all of them are shown in these figures. This patent does recognize that all these methods can be singularly useful to accomplish the herein invented secondary tightening of the harness effect so one could mention many of such mechanical techniques and not begin to mention them all. To name a few of the better known mechanical devices which could also be successfully applied to the invented secondary tightening of the harness herein disclosed, one could mention mechanical means like levers or block and tackle or lead screws or ratchet devices and so forth. It should be noted that in any embodiment utilizing a tightening means which doesn't employ air or gas pressure that a back cushion for the horse 21 should be employed. This could be any shape or material but is shown as a circular cushion of foam in this figure.
FIG. 5 is a view like FIG. 1 but showing item 12 a which is an extended air pressure receptacle that goes down along the sides of the horse to give an increased tightening effect when inflated. If so desired it is obvious that the air bag 12 a could be elongated enough to go the whole way around and underneath the horse's belly without violating the subject matter taught in this patent.
FIG. 6 is view C—C showing the underside of the assembly shown in FIG. 5 which gives only one example of what shape the extended air bag could acquire. Many shapes are possible and would work properly without violating this patent's teachings.
FIG. 7 is a side view of one design of a nonessential but useful cover for the assemblies shown in FIGS. 1 through 6. It is made of a heavy fabric or similar material and utilizes hook and loop fastener strips along its inside edges to hold it closed around the top, mechanical parts of these assemblies and in a position which folds it around and over the top and bottom of said assemblies. This cover 35 lays against the horse's back underneath the harness assembly and folds around and up and over the top of the harness assembly. Item 32 is an access hole to allow a pump or winch or lever handle etc. to project through the cover 35 so that a user could access said handle while this cover is in place. This cover 35 would cover only the top assembly of parts of said harness assembly allowing items 14 , 18 and 19 to project beyond its edges. It would have its lower border positioned just at the downward curve in straps 14 . Items 33 and 31 are hook fastener strips and items 34 and 30 are loop fastener strips which mate with one another to hold the cover closed around the harness assembly when this cover 35 is folded through its center located at the juncture of strips 33 and 34 .
FIG. 8 is a view of a horse wearing the Grab Saddle System. The Grab Saddle 43 and its harness, embodiments of which are shown in FIGS. 1, 3 , 5 and 10 , form a system which is a complete seating attachment for a rider on a horse. One embodiment of Grab Saddle is shown in FIGS. 10, 11 and 14 . Harness strap 14 fits through Grab Saddle slots 42 in slot flap 40 thus securing Grab Saddle to the straps 14 and locking it in position on the horse. There are no other parts necessary such as saddle blankets or saddle pads etc. since all of the parts which comprise the Grab Saddle system and which contact the horse's skin are made of fabric. The Grab Saddle System gives the rider a much more secure seating on the horse than any other saddle system known. The secondary tightening device described in several of these previous figures may be included as a part of this Grab Saddle System or it can be omitted. It is not essential for the proper operation of this Grab Saddle System. It is, however, an enhancement to the operation of the Grab Saddle System when incorporated into that system. More explanations of the item numbers in FIG. 8 which has not yet been given will be found by referring to FIGS. 10, 11 and 14 where the enlarged detail of Grab Saddle is easier to reference.
FIG. 9 is a view like FIG. 8 but showing another embodiment of the harness for Grab Saddle. Item 50 is a connector between item 55 around the horse's neck and item 55 which is around the horse's chest. Items 50 and 55 can be made from a strong canvas like material such as some of the latest high strength fabrics made from man made fibers or it can be made of a rigid or semi-rigid material such as metal or plastic or fiber glass etc.. The choice depends on how much like a current rigid saddle tree the user wants these parts to be. The more rigid, the more firm the harness will be in maintaining its positioning from side to side on the horse during the rider's mounting or during sharp turning while riding. Item 54 is an air pressure valve fitting which can accept the connection of an air pressure hose from an air pump or other source of pressurized gas to allow inflation and deflation of said items 55 so the invented secondary tightening of the harness function can be accomplished utilizing the expansion of the air chambers found inside items 55 . Item 53 is a common girth strap whose connection and also primary length adjustment is made using at least one of the buckles 51 which buckles also permit the same connection and length adjustment for item 52 which is a neck harness strap and is attached to this same harness assembly 55 . A single, adjustable connector strap goes between the horses front legs and is connected between and helps to hold straps 52 and 53 in position relative to one another. It is not shown in FIG. 9 but such straps are in common use between horse's front legs and need no further explanation here to be understood by those who posses even a limited amount of horse knowledge. This connector strap between the horse's front legs has its own length adjustment buckle. This connector strap's main function is to keep the neck strap 52 from riding up the front of the horse's neck when in use. These straps can be made from leather or a strong fabric etc. but may also be covered by a soft sleeve of wool for example, to prevent damage to the animal's skin.
FIG. 10 is a side view of one embodiment of Grab Saddle as described in my previous patent U.S. Pat. No. 5,423,164. Item 43 is the saddle proper and also gives indication of what part of the saddle is the portion where the rider actually sits. Item 40 is one of the two front slot flaps whose slots 42 permit passage in and out by the harness straps 14 . This secures the Grab Saddle to its harness and therefor to the horse. These items 43 and 40 are the only items that are essential to the proper operation of the grab saddle. All the other items described by this FIG. 10 are non essential attachments which are enhancements to the operation of grab saddle but are not essential to that proper operation. Item 64 is one of two identical buckles which allow the Grab Saddle girth strap 46 to be attached to Grab Saddle proper. This girth strap goes around the horse's belly to provide additional attachment for Grab Saddle to the horse. It can be covered with a wool or some other fabric cushioning sleeve to protect the horse's belly skin. Item 62 is one of two identical zippers which exist on both ends of the Grab Saddle girth strap which provide, when open, an opening for the stirrup to pass through and when zipped up against the stirrup strap 49 each zipper captures its protruding stirrup 48 and holds it perpendicular to the length of the horse. This allows it to be in the proper position for the rider to get their foot into the stirrup without the problem now current in all saddles where the rider must twist the stirrup 90 degrees before the foot can be inserted. Item 63 is the length adjustment and bottom attachment buckle for the Grab Saddle girth strap. It allows for adjustment of said girth strap for the size of the horse's belly so Grab Saddle can fit a wide range of horses. Items 61 are zippers which hold the cover flaps 45 closed in place covering over the hook fastener strips 44 when they are not needed to hold the rider in place in the saddle. Items 47 are the snap fasteners employed on Grab Saddle to hold the cover flaps 45 folded back and away from the hook fastener strips 44 when the rider needs the fastener strips 44 exposed and available to hold the rider in place on the horse. The hook fastener strips 44 are exposed by opening the zippers 61 and folding cover flaps 45 in half back upon themselves and snapping snaps 47 onto each other to keep cover flaps 45 locked in their open position so they don't fall back and cover over the hook strips 44 until the rider is done riding. To dismount, the rider needs only to kick their right leg out and away from the horse to disengage the loop fastener strip on their pants leg or chaps from the hook fastener strip on Grab Saddle. This allows them to dismount normally without any delay in dismounting being caused by the hook and loop fastener strip connections that hold them securely on their mount while riding. After the rider's right leg has been kicked loose, the rider's left leg will come free from its hook fastener strip 44 without any further effort or notice on the rider's part as the dismounting progresses. When needed, because of different types of riding requirements, the top cover flaps may be left closed and the bottom cover flaps left open so that only the rider's calf portions of their legs will be attached to the hook strips 44 while riding. Likewise, if the rider chooses, the bottom cover flaps may be left closed while the top cover flaps are opened. This will insure that only the rider's thigh portions of their legs will be attached to the hook strips 44 while riding. This Grab Saddle feature gives riders using Grab Saddle control over how much and what type of leg attachment to Grab Saddle they want while riding. Item 60 is a flap made of fabric sewed onto Grab Saddle proper which protects the horse's skin on its back from possible abrasion by the seat cushion pocket zipper 41 which is used to open and close the seat cushion pocket where the rider may insert a foam or air cushion that will protect their posterior from hard bouncing while they ride.
FIG. 11 is the same view as FIG. 10 but shows the cover flaps 45 unzipped and folded back and snapped in their retracted position using snaps 47 thus exposing hook fastener strip 44 so it can mate with the loop fastener strip attached to the rider's leg when said loop fastener strip comes in contact with the hook fastener strip as the rider is mounting into the saddle. It is possible to use Grab Saddle successfully with only items 40 , 42 , 43 and 44 in place on Grab Saddle. Any other items shown on FIGS. 10 and 11 are simply additional items to make Grab Saddle more efficient.
FIG. 12 is a cross sectional view of item 55 a which is the same as item 55 as shown in a side view in FIG. 9 except that as item 55 a it has the addition of a metal or plastic rigid or semi-rigid stay or strap 58 which provides a frame against which the regular item 55 as shown in FIG. 13 can support itself. Item 58 thereby acts to stiffen the whole harness assembly. This adds somewhat to the stability of the harness assembly when attached to the horse and helps prevent slipping sideways of the saddle. Item 55 a also contains an inflatable air pressure tube 56 which contains air or some other compressed gas 57 . This tube 56 is covered by a sleeve 59 made of a canvas like fabric. This inflation of said tube 56 accomplishes the invented secondary tightening of the harness function. This occurs as the gas expands the dimensions of item 55 around the horse after the user or rider has first pulled the girth strap 53 and neck strap 52 and their connector strap as tight as possible by hand.
FIG. 13 is a cross sectional view of the same item 55 shown in the side view in FIG. 9 . It is an inflatable air pressure tube 56 which contains air or some other compressed gas 57 . This tube 56 is covered by a sleeve 59 made of a canvas like fabric. This inflation of said tube 56 accomplishes the invented secondary tightening of the harness as the gas expands the dimensions of item 55 around the horse after the user or rider has first pulled the girth strap 53 and neck strap 52 and their connector strap as tight as possible by hand thereby accomplishing the primary tightening.
FIG. 14 is an end view of one embodiment of Grab Saddle. All of these items have been explained by number in previous explanations of the figures. In FIG. 14 however, the full length of the seat cushion pocket zipper 41 may be seen with its accompanying fabric flap 60 . Also, the insertion of the stirrup straps 49 through the opening in the Grab Saddle girth straps 46 may be seen. The relative position of several other items may also be noticed.
FIG. 15 is the same as FIG. 9 but illustrates yet another design approach to effecting the invented secondary tightening of the harness effect by utilizing a compressed gas operated piston device 66 with an internal coil spring return. Such compressed gas piston cylinders are readily available on the market and need no elaboration here as to their construction. They extend their piston rod out of its cylinder when gas pressure or hydraulic pressure is introduced into that cylinder and then their internal coil spring automatically retracts the piston rod back into their cylinder when said pressure is allowed to escape that cylinder. This piston assembly 66 is placed in line with item 55 on both sides of the horse so as to extend when air or some other gas pressure is introduced into its cylinder's interior. This extension of the piston rod then allows the rider or horse handler to hand tighten the neck strap 52 and the girth strap 53 and their connector strap and then buckle them off to hold that preliminary tightened position. After that initial tightening is accomplished as described, the gas pressure or hydraulic pressure inside the cylinder is released to allow the internal coil spring inside the cylinder to pull the piston rod back into the cylinder as far as the harness straps will allow it to go. This arrangement will keep the harness straps around the horse under constant spring tension and thereby keep saddle slippage from occurring as often.
It is obvious that the embodiments of this invention could be successfully effected using many different types of materials other than those described in this patent and even different from those normally used currently by horse saddles for the parts described in these FIGURES. I do not intend to limit these designs to only steel parts or some other metal or wood or plastic parts or leather parts. The steel or wood parts, for example, could be fiberglass or some other plastic or even some other material such as a sweat wicking fabric or graphite fiber filled composite material. The leather parts could instead be made of a high strength fabric or plastic or still some other material.
It is also obvious that there are exhibited on the FIGS. 10 and 11 in the drawings, many mechanical means and items which are not essential to the basic operation of Grab Saddle as a safety device for horse back riding. The four items in FIG. 11 which are essential are items identified as item 40 , 42 , 43 and 44 . All the other items shown in that FIGURE and FIG. 10 are extra to improve the efficiency of Grab Saddle.
It is also obvious that there are many mechanical methods of tightening straps around the body of an animal that have not all been defined exactly in this patent. This patent however encompasses all such means of decreasing the circumference of the girth straps and harnesses with which saddles are held onto horses to achieve the invented secondary tightening of the harness effect.
It is also obvious that other means of enlarging the preferred embodiment's inflatable gas bag which tightens the girth around the horse for its secondary tightening of the harness could be utilized, such as increasing the size of said gas bag hydraulically rather than pneumatically or such as sourceing the compressed gas for pneumatic inflation from a carbon dioxide pressure cylinder rather than pumping the air into the inflatable tube to enlarge it thereby tighten the harness a given amount as my patent teaches.
It is obvious that there are many different mechanical methods to control the up and down inflation and deflation of the inflatable tube or air bag and this patent intends to encompass all such designs.
It is also obvious that the gas bags or inflatable containers for pressurized gas or liquids identified in the drawings shown in this patent could be of any useful material and configuration and possibly extend entirely around the animal rather than just exist under the top portion of the harness assembly as shown in these drawings.
It is also obvious that different strap tightening mechanisms are well known and many different approaches to strap tightening could prove to be equally effective for this grab saddle system. The piston mechanism 66 shown in FIG. 15 used to shorten the length of the girth strap 53 and the neck strap 52 or the winch as shown in FIGS. 3 and 4 which can be used for the same purpose or the air bladder as shown in FIGS. 1 and 2 can all be used to effect this secondary tightening of the saddle straps. So it is obvious that the shortening of straps 52 and 53 which effects their tightening can be accomplished by many different mechanical devices or designs such as those already described earlier in this patent. Some likely mechanical devices that qualify as candidates to provide this secondary shortening of the straps that hold the saddle in place would be lead screws or block and tackles or sprockets and chain or ratchet mechanisms or lever arms, etc..
It is also obvious that the secondary tightening device described in several of these previous figures may be included as a part of this Grab Saddle System or it can be omitted. It is not essential for the proper operation of this Grab Saddle System. It is, however, an enhancement to the operation of the Grab Saddle System when incorporated into that system.
It is also obvious to anyone that rides that the devices described here in this specification and the claims can easily be adapted for use with regular, old fashioned saddles and tack. The concepts this patent covers are mainly the removing of the saddle's structure from under the rider and placing it forward onto the horse's withers as well as the secondary tightening of that structure as well as the safety feature of hook and loop fastener strips holding the rider in place to prevent most accidental dismounts. Of course there are other concepts explained as well as those listed immediately above which are taught for the first time here in this patent, but those I have listed immediately above are the primary concepts taught in this patent.
It is also obvious that the Grab Saddle and Grab Girth combination, once they have been connected together on the horse's back, are not only a great safety device but also a great therapy saddle for healing lame horses to be used when they are exercised by having a rider ride them. It is also obviously a great saddle for helping disabled people to stay on their therapy horse when they ride to improve their health. Grab Saddle, when used together with Grab Girth, completely eliminates the need for a regular saddle to be used although they can be used in conjunction with some designs of regular saddles if the rider desires. It is obvious that common buttons, etc. can be substituted for the snaps and zippers etc. used on Grab Saddle and Grab Girth. | To improve the safety of horseback riding, a fabric saddle with hook fastener strips sewed to its side fenders attaches to the horse using a new design of harness that gives the rider the ability to mechanically make a secondary tightening of that harness around the horse after the standard initial manual girth strap tightening has been done. This secondary tightening has the characteristic of being controlled so as not to harm the horse yet it snugs the saddle up so there is much less likelihood of the saddle slipping off the horse's back. As the rider mounts, the loop fastener strips on the rider's pants legs match with the hook fastener strips on the saddle and hold the rider onto the animal so the rider is not accidentally thrown off the horse. Quick dismount is not inhibited since the hook and loop fastener strips separate readily when the riders kick their legs away from the horse. | 1 |
FIELD
[0001] This invention relates to vapor management systems of vehicles and, more particularly, to a leak detection method and system for high pressure automotive fuel tank.
BACKGROUND
[0002] A known fuel system for vehicles with internal combustion engines includes a canister that accumulates fuel vapor from a headspace of a fuel tank. If there is a leak in the fuel tank, the canister, or any other component of the fuel system, fuel vapor could escape through the leak and be released into the atmosphere instead of being accumulated in the canister. Various government regulatory agencies, e.g., the U.S. Environmental Protection Agency and the Air Resources Board of the California Environmental Protection Agency, have promulgated standards related to limiting fuel vapor releases into the atmosphere. Thus, there is a need to avoid releasing fuel vapors into the atmosphere, and to provide an apparatus and a method for performing a leak diagnostic, so as to comply with these standards.
[0003] An automotive leak detection on-board diagnostic (OBD) determines if there is a leak in the vapor management system of an automobile. The vapor management system can include the fuel tank headspace, the canister that collects volatile fuel vapors from the headspace, a purge valve and all associated hoses. These systems however, require pressure to be bled-off before tank diagnostics can be run.
[0004] In some vehicle applications (e.g., plug-in hybrid) the fuel tank is held at elevated pressures in order to suppress the evaporation of gasoline, and therefore reduce the need to store and process any vented gasoline vapor.
[0005] Thus, there is a need for a diagnostic method and system to detect vapor leakage in a high pressure fuel tank environment, without having to bleed off the pressure.
SUMMARY
[0006] An object of the invention is to fulfill the need referred to above. In accordance with the principles of an embodiment, this objective is achieved by a method of determining a leak in a vapor management system of a vehicle. The system includes a fuel tank having liquid fuel therein and a vapor cavity above the liquid fuel; a vapor collection canister; a tank pressure control valve between the tank and canister and defining a high pressure side, including the fuel tank, and a low pressure side, including the canister; a vacuum source; a purge valve between the canister and vacuum source; a leak detection valve connected with the canister; and a processor. The method provides a sense tube in the tank. The sense tube has an open end disposed near a bottom of the tank such that fuel in the tank may enter the open end. A differential pressure sensor has one side thereof connected to the sense tube and another side thereof connected to the vapor cavity so that the pressure sensor can measure a differential pressure (DP) between a volume of the vapor cavity and a volume of the sense tube containing the liquid fuel. A temperature sensor is provided in the vapor cavity, with signals from the pressure sensor and temperature sensor being received by the processor. The differential pressure (DP) and the temperature (T) are measured at certain time intervals to determine the temperature at time zero (T 0 ), the differential pressure at time zero (DP 0 ), the temperature at a certain time (T t ), and the differential pressure at a certain time (DP t ), and when (T t -T 0 ) is greater than a certain value, DP t is compared to a certain differential pressure value.
[0007] In accordance with another aspect of an embodiment, a vapor management system for a vehicle includes a fuel tank having liquid fuel therein and a vapor cavity above the liquid fuel; a vapor collection canister; a tank pressure control valve connected between the tank and canister, the control valve defining a high pressure side, including the fuel tank, and a low pressure side, including the canister; a vacuum source; a purge valve connected between the canister and vacuum source; a leak detection valve connected with the canister, and a processor. A sample tube structure has a sense tube disposed in the tank with the sense tube having an open end disposed near a bottom of the tank such that fuel in the tank may enter the open end. A differential pressure sensor has one side thereof connected to the sense tube and another side thereof connected to the vapor cavity so that the pressure sensor can measure a differential pressure (DP) between a volume of the vapor cavity and a volume of the sense tube containing the liquid fuel. A temperature sensor is provided in the vapor cavity, with signals from the pressure sensor and temperature sensor being received by the processor. The processor is constructed and arranged 1) to receive a differential pressure (DP) measurement and a temperature (T) measurement at certain time intervals to determine the temperature at time zero (T 0 ), the differential pressure at time zero (DP 0 ), the temperature at a certain time (T t ), and the differential pressure at a certain time (DP t ), and 2) when (T t -T 0 ) is greater than a certain value, to compare DP t to a certain differential pressure value.
[0008] Other objects, features and characteristics of the present invention, as well as the methods of operation and the functions of the related elements of the structure, the combination of parts and economics of manufacture will become more apparent upon consideration of the following detailed description and appended claims with reference to the accompanying drawings, all of which form a part of this specification.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The invention will be better understood from the following detailed description of the preferred embodiments thereof, taken in conjunction with the accompanying drawings, in which:
[0010] FIG. 1 is a schematic illustration showing a diagnostic vapor management system for detecting vapor leakage in a high pressure fuel tank environment, according to an embodiment of the present invention.
[0011] FIG. 2 is an enlarged view of the sample tube structure of FIG. 1 shown mounted to the fuel tank.
[0012] FIG. 3 is a view of the sample tube structure of another embodiment, shown mounted to a portion of a fuel tank.
[0013] FIG. 4 is a graph, using a method of one embodiment, showing that with zero leakage, the differential pressure remains zero.
[0014] FIG. 5 is a graph, using a method of another embodiment, showing that with zero leakage, the differential pressure remains at about 8 mbar.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0015] Referring to FIG. 1 , a diagnostic vapor management system for a high pressure fuel tank of a vehicle is shown, generally indicated at 10 , in accordance with an embodiment. The high pressure (sometimes called “non-integrated”) system 10 comprises of a fuel tank, generally indicated at 12 , a charcoal, vapor collection canister 14 , a tank pressure control valve 16 , and a sample tube structure, generally indicated at 15 . The sample tube structure 15 may be connected with the control valve 16 , and has a portion disposed in the tank 12 . The sample tube structure 15 is connected to one side of a differential pressure sensor 17 disposed in a vapor cavity 28 of the tank 12 . The system 10 also includes a vacuum source 18 , such as an intake manifold of the engine, a purge valve 19 between the canister 14 and vacuum source 18 , a leak detection valve, generally indicated at 20 , and a filter 22 . A temperature sensor 26 is also located within the vapor cavity 28 of the fuel tank 12 . In the embodiment, the pressure sensor 17 and temperature sensor 26 are electrically connected to a processor, generally indicated at 30 , within the leak detection valve 20 . If desired, the processor 30 can be provided remote from the leak detection valve 20 .
[0016] It is understood that volatile liquid fuels, e.g., gasoline, can evaporate under certain conditions, e.g., rising ambient temperature, thereby generating fuel vapor. Fuel vapors that are generated within headspace 28 of tank 12 are collected in the vapor collection canister 14 . At times conducive to canister purging, the collected vapors are purged from canister 14 to the engine (not shown) through the purge valve 19 . The canister 14 vents to atmosphere through the particulate filter 22 , allowing engine manifold vacuum 18 to draw air into and through canister 14 where collected vapors entrain with the air flowing through the canister and are carried into the engine intake system, and ultimately into engine where they are combusted.
[0017] The system 10 is divided into two parts by the tank pressure control valve 16 . A low pressure side, generally indicated at 32 , is shown in dot-dashed lines in FIG. 1 and includes the canister 16 , while a high pressure side, generally indicated at 34 , is shown by a thick black line in FIG. 1 and includes the fuel tank 12 . The system 10 is preferably for use in a plug-in hybrid tank system.
[0018] Leak diagnostic on the low pressure side 32 is conducted by the leak detection valve 20 , using a first, or low pressure algorithm 36 executed by the processor 30 , in a manner described in U.S. Pat. No. 7,004,014, the content of which is hereby incorporated by reference into this specification. In particular, in the course of cooling that is experienced by the system 10 , e.g., after the engine is turned off, a vacuum is naturally created by cooling the fuel vapor and air, such as in the headspace 28 of the fuel tank 12 (when valve 16 is open) and in the charcoal canister 14 . The existence of a vacuum at a predetermined pressure level indicates that the integrity of the system 10 is satisfactory. Thus, signaling 38 , sent to an engine management system (EMS), is used to indicate the integrity of the system 10 , e.g., that there are no appreciable leaks. Subsequently, a vacuum relief valve 40 at a pressure level below the predetermined pressure level, protects the canister 14 and hoses by preventing structural distortion as a result of stress caused by vacuum in the system 10 .
[0019] After the engine is turned off, the pressure relief or blow-off valve 42 allows excess pressure due to fuel evaporation to be vented, and thereby expedite the occurrence of vacuum generation that subsequently occurs during cooling. The pressure blow-off 42 allows air within the system 10 to be released while fuel vapor is retained. Similarly, in the course of refueling the fuel tank 12 , the pressure blow-off 42 allows air to exit the fuel tank 12 at a high rate of flow if the valve 16 is open.
[0020] While the high pressure side 34 could be equalized with the low pressure side 32 for the purpose of conducting a leak check on the entire system 10 , this would eliminate the advantage of holding fuel tank at elevated pressure. The pressure sensor 17 and temperature sensor 26 allow a second, or high pressure algorithm 44 executed by the processor 30 to detect a leak on the high pressure side 34 without the need to vent the tank pressure through the canister 14 , as explained below.
[0021] In accordance with an embodiment and as best shown in FIG. 2 , the tank 12 is divided into two parts. The vapor cavity 28 is the area above the liquid gasoline 46 . The sample tube structure 15 includes a cylindrical sense tube 47 having an open end 48 that is positioned such that the open end 48 is close to the bottom 50 of the tank 12 . The sense tube 47 is constructed and arranged such that the liquid gasoline 46 can enter from the bottom (open end 48 ) only. The tank filler tube 51 is also shown.
[0022] FIG. 3 shows an example embodiment of the sample tube structure 15 . The sample tube structure 15 includes a housing 52 coupled to the tank 12 so as to extend outside of the tank 12 . The sense tube 47 is connected to one side 54 of the differential pressure sensor 17 , which can be provided in the housing 52 or in the vapor cavity 28 . The other side 56 of the pressure sensor 17 is connected to the vapor cavity 28 so that the pressure sensor 17 measures the difference in pressure between the volume of the vapor cavity 28 and the volume of the sense tube 47 containing the liquid gasoline 46 . The temperature sensor 26 is mounted so as to measure the temperature in the fuel tank vapor space 28 . The sample tube structure 15 also includes an optional equalization valve 58 disposed in the housing 52 . The equalization valve 58 can be used to equalize the pressure between the sense tube 47 and the tank vapor cavity 28 at the start of the diagnostic test. In the embodiment of FIG. 2 , the processor 30 is shown to be disposed in the housing 52 of the sample tube structure 15 . However, as noted above, the processor 30 can be disposed remotely (as in FIG. 1 ).
[0023] An important feature of the sample tube structure 15 is that the fuel and air inside the sense tube 47 is continually being ‘refreshed’ by the fuel in the main tank 12 . This takes place due not only agitation, but during the process of refueling from the near empty condition, when the bottom of the sense tube 47 is not covered, a direct air passage is created. All of these actions guarantee that the fuel and air composition in the sense tube 47 is identical to that of the main tank 12 .
[0024] There are two basic methods of using the sample tube structure 15 to run a leak diagnostic. The first method starts with the pressure and liquid level equal in the two volumes as shown in FIG. 2 . The second method starts with the pressure inside the sense tube 47 at a different level than in the tank 12 .
[0025] The first method that starts with equalized pressure is as follows. At the start of the diagnostic, the equalization valve 58 is opened momentarily to balance the pressure and liquid level in the sense tube 47 and the main tank 12 . This condition is shown in FIG. 2 . The differential pressure sensor 17 should now read zero at the start of the test. At some regular interval, e.g., every 10 minutes, the temperature (T) and differential pressure (DP) are continually measured to determine the temperature at time zero (T 0 ), the differential pressure at time zero (DP 0 ), the temperature at a certain time (T t ), and the differential pressure at a certain time (DP t ). If the system 10 has zero leakage, the pressure in the tank 12 should vary with respect to the temperature in a predictable and repeatable fashion. The pressure inside the sense tube 47 will also vary with respect to the temperature in exactly the same measure since the air vapor and liquid fuel composition inside and outside the sense tube 47 are identical. If there is zero leakage, the differential pressure sensor 17 will always measure ZERO. This behavior is shown in FIG. 4 on a test tank 12 that is first heated then cooled. If leakage is present in the fuel tank, then the differential pressure will be NON-ZERO. To ensure that a valid test condition is available, a minimum temperature change should be achieved before the pressure results are evaluated.
[0026] In summary, the following logic describes the first leak diagnostic with equalization:
[0000] If ( T t −T 0 )≦ x then NO TEST POSSIBLE
[0000] If ( T t −T 0 )≧ x AND ( DP t ≠0) THEN Leak Detected
[0000] If ( T t −T 0 )≧ x AND ( DP t =0) THEN Leak Test PASS
[0027] An alternate, second method of using the sensing tube structure 15 to run a leak diagnostic can be performed when/if the pressure is not equalized at the start of the test. For this form of the test, the equalization valve 58 would not be required. This would simplify the hardware and reduce the chance of malfunction due to valve leakage or failure. The starting condition, DP 0 , in FIG. 5 is subject to several variables, including tank fill level, fuel composition and temperature. However, the tank and the sense tube 47 are both subject to the same variables and thus, generally cancel these effects. At some regular interval, e.g., every 10 minutes, the temperature (T) and differential pressure (DP) are continually measured as above. If the system 10 has zero leakage, the pressure in the tank should vary with respect to the temperature in a predictable and repeatable fashion. The pressure inside the sense tube 47 will also vary with respect to the temperature in exactly the same measure. If the system 10 has zero leakage, then the differential pressure at some time (t) should equal the starting pressure, or in other words DP t =DP 0 . This is shown in FIG. 5 as the tank 12 is heated and then cooled.
[0028] In Summary, the following logic must be satisfied to complete a leak diagnostic:
[0000] If ( T t −T 0 )≦ x then NO TEST POSSIBLE
[0000] If ( T t −T 0 )≧ x AND ( DP t ≠DP 0 ) THEN Leak Detected
[0000] ( T t −T 0 )≧ x AND ( DP t =DP 0 ) THEN Leak Test PASS
[0029] Thus, the use of the sample tube structure 15 is effective in determining if a vapor leak occurs in a high pressure fuel tank environment, without the need to bleed-off pressure.
[0030] The foregoing preferred embodiments have been shown and described for the purposes of illustrating the structural and functional principles of the present invention, as well as illustrating the methods of employing the preferred embodiments and are subject to change without departing from such principles. Therefore, this invention includes all modifications encompassed within the spirit of the following claims. | A vapor management system ( 10 ) includes a sense tube ( 47 ) disposed in a fuel tank ( 12 ). A differential pressure sensor ( 17 ) has one side connected to the sense tube and another side connected to a vapor cavity so that the pressure sensor can measure a differential pressure (DP) between a volume of the vapor cavity and a volume of the sense tube containing liquid fuel. A temperature sensor ( 26 ) is in the vapor cavity. A processor 1) receives DP and T measurements at certain time intervals to determine the temperature at time zero (T 0 ), the differential pressure at time zero (DP 0 ), the temperature at a certain time (T t ), and the differential pressure at a certain time (DP t ), and 2) when (T t -T 0 ) is greater than a certain value, compares DP t to a certain differential pressure value. | 1 |
BACKGROUND OF THE DISCLOSURE
A dipmeter is logging device which determines the dip of a formation intercepted by the borehole. Customarily, they use extendable arms which carry resistivity measuring pads on the arms for contact against the sidewall of the well borehole. The dipmeter is pulled up the borehole, measuring changes in formation resistivity (or its inverse conductivity) as it travels along the well borehole. The dip angle of the formation boundary or interface (a change in resistivity) is indicated by the incremental shift between the respective pads which note passage of the change in resistivity. It is well known to detect the boundary of a strata or formation, thereby determining the dip angle with respect to the borehole and an imaginary horizontal plane. Heretofore, current conductive electrode type dipmeters typically inject current into the formation in a low frequency range, typically about one to five kilohertz. Sharp angular dip resolution requires that the electrode buttons on the electrode pads be quite small. Excessive size degrades the sharpness of the measurement. In other words, vertical spatial resolution is poor if the buttons are large. Ordinarily, the dipmeter generates a relatively large current which is transmitted from some upper part of the sonde enclosing the dipmeter and which is returned to a lower part of the sonde. The current flow through the formation is dependent on resistivity. The formation current flow is intercepted by the small buttons on the pads. Ordinarily, all the pads extending from the dipmeter will measure the change in resistivity occurring at a boundary when the pads move or slide over the boundary intercept in the borehole.
The foregoing system works quite well so long as formation resistivity can be measured in isolation. Isolation, however, is not always possible. More wells are now being drilled with oil based muds. At the low kilohertz frequency range mentioned above, such muds are essentially nonconductive materials. Drilling muds form a mud cake on the sidewall of the borehole. If the mud cake is nonconductive, there is difficulty in making conductive contact by the small buttons mounted on the electrode pads of the dipmeter. Scrapers and other types of blades mounted adjacent to the electrodes have been used to cut the insulative mud cake so that better electrical contact can be obtained. That is noisy at best. At worst, it creates erratic signals which may be a result of noise so that the noise looks like boundary resistivity changes. This makes log interpretation much more difficult.
Such low frequency dependent dipmeters are additionally limited in highly conductive borehole fluids, particularly those which become commingled with brine. The brine is highly conductive. The current emitted by the electrodes on the dipmeter is transmitted in an altogether different fashion and the detected signals thus become much less reliable. To the extent that any measure of signal reliability is obtained by dragging contact between the buttons on the electrode pads and the adjacent formation, such signal improvement is overwhelmed by the increase in noise derived from dragging the button across the irregular surface of the rock formations. In U.S. Pat. Nos. 4,739,272 and 4,780,678 and also in a publication at the 28th Annual SPWLA Logging Symposium (1987) there is discussed an inductive dipmeter apparatus, which operates similar to miniaturized versions of conventional induction tools, and which contains both transmitter and receiver coil arrays in each pad. This method, while successful to a degree, suffers from the problem of requiring extraordinary accuracy in assembly of the coils to maintain mutual coupling balance, while the spatial resolution (in the range of one to two inches) is generally regarded as barely adequate for accurate dipmeter interpretation.
The present disclosure sets out a dipmeter which overcomes all these problems by providing an entirely different approach to dipmeter measurements. The present approach uses a high frequency induction measurement approach. Instead of having a point contact electrode, and relying on point contact with the formation to detect the boundary between adjacent strata, this approach utilizes small coils to detect signals from the formation. Moreover, a higher frequency is used, preferably in the range of about one to ten megahertz. The sonde is much simpler to construct because it does not have to be constructed to form an injected current which requires division of the sonde into electrically isolated components. In this particular instance, a transmitter coil forms a relatively high frequency field which is directed into the formation. The electrode mounting mechanism of this disclosure is thus the same as that used heretofore, i.e., multiple pads on mechanically linked arms are used. However, the mode of connection of the pads with the formation and particularly the mode in which the signal is obtained is markedly improved. Accordingly, an entirely different approach for obtaining dipmeter measurements is set forth. Even so, the mechanics of the dip meter tool remain substantially the same, and dipmeter log interpretation remain substantially the same.
BRIEF DESCRIPTION OF THE DRAWINGS
So that the manner in which the above recited features, advantages and objects of the present invention are attained and can be understood in detail, more particular description of the invention, briefly summarized above, may be had by reference to the embodiments thereof which are illustrated in the appended drawings.
It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
FIG. 1 shows a dipmeter in accordance with the teachings of the present disclosure utilizing a transmitter coil in the upper part of the device to form an induced field in the formation and includes multiple pads which are mounted to extend radially outwardly for sliding contact against the well borehole wherein phase detector measuring circuits are incorporated in the pads;
FIG. 2 is a block diagram schematic showing the cooperation of adjacent detector coils which provide a measurement of phase shift;
FIG. 3 shows dipmeter phase shift versus resistivity for different spacings of the detector coils;
FIG. 4 shows a normalized phase shift differential which has been superimposed over a resistivity profile; and
FIG. 5 shows a normalized phase shift differential which has been superimposed over a resistivity profile for a more closely-spaced set of beds.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Attention is directed to FIG. 1 of the drawings where the dipmeter 10 of the present disclosure is set forth. It incorporates an elongate housing or package known as a sonde 10. The sonde incorporates an inclinometer 11 which is at the upper end of the tool. The upper portion of the sonde 12 is constructed for connection with a logging cable (not shown) so that the tool can be raised in a well borehole to conduct logging activities. The sonde is encapsulated within a housing 13 which is of rugged construction to resist ambient pressures and temperatures encountered during operation. A portion of the sonde has a reduced neck diameter so that it can support a transmitter coil 15. The transmitter coil is conveniently wrapped as multiple turns around the smaller neck portion. This coil is driven by an oscillator and forms a field to be described. The transmitter coil 15 creates a field in the formation fully around the borehole and the field causes currents to flow dependent on the formation resistance.
There are measurement circuits 16 included within the housing. The measurement circuits 16 cooperate with telemetry circuits to deliver the output signals through the logging cable for transmission to the surface. The lower portions of the dipmeter 10 include multiple arms. Two have been shown in FIG. 1, but it will be appreciated that it is normal to use at least three, often four and sometimes six. Since they are all similar and differ only in their position on the dipmeter 10, it is thought that description of one will suffice for all the others. To this end, an arm 17 connects with a mounting plate 18. The plate 18 is held parallel to the sidewall. Another arm 19 assists in holding the plate parallel to the sidewall. Another link 20 is included and it connects with a slidable collar near the base of the dipmeter. By appropriate and well known mounting mechanisms, the pad to be described is urged into contact with the adjacent wall of the borehole to make measurements.
The apparatus includes a pad 21. It is formed of a sacrificial ceramic material. It encounters rough wear and is ultimately worn away and must be replaced when worn. It is provided with a slightly curving face so that it can slide smoothly against the wall, keeping in mind that it is being abraded by the rough rock wall which confronts it. The ceramic pad 21 has embedded therein two coils. The upper coil 22 is identical to the lower coil 24, the two coils differing only in vertical spacing. The coils are wound about an axis which is parallel to the axis of the dipmeter 10. They are relatively small coils. They detect small current flows in the formation and hence create relatively small output signals. To this end, they can be wound of quite fine wire with many turns to form an output signal. This enables the coils to be quite small in physical dimensions. The coils can be round and hence are wound on a cylindrical coil form if desired. Alternately, the pad can have substantial angular contact with the well borehole and, in that sense, is a portion of an arc. If that is the case, the coils 22 and 24 can have substantial width, and can even be formed of conductors plated onto a two-sided printed circuit board which is curved to conform to the cylindrical borehole in which the device is used. In any event, the two coils are spaced vertically from one another by a specified distance. It is ideal that they be relatively close, typically with vertical spacing of about 0.5 inches or as small as 0.2 inches. The two coils have signals induced therein and form their output signals which are delivered to a differential system related in FIG. 2 that will be described in detail later.
Note should be taken of the inductive coupling between the transmitter coil 15 and the formations adjacent to the borehole. Typically, the transmitter coil 15 is about thirty to seventy inches above the measurement pads. The transmitter coil is provided with a continuous wave (CW) signal which provides a current of perhaps one ampere or more. The preferred operating frequency is in the range of about one to ten megahertz and about five megahertz is preferred. For various reasons, the frequency range can be extended. The coil 15 forms a longitudinal magnetic field with an azimuthal electric field. The field induces current flow in the formations adjacent to the well borehole. More generally, as outlined in the U.S. Pat. No. 3,551,797 (now expired), it can be assumed that plane-parallel waves at the frequencies contemplated pass in the vicinity of the receiver coils at a velocity dependant on local resistivity. Attention is directed to FIG. 3 of the drawings which shows phase shift to be a function of formation resistivity. In FIG. 3, where spacing is seventy inches from the transmitter coil 15 to the pads, the phase shift is shown over about four orders of magnitude of resistivity. The present apparatus need not detect absolute phase shift but it does measure differential phase shift as will be explained. In FIG. 2 of the drawings, the transmitter coil 15 is shown connected with a CW transmitter 25. The transmitter forms a field inducing current flow in the formations and in turn, signals are detected in the pad coils 22 and 24. As shown there, 22 is connected with an amplifier 26, and the coil 24 is connected with an amplifier 27. In turn, they form outputs for duplicate band pass filters 28 and 29. These outputs are provided through additional comparators configured as zero crossing detectors 30 and 31. These two signals are then provided to a phase shift detector 32. The output of the PSD 32 is then delivered to an analog to digital converter 33. The phase shift differential (measured either in degrees or in time differential) is then output to the surface. As will be understood, the phase shift is represented by a digital word formed by the ADC 33.
Through the use of this differential circuit, absolute values are meaningless. Accordingly, the currents formed in the formation may vary for a multitude of reasons, but current amplitude is no longer important. What is significant is the phase shift between the two coils 22 and 24. There will be an interaction of the formation with the field imposed on the formation by the coil 15. Particularly at a change in resistivity, there will be a change in phase shift as suggested by FIG. 3. The change of phase shift depends in part on the resistivity difference across the boundary. It also depends in part on the spacing of the two coils 22 and 24. FIG. 3 is a representative showing of phase shift with two different curves, one from receiver coil spacing of 0.5 inches, and the other showing spacing of 0.2 inches. The curves of FIG. 3 are at a representative frequency of five megahertz. If the frequency is different, the values might change somewhat, but the same differential relationship will generally hold true. That is, closer coil spacing shows a reduced phase shift differential between the two coils.
Attention is now directed to FIG. 4 of the drawings which shows a normalized differential phase over a logged interval. The differential phase shift is defined as the change in the phase measured by the aforementioned apparatus between successive measurements at an incremental change in depth, divided by average phase shift as follows: ##EQU1## Normalized differential phase shift, where φ z is the phase measured at depth z and φ z-1 is the phase measured at depth z-1, i.e. previous depth sample. The depth samples may be as fine as 0.2 to 0.5 inches. This differential method of signal processing is a feature of the present invention and is possible because of the elimination of sliding contact noise typical of more traditional designs. As will be understood, when both coils are adjacent a common strata and the boundaries of that strata are quite remote from the two coils, the differential phase shift substantially decreases to some very small value. However, the differential changes substantially when the boundary between two strata relatively passes the two coils. On this event, a very different phase shift signal is created; that is, a disturbance in the differential phase is output. When such a boundary is encountered, the boundary causes a change in differential phase shift that can readily be two or three orders of magnitude greater. While it is a small differential prior to the boundary passage, such a change is quite noteworthy and provides an indication of the boundary passing the pair of coils. For instance in FIG. 5 with an expanded depth scale, at the depth of 486 feet, there is a large change in measured differential phase shift indicated by the dotted line 40. That in turn indicates a strata boundary at 42 where the line 43 indicates the relative thickness of the particular strata. The line 43 extends from the differential phase peak measurement 40 to the next peak measurement 44. The line 43 thus represents the thickness of that particular strata between the boundaries represented at 40 and 44. It is apparent that a strong response is obtained at boundaries separated by only a few inches, as in thinly laminated rock formations.
The coils 22 and 24 sample the magnetic field which is parallel to the well borehole at the face of the borehole. The currents in the formation induce voltages in the coils showing the phase shift dependency exemplified in FIG. 3 of the drawings. Moreover, phase shift provides a relatively accurate measurement of formation resistivity in the immediate vicinity of the pad. Referring again to FIG. 3, it again shows that phase shift is directly related to formation resistivity. Absolute measurement of formation resistance is not essential to a dipmeter; it is, however, helpful to obtain some correlation between the dipmeter log and tools which make resistivity measurements. This enables the dipmeter data of the present disclosure to be correlated to data from other types of instruments. Even though the present apparatus is not intended for resistivity measurements, such data can be obtained and correlated with boundary identification.
In the presence of oil based drilling fluids which are nonconductive or salt water which is highly conductive, the disclosed apparatus still functions in the same way. Contact noise is no problem because there is no attempt made to obtain mechanical contact between the coils and the surrounding sidewall of the borehole. Moreover, the fluids in the borehole have less impact in this circumstance than they do in contact measurements because the coils 22 and 24 respond to induced currents in the formation. That is, currents are created in the formation resulting from the field focusing into the formation so that borehole fluid has reduced significance. Since the field is substantially in the formation, the signals in the detector coils 22 and 24 are less impacted by borehole fluid. Moreover, the choice of frequency fairly well limits the depth of penetration of the field induced currents into the formation. It is possible, of course, to select frequencies where the currents flow many feet beyond the borehole. That is not intended in this instance. Rather, it is intended that the current flow be induced in the formation close to and parallel to the borehole, and relatively close without extending deep into the formation. In that sense, the present device does not operate like resistivity tools which use current emitting and focusing electrodes to direct the current flow deep into the formation. Accordingly, the induced field in the formation is shaped so that measurements are obtained from formation boundaries, and are less impacted by the fluids in the borehole, and also smaller inaccuracy is introduced by the angle of dip of the bed boundaries, which causes problems with deeper penetrating measurement techniques.
In similar fashion to traditional dipmeters, the advent of formation boundaries at each pad is duly noted, and the multiple traces from the several pads are analyzed in the known manner. The output signals are correlated to determine the dip of the boundary creating the change in differential phase shift.
While the foregoing is directed to the preferred embodiment, the scope is determined by the claims which follow. | A dipmeter has a coil forming a medium frequency field (e.g., five megahertz); the field interacts with the formation to form induced currents in the formations dependent on resistivity. The formation boundaries create a phase shift contrasting with the shift occurring in the formation so that a pair of closely spaced coils on a shoe locates relative transition of a formation boundary. The boundary is located by the several dipmeter arms. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a §371 filing of PCT application PCT/FI2015/050683 filed on Oct. 12, 2015, which claims priority from Finnish application FI 20145903 filed on Oct. 14, 2014. The disclosures of these applications are included by reference herein in their entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to a screen cylinder that is particularly suitable for screening, filtering, fractionating, or sorting cellulose pulp or fibre suspensions of the pulp and paper industry or other similar suspensions. The present invention relates more particularly to screening devices of the type comprising a plurality of screen wires positioned axially and at a small spacing parallel to each other. The plurality of screen wires forms a screening surface facing the pulp or fibre suspension to be screened and adjacent wires form screening openings therebetween allowing an accept portion of the pulp or fibre suspension to flow therethrough.
BACKGROUND OF THE INVENTION
[0003] Some of the first wire screens that appeared on the market had a smooth surface, which had been adapted from screens used for filtration. The constituent wires had a generally triangular shape, with one side of the generally triangular wire forming the surface facing the pulp suspension to be screened. One very significant problem resulting from the use of smooth cylinders was that screen capacity was very low, with the screen exhibiting a very high hydraulic resistance and the screen openings quickly filling with pulp fibres. This problem was solved by the development of contoured screen surfaces. The contours are present circumferentially, and can be created by tilting the screen wires. Alternatively, the side of the generally-triangular wire facing the pulp suspension to be screened can have a more complex, non-planar, shape to generate the contour, as is described in U.S. Pat. No. 5,255,790. In other alternative screen configurations, both a more complex wire shape and tilting have both been used.
[0004] Contours may be circumferentially symmetric relative to the screening openings defined between adjacent wires. The problem with symmetric contours is that the flow of the pulp suspension being presented to the contour is highly dissymmetric. There is typically a rotor on the side of the cylinder facing the pulp suspension to be screened, although in some cases the cylinder is rotated relative to some stationary structures to create a similar effect as the moving rotor adjacent a stationary cylinder. In the most typical case of the moving rotor and stationary cylinder, the rotor induces a circumferential motion in the pulp suspension and this flow is more or less parallel to the surface of the cylinder. A small part of this generally circumferential flow turns and passes more or less radially through each of the openings in the screen cylinder. A dissymmetric contour shape solves the problem of a dissymmetric flow and in particular, a flow that has very different flow patterns on the upstream and downstream sides of the opening since the character and design objectives for the impinging flow is somewhat different than the downstream flow.
[0005] The contour formed at the entry to each of the screen openings serves one or more of the following functions: First, the contour may streamline the flow that turns from the generally circumferential flow and passes radially through the opening, and thus acts to avoid the creation of vortices within the opening that might otherwise increase hydraulic resistance and limit capacity. Second, the contour may induce turbulence at the surface of the screen cylinder to break up any weakly-bound flocs of fibres approaching the opening or any loose accumulations of fibres within the opening. Finally, the contour may avoid the creation of a localized flow bifurcation at the entry to the opening, which can cause fibres to become immobilized and accumulate.
[0006] Various wire and contour shapes have been proposed with the goal of creating an optimal design. A typical contour is dissymmetric with a gradual slope adjacent the downstream side of the opening and an abrupt step on the upstream side of the opening. The particular features on the upstream and downstream sides of the opening are developed in consideration of the strong circumferential flow induced by the rotor.
[0007] DE-U1-9108129.7 discusses, as an example of a document disclosing a number of different cross sections for the screening bars or wires, a wedge wire screen cylinder for sorting fiber suspensions. The basic approach is that the screen cylinder is formed of identical wires having a shaped end extending to a constant radius from the cylinder axis. The document teaches several options for the end shapes for the wires including a slanted surface facing the fiber suspension to be screened, i.e. away from the support rings combining the identical wires to a screen cylinder. In accordance with the German document it is known that irregular end surface of the wires at their shaped ends, i.e. surfaces not parallel with the circumference of the screen cylinder improves the screening capacity and quality by creating micro turbulence on the screening surface. It has, for instance, been taught in the document that wires having a slanted shaped end surface may be arranged side by side either such that each wire has its shaped end surface slanting in the same direction or such that at one point of the circumference of the screen cylinder a set of wires have been turned to have their shaped end surfaces slanting in an opposite direction compared to a set of earlier wires or such that adjacent wires have their shaped end surfaces slanting in opposite directions. In fact, the turning of every second wire in a screen cylinder such that their shaped end surfaces are slanting in opposite direction compared to the shaped end surfaces of the rest of the wires results in a milder or weaker turbulence than if all the shaped end surfaces were slanting in the same direction. In any case, as the radius of the shaped end surfaces of all wires of the screen cylinder is constant, and the wires are identical, the chances of affecting the magnitude of the turbulence are limited.
[0008] One problem with even an optimized wire shape, and hence an optimized, dissymmetric, contour shape, is that the fibre length distribution of the pulp suspension can vary according to such factors as the species of the original wood from which the pulp was derived, the means of reducing the wood to fibres and the subsequent processing of the fibres. The fibre length distribution can even change within a multi-stage screening system because fibre fractionation within one stage of screening will alter the fibre length distribution for subsequent screening stages. The problem of having various fibre length distributions in different screening applications has been resolved by having a range of wire widths available for a particular overall wire cross-sectional shape. Different wire widths can thus be used in different cylinders in consideration of the particular fibre length distribution in the pulp to be screened.
[0009] Another problem with even an optimized, dissymmetric, contour shape, is that some mill applications have a particular need for increased screen capacity while other mill applications have a particular need for increased debris removal or for an increased level of fibre fractionation. A change in the size of the opening could be used to provide this trade-off in performance, but mill applications may stipulate a particular opening size to ensure a particular level of debris removal, especially to guard against the passage of debris that are larger than the stipulated opening size. A solution to this problem is obtained by providing different contour depths for different screen cylinders. A deeper contour generally provides increased capacity, while a shallower contour generally provides increased debris removal efficiency and a higher level of fibre fractionation. Changes in contour depth can be achieved by tilting the wires slightly or by changing the cross-sectional wire shape while still maintaining the overall contour design, or by both.
[0010] Yet another problem exists for coarse screening and other pulp screening applications where the incoming pulp is characterized by: a very high level of contaminants, abrasive contaminants, relatively large and often stringy contaminants, contaminants called pulp flakes, which are formed of strongly-bonded pulp fibres, or most typically a combination of these problematic pulp constituents. Such pulp suspensions can be created, for example, from post-consumer, recycled pulp furnishes, such as old corrugated containers that have received only a preliminary level of treatment and where only a minimal amount of the contaminants has been removed. The large contaminants in this suspension may become wedged within the screen cylinder openings and will require a significantly higher level and scale of turbulence than is provided by the aforementioned cylinder contours. The pulp flakes may be rejected by the pulp screen as contaminants which, in turn, results in the loss of potentially good fibre. In addition, the large and stringy contaminants may agglomerate into very large masses and become wedged between the screen cylinder and rotor.
[0011] A solution to this problem has been found by adding bars to the surface of the screen cylinder facing the pulp suspension to be screened. The bars typically extend the full length of the cylinder and are aligned either parallel to the cylinder axis, and thus parallel to the screen wires, or at a relatively small angle to the cylinder axis. There will be many times fewer bars than cylinder wires. The bars act to create a much deeper surface feature compared to the contours found in the plurality of screen cylinder wires. Unlike the wire contours, the bars are not intended to streamline the flow flowing into and through the openings or to produce micro-turbulence, but instead are intended to provide a somewhat different and substantially more aggressive mechanical action. The bars generate macro-turbulence, shearing forces and particle impact, and thus provide a distinct and complementary function to the function of the wire contours.
[0012] In particular, the bars are intended to do the following: First, the bars may provide large-scale macro-turbulence that increases screen cylinder capacity and avoids blockage of the cylinder openings. Second, the bars may act on pulp flakes through impact and fluid shear to break apart the flakes and create useful fibre from flakes that would otherwise be rejected as debris. Third, the bars may help avoid the agglomeration of plastic strings and other large debris that could jam within pulp screens treating highly-contaminated pulp suspensions. Finally, the bars may decelerate the pulp suspension and especially the abrasive contaminants in the suspension to reduce wear on the screen contours.
[0013] The bars are typically rectangular in cross-section. They can be applied to cylinders made of a plurality of wires either by attaching the bars to the surface of the wires facing the pulp to be screened, or by installing the bars on top of wires that have been modified to receive the bars, or in place of certain wires, as described in U.S. Pat. No. 5,472,095. The most typical approach, however, is to install the bars by welding them onto the surface of the wires facing the pulp to be screened using either a fillet or stitch weld along the sides of the bar that extend more or less axially.
[0014] There are some problems in this approach, however: First, the welding operation is an additional and time-consuming step in manufacturing. Second, the high temperatures used in welding can create distortions in the adjacent wires, which need to be very straight to ensure that the dimensions of the openings are accurate and precise. Third, fillet welds can block the openings adjacent the bar and lead to a loss in the open area of the screen cylinder and screen capacity. Fourth, the bars themselves can be quite wide and thus will further reduce the open area and screen capacity of the cylinder.
[0015] Instead of bars, one could consider using an array of wires with different cross-sectional shapes within a particular screen cylinder, as has been shown, for example, in U.S. Pat. No. 4,846,971 and U.S. Pat. No. 6,131,743. Such arrays could include a wire with a cross-sectional height that is greater than the other wires and that creates a distinctly deeper contour compared to some of the adjacent wires, or even to include a wire with a large, rectangular head that is like the shape of a bar.
[0016] WO-A1-03102297 may be taken as a further more detailed example of a cylinder comprising two different wires for forming the surface. The WO-document discusses a screen basket where the screen cylinder is formed of a plurality of first bars having a shaped end and a plurality of second bars having a shaped end. The screen surface is formed of the first and the second bars such that after, for instance, five adjacent first bars there is a second bar, then five first bars and one second bar etc. The shaped ends of the first bars of the screen cylinder have a first radius and the shaped ends of the second bars have a second radius. The first radius is greater in an outflow screen cylinder than the second radius. In other words, the shaped ends of the second bars extend farther from support rings common to both the first and the second bars, the rings supporting both the first and the second bars at their ends opposite to the shaped ends thereof. Both the first and the second bars have surfaces slanting in the same direction. The basic idea of providing the screen cylinder with the second bars having their shaped ends extending at a smaller radius than the shaped ends of the first bars, is to keep abrasive solid particles from abrading the shaped ends of the first bars until the shaped ends of the second bars have worn out significantly. However, as the function of the shaped ends of the second bars extending higher in the screening cavity than the first wires is to wear out and by doing that to protect the shaped ends of the first wires from wearing, the extension of the shaped ends of the second wires above the shaped ends of the first wires (radius 11a minus radius 10a in FIG. 4 of the WO-document) is, in accordance with the drawings of the WO-document of the order of the width of the screening slot or even less, i.e. usually between about 0.2 and 0.7 mm. In other words, the WO-document teaches that, in order to protect the shaped ends of the first wires, the second wires need not be significantly higher, but have an advantageously formed shaped end for directing the abrasive particles to a path above the first wires. Thus the gently sloping leading surface of the shaped ends of the second wires is crucial for the operation of the screen basket of the WO-document, i.e. aiding in throwing the abrasive particles to such a path that passes the downstream first wires without wearing such. Furthermore, the shaped end of the second wire has a bevelled trailing surface to control the turbulence in front of the screening opening or slot.
[0017] However, performed experiments have shown that simply using incrementally larger forms of wires and, for instance, deeper contours do not lead to the desired results, which are to improve capacity, to efficiently break up fiber flakes, to achieve efficient debris removal, and to ensure reliable operation in the presence of stringy contaminants. The problem with simply using incrementally deeper contours to address the problems of coarse screening and similar screening processes is that contour depth has been found with screen wires to merely alter the relative strength of the actions associated with these contours, so that one can seek to alternatively achieve either more capacity or a higher level of debris removal. In coarse screening and similar screening processes, one typically needs a more fundamental change in the screening action to provide the aforementioned macro-turbulence, shearing forces and particle impact.
[0018] In addition, various wire shapes that might be considered to replace bars are not of optimal shape for the intended actions. These bar-wire shapes typically present a symmetric surface feature, while the strong circumferential flow suggests the need for very different actions from the leading and trailing edges of the bars. One important problem that is not addressed by simply having different simple cross-sectional shapes for the wires that would replace the bars, and generate a symmetric surface feature, is the need to eliminate the abrupt downward step on the downstream side of these wires. The abrupt step on the downstream side leads to the creation of a bound vortex or recirculating zone and, in turn, the possibility of increased power consumption by the rotor and accelerated wear on the adjacent downstream wires. Another important problem that is typically not addressed is the need to preserve an abrupt upward step with a sharp edge to provide the impact and shear that is believed to be important for dispersing pulp flakes.
[0019] Another problem to be considered is the functional lifetime of any wire shape that is intended as a replacement for the bars. The need for an upward step with a sharp edge along with the presence of the aforementioned abrasive contaminants can lead to rapid wear of the bar and compromised a subsequent drop in performance. Hard chrome plating and alternate wear-resistant surface treatments have been traditionally applied to cylinders to minimize wear and extend lifetime. In addition, the bars have sometimes been made of materials that are harder and more wear resistant than the material used for the wires in respect of the especially high-wear environment of the bars.
SUMMARY OF THE INVENTION
[0020] It is therefore an object of the present invention to minimize the above-mentioned drawbacks and provide an improved screen cylinder.
[0021] It is also an object of the present invention to provide an easily manufactured and assembled screen cylinder with a minimal amount of manufacturing steps, and preferentially a single manufacturing method to attach wires with different purposes to the cylinder structure.
[0022] It is also an object of the present invention to minimize the inventory of wires and related components that must be maintained in stock to create different cylinders for different applications and thus to minimize inventory costs.
[0023] It is also an object of the present invention to address the disparate challenges of coarse pulp screening and similar screening applications, which are superimposed upon the already-significant challenges of the typical pulp screening process.
[0024] It is also an object of the present invention to maximize the open area of the screen cylinder by not blocking slots with weld and by including, wherever possible, functional openings between the wires that would replace the bars.
[0025] It is also an object of the present invention that the wires that would replace the bars would be amenable to wear-resistant technologies such as specialized coatings or the use of alternate wire materials.
[0026] In accordance with a preferred embodiment of the invention, the cylinder is made of a plurality of wires, which includes circumferential sections comprising at least one, and typically several, screen-wires and circumferential sections comprising at least one, and typically several, “bar-wires”. These so-called “bar-wires” are wires that are specifically intended to reproduce and ideally enhance the action of bars that have been used in traditional wedgewire cylinders where bars are welded to the surface of the screen-wires. Several bar-wires may be arranged in series with the intent of providing a more gradual downstream slope among the collection of bar-wires, or a higher upward step on the upstream side of the bar-wire section. Alternatively, a saw-tooth arrangement of bar-wires might be used to provide a more complex action on the pulp suspension to be screened. The use of several adjacent bar-wires may also follow from the need to create a stronger support structure given that these bar-wires may be subjected to the impact of large and hard contaminants. The use of several bar-wires rather than a single bar-wire also provides an additional degree-of-freedom for designers seeking to use an existing inventory of wires and wire shapes.
[0027] It is most desirable that the method of manufacturing a screen cylinder according to the invention uses essentially the same method to secure all of the screen-wires and bar-wires in the screen cylinder structure. However, additional reinforcement, by means of for instance welding, may be used for securing either the screen-wires, the bar-wires or both. The bar-wires may be drawn from the same inventory of wires as the screen-wires. It may also be that a wire with a greater wire height than the screen-wires is used for the bar-wires. Alternatively, or in addition, bar-wires may be secured into the cylinder structure in a way that elevates certain bar-wires relative to the adjacent screen-wires. Accordingly, there would be a commonality among the screen-wires and bar-wires, and especially to the the foot part of the wires, i.e. opposite the end of the wires that face the pulp to be screened, whereby this foot-part feature fits into the notches, recesses or openings in the receiving part of the screen cylinder structure related to the mechanism of securing the wires to the cylinder.
[0028] An important feature of the screen cylinder of the present invention is that the surfaces of the screen-wires and the bar-wires that face the pulp to be screened are predominantly dissymmetric, when traversed circumferentially. This dissymmetry can thus be created by altering the cross-sectional shapes of the screen-wires and bar-wires, or by tilting the screen-wires or bar-wires, or by a combination of these effects. The dissymmetry thus creates an orientation relative to the circumferential flow. The surface of at least one of the bar-wires in each bar-wire circumferential section has a reverse orientation to the surfaces of the majority of the screen-wires.
[0029] Most typically, the tops or peaks of at least some of the bar-wires will be elevated relative to the tops of the majority of the screen-wires.
[0030] Also, the tops of the bar-wires have a sharp leading edge possibly formed of wear resistant material or provided with a wear resistant coating.
[0031] The combination of these effects provide a relatively abrupt upward-step feature on the upstream side of the bar-wire section, and a generally-sloped downstream side of the bar-wire section to avoid the creation of a recirculating zone immediately downstream of the bar-wire section where accelerated wear and wasteful energy loss could occur.
[0032] The characterizing features of the screen cylinder of the present invention will become apparent from the appended patent claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] In the following, the screen cylinder will be explained in a more detailed manner with reference to the accompanying drawings of which:
[0034] FIG. 1 illustrates schematically a wire screen cylinder of prior art;
[0035] FIG. 2 illustrates schematically a section of a screen cylinder of prior art showing the dissymmetric screen wires and contours and the circumferential flow induced by the rotor;
[0036] FIG. 3 illustrates schematically a section of a screen cylinder of prior art showing a bar attached to the plurality of screen-wires;
[0037] FIG. 4 illustrates schematically a section of a screen cylinder in accordance with a first preferred embodiment of the present invention;
[0038] FIG. 5 illustrates schematically and in an enlarged scale a section of a screen cylinder in accordance with a first preferred embodiment of the present invention;
[0039] FIG. 6 illustrates schematically a section of a prior screen cylinder typically used for filtration and formed of symmetric screen-wires and a symmetric bar-wire therebetween;
[0040] FIG. 7 illustrates schematically a section of a screen cylinder in accordance with a second preferred embodiment of the present invention;
[0041] FIG. 8 illustrates various alternatives for the cross section of the screen-wires or bar-wires used in the present invention;
[0042] FIG. 9 illustrates schematically a section of a screen cylinder in accordance with a third preferred embodiment of the present invention;
[0043] FIG. 10 illustrates schematically a section of a screen cylinder in accordance with a fourth preferred embodiment of the present invention;
[0044] FIG. 11 illustrates schematically a section of a screen cylinder in accordance with a fifth preferred embodiment of the present invention; and
[0045] FIG. 12 illustrates schematically a section of a screen cylinder in accordance with a sixth preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0046] FIG. 1 shows, in a very schematic and simplified manner, a wedge wire screen cylinder, 10 , of prior art about a central axis, 12 . The end rings, or the top and bottom rings of the screen cylinder, are shown as 14 and 16 respectively. Three support elements, here rings, 18 , are shown, but there will more typically be many such support elements, 18 , spaced axially. The prior art screen cylinder, 10 , is made of substantially axially-oriented screen wires, 20 , which are the so-called “wedge wires”. Originally the generally triangular wire cross-section resembled a wedge, and most often still do. These screen wires are attached to support elements, 18 , and, on the other hand, at their axial ends either directly or via the outermost support rings to the end rings, 14 and 16 , situated at the opposite ends of the screen cylinder, 10 . Note that in this schematic drawing, the screen wires, 20 , have not been sketched in detail or to scale and only a few of the screen wires are shown, while a typical screen cylinder would have a plurality of screen wires extending essentially around the full circumference of the screen cylinder. Most often, the wedgewire screen cylinder, 10 , is of the so-called “outflow” type like in FIG. 1 . This means that the screening surface facing the pulp suspension to be screened is the inner surface of the screen cylinder, 10 , and the flow of accept pulp proceeds radially outward through the cylinder openings. To make this operation possible, the screen wires are normally attached to the radially inward rim of the support elements, i.e. the support rings, 18 , in this case. However, so-called “inflow” type wedgewire screen cylinders are also known whereby the screening surface facing the pulp suspension to be screened is the outward surface of the screen cylinder, 10 , and the accept flow proceeds radially inward through the cylinder openings. In either the outflow or the inflow configuration, elements of the support structure, in this case the support rings, 18 , are arranged along the length of the screen wires, 20 , in such a manner that the axial distance between the support rings, 18 , is about 20 to 100 mm depending on the size and the application of the screen cylinder, 10 .
[0047] FIG. 2 illustrates schematically a section of a screen cylinder, 10 , of prior art showing the dissymmetric screen wires, 20 , with dissymmetric contours and the circumferential flow, F, induced by the rotor and, in particular, by the rotor foil, 24 . The distance between the adjacent screen wires, 20 , defines screen cylinder openings, or screen slots, 22 . The slot width is normally set at some particular value in the range of 0.10 to 0.30 mm depending on the application of the screen cylinder, 10 . However, in coarse screening applications, slot widths as large as 0.80 mm may be used. Conversely, future design and manufacturing improvements may make slot widths less than 0.10 mm practical. A common way of fastening and properly positioning the screen wires, 20 , to the support elements or support rings, 18 , is to provide transverse notches or recesses or openings in the support elements, 18 , where the screen wires, 20 , are inserted. The screen wires, 20 , may include a feature on the aforementioned foot part of the wire whereby this foot-part feature fits into the notches, recesses or openings. A further manufacturing step, such as welding, gluing, soldering, riveting or clamping, is then typically taken after the wires, 20 , are installed in the support elements, 18 , to attach the wires even more securely, and especially to avoid any axial movement of the wire. The support elements, 18 , may have a simple rectangular cross-section or they may have a substantially more complex shape to support a clamping or riveting action, for example. The screen wires, 20 , may be installed into the support elements, 18 , while the support elements are in a circular form, i.e. as a support ring. Alternatively, the screen wires, 20 , may be installed in the support elements, 18 , while the support elements are flat and this assembled mat of screen wires, 20 , and support elements, 18 , is then formed into a cylinder.
[0048] FIG. 3 illustrates schematically a section of a screen cylinder, 10 , of prior art (U.S. Pat. No. 5,472,095) showing bars, 26 , attached to the plurality of screen wires, 20 , and in particular, to the surface of the screen cylinder facing the pulp suspension to be screened. The bars, 26 , extend the full length of the cylinder, 10 , although only a small section of the cylinder is shown in FIG. 3 . The bars are aligned either parallel to the cylinder axis, 12 , and thus parallel to the screen wires, 20 , or at a relatively small angle to the cylinder axis, as is shown in FIG. 3 . There will be many times fewer bars, 26 , than cylinder wires, 20 . The bars, 26 , are typically rectangular in cross-section. They can be applied to cylinders made of a plurality of wires either by attaching the bars to the surface of the wires facing the pulp to be screened, or by installing the bars on top of wires that have been modified to receive the bars, or in place of certain wires. The most typical approach, however, is to install the bars by welding them onto the surface of the wires facing the pulp to be screened using either a fillet or stitch weld along the sides of the bar that extend more or less axially.
[0049] FIG. 4 illustrates schematically a section 100 of a screen cylinder in accordance with a first preferred embodiment of the present invention. The screen cylinder section 100 is made of a plurality of wire sections, which include a plurality of screen-wire sections and a plurality of bar-wire sections (shown in FIGS. 4-12 ). Each screen-wire section is formed of at least one and preferably a plurality of screen-wires, 30 . The bar-wire sections comprise at least one (shown in FIGS. 4, 5, 7 ) and typically several (shown in FIGS. 9-12 ) bar-wires, 32 . The screen-wires and the bar-wires are fastened to a support structure, 34 . Here the support structure is formed of a plurality of support rings, 34 , provided with transverse notches, 36 , into which the foot, 38 , of each of the screen-wires, 30 , and each of the bar-wires, 32 , is fitted. The support structure may be, in addition to support rings, whatever type is applicable with wedge wires like, for instance, a skeleton (CA-A1-2 609 881) or a frame cylinder construction (U.S. Pat. No. 6,915,910) to which the wedge wires are either directly attached or via the support rings supported.
[0050] An essential feature of the screen cylinder of the present invention, as shown in FIGS. 4, 5 and 7 , is that the a majority of the screen-wires, 30 , 130 , and the bar-wires, 32 , 132 , have dissymmetric (in relation to a radial centreline plane) wire head surfaces, 40 , 140 and 42 , 142 as opposed to a prior art screen cylinder illustrated in FIG. 6 , where the head surfaces are symmetric in relation to a radial centreline plane. The wire head is defined here as the part of the wire above a line that connects the entry to the openings on either side of the wire. The openings, in turn, are defined as the location of the minimum gap between adjacent wires.
[0051] The wire head surface can be defined by the changing radius relative to the central axis, 12 (shown in FIG. 1 ), of the screen cylinder as one moves along the surface circumferentially from one opening to the next. Different wire shapes create different changes in radius, with the radius instantaneously increasing, decreasing, or remaining constant as a trace is made circumferentially. For a symmetric wire surface, the values of the radius relative to the location of the slots are the same regardless of whether one moves clockwise or counter clockwise along the surface. For a dissymmetric surface the values are not independent of the direction of motion, not at least for the entire width of the wire.
[0052] The dissymmetry of the screen-wires, 30 , and the bar-wires, 32 , is expressed in the radius of the various parts of the head surfaces, 40 and 42 . The radius is measured, naturally, from the axis of the screen cylinder. Here, in FIG. 4 , an inflow screen cylinder is shown, i.e. a screen cylinder where the pulp to be screened is fed to the outside of the screen cylinder and the accepts pass the cylinder slots to a direction towards the axis of the cylinder. Thus, the screen-wire 30 has two radii between which the screen-wire fits, i.e. a foot radius, Rfs, and a radius, Rps, of the peak circumference, i.e. the radius of the point or peak, 40 p , at the head surface, 40 , farthest away from the foot, 38 . In a corresponding manner, the bar-wire, 32 , has two radii between which the bar-wire fits, i.e. a foot radius, Rfb, (here it happens to be the same as the foot radius, Rfs, of the screen-wire, but the, Rfb, may be either smaller or greater than, Rfs) and a radius, Rpb, of the peak circumference, i.e. the radius of the point or peak, 42 p , at the head surface, 42 , farthest away from the foot, 38 .
[0053] As to the screen-wire, 30 , it has on its head surface, 40 , a circumferential mid-point, Mps, i.e. a point that is located by drawing a circumferential arc between the entrances to two adjacent openings (defining a circumferential width of a wire at the level of the entries) and drawing a perpendicular bisector thereto, whereby the circumferential mid-point is the crossing point of the bisector and the head surface, 40 . The mid-point, Mps, divides the head surface, 40 , into two parts: a first surface part, 40 l , and a second surface part, 40 t . The first surface part, 40 l , may also be called a leading surface part as it is the first surface part receiving the flow of pulp or fibre suspension. The second surface part, 40 t , may also be called a trailing surface part, as it is the surface part allowing the flow of pulp or fibre suspension to be discharged from above the screen-wire. In one particular embodiment, when considering an outflow screen, the average radius of the first surface part, 40 l , of the screen-wire, 30 , is greater than that of the second surface part, i.e. the trailing surface part, 40 t , of the head surface, 40 . In another particular embodiment, when considering an inflow screen, the average radius of the first surface part, 40 l , of the screen-wire, 30 , is less than that of the second surface part, i.e. the trailing surface part, 40 t , of the head surface, 40 .
[0054] As to the bar-wire, 32 , it has on its head surface 42 a circumferential mid-point Mpb, i.e. a point that is located by drawing a circumferential arc between the entrance to two adjacent openings (defining a circumferential width of a wire at the level of the entries) and drawing a perpendicular bisector thereto, whereby the circumferential mid-point Mpb is the crossing point of the bisector and the head surface 42 . The mid-point Mpb divides the head surface, 42 , into two parts: a first surface part, 42 l , and a second surface part, 42 t . The first surface part, 42 l , may also be called a leading surface part as it is the first surface part receiving the flow of pulp or fibre suspension. The second surface part, 42 t , may also be called a trailing surface part, as it is the surface part allowing the flow of pulp or fibre suspension to be discharged from above the bar-wire. In one particular embodiment, when considering an outflow screen, the average radius of the first surface part, 42 l , of the bar-wire, 32 , is less than that of the second surface part, i.e. the trailing surface part, 42 t , of the head surface, 42 . In another particular embodiment, when concerning an inflow screen, the average radius of the first surface part, 42 l , of the bar-wire, 32 , is greater than that of the second surface part, i.e. the trailing surface part, 42 t , of the head surface, 42 .
[0055] Another essential feature of the invention is that the peak 40 p of the screen-wire 30 is at the second or trailing surface part 40 t thereof, whereas the peak 42 p of the bar-wire 32 is at the leading or first surface part 42 l thereof. However, in case the peak/s of the screen-wire and/or bar-wire is at the mid-point Mps and/or Mpb, the peak/s is/are considered to be at the above mentioned surface parts. But in such a case, naturally, the average radius of the surface part in question defines the required dissymmetry of the screen-wire or bar-wire as discussed on the two closest paragraphs above.
[0056] A further essential feature of the present invention is discussed in FIG. 5 where a bar-wire 32 , two screen-wires 30 and the direction of rotation of the rotor by means of arrow F are shown. The feature essential in view of breaking the pulp flakes is the sharp leading edge 42 e of the bar-wire 32 . The leading edge 42 e is located between the head surface 42 and the side surface 42 s of the bar-wire. The side surface 42 s is the surface at the wire head being positioned at a side of the head surface, and, when in use, facing the flow of pulp suspension. The leading edge 42 e could be perfectly sharp but it has, in practice always for manufacturing reasons, a small radius r, (or the radial extension of a bevel) normally of the order of from one tenth to a few tenths of a millimeter. However, to define the required sharpness of the leading edge 42 e the dimension of the radius is compared to the radial height h 1 , i.e. a radial distance between the peaks 40 p of the screen-wire 30 and the peak 42 p of the bar wire 32 . The sharpness of the leading edge 42 e is defined as the radius r being at most one half of the radial height h 1 , preferably at most one quarter of the radial height. Additionally, the proper operation of the bar-wire 32 requires that the trailing part 42 t of the head surface 42 of the bar-wire 32 is slanting from the leading part 42 l . Thus, preferably but not necessarily, to guarantee efficient breaking up of fiber flakes at the leading edge 42 e the leading edge angle γ, i.e. the angle between the leading part 42 l of the head surface 42 and the side surface 42 s of the bar wire 32 is between 45 and 90 degrees.
[0057] To clarify that the same approach applies to wires having themselves a symmetric cross-section FIGS. 6 and 7 have been sketched. FIG. 6 illustrates schematically a section of a prior art screen cylinder of the type used in filtration having symmetric screen-wires and a symmetric bar-wire therebetween. Since both the screen-wires and the bar-wire have been fastened to the support structure such that their centreline plane, i.e. plane of symmetry (shown by vertical lines), is radial, the screen surface facing the pulp that is to be screened is flat, i.e. non-contoured, except for the bar-wire elevated from the level of the screen-wires. However, now that the head surface of the bar-wire is not slanting the head surface of the bar-wire guides most of the flow past the first screening slot immediately following the bar-wire, and, additionally, creates a strong field of turbulence that subjects a strong wearing action to the first screen-wire downstream of the bar-wire.
[0058] In FIG. 7 a section of a screen cylinder in accordance with a second preferred embodiment of the present invention is schematically illustrated. Here the screen-wires, 130 , and the bar-wire, 132 , have, again, a symmetric cross section, but, as the axis or plane of symmetry (shown by inclined lines) is not in radial direction, i.e. the wires, 130 and 132 , are installed to the support structure, 34 , in a tilted position, the screen surface has a contour. Now that the screen-wires, 130 , are tilted to the right and the bar-wire, 132 , is tilted to the left, i.e. to the opposite or reverse direction in relation to the screen-wires, an abrupt upward step is created in the flow direction F. In this embodiment, too, the heads of the screen-wires, 130 , have a circumferential mid-point, Mps, a first or leading surface part, 140 l , and a second or trailing surface part, 140 t . In a corresponding manner, the heads of the bar-wires, 132 , have a circumferential mid-point, Mpb, a first or leading surface part, 142 l , and a second or trailing surface part, 142 t . Thus, in accordance with the present invention, the peak of the screen-wires, 130 , is at the trailing or second surface part, 140 t , whereas the peak of the bar-wire, 132 , is located at the first or leading surface part, 142 l.
[0059] In FIG. 8 a few cross-sections of screen-wires or bar-wires are shown with their centreline planes. The three first wires from the left are not symmetrical in relation to the centreline plane of the wire, whereas the rightmost wire is symmetrical (requiring, when taken into use, tilting). There are a few features in common to all shown variations of the bar-wire. Firstly, the second or trailing surface part of the head surface of the bar-wire, i.e. the surface part to the left from the vertical line representing the centreline plane of the wire, is sloping from the first or leading surface part of the head surface towards the support structure represented by the horizontal line. The angle of slope, i.e. the angle in a radial plane between the second or trailing surface and the circumferential direction, is, preferably but not necessarily, of the order of 15 to 45 degrees, more preferably between 15 and 35 degrees. Secondly, the peak of the head surface of the bar-wire is located at the first or leading surface part of the bar-wire. Thirdly, the leading edge between the first or leading surface part of the head surface of the bar-wire and the side surface is sharp, though for manufacturing reasons rounded (or bevelled). And fourthly, the peak may, however, be located at a distance from the side surface, as shown by the leftmost bar-wire, or the first or leading surface part of the head surface may be flat, i.e. positioned in circumferential direction, that is, in a direction perpendicular to the centreline plane of the bar-wire. The latter option is, in a way, a preferred one, as it offers more bar-wire material to wear out, i.e. increases the lifetime of the bar-wire and the entire screen cylinder. Thus it is clear that all both disclosed and non-disclosed non-symmetrical wire cross sections may be used in the invention in both tilted and non-tilted (centreline plane in radial direction) configuration, and that all such wires that have a symmetrical cross-section in relation to its centreline plane may be arranged in tilted position to fulfil the requirements of the present invention. Also, the cross-sections of the screen-wires and the bar-wires of a screen cylinder may be similar, but it is as well possible to use different cross sections.
[0060] As has been discussed above in connection with FIGS. 4, 5 and 7 , the dissymmetry of the contour of the bar-wire, 32 / 132 , is opposite, or in reverse orientation, to that of more common screen-wire, 30 / 130 , i.e. the leading or first surface part, 42 l / 142 l of the head surface, 42 / 142 , is at a shorter radial average distance from the axis of the screen cylinder in an outflow screen cylinder than the trailing or second surface part, 42 t / 142 t , of the head surface, 42 / 142 , for this typical example. In an inflow cylinder the leading or first surface part, 42 l / 142 l , of the head surface, 42 / 142 , is at a greater radial average distance from the axis of the screen cylinder than the trailing or second surface part, 42 t / 142 t , of the head surface, 42 / 142 .
[0061] Thus, the peak, 42 p , of the head surface, 42 / 142 , i.e. the highest part or point thereof, is located on the leading surface part, 42 l / 142 l , of the head surface, 42 / 142 . In other words, and in general terms, the bar-wires, 32 / 132 , have a reverse orientation to the more common screen-wires, 30 / 130 . The “reverse orientation” above means that the screen wires have at their head, i.e. the surface facing away from the support structure, an inclined slope generally facing the impinging pulp suspension flow along the screen surface for the particular wire shapes shown in FIGS. 4, 5 and 7 , whereas the bar-wires have at their head surface facing away from the support structure an average inclined slope facing away from the impinging pulp suspension flow along the screen surface. In other words, the average angle α of slope of the screen wires open in the direction of the pulp flow along the screen surface, whereas the average angle β of slope of the bar-wires opens against the direction of the pulp flow, i.e. the average angles α and β of slope of the screen-wires and the bar-wires open in opposite directions for the particular wire shapes shown in FIGS. 4, 5 and 7 .
[0062] The leading part 42 l of the head surface 42 of the bar-wire 32 joins, at a preferred but not necessary angle γ of 45 to 90 degrees, preferably of 60-85 degrees, to a side surface 42 s of the head 42 (when not taking into account the rounding or bevel), for the particular wire shape shown in FIG. 4 . The side surface 42 s is, preferably, at an angle of 70-110 degrees to the circumferential direction represented by the flow, F, or at an angle of ±20 degrees to the radial plane of the bar-wire, 32 , established by the cylinder axis.
[0063] By means of this configuration of the head, 42 , of the bar-wire, 32 , the flow of the pulp suspension in the direction, F, meets the side surface, 42 s , which creates a substantially more aggressive mechanical action than any screen-wire, 30 . The bar-wire, 32 , with its side surface, 42 s , leading edge 42 e , and the leading surface part, 421 , generates macro-turbulence, shearing forces and particle impact, and thus provides a distinct and complementary function to the function of the more common screen-wire contours.
[0064] FIGS. 9-12 illustrate schematically screen cylinder designs of other preferred embodiments of the present invention, where a bar-wire section, comprising several bar-wires, 32 , arranged in series, is located among the more common screen-wires, 30 , of screen-wire sections. The bar-wire sections, comprising at least one but often several bar-wires, 32 , are preferably, but not necessarily, evenly spaced within the screen cylinder circumference. The percentage of the circumference occupied by bar-wires is in the range of 1 to 20%, and typically between 5 and 15%. The intent of arranging several bar-wires in series may be to provide: a) a saw-tooth arrangement for a more complex action by, for instance, three bar-wires, 32 , arranged at the same height with one another ( FIG. 9 ); b) a more gradual downstream slope among the series of bar-wires, 32 , ( FIG. 10 ); c) a higher upward step on the upstream side of the collection of bar-wires, 32 ( FIG. 11 ), where the third (the right-hand side) bar-wire could as well be arranged somewhat higher in the series, whereby an even higher step would be provided between the screen-wires and the leading (right-hand side) bar-wire, or d) an arrangement (FIG. 12 ), where the central bar-wire, in the bar-wire section, is not reversed in relation to the screen-wires 30 .
[0065] As to dimensioning the bar-wires, and especially the radial elevation h 1 ( FIG. 5 ) of the bar-wire peak relative to the peak of the screen-wires, the elevation h 1 is between 1 and 8 mm, preferably between 1 and 6 mm, and more preferably between 1 and 4 mm. When referring to FIG. 4 and the discussion in connection therewith, the above elevation h 1 may be calculated as the difference between radii Rpb and Rps, i.e. Rpb-Rps (for an inflow screen) or Rps-Rpb (for an outflow screen).
[0066] The use of several adjacent bar-wires may also follow from the need to create a stronger support structure given that the bar-wires may be subjected to the impact of large and hard contaminants. The use of several bar-wires rather than a single bar-wire provides an additional degree-of-freedom for designers seeking to use an existing inventory of wires and wire shapes. Regardless of whether one or several bar-wires are used in a bar-wire circumferential section, a majority of the screen-wire and bar-wire heads are both generally dissymmetric and, in particular, at least one of the bar-wire heads in the bar-wire section has a reverse orientation to the screen-wire heads. Alternatively, the screen-wires and the bar-wires may be tilted but with the same final result where at least one of the bar-wire surfaces has a reverse orientation to the screen-wire surfaces.
[0067] In addition to solving all of the aforementioned problems with the current design of a cylinder with bars, the proposed invention also minimizes the required inventories of wire types, since one may be able to simply reverse the direction of a screen-wire to create a bar-wire. It will typically be advantageous to have the bar-wires appear as larger than the screen-wires, but this can be achieved in the following ways or some combination thereof: First, in cases where different wires are maintained in inventory to provide different screen-wire contour depths for different cylinders, a larger wire, with increased contour depth, may be selected for use as the bar-wire. Second, in cases where different contour depths are achieved by wire tilting, the bar-wire would be both reversed and installed with a reduced amount of tilt. Finally, the means of attaching the wire to the support structure could be modified so as to make the bar-wire appear higher. For example, where the screen wires, including the bar-wires, are installed in notches in a support ring, the notches for the bar-wires would be formed at a location closer to the notched edge of the support ring than for the screen-wires.
[0068] Hard chrome plating and alternate wear-resistant surface treatments have been traditionally applied to cylinders to minimize wear and extend lifetime. In addition, the bars have sometimes been made of materials which are harder and more wear resistant, such as Stellite™, than the 316L stainless steel material commonly used for the wires in respect of the especially high-wear environment of the bars.
[0069] As can be seen from the above description, a new screen cylinder has been developed, eliminating at least some disadvantages of the prior art screen cylinders. While the invention has been herein described by way of examples in connection with what are at present considered to be the preferred embodiments, it is to be understood that the invention is not limited to the disclosed embodiments, but is intended to cover various combinations and/or modifications of its features and other applications within the scope of the invention as defined in the appended claims. | The present invention relates to a screen cylinder that is particularly suitable for screening, filtering, fractionating, or sorting cellulose pulp or fiber suspensions of the pulp and paper industry or other similar suspensions. The present invention relates more particularly to screening devices of the type comprising a plurality of screen wires positioned axially and at a small spacing parallel to each other, and a plurality of bar-wires arranged in a reverse orientation to the screen wires. | 3 |
FIELD AND BACKGROUND OF THE INVENTION
The present invention relates generally to the field of oil lamps and in particular to a new and useful oil lamp having a porous diffuser for imparting a fragrance into the air from the oil lamp.
Many different types of oil-burning lamps are known. Some lamps incorporate a fragrance into the fuel oil, while others provide for a separate fragrant emitting portion, or emanator.
U.S. Pat. No. 5,840,246, for example, is for an oil lamp having a porous emanator supported on the neck of a container holding a flammable liquid, such as oil. A wick holder passes through the center of the emanator and supports a wick therein. The wick is in contact with the oil and draws oil up above the emanator for combustion. The emanator is impregnated with a fragrance, which is released into the air, especially when the wick is lit.
The wick holder in U.S. Pat. No. 5,840,246 is not used to draw oil and fragrance from the flammable liquid up to the emanator; the holder is an optional component for supporting the wick.
The oil lamp claimed by U.S. Pat. No. 4,892,711 has a canister holding the fuel oil, a burner assembly supported on the canister, and a fragrance element spaced from the burner assembly. In a preferred embodiment, the fragrance dispensing element is “ring-like” and it is “mounted on said canister and surrounding said burner assembly”. Only the fragrance element contains a fragrance in the oil lamp of U.S. Pat. No. 4,892,711, and the element does not contact the wick.
A leak-proof lamp is shown in U.S. Pat. No. 5,000,678 which has an inner flange having substantially the same frusto-conical shape as the outer covering that is fit over the opening of the fuel oil container. The inner flange extends into the opening of the container and seals against the inner wall of the container opening. The outer covering has a bottom edge which is secured around a horizontal lip on the container opening. The inner flange is secured to the outer covering by spot welding, or they can be formed integral.
Other lamps include U.S. Pat. No. 5,891,400 for a heat-activated volatile substance dispenser. The dispenser has two containers, an inner container holding a heat source, such as a candle and an outer container surrounding the inner container forming an annulus holding a gel incorporating the volatile substance. The inner container has an open top and holds a burnable material, such as a candle. The combustion of the candle in the inner container causes the gel in the annulus to release fragrance when heated by the walls of the inner container.
Other patents disclose oil lamps having drip collars around the neck, such as U.S. Pat. No. 40,094. The body of the lamp vessel is generally cylindrical with rounded sides and a neck opening at the top. An annular depression is formed around the neck opening to catch dripping oil and prevent it from falling outside the lamp body. There is no fragrance emitting portion on this lamp.
A fuel supply vessel for an oil burning incubator lamp has a centrally located raised neck for supporting the lamp and holding the wick in position to deliver fuel to the lamp from the vessel is taught by U.S. Pat. No. 871,016. The fuel supply vessel has a raised outer edge as well, to form a reservoir pan around the raised neck on top of the vessel. The reservoir is filled with water to dissipate heat from the burning lamp wick.
U.S. Pat. No. 3,790,332 shows a oil lamp candle having a wick holder which floats on the fuel oil in a container, such as a glass. The wick holder is a cylindrical boat with a raised central portion supporting the wick above the outer edge of the boat, and forming an annular space inside the boat. The annular space is not disclosed as being filled by any substance and is left open.
U.S. Pat. No. 3,958,917 teaches a scented ring for use with candles made of a wax-like material impregnated with a fragrant composition. The ring is positioned around the wick of a wax candle and is consumed by use, while releasing fragrance.
An oil lamp for diffusing fragrance contained in the oil is disclosed in U.S. Pat. No. 5,669,767. The lamp has a metal tube wick holder supported by a perforated cone in the neck of the lamp vessel. The burning wick heats the tube, which in turn heats the oil, causing it to release fragrance into the air through the perforations in the cone.
A primary difficulty experienced by many prior art oil lamps which emit a fragrance is to provide a sufficient amount of fragrance from the lamp. This problem is apparent especially when the fragrance is combined in the oil being burned. The intent of these lamps is that the oil and fragrance will both drawn up the wick and fragrance will be released. However, typically, both the fuel oil and fragrance oil are burned, generating either only a “fuel” smell, or a burnt smell from combustion of the fragrance.
Lamps which have separate fragrance emanators suffer from the difficulty of ensuring the fragrance is released at a sufficiently high rate so that the fragrance is smelled over the burning of the fuel oil. It is common to use the heat of the flame burning fuel oil to warm a separate emanator, usually by placing them in proximity to each other, to enhance the release rate of fragrance from the emanator.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an oil lamp which emits a strong fragrance, especially when lighted.
It is a further objection of the invention to provide an oil lamp which includes protection from spills and leaks.
Yet another object of the invention is to provide an oil lamp having a diffuser for fragrance oil combined with the fuel oil.
Accordingly, an oil lamp is provided having a container with a top opening, a ceramic diffuser mounted in the top opening, a sealing gasket between the top opening and ceramic diffuser, a wick holder covering the ceramic diffuser and secured to the top opening, and a wick passing through the ceramic diffuser and one end extending above the wick holder. The other end of the wick extends into a mixture of fuel oil and fragrance in the container. Fragrance and fuel oil are both drawn up the wick. Some oil is absorbed by the ceramic diffuser and diffused into the air surrounding the oil lamp. Other fuel oil and fragrance are burned at the top end of the wick above the wick holder.
The oil lamp contains a mixture of fuel oil and about 3-5% wt. of perfume. The intensity of the perfume is sufficient to mask the smell of burning fuel oil and perfume and provides a scent which is at least as intense as perfumed wax candles.
The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects attained by its uses, reference is made to the accompanying drawings and descriptive matter in which a preferred embodiment of the invention is illustrated.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a top, front, side perspective view of an oil lamp according to the invention;
FIG. 2 is a is a sectional side elevational view of the oil lamp of FIG. 1;
FIG. 3 is an exploded top, front, side perspective view of the components of the oil lamp of FIG. 1;
FIG. 4 is an enlarged sectional side elevation of the top portion of the oil lamp of FIG. 2;
FIG. 5 is a top, front, side perspective view of a diffuser of the invention used in the oil lamp of FIG. 1;
FIG. 6 is a sectional side elevational view of an alternate embodiment of the diffuser according to the invention; and
FIG. 7 is a further embodiment of the oil lamp having a lampshade.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, in which like reference numerals are used to refer to the same or similar elements, FIG. 1 shows an oil lamp 5 having a container 10 for holding fuel oil and a perfume, an outer cover 40 and a fiber wick 50 . The outer cover 40 protects the fragrance diffusing portion of the lamp 5 and helps to seal the top opening of the container 10 . The container 10 can be any known shape which provides a decorative look and will stand substantially upright so that a flame on wick 50 can burn without disruption. A container shape having a reduced cross-sectional area at the bottom is preferred so that less fuel is wasted due to lack of access to the wick 50 .
FIGS. 2 and 3 show the components of the lamp underneath the outer cover 40 .
FIG. 2 displays the internal portions of the oil lamp 5 , including ceramic diffuser 30 , the top opening 12 of container 10 having inner wall 18 and fuel oil and fragrance mixture 100 in the container 10 . Fuel oil and fragrance mixture 100 is drawn up fiber wick 50 into contact with ceramic diffuser 30 for diffusing the fragrance into the air. The wick 50 has a top end 60 which extends through wick holder 55 on the outer cover 40 . In a preferred embodiment, the wick 50 is doubled over forming a loop at top end 60 . Such a construction assists manufacture of the oil lamp 5 . The top end 60 receives fuel oil and fragrance mixture 100 and can be lighted to burn fuel oil from the mixture 100 .
As best seen in the exploded view of FIG. 3, the outer cover 40 has several vents 45 through the sides. The vents 45 are provided for permitting fragrance drawn through the wick 50 —shown as a single strand embodiment in FIG. 3 —and absorbed by the ceramic diffuser 30 to be emanated by diffusion into the air surrounding the lamp 5 . Different numbers and sizes of vents 45 may be used, provided the structural integrity of the outer covering 40 is maintained.
A sealing gasket 20 is interposed between the lower surface of the ceramic diffuser 30 and the upper surface 16 of top opening lip 15 on container 10 . The outer cover 40 fits over the ceramic diffuser 30 and secures it in place on the sealing gasket 20 to provide a seal between the diffuser 30 and container top opening 12 . It is intended that the fuel oil and fragrance mixture 100 can only exit the container 10 via the wick 50 or by diffusion through ceramic diffuser 30 , as described in greater detail below.
FIG. 4 shows the upper portion of the lamp 5 in greater detail, so that the seal provided around the upper surface 16 of the top opening 12 is more clearly seen. The sealing gasket 20 fits between the upper surface 16 and the lower edge of the diffuser 30 . The lower edge is formed as a flange surface 33 with an adjacent vertical wall 32 . The flange surface 33 contacts the sealing gasket and provides the sealing surface with the upper surface 16 . The vertical wall 32 is used to help position the ceramic diffuser 30 over the top opening 12 . The vertical wall 32 may contact top opening wall 18 to further improve the seal as well.
The outer cover 40 fits over the ceramic diffuser 30 and has an inwardly turned bottom edge 42 which fits over top opening lip 15 . The bottom edge 42 is formed by crimping. Pressure from the top of the outer cover 40 adjacent the wick holder 55 holds the ceramic diffuser 30 against sealing gasket 20 and upper surface 16 , forming a substantially leak-proof seal. The seal is intended to prevent large volume spills through the vent holes 45 when the oil lamp 5 is tipped over by accident.
Spills of the mixture 100 are substantially prevented since the wick 50 preferably occupies a majority of the space in wick passage 35 of the ceramic diffuser 30 . Small amounts of mixture 100 may escape through gaps between the wick 50 and wick holder 55 opening or air vent 56 . The wick 50 occupies substantially the entire wick holder 55 opening in order to be held in position properly. The greater the contact made between the wick 50 and walls of wick passage 35 , the greater the amount of fragrance that will be emanated from the ceramic diffuser 30 as well.
FIG. 5 displays the ceramic diffuser 30 so that the exterior shape can be seen. The shape is preferably similar to the contours of the outer cover 40 so that the maximum surface area and volume for the diffuser 30 are obtained. It should be noted that while the wick passage 35 is shown through the center of the diffuser 30 , it may be placed off-center, provided the wick 50 can still be positioned through a wick holder 55 in the outer cover 40 . The wick holder 55 may be placed off-center in such case as well. Further, the wick holder 55 and diffuser 30 can be non-circular.
An alternate shape of the ceramic diffuser 30 is shown in FIG. 6 which has an extended portion, or tail 130 . The tail 130 is sufficiently long to extend into the fuel oil and fragrance mixture 100 , so that oil and fragrance are directly absorbed by the diffuser 30 . The wick passage through the diffuser 30 is extended through the tail 130 to provide access for the wick 55 to the mixture 100 .
In a further embodiment, a non-combustible lampshade 200 may be positioned over the oil lamp 5 and supported on the top edge 48 of the outer cover 40 , as shown in FIG. 7 .
Preferred materials for the components of the oil lamp 5 include plastics, such as thermoplastics, metal, glass and ceramic for the container 10 , although durable plastics are most preferred. PVC is preferred for a clear plastic container. The ceramic diffuser 30 is preferably made of an alumina bisque, but other porous ceramics and materials such as POREX foam and cellulose are acceptable for use as well.
Mercury porosimetry and nitrogen adsorption measurements of alumina bisque pore size and pore volume indicate acceptable diffuser ranges have pore sizes of about 0.5 to 2.0 microns and pore volumes of about 0.15 ml/g to 0.30 ml/g. The optimum size and volume of the reticulated pores depends upon the hydrophobic character of the diffuser and the fragrance/oil mixture. For example, a hydrophobic diffuser and a hydrophobic fragrance/oil mixture can accommodate larger pore size and volume for mass transport through the diffuser. A more hydrophilic diffuser, such as cellulose, requires a smaller pore size and volume to maximize capillary action for mass transport. One skilled in the art will understand that the addition of combustible, oil soluble surface-active materials to the lamp oil can be used to optimize various diffuser and fragrance/oil combinations.
The diffuser can be shaped differently to further increase the diffusion surface area, such as by including fins or other surface texture, provided it does not interfere with the outer cover 40 .
The outer cover 40 is preferably made entirely of metal or other non-combustible, heat-conducting materials, since the flame of the lamp is in close proximity to the top of the cover 40 . The heat transfer properties of the material used should be selected to heat the ceramic diffuser to enhance evaporation of fragrance or fuel plus fragrant oil from the saturated diffuser body, but also to limit the heat transfer to the diffuser to about 50° F. less than the flashpoint of the fuel and fragrance mixture 100 , or less than about 175° F.
The enhanced evaporation of the fragrance causes more liquid mixture 100 from the oil lamp container 10 to be absorbed into the diffuser, to replace the liquid that had evaporated due to the extra heating of the diffuser.
Bendable metals such as tin which are easily crimped over to form the bent lower edge 42 are preferred for use for the outer cover 40 . The outer cover 40 may also have a plastic lining of a non-combusting material to improve the seal between the outer cover 40 and diffuser 40 .
The fuel oil can be any known type used in oil lamps, but paraffin lamp oil is preferred. The fragrance is preferably present in the mixture in an amount between 3-7% wt. of the total mixture, with about 5% being most preferred. Perfumes and other fragrance oils can be used for the fragrance.
In use, the lamp 5 is lighted, and heat from the flame at the top end 60 of fiber wick 50 heats the metal outer cover 40 . Heat is transferred to the ceramic diffuser 30 , which has received oil and fragrance mixture 100 from the wick 50 passing through wick passage 35 . The heat causes more of the fragrance absorbed by the ceramic diffuser 30 to evaporate and diffuse into the air through the vents 45 in the outer cover 40 .
In the event that the lamp 5 is tipped over, the sealing gasket 20 and wick 50 prevent large amounts of oil from leaking out of the lamp 5 . At the same time, the ceramic diffuser 30 directly absorbs more of the mixture 100 due to contact from tipping. The ceramic diffuser 30 becomes saturated, but will not drip and provides a seal for the container 10 . This permits the oil lamp 5 to be safely shipped in an assembled state.
The lamp 5 of the invention improves over prior disposable lamps which have separate fragranced emanators since the oil and fragrance are used up at the same rate. Further, when preferred materials are used, testing has shown that the lamp 5 of the invention can provide a fragrance to an area having substantially the same effect as commercially available 3″×3″ pillar-type candles.
The oil lamp 5 provides a self-contained, spill proof lamp which can be manufactured in many different fragrances simply by changing the fragrance added to the oil mixture, rather than having to substitute different emanators or scent packets or supplies.
While a specific embodiment of the invention has been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles. | An oil lamp emitting a fragrance has a container including a fuel oil and a fragrance and a wick for drawing fuel oil out of the container for burning. A separate ceramic diffuser is positioned adjacent the top of the lamp, near the combustion end of the wick. The ceramic diffuser receives a combination of fuel oil and fragrance and diffuses the fragrance into the air. The diffusion is increased when the lamp is lighted. The lamp provides a scent to the surrounding air which is similar in strength to fragranced wax candles. | 5 |
BACKGROUND
[0001] The present invention relates to a pulsation damper for an oscillating positive-displacement pump, having an inlet connection element, an outlet connection element, and a line that connects these elements and is connected to a damping chamber inside the pulsation damper, where provided in the damper housing, in which the inlet connection element is connected to the damping chamber by a connecting channel, is a damping element made of an elastic material.
[0002] Pulsation dampers have the object of reducing pressure fluctuations produced by an oscillating positive-displacement pump. Oscillating pumps have the characteristic that they convey liquid or gas, as a pumping medium, only during 180° of a rotation, thus causing pulsations. In slow-running pumps, this results in a correspondingly irregular delivery stream, while in fast-running pumps pressure fluctuations occur. This is undesirable for many applications.
[0003] Pulsation dampers are known in various specific forms.
[0004] From DE 1 963 709, a damper is known with which pressure impacts in line networks can be prevented or reduced. For this purpose, this device has a damping chamber in which an elastically flexible component is placed. In this way, it is possible to dampen pressure impacts that occur in line networks when outlet fittings connected thereto are closed. In connection with oscillating positive-displacement pumps, such dampers do not yield sufficient smoothing of the delivery stream flow or of the occurring pressure pulsation.
[0005] From U.S. Pat. No. 3,035,613, a pulsation damper for use in tubes or lines is known, that is in particular directed to damping pressure surges in pipe lines. A connecting channel is connected to a damping chamber, that includes a ring-shaped damping element made of an elastic material that is filled, for example, with air.
[0006] This damper does not provide, in connection with an oscillating positive-displacement pump, a sufficient smoothing of the delivery stream flow or of the occurring pressure pulsation
SUMMARY
[0007] The object of the present invention is to create a pulsation damper that enables a high degree of damping of the occurring pressure fluctuations, in particular in connection with an oscillating positive-displacement pump. A simple adaptation, as needed, to pumps having different pump capacities, and/or to different system pressures, is also to be provided. Finally, the pulsation damper should have a simple, compact design.
[0008] In order to achieve this object, it is proposed that the pulsation damper for a positive-displacement pump have at least two damping chambers connected in series be provided inside a damper housing, and that for this purpose a line segment connected to the inlet connection element have a connecting channel to a first damping chamber, as well as being connected, via an inlet throttle element, to a second damping chamber that is connected with the outlet connection element via an outlet throttle element, that the damping chamber is separated by a separating membrane into a receiving space for the damping elements made of elastic material and an area that conducts the pumping medium.
[0009] The connection in series of a plurality of damper stages achieves a high degree of damping that increases exponentially with the number of damper stages. The throttle elements, in connection with the damping chambers, form damping elements that are able to intermediately store and re-emit pumping medium when pressure fluctuations occur. Through the throttle elements, during a pressure impact a dynamic pressure is built up, through which a pressure charging of the damping elements, and a throttled emission of pumping medium, is possible during the pressure fall-off phase that follows the pressure phase.
[0010] Through the passage cross-section of the throttle elements, an adaptation to the desired degree of damping or to the permissible remaining pulsation after the damper is possible. Likewise, the dynamic pressure, and therewith the occurrent pressure loss of the damper, can be adjusted via the throttle elements. In this way, the damper can be adapted to a large number of types of pump having different pumping capacities and/or system pressures, without further modifications.
[0011] Through the partitioning of the damping chamber with the separating membrane into the receiving space for the damping element and the area for conducting the pumping medium, the damping elements can not come into contact with the pumping medium, so that the desired damping element with the desired damping characteristics can be selected, and a resistance to the pumping medium is not a consideration. In this way, aggressive pumping medium can be handled without problems through appropriate material selection of the separating membrane.
[0012] In order to enable such an adaptation to be carried out easily, and even retrofitted if necessary, the inlet and outlet throttle elements are formed as exchangeable inserts. They can be screwed in as bushings or pressed in.
[0013] Nozzles, diaphragms, stepped nozzles, capillary vessels, or adjustable nozzles, for example needle valves, can be used.
[0014] Preferably, the damping material used inside the receiving space of the damping chamber for the damping elements has an approximately linear elastic characteristic. The elastic damping elements thus have characteristics similar to that of a spring, which is desirable. These elastic characteristics achieve a particularly good damping effect. For example, a damping material can be used that can be compressed even in a closed space, which is not possible for example if rubber is used as a displacement material.
[0015] According to a construction of the present invention, the non-loaded separating membrane that limits the liquid-conducting area of the damping chamber(s) is situated at a distance from the damping material.
[0016] If the damper is used for a low system pressure, only the soft separating membrane acts as an elastic element. This makes it possible to effectively dampen even small pressure spikes. Given a higher system pressure, the separating membrane is supported partly or completely on the damping material. It is thus protected against excessive expansion and damage, and in this operating state a damping also takes place by means of the damping material.
[0017] Another construction provides that the damping elements have a filling volume that is greater than the volume of the receiving space for the damping elements, limited by the separating membrane in the non-loaded state, and that the separating membrane is pre-stressed by the damping elements. If the damper is used for a high system pressure, the separating membrane is pre-stressed by the damping material in the direction opposite to that of the excursion under pressure. In this way, a relatively soft damping material can be used even for a high system pressure, and the damping is optimized over a large pressure range.
[0018] Advantageously, the damping elements of the second damping chamber are more flexible or have a softer elasticity than those of the first damping chamber. In the first stage, which has a harder construction, the large pressure spikes are thereby compensated, and in the second, softer damping stage the remaining pressure fluctuations are compensated.
[0019] According to a specific embodiment of the present invention, the pulsation damper has a two-part housing having a housing head and a housing lower part, the separating membrane being situated in the separating plane as a sealing element.
[0020] In this way, the separating membrane forms not only the division of the damping chambers into the receiving space and the area that conducts the pumping medium, but also seals the individual chambers and channels against one another and outwardly.
[0021] It is advantageous if the inlet and outlet connection elements, the line channels, the inlet and outlet throttle elements, and the areas of the damping chambers that conduct pumping medium are all situated in the housing head, and the receiving spaces for the damping elements are provided in the housing lower part. In this way, all functional areas of the pulsation damper are easily accessible after the separation of the housing head and the housing lower part.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] Additional embodiments of the invention are indicated in the subclaims. In the following, the present invention is explained in its primary details, on the basis of the accompanying drawings.
[0023] [0023]FIG. 1 shows a cross-sectional representation of a pulsation damper,
[0024] [0024]FIG. 2 shows a plan view of the pulsation damper indicated in FIG. 1, and
[0025] [0025]FIG. 3 shows a cross-sectional view of a pulsation damper in a specific embodiment that is modified in relation to that shown in FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0026] A pulsation damper 1 shown in FIG. 1 is used for the damping of pressure fluctuations that are produced by an oscillating positive-delivery pump. The pressure connection elements of such a positive-delivery pump can be connected to inlet connection element 2 of the pulsation damper 1 for the damping of the pressure fluctuations, in order to reduce these pressure fluctuations. The pumping medium, supplied at the inlet connection element 2 , exits at an outlet connection element 3 of the pulsation damper 1 , having been smoothed with respect to the pressure fluctuations. The pulsation damper 1 has a housing 4 in which two damping chambers 5 , 6 are provided. A line segment 7 having a branching point 8 into the first damping chamber 5 is connected to the inlet connection element 2 . In addition, the line segment 7 is connected to the second damping chamber 6 via an inlet throttle element 9 . From this damping chamber stream then flows through an outlet throttle element 10 to the outlet connection element 3 .
[0027] Inside the damping chambers 5 and 6 , there are placed damping elements 11 made of elastic material. The damping elements 11 are situated in a receiving space 13 or 14 that is divided by a separating membrane 12 inside the respective damping chamber 5 or 6 . The remaining part of the damping chambers 5 , 6 above the separating membrane 12 is the pumping-medium-conducting area 15 , 16 .
[0028] The inside volume of the pumping-medium-conducting area at least of thr first damping chamber 5 , but if necessary (as shown in FIG. 1) also of the two areas 15 , 16 , corresponds at least to the delivery capacity of a pump stroke, but the pumping medium (gaseous or liquid) also plays a role here. A small volume of the pumping-medium-conducting areas 15 , 16 is provided for liquids, while a larger volume, as shown in FIG. 3, is provided for gaseous pumping media.
[0029] The volume of the receiving spaces 13 , 14 , with the damping material situated therein, corresponds to a multiple of the delivery capacity of a pump stroke, preferably to approximately ten times this capacity.
[0030] As can be seen in FIGS. 1 and 3, the damping elements 11 fill the receiving spaces 13 or 14 completely. Nonetheless, an elastic flexibility is present, which would not be possible using a material similar to rubber.
[0031] In the exemplary embodiment, the filling volume of the receiving spaces 13 and 14 with damping material is provided such that the receiving spaces are already filled when the separating membrane 12 is relaxed.
[0032] However, it is also possible for a smaller filling volume to be provided, so that the non-loaded separating membrane 12 , which limits the respective receiving space 13 or 14 of the damping chambers 5 , 6 , is situated at a distance from the damping material. The separating membrane 12 , which is then exposed in the non-loaded state and is distanced from the damping material by an air gap, acts as an elastic element that can effectively dampen small pressure spikes. Given a higher pressure loading, the separating membrane 12 is deformed until it comes into contact with the damping elements 11 and is supported by these elements in elastic fashion. In addition, it is possible that enough damping material is placed into the receiving spaces 13 , 14 that the separating membrane 12 is somewhat deflected, and thus pre-stressed, at the pumping-medium-conducting areas 15 and 16 . In this way, it is possible to use a comparatively soft damping material, while nonetheless achieving a good damping effect even given high system pressures. In particular, in this way an optimal damping effect can be achieved over a large pressure range. In addition, the pre-stressing of the damping material enables a compact construction of the damper and the use of the same housing parts for low-pressure use and for high-pressure use.
[0033] In the two receiving spaces 13 and 14 , the damping elements 11 having different spring characteristics can also be used; here it is useful to use a somewhat harder material in the receiving space 13 of the first damping chamber 5 than is used in the receiving space 14 of the second damping chamber 6 . In this way, large pressure spikes can be compensated by the first damping element with damping chamber 5 , while the remaining pressure fluctuations can be compensated to the greatest possible extent in the second damping element with the damping chamber 6 .
[0034] Through the two damping chambers 5 and 6 , which are connected in series, a particularly godd damping effect is achieved in a small space. During the pressure phase, which extends over approximately 180° of a rotation in a positive-delivery pump, a system pressure is built up that produces a dynamic pressure through the inlet and outlet throttle elements 9 and 10 , by means of which the separating membrane 12 is deflected towards the damping elements 11 in the area of the damping chamber 5 . These damping elements, made of elastic material, build up a counter-load having the same order of magnitude. The constant modification of the delivery quantity due to the oscillating pump characteristic, or the pressure fluctuations that occur as a result of this, have the result that pumping medium is intermediately stored and then emitted again. Like the pressure force at the pump side, which represents a surface load, the damping elements likewise build up the counter-force as a surface load. Due to the construction and the manner of operation as a surface load, the dividing membrane 12 has the property of having a soft effect given a local loading, and a hard effect given a surface loading. For this reason, this type of damper can also be used with high system pressures.
[0035] In the exemplary embodiment, the pulsation damper 1 , as already mentioned, has a two-stage construction, in which the two damping units are connected in series. Per stage, a reduction of the pressure amplitude by a particular factor is possible. The remaining pulsation of the first stage is further reduced in the second stage. By this serial arrangement, a damping is possible that potentially increases with the number of stages. Due to the housing of both damping stages in one housing 4 , a compact constructive form is possible, and a more economical manufacturing is possible than is the case with the use of two separate individual dampers connected in series via lines.
[0036] The inlet throttle element 9 has the job of producing a dynamic pressure towards the pump. During a pressure impact from the pump, this dynamic pressure loads the first damper having the damping chamber 5 , and, via the inlet throttle element 9 , also loads the second damper having the damping chamber, During the lower pre-pressure time periods, the pumping medium content stored in the damper is re-emitted to the system, throttled via the outlet connection element 3 .
[0037] Through an appropriate selection of the passage cross-sections of the inlet throttle element 9 and of the outlet throttle element 10 , the desired damping effect, or the allowable remaining pulsation after the pulsation damper 1 , is achieved. Likewise, the allowable dynamic pressure, or pressure loss, of the pulsation damper 1 can be adjusted via the passage cross-section of the throttle elements. If the throttle elements are formed as exchangeable inserts, the pulsation damper 1 can be adapted to a large number of pump types and different flow rates while retaining a constant constructive volume. In the depicted exemplary embodiment, the throttle elements 9 , 10 are formed as bored holes, in non-exchangeable fashion.
[0038] In the exemplary embodiment, the housing 4 has a two-part construction, having a housing head 17 and a housing lower part 18 , with the separating membrane 12 being situated in the separating plane in continuous fashion as a sealing element. It thereby covers both of the damping chambers 5 and 6 , and extends up to the outer edge of housing 4 , so that the individual chambers are sealed against one another and outwardly. As is shown in FIG. 2, the housing 4 can have a round construction. Here the two damping chambers 5 to 6 each extend approximately over half of the circular cross-section. In the exemplary embodiment, the housing head 17 and the housing lower part 18 are held together by four screws.
[0039] In the housing head, the inlet and outlet connection elements 2 or 3 are situated diametrically opposite one another; here the line segment 7 is connected to the inlet connection element 2 , and a line segment 7 a is connected to the outlet connection element 3 . The line segment 7 a is connected with the second damping chamber 6 via the outlet throttle element 10 . From the line segment 7 , the branch 8 goes to the first damping chamber 5 , and the inlet throttle element 9 leads from the line segment 7 into the second damping chamber 6 .
[0040] [0040]FIG. 3 shows a modified specific embodiment of a pulsation damper 1 a , in which the first damping chamber 5 a is situated concentrically around the second, centrally situated damping chamber 6 a , thus forming an annular chamber. However, the design of this pulsation damper 1 a corresponds in principle to that shown in FIG. 1. | A pulsation damper which is used for damping pressure variations in an oscillating positive-displacement pump connected thereto is provided. The pulsation damper includes an inlet connection element, an outlet connection element and a line connecting the elements whereby these three components are connected to at least two damper chambers inside the pulsation damper, the damper chambers being connected in series inside the damper housing. One section of the line connected to the inlet connection element includes a connection channel to a first damper chamber and is joined to a second damper chamber via an inlet throttle element. The second damping chamber is connected to the outlet connection element via an outlet throttle. Damper elements made of an elastic material are disposed within the damper chambers. | 5 |
BACKGROUND OF THE INVENTION
Gas discharge lamps can be operated most efficiently by AC (alternating current) power at a relatively high frequency (on the order of 35 KHz (kilohertz). However, line AC power is supplied by utility companies at low frequencies of around 50 or 60 Hz (hertz). To obtain high efficiency operation of the lamps, the AC power at the first low frequency is converted to AC power at a second high frequency.
The conversion of the AC power from one frequency to another is accomplished by a ballast circuit. The AC power at the first low frequency is rectified into DC (direct current) power, and then stored as energy in a relatively large electrolytic capacitor. The energy stored in the electrolytic capacitor is then chopped by an inverter into AC power at a second high frequency.
In this kind of circuit, whenever the voltage of the line AC power is greater than the voltage stored in the electrolytic capacitor, a relatively large surge of current passes into the electrolytic capacitor, causing the line current drawn to be "peaky". This circuit thus has a poor power factor.
One solution is to place a floating voltage supply in series with the incoming line to the capacitor. Such a supply presents several problems. First, the voltage on the supply must be controlled so as to match the voltage on the electrolytic capacitor, otherwise the waveform of the power drawn from the line will be distorted. Second, the impedance of the supply must be adjustable so as to control the amount of power drawn from the power line. If not, the inverter will either produce too much power or there will be little correction of the power factor. Finally, the source of the power for the floating voltage supply must be stable and have low impedance.
A circuit which provides a floating voltage supply in series with the incoming line and has an adjustable impedance and an adjustable voltage level is thus desirable.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a push pull parallel resonant circuit for energizing gas discharge lamps in which the power factor correction signal is derived from an isolated winding on the output transformer.
FIG. 2 shows a push pull parallel resonant circuit for energizing gas discharge lamps in which the power factor correction signal is derived from an autotransformer tapping on the primary winding of the output transformer.
FIG. 3 shows a current fed half bridge driven parallel resonant circuit for energizing gas discharge lamps in which the power factor correction signal is derived from an isolated winding on the output transformer.
FIG. 4 shows a current fed half bridge driven parallel resonant circuit for energizing gas discharge lamps in which the power factor correction signal is derived from an autotransformer tapping on the primary of the output transformer.
FIG. 5 shows a push pull parallel resonant circuit for energizing gas discharge lamps in which the power factor correction signal is derived from an isolated winding on the current feed inductor.
FIG. 6 shows a current fed half bridge driven parallel resonant circuit for energizing gas discharge lamps in which the power factor correction signal is derived from an isolated winding on the current feed transformer.
FIG. 7 shows a push pull parallel resonant circuit for energizing gas discharge lamps in which the power factor correction signal is derived from an autotransformer tapping on the current feed inductor.
FIG. 8 shows a current fed half bridge driven parallel resonant circuit for energizing gas discharge lamps in which the power factor correction signal is derived from autotransformer tappings on the current feed inductor windings.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A circuit which has a floating power supply and an adjustable voltage and impedance level is described below. The floating power supply is provided by a high frequency rectifier driven through a capacitor by windings on a transformer. The voltage may be adjusted by varying the number of windings on the transformer. The impedance may be adjusted by changing the size of the capacitor. Such a circuit can be used to cause an electronic ballast to display a high power factor to the AC power line with a minimal number of components.
FIG. 1 shows a push pull parallel resonant circuit for energizing gas discharge lamps in which the power factor correction signal is derived from an isolated winding on the output transformer. Terminals 110, 120 of line rectifier 100 are coupled to a source of AC power at a relatively low frequency such as 60 cycles per second. Rectifier 100 may be a bridge rectifier. Line rectifier 100 converts the AC voltage to pulsating rectified DC voltage. Capacitor 122 prevents high frequency signals from the operation of the circuit from escaping out onto the power line. It is common practice to use some inductive components (not shown) to enhance this effect. One output terminal of the line rectifier 100 is connected to the input of a high frequency rectifier 200. (The positive terminal is shown used here, but with suitable orientation of the components either terminal may be used.)
High frequency rectifier 200 is suitable for operation at relatively high frequencies such as 35 KHz. The positive output terminal of line rectifier 100 is coupled to the negative DC output terminal of high frequency rectifier 200. The positive DC output terminal of high frequency rectifier 200 is coupled to the negative input terminal of line rectifier 100 by storage capacitor 210.
Storage capacitor 210 provides a stable reservoir of charge at relatively constant voltage for running the inverter 300. Inverter 300 is comprised of an output transformer 310, and a driver circuit including current feed inductor 320, switches 340 and 350 and resonant capacitor 330.
The driver circuit serves to apply the relatively constant current from the current feed inductor 320 to the primary of transformer 310 in alternate directions as the switches 340 and 350 are alternately switched on and off at the resonant frequency of capacitor 330 and the primary inductance of transformer 310. Capacitor 330 and the output transformer primary inductance constitute a resonant tank in which charge constantly circulates back and forth at the resonant frequency. If the amplitude of the oscillation becomes too large, then the voltage at the center tap of transformer 310 becomes high enough to decrease the current through feed inductor 320, thus decreasing the drive and ensuring a constant amplitude for the oscillation. Switches 340 and 350 are usually driven by auxiliary windings on the output transformer (not shown).
A feedback circuit is provided from the output transformer to the high frequency rectifier 200, via power factor correction winding 390 and capacitor 400 to high frequency rectifier 200.
High frequency rectifier 200 is thus energized through capacitor 400 by the relatively constant voltage high frequency signal derived from power factor correction winding 390. By adjusting the number of turns in power factor correction winding 390, there is a means for controlling the level of the DC voltage across the output terminals of high frequency rectifier 200. Matching the open circuit level of the voltage across the output terminals of high frequency rectifier 200 to the voltage level across the DC storage capacitor 210 significantly improves the power factor of the circuit. When the input voltage at terminals 110, 120 is non zero, the current drawn from the AC line is limited only by the output impedance of high frequency rectifier 200. It may be shown by mathematical analysis that at frequencies comparable to 60 Hz this impedance is a resistance, of magnitude inversely proportional to the value of capacitor 400. Therefore, the operating power level of the inverter is controlled by the value of capacitor 400. A large capacitor gives a high power level and vice versa. Since only the resistive impedance of high frequency rectifier 200 limits the incoming line current, then when the voltage provided at the output of high frequency rectifier 200 matches the voltage across storage capacitor 210, the current drawn from the power line will be purely sinusoidal as corresponds to a resistive impedance.
Load winding 360 couples the output power to the lamps 380 via current limiting capacitor 370. Normally additional circuitry is provided, (not shown) to sense when an overvoltage condition exists due, for example, to a lamp being removed. In this circumstance it is desirable either to shut down the boosting action or to shut down the entire inverter.
For this circuit to present a high power factor to the AC power line, a constant high frequency voltage may be applied to the high frequency rectifier 200 through capacitor 400. For parallel resonant circuits there are several convenient ways to produce this voltage.
For example, FIG. 2 shows a parallel resonant push pull ballast circuit in which the power factor correction signal is derived from autotransformer tappings 361 and 371 on the primary of the output transformer. The exact number of turns from the center to each tapping point determines the voltage being applied to the high frequency rectifier 200. In this case the values of the capacitors 410 and 420 determine the power level of the system. With this autotransformer as in all autotransformers, the output voltage may be either greater than or less than the input voltage.
FIG. 3 shows an arrangement for a current fed half bridge driven parallel resonant ballast in which the power factor correction signal is derived from a winding 331 on the output transformer, and the output power level is set by the value of capacitor 401.
FIG. 4 shows another current fed half bridge driven parallel resonant ballast in which the power factor correction signal is derived from an autotransformer tapping 332 on the primary winding of the output transformer. Power is controlled by capacitor 402.
Sufficiently constant high frequency signals to use for power factor correction may also be derived from the current feed inductor of a current fed inverter. For example, FIG. 5 shows a parallel resonant push pull ballast in which an auxiliary winding on the current feed inductor 333 is used to provide the power factor correction signal, through power limiting capacitor 403. This same technique will also work for a current fed half bridge driven parallel resonant ballast, as shown in FIG. 6. Here the power factor correction signal is provided by an auxiliary winding 334 on the current feed transformer.
When the power factor correction signal is derived from a current feed inductor, autotransformer techniques may also be used to adjust the voltage, with direct coupling. This is shown for the case of a parallel resonant push pull ballast in FIG. 7, where the power factor correction signal is derived from an autotransformer extension 335 on the current feed inductor. This same principle may also be applied to a current fed half bridge driven parallel resonant circuit with a split current feed inductor, as shown in FIG. 8. Since the current feed is split here, then two auto transformer extensions 336, 337 are possible and two corresponding high frequency rectifiers are used. This arrangement can also be made to work with only one autotransformer extension and one high speed rectifier. However, in order to spread the power loading as evenly as possible over the windings of the current feed transformer, the twin tapping arrangement may be preferred. | A parallel resonant circuit for powering a gas discharge lamp achieves power factor correction by using a floating power supply having adjustable voltage and impedance level. The floating power supply is powered by a transformer and placed in series with the rectified AC power line. | 8 |
FIELD OF THE INVENTION
The present invention relates to heat-exchange devices and more particularly to steam generators for steam power plants.
The present invention may be most advantageous in case of steam generators with forced fluid (steam) circulation operating with steam or gas turbines rated at 300 MW and over.
PRIOR ART
Known in the art are steam generators, comprising a furnace device and a linked gas pass built up of water walls adapted for fluid circulation, said linked gas pass communicating with the furnace device, having a chamber for partial hot gas cooling and being subdivided by water walls into mutually parallel sections.
In said steam generators, the water walls are all-welded constructions made up of tubes adapted for the circulation of fluid, in this particular case, of steam. The furnace device is a high-turbulence combustion chamber featuring high heat liberation per unit furnace volume, said combustion chamber being made integrally with the chamber for partial hot gas cooling that is arranged thereabove constitutes a portion of the gas pass and whose walls are made up of the water walls of diversified configuration.
The front and rear water walls of the combustion chamber and of the chamber for partial hot gas cooling are built up of the water walls bent in a vertical plane and having an intricate configuration. The side water walls of the combustion chamber together with the chamber for partial hot gas cooling are formed by flat water walls similar in their outline to that of the front and rear water walls.
Moreover, mounted at the rear wall of the chamber for partial hot gas cooling parallel to its side walls are division walls; four said walls are mounted in each chamber section, each said wall having a width equal to 1/4 of that of its side wall.
The remaining portion of the gas pass, which is a gas duct accommodating a vertical partition, is arranged close to the chamber for partial hot gas cooling, at its side. The duct is made up of the water walls of four types, each said type being bent in a different manner. The water walls of the first type make up the front duct wall facing the chamber for partial hot gas cooling. The water walls of the second type form the side walls, those of the third type -- the rear wall and the flat water walls of the fourth type make up the partition. In this case the partition is mounted parallel to the front water wall and subdivides the duct interior into two vertical spaces in communication with one another through openings provided in the bottom portion of the partition. The space defined by the partition and the front duct wall communicates in its top portion with the chamber for partial hot gas cooling. The resulting zigzag conduit formed thereof is adapted for the passage of hot gases from the furnace device through the entire gas pass assuring repeated alteration in the direction of gas flow.
The chamber for partial hot gas cooling, referred to hereinafter as a partial gas pass cooling chamber, and its zigzag conduit are interconnected through a transverse passage made up of the two L-shaped water walls. Said walls are rigidly fixed with one their end to the top portion of the rear water walls of the partial gas pass cooling chamber and with their other end to the top portion of the front duct wall. At the points of attachment of said passage interconnecting the waterwall tubes the chamber and duct walls are provided with slots for the passage of hot gases from the partial gas pass cooling chamber through the transverse passage into its zigzag conduit.
Each of said spaces of the gas pass conduit accommodates convection heating surfaces.
Arranged above each of these spaces are two ducts in rolled plates, of which one is adapted for sealing the spaces of the zigzag gas pass conduit and the other one for discharging hot gases from the gas pass.
In the described steam generator all the water walls defining the generator are arranged so that the tubes of each water wall are essentially disposed concordantly to the direction of hot gas flow.
In this case all the water walls defining the furnace device, convection surfaces and the linked gas pass are suspended from a framework made in shape rolled stock, said framework being a rather complicated and cumbersome construction.
Moreover, to provide proper rigidity of the entire steam generator structure use is made of the so-called stiffening belts which are beams of shaped iron encompassing the furnace device and the linked gas pass at different levels in height.
However, owing to inevitable diversity of configurations of the water walls making up the steam generator, the use of the water walls of unified design presents a serious problem, complicating thereby the generator erection techniques. Moreover, said steam generator has difficult-of access zones, a feature which impedes its operation.
The construction of such a steam generator involves high metal consumption.
Among the other disadvantages of the prior-art steam generators of the type described is the water wall arrangement owing to which the tubes with the fluid circulating therein run concordantly to the direction of hot gas flow. Under these conditions the temperature of each water wall differs from that in the other water-wall tubes. Insofar as the spaces of the gas pass conduit are defined by various water walls, their junctions feature low strength which accounts for operational unreliability of said steam generator.
Moreover, the water walls of the diversified types require diverse hangers to attach them to the generator framework, a feature which complicates the sealing of the places through which the hangers extend into the ducts located above the spaces of said gas pass conduit.
Such a principle on which is based the attachment of the entire steam generator structure leads to a substantially higher metal requirements of the supporting structures, and creates serious difficulties in erection, operation and repairs of said steam generator.
SUMMARY OF THE INVENTION
The main object of the present invention is to provide a steam generator for a steam power plant, said steam generator having a gas pass whose design will enable an extensive application of water walls of unified design.
Another object of the invention is to provide an adequate rigidity and reliability of the entire steam generator structure.
Still another object is a considerable reduction in metal requirements of the steam generator.
The above and other objects are achieved in a steam generator for a steam power plant, said steam generator comprising a furnace device and a linked gas pass communicating therewith and made up of water walls adapted for fluid circulation, said gas pass having a chamber for partial hot gas cooling subdivided into mutually parallel sections.
According to the invention, the entire gas pass is built up of the water walls arranged one above another in height and bent in a horizontal plane, each element of each said water wall having a different number of bends and the adjacent water walls being interconnected through the top points of their bends, this resulting in the formation of gas pass sections together with said sections of the chamber for partial hot gas cooling.
Thus, the sectionalized gas pass has the serious advantage over that in the prior-art steam generators.
A system of such rigidly interconnected sections constitutes the basis of the steam generator structure featuring high rigidity and a high bearing capacity. Said structure does not require an awkward and metal-consuming framework, stiffening belts and hangers for fastening the water walls to the framework, a feature which facilitates substantially the erection, operation and repairs of the steam generator and diminishes its metal requirements.
Moreover, this embodiment makes it possible to assemble steam generators of various capacity of standard elements. Owing to the above-outlined principle the steam generator of the invention has a much larger heating surface per one meter of gas pass height as compared with the prior-art steam generator of the type described.
It is expedient that each element of each water wall be an all-welded construction of tubes arranged one above another and mutually parallel, said element being disposed so that its tubes be directed essentially at right angles to the direction of hot gas flow.
In this embodiment, the water-wall tubes are exposed to a transverse flow of hot gases, a feature contributing to an intense heat exchange between the hot gases and the fluid circulating in the tubes. This allows enhancing the efficiency per unit heat-exchange surface of the steam generator, which in turn makes it possible to decrease its overall dimensions in comparison with the prior-art steam generators of the same capacity and of the type described.
It is also sound practice that each element of each water wall have at least two inlet and two outlet headers, the tubes of said water wall element being connected to each header so that the fluid in the neighboring tubes are in counter flow.
Such an embodiment enables a uniform distribution of the fluid temperature within each water wall element. Moreover, this results in the neighboring elements of each water wall featuring a minimum temperature gradient which creates favorable conditions for their joints and, hence, ensures reliable operation of the steam generator.
Thus, as compared with the prior-art units, the herein-proposed steam generator is made up of water walls of unified design, is simple in erection and servicing, its structure featuring adequate rigidity and reliability in service.
BRIEF DESCRIPTION OF THE DRAWING
The nature of the invention will be clear from the following detailed description of one of its possible particular embodiments to be had in conjunction with the accompanying drawings in which:
FIG. 1 shows diagrammatically a steam generator for a steam power plant (a longitudinal sectional view), according to the invention;
FIG. 2 is a section taken along line II--II in FIG. 1;
FIG. 3 diagrammatically shows a top element of one of the water walls, in enlarged perspective view;
FIG. 4 shows diagrammatically a central element of one of the water walls on enlarged perspective view;
FIG. 5 shows diagrammatically a bottom element of one of the water walls, on enlarged perspective view;
FIG. 6 is a sectional view taken on line VI--VI in FIG. 1;
FIG. 7 shows unit D of FIG. 1 in enlarged view;
FIG. 8 shows unit C of FIG. 2 in enlarged view;
FIG. 9 shows unit E of FIG. 8 in enlarged view;
FIG. 10 shows another possible embodiment of unit E of FIG. 9 in enlarged view;
FIG. 11 shows diagrammatically a first embodiment of a doubled steam generator;
FIG. 12 shows a second embodiment of the doubled steam generator;
FIG. 13 is a perspective view showing the assembly of the top, central and bottom water walls; and
FIG. 14 is a perspective view showing the relative arrangement of the structural elements forming the gas pass and the connection surface in each of the cells of the gas conduits.
DETAILED DESCRIPTION
A steam generator for a steam power plant is mounted on a welded base 1 (FIG. 1) made from shape rolled stock.
The steam generator comprises a furnace device 2 and a linked gas pass 3 in communication therewith. In this case a part of the gas pass 3 adjoins the furnace device 2 and constitutes a partial hot gas cooling chamber 4, referred to hereinafter as a partial gas pass cooling chamber 4.
The furnace device 2 is arranged below the chamber 4 serving for partial cooling of the gas pass 3 and is a high-turbulence combustion chamber featuring high heat liberation per unit furnace volume; said combustion chamber may have any known configuration adaptable for this purpose.
The linked gas pass 3 is built up of water walls 5 arranged one above another in height and bent in a horizontal plane, said water walls 5 being bent so as to provide the formation of sections "A" (FIG. 2) in the chamber 4 for partial cooling of the gas pass 3 and sections "B" in the remaining portion of the linked gas pass 3. Each section "A" communicates with one of the sections "B", this resulting in the building up in the linked gas pass 3 of mutually zigzag conduits 6 with vertical spaces 6a, 6b and 6c adapted for the passage of hot gases generated in the furnace device 2 (FIG. 1) (the direction of hot gas flow is indicated by arrows).
Each water wall 5 is built up in height of three elements: a top element 7, a central element 8 and a bottom element 9. Each water wall 5 may have several central elements 8 but their number in each of the water walls 5 must be one and the same.
Each of the elements 7, 8 and 9 is an all-welded panel made up of tubes arranged parallel to one another in one row in the plane of the drawing (FIGS. 3 through 5), each panel 7, 8 and 9 having a different number of bends. Thus, the top panel 7 (FIG. 3) has three bends in the drawing plane. In this case its portions 10-12 form a concavity "a," its portions 12 and 13 forming an open convexity "b."
The central panel 8 (FIG. 4) has seven bends in the drawing plane, its portions 14-16 forming a concavity "c," portions 16-18 -- a convexity "d," portions 18-20 -- a concavity "e" and portions 20-21 -- an open convexity "f."
The bottom panel 9 (FIG. 5) has five bends in the drawing plane, its portions 22-24 forming a concavity "g," portions 24-26 -- a convexity "h" and portions 26-27 -- an open concavity "k."
The width of the concavity "a" of the top panel 7 (FIG. 3) 7 (FIG. 7) is equal to the total width of the concavity "e" and the incomplete convexity "f" of the central panel 8 (FIG. 4) whereby the panels 7 and 8 on assembly form a passage "n" (FIG. 1) running between the spaces 6b and 6c of the zig-zag conduit 6.
The width of the concavity "D" of the central panel 8 (FIG. 4) amounts to that of the concavity "g" of the bottom panel 9 (FIG. 5).
The total width of the convexity "d" and concavity "e" of the central panel 8 (FIG. 4) is equal to the width of the convexity "h" of the bottom panel 9 (FIG. 5), whereby the panels 8 and 9 on assembly form a passage "p" (FIG. 1) interconnecting the spaces 6a and 6b of the zigzag conduit 6 in each section "B."
Said three panels 7-9 (FIGS. 3 through 5) on assembly form with their concavity "a" (partly) and concavities "c" and "g" three sides of the section "A" (FIG. 2) of the chamber 4 for partial gas pass cooling.
With a portion of the concavity "a" (FIGS. through 5), convexity "d" and a portion of the convexity "h" they form the space 6a (FIG. 1) of the zigzag conduit 6 of each section "B";
with a portion of the open convexity "b" (FIGS. 3 through 5), the concavity "e" and a portion of the convexity "h" the space 6b (FIG. 1) of the zigzag conduit 6 of each section "B";
with a portion of the open convexity "b" (FIGS. 3 through 5), incomplete convexity "f" and the open concavity "k" -- the space 6c (FIG. 1) of the zigzag conduit 6 of each section "B".
In this case the spaces 6a, 6b and 6c of each section "B" and section "A" in communication therewith are defined from three sides by one water wall 5. The fourth side of said sections is built-up of the adjacent water walls 5 upon connecting the top points of the bends of the corresponding panels 7, 8 and 9 of said water walls 5.
The fourth sides of the spaces of the extreme sections "A" and "B" form flat water walls 28 (FIG. 2).
The panels 7-9 (FIG. 8) of the water walls 5 can be interconnected through their top points by using one of the two possible embodiments: the first one (FIG. 9) envisages the use of a coupling plate 29 to which a heat-insulating compound "S" is applied, the second one (FIG. 10) comprises a tube 30 in which working fluid is circulating to equalize the temperature of the elements.
According to both these embodiments, welded with one of its edges to each panel along the generatrix of each bend top point is a rib 31 in the form of a plate located in a plane essentially normal to the tangent to the bend top (in the drawing plane).
According to the first embodiment (FIG. 9) the ribs 31 of the adjacent bend top points are interconnected by means of the coupling plate 29 welded therebetween. The junction of the bend tops is coated with the insulating compound "S."
According to the second embodiment (FIG. 10), the ribs 31 of the adjacent bend tops are interconnected with the aid of the tube 30 having two diametrically opposite ribs disposed along its generatrix. Each of said ribs is welded along its length to a corresponding rib 31, as is shown in FIG. 10.
The sections "A" and "B" are protected from above and from below by flat water walls, 32 and 33 respectively (FIG. 1). The rear wall of the linked gas pass 3 made up of the flat water wall 34 is provided with an outlet "L" for hot gases.
The water walls 5 are arranged so that the tubes in each of their panels 7, 8 and 9 are directed essentially at right angles to the direction of hot gas flow. In this case each of the panels 7, 8 and 9 (FIG. 6) of the water wall 5 has two inlet and two outlet headers 35. Each of the tubes of the water-wall panels 7, 8 and 9 is connected with one its end to the inlet header 35, its other end being coupled to the outlet header 36. But the tubes are connected so that similar ends of the two adjacent tubes are coupled to unlike headers. As a result, the fluid in the adjacent tubes is in a counterflow.
The outlet headers (not shown in the drawing) of the water walls 5a forming the furnace device 2 (FIG. 1) are coupled in a known manner through a mixer (not shown in the drawing) with the inlet headers 35 of the panels 9 and water wall 38.
The outlet headers 36 of the panels 9 and water wall 33 are coupled with the inlet headers 35 of the panels 8. The outlet headers 36 of the panels 8 are coupled with the inlet headers 35 of the panels 7. The outlet headers 36 of the panels 7 are coupled with the inlet headers (FIG. 7) of the water wall 32.
The outlet headers 37 of the water wall 32 are connected in a known manner to the inlet headers (not shown in the drawing) of convection surfaces 38 (FIGS. 1 and 6) which are accommodated in the spaces 6a, 6b and 6c and coupled with various turbine stages (not shown in the drawings).
To increase the output of the steam power plant and to provide an optimum layout of the steam generator and of the other plant equipment, the layout with doubled steam generators can be employed.
Said layout with the doubled steam generators can have two embodiments;
The first embodiment (FIG. 11) envisages an adjacent arrangement of the furnace devices 2. The outlets "L" for hot gases are directed into opposite sides, the direction of hot gas flow in the zigzag conduit 6 being indicated by arrows.
The second embodiment (FIG. 12) envisages a spaced arrangement of the furnace devices 2. In this case the length of the water walls 5 is equal to a double length of the walls 5 in the above-outlined steam generator, according to the invention, the water walls 5 forming concurrently, according to the second possible embodiment, both gas passes 3 with a common hot gas outlet "L."
The steam generator for a steam power plant operates in the following manner.
The tubes of all the water walls 5 and 5a are filled in a known manner with fluid, in this particular case with water, fed through the inlet headers 35. An air-fuel mixture is supplied into the furnace device 2 (FIG. 1), and flame ignition is effected.
The fuel burns up with the ensuing generation of hot gases in the furnace device 2.
The hot gases at a temperature of 1400°-1600° C enter the sections "A" of the chamber 4 for partial gas pass cooling where in a heat exchange between the hot gases and the fluid circulating in the tubes of the water walls 5 takes place. As the temperature of the fluid rises, the pressure in the tubes of the water walls 5 and 5a will grow and the fluid commences to circulate.
From the tubes of the water walls 5a making up the furnace device 2 water flows into the tubes of the water walls 5, making up the gas pass 3.
In the tubes of the bottom panel 9 some steam is generated and in the tubes of the water-wall panels 8 and 7 water is completely converted to steam. Next the working fluid (steam) enters the tubes of the panel 32.
In the sections "A" of the chamber 4 for partial gas pass cooling hot gases are simultaneously cooled to a temperature of 1000-1100° C. This is necessary to create optimum operating conditions for the convection surfaces 38 accommodated in the spaces 6a of the zigzag conduit 6 of each section "B." Hot gases enter said spaces 6a through the passages "m" from the sections "A" of the chamber 4 for partial gas pass cooling. Here the steam admitted from the tubes of the panel 32 is superheated to a temperature at which it is then delivered to the turbine. Reheat steam passes in succession to the convection surfaces 38 accommodated in the spaces 6c and 6b of each zigzag conduit 6. Here the steam is superheated to a preset temperature to be returned to the turbine. The gases flow from the space 6a through the passage "p" into the space 6b from which they proceed through the passage "n" into the space 6c and then through the outlet "L" to the heating surfaces not associated with the proposed steam generator.
It should be noted that heat exchange between the hot gases and the fluid circulating in the water walls 5 takes place with the water-wall tubes being exposed to a transverse flow of the hot gases travelling with a high speed, especially in the spaces 6a, 6b and 6c.
The steam generator operates on a continuous steam generation cycle. | A steam generator for a steam power plant, comprising a furnace for generating hot gases and a gas pass in communication therewith, the gas pass having a sectionalized chamber for hot gas cooling. The entire gas pass together with the chamber constitute a single construction unit built up of water walls arranged one above another in height and bent in a horizontal plane so that each element of each water wall has a different number of bends. The adjacent water walls are interconnected through the top points of the bends forming sections of the entire gas pass together with the sections of the cooling chamber. This results in the formation of a system of rigidly interconnected sections which constitutes the basis of the steam generator structure featuring high rigidity and a high bearing capacity. This allows obviating any additional appliances for fastening the generator and, hence, diminishing materially the metal requirements and simplifying both the erection and operation of the steam generator. | 5 |
FIELD OF THE INVENTION
[0001] The present invention applies to the aerospace and industrial field, specifically to the field of one- or multi-stage axial compressors.
[0002] The invention relates to a method and a device for predicting the instability of an axial compressor which allows protecting said compressor against the instabilities of devices of this type. The present invention could be used in all those products requiring the use of said compressors, such as aircraft engines, turbofans, turboshafts, or turboprops in the aerospace field, gas turbines in the energy field, air conditioning systems in the civil field, and gas compression systems in the chemical or oil industry.
STATE OF THE ART
[0003] One of the most important aspects for determining the performance of machines equipped with axial-flow compressors is the instability of the compression system. A two-dimensional graph can be defined for an axial compressor in which the x-axis represents the pressure difference and the y-axis represents the mass flow. This same graph can be defined for a single row of blades. Depending on the capacity defined by both variables and according to the work conditions, the operating point of the compressor will be located in a point of the plane. The plane comprises two regions, a stable region and an unstable region. Both regions are separated by a line which is referred to as the “stability line” and establishes the boundary between both regions. Typically, the stability line is such that its intersection with a horizontal line corresponding to a constant pressure path, leaves the unstable region to the left (lower mass flows) and the stable region to the right (greater mass flows). Predicting the instability in a compressor is predicting that a determined operating capacity is located to the left of the stability line.
[0004] Although there are works with analytical results and also with numerical results which allow establishing stable work conditions with a certain degree of safety (by means of experiments; for example, by following constant pressure conditions and varying the mass flow, it is possible to gradually determine points of the plane where instabilities appear), the determination and configuration of this stability line (typically represented by means of a increasing function) has not been analytically established up until now.
[0005] This instability can manifest in different ways and accordingly it usually receives different names, such as stall, rotating stall, deep stall and surge.
[0006] Particularly, the stall conditions indicate that the boundary layer in the blades of the rotor is shed because the flow is unable to follow the profile of the blade and therefore said aerodynamic profile no longer exerts a correct “lift” action. As a result, the efficiency drops, which can lead to the situation in which it is impossible to maintain the pressure difference in the compression stage.
[0007] The terms stall, rotating stall and deep stall refer to different physical phenomena the effect of which is the disruption from a lesser to higher degree of the internal flow of the compressor.
[0008] The term surge refers to the limit condition in which there is a strong loss of compression.
[0009] The efforts to understand and improve the stability of axial compressors, especially for aeronautic propulsion applications, which have been made over the last few decades have allowed understanding that there are several triggers or events initiating the phenomenon. A possible mechanism referred to as modal inception is known, which occurs when there are long wavelength perturbations the amplitude of which wavelength gradually increases under the instability conditions of the entire compression system. Another possible mechanism referred to as spike inception is known, which involves short wavelength perturbations the amplitude of which wavelength rapidly increases under large angles of incidence of the rotor. However, there may still be other mechanisms. In fact, it has been asserted that the short and long wavelength perturbations alone are not enough to predict the instability and that all the wavelengths should be considered in order to describe the phenomenon. Furthermore, the situation is even more complex given that, as is known, the precursors of the instability can be coupled.
[0010] Thus, the publication of Day et al. [Day, I. J., Breuer, T. Escuret, J., Cherrett, M. and Wilson, A., Stall Inception and the prospects for active control in four high speed compressors, ASME J. Turbomachinery, Vol. 121, pp. 18-27] shows the study of four high speed compressors for aeronautical applications in which it is concluded that at the time of its publication, the precursors of the instabilities were still not well known in engines of this type and to demonstrate this the following experimental evidence was submitted:
[0011] 1) in two of the compressors, when they operated at maximum capacity, a new type of precursor of the high-frequency instability was detected,
[0012] 2) although in most causes the rotating stall failure preceded the surge failure, the origin of the instability could not be identified in terms of low or high wavelength perturbations,
[0013] 3) in one of the compressors the instability occurred so quickly that the onset of the rotating stall could not be detected before the loss of compression, and
[0014] 4) in all the compressors there were perturbations in all the rotation operating conditions.
[0015] The precursors of the instabilities continue to be unknown today in engines of this type.
[0016] In addition, the fluid structures of the regions in which the compressor stalls have also been the object of in-depth study. For example, it is asserted that during the evolution of an instability initiated by low-frequency perturbations, high-frequency perturbations can appear and disappear, but that they ultimately remain. With an additional reduction of the air flow going through the compressor, both perturbations coexist simultaneously and the instability leads to a large region of the compressor stalling and to a deep stall condition. It is also asserted that though it seems obvious that both phenomena are associated with instability, the behavior of the low- and high-frequency perturbations in the process is unknown. The complexity of the phenomenon has also been discussed and investigated numerically in a single-stage compressor elaborated by NASA, from which it was deduced that the low-frequency modes dominated the flow for mass air flows below and above a determined range of mass flows. However, it was subsequently argued that this result contradicted the explanation which asserted that the loss of compression is due to low-frequency perturbations the characteristic time of which exceeds the dwell time. It has also been shown that the factors which condition the evolution of the compressor towards stall have still not been clarified.
[0017] In addition, as Greitzer established in his publication [Greitzer, E. M. Surge and Rotating Stall in Axial Flow Compressors. Part I: Theoretical Compression System Model. Engineering for power, Vol. 98, No. 2, 1976, pp. 190, 198.], the times which are needed for a stall region to develop within the compressor can be long enough so that the flow going through the compressor experiences significant changes. He thus generated a first order mathematical model to simulate the effect that this time delay produced in the evolution of transients during the instability. However, the prediction process was not complete given that it did not include the model which predicted the performances of the compressor in the low mass flow regions in which the instabilities were present.
[0018] Patent JP 2008223624 discloses a prediction system in which a stall sign is established which warns of the proximity of the operating point to instability, together with a control system which corrects the situation. This system computes an index for evaluating the risk existing at a determined time that the instability will occur. The system comprises a time averaging and another circumferential averaging for evaluating the risk index, as well as a time correction for compensating the possible time delays generated in the averaging operations only performed on the pressure existing at different points of the compressor.
[0019] Patent WO 2007135991 discloses an apparatus for computing a risk index, which warns of the proximity to the unstable region, based on the analysis of the time series produced by one or several pressure sensors placed in the wall of the compressor and distributed along the circumference. A stable and highly precise risk evaluation index capable of managing active control systems is thus obtained. As an example of the type of control system, patent JP 2003227497, which describes a system of grooves which open and close according to the signal produced by a risk index, such that the compressor can continuously operate in the stable region as a result of the increase of the air flow going through it, can be consulted.
[0020] A somewhat simpler prediction and control system can be found in JP 2001132685. In this device, the instability is avoided by means of a pressure sensor installed in the casing of the compressor and an amplifier which obtains the pressure variations, which are subsequently converted to a direct current. When this direct current exceeds a previously determined value, the active control system is activated, which system can consist of stopping the installation or of opening bleed valves which increase the flow. Though this system has a prediction technique that is slightly different from the previous ones, its precision continues to be compromised because it exclusively uses pressure as the only risk variable.
[0021] U.S. Pat. No. 5,908,462 describes a completely different approach to solve this technological problem. This system uses dimensional analysis, the similitude of the system when it is written in dimensionless notation, to derive a surge limit that is invariant to suction conditions of the compressor which can vary, for example, by changing the geometry of the inlet guide blades. The method uses the linear or nonlinear combination of dimensionless variables different from those used before. Nevertheless, the main limitation of this patent is that the optimal ratio of the dimensionless variables which makes it possible to predict the risk index with greater reliability is unknown.
[0022] Finally, WO 9403862 describes a method for monitoring and controlling a compressor. The device again is based on measuring pressure fluctuations with at least one pressure sensor and obtaining a frequency signal having at least one peak in the region of characteristic frequencies assigned to one of the compression stages and which is used to generate at least one parameter indicative of the operational status of the compressor. In the event that this parameter lies beyond a predetermined range, a signal is generated which is used to control the compressor. Again, this patent dispenses with physical parameters other than pressure.
[0023] It is therefore desirable to provide a device and method for protecting that allows knowing the imminent onset of instability, as well as the margin of safety existing at an operating point both in the operation and in the design, preventing the drawbacks existing in the earlier systems of the state of the art.
DESCRIPTION OF THE INVENTION
[0024] The invention solves and improves limitations existing in the state of the art with respect to the aforementioned patents, which perform an averaging only with respect to the pressure existing at different points of the compressor. For the purpose of preventing the compressor from stalling without prior notice, the present invention takes a measurement in which a larger number of fluid variables is involved, such as the rotational velocity of the compressor, or the outlet temperature thereof. In one embodiment, this measurement entails averaging the acquired values. A more complete and stable measurement is thus obtained for predicting the instability because it adds more relevant physical information for the computation of the risk index. In addition, the invention solves the lack of knowledge about the optimal ratio between the dimensionless variables such that the risk index becomes predictable with greater reliability and robustness at all the operating points of the compressor.
[0025] A first aspect of the invention relates to a method capable of predicting the instabilities of a one- or multi-stage axial compressor. More specifically, it relates to a method capable of computing a risk index such that a control system which is installed in the engine or machine in which the compressor operates will have the necessary information to evaluate the degree of danger existing at said operating point and will carry out the necessary actions to prevent the instabilities which would lead to the situation of danger.
[0026] According to a second aspect of the invention, another object of this invention is a device suitable for carrying out the method for predicting the instability in one or in all the stages of the compressor as well as for protecting each stage by using control means capable of changing the operating conditions thereof.
[0027] The proposed device comprises a series of measuring devices (in the embodiment it will be seen that it comprises calculators, sensors and systems for conditioning the signal) the purpose of which is to provide either by direct measurement, by computation from indirect measurements, or by estimating the parameters necessary for the computation, a value of the pressures, temperatures and velocities at the outlet of each stage, means if the latter are weighted; and a computing device the purpose of which is to compute a risk index for each stage from the values provided by the measuring devices. According to one embodiment, a control system which allows correcting the situation both in the operation and in the design is supplied with the set of risk indexes.
[0028] Therefore, according to an embodiment of this second aspect of the invention, a device is provided which is capable of producing a risk signal, which is a function of the proximity of the operating point to the stability line, for each row of blades that can be used to manage an active control system. In this invention, a row of blades is each of the rotors or stators forming the compressor.
[0029] The device consists of a computing unit which takes, for each row of blades (rotor or stator), the static pressures at the inlet and the outlet of the row, the static enthalpy at the outlet, the rotational velocity of the row, the absolute velocity (magnitude and direction) of the fluid at the outlet of the row and the axial solidity thereof and generates a risk index which is a claim of the present invention. This risk index is defined below.
[0030] Where subscript j is in charge of identifying the row (it can be a rotor or a stator) of the evaluated compressor, subscript I specifies the properties at the inlet of the row, and subscript O specifies the properties at the outlet of the row, then the risk index for row j is evaluated by means of the expression:
[0000]
IR
j
=
exp
[
1
+
2
h
j
;
O
[
(
P
j
;
I
P
j
;
O
)
γ
j
-
1
γ
j
-
1
]
[
(
V
x
)
j
;
O
+
(
σ
x
)
j
(
V
θ
)
j
;
O
-
U
j
]
2
]
(
Equation
1
)
[0031] The variables in this expression are defined as can be seen in Table 1.
[0000]
TABLE 1
Set of variables used to define the risk index of a row of blades.
IR j
Risk index of the row j
h j;O
Static enthalpy of the gas at the outlet of the row j
P j;I
Static pressure of the gas at the inlet of the row j
P j;O
Static pressure of the gas at the outlet of the row j
γ j
Ratio of specific heats of the gas in the row j
(V x ) j;O
Axial velocity of the gas at the outlet of the row j
(V θ ) j;O
Absolute tangential velocity of the gas at the outlet of
the row j
U j
Tangential velocity of the row (its value is zero if the
row is a stator)
(σ x ) j
Axial solidity of the row j.
[0032] According to the present invention, this risk index predicts an instability in the row j, and therefore in the compressor, when IR j is less than a reference value I ref , preferably one. This risk index predicts a stable behavior of the stage j when IR j is greater than the reference value I ref . Therefore, the instability line of the row is at those operating points where IR j is equal to I ref .
[0033] When the reference value I ref is one, there is a criterion for establishing a prediction about the instability. Nevertheless, it is possible to consider a shifted reference value I ref . If a safety value v saf >0 is defined and I ref is 1+v saf , then the prediction for the work conditions of the compressor is instability with a margin of safety defined by v saf . The protective actions adopted using this prediction will be put into effect sooner than if the value 1 for I ref is used in the assessment of the risk index IR j .
[0034] In contrast, there will be situations in which, assuming the risk, the compressor is allowed to slightly enter the instability region. In this case, having defined a risk value v r >0, the value to be taken for I ref is 1-v r .
[0035] Notwithstanding the foregoing, the preferred value for I ref is considered as one and the following descriptions and reasoning will be carried out using one but it does not mean that the previous generalization for the reference value I ref cannot be applied.
[0036] Given that the relevant information meets the condition IR j =1 and the good mathematical properties of the function shown in Equation 1, since it is well defined at any operating point, is continuous and derivable, all those risk indexes derived from the foregoing such that they reproduce the same condition of stability with the same mathematical properties are also object of the present invention. For example, the following are also risk indexes: IR j −1 when IR j −1=0; ln(IR j ) when ln(IR j )=0; ln(IR j )−1 when ln(IR j )−1=1; IR j 2 when IR j 2 =1; as well as equivalent expressions obtained from performing mathematical operations on the previous indexes. Therefore, those expressions which are deduced from the condition given by equation 1, equal to 1 by applying changes by algebraic manipulation such that they only modify the way of expressing the same condition shall be considered equivalent expressions. The same applies to the case in which I ref is not one, the preferred value.
[0037] With the stability criterion object of the present invention, the compressor is considered completely stable when all its rows are, i.e., when IR j is greater than one for any value of j (including rotors and stators).
[0038] With the stability criterion object of the present invention, the compressor is considered operatively stable when all its rotors are, even if its stators are not, i.e., when IR j is greater than one for any value of j for which U j >0.
[0039] The variables of Table 1, which are necessary for computing the risk index, must be understood in the context of the present invention as both time and spatially characteristic values of the row. For this reason, said variables can be obtained by pooling the information from several spatial and time positions by means of filtering techniques which eliminate rapid fluctuations and variations while they retain the slow ones: in this sense, they are both time and spatially averaged variables, i.e., they can be the instantaneous pressures or velocities existing in a determined axial and azimuthal position of the row, for example on the casing of greater radius in a determined angular position thereof, or they can be a spatial averaging of the values measured at different points angularly distributed over both the outer and the inner casing, or measurements can be taken in the stream located far from of the walls, or it can be the result of a weighting of all of them. Likewise, the velocities and the pressures can, though do not have to be, understood as a time averaged value over a time range greater than the natural fluctuations generated by the passage of the blades and the noise from the engine or machine. Likewise, the axial solidity (σ x ) j must be understood as the characteristic value obtained from multiplying the number of blades Z of the row j by the axial chord c x and from dividing said result by 2πr, where r is a characteristic value of the radius of the blade in the row j and c x is a characteristic value of the axial chord in the row j. For example, the values of any intermediate section of the blade, or the values of the section of the tip of the blade, or the values of the section with less axial solidity, could be taken as the characteristic value of the axial chord and of the radius.
[0040] Likewise, the variables of Table 1 can be obtained by direct measurement, by derivation from the corresponding indirect magnitude measurements, and by computation from the corresponding physics equations. For example, the following can be obtained:
the static pressures by means of piezoresistive pressure sensors, piezoelectric pressure sensors, or a combination of both; the static enthalpy by means of thermocouples located such that they acquire the static temperature and the subsequent computation of the enthalpy using of thermodynamic laws implemented in the device; and the velocities:
1) the axial and azimuthal velocities by means of hot wire or plate anemometers; 2) indirectly by means of measuring the static and stagnation pressures, for example using pitot tubes; 3) they can be estimated by means of computation from the compressor geometry, from the compressor map; etc.
[0047] The device is therefore a detector of the instability of the compressor, if the compression system is provided with one or a plurality of sensors, each placed in any one position of the set of possible positions, such that a characteristic, preferably time stable signal is generated which supplies a computing device, where Equation 1 is implemented, which equation generates the index IR j that will serve to evaluate the risk of instability. An index or set of indexes is thus obtained which allows evaluating the risk of the loss of compression.
[0048] Therefore, there is a signal in the device with the capacity to detect the loss of compression in the row j and, more importantly, of predicting the point at which it will occur. It is a device which depends on variables, which are or are not time and spatially averaged, that supply an analytical expression, which is well defined for all the operating points, such that reliable, robust and stable control systems can be achieved. Furthermore, the inlet variables can be obtained by means of direct measurement and subsequent time and spatial average, so the criterion is independent of the inlet or outlet perturbations caused by the rows of blades before or after the monitored row and by the actual active control systems. The stability limit of the row, given by the condition IR j =1, is independent of the operating conditions, such that an operating point can have an IR j that can be far from or close to said line. As has been described above, even though the theoretical value at which the instability occurs is established by IR j =1, those devices which use the IR j =I ref criterion where in practice I ref , the reference value, is a value (usually close to one) which takes into account the possible deviations from the theoretical value produced by the errors in the measurement, averaging and estimation of parameters, are also object of the present invention.
[0049] The IR j value of the real operating point is a number which can be used to implement the algorithms for the prevention of instabilities due to the fact that it is a signal which specifies the level of safety of the operating point in each row and which could therefore be used to control the compressor or the machine in which it is installed. The loss of compression or the onset of the instability can be prevented by means of control algorithms which could, for example, vary the suction conditions, by means of changing the angle of incidence of the guide blades, by means of opening bleed valves, etc. This is because the risk index of each stage is computed in real time by means of the information captured by the sensors installed in the monitored row.
[0050] Therefore, the technological problem solved by the present invention is that of being able to determine the degree of safety of the operating point of the compression system for the purpose of reporting on the working of the compressor and preventing this compressor from stalling, or from entering a potentially dangerous region, without prior notice. The relevant physics of the problem is included by means of Equation 1, not only the evolution of the pressure at different points of the compressor, while at the same time it presents good mathematical properties such as the fact that the equation is well defined, is continuous and derivable at any operating point. An index or set of indexes is thus obtained which allows evaluating the risk of a loss of compression, provided with high noise immunity, high sensitivity and high stability, which entails a high reliability in the active control systems which are implemented in the control devices.
[0051] Therefore, the principal advantage of the present invention with respect to other possible solutions is that it allows implementing an analytical algorithm for predicting instabilities which is simple, precise, reliable and robust. Its information can therefore be used to perform the corrective actions considered appropriate in each case for the purpose of maintaining the safety and integrity of the entire system.
[0052] As has been described, the invention which is presented contemplates a method for predicting the instability of an axial compressor according to claim 1
[0053] In an axial compressor comprising one or more rows of blades of rotors and stators, the risk index is evaluated in at least one row. If the measurement is carried out in a plurality of rows, when the risk index of any of them is less than one, the method determines that there is a condition of instability.
[0054] If the measurements are averaged, they allow a stable method such that a device suitable for carrying out said method will be capable of predicting the instability under any circumstance.
[0055] The prediction of the instability allows performing later steps in the method which give rise to the protection of the compressor. One of these steps is acting by means of corrective measurements on the work conditions of the compressor, shifting it to a stable region.
[0056] In a preferred embodiment, the method for the prediction can comprise the use of control means which generate a control signal depending on IR j and act on the geometry and parameters of the compressor.
[0057] Another step which can be carried out in the method of the invention is the generation of an alarm signal. Preferably, the IR j value corresponding to the tripping of one or several alarms in the method for prediction in question is less than or equal to one or to a value previously established depending on the desired margin of safety.
[0058] All those methods determined by any of the combinations provided in independent claims 2 to 9 are considered to be incorporated by reference in this description.
[0059] Another object of this invention is the device according to claim 10 , and particularly of dependent claims 11 to 16 , suitable for carrying out the method for predicting the instability; and optionally the subsequent action with alarm measurements, correction of the operating conditions of the compressor or both.
[0060] In this device, the conditioning means of the measuring means can be configured to compute, from the measurements obtained by the sensing means, the variables used by the computing device for computing the IR j and for performing a time and spatial average thereof.
[0061] P j;I , P j;O , (V x ) j;O and (V θ ) j;O , are preferably associated with values selected from:
values determined by a spatial and time position obtained in the row j of blades; values determined by a spatial and time average of values obtained in the row j of blades; and with a combination of the foregoing.
[0065] Finally, obtaining the variables necessary for generated the risk index can be selected from:
obtaining directly by measuring; obtaining indirectly by computation from measuring related magnitudes; obtaining indirectly by computation from related physics equations.
BRIEF DESCRIPTION OF THE DRAWINGS
[0069] An embodiment of the invention will be described below by way of non-limiting illustration in reference to a series of drawings to aid in understanding the invention.
[0070] FIG. 1 schematically shows the basic geometry of an axial compressor with several rows of blades.
[0071] FIG. 2 shows the block diagram corresponding to the device object of the invention.
[0072] FIG. 3 schematically shows a characteristic section of the row of blades to be monitored.
[0073] FIG. 4 shows the breakdown of the absolute velocity V into the axial velocity V x and the tangential velocity V θ .
[0074] FIG. 5 shows a possible diagram for implementing a measuring device at the outlet of a row of the axial compressor.
[0075] FIG. 6 illustrates a possible measuring process.
DETAILED DESCRIPTION OF AN EMBODIMENT
[0076] The present invention applies to axial compressors of one or several rows 100 of blades the basic geometry of which is schematically shown in FIG. 1 . The sole purpose of this figure is to illustrate the application of the device object of the invention, such that the compressor could have a different number of shafts, of rotors R or of stators S, or different relative positions with respect to one another, or different auxiliary mechanisms or elements. The figure shows several rows 100 of blades, some of them are stators S 1 , S 2 , . . . and others are rotors, R 1 , R 2 , . . . . There can also be different shafts for moving the rotors R. For example, FIG. 1 schematically shows two shafts, 103 and 104 , such that the depicted rotors R 1 and R 2 can have rotation operating conditions different from the rest. In the figure, each inlet or outlet of a row 100 of blades is referred to with the number of the row and a semicolon (;) followed by a letter I or O depending on whether it is, respectively, the inlet or the outlet of the row. In this embodiment, the outlet of the row j conveniently coincides with the inlet of the row j+1, such that it is verified that the properties of the fluid in the section j;O coincide with those of the section j+1;I, as is schematically shown in the figure. In addition, the stators S have no rotational velocity, whereas the rotors R have the rotational velocity imposed by the shaft which supports them. Thus, the tangential velocity of a blade of the row j imposed by the rotation shall generally be referred to as U j . Obviously, when the row j is a stator S, U j will be zero. The measuring devices at the inlet of the row j are referenced as 101 and the measuring devices at the outlet of the row j as 102 .
[0077] FIG. 2 depicts a diagram of the device object of the invention. Said figure shows, for any complete compressor, such as that of FIG. 1 for example, the measuring devices 101 and 102 in each row 100 of blades to be monitored. These measuring devices 101 and 102 , are distributed along the compressor such that they take information from the inlet and the outlet of each row 100 of blades. For each row 100 to be monitored, the computing device 201 computes, by means of Equation 1, its risk of instability index IR j . Subsequently, the value of each risk index computed is used in the control means 202 for supplying a control algorithm in charge of generating a control signal which ultimately changes the geometry, or the operating point of the compressor, of the machine or of the engine 203 . The control means 202 are any device acting on the compressor geometry, on the power the compressor receives, or on the air flow conditions managed both at the inlet and at the outlet.
[0078] The computing device 201 compares the risk index of each row 100 of blades with one. At this point, given that the condition IR j =1 is the stability limit, it is possible that in determined applications it is appropriate to introduce a possible safety factor in the computing device 201 such that correction starts by means of the control means 202 when the risk index drops to a value somewhat greater than one. For example, the safety factor can be established at IR j =1.05, such that there is a 5% margin of safety until the situation of imminent danger. Thus, the suitable decisions would be made before the imminent loss of compression and possible deviations due to errors in the measurement, averaging and estimation of parameters would be taken into account.
[0079] FIG. 3 schematically shows a characteristic section of the row 100 of blades to be monitored. The inlet measuring device 101 is seen before the blades 300 , whereas the outlet measuring device 102 is seen after it. An essential feature of the present invention is that the risk index depends on the absolute outlet velocity V j;O . This velocity is depicted in the figure along with the absolute inlet velocity V j;I and the translation velocity U j . The figure also shows the axial chord c x and the spacing 2πr/Z of the section taken as the characteristic section of the row 100 of blades which determine the axial solidity thereof.
[0080] In order to completely determine the characteristic vector V, it is necessary to know the modulus and the direction of the velocity. FIG. 4 shows the breakdown of the absolute velocity V into the axial velocity V x and the tangential velocity V θ . For such reason, the outlet measuring devices 102 must be capable of directly or indirectly measuring or estimating the absolute velocity of the gas at the outlet of the row 100 .
[0081] Four possible embodiments of the invention are described by way of example, and without intending to limit the scope.
Mode 1:
[0082] In this embodiment of the invention, schematically shown in FIG. 5 , the outlet measuring device 102 of the row j 100 is formed with a set of sensors 501 and a signal conditioning and processing device 502 . Generally, the number of sensors and their position will depend on the possibilities of the installation. As an example, FIG. 5 schematically shows a device with five measuring stations, 511 to 515 , which, in order to have better characterization of the fluid field at the outlet of the row 100 , can be alternatively distributed on the outer and inner casing of the compressor and angularly and equally spaced from one another. In turn, each measuring station 511 to 515 will be formed by a group of sensors the purpose of which will be to provide the information measured, 521 to 525 , necessary for elaborating the pressure, velocity and temperature data shown in Table 1 and which are necessary for computing the risk index by means of Equation 1. Thus, the signals present in the information measured, 521 to 525 , at the outlet of each group of sensors correspond with the time evolution of the magnitudes measured at each spatial position determined by the corresponding station.
[0083] The signal conditioning and processing device 502 is in charge of obtaining a time and spatial averaging from the information measured, 521 to 525 , by the set of sensors 501 . The time averaging can be carried out by means of applying a low pass filter to each sensor of the set of sensors 501 . This time averaging can be physical (for example, if the lengths of the ducts carrying the pressure signal to the piezoresistive sensor are large enough) or electronic (if a low pass filter is incorporated at the outlet of the piezoresistive sensor or of the thermocouple). These filtering devices, 531 to 535 , eliminate the rapid fluctuations in the measurement signal. The noise and high frequency time variations such as those induced by the passage of the blades in front of the sensors, are thus eliminated. The obtained low frequency signals, 541 to 545 , differ from one another in that they come from measuring stations, 511 to 515 , located in different spatial positions. The spatial filtering device 550 is arranged to establish a measurement which characterizes the entire outlet of the row 100 of blades. The spatial averaging can be done by taking the mean value of the obtained low frequency signals, 541 to 545 , coming from the time filtering. Thus, the resulting signal 551 at the outlet of the spatial filtering device 550 is the mean value of the obtained low frequency signals 541 to 545 . However, any other weighting of the obtained low frequency signals 541 to 545 could be taken to generate the outlet of the spatial filtering device 550 . In the same manner, all those devices in which the spatial averaging is performed first and then the time averaging is performed, or those in which both are performed at the same time, could also be examples of application.
[0084] The resulting set of signals 551 for each of the rows 100 of the compressor characterizes the operating point of the compressor in a stable and reliable manner. They are a set of signals necessary for elaborating the pressure, velocity and temperature data shown in Table 1 and which are necessary for computing the risk index by means of Equation 1. Thus, the resulting set of signals 551 will be received in the computing device 201 for the subsequent computation of the risk index of the row 100 of blades. Obviously, the computing device 201 also requires information from the measuring device 101 at the inlet of the row, the practical embodiment of which can be implemented in the same manner as has been herein described for the measuring device 102 at the outlet of the row.
Mode 2:
[0085] This embodiment is the same as mode 1 , but it specifies a manner of carrying out the measuring stations 511 to 515 of FIG. 5 . Thus, by way of example, FIG. 6 shows a possible implementation of each of these measuring stations 511 to 515 . Each of these stations, for example 511 , consists of a set of four sensors. The device consists of three pressure connections 601 , 602 and 603 which end in their respective pressure sensors and of a temperature sensor 604 . The three pressure connections, 601 to 603 , are oriented with respect to the stream of gas, such that the pressure connection 602 is oriented axially and pressure connection 603 tangentially. Connection 601 is oriented transverse to the movement of the gas for the purpose of acquiring the static pressure of the stream of gas. In turn, the temperature sensor 604 is configured to acquire the static temperature.
[0086] After the corresponding time filtering devices 531 to 535 and the spatial filtering device 550 , the resulting signals 551 can be used to supply the device object of the invention. For example, with the value of the static temperature present in the resulting set of signals 551 , the computing device 201 can obtain (for example, by means of interpolating the gas which is compressed in the corresponding thermodynamic tables) the static enthalpy h j;O and the ratio of specific heats γ j;O . Thus, from the measuring devices 101 and 102 and from the averaged pressure and enthalpy values, the computing device 201 can obtain the absolute axial and tangential velocities, applying to each shaft the following expression (or one of those obtained by the laws of fluid mechanics, or by the calibration laws of the velocity sensors that are used):
[0000]
(
V
x
)
j
;
O
=
2
h
j
;
O
[
(
P
(
602
)
P
(
601
)
)
γ
j
;
O
-
1
γ
j
;
O
-
1
]
(
Equation
2
)
(
V
θ
)
j
;
O
=
2
h
j
;
O
[
(
P
(
603
)
P
(
601
)
)
γ
j
;
O
-
1
γ
j
;
O
-
1
]
(
Equation
3
)
[0000] wherein P( 601 ), P( 602 ) and P( 603 ) are the time and space averages of the pressures measured by the pressure connections 601 , 602 and 603 , respectively. Subsequently, the set of velocity, static pressure and static enthalpy signals can be used to compute the risk index provided by Equation 1.
[0087] Obviously, this figure schematically shows the working of a possible velocity sensor, which can be replaced with more complex systems, such as commercial pitot tubes or hot wire or plate anemometers, among others, without limiting the scope of the invention.
Mode 3:
[0088] This working mode is the same as mode 2 , with the exception that the pressure connections 601 , 602 and 603 are replaced with hot wire anemometers.
Mode 4:
[0089] This working mode is the same as mode 1 , with the exception that the velocities, pressures and temperatures are computed by means of a numerical code of a solution of the fluid field. Thus, the measuring stations 511 to 515 are, rather than being a set of sensors, a numerical code of computation and the signals corresponding to the information measured 521 to 525 , the solutions provided by the numerical code of computation at determined points of the computational grid as a function of time.
[0090] It is finally concluded that the invention comprises a device which manages a risk index with the capacity to provide a real-time warning of whether or not the operating point of the compressor is stable, and in the event that it is, it is capable of reporting the margin of safety. This risk index can be used to stabilize the system (engine or machine in which the compressor is installed) by means of an active control device. It can also be used during the design for stabilizing by means of a process of optimizing the operating points of the system of turbomachinery. The process can be implemented in the control units of said systems, in hardware or software devices, in digital integrated circuits such as application specific integrated circuits (ASICs), field programmable gate arrays (FPGAs) and in the memory of microprocessors.
[0091] Its immediate industrial application is in all those sectors in which the safety of the operation is essential, as is the case of the aerospace field. Its implementation as part of the control system of machines equipped with axial compressors allows reducing operating and maintenance costs as well as increasing the reliability of compression systems.
[0092] Having clearly described the invention, it is hereby stated that the particular embodiments described above can be subject to modifications in detail provided that such modifications do not alter the fundamental principle and essence of the invention. | The present invention relates to a method and device for predicting the instability of an axial compressor, which is applicable to the aerospace and industrial field, specifically to the field of one- or multi-stage axial compressors. The invention relates to a method and a device for predicting the instability of an axial compressor which allows protecting said compressor from the instabilities of devices of this type. The present invention could be used in all those products requiring the use of said compressors, such as aircraft engines, turbofans, turboshafts, or turboprops in the aerospace field, gas turbines in the energy field, air conditioning systems in the civil field, and gas compression systems in the chemical or oil industry. | 5 |
[0001] The present invention discloses a method for the preparation of high purity 2-methyl-1,4-naphthoquinone (Menadione, 2 isomer) and its derivatives, in which the 6-methyl-1,4-naphthoquinone isomer (6 isomer) formed as a byproduct during the 2-methyl-naphthalene oxidation is extracted selectively as a bisulfite adduct. The bisulfite solution is then treated in a recovery step (involving a (3-cleavage reaction to form pure Menadione) which allows minimizing the Menadione losses due to the bisulfite solution treatment.
BACKGROUND OF THE INVENTION
[0002] Several processes for producing Menadione are known in the art.
[0003] One common technique is the oxidation of 2-methyl-naphthalene by using sodium dichromate in aqueous sulfuric acid solution. In this case, despite the low selectivity for, the 2-isomer, the high degree of destruction of the 6-isomer due to the added excess hexavalent chromium results in a final product containing a high content of Menadione. For example, the U.S. Pat. No. 3,751,437 discloses that although the reaction selectivity for the 2-methyl-1,4-naphthoquinone is not very high (50-53%), the final product is mainly composed of Menadione (94-97%), some unreacted 2-methyl-naphthalene (2-MNA) and small amounts of undefined impurities. The main drawbacks of this process are the very low selectivity of the reaction for the formation of the 2-methyl-1,4-naphthoquinone isomer, the need for excessive amounts of highly toxic hexavalent chromium as oxidizing agent and the creation of significant amounts of basic chromium sulfate as the reaction byproduct.
[0004] In order to resolve these problems related to the process described above, the use of other oxidizing agents has been proposed in the state of the art. However, in all the proposed alternatives using other oxidizing agents, the 6 isomer is present in the final product mixture at much higher ratios. For example, when hydrogen peroxide (in the presence of a methyltrioxorhenium catalyst) is used to oxidize 2-MNA, the final methyl-quinones are composed of 86% of 2 isomer and 14% of 6 isomer i.e. a ratio of 2 to 6 isomer of 7:1 (W. Adam, W. A. Herrmann J. Lin, C. R. Saha-Moeller, R. W. Fischer and J. D. G. Correia, <<Homogeneous catalytic oxidation of arenes and a new synthesis of vitamin K3, Angew. Chem. Int. Ed. Engl., 33, p. 2475-2477 (1994)). In another example, when 2-MNA is oxidized using ammonium persulfate (in the presence of catalytic amounts of cerium ammonium sulfate and silver nitrate), the ratio of the 2 to 6 isomer was around 3:1 (J. Skarzewski, <<Cerium catalyzed persulfate oxidation of polycyclic aromatic hydrocarbons to quinones, Tetrahedron, 40, p. 4997-5000 (1984)). The use of ceric sulfate as oxidant in an acetonitrile-sulfuric acid mixture also resulted in relatively high amounts of 6 isomer in the final product, i.e. 2 to 6 isomer ratio of 6.5:1 (IN 157224 A).
[0005] While the use of highly toxic hexavalent chromium as well as the creation of a considerable amount of the basic chromium sulfate is avoided in the methods of the state of the art cited above, the final reaction mixture contains significant amounts of the 6 isomer which is quite difficult to separate from the desired 2 isomer due to the similar properties of the two isomers. There are different proposals in the art to separate the two isomers. The most relevant strategies are:
Avoiding the creation of the 6 isomer by using a different raw material and a Diels-Alder reaction Separating the undesired 6 isomer by its selective transformation in methyl-anthraquinone Treating the final product mixture with an aqueous bisulfite solution to separate the 6 isomer
[0009] However, all of these strategies suffer from major disadvantages:
[0010] The U.S. Pat. No. 5,770,774 proposes to avoid making the 6-isomer by using 2-methyl-1,4-benzoquinone as raw material. This product is reacted with 1,3-butadiene in a Diels-Alder reaction to make 2-methyl-4-a,5,8,8a-tetrahydro-1,4-naphthoquinone, which is then oxidized to 2-methyl-1,4-naphthoquinone.
[0011] There are several problems associated with this procedure. For one, the raw material 2-methyl-1,4-benzoquinone is expensive and not readily available in large amounts. Furthermore, 1,3-butadiene is a highly toxic agent. Finally, the reaction presupposes the presence of a Lewis acid catalyst in order to proceed.
[0012] The U.S. Pat. No. 5,329,026 discloses the reaction of 6-methyl-1,4-naphthoquinone with 1,3-butadiene to make 1,4,4a,9a-tetrahydro-6-methylanthraquinone. The latter molecule can then be oxidized to the methyl-anthraquinone by adding sodium hydroxide and bubbling air as oxidation agent. The 2-methyl-1,4-naphthoquinone isomer hardly undergoes the same Diels-Alder reaction with the 1,3-butadiene due to the steric hindrance and difference in electron density.
[0013] In addition to the problems of the previous process (use of highly toxic 1,3-butadiene), there are further disadvantages associated with this process: it has to be conducted at high temperatures (ca. 120° C.) and high reaction pressure, thus necessitating the use of expensive apparatuses like autoclaves with a high energy consumption. Furthermore, the reaction time is very long (up to 4 hours).
[0014] The Japanese Application 60252445 A discloses the treatment of the final product mixture with an aqueous bisulfite solution to separate the 6-isomer. The organic solvent containing the starting and the final products of the 2-MNA oxidation reaction is first cooled down to precipitate part of the 2-MNQ formed during the oxidation. The remaining solvent phase is then treated with a bisulfite solution to extract most of the 6 isomer as well as part of the 2-isomer as bisulfite adduct that is soluble in the aqueous phase. Due to the fact that the 6-isomer reacts much faster than the 2-isomer, the remaining solvent phase presents a much higher ratio of 2- to 6-isomer. The organic phase is cooled down to obtain 2-MNQ crystals (94% purity). The solvent filtrate is treated in a selective bisulfitation step in which typically 25-30% of 2-MNQ is extracted in order to reach around 90% 6-MNQ extraction rates (this represents around 8 to 10% of the total 2-MNQ produced during the oxidation step). The aqueous solution containing bisulfite adducts of 2-MNQ and 6-MNQ becomes a waste.
[0015] The 2-MNQ crystals from the first crystallization are dissolved in the organic phase and recrystallized (around 65% precipitation yield). The 2-MNQ produced contains still on average 2% of the 6-MNQ isomer. The aqueous phase of the oxidation step is extracted in an extraction step using extra solvent that is then combined with the solvent from the second crystallization step. The obtained mixture needs to go through an additional step of solvent evaporation in order to concentrate the organic phase before its use in the next oxidation cycle. The overall process is presented in FIG. 1 .
[0016] There are various drawbacks associated with the process as described above.
[0017] Firstly, significant amounts of 2-MNQ (around 8% in first cycle of example 3 and around 10% overall assuming a yield of 2-MNQ crystals of 55% and the assumed 65% overall yield for a cerium sulfate process) are lost in the bisulfitation step and not recovered.
[0018] Second, the produced 2-MNQ is not of a very high purity after the first crystallization due to the fact that the selective bisulfitation is not carried out before this crystallization. The purity of 2-MNQ even after the second (final) crystallization is less than 98% due to the fact that 10% of the original 6-MNQ is still left in the solvent after the selective bisulfitation (a higher extraction rate results in excessively high 2-MNQ extraction and loss rates).
[0019] Third, an important part of the produced 2-MNQ is recycled back to the oxidation reactor (around 35% in the example 3) which may result in overoxidation and further losses of 2-MNQ.
[0020] Fourth, the organic phase of the extraction of the aqueous phase from the oxidation step is mixed with the filtrate from step 4 (after the second crystallization) and before it gets recycled it needs to be concentrated by evaporation. This adds additional steps and costs to the process.
[0021] Chengying et al later proposed an approach similar to the Japanese patent based on using 2-MNQ precipitation, followed by bisulfitation reaction and finally the re-dissolution of the precipitated 2-MNQ in the initial solvent phase to separate the 6 isomer from the 2 isomer (<<Process improvement on synthesis of 2-methyl-1,4-naphthoquinone, Song Chengying, Wang Liucheng, Zhao Jianhong and Xu Haisheng, Chemical Reaction Engineering and Technology, vol. 23, No. 4, August 2007). Contrary to the Japanese patent approach, the ratio of 2-MNQ to solvent proposed by these authors seems very low (a weight ratio of solvent to 2-MNQ of 4 compared to between 12 and 120 in the case of the Japanese patent). At this ratio, around 95% of the 2-MNQ formed will precipitate at the first crystallization step. However, this will be accompanied also by a high rate of 6-MNQ precipitation resulting in a low purity of the first 2-MNQ crystals. Therefore, despite high extraction rates of dissolved 6-MNQ at the bisulfitaion step, once the first 2-MNQ crystals are re-dissolved in the solvent phase after the selective bisulfiation step, the residual 6-MNQ in the final 2-MNQ obtained in the second crystallization step should be significantly higher than the 0.5% claimed by the authors resulting in a relatively low purity of final 2-MNQ product.
Problem Underlying the Invention
[0022] The technical problem to be solved is to devise a method for producing Menadione and Menadione derivatives which overcomes the disadvantages of the processes disclosed in the state of the art.
[0023] Specifically, the process to produce Menadione and Menadione derivatives shall avoid the use of aggressive oxidizing agents like hexavalent chromium, without compromising the purity of the Menadione or its derivatives.
[0024] Furthermore, the envisaged process shall avoid the application of high temperatures and pressures as well as toxic reagents.
[0025] Finally, the envisaged process shall achieve a selectivity, yield and purity that is at least comparable, if not better than what is currently known in the art.
DESCRIPTION OF THE INVENTION
[0026] The technical problem outlined above is surprisingly solved by a process to produce Menadione and its derivatives as disclosed in the claims.
[0027] Specifically, the method according to the invention is based on treating the organic phase from the oxidation step of 2-MNA with an aqueous solution of a bisulfite salt in such a manner that the 6-MNQ isomer is reacted with a higher selectivity than that of 2-MNQ. The organic phase after the selective bisulfitation step (SB), is then sent to another bisulfitation step in which most of the remaining 2-MNQ and 6-MNQ are extracted as bisulfite adducts in the aqueous bisulfite solution. The final organic phase containing very small residual amounts of 2-MNQ is enriched in 2-MNA and recycled back to the oxidation step. The aqueous phase from the SB step is then sent to a recovery step in which (if necessary) the interfering bisulfite ions are removed from the solution and the pH is increased to more than 8.5, more preferably to between 10 and 12 and most preferably between 11 and 12 in the presence of the organic phase (preferably from the non selective bisulfitation step). In an alternative embodiment, the increase in pH is carried out in the absence of a solvent and the precipitated 2-MNQ may then be recovered as a solid by a liquid-solid separation method such as filtration. The organic phase from the recovery step may be cooled down to precipitate very pure 2-MNQ solid that may be separated by any solid-liquid separation method. The obtained 2-MNQ presents a very high purity in terms of absence of the 6-MNQ isomer due to the fact that the bisulfite adduct of the 6-MNQ isomer hardly undergoes the β-cleavage reaction during the recovery step. The remaining organic phase may be sent to the non selective bisulfitation step to convert most of the residual 2-MNQ into 2-MNQ bisulfite adduct along with the solvent phase from the SB step and be recycled to the oxidation step as mentioned before. The bisulfite adduct of 2-MNQ contained in the aqueous phase from the non selective bisulfitation step may be precipitated by known methods (e.g. cooling, salt addition, solvent addition, etc) and dried to obtain the solid form of the bisulfite adduct of Menadione. Alternatively, it may be used to form other derivatives of vitamin K3 such as MNB, MPB, etc, at a high yield and high purity.
[0028] The residual amount of 2-MNQ contained in the spent oxidant solution after the 2-MNA oxidation step may be extracted using the solvent from the non selective bisulfitation step before its recycling to the oxidation step.
[0029] FIG. 2 shows the different steps involved in the method according to the invention.
[0030] The solid Menadione obtained from the recovery step preferably contains less than 0.5% w/w % of the 6-MNQ isomer, more preferably 0.2% and most preferably less than 0.1%, which is considerably less than the typical 2% content reported in the state of the art, e.g. the Japanese patent 60-252445. The preferred 2-MNQ recovery yields according to the invention are around 90%, more preferably 92% and most preferably 95%. Furthermore, with an extraction rate during SB step of preferably 30%, more preferably 28% and most preferably 25% of the 2-MNQ produced during the oxidation step, the total loss of 2-MNQ due to SB and recovery step combined would be around 1.5% to 3% which is again considerably lower than the 8% to 10% losses observed when selective bisulfitation is used without combination with the recovery step (e.g. Japanese patent 60-252445).
[0031] The 2-MNA oxidation step preferably takes place at a temperature in the range of 0 to 100° C., more preferably 25-60° C. and most preferably 25-40° C.
[0032] The 2-MNA oxidation step according to the invention can be executed using any suitable oxidizing agent known in the art. However, it may be preferred that said oxidizing agent is selected from the group consisting of a Ce(III)/Ce(IV) salt redox couple.
[0033] The selective bisulfitation step according to the invention may be carried out at a temperature in the range of 0-70° C., more preferably 10-50° C. and most preferably 25-40° C. Any bisulfite salt capable of dissolving in water may be used as a bisulfitation agent. However, it may be preferred that the bisulfite salt is selected from the group consisting of sodium or potassium bisulfite. Preferably, the bisulfite solution according to the invention has a concentration of 0.1 to 4 M, more preferably 0.5 to 2 M and most preferably 0.5 M.
[0034] The non-selective bisulfitation step according to the invention may be carried out at a temperature in the range of 0-70° C., more preferably 10-50° C. and most preferably 25-40° C. Any bisulfite salt may be used as a bisulfitation agent. However, it may be preferred that the bisulfite salt is selected from the group consisting of sodium or potassium bisulfite.
[0035] It has also been observed that the selectivity of the selective bisulfitation varies according to the agitation conditions. As the agitation is increased, a higher extraction yield of 6-MNQ may be obtained at a lower 2-MNQ extraction rate, which also minimizes the losses of 2-MNQ as it may be seen from examples 1 to 3. Thus, it may be preferred that the selective bisulfitation takes place under agitation. However, the agitation should not be too vigorous as to result in the formation of a stable emulsion between the organic phase and the aqueous bisulfite solution. The determination of the precise agitation conditions is within the routine capability of the skilled person.
[0036] Also the other derivatives of vitamin K3 produced from the current proposed method show an important improvement in the quality of the final product. For example, MNB produced using the proposed process contains no detectable amounts of the 6 isomer derivative, whereas without the SB step, the final MNB contains typically between 0.1% and 1% of the 6 isomer derivative. Also, the application of this approach allows maximizing the precipitation yield of the vitamin K3 derivatives, as the very low concentration of the 6 isomer bisulfite adduct allows maximizing the precipitation rate of the 2 isomer adduct or its derivatives without provoking the precipitation of the 6 isomer adduct derivatives which would result in a less pure vitamin K3 derivative.
[0037] The present invention contemplates the production of Menadione and its derivatives. It may be especially preferred that said derivatives are selected from the group consisting of Menadione bisulfite adducts that may be isolated as organic salts containing an inorganic cation such as sodium (MSB) or potassium or an organic cation as protonated forms of compounds such as Nicotinamide (MNB), dimethylPyrimidinol (MPB), p-Amino-Benzoic acid, etc.
[0038] In summary, the present invention has several advantages compared to the prior art:
In comparison to the methods according to the state of the art, the use of oxidizing agents other than hexavalent chromium or an excess amount of it becomes possible without compromising the purity of the vitamin K3 or its derivatives produced. In comparison to the methods in the art which propose the use of Diels-Alder reactions, the application of high temperatures, high pressures and highly toxic reagents is avoided. Specifically in comparison with the approach according to the Japanese patent 60-252445, the following improvements have been achieved:
The total loss of 2-MNQ due to the combined SB-Recovery steps is between 1.5% and 3%, compared to 8% to 10% for the Japanese patent. The residual concentration of the 6-MNQ isomer in the isolated 2-MNQ solid is less than 0.2% compared to the typical average of 2% reported in the Japanese patent. The use of higher agitation conditions also results in improved selectivities. The need for the evaporation step of the combined organic phases of the extraction of the aqueous phase (from the oxidation step) and the filtrate from crystallization step is avoided by doing a second bisulfitation and by using the final organic phase for the extraction of the aqueous phase of the oxidation step. A very small fraction of the formed 2-MNQ is recycled back to the oxidation step which minimizes additional losses due to overoxidation of already formed 2-MNQ (less than 2% of 2-MNQ is sent back to oxidation step compared to up to 30% in the Japanese patent).
[0047] The process according to the invention will be further explained in the following, non-limiting examples.
Example 1
[0048] 380 ml of a sodium bisulfite solution having a bisulfite concentration of 0.5 M were transferred to a 2 liter reactor containing 1580 ml of a water immiscible aliphatic solvent containing 0.0214 M of 2-MNQ and 0.0042 M of 6-MNQ. The reactor was equipped with a conventional 4 blade propeller and the agitation speed was set to 400 rpm. Samples of the organic phase were taken and analyzed by GC to determine the residual concentration of the 2 and 6 MNQ isomers. The results are presented in table 1 below:
[0000]
TABLE 1
2-MNQ to
% of 2 isomer in
Bisulfitation
Extracted
Extracted
6-MNQ
the total methyl-
Time
2-MNQ in
2-MNQ
6-MNQ in
6-MNQ
ratio in
1,4-naphthoquinone
(sec)
solvent (M)
fraction
solvent (M)
fraction
solvent
in solvent
0
0.0214
0%
0.0042
0%
5.1
84%
60
0.0213
1%
0.0035
16%
6.0
86%
120
0.0211
2%
0.0029
31%
7.2
88%
180
0.0195
9%
0.0023
45%
8.4
89%
300
0.0188
12%
0.0017
59%
10.8
92%
660
0.0164
24%
0.0009
79%
18.6
95%
900
0.0150
30%
0.0007
85%
23.0
96%
1800
0.0119
45%
0.0004
90%
29.3
97%
[0049] As it may be seen, after 30 minutes of reaction, the 2 to 6 isomer ratio in the organic phase has increased from the original value of 5,1 to more than 29 (around 97% of the 1,4-methyl-naphthoquinone in the solvent is the 2 isomer).
Example 2
[0050] 400 ml of a sodium bisulfite solution having a bisulfite concentration of 0.5 M were transferred to a 2 liter reactor containing 1600 ml of a water immiscible aliphatic solvent containing 0.0247 M of 2-MNQ and 0.0052 M of 6-MNQ. The reactor was equipped with a conventional 4 blade propeller. In order to improve the agitation conditions compared to those used in the prior example, two baffles were installed in the reactor and the agitation speed was set to 500 rpm. Samples of the organic phase were taken and analyzed by GC to determine the residual concentration of the 2 and 6 MNQ isomers. The results are presented in table 2 below:
[0000]
TABLE 2
2-MNQ to
% of 2 isomer in
Bisulfitation
Extracted
Extracted
6-MNQ
the total methyl-
Time
2-MNQ in
2-MNQ
6-MNQ in
6-MNQ
ratio in
1,4-naphthoquinone
(sec)
solvent (M)
fraction
solvent (M)
fraction
solvent
in solvent
0
0.0247
0%
0.0052
0%
4.8
83%
120
0.0235
5%
0.0039
25%
6.1
86%
300
0.0220
11%
0.0024
53%
9.0
90%
600
0.0199
20%
0.0010
81%
20.2
95%
780
0.0184
26%
0.0007
87%
28.2
97%
1080
0.0158
36%
0.0004
92%
38.8
97%
1200
0.0145
41%
0.0004
93%
39.1
98%
1500
0.0135
45%
0.0004
93%
38.0
97%
1800
0.0115
53%
0.0003
93%
33.8
97%
[0051] It may be seen that the more vigorous agitation results in a better selectivity for 6 isomer extraction. In fact compared to example 1, to reach an organic phase containing 97% of the 2 isomer, only 26% of the 2-MNQ contained in the original solvent was extracted (compared to around 45% for the agitation conditions of example 1). Also the higher agitation allows to reach the 97% content in the solvent in a much shorter time (13 minutes compared to 30 minutes in example 1). It is also important to see that the residence time has also an effect on the selectivity since after certain period, the purity does not improve but the fraction of extracted 2- MNQ increases.
Example 3
[0052] 750 ml of a sodium bisulfite solution having a bisulfite concentration of 0.5 M were transferred to a 4 liter reactor containing 3000 ml of a water immiscible aliphatic solvent containing 0.0229 M of 2-MNQ and 0.0042 M of 6-MNQ. The reactor was equipped with a Silverstone propeller instead of the conventional agitation propellers used in examples 1 and 2. The agitation speed was 3400 rpm. Samples of the organic phase were taken and analyzed by GC to determine the residual concentration of the 2 and 6 MNQ isomers. The results are presented in table 3 below:
[0000]
TABLE 3
2-MNQ to
% of 2 isomer in
Bisulfitation
Extracted
Extracted
6-MNQ
the total methyl-
Time
2-MNQ in
2-MNQ
6-MNQ in
6-MNQ
ratio in
1,4-naphthoquinone
(sec)
solvent (M)
fraction
solvent (M)
fraction
solvent
in solvent
0
0.0229
0%
0.0042
0%
5.5
85%
60
0.0220
4%
0.0030
28%
7.3
88%
180
0.0211
8%
0.0024
43%
8.9
90%
300
0.0205
10%
0.0016
62%
12.9
93%
420
0.0191
16%
0.0010
77%
19.9
95%
540
0.0184
19%
0.0007
82%
25.1
96%
600
0.0182
20%
0.0006
84%
28.2
97%
720
0.0177
23%
0.0005
88%
34.3
97%
[0053] It may be seen that the more vigorous agitation results in even higher selectivity for 6 isomer extraction. In fact compared to example 1 to reach an organic phase containing 97% of the 2 isomer, only 20% of the 2-MNQ contained in the original solvent was extracted (conpared to around 45% for the agitation conditions of example 1 and 26% for example 2). Also the higher agitation again allows to reach the 97% content in the solvent in a much shorter time (10 minutes compared to 30 minutes in example 1 and 13 minutes for example 2).
Example 4
[0054] An organic phase containing 430 parts of 2-MNA, 65 parts of 2-MNQ and 14 parts of 6-MNQ was oxidized in a continuous mode by a ceric and cerous methanesulfonate aqueous mixture. The organic phase at the oxidation step outlet contained 17 parts of 2-MNA, 275 parts of 2-MNQ and 56 parts of 6-MNQ. The organic phase was then put in contact with a sodium bisulfite solution to form the bisulfite adduct of both isomers. The organic phase at the bisulfitation reactor outlet contained 28 parts of 2-MNQ and 4 parts of 6-MNQ representing 90% and 94% of extraction during bisulfitation for the 2 and 6 isomers, respectively. The analysis of the final aqueous phase showed a concentration of 0.92 M for the 2-MSB and 0.19 M for the 6-MSB adducts. The aqueous phase was then mixed in equimolar ratio with a solution of nicotinamide in water and then concentrated sulfuric acid was added gradually over a period of 150 minutes. Starting from the end of the sulfuric acid addition, samples of the solid MNB were taken from the suspension and washed with water and analyzed for the presence of the 6 isomer of the Methyl-naphthoquinone Nicotinamide Bisulfite (6-MNB). As it may be seen from table 4 below, the concentration of the 6-MNB starts to increase after 4 hours of elapsed time between the end of acid addition and the solid filtration to reach up to 0.72% and even 2.74% after 5 hours.
[0000]
TABLE 4
Waiting time before
6-MNB in final
filtration (min.)
MNB solid (%)
5
0.13%
65
0.20%
125
0.16%
185
0.18%
245
1.15%
305
2.74%
Example 5
[0055] 2-MNA was oxidized in the same manner as described in example 4. However, in this case the organic phase was reacted continuously with an aqueous solution of sodium bisulfite in a selective bisulfitation reactor in which the residence time and agitation conditions were set so that 78-79% of the 6-MNQ and only 25-28% of the 2-MNQ were extracted from the organic phase as their bisulfite adduct. Once the concentration of residual sodium bisulfite reached 0.5 M, fresh concentrated sodium bisulfite solution was added to the selective bisulfitation and equivalent volumes of the aqueous phase were removed from the reactor so that the concentration of all species in the aqueous phase remained practically constant. Table 5 below shows the concentration of adducts of the 2 and 6 isomers in the removed aqueous phase.
[0000]
TABLE 5
Component
2-MSB (M)
6-MSB (M)
Concentration
0.833
0.315
[0056] During the continuous operation of the selective bisulfitation reactor, 4 samples of the organic phase were taken and reacted with the same sodium bisulfite solution in a consecutive way in order to increase the concentration of the residual 2-MSB and therefore mimic a continuous bisulfitation reaction. The results in terms of 2-MNQ and 6-MNQ concentrations in the initial and final solvent phase as well as the concentration of the 2-MSB and 6-MSB in the aqueous bisulfite solution are presented in table 6 below.
[0000]
TABLE 6
2-MNQ in
6-MNQ in
2-MNQ in
6-MNQ in
Bisulfitation
initial
initial
final
final
2-MSB
6-MSB
cycle
solvent (M)
solvent (M)
solvent (M)
solvent (M)
(M)
(M)
1
0.0149
0.0006
0.0001
0.0000
0.232
0.0008
2
0.0054
0.0005
0.0006
0.0000
0.3398
0.0018
3
0.0054
0.0005
0.0021
0.0000
0.4084
0.0023
4
0.0054
0.0005
0.0010
0.0000
0.499
0.0024
[0057] 100 parts of the final aqueous bisulfite solution containing 0.499 M of 2-MSB and 0.0024 M of 6-MSB were then used to prepare MNB by addition of an aqueous solution containing 15 parts of water and 6 parts of nicotinamide. 4.13 parts of sulfuric acid 93% were added gradually to the mixture over a period of 30 minutes. After a waiting period of 60 minutes, the precipitated MNB was filtered and washed with water and the solid MNB was then dried and analyzed for the presence of 6-MNB impurity. The concentration of the residual 2-MSB reached 0.07 M corresponding to 83% of precipitation efficiency. In another experiment, the MNB precipitation was performed with the same amounts of the same products, but the solid precipitated MNB was filtered after 5 hours of waiting and then washed, dried and analyzed for the presence of 6-MNB. The residual concentration of 2-MSB after 5 hours was at 0.06 M corresponding to more than 85% of MNB precipitation. The composition of the solid MNB samples obtained after 1 and 5 hours are presented in table 7 below.
[0000]
TABLE 7
Waiting time before
6-MNB in final
filtration (min.)
MNB solid (%)
60
<0.001%
300
0.012%
[0058] Compared to the results presented in example 4, it may be seen that even after 5 hours of waiting period before filtration, the amount of 6-MNB is more than 140 times less (0.012% compared to 2.74% in example 4).
[0059] The aqueous phase from the selective bisulfitation step was treated in a recovery step in which the aqueous phase is treated with an alkali reagent (in this case NaOH 10%) to increase the solution pH (in this case 11) in the presence of an organic solvent in order to recover the 2-MSB adduct as 2-MNQ and minimize the losses of vitamin K3 due to the selective bisulfitation step. The experiment was carried out four times to mimic a continuous recovery step and to produce enough organic phase volume for the next step in which the obtained 2-MNQ was transformed in its bisulfite adduct. As it may be seen in table 8 below, in all the recovery experiments, the amount of 6-MNQ in the solvent was very small representing in average around 6% of the total methyl-naphthoquinones in the final organic phase.
[0000]
TABLE 8
2-MSB in
6-MSB in
2-MNQ
initial
initial
2-MNQ in
6-MNQ in
2-MNQ in
6-MNQ in
MSB
MSB to
recovery
aqueous
aqueous
initial
initial
final
final
Extraction
2-MNQ
experiment
phase (M)
phase (M)
solvent (M)
solvent (M)
solvent (M)
solvent (M)
yield
yield*
1
0.1524
0.0756
0.0001
<0.0001
0.0127
0.0014
90%
92%
2
0.1423
0.0529
0.0006
<0.0001
0.0273
0.0015
84%
89%
3
0.1423
0.0141
0.0006
<0.0001
0.0302
0.0015
91%
92%
4
0.1445
0.0563
0.0015
0.0004
0.0322
0.0016
93%
92%
*based on converted MSB
[0060] The organic phase from the 2-MNQ recovery experiments were then made to react with a sodium bisulfite solution to transform the 2-MNQ into its water soluble bisulfite adduct (2-MSB). The same bisulfite solution was used repeatedly to mimic a continuous bisulfitation reaction and in order to reach a high 2-MSB concentration. The amount of the bisulfite adduct of the 6 isomer (6-MSB) was at a non detectable limit (see table 9 below).
[0000]
TABLE 9
2-MNQ in
6-MNQ in
2-MNQ in
6-MNQ in
Bisulfitation
initial
initial
final
final
2-MSB
6-MSB
cycle
solvent (M)
solvent (M)
solvent (M)
solvent (M)
(M)
(M)
1
0.0127
0.0014
0.0001
0.0000
0.143
Nd
2
0.0290
0.0014
0.0009
0.0004
0.532
Nd
3
0.0320
0.0016
0.0014
0.0009
0.749
Nd
[0061] The obtained aqueous solution of 2-MSB was then used to produce MNB. 75 parts of the final aqueous bisulfite solution containing 0.749 M of 2-MSB and <0.0001M of 6-MSB was then used to prepare MNB by addition of an aqueous solution containing 17 parts of water and 6.8 parts of nicotinamide. 4.64 parts of sulfuric acid 93% was added gradually to the mixture over a period of 30 minutes. After a waiting period of 300 minutes, the precipitated MNB was filtered and washed with water and the solid MNB was then dried and analyzed for the presence of 6-MNB impurity. No detectable amount of 6-MNB was found in the precipitated MNB. The concentration of the residual 2-MSB reached 0.055 M corresponding to around 92% of precipitation efficiency.
Example 6
[0062] An aqueous 0.08 M sodium bisulfite solution containing 0.1524 M of 2-MSB and 0.0284 M of 6-MSB was treated with 10% NaOH solution in the presence of an organic solvent. The final organic phase was then separated, cooled to −15° C. during 12 hours and filtered to separate the precipitated 2-MNQ solid. The experiment was repeated 4 times and the results are presented in table 10 below:
[0000]
TABLE 10
Recovery
2-MSB
6-MSB
and
initial
initial
2-MNQ
6-MNQ
2-MNQ
6-MNQ
2-MNQ
2-M
recipitation
aqueous
aqueous
initial
initial
final
final
in
precipi
experiment
phase (M)
phase (M)
solvent (M)
solvent (M)
solvent (M)
solvent (M)
solvent*
yiel
1
0.1524
0.0284
0.0019
0.00035
0.03239
0.00127
0.014743
54.5
2
0.1524
0.0284
0.0019
0.00035
0.03243
0.00127
0.014329
55.8
3
0.1524
0.0284
0.0019
0.00035
0.03401
0.00133
0.013886
59.2
4
0.1524
0.0284
0.0019
0.00035
0.03484
0.00121
0.013309
61.8
*After cooling at −15° C. during 12 hours
indicates data missing or illegible when filed
[0063] The average precipitation yield was around 58%. The solids obtained were combined and dried under vacuum at around 34 kPa (−20inch Hg) in the presence of P 2 O 5 during 72 hours. The final dry solid sowed a 2-MNQ content of more than 98,5% and less than 0,13% of 6-MNQ. | The present invention discloses a process for the production of 2-methyl-1,4-naphthoquinone and its bisulfite adducts, comprising the following steps: a) oxidizing 2-methyl-naphthalene (2-MNA) to achieve an organic phase containing 2-methyl-naphthoquinone (2-MNQ) and 6-methyl-naphthoquinone (6-MNQ); b) subjecting said organic phase to treatment with an aqueous solution of a bisulfite salt to extract preferentially the 6-MNQ isomer from the organic phase; c) separating said organic phase from the aqueous phase; d) subjecting the organic phase of process step c) to a second bisulfitation step with an aqueous solution of a bisulfite salt, resulting in an organic phase containing 2-MNA and trace amounts of 2-MNQ and an aqueous phase containing 2-MSB and trace amounts of 6-MSB; e) optionally removing interfering bisulfite ions from the aqueous phase of process step c); f) raising the pH of the aqueous phase from step c) or e) to higher than 8.5 in the presence of a solvent resulting in an organic phase containing 2-MNQ; g) combining the organic phase from step f) with the organic phase being treated in the process step d); h) recycling the organic phase from step d) back to step a) to be used as solvent for the oxidation reaction of 2-MNA. | 2 |
CROSS REFERENCE TO RELATED APPLICATION
This application is a national phase of PCT/FR99/01402 which was filed on Jun. 14, 1999 and was published by the International Bureau in English on Dec. 23, 1999.
FIELD OF THE INVENTION
The invention relates to a method of searching for images, each one of which has been recorded in a data base in the form of a structured information index and in a way that favors a subsequent search for a specified element in the images of this data base.
A simple technique used to search for a specified detail in an image consists of consulting a catalogue that describes the image using text or using key words, but the drawing up of the catalogue takes time and it is not possible to guarantee that the images will be described with objectivity and that the details in which one will be interested in the future will be perceived at the time. Finally, the description will not generally be precise enough since the details will generally be identified by their category (building, vehicle, individual person, etc.) while in general a particular individual item will be asked for from this category, which will require examination of all the images in which this category of elements is present.
Another solution consists of looking for an object by describing its outline shape and its texture and looking for this in the data bank of images. It is then necessary to extract the corresponding information on digital modeling of the images broken down into points. Unfortunately, no extraction method exists for the outline or texture of an object which is effective in all cases, and these methods result in failure when the objects are partially masked or when they are illuminated to different extents in the sample provided for the search and in the image in which this sample must be discovered.
Another method consists of comparing the sample provided with each of the parts of each of the images, the comparison resting on the tints of the points of the sample and the points of the images. However, this method is impractical for a search that is at all large.
A final category of methods, to which the invention belongs, consists of modeling the images by means of an index that represents characteristics of the image. The sample to be looked for will be modeled in the same way in order to give an index in analog form and the comparison will rest on the indices. If a comparison is judged to be positive, the corresponding image will be extracted and examined.
Recently there has been much interest in the compression of images using their fractal properties, in order to provide indices which occupy little memory space while permitting subsequent reconstruction of an image of satisfactory quality; these indices can, as will be seen, be used in the invention for comparisons leading to the search for samples provided that certain precautions are taken when they are drawn up.
A fractal object has the property of being identical to its parts: if a fragment of it is isolated and enlarged, it is found to be identical to the initial object. The image of a fractal object can be obtained by applying certain geometrical transformations repeatedly to a starting image, which is then deformed to converge towards the image of the fractal object that is called the attractor of the geometric transformation. The starting image can be chosen in any fashion whatsoever.
Normal images are not fractal images, but it is nevertheless possible to find quite simple geometrical transformations for which these images are attractors. The image can then be reconstituted by simply knowing an index that expresses these geometric transformations and applying these transformations several times to any starting image whatsoever: it is then enough to simply record the index in the data base, without it being necessary to record the image itself in digital form, which would take up much more space.
In practice, the geometric transformations are determined by dividing the image into sectors or ranges and making a domain of the same image, that is to say another part of the image, correspond to each of these ranges. In practice, this other part of the image has a greater surface area since suitable geometric transformations should contract or shrink the details on which they act. The correlations by which the ranges and the domains are made to relate to one another are chosen so that the domains resemble the ranges with which they are associated, that is to say that they have a similar appearance once they have possibly had certain modifications made to them, modifications of luminosity, contrast and color, or modifications of shape through rotation or through symmetry.
It is essential that the indices of the images and the samples in these images to be looked for, are at least partially composed in the same way, that is to say that homologous ranges are related to homologous domains, so that they are comparable. With regard to this, an important risk is linked to the sizes of the image and the sample which are often very different the domains and ranges that are made to correspond in the sample through a fractal transform are generally close to one another, while in a large size image they can be much further apart; corresponding ranges of the sample and the image will then be associated with different domains, that of the index and the image being outside the sample if precautions have not been taken.
It is not then possible for corresponding parts of the sample and image indices to be identical, and the search will be unfruitful if this circumstance occurs too often. With regard to this, one should make it clear that the domains associated with one and the same range by the indices of the sample and the image are chosen arbitrarily in most of the known methods, which means that these domains are generally different in any case and that the presence of the sample in the image should be taken as being probable if just a few fragments of their indices are identical. However the disadvantages of this situation are much more accentuated if the problem indicated above has not been resolved.
French patent application No. 96.11751 of the Sep. 26, 1996 provides one solution: a decision is made to limit the distance between each of the ranges of the images and the domains which are respectively associated with them through the index. This enables one to associate a specified range with identical domains of the image and of the sample with greater probability. The risks of an unfruitful comparison of the indices when the sample is indeed present in the image being examined are thereby reduced.
However, other risks of failing to make a comparison are not avoided by proceeding in this way: since the geometric transformations are normally defined by Cartesian co-ordinates which express the distance between the ranges and the domains related to them, the comparison will not be possible if the sample and the image are viewed from different angles and therefore have different co-ordinate axes. It is also necessary to ensure that the division of the sample and the image into domains and ranges are comparable without dividing up the image or the sample in too arbitrary a fashion, that is to say by avoiding splitting the essential details or by associating very different portions of elements inside one and the same domain or one and the same range.
BRIEF DESCRIPTION OF THE INVENTION
The invention has been designed to remedy these difficulties. It consists of combining certain techniques of the art of modeling images—some of which are known individually—with a method of composing the index, the idea of which resembles that of the previous application but which is less arbitrary and more methodical, so as to construct the indices in a substantially invariant fashion, that is to say independent of any interference which could affect the image. Hence, the indices of the sample to be looked for and the images in which it is present will resemble one another even if the images have been subject to noise and if the sample does not appear in the same way.
Noise, defects and interference of the images exert an influence that is just as great on the indices based on properties other than the fractals. The objective of the invention is to be free from this influence to a large degree by making the indices invariant or independent of slight interference which can affect the images and compromise the comparisons.
Instead of the divisions of the image being arbitrary and regular, as is the case in numerous methods where the image is divided into similar rectangles, the divisions are defined by points of interest which correspond to places where the images have properties which vary greatly and which, in practice, are generally positioned at the angles of details represented on the image. Hence these divisions better follow the outlines of the details and the properties extracted from their contents will be more homogeneous, which will allow them to be better defined and hence better compared with less uncertainty. Furthermore, by ensuring that the index is constructed either with the contents of the portion being considered or with that of neighboring portions, that is to say defined portions, an important arbitrary element in the construction of the indices is removed since it will no longer be possible to choose the domains and the ranges made to correspond by a fractal transform, which is beneficial to the quality of the image to be reconstructed but harms the comparisons.
However, this will not allow one to obtain an invariance of the indices since the points of interest, which are the basis for the non-uniform division of the image, are still sensitive to noise or other photographic conditions of the kind which cannot be avoided since they depend on the circumstances under which each image was created. The image divisions will be modified as a consequence and the invariance of the indices will therefore be affected. However, it will be seen that this harmful effect will be considerably attenuated if the intersections of the link lines are used as possible vertices of the polygons forming the portions of the image and if these polygons can partially or totally cover one another, encroaching one upon the other, something that is not retained in the usual methods where the indices are not used for the purposes of making comparisons but only to reconstruct the images.
The index itself can express fractal properties of the image. In this case, it conforms to the invention when the index expresses the relating of different portions of the image having comparable appearances, the different portions comprising the divisions of the image and sub-divisions of the image obtained by dividing up the divisions, each of the sub-divisions being related in the index with each of the divisions adjacent to the division which contains said sub-division, said adjacent divisions constituting said neighboring portions.
However, it can also express properties intrinsic to the portions of the image themselves. It is then proposed to express them in the index in the form of mathematical moments which permit the quantifying of these properties and contribute to ensuring the invariance of the indices. These moments are preferably sums, over each of the image portions, of terms calculated for each point of said image portion which are proportional to a parameter expressing one aspect of the point and to a power determined for a barycentric co-ordinate of the said point.
The barycentric co-ordinates can further be employed to calculate types of index other than mathematical moments, for example the Fourier transforms; their advantage is that they are linked to the shape of portions from division of the image, and therefore they stem indirectly from the points of interest and from the elements of the image, but not from either the orientation or the position of the elements in the image.
These aims, features and advantages of the invention as well as others, will be better be understood from the commentary to the Figures which follows and which is used to reveal the technical context and a particular embodiment of it
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view of an image sub-divided into ranges;
FIG. 2 is a view of the same image divided into domains;
FIG. 3 is a graph symbolizing a fractal transformation index;
FIG. 4 is a view of a sub-division or division mesh of another image;
FIG. 5 illustrates a perfecting of the mesh creation technique;
FIG. 6 is a diagram of a part of a mesh that explains a fundamental element of the invention;
FIG. 7 is analogous to FIG. 6 and illustrates another aspect of the invention,
FIGS. 8A and 8B help to grasp the consequences of the instability of mesh points of the image,
and FIGS. 9A and 9B help to explain how these consequences are reduced with the invention.
DETAILED DESCRIPTION
The general principles for compression of an image by an index expressing its fractal properties will be recalled: FIG. 1 represents an image, formed here from a mosaic of two colors with appearing on it a division into square ranges, numbered here in accordance with the horizontal rows from R 0 to R 63 , by a grid. FIG. 2 represents a division of the same image into sixteen domains, numbered in the same way from D 0 to D 15 each one of which has the surface area of four ranges and like them a square shape.
This image of simple shape enables one easily to relate domains with ranges. Hence ranges R 0 , R 1 , R 4 , R 5 , etc. entirely white have a physiognomy identical to a domain that is entirely white such as D 0 (or D 3 or D 14 for example); the entirely black ranges such as R 2 and R 3 could be related to an entirely black domain such as D 1 or D 13 , but one could also relate them to relationship with the domain D 0 , which has the same appearance with a change of luminosity; the ranges such as R 18 and R 27 split into black and white along a diagonal will be related to the domain D 5 with the same appearance; R 35 , R 42 , R 49 and R 56 with D 9 for the same reason; the range R 12 will be related to the domain D 11 which has the same appearance with a rotation of a quarter of a turn. One is content with imperfect similarities between domain and range in order to establish these relationships in practical situations.
This set of correspondence relationships can take the form of a graph, a part of which is given in FIG. 3 . The application of the fractal transformation defined by the index consists, in concrete terms and starting with any starting image whatsoever that has been divided and sub-divided into sixteen domains and sixty four ranges, of constructing a new image in which, for each of the ranges one transfers, for each of the ranges, the content of the domain of the starting image which is associated with it by the graph and the index after having applied to it the required change of scale and possibly the modifications in luminosity, orientation etc. contained in the index. By repeating these operations, there is convergence towards the image in FIG. 1 whatever the starting image might be.
The transformations of a fractal kind which make up the index are therefore given by equation (1):
Wi=(γ i x i y i tx i ty i s i o i ). In reality, one is concerned with writing a transformation W i in vector form, where γ i is an index designating an isometry from among a list previously drawn up, in order to pass from the domain to the associated range, such as a rotation, a reflection, a symmetry or a modification of scale; x i and y i are the position co-ordinates of the domain; tx i and ty i are the translation co-ordinates to pass from the domain to the associated range; and s i and o i are coefficients of contrast and luminosity which enable one to modify the levels of grayness in the domain to obtain those levels of the associated range. The coefficient of contrast s i permits one to regulate the difference in the levels of grayness of the points of a range by modifying the equivalent difference among the points of the domain which is associated with it, and the coefficient of luminosity o i allows one to lighten or darken the range in relation to the domain.
We will now begin an actual method of creating the mesh for the division of the image. The mesh of the preceding figure was regular and depended on the dimensions and the orientation of the edges of the image without either the position or the size of the details of the image being considered. If an object present in this image was moved, turned or represented on a different scale, it would therefore be divided in another way. As such differences of position and orientation of contents are inevitable between an image and a sample to be rediscovered, the boundaries of the ranges and domains would not coincide on the two representations of the object, and the indices to be compared would not be constructed in the same way. This is why it is proposed to replace such a mesh which is regular and depends on the edges of the image by an irregular mesh drawn up in relation to the content of the image. The development of the mesh then comprises two essential steps.
1) Firstly, mesh nodes, also called sites, are created, that is to say junction points of the lines dividing up the image. The mesh nodes will, in practice, be points of interest in the image, which various known processes enable one to detect. Each point of the image is characterized by exploiting notions of differential geometry such as measurements of gradient or of curvature, or 1 st or 2 nd order derivatives in several directions. Heuristics expressed from these values then enable one to classify each point. One digital detector is the Harris detector which is based on the calculation of the Hessian matrix H, produced from the image and convoluted with a Gaussian. The criterion for selection of the points of interest is based on the local maximums from the formula: det(H)−k.Trace 2 (H), with det(H)=determinant of H, k=constant and Trace 2 (H)=square of the trace of H. Although one can imagine several ways of proceeding, one may consider the recognition of areas or patches of different colors on the image and position the nodes at the angles of the lines of separation between these patches and at the intersections of these lines with the edge of the image. An example is shown in FIG. 4, where four patches C 1 to C 4 are apparent, and the nodes are at the points of concurrence of the triangles (some have been given the reference N). It can be seen that the mesh is completely irregular, that is to say that the nodes are positioned at distances which are very different. It is recommended that the parts of the image which have too much texture are obliterated, that is to say the parts which have repeated variations in color over a small surface area, such as the detail C 5 which has been removed from C 3 . Such areas are provided, for example, by grass, the sea or brick walls.
2) Next the divisions of the image are constructed from the nodes. These are polygons, the nodes of which are the vertices. A simple way of dividing has been proposed by Delaunay and is shown in FIG. 4 : the polygons are all triangles. Here again, software enables one to construct a network of triangles from a network of nodes. It is obvious that other ways of proceeding are possible: one may proceed with different polygons and all the polygons might not have the same number of vertices.
This latter characteristic can arise from a process for correcting the mesh: adjacent polygons which comprise homogeneous regions or almost homogeneous regions of the image can be fused into a single region, which then has a greater number of sides, so as to simplify the mesh.
The fusing of polygons enables one to reduce the size of the index of the image by fusing together polygons having visual -characteristics that are close (having similar indices or characteristics). The resulting polygon will be considered to incorporate an area of intermediate appearance.
Reference may be made to FIG. 5 for a specific explanation of a polygon fusion process and its consequences.
A polygon forming a range R of the modeled image, here a quadrilateral, is, in reality made up of three image parts with different levels of grayness which come together at a point P; the range R is seen to have a mean level of grayness, which is not very satisfactory since the image becomes blurred and the potential point of interest p has disappeared. This is why the simplified mesh at range R would be advantageously associated with a finer mesh, obtained before fusion in which the range R would be replaced by smaller polygons P′ 1 , P′ 2 , P′ 3 and P′ 4 which sub-divide it and accepts one side of the range R as a side and the point p as a vertex; here one is concerned with triangles each of which coincides with the range R on just one side and has two other sides leading to the point p. One could also, among other possibilities, model a quadrilateral in place of the two triangles P′ 3 and P′ 4 which are situated on the same portion of the range R.
It would also be possible to intervene in the opposite way, by detailing or dividing up more finely the mesh obtained originally: taking the diagram in FIG. 5, the mesh at range R would first be created and then the division of this range R would be decided in order to form the polygons P′ 1 , P′ 2 , P′ 3 and P′ 4 . It would then be conceivable to alternatively apply one or more of these methods of fusion and division of the polygons of the mesh. The co-ordinates of the point of interest p created in this way could be chosen in a manner that provides the most clear division of the image, or could be arbitrary: the point p will then possibly be at the barycenter of the range R.
Fusing polygons permits one to reduce the size of the index and therefore increase the compression of the image while at the same time it is possible that certain useful details are erased, while dividing the polygons has the opposite effects. Hence use may or may not be made of one of these techniques or both of them may be used at the same time according to whether one wishes to give more emphasis to the quality of the reconstituted image or to its compression.
The above has been the explanation of characterization techniques using an index that one endeavors to make both succinct and faithful. However, the indices constructed in this way do not provide an adequate probability of success if they are used for the search for samples by comparison, even if, in the case of an index based on the fractal properties, one resorts to the condition of patent 96.11751 which reduces the arbitrary nature of the selection of the domains and ranges brought into correspondence with them. Additional measurements are therefore proposed that conform to improvements in the invention in order to adapt these techniques to the present application.
An important reason for the inadequacies of the techniques mentioned above arises from the selection of the points of interest: whatever they might be in general at particular places on the image, as angles of its principal details, it may be observed that the list of them is very sensitive to interference introduced by noise or by other causes. One may then find oneself in the situation of FIGS. 8A and 8B where an analog block is defined by five points of interest A, B, C, D and E in one case and by four (A, B, C and D) in the other, the point of interest E situated between the preceding ones, having been omitted. The mesh will allow division of the block into four triangles (ABE, BDE, ACE and CDE) in the first case and into only two (ABC and BCD) in the other, none of which coincide with the previous triangles. The indices describing the block will therefore be completely different and of no use for the comparison.
A method of remedying this disadvantage is the creation of a redundant mesh called a semi-exhaustive mesh, that is to say one in which the modeling polygons encroach into one another: FIGS. 9A and 9B represent such networks of triangles, formed in practice by joining all the points of interest-of the mesh that are closer than an accepted distance, by mesh lines and then taking as portions of the image to be indexed all the triangles formed by three of these mesh lines, in the case of the same points of interest as in FIGS. 8A and 8B. Such a method increases the probability of finding similarities between two images in which one and the same detail is present, even if points of interest have been omitted on one or the other modeling. In concrete terms, three new points of interest F, G and H at the intersections of the lines AE and BC, AD and BC, and CE and AD respectively appear and all triangles which include three of these points of interest A to H as vertices and whose sides are mesh lines, are accepted as triangles for modeling the image: here there are twenty one of them (ABC, ABD, ABE, ABF, ABG, ACD, ACE, ACF, ACG, ACH, ADE, BCD, BCE, BDE, BDG, BEF, CDE, CDG, CDH, CEF, DEH); the same modeling method, in the absence of the point E and as a consequence points F and H, enables the block to be modeled in eight triangles (ABC, ABD, ABG, ACD, ACG, BCD, BDG, CDG), much less numerous but all identical to certain of those from the mesh in FIG. 9A, which will permit the construction of indices that are partially identical and hence comparable since it is enough for a specified percentage of lines in the indices to be similar to judge that the comparison is positive.
The improvement relating to the use of the semi-exhaustive mesh is not appropriate to the compression of the image and demands much longer calculation times for coding into the index, but it is justified in this application.
If the image must be reconstructed from an index, it is preferable to use an ordinary index produced from division of the image without any overlapping of the polygons. The data base will then contain two indices for each of the images, one of which will be used for the sample search and the other for its reconstitution.
Even if the points of interest can easily be omitted when the image is disrupted, they tend to preserve an invariant assembly arrangement since they depend on the shape of the elements of the image: if these elements are to be found in different positions on the two images, the points of interest will be displaced in groups and the areas surrounded by these groups will be modeled in the same way, by similar portions. The mesh defined by points of interest therefore not only encourages division of the image into portions that are more homogeneous which would be an advantage for the compression of images but also the searches carried out from these indices will remain fruitful even if the objective of the search is not in the same position or at the same angle of inclination on the image and on the sample.
However, as the indices set up with the fractal properties are not associated with image ranges but with relationships between ranges and domains, an identical mesh is not sufficient to guarantee fruitful comparisons between a sample and an image, since it is necessary that the identical ranges are associated with identical domains. Another characteristic of this embodiment, which will now be described in connection with FIG. 6, provides a solution to this difficulty. Domains D of the modeling of the image are represented here, which are sub-divided into ranges R. Domains and ranges are assumed to be triangular but the method proposed here is applicable to any polygonal shape. The index for the fractal transformation of the image, can be established by associating with each of the ranges R, the set of domains (Di) which are adjacent through sides to the domain (Db) to which the range R belongs, the number of which is equal to that of the number of sides of domain Db. It can also be established from the breakdown of the image into polygons taken as domain blocks; the dividing of the range into blocks is obtained by dissociating each triangle from three other triangles by using the barycenter to the starting triangle; each range triangle is characterized by using the domain triangle that contains it. It can be seen that the index then becomes entirely defined by the shape of the mesh and therefore that the very similar indices could always be obtained for one and the same object present in different images on condition that a method of creating the mesh is chosen that only depends on the contents of the image such as the method which has been explained above.
The index may consist, as is usual, of a collection of values corresponding to the parameters of equation (1), that is to say, values that indicate, in particular, the Cartesian co-ordinates xi and yi of each of the starting domains Di and the translation co-ordinates txi and tyi which lead from these domains Di to the range R which is associated with them. This way of proceeding has the disadvantage however that the x and y co-ordinates depend on the position of the object in the image and that the co-ordinates tx and ty depend on the orientation of the object in the image. It is therefore proposed to use different parameters, and, in particular to use barycentric co-ordinates for each of the ranges R in order to further reinforce the invariance of the indices.
The barycentric co-ordinates of a group of points, such as the vertices of a triangle (A, B, C) are numbers α, β, γ equal in number to that of the reference points A, B, C and which define the position of any point p by p=αA+βB+γC, as a function therefore of the points A, B and C. The relationship α+β+γ=1 is respected on the perimeter of the triangle ABC and furthermore, α, β and γ are all between 0 and 1 inside this perimeter.
The geometric transformations, which cause any two polygons with the same number of vertices to pass from a domain D to a range R, can be broken down into a translation, an isometry (rotation, symmetry, etc.) and a deformation. The index for the fractal transformation will then also have to contain digital coefficients that express the respective importances of these three operations for each of the relationships between domain and range, and the totality of these coefficients, if the index must be used to reconstitute the image in the way indicated above or at least a part of the coefficients if the index is only being used for comparisons. Whatever the case may be, the fractal transformation can be symbolized by a series of equations (2) w ( D i ) = R ~ = ∑ j = 0 d - 1 a i d a ′ j + s i o ¨ ( D i ) + t i ( 2 )
where D i and R designate a domain and a related range, the index “˜” signifies that the fractal transformation w k only enables one to reconstitute the range R approximately, a i d , s i and t i are the coefficients mentioned above for the geometric transformations, where t i quantifies the translation on the image, s i the isometry φ and a i d the deformation. s i can be an angle value for a rotation, t i polar co-ordinates expressing the distance between the barycenters of the domain D i and of the range {tilde over (R)} and the direction of a straight line joining these two points, and a i d are coefficients giving barycentric co-ordinates of the range {tilde over (R)} in relation to the barycentric co-ordinates α j of the domain D i ; j finally designates the number of vertices of the polygons.
If domains D and range R are triangular, the equations (2) become:
w ( D á,â,ã i )={tilde over (R)}= a i á+b i â+c i ã+s i ö (D i )+ t i (3)
However, it conforms to the invention to incorporate in the index, the transformations w that relate all the domains D i , adjacent to the domain D b to which the range R belongs, and this range R, so that the overall transformation that enables one to obtain the range {tilde over (R)} is redundant and is made up of k equations (2) or (3), where k designates the number of domains D i which are relevant to providing the equations (4) starting from equations (3): w k ( D a ′ , a ^ , a ~ i = 1 , k ) = R ~ = ∑ i = 1 k ( a i a ′ + b i a ^ + c i a ~ + s i o ¨ ( D i ) + t i ( 4 )
The fractal transformations w k can be expressed by vectors of co-ordinates (or matrices with k lines) v:
V =[( a i ),( b i ),( c i ),( s i ),( t j )] (5)
where i varies from 1 to the number of domains D i being considered, generally three if all the domains are triangular, except at the edges of the image.
It has been seen that the coefficients a, b and c do not depend on either the position or the scale or the orientation on the image of the object used as a support for the domains D and for the ranges R brought into relation with them thanks to the use of barycentric co-ordinates. It would be advantageous to define the translation co-ordinates t i in order to obtain the same independence. For example, the distance and the direction of the displacement corresponding to this translation could be expressed by taking, as a reference, not the dimensions and the orientation of the image but those of the domain D.
Up to now, the description of the invention has been developed in relation to the indices drawn up according to the fractal properties, since these indices have largely been developed in order to compress and then reconstruct images. However, the invention can be applied to other types of index, since the criteria proposed (points of interest, supplementary points of interest, semi-exhaustive mesh, barycentric co-ordinates) do not depend on the content of the portions of the image. The indices may all naturally express, instead of relationships between the respective portions of the image and others from these portions, the contents of the portions themselves. Thus one can use moments m of order n of barycentric co-ordinates, which can be defined by the equations (6) for a triangular polygon such as one of the ranges R defined by its barycentric co-ordinates m a ′ n = ∫ R a ′ n · ( k - k _ ) m a ^ n = ∫ R a ^ n · ( k - k _ ) m a ~ n = ∫ R a ~ n · ( k - k _ ) } ( 6 )
where á n .(k-{overscore (k)}), for example, is the power at the order n of the barycentric co-ordinate α of a point from the range R multiplied by a coefficient k which characterizes this point and can be its level of grayness; {overscore (k)} designates the mean of this coefficient over all the points of range R.
The index thus contains the moments of the distribution of the image points (pixels) contained in each polygon at different orders, expressed from the barycentric co-ordinates.
In practice, one can insert a weighting through the Gaussian function G(α, β, γ) so as not to favor the influence of points distant from the barycenter, and to thereby reduce the sensitivity of the calculation to errors in the positioning of the vertices of range R; the equations (6) then become (7): m a ′ n = ∫ R a ′ n · ( k - k _ ) · G ( a ′ , a ^ , a ~ ) m a ^ n = ∫ R a ^ n · ( k - k _ ) · G ( a ′ , a ^ , a ~ ) m a ~ n = ∫ pR a ~ n · ( k - k _ ) · G ( a ′ , a ^ , a ~ ) } ( 7 )
One then makes its moments of order 0 to n correspond to a range R; the vector v of the equation (5) is then replaced by a vector v″ (8) V ′ = 1 o ′ 2 ∂ ⋓ e - ( a ′ 2 + a ^ 2 + a ~ 2 ) 2 o ′ 2 [ m a ′ i , m a ^ i , m a ~ i ] ( 8 )
The polygons have thus been characterized by using relationships based on the contrast and the luminosity, that is to say on the levels of grayness. It would be possible to characterize them by their color, or indeed by their texture, using a Fourier transform, for example. In all these variants of the method based on the moments, ranges are not related to domains, but the elements of the mesh are only characterized by the properties of their points.
The search for the sample on an image is done in the usual way: the sample is compressed in the same way as the images to obtain a sample index made up of vectors, such as V and V′ met with above, that are individually compared with the vectors of the image under consideration. A criterion of similarity for the vectors is introduced in order to decide if a sample vector can be correlated with an image vector. If the search for correlation is positive for a certain number of vectors, it is of interest to determine the spatial organization of these correlated vectors of the sample in order to verify if it coincides sufficiently with that of the corresponding vectors of the image taking into account that the position and the orientation of the sample can be any position and orientation whatsoever on the image if effectively found there. For this the distances and the angles between the two groups of correlated vectors are calculated by the usual mathematical formulae. There are several ways of calculating a vector distance, but the Euclidean distance is generally a good criterion of correlation for this application. A location score is finally calculated by evaluating the correlation of the distances and angles between corresponding vectors between the two indices: the image can be extracted from the data base by the searcher if this score appears promising to him. As has already been indicated, the image can be consulted by any means, depending on whether a digital material representation of it exists in a memory or only the index, the image then being reconstituted by applying the geometric transformation that these vectors define.
The invention may be of interest in a certain number of fields such as remote detection where aerial satellite images are used, medical imaging by tomography, advertising, where it can be used to find again images previously composed, and monitoring and safety applications in order to locate defects or abnormal behavior of systems. More precisely, it can find uses when the volume of recorded images is high or in order to identify a precise detail, a face for example. | Efforts are made to construct a digital index that represents properties or the appearance of portions of an image so as to automatically rediscover in it a sample of the image during a subsequent search, after having set up a sample index in the same way and having compared the indices while searching for similarities. In this invention, the mesh dividing up the image or the sample into portions is founded on points of interest and is not uniform, and the index is made up of information coming, for each portion, from this same portion or from a specified assembly of neighboring portions. Furthermore, a redundant mesh is proposed (FIG. 9 A) in order to describe the image several times and to attenuate the consequences of any omissions from the points of interest (E) on the other modeling (FIG. 9 B). | 8 |
[0001] This application claims the benefit of provisional application 60/261,186 filed Jan. 16, 2001.
FIELD OF THE INVENTION
[0002] The present invention is directed toward a method and apparatus for strengthening the frame of a door, and, more specifically, toward a device mounted inside a hollow-core door to reinforce a portion of the door stile in the vicinity of openings that accommodate locking or latching hardware.
BACKGROUND OF THE INVENTION
[0003] Doors have traditionally been formed from solid pieces of wood. As wood has become increasingly expensive, alternative types of doors have become more common. One such alternative door is formed by two parallel vertical stiles connected by top and bottom rails to form a rectangular frame and two thin panels or door skins attached to the frame to form a door with a hollow-core. Such doors are lighter than solid wood doors, have a lower material cost, and, if the space between the door skins is filled with a suitable insulating material, may provide better thermal insulation.
[0004] A first pair of aligned openings is provided in the door skins to receive a door handle or latching assembly and, optionally, a second pair of openings may be provided to accommodate a deadbolt or other lock. Latch bores extend through the stile next to these openings to allow a live bolt and/or a deadbolt to pass through the stile and into a corresponding opening in a doorjamb adjacent the latch side of the door. Optionally, a lock block with bores aligned with the door skin openings may be attached to the stile inside the door next to the latch bore to provide a secure mounting location for the door handle and lock hardware.
[0005] Drilling latch openings though a stile weakens the stile significantly, and it is known that doors may be forced by delivering a sharp kick or otherwise applying a force in the area of the latch bore to split the wooden stile. This weakening occurs even when a solid piece of a sturdy wood is used; with lighter woods, such as sometimes used in hollow-core doors to reduce weight, the problem is even more significant. When an ordinary door is kicked near the lock assembly, the metal strike plate in the doorjamb holds the distal end of the door bolt relatively securely while the door is forced slightly inwardly. As the door moves, the latch or bolt pivots within the bore, and if a great enough force is applied, snaps the stile near the latch bore. Once the end of the bolt inside the door begins to pivot, it can act as a lever to pry the strike plate out of the doorjamb when further force is applied to the door. If a first kick does not completely open the door, the latch will be damaged enough to allow some play and let the door move back and forth. Weakened in this manner, it is highly likely that a subsequent kick will completely break the bolt from the door and allow the door to be opened.
[0006] This problem has been recognized, and various attempts have been made to address it. For example, it is known from U.S. Pat. No. 5,586,796 to provide metal plates on the inside and outside faces of a door to reinforce the area around the lock and latch. While this approach does provide some additional strength, it also adversely affects the appearance of a door, giving it a commercial or industrial look. Alternately, U.S. Pat. No. 4,832,388 shows the use of unusually long screws for securing a strike plate to a doorjamb and for securing a reinforcing plate to the outer edge of the door, the screws being installed at an angle to the door and the doorjamb to make them more difficult to remove by force. However, this method requires that a large mortised region be formed on the outside edge of the door to accommodate the reinforcing plate. Moreover, because the reinforcing plate will be visible when the door is open, the plate should be made from a material with a finished appearance that matches the other door hardware, adding to the cost of the door. Furthermore, the oversized reinforcing plate may not be as aesthetically pleasing as the smaller plates that generally surround the live bolt of a door.
[0007] It would therefore be desirable to provide a reinforcement for a door that is economical to produce and install, that can be sold as an integral part of a hollow-core door, and that can be used without affecting the outward appearance of a door.
SUMMARY OF THE INVENTION
[0008] These problems and others are addressed by the present invention which includes a reinforcing plate mounted inside a door frame on the inner edge of the stile through which latch bores are drilled. In a preferred embodiment, the plate includes an opening aligned with each bore in the stile so that a live bolt or deadbolt can pass therethrough. When the door is closed and the bolt is extended, the bolt also extends though a strike plate mounted on a doorjamb and into an opening in the doorjamb. In one embodiment, the plate includes a flange surrounding each opening which flange extends into each bore to reinforce the bore and the stile. The flange preferably has at least one portion that is wider than the bore into which it is placed and may have outwardly flared or barbed end edges to help secure the plate to the stile. Alternately, or in addition, the plate may be dimpled or punched at locations spaced from the openings to form protrusions that extend into the stile to help secure the plate.
[0009] In a second embodiment, the plate is provided with several groups of screw holes arranged in circular regions lying on either side of each of the plate openings along the longitudinal centerline of the plate. When a latch plate is installed on the outer edge of the latch stile of a door incorporating the subject reinforcing plate, longer-than-usual screws are used to attach the latch plate to the stile, which screws extend thought the stile and pass through one of the screw holes in the plate and into the body of the lock block.
[0010] The plate in the door assembly of the preferred embodiment of the present invention provides support for a section of the bolt inside the door, away from the doorjamb. Thus, if a forced entry is attempted, the bolt is less likely to pivot in the door, and an intruder will essentially need to press the bolt, the reinforcing plate and the strike plate in a direction normal to the plane of the door to obtain entry. Because the reinforcing plate is securely mounted to the stile and the strike plate is secured to the doorjamb, a significant effort will be required to force the door open. While enough force will break any door, the present invention makes it appreciably more difficult to break down a door in the above-described manner.
[0011] Preferably, the subject plate is press-fitted to the inner edge of the stile while the door is being manufactured and thus does not require separate fasteners or adhesives to hold it in place. Furthermore, because the plate is inside the door, there is no need to provide a mortise to accommodate the plate and keep it flush with another surface. Also, because the plate is hidden after it is installed, it can be formed from an unfinished sheet of material, and the same material can be used on any door without regard for its outward appearance.
[0012] It is therefore a principal object of the present invention to provide a method of reinforcing a door that does not affect the outward appearance of the door.
[0013] It is another object of the present invention to provide an internally mounted reinforcing plate for a door stile.
[0014] It is another object of the present invention to provide a reinforcing plate that can be press-fitted to a frame of a door during manufacture.
[0015] It is yet another object of the present invention to provide a reinforcing plate having at least one flanged opening that is received in a latch bore in a door stile for reinforcing the stile.
[0016] It is yet a further object of the present invention to provide a method of reinforcing the frame of a door having more than one latch bore for accommodating more than one bolt.
[0017] In accordance with these objectives, a door is disclosed that includes a first stile having a front wall, a rear wall, an inner wall, and an outer wall; a second stile parallel to and spaced from the first stile and including an inner wall facing the first stile inner wall; a first door skin connected to the first stile and to the second stile; a second door skin connected to the first stile and to the second stile; a first lock bore extending through the first door skin and the second door skin; and a first latch bore extending from the first lock bore through the first stile inner wall and the first stile outer wall. The door also includes a reinforcing plate connected to the first stile inner wall having a first opening aligned with the first latch bore.
[0018] A method of forming a reinforced door is also disclosed, which method comprises the steps of: 1) taking a frame formed from first and second parallel side stiles having facing inner walls, a top rail connected between the first and second stiles and a bottom rail connected between the first and second stiles, 2) forming a latch bore having a diameter through the first stile, 3) taking a reinforcing plate including a flanged opening having a width greater than the first diameter and aligning it with the latch bore and pressing the flange into the latch bore until the plate contacts the stile and then attaching first and second door skins to the frame.
[0019] Another embodiment of a door according to the present invention includes a door frame having a latch stile, a hinge stile, and a top rail and a bottom rail connected between the latch stile and the hinge stile, the latch stile having an inner wall facing the hinge stile and a latch bore though the inner wall. A reinforcing shield has an opening with a flange with a first portion of the flange having a width greater than the width of the latch stile latch bore extends into the latch stile latch bore. A reinforcing shield overlies the latch stile inner wall and includes at least one projection extending into the latch stile at a location spaced from the latch stile latch bore. A lock block has a lock bore connected to the latch stile inner wall and has a lock block latch bore aligned with the latch stile latch bore. First and second door skins are connected to the door frame and having openings aligned with the lock bore.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] These and further objects and advantages of the invention will be better understood after a reading of the following detailed description of the invention together with the following drawings.
[0021] [0021]FIG. 1 is a side elevational view, with a portion broken away, of a door assembly including a reinforcing plate according to the present invention.
[0022] [0022]FIG. 2 is a top plan view of the reinforcing plate of FIG. 1.
[0023] [0023]FIG. 3 is a cross sectional view taken along line 3 - 3 of FIG. 2.
[0024] [0024]FIG. 4 is an enlarged detail of a portion of FIG. 3.
[0025] [0025]FIG. 5 is a cross sectional view taken along line 5 - 5 of FIG. 1.
[0026] [0026]FIG. 6 is a cross sectional view taken along line 6 - 6 in FIG. 1.
[0027] [0027]FIG. 7 is a top plan view of a second embodiment of a reinforcing plate according to the present invention.
[0028] [0028]FIG. 8 is a sectional view of a door incorporating a latch plate and the reinforcing plate of FIG. 7 positioned adjacent a door jamb.
[0029] [0029]FIG. 9 is a flow chart showing a method of assembling the door assembly of FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
[0030] Referring now to the drawings, wherein the showings are for the purpose of illustrating a preferred embodiment of the invention only, and not for the purpose of limiting same, FIGS. 1 and 6 show a door 10 comprising a door frame 12 including a latch stile 14 , a hinge stile 16 , upper and lower rails 18 connecting the latch stile to the hinge stile and two door skins 20 connected to opposite sides of door frame 12 in a well known manner. (“Upper,” “lower” and other directional terms used herein refer to a door positioned in a normal vertical orientation.) As best seen in FIG. 5, latch stile 14 has an inner wall 22 , an outer wall 24 , an upper latch bore 26 and a lower latch bore 28 extending though the stile between inner wall 22 and outer wall 24 . A lock block 30 is attached to latch stile 14 in a conventional manner, such as by staples, screws, bolts, fasteners, glue, etc. (not shown) and includes a lower opening 32 for receiving hardware associated with a door latch (not shown) and an upper opening 34 for receiving an auxiliary lock, such as a deadbolt, the bolt portion 35 of which is shown in phantom lines in FIG. 5. A lock block upper latch bore 36 extends from upper opening 34 though a side wall of the lock block while a lock block lower latch bore 38 extends from lower opening 32 through the lock block side wall. Door skins 20 are provided with an upper pair of aligned openings 40 that align with upper opening 34 in the lock block and a lower pair of aligned openings 42 that are aligned with lower opening 32 in the lock block. The door may also include insulation 44 of any conventional type, such as foam insulation.
[0031] Door 10 further includes a reinforcing guard or plate 50 , shown separately from door 10 in FIGS. 2 - 4 , that is preferably formed from 0.035 inch thick galvanized steel, which plate includes a front face 52 , a rear face 54 , top and bottom edges 56 , side edges 58 , an upper hole 60 and a lower hole 62 . The distance between the side edges 58 is approximately equal to the width of the stile to which the plate will be attached as shown in FIG. 6. The upper and lower holes are centered between the side edges 58 and located near the top and bottom edges of the plate and are formed in a manner that produces flanges 64 around both openings extending from rear face 54 of the plate. Furthermore, the flanges are provided with outturned end edges 66 . These outturned end edges bite into the wood of latch stile 14 to help hold plate 50 in place as will be described hereinafter and, as the sharp edges point away from the centerline of the holes, the risk that a person installing hardware though the plate will come into contact with these sharp edges is reduced. Dimples 68 , as best shown in FIG. 5, are formed in plate 50 after it is attached to stile 14 by pressing a diamond-shaped tool into the plate to deform the plate and force portions of the plate into the stile 14 . These dimples, together with the force fit of the flanges in the bores in the latch stile, securely hold plate 50 in place without the use of adhesives or additional hardware.
[0032] Referring again to FIG. 5, a portion of door 10 is shown positioned adjacent to a doorjamb 70 which doorjamb includes an upper bolt opening 72 surrounded by an upper strike plate 74 and a lower bolt opening 76 surrounded by a lower strike plate 78 . When door 10 is closed, upper bore 26 aligns with upper bolt opening 72 and lower bore 28 aligns with lower bolt opening 76 . Bolt 35 is shown extending from upper opening 34 through lock block upper latch bore 36 , reinforcing plate upper hole 60 , upper latch stile bore 26 , strike plate 74 and into opening 72 in the doorjamb. A live latch bolt would extend through the lower latch stile bore into the doorjamb in a similar manner.
[0033] An attempt to force open door 10 would likely involve the application of a sharp force to the area of the door between openings 40 and 42 in the door skins. Such a force applied to an un-reinforced door would likely cause bolt 35 to twist in upper bore 26 and shatter the wood of latch stile 14 which is relatively thin in the area around the latch bores. Reinforcing plate 50 secures bolt 35 against such twisting, so that bolt 35 can only move normally to door skins 20 under the application of a force normal to the surface of the door. In order to forcibly open a door including a reinforcing plate 50 , the bolt would have to press against reinforcing plate 50 and strike plate 74 and move them directly out of the page as seen in FIG. 5. This would require substantially more force than would be required to pivot bolt 35 and split the wood of stile 14 of an un-reinforced door, because the flanges 64 and dimples 68 substantially prevent face 58 of the plate from sliding relative to inner wall 22 of stile 14 .
[0034] A method of assembling a door that includes a reinforcing plate 50 will now be described with reference to FIG. 7. This method includes the steps of providing a door frame having a latch stile, a hinge stile and top and bottom rails connecting the stiles, forming at least one latch bore through the latch stile having a diameter, providing a reinforcing plate having a flanged opening with an outturned free end larger than the diameter of the latch stile bore, aligning the flange with the latch stile bore and pressing the flange into the latch stile bore until the flat portion of the plate contacts the stile, and then, optionally, pressing a tool against the flat portion of the plate to form dimples extending into the stile, then attaching a lock block over the reinforcing plate and attaching door skins to the door frame.
[0035] A second embodiment of a reinforcing plate according to the present invention is shown in FIGS. 7 and 8 wherein elements identical to elements of the first embodiment are identified with the same reference numerals and wherein elements of the alternate reinforcing plate that correspond to elements of the reinforcing plate of the first embodiment are identified with like reference numerals and primes. In this embodiment, reinforcing plate 50 ′ includes a plurality of screw holes 80 arranged in generally circular groups 82 on either side of holes 60 ′ and 62 ′ in the plate along the longitudinal midline of the plate. The screw holes are preferably about ⅛ inch in diameter and the diameter of the circular groups is about ½ inch, so that very little space is left between the screw holes. Plate 50 ′ is installed against latch stile 14 in the same manner as the reinforcing plate of the first embodiment. However latch stile 14 is provided with a latch plate 84 which includes a first opening 86 that surrounds upper bore 26 in the latch stile and a second opening 88 that surrounds lower bore 28 in the latch stile. Latch plate 84 also includes openings 90 adjacent openings 86 and 88 for receiving fasteners such as screws 92 to secure the latch plate to the latch stile. Normally, a latch plate would be attached to a latch stile using a ⅝ or ¾ inch screw, but in this embodiment, screws 92 are at least about 1⅜ inches long so that they will extend though the stile and reinforcing plate and into the lock block.
[0036] A door including reinforcing plate 50 ′ is assembled in the manner described above and then latch plate 84 is positioned on the outside of the latch stile with latch plate opening 86 aligned with upper bore 26 . Each of openings 90 in the latch plate is located directly opposite latch stile 14 from one of the circular groups 82 of screw holes 80 . When a screw 92 is inserted through the latch plate and driven through the latch stile, its leading end will engage one of the plurality of holes in one of the groups of holes and pass through that hole and into lock block 30 . This arrangement helps anchor the lock block securely to the latch stile and holds reinforcing plate 50 ′ very securely between these two elements, even when a forced entry is attempted.
[0037] The present invention has been described above in terms of a preferred embodiment. Modifications and additions to this embodiment will become apparent to those skilled in the art upon a reading and understanding of the above description and the accompanying drawing figures. For example, the reinforcing plate is shown as having two openings, but could just as easily have a single opening for use in situations where a deadbolt is not present, or three or more openings where the number of bolts extending though the stile so requires. It is intended that all such obvious modifications and additions be covered by this application to the extent that they are included within the scope of the several claims appended hereto. | A door assembly is disclosed that includes a latch-side stile with bores for accommodating one or more bolts that extend through the stile and into an adjacent doorjamb to secure door with respect to the doorjamb. A reinforcing plate is mounted on the inner edge of the latch-side stile with flared flanges extending into the stile bores to hold the plate in place and to make it more difficult to force the door open by kicking the door in the area of its latch and lock. A method of assembling a door including such a reinforcing plate is also disclosed. | 8 |
RELATED APPLICATIONS
None
FIELD OF INVENTION
This invention pertains to a rail support assembly including a shoulder and a clip engaging the shoulder and arranged to hold a rail in place, the shoulder being shaped to prevent it from rotating with respect to a supporting plate.
DESCRIPTION OF THE PRIOR ART
Trains running on rails are the most efficient way of transporting all industrial, agricultural as well as consumer products. Typically rails are supported on ties by support assemblies including a bottom plate disposed on ties, a pair of shoulders disposed on top of the plate on either side of a rail and clips made of a steel bar formed into a predetermined shape and arranged to secure the rail. One end of each clip engages a respective shoulder and the rest of the clip rests on top of a rail flange and biases the flange (and therefore the rail) downward toward the plate.
This assembly has been found to be working reasonably well, however one problem with it is that typically railroad cars are extremely heavy and apply tremendous pressure and torsional forces on the rails, especially when rails curve. As a result, sometimes whole sections of rails separate from the ties because the support assemblies are not able to resist these effects.
The present invention provides a solution to this problem.
SUMMARY OF THE INVENTION
A rail support assembly for supporting a rail of a railroad track constructed in accordance with this invention includes a plate having a shoulder hole, a shoulder having a boss sized and shaped to fit through said shoulder hole, the boss and shoulder having matching non-rotational shapes selected to prevent the shoulder to rotate with respect to said plate, the plate having a clip receiving member; and an elastic clip having a first end received in the clip receiving member and a rail retaining portion, the elastic clip being positioned by the shoulder to retain the rail on the plate.
In one aspect of the invention, the railroad track includes a tie and The plate includes a mounting member mounting the plate on the tie.
In one aspect of the invention, the plate includes spike holes receiving spikes to attach said plate to said tie.
In one aspect of the invention, the boss and the shoulder hole have a generally square shape with rounded corners.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an isometric view of a section of a rail and its supports;
FIG. 2 shows a top view of a rail support assembly constructed in accordance with this invention;
FIG. 3 shows a side sectional view of the rail support assembly; and
FIG. 4 shows an exploded view of the rail support assembly.
DETAILED DESCRIPTION
Referring first to FIG. 1 , a railroad track 10 includes a track bed 12 with a plurality ties 14 . Ties 14 are typically made of treated wood, or concrete. A rail 16 is supported on the ties 14 by a support assembly 18 . The rail 16 includes a bottom flange 20 , a vertical web 22 and a top 24 . A second rail identical to rail 16 extends in parallel thereto but has been omitted for the sake of clarity.
As shown more clearly in FIGS. 2-4 , rail support assembly 18 includes a plate 30 . Plate 30 is generally rectangular having a width substantially equal to the width of tie 14 and extending along the top surface of the tie 14 . The plate 30 is formed with two transversal ridges 32 A 32 B. Each ridge includes a vertical wall 36 A, 36 B and a sloping wall 38 A, 38 B. The distance between the two vertical walls 36 A, 36 B is equal to the width W of the flange 20 of rail 16 . Therefore the rail 16 can be seated solidly on top of the plate 18 with the flange 20 firmly seated between the ridges 32 A, 32 B.
Optionally, a pad (not shown) may be provided between the rail 16 and the plate 30 .
The plate 20 has two segments 34 A, 34 B disposed between the ridges 32 A, 32 B and the short edges of the plate 20 as shown. Segment 34 A is formed with two smaller holes 40 , 42 and a large hole 44 . Importantly, large hole 44 has a generally square shape with rounded corners, as at 46 .
Referring back to FIG. 2 , four conventional spikes 50 pass through holes 44 and secure the assembly 18 to the tie 14 .
Attached to plate 30 is a shoulder 52 . This shoulder 52 includes a base 54 having a somewhat square configuration with sloping sides, as at 56 . The base 54 also has a flat bottom surface 58 with a boss 60 extending downwardly from the surface 58 . The boss 60 has the same shape and size as hole 44 . The boss 60 has an outer surface with a circumferential groove 64 .
The shoulder 52 further includes a clamping wall 70 having a somewhat cylindrical outer surface 72 terminating in a sloping edge 74 . The clamping wall 70 is sized and shaped so that when the shoulder 52 is attached to the plate 18 , the slopping edge 74 abuts an upper portion of sloping wall 38 A on the plate. The clamping wall 70 also includes an inner surface 76 . This inner surface 76 has a partial cylindrical shape and forms with wall 38 A a horizontal hole 78 .
In one embodiment, the clamping wall 70 is provided with an end portion 80 on the inner surface 76 . The end portion 80 is formed with a semicircular cutout 82 . This cutout forms an opening 84 for hole 78 .
In an alternate embodiment, shoulder 52 A (also shown in FIG. 4 , end portion 80 A extends across inner surface 76 A so when the shoulder is attached to the plate, there is no opening into the hole 78 .
Assembly 18 further includes a clip 90 . The clip 90 has one end 92 that is straight, an intermediate portion 94 and another straight portion 96 . The clip 90 preferably has a constant cross section. Its first end 90 is sized and shaped to fit into the hole 78 as shown. In this position, the rest of the clip is positioned so that its other end 94 biases the flange 20 downwardly towards the plate 18 . The clip 90 is made of steel or other high strength, somewhat flexible material to insure that the rail is firmly attached to the tie 12 through assembly 18 . The flexibility of the clip 90 allows the rail to move up and down slightly as a car goes by on the rail 16 . In the embodiment on the right side of FIG. 3 rocks or other undesirable objects trapped in hole 78 are pushed out through opening 84 .
The shoulder 52 is preassembled with the plate 20 , for example by press-fitting the boss 62 through hole 44 . During this operation, pressure is also applied to the bottom portion of the plate 20 causing some of the material of the plate 20 to enter into and even fill slot 64 , as shown at 66 in FIG. 3 . As a result, the shoulder 52 is firmly mounted and secured to plate 20 and cannot be dislodged easily. Moreover, because the boss 60 and hole 44 are both non-circular, the boss does not rotate with respect to plate 20 but remains firmly attached to it even while the assembly is subjected to extremely high pressures and torsional forces due to a train of several wheels passes by. Since the shoulder is securely mounted, the clip 90 is secured and remains secured to the plate 20 and will not rotate even under strong forces thereby permanently engaging clip 90 , and therefore the rail 16 .
Numerous modifications may be made to the invention without departing from its scope as defined in the appended claims. | A rail support assembly for mounting and supporting the rail of a railroad system, the assembly including a plate disposed under the rail and including a shoulder hole, a shoulder arranged and constructed to fit in said shoulder hole without rotation with respect to the plate, and a clip having an end received by said shoulder and arranged to bias the rail toward the plate. | 4 |
BACKGROUND OF THE INVENTION
The present invention concerns an absorbent article comprising a segmented absorbent body and a method of producing an absorbent body, in particular a segmented absorbent body. The absorbent body is preferably arranged between a liquid-permeable cover layer and a liquid-impermeable backing layer.
It is known from the state of the art how to produce absorbent articles containing the absorbent bodies. As a rule, these absorbent bodies are arranged between a liquid-permeable cover layer and a liquid-impermeable backing layer. Such absorbent articles include, for example, menstrual hygiene napkins, disposable diapers, training diapers and incontinence articles for adults as well as similar articles. As a rule, the absorbent bodies of the traditional type contained in these absorbent articles contain pulped cellulose or sheeting materials of cellulose/synthetic fiber blends as the absorbent material.
These materials are supposed to serve to absorb body fluids such as menstrual fluid and retain them in a napkin. The menstrual fluid should preferably remain inside the absorbent article even under pressure and if possible it should not be detectable from the outside. The absorbent article and in particular the absorbent body in the absorbent article should prevent the secreted body fluids from soiling the wearer's body and/or spotting the adjacent items of clothing.
The sheeting materials used for the absorbent material are either arranged continuously (i.e., they cover the total length of the napkin or they form rectangular inserts, for example) or they may have cutouts. The cutouts are preferably arranged in a top layer of the absorbent material and should serve to convey the fluid away from the body of the wearer of the absorbent article as rapidly and efficiently as possible and to release it downward into the other absorbent and storing layers of the absorbent article.
There are several possibilities of storing the fluid delivered in the absorbent article. One of these possibilities is to convey the fluid secreted as rapidly and directly as possible to a lower area of the article which is preferably arranged directly above the liquid-impermeable backing layer, from whence the fluid is then distributed in the longitudinal direction. As soon as this bottom absorbent distributor layer becomes saturated with the fluid secreted, the absorbent layers closer to the wearer's body then become saturated with the fluid.
Another possibility is for the secreted body fluid to be distributed as rapidly as possible in the longitudinal directions of the napkin, from whence in the remaining course it then diffuses toward the side of the absorbent article facing away from the wearer's body.
Apart from providing a cutout in an upper area of the absorbent material in an absorbent article, there are various other possibilities for improving the distribution of fluid in an absorbent article. These possibilities involve, for example, providing various layers within the absorbent article to function as flow layers, storage layers, transfer layers or distributing layers. Such layers may be defined by different materials, for example. Another possibility is to provide embossed lines in a layer of the absorbent material in an absorbent article through which the fluid is guided in predetermined and preferred paths, thus preventing the area of the absorbent article exposed to the fluid from becoming saturated.
Another possibility of preventing leakage and promoting penetration of the secreted fluid into the interior of the absorbent material is to provide elastic or elevated side areas (cuffs) which should prevent leakage at the sides.
With the absorbent articles described above, it is also important that the absorbent article is adapted to the shape of the wearer's body, preferably conforming to the shape of the wearer's body, so that the wearer is not hindered by the absorbent article. It is especially preferable for the absorbent article not to be perceived by the wearer at all. Furthermore, the absorbent article should be prevented from rubbing against the wearer's body in a manner that would be unpleasant for the wearer, even leading to red and irritated skin. There have been various proposals for achieving such an optimum suppleness and adaptability to the wearer's body. Many of these proposals concern the use of materials that are already rather supple anyway and therefore offer increased comfort for wear. However, such materials are often less suitable than an absorbent material for their actual function. A typical absorbent material such as coform will have a certain stiffness which can be reduced only by also surrendering certain advantageous absorbent properties.
SUMMARY OF THE INVENTION
Therefore, one object of the present invention is to provide an absorbent article that does not have the above-mentioned disadvantages according to the state of the art. In particular, one object of the present invention is to provide an article that prevents in particular leakage of secreted fluid into the side areas of the absorbent article (side leakage) in an improved manner.
Another object of the present invention is to provide an absorbent article which permits especially good suppleness and individual adaptation to the wearer's body.
Finally, another object of the present invention is to reduce the stiffness of a continuous web of material in such a manner that it leads to an improved suppleness and better adaptation to the wearer's body.
The term “segmented” as used here is understood to refer to the subdivision of the absorbent body into subareas, i.e., segments, defined by at least one dividing seam or fold line.
The term “dividing seam” or “fold line” is understood to refer to the areas of a material processed for separation to form the segments of the absorbent body. That is, the dividing seam, or fold line, refers to creases, cuts or other indentations formed in the absorbent body to define segments of the absorbent body that are capable of folding relative to each other. The term “processed for separation” is thus understood here to refer to the separation methods, e.g., methods of creasing, punching, cutting, indenting, etc. known in the state of the art by means of which individual areas of a material layer can be separated, e.g., segmented, from one another. “Processing for separation” thus produces in general dividing seams, or fold lines in these materials.
The dividing seam may consist of a continuous or interrupted dividing line. If the dividing seam is executed in the form of an interrupted dividing line, the different areas of material are still joined together by bridge areas. In addition, a dividing seam can be worked through the entire thickness of one or more layers of material or through only partial areas of the thickness or one or more layers of material. The latter is preferred if the layer of material is still to form a unit.
Providing an absorbent body which is segmented by at least one dividing seam in at least partial areas yields an absorbent article which achieves optimum suppleness and individual adaptation to the wearer's body. The segmentation, which forms intended breaking points, eliminates or reduces the stiffness of the absorbent material in an inventive manner, leading to improved suppleness. In addition, the dividing seams improve the rapid penetration of the secreted fluid into the depth of the absorbent body, thus preventing side leakage in an improved manner and thereby also preventing soiling of the wearer's body and/or clothing.
The dividing seams yield stable individual elements that emboss and compress the absorbent body. Thus, areas of different density are formed within each individual element. Density gradients are formed along the dividing seams, optimizing fluid transport. On the whole, the absorbent body is especially compressed in the area around the dividing seams. The fluids such as menstrual fluid to be absorbed by the absorbent body may consist of various components which have different properties and are transported to different extents through a uniformly structured absorbent body. Due to the presence of areas of different density and due to the density gradient prevailing along the dividing seams, it is possible for each fluid component to find an area especially suitable for its transport.
To further improve upon the side leakage protection, it is especially preferable to increase the number of dividing seams in the edge area of the absorbent body.
The segmentation of the absorbent body yields many small individual elements that are stabilized on all sides and are especially preferably applied to a flexible elastic substrate. Therefore, the segments are displaceable with respect to one another. Thus, the absorbent body can be adapted especially well to the body contours of the wearer.
In a preferred embodiment of this invention, the absorbent body has at least two layers, with at least one of the layers being segmented. This permits an optimum combination of the properties of the segmented layer with those of an unsegmented layer, for example.
Preferred shapes for the segments created by the dividing seams in the absorbent body may be squares and/or diamonds and/or circles as well as any other suitable geometric shape. In another especially preferred embodiment of this invention, the absorbent body is designed with at least two layers, where at least one layer of the absorbent body facing the wearer's body is smaller than at least one other layer of the absorbent body facing away from the wearer's body.
The layer of the absorbent body facing the wearer's body faces the wearer's body when the absorbent article is in use and is thus arranged over the layer of the absorbent body facing away from the wearer's body. The latter faces away from the wearer's body when the absorbent article is in use.
Providing an absorbent body which is designed with at least two layers yields various functions as follows, where at least one layer facing the wearer's body and at least one layer facing away from the wearer's body are formed, and at least one layer of the absorbent body facing the wearer's body is smaller than at least one other layer of the absorbent body facing away from the wearer's body, so that the entire absorbent material has a predetermined “intended breaking line”:
providing an “intended breaking line” as defined above yields optimum suppleness and individual adaptation to the wearer's body, providing the two-layer absorbent body where the layer of the absorbent body facing the wearer's body is smaller than the layer of the absorbent body facing away from the wearer's body creates a liquid storage area in the center of the napkin to improve the side leakage protection, preferably the minimum of one layer of the absorbent body facing the wearer's body has less than 70% of the area of the minimum of one layer of the absorbent body facing away from the wearer's body; even more preferably, the minimum of one layer of the absorbent body facing the wearer's body has less than 50% of the area of the minimum of one layer of the absorbent body facing away from the wearer's body; even more preferably, the minimum of one layer of the absorbent body facing the wearer's body has less than 30% of the area of the minimum of one layer of the absorbent body facing away from the wearer's body.
The minimum of one layer of the absorbent body facing the wearer's body is formed by the shaping methods known in the state of the art. It is especially preferable for the minimum of one layer of the absorbent body facing the wearer's body to be punched out or cut out.
The term “layer” as used in the present invention includes layers of one or more materials as well as multilayer composites such as laminates.
In an especially preferred embodiment of the present invention, one or more layers arranged beneath and/or above the minimum of one layer of the absorbent body facing the wearer's body has been processed for separation and thus segmented along the same contours as the minimum of one layer of the absorbent body facing the wearer's body.
The shaping of the minimum of one layer facing the wearer's body can be performed here by one of the methods known in the state of the art, such as cutting off or out, molding, punching, etc. The layer of the absorbent body facing away from the wearer's body as well as the layers of the absorbent body above and/or below that are processed for separation, e.g., cut or punched.
In another especially preferred embodiment of the present invention, the minimum of one layer of the absorbent body facing the wearer's body and one or more of the layers arranged above and/or below that are processed for separation along the same contours as the minimum of one layer of the absorbent body facing the wearer's body.
According to an especially preferred embodiment of the present invention, not only the minimum of one layer of the absorbent body facing the wearer's body is punched out or cut out, but also additional layers which may be present in the napkin are also punched or cut out.
Apart from the minimum of one layer of the absorbent body facing the wearer's body, it is especially preferable for the layers of the absorbent body facing away from the wearer's body beneath that to be processed for separation. However, then preferably the “frame grid” of the minimum of one layer of the absorbent body facing the wearer's body remains in the napkin, while the “punched grid” of the minimum of one layer of the absorbent body facing the wearer's body is removed in any case. The term “frame grid” as used here is understood to refer to the part of a layer of material located outside a dividing seam provided in it, e.g., a punched or cut area, and forming a part of the absorbent article. In other words, the minimum of one layer of the absorbent body facing away from the wearer's body is segmented by separation processing into a frame grid and an area enclosed by the frame grid. The term “punched grid” here is understood to refer to the part of a layer of material located outside the dividing seam, e.g., the punched or cut area, and not forming part of the absorbent article. The “frame grid” of course has a preferred shape for the absorbent article, which in the present case preferably corresponds to the overall shape of the absorbent article. This yields the absorbent body according to this invention, comprising at least one layer facing the wearer's body which is smaller, due to removal of the “punched grid”, than the minimum of one layer arranged at a distance from the body, likewise processed for separation, e.g., cut or punched, and where the “frame grid” forms a part of the absorbent article, however.
By providing an absorbent body having at least two layers, where the minimum of one layer of the absorbent body facing the wearer's body has a smaller area than the minimum of one layer of the absorbent body facing away from the wearer's body, and due to the fact that the layer of the absorbent body facing away from the wearer's body has been punched and/or cut in a manner corresponding to the punched or cut out area of the layer of the absorbent body facing the wearer's body, this provides an absorbent article which eliminates the stiffness of a continuous web of material due to the cutouts and/or punched areas, in addition to an optimum suppleness and an individual adaptation to the wearer's body and an improvement in side leakage. It is known that the preferred absorbent material used in absorbent articles has a certain stiffness. If an entire web of material of such an absorbent material is provided in an absorbent article, as is usually necessary to guarantee adequate absorption and storage properties of the absorbent article, this leads to a stiffness of the absorbent material which makes the absorbent article uncomfortable to wear on the whole.
This leads to a suboptimal suppleness, and adaptation to the individual wearer's body is not guaranteed. The stiffness of a continuous web of material can be eliminated in an inventive manner by the cutout/punched out areas in the minimum of one layer of the absorbent body facing away from the wearer's body. This leads to a great improvement in suppleness and the possibility of an individual adaptation to the body of the wearer.
Furthermore, the permeable areas of the cutout or punched out areas facilitate more rapid penetration of the secreted fluid deeper into the napkin and thus prevent side leakage in an improved manner and thus prevent soiling of the wearer's body or the adjacent clothing in the area of the absorbent article and thus contribute toward a reduction in surface moisture. This effect is increased by the altered capillarity of the materials in the immediate vicinity of the punched out/cutout areas. The material is compressed there', thus increasing the capillarity. This causes a more effective fluid transport into these areas which thus function as “intended penetration areas” where the fluid is transported especially rapidly and effectively.
Preferably the minimum of one layer of the absorbent body facing the wearer's body, which is smaller than the minimum of one layer of the absorbent body facing away from the wearer's body, is in the shape of an oval. Other possible shapes include a rectangular shape, a tongue shape, a triangular shape, a circular shape, a trapezoidal shape or an hourglass shape. Any other geometric shape is also conceivable for the present invention, as long as it meets the requirements specified above.
In another preferred embodiment of this invention, additional dividing seams, e.g., cut-out or punched-out areas, are provided in the minimum of one layer of the absorbent body facing the wearer's body and/or within one or more layers of the absorbent body arranged above and/or below that. These additional dividing seams, e.g., cut-out or punched-out areas, are arranged inside the areas of the above-mentioned layers determined by the shape of the minimum of one layer of the absorbent body facing the wearer's body. For example, the minimum of one layer of the absorbent body facing the wearer's body may have an oval shape and may have additional oval cut-out or punched-out areas concentric with the former. The additional layers of the absorbent body may also have these additional oval punched out areas arranged concentrically, where the corresponding punched areas in the different layers essentially coincide.
The additional dividing seams, e.g., cut-out or punched-out areas in the various layers of the absorbent body, improve the suppleness and adaptability to the body of the individual wearer through the resulting segmentation, while also improving the fluid transport within the absorbent article.
Preferably the absorbent article according to the present invention comprises the following components:
a) a liquid-permeable cover layer and
b) a liquid-impermeable backing layer,
where the absorbent body is arranged between the cover layer and the backing layer.
The minimum of one layer of the absorbent body facing away from the wearer's body preferably has elongated side areas. The cover layer and/or the backing layer may extend laterally outward from the elongated side parts of the absorbent body to provide a pair of elongated side edges for the absorbent article. The cover layer is arranged on the side facing the wearer's body and should be arranged next to the wearer during use. The backing layer is arranged parallel to the cover layer and should be next to the wearer's underwear garment when being used.
The cover layer may be manufactured from materials known in the state of the art. They should be liquid permeable. Known materials include, for example, card weaves and spunbonded nonwovens made of polyester, polypropylenes, polyethylene, nylon or other heat-bonded fibers. Other polyolefins such as copolymers of polypropylene and polyethylene, linear, low-density polyethylene fiber nonwovens which are finely perforated or mesh-like materials are also suitable. Other suitable materials include composite materials of polymers and a nonwoven material. The composite layers are usually formed by extrusion of a polymer on a layer of a spunbonded nonwoven to form an integral layer. This material is preferred, because the outer surface is not irritating to the skin of the wearer and it has a pleasant feel.
With regard to the above-mentioned cover layer, it is also advantageous that this cover layer has the following features. In general, a cover layer is provided to achieve the greatest possible comfort and great adaptability to the wearer's body and should divert fluid to the body under it. The cover layer may be constructed of a relatively nonabsorbent liquid-permeable material, where the cover layer may be constructed of any woven or nonwoven material through which body fluid which contacts its surface can flow easily. The cover layer is preferably made of a material that permits the passage of fluid without drawing the fluid horizontally in parallel to the cover layer to any great extent. In addition, the cover layer should retain little or no fluid in its structure, so that a relatively dry surface is provided next to the wearer's skin. In general, the cover layer is a single layer of a material with a width sufficient to cover the surface of the absorbent body facing the wearer's body. The cover layer preferably extends to the longitudinal edges and is bonded to the backing layer. The cover layer may be bonded to the backing layer using any known method which does not leave any hard or uncomfortable residues that would annoy the wearer. Those skilled in the art are familiar with methods of bonding the various materials and for bonding other possible materials in the absorbent article according to the present invention, including the use of pressure-sensitive adhesives, hot-melt adhesives, two-sided adhesive sheets, ultrasonic welding and heat sealing, to name but a few. Adhesives such as hot-melt adhesives may be used uniformly or in the form of a continuous or noncontinuous layer.
The cover layer may be designed in two parts. Two parts here means that the cover layer may consist of an outer area and a central area. The outer area is preferably essentially in the area of the longitudinal edges of the absorbent article and, if there are wings on the napkin, it may also be designed in the area of the wings, where the central area is designed in the remaining central area of the absorbent article. The two parts of the cover layer can be bonded together. Such a bond can be produced by using a hot-melt adhesive or by providing a welded seam. Other forms of bonds that are known in this field of the art are also included here.
If the cover layer is designed in two parts, the central area of the cover layer and/or the outer area of the cover layer may be a spunbonded nonwoven of polypropylene having an especially thick fiber and thus a high denier. Furthermore, this spunbonded nonwoven may contain more pigment, e.g., have a higher titanium dioxide content to improve the masking properties. Such a polypropylene spunbonded nonwoven with the properties described above may have, for example, a basis weight of 15 to 50 g/m 2 preferably 20 g/m 2 . In a preferred embodiment, it is 70 mm wide.
Other possible materials for the outer area of the cover layer and/or the inner area of the cover layer include spunbonded nonwovens or carded nonwovens of polypropylene, for example, with a basis weight of 15 to 50 g/m 2 , preferably 20 g/m 2 . The preferred composition of the cover layer is a two-part cover layer, where the outer area of the cover layer is made of a polypropylene spunbonded nonwoven with a basis weight of 20 g/m 2 , and where the inner area of the cover layer is made of a perforated polypropylene spunbonded nonwoven in a weight of 20 g/m 2 . The two parts of the cover layer are preferably bonded by a welded seam.
The backing layer may be made of any desired material that is liquid-impermeable. The backing layer preferably allows atmospheric vapor and moisture to pass through the absorbent article while preventing body fluid from passing through. A suitable material is a microembossed polymer film such as polyethylene or polypropylene with an approximate thickness of 0.025 to 0.13 mm. Two-component films may also be used, as well as nonwoven materials or woven materials which are treated to make them liquid impermeable. Other suitable materials include films filled with CaCO 3 or polyolefin in foams. A polyethylene foam with a thickness in the range of approximately 0.5 mm to approximately 10 mm can be mentioned as an example.
The absorbent body in the absorbent article provides a means for absorbing the secreted fluid, in particular menstrual fluid. The total absorption capacity of the absorbent body should correspond to the anticipated loading in the course of the intended use of the absorbent article. In addition, the size and shape of the absorbent body may vary. As explained above, the absorbent body may have the various shapes mentioned above in the area of the minimum of one layer of the absorbent body facing the wearer's body. The minimum of one layer of the absorbent body facing away from the wearer's body may also have various shapes, but at any rate it should be larger than the minimum of one layer facing the wearer's body. It can function as a secondary reservoir. The layer of the absorbent body facing away from the wearer's body may be, for example, rectangular with rounded longitudinal edges, tongue-shaped or oval or it may have any other known geometric shape known in the related art.
The absorbent body is generally made of one or more materials which together are essentially hydrophilic, compressible, adaptable and non-irritating for the skin of the wearer. Suitable materials are well known in the field and include, for example, various natural or synthetic fibers, cellulose fibers, regenerated cellulose or cotton fibers or a blend of cellulose and other fibers, melt-blown polymers such as polyester and polypropylene. The absorbent layers may also include other well-known materials which are used with absorbent articles, including several layers of a cellulose filling, rayon fibers, cellulose sponge, hydrophilic synthetic sponges, such as polyurethane and the like.
In addition, especially when used in incontinence articles, the absorbent body may contain superabsorbers which are very effective in retaining body fluids. Superabsorbers have the ability to absorb a large amount of fluid in relation to their own weight. Typical superabsorbers used in absorbent articles such as sanitary napkins can absorb between approximately 5 and 60 times their weight in body fluids.
A preferred material for the absorbent layer is a coform material which contains, for example, cellulose and polypropylene in a weight ratio of 70:30 and has a basis weight of 150 g/m 2 and is used together with a polypropylene spunbonded nonwoven backing with a basis weight of 17 g/m 2 . As an alternative, for example, a coform material containing cellulose and polypropylene in a weight ratio of 60:40 and having a basis weight of 90 g/m 2 may also be used together with a polypropylene spunbonded nonwoven backing with a basis weight of 20 g/m 2 .
Another layer may be provided on the side of the absorbent body facing the wearer's body, acting as the transfer layer and transfers the fluid to the absorbent body in a suitable manner. This transfer layer is preferably punched or cut out in the same way as the minimum of one part of the absorbent body facing the wearer's body. This transfer layer especially preferably has an open structure which is especially permeable for fluids and has large pores but a low density. For example, laminates of spunbonded nonwoven and carded nonwovens are suitable, with the fluffy side facing up. Such a transfer layer may also have a laminating function (dry and clean).
The transfer layer and/or the minimum of one layer of the absorbent body facing the wearer's body can be differentiated visually from the rest of the sanitary napkin, for example by using a different color for the transfer layer and/or the minimum of one layer of the absorbent body facing the wearer's body than for the rest of the absorbent article.
The transfer layer and/or the minimum of one layer of the absorbent body facing the wearer's body are preferably punched or cut out and applied to one or more other absorbent layer(s) of the absorbent body, preferably made of coform, and preferably bonded together by one of the possible methods mentioned above.
Although the transfer layer and/or the upper layer of the minimum of one layer of the absorbent body facing the wearer's body may have a laminating function, this laminating function may also be assumed, instead or in addition, by the cover layer. The cover layer may in this case contain approximately 1% to 6% titanium dioxide pigment and may have a clean and attractive appearance.
In another preferred embodiment of this invention, the liquid-permeable cover layer may also have a plurality of openings which are formed in it. The size of these openings should be such that a fluid can pass through the cover layer and thereby enter the absorbent body. The openings may be arranged in a longitudinal direction or may be localized in larger numbers in a certain area, which is assumed to be the area that will come in contact with the fluid. The openings should increase the rate at which the body fluids can reach the absorbent body. This facilitates providing a much drier surface for the cover layer than if the openings were not present.
The part of the absorbent body facing the wearer's body may preferably have embossed lines through which the fluid is guided along especially preferred pathways. These embossed lines may also be provided in the transfer layer and/or individual or all of the other layers of the absorbent body.
The cover layer may also be treated with a surfactant to make it more hydrophilic and thus support the absorption of fluid. The surfactant may contain topical additives or internally added materials such as polysiloxanes.
Furthermore, the absorbent article may have another layer on the side of the absorbent body facing away from the wearer's body to act as a distributing layer. In a preferred embodiment, this distributing layer is folded. It may serve as the primary reservoir. It advantageously contains especially small pores and thus has the greatest capillarity in the system of the preferred absorbent article according to the present invention. A melt-blown fiber layer is especially preferably used for the distributing layer. This melt-blown layer of polypropylene, for example, may have a basis weight of 65 g/m 2 and in a preferred embodiment it is folded to a final width of 45 mm and a length of 125 mm.
Some or all of the individual layers of the absorbent article may be bonded together in some areas or in totality. In a preferred embodiment, their bonding can be accomplished by using a hot-melt adhesive. Other bonding methods known in the related art, however, should also be included within the scope of the present patent application.
In another preferred embodiment of this invention, the absorbent article according to the present invention has wings on its longitudinal side edges, where the minimum of one layer of the absorbent body facing away from the wearer's body may continue into these wings but need not necessarily extend into these wings. The wings and the longitudinal body of the absorbent article may be provided with a longitudinal adhesive system consisting of a hot-melt adhesive, for example, with a preferred area of 50×190 mm for the longitudinal body of the absorbent article and a preferred area of 20×50 mm for the respective wing adhesive systems of the absorbent article. The longitudinal adhesive system and the wing adhesive systems are each preferably covered by silicone paper or some other possible covering which is known in the state of the art.
The absorbent article according to the present invention is preferably used as a sanitary napkin or as an incontinence diaper.
Furthermore, the absorbent body according to the present invention may include a flow layer and a reservoir layer in a manner familiar to those skilled in the art. Suitable flow layers are made, for example, of cellulose, cellulose-synthetic fiber blends such as coform materials, airlaid-cellulose-synthetic fiber blends, foam materials or high-loft nonwovens and they may contain superabsorbers as an additional component.
Suitable reservoir layers are characterized, for example, by the materials mentioned above for the absorbent body. In an especially preferred embodiment, the minimum of one layer of the absorbent body facing the wearer's body acts as a flow layer.
The absorbent article according to the present invention especially preferably has a density and/or pore gradient. The layer next to the body has the lowest density and the layer next to the liquid-impermeable backing layer has the greatest density.
This facilitates diversion of fluid away from the wearer's body.
Such a density and/or pore gradient can be produced in a manner known to those skilled in the art, e.g., by using materials of different densities or by using different pore sizes, etc.
In another aspect, the present invention provides a method of producing an absorbent body, in particular a segmented absorbent body. These absorbent bodies are used in particular in the absorbent articles according to this invention.
A first method according to this invention includes the following steps: a first web of material is brought over a first rotating conveyor element; the first web of material is processed for separation by a second rotating conveyor element along a closed line, creating a first closed dividing seam through the entire thickness of the first web of material; the part of the first web of material outside the first dividing seam is conveyed away over the first rotating conveyor element; the minimum of one part of the first web of material bordered by the first dividing seam is conveyed further with the second rotating conveyor element; a second web of material is conveyed over a third rotating conveyor element; the minimum of one part of the first web of material bordered by the first dividing seam is deposited on the second web of material, and the second web of material is processed for separation by the second rotating conveyor element along the peripheral shape of the minimum of one part of the first web of material bordered by the first dividing seam, thereby creating a minimum of one second self-contained dividing seam through at least partial areas of the thickness of the second web of material, and the minimum of one first and second self-contained dividing seam essentially coincide.
The first web of material and the second web of material may comprise individual materials or multiple materials.
The first web of material and the second web of material may each be composed of one or more layers which may preferably be bonded together with adhesive and which may consist of different materials. The first web of material may comprise in particular layers of the materials used in the minimum of one layer of the absorbent body facing the wearer's body as well as the transfer layer of the absorbent article according to this invention.
The second web of material may comprise in particular layers of the materials used in the minimum of one layer of the absorbent body facing away from the wearer's body and the distributing layer of the absorbent article according to this invention.
The term “self-contained dividing seam” as used in the present invention is understood to refer to dividing seams which define an internal closed geometric shape in a web of material.
The minimum first and second self-contained dividing seams may assume any suitable geometric shape, but the especially preferred shapes are an oval, a triangle, a circle, a tongue or an hourglass. The shape of the layer of the absorbent body facing the wearer's body in the finished absorbent article according to this invention is determined by the shape of the first dividing seam.
In an especially preferred embodiment of the method according to this invention, the second web of material and the minimum of one part deposited on the former and bordered by the first dividing seam is separated into individual units in another step, with each unit comprising a part of the first web of material bordered by the first dividing seam and a frame grid formed by the second web of material.
The term “frame grid” as used here, by analogy with the articles according to this invention described here, is understood to be the part of the material of the absorbent material which remains outside the second dividing seam. The frame grid thus corresponds, for example, to the part of the layer of the absorbent article according to this invention facing away from the wearer's body outside the second dividing seam. The frame grid includes the area of the second web of material defined by the second dividing seam.
In another preferred embodiment of the two methods according to this invention as described here, the individual steps of the method are repeated continuously.
In an especially preferred embodiment of the method according to the present invention, the first web of material is conveyed at a rate corresponding to the peripheral speed of the second conveyor element. This embodiment of the method can be used in particular with the absorbent articles produced according to this invention, when the difference in length between the part of the web of material bordered by the first line, corresponding to the layer of the absorbent body facing the wearer's body and the frame grid formed by the second web of material or the layer of the absorbent body facing away from the wearer's body is not very great, e.g., amounting to less than 25%.
One embodiment of the method according to this invention in which the first web of material is conveyed intermittently and the second rotating conveyor element rotates continuously is especially preferred.
This has the advantage that the cost of materials can be minimized. Due to the intermittent conveyance of the first web of material over the first rotating conveyor element with a second conveyor element rotating continuously at the same time, the first self-contained dividing seams can be worked into the first web of material in a closer sequence in successive separation processing steps than if the first and second conveyor elements were running continuously in synchronization. Therefore, the amount of the first web of material used for the absorbent article can be increased, and the amount of the first web of material discarded and thus the amount of waste can be minimized.
This process management is especially preferred if the difference in length between the layer facing the wearer's body and the layer facing away from the wearer's body is relatively great in the absorbent article produced, e.g., greater than 25%. In these cases, due to the more effective utilization of the first web of material, the method can be less expensive. Intermittent conveyance is understood here to refer to both conveyance at two different successive speeds and interrupted conveyance in phases.
In a most especially preferred embodiment of the method according to this invention, the first and second rotating conveyor elements run in synchronization during the separation working of the first web of material. This has the advantage that the shape of the minimum of one part of the first web of material bordered by the first dividing seam corresponds exactly to the shape of the second dividing seam in the second web of material, when the same dividing elements are used for the two separation processing steps.
In another especially preferred embodiment of the method according to this invention, the rotating conveyor elements are designed in the form of rolls or wheels. These designs permit an especially simple and inexpensive embodiment of this method.
In another especially preferred embodiment of the method according to this invention, the first web of material is processed for separation by means of at least one separating element mounted on the second rotating conveyor element.
It is also especially preferred for the second web of material to be processed for separation by means of at least one separating element mounted on the second rotating conveyor element.
This makes it possible to mount similar separating elements on the second rotating conveyor element, which is especially economical.
The separating element may be, for example, all known cutting or punching devices with which those skilled in the art are familiar. They may be mounted on the second conveyor element in a fixed mount or so they can be telescoped outward.
Due to the fact that the minimum of one part of the first web of material bordered by the first dividing seam is deposited on the second web of material by means of the second conveyor element, this yields a composite web of material in which a particular structure is preformed. In subsequent separation of the composite web of material into separate individual units, these units each include a top layer and a bottom layer, with the top layer having a smaller surface area than the bottom layer, and the bottom layer having a dividing seam corresponding to the shape of the top layer.
In another especially preferred embodiment of the method according to this invention, in another step, the second web of material and the minimum of one part of the first web of material, bordered by the first dividing seam and deposited on the second web, are divided into individual units, with each unit comprising a part of the first web of material bordered by the first dividing seam plus a frame grid formed by the second web of material.
In an especially preferred embodiment of the method according to this invention, an adhesive layer is applied at least to partial areas of the second web of material in order to bond the second web of material adhesively to at least parts of the first web of material. It is especially preferable to provide an adhesive layer only on those areas of the second web of material where the minimum of one part of the first web of material bordered by the first dividing seam has been deposited.
In an especially preferred embodiment of the method according to this invention, a reduced pressure is created in an area of the second conveyor element to support the conveyance of the minimum of one part of the first web of material bordered by the first dividing seam on the second conveyor element.
It is advantageous here to design the second conveyor element as a hollow wheel or roller, where the conveyor element designed to be hollow is preferably subdivided into angular segments by at least one inner bulkhead, and these angular segments may be acted upon by pressure independently of one another in the form of a reduced pressure reservoir, a balanced pressure reservoir or an excess pressure reservoir. The segment of the conveyor element with which the web of material is conveyed is preferably acted upon by reduced pressure.
As an alternative, however, other methods known to those skilled in the art may also be used to support or accomplish the adhesion of the web of material to the second conveyor element and, thus, conveyance of the web of material.
In addition, in another especially preferred embodiment of the method according to this invention, deposition of the part of the first web of material bordered by the first dividing seam onto the second web of material can be accomplished or supported by an excess pressure produced in the area of the second conveyor element.
Deposition of the part of the first web of material bordered by the first dividing seam on the second web of material is supported or accomplished by applying an excess pressure to a suitable angular segment of the conveyor element.
As an alternative, deposition of the part of the first web of material bordered by the first dividing seam onto the second web of material can be supported or accomplished by an elastic ejector.
In another especially preferred embodiment of the method according to this invention described here, several first and second self-contained dividing seams are worked side-by-side into the first and/or second webs of material in spaced apart relationship. This has the advantage that wider webs of material can be used and thus, higher piece numbers of the absorbent articles can be produced per unit of time.
Although the minimum of one first dividing seam always extends throughout the entire thickness of the first web of material, and thus the forms described above are separated from the first web of material, the second dividing seam can extend throughout the entire thickness of the second web of material, or only through partial areas of the thickness of the second web of material. Thus, in the latter case, an intended breaking line is created in the material of the second web of material.
In the absorbent article produced by the method according to this invention, the shape of the layer of the absorbent body facing the wearer's body is determined by the minimum of one first dividing seam.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will now be described in detail with the help of the accompanying figures, where:
FIG. 1 is a top view of a preferred embodiment of the present invention;
FIG. 2 is cross section through a preferred embodiment of the present invention;
FIG. 3 is a perspective view of a preferred embodiment of the present invention in a partially cutaway view;
FIGS. 4 through 7 are preferred segmentations in an absorbent body which can be used in preferred embodiments of the present invention;
FIG. 8 is a device for carrying out the method of producing an absorbent article;
FIG. 9 is another device for carrying out the method of producing an absorbent article; and
FIGS. 10 a through k are especially preferred shapes and punched patterns of the layer of the absorbent body facing the wearer's body.
The reference numbers used in the figures have the following meanings:
1 : outer cover layer 2 : hot-melt adhesive 3 : central cover layer 4 : transfer layer 5 : layer of the absorbent body facing the wearer's body 6 : layer of the absorbent body facing away from the wearer's body 7 : distributing layer 8 : backing layer 9 : wing adhesive system 10 : covering of the wing adhesive system 11 : longitudinal body adhesive system 12 : covering of the longitudinal body adhesive system 13 : welded seam 14 : wing 15 : dividing seam 20 : first conveyor element 21 : second conveyor element 22 : separating element 24 : third conveyor element 25 : first web of material 26 : second web of material 28 : first self-contained dividing seam 29 : second self-contained dividing seam 30 : part of the web of material bordered by the first dividing seam 31 : part of the first web of material outside the first dividing seam 33 : loop forming roller 35 : loop forming roller 36 : tension rollers 37 : tension rollers 38 : d.c. motor 39 : reduced pressure area 40 : screen 41 : excess pressure area 42 : adhesive device 43 : adhesive layer 45 : width adjusting roller 46 : draw-off roller 47 : web width 48 : composite web 50 : absorbent body
DETAILED DESCRIPTION
The sanitary napkin illustrated in FIGS. 1 and 2 has essentially an hourglass shape with wings 14 that project outwards being formed in the middle of the longitudinal sides and which are tapered toward the middle. The length of the sanitary napkin may be 238 mm, for example, and the width including the two wings 14 is 150 mm, for example. The top layer of the sanitary napkin is formed by an outer cover layer 1 and a central cover layer 3 . The central cover layer 3 extends along a central strip over the entire length of the sanitary napkin. The width of the central cover layer 3 may be 70 mm, for example. The central cover layer is made of a perforated polypropylene spunbonded nonwoven with a basis weight of 20 g/m 2 .
The outer cover layer 1 overlaps with the central cover layer 3 and is bonded to it in the overlap area. This bonding can be accomplished by a welded seam, for example. As an alternative, the two cover layers 1 and 3 may also be bonded together by a hot-melt adhesive. The outer cover layer is also made of a perforated polypropylene spunbonded nonwoven with a basis weight of 20 g/m 2 .
The multi-layer absorbent body of the sanitary napkin is located beneath the central cover layer. In the advantageous embodiment of this invention described here, the absorbent body includes as the top layer the transfer layer 4 . The layer of the absorbent body 5 facing the wearer's body is beneath the transfer layer 4 and may also be referred to as an absorbent core. The layer of the absorbent body 6 facing away from the wearer's body is also arranged beneath the layer 5 with the distributing layer 7 arranged beneath it.
The transfer layer 4 is bonded to the central cover layer 3 over its upper surface by means of a hot-melt adhesive 2 . The transfer layer 4 consists of a laminate of a spunbonded nonwoven and a carded nonwoven with a basis weight of 52 g/m 2 and is arranged in such a manner that the fluffy side of the laminate faces upward, i.e., in the direction of the wearer's body. In addition, the transfer layer is differentiated in color from the remainder of the sanitary napkin.
The layer of the absorbent body 5 facing the wearer's body is arranged beneath the transfer layer 4 . The transfer layer 4 and the layer of the absorbent body 5 facing the wearer's body are bonded together by means of a hot-melt adhesive 2 . The transfer layer 4 and the layer of the absorbent body 5 facing the wearer's body are punched out in the form of an oval in the present advantageous embodiment of this invention, and they are arranged in the central area of the sanitary napkin. The oval shape has a length of 110 mm, for example, and a width of 45 mm. The layer of the absorbent body 5 facing the wearer's body is made of a coform material, for example, containing cellulose and polypropylene in a weight ratio of 70:30 and having a basis weight of 150 g/m 2 . It is used together with a spun-bonded nonwoven carrier of polypropylene with a basis weight of 17 g/m 2 . The laminate of coform material and spunbonded nonwoven carrier has a line embossing with compressed areas.
Especially preferred shapes of layer 5 facing the wearer's body which may be used as an alternative to the oval shape are illustrated in FIGS. 10 a - k . In addition, the layers 5 of the absorbent body facing the wearer's body, as shown in FIGS. 10 a - k , have internal dividing seams 15 which further segment the layers 5 . These dividing seams also may be provided in the same way in layers 4 , 6 , 7 of the absorbent body above and/or beneath that.
The layer of the absorbent body 6 facing away from the wearer's body is arranged beneath the layer of the absorbent body 5 facing the wearer's body. The layer of the absorbent body 6 extends essentially over the same area as the central cover layer 3 , but is shorter in the area of the rounded transverse ends of the sanitary napkin, so that the central cover layer 3 projects over the layer of the absorbent body 6 facing away from the wearer's body in this area. The layer of the absorbent body 6 facing away from the wearer's body may be 220 mm long and 70 mm wide, for example, and made of a coform material of cellulose and polypropylene in a weight ratio of 60:40 and with a basis weight of 90 g/m 2 . It is used together with a spunbonded nonwoven carrier of polypropylene with a basis weight of 20 g/m 2 .
An oval punched area provided in the central area of the layer of the absorbent body 6 facing away from the wearer's body corresponds in size and shape to the layer of the absorbent body 5 facing the wearer's body and to the transfer layer 4 . Due to the punched area, the layer of the absorbent body 6 facing away from the wearer's body is divided into an inner area and an outer area. The outer area represents the frame grid. The inner oval area of the layer of the absorbent body 6 facing away from the wearer's body lies with complete coverage beneath the layer of the absorbent body 5 facing the wearer's body. The top surface of the layer of the absorbent body 6 facing away from the wearer's body is bonded to the central cover layer 3 by means of a hot-melt adhesive 2 in the area not covered by the layer of the absorbent body 5 facing the wearer's body.
In the central area of the sanitary napkin, the distributing layer 7 is arranged beneath the layer of the absorbent body 6 facing away from the wearer's body. The distributing layer 7 is made of a web of embossed melt-blown material of polypropylene with a basis weight of 65 g/m 2 folded on itself to yield a final width of 45 mm with a length of 125 mm, for example. A liquid-impermeable backing layer 8 arranged beneath the distributing layer 7 is made of a polyethylene film with a basis weight of 25 g/m 2 . The liquid-impermeable backing layer prevents the fluid that has penetrated into the sanitary napkin and been retained there from escaping outward from the absorbent layers at the bottom. The backing layer 8 is bonded to the layer of the absorbent body 6 facing away from the wearer's body and to the central cover layer 3 and the outer cover layer 1 by means of a hot-melt adhesive 2 .
In the area of the wings 14 , wing adhesion systems 9 are provided on the outer surface of the backing layer 8 facing away from the wearer's body; by means of these wing adhesion systems, the wings 14 can be attached to the side of the wearer's underwear facing away from the wearer's body. The adhesive material may be, for example, a hot-melt adhesive. To protect the adhesive surfaces of the wing adhesion systems 9 , they are provided with a covering 10 of silicone paper which can be removed from the adhesive elements before using the sanitary napkin. Before use, the two wings 14 and the side areas of the sanitary napkin can be folded onto the central cover layer 3 , so that the wing adhesion systems 9 come to lie side by side. The two wing adhesion systems 9 may then be covered with the covering 10 of silicone paper which may have an area of 70 mm×60 mm, for example.
Additional fixation of the sanitary napkin to the wearer's underwear is made possible by the longitudinal body adhesive system 11 which extends over the central area of the outer surface of the backing layer 8 over an area of 50 mm×190 mm. The sanitary napkin can be attached to the inside of the wearer's underwear with the longitudinal body adhesive system 11 . The longitudinal body adhesive system 11 may also be formed by a hot-melt adhesive, for example, and is protected by a second covering 12 which is detachably attached to it. The covering 12 of the longitudinal body adhesive system is also made of silicone paper and has an area of 60 mm×200 mm. The covering 12 is removed before using the sanitary napkin, thus exposing the adhesive surface of the longitudinal body adhesive system 11 .
FIGS. 4 through 7 illustrate various segmentation patterns which can be provided in the absorbent body 50 or individual layers of the absorbent body 50 of the absorbent article. FIG. 4 illustrates a square segmentation and FIG. 5 illustrates rhomboidal segmentation. FIG. 6 shows the segmentation in the form of a plurality of circular dividing seams 15 .
When using an oval-shaped minimum of one layer 5 of the absorbent body facing the wearer's body, the segmentation illustrated in FIG. 7 of at least one of the layers 4 , 6 , 7 of the absorbent body 50 arranged above and/or beneath it is especially advantageous. Due to the dividing seams 15 extending radially outward from the oval peripheral shape of the minimum of one layer 5 of the absorbent body facing the wearer's body (soleil notching), an especially easy basket shaping of the absorbent article and thus improved suppleness (body fit) to the wearer's body are achieved.
FIG. 8 illustrates a device for carrying out the method according to this invention.
A first running web of material 25 of absorbent material is conveyed over a conveyor unit (not shown here), e.g., driven conveyor rolls or belts or rollers to two loop-forming rollers 33 , 35 . A supply loop of the first web of material 25 is formed by the two loop-forming rollers 33 , 35 . As an alternative, instead of the loop-forming rollers 33 , 35 , other storage devices with which those skilled in the art are familiar may also be used. The first web of material 25 is then conveyed to a first conveyor element 20 by a pair of tension rollers 36 , 37 that are synchronized but driven intermittently. The first conveyor element 20 is designed here as a counter-cutting roller. The irregular or intermittent drive of the tension rollers 36 , 37 is accomplished by an electronically controlled d.c. motor 38 , but it may also be provided by other means such as a corresponding hydraulic or mechanical system. For example, it is also conceivable to use cams or disks.
The first web of material 25 is guided between the first conveyor element 20 and a second conveyor element 21 which is designed here as a cutting roller. The cutting roller 21 has a stationary internal bulkhead about which the roller rotates. The bulkhead is configured to separate the interior of the roller (e.g., between the bulkhead and the roller itself) into two areas. The first area, indicated by the reference numeral 39 in FIG. 8 and the reference arrow 39 extending therefrom to the roller 21 , is in fluid communication with a vacuum line, which is indicated by the other reference arrow extending from the reference numeral 39 in FIG. 8 , so that the first area is always subject to a vacuum as the roller rotates relative to the bulkhead. The second area, indicated by the reference numeral 41 in FIG. 8 , is in fluid communication with a positive pressure line, also indicated by the reference numeral 41 in FIG. 8 , for receiving pressurized air or gas therein so that the second area is always subject to positive pressure as the roller 21 rotates relative to the bulkhead. Mesh-like screens 40 are applied to the outer shell of the cutting roller 21 at regular intervals along the circumference of the roller. Due to the rotation of the outer shell of the cutting roller 21 either a vacuum pressure or positive pressure can act in the area of each screen 40 . Individual separating elements 22 are arranged around each screen 40 . These separating elements here are designed as punching devices; as an alternative, however, cutting devices may also be used. Those skilled in the art are familiar with suitable cutting or punching devices. Individual areas 30 of the first web of material are punched out by the punching devices 22 and are conveyed further on the cutting roller 21 by the vacuum pressure acting through the screens 40 in the punched area as the cutting roller rotates past the first area 39 defined by the bulkhead.
The parts 30 of the web of material bordered by the first dividing seam in the method described here are oval. They are referred to below as the absorbent core 30 . The part 31 of the first web of material outside the first dividing seam, i.e., the punched grid, is conveyed away after punching over the mating cutting roller 20 and a width adjusting roller 45 and draw-off roller 46 . The first web of material 25 is under continuous tension due to the width adjusting roller 45 and the draw-off roller 46 .
Due to the intermittent drive of the tension rollers 36 , 37 , the first web of material 25 reaches a speed corresponding to the peripheral speed of the cutting roller 21 only during the punching operation. Therefore, the distance between two punched-out areas in the punched grid, referred to here as the web width 47 , can be kept as small as possible. This is especially advantageous if the absorbent cores 30 are deposited onto the second web of material at a relatively great distance from one another, e.g., if this distance exceeds the length of the absorbent cores 30 by 25%.
A third conveyor element 24 is arranged next to the cutting roller 21 at a distance from the first conveyor element 20 in the direction of production. A second web of material 26 , also an absorbent material, is conveyed over an unwinder (not shown) and between the cutting roller 21 and the third conveyor element 24 . Due to the punching devices 22 mounted on the cutting roller 21 , punched areas (e.g., fold lines) are being worked into the second web of material continuously, having essentially the same shape and size as the punched absorbent cores 30 punched out of the first web of material 25 . The absorbent cores 30 are deposited on the second web of material 26 simultaneously with the punching operation. To do so, the cutting roller rotates relative to the bulkhead so that the absorbent core 30 is rotated into fluid communication with the second area 41 , which is subject to positive pressure. The positive pressure thus acts on the absorbent core 30 through the corresponding screen 40 during the punching operation to urge the core away from the roller 21 and toward the second web of material. By simultaneously depositing the absorbent cores 30 on the second web of material and punching the second web of material 26 , the result is that the second web of material is punched in the resulting composite web 48 along the contours of the absorbent cores 30 deposited on the web.
Adhesion between the absorbent cores 30 and the second web of material is supported by application of adhesive 43 by an adhesive device 42 before punching.
An intermittent drive of the first web of material is not necessary if the distance between two successive absorbent cores 30 exceeds its own length by less than 25%. The elasticity of the first web of material here makes it possible for the first web of material to be conveyed towards and away at a lower speed than the peripheral speed of the cutting roller 21 . Therefore, it is also possible to reduce the amount of the punched grid in the first web of material. FIG. 9 illustrates a method in which two methods as described above are combined in succession. In the method illustrated here, the composite web 48 produced in the first method is used as the second web of material in the successive method.
This makes it possible to deposit additional absorbent cores 30 ′ punched out of a third web of material onto the composite web 48 in corresponding manner and then to segment the composite web 48 through additional punching. The absorbent cores 30 ′ deposited on the composite web 48 in the subsequent procedure may have the same or different shapes and sizes as the absorbent cores 30 punched out of the first web of material and already deposited on the composite web. | An absorbent article, such as a sanitary napkin or an incontinence diaper, has an absorbent body having at least one fold line formed therein defining at least two segments of the absorbent body. The segments formed by the at least one fold line are generally foldable relative to each other along the at least one fold line to facilitate conformance of the absorbent article to the wearer's body. In a method of forming the absorbent body, a first cut-out from a first web material is passed through a nip along with a second web material whereby the cut-out from the first web material overlays the second web material. A fold line is then formed in the second web material at the peripheral edge of the cut-out of the first web material as the cut-out and second web material pass through the nip. | 0 |
BACKGROUND OF THE INVENTION
The present invention relates to the structure of buildings; and more particularly to buildings having a pyramidal shape.
Since the beginning of time, housing and general shelter construction has been of great importance. Many societies have continuously attempted to develop low cost, easily constructed buildings capable of a variety of uses including residences, storage and like applications. The obvious use of a building is to provide shelter against the atmospheric elements. In many locations climatic conditions produce storms with high velocity winds which require that buildings constructed there be able to withstand the forces generated by such winds.
It is also desirable to be able to construct building structures formed of a plurality of prefabricated panels. These panels can be produced in factories under controlled conditions and quality standards. Mass production techniques also reduce the cost of prefabricated panels. The costs can be reduced further when the panels have common shapes with the number of different shapes being kept to a minimum.
There is also a need for temporary shelters which can be stored in a collapsed state and quickly assembled when a need arises. For example, these temporary shelters find use in the aftermath of disasters to provide housing for victims displaced from their homes. In addition, collapsible shelters can be utilized by military personnel and others when traveling.
While pyramids can provide structural and other benefits, the construction is not collapsible. Moreover, windows, doors and other openings are difficult to introduce to the slanted walls. Also, pyramids are not readily modular for combination to create larger structures.
SUMMARY OF THE INVENTION
The general object of the present invention is to provide a sturdy building structure.
Another object is to provide a building structure that is fabricated from panels of similar shape and size which facilitate prefabrication and erection.
A further object is to provide a structure in which the interconnected panels become self supporting without the need for internal members.
A still further object is to provide self supporting structures that can be adjoined as modular units to construct larger buildings in a variety of floor plan arrangements.
Yet another object of the present invention is to provide a shelter that can be collapsed for storage and transport.
These objects are fulfilled by a building having a plurality of sloping, rigid panels adjoining one another in the general form of a pyramid. Adjacent sides are joined along a separate ridge seam that extends downward from a common vertex and at least two adjacent sloping panels are truncated transversely to the ridge seam therebetween to form a vertical opening. Other pairs of adjacent panels can be truncated similarly to provide additional openings to the building.
The basic embodiment of this structural concept has four oblique quadrilateral rigid panels joined together with all the panels meeting at a common vertex. The quadrilateral shape of the panels form triangular openings at the bottoms of two opposite ridges. In large scale embodiments, these openings are closed by structural elements that include windows and a door.
The building structure of the invention can be utilized as a modular unit that can be interconnected to other units in straight or staggered fashion to construct larger buildings. The different arrangements can provide a variety of floor plan possibilities. Significantly, each modular unit enjoys its own structural stability and contributes to the overall strength of the larger structure.
This pyramidal building design can also be applied to temporary shelters, as substitutes for tents commonly used in diaster relief for example. In this version, the panels can be joined by hinges along the ridge enabling the structure to collapse into a flat form for storage and transport. The triangular openings of the shelter can be closed by flexible material, such as canvas or plastic, because the panels provide a self-supporting shell.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric view of a building according to the present inventions;
FIG. 2 is top view of the building;
FIG. 3 is a plane view of a panel which forms part of the building;
FIG. 4 is an isometric view of another embodiment of building having a floor that is elevated above the ground;
FIG. 5 is a plane view of a smaller, transportable embodiment of he building structure in a collapsed state; and
FIG. 6 illustrates two buildings attached to form a larger structure.
FIG. 7 illustrates an alternative embodiment of staggered units.
FIG. 8 snows a floor plan of an embodiment constructed from the staggered connection of three units according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
With initial reference to FIGS. 1 and 2, a building 10 is a permanent structure having multiple stories with an interior subdivided by walls and floors. The generally four-sided pyramidal structure of the illustrated building 10 is formed by four rigid panels 11, 12, 13 and 14, although different numbers of panels may be provided. In the assembled building, the panels 11-14 create a slanted roof that extends from the ground upward to two roof ridges 16 or 18 which meet at a common vertex 20. The building 10 has one half formed by the first and fourth panels 11 and 14, which join at a side ridge 22 extending between the ground and vertex 20. The other half of the building comprises the second and third panels 12 and 13 which are joined along another side ridge 24 that extends from the ground to the vertex 20.
The four rigid panels 11-14 have similar oblique shapes. In particular, the first and third panels 11 and 13 are identical, and the second and fourth panels 12 and 14 are mirror images of the first and third panels as evidenced in FIG. 2. With this similarity understood, the structure of the panels will be described with respect to the first panel 11 shown in detail in FIG. 3. The first panel 11 has four edges 26, 27, 28 and 29 forming a preferably oblique panel wherein none of the edges is either perpendicular or parallel to any of the other edges. Other quadrilateral panels, such as trapezoidal panels, may be used within the broad concept of the present structural design. For the preferred panel, the first and second edges 26 and 27 meet at a first corner 30 and extend from one another at an acute angle 31. The second and third edges 27 and 28 come together at a second corner 35 at an obtuse angle 32. The third and fourth edges 28 and 29 of the first panel 11 join at an obtuse angle 33 at the third corner 36. Finally, the fourth edge 29 meets the first edge 26 at the fourth corner 37 with an acute angle 34 therebetween. The first and third edges 26 and 28 are opposed to one another on opposite edges of the first panel 11 with the first edge 26 being longer than the third edge 28. The second and fourth edges 27 and 29 also are opposed to each other on opposite edges of the first panel 11 with the fourth edge 29 being slightly longer than the second edge 27 in the preferred embodiment.
When the four panels 11-14 are joined together to form the structure of building 10, the first edges 26 of the first and fourth panels 11 and 14 are joined together to form side ridge 22. Similarly, the first edges 26 of the second and third panels 11 and 13 come together at the other side ridge 24. The second edges 27 of the first and second panels 11 and 12 are connected at one roof ridge 16, and the joining of the second edges 27 of the third and fourth panels 13 and 14 forms the other roof ridge 18. In the assembled structure, the fourth edge 29 of each panel 11-14 rests on the ground. The assembly of panels 11-14 is symmetrical about a first vertical plane that contains the two roof ridges 16 and 18 and also is symmetrical about a second vertical plane that contains the two side ridges 22 and 24 as is apparent in FIG. 2. The panels assembled in this manner are self supporting in that internal support members are not required. Although internal walls may be provided to subdivide the interior space into rooms, such internal walls are non-load bearing with respect to the exterior panels.
Referring to FIGS. 1 and 2, the third edges 28 of the four panels 11-14 create a pair of triangular openings 38 and 39 on opposite sides of the building 10. The present structural concept may be implemented with only one opening or more than two openings by truncating the ridges 16, 18, 22 and 24 at what otherwise would be bottom corners of a pyramidal structure. Each opening 38 and 39 is closed by a structural element 40 and 42, respectively. Although only structural element 40 is visible in FIG. 1, the structural element 42 closing the other triangular opening 39 is similar to the illustrated element 40 because of the symmetry of the building about side ridges 22 and 24. Structural element 40 comprises a pair of triangular walls 44 and 46 which bow inward slightly at central vertical joint 49 and each triangular wall 44 and 46 has a hypotenuse which extends along the third edge 28 of an adjoining panel 13 or 14. The adjacent panels 13 and 14 may extend outward from the triangular walls 44 and 46 providing an overhang. The first triangular wall 44 has a window 47 and the second triangular wall 46 has a door 48 for access to the interior of the building 10. Alternatively, one or both of the triangular walls 44 and 46 can be formed entirely of glass panels to provide window walls which allow natural light into the building 10.
FIG. 4 illustrates an embodiment in which pyramidal building 100 is raised above the ground as may be desirable on beach front property or in other areas prone to flooding. The structure of building 100 is similar to that of building 10 in FIG. 1 in that the latter building is formed by four quadrilateral panels 102 joined to form a pyramid with truncated corners that create openings 104 on opposite sides of the building. The openings are closed by structural elements 105 which comprise planar walls recessed from the adjacent edges of the truncated panels 102.
Each panel 102 has a pair of legs 106 contiguous therewith which raise the floor 108 of the building 100 above the ground and stairs 110 provide access to the elevated floor. Additional structural members (not shown) may be required to support the floor 108 from below. The spaced apart legs 106 create openings to the region beneath the building so that in flood prone geographical areas water is allowed to flow under the building. This raised version of the building concept also can be used to create storage space under the structure even in non-flood prone areas.
Although buildings 10 and 100 are permanent structures with several rooms on different floor elevations, the present building concept also can be utilized to provide a smaller, transportable shelter as an alternative to tents. In this transportable shelter 50, the four oblique quadrilateral rigid panels 11-14 are assembled in the same manner as the larger structure shown in FIGS. 1 and 2, but with flexible connectors 52, such as hinges, fastening adjacent panels as shown in FIG. 5. Such connection enables the shelter 50 to fold flat so that the first and fourth panels 11 and 14 lie in a common plane and the second and third panels 12 and 13 also lie in a common plane. In the collapsed state, the inner surfaces of the first and fourth panels 11 and 14 lie against inner surfaces of the second and third panels 12 and 13. Alternatively, the panels can be connected with removable fasteners that enable the panels to be separated for storage and transport. The rigid panels 11-14 of the collapsible structure can be fabricated of a lightweight material, such as a plastic foam, which has a sufficient degree of rigidity while providing a lightweight assembly that is easily transported. In the assembled state, the edges of adjacent panels interlock, for example by a tongue and groove mechanism, to provide a weather tight joint.
A larger structure 60 can be fabricated as shown in FIG. 6 by joining two or more pyramidal shelters 50 (or even permanent buildings 10) at their triangular openings 62 formed by the truncation of the bottom corners. In this combination, the joined openings 62 do not have to be closed by a structural element 64 as does the exposed opening 66. Referring to FIG. 7, two or more pyramidal shelter 50 can be adjoined in offset manner to provide a variety of interior space arrangements. For example, as illustrated in FIG. 8, a floor plan of three staggered structures 50 provides an elongated central area 72 with a plurality of shorter areas 74 to the sides. The staggered arrangement also increases the available space for windows and doors. The modularity of the units 50 can also contribute to facilitated construction.
Because the panel assembly of each transportable shelter 50 is self-supporting, the exterior structural element 64 can be formed by a pair of flexible sheets 68 which close the triangular opening 66. Such sheets 68 may be made of canvas or plastic, including a transparent plastic to allow sun light into the shelter. The two sheets 68 are fastened by a closure mechanism 70, such as a zipper, along the vertical seam to provide a passage for ingress and egress.
The foregoing description was primarily directed to preferred embodiments of the invention while some attention was given to various alternatives within the scope of the invention. It is anticipated that one skilled in the art will likely realize additional alternatives that are not now apparent from the disclosure of embodiments of the invention. Accordingly, the scope of the invention should be determined from the following claims and not limited by the above disclosure. | A generally pyramidal structure is formed by a plurality of sloping sides with adjacent sides abutting along a ridge joint which intersects a common vertex. The pyramid is truncated, thereby creating an opening transverse to one ridge joint and extending through the two adjacent sloping sides. The opening typically is closed by a vertical structural element. This pyramidal building design can be applied to structures of different sizes from small collapsible shelters, as substitutes for tents, to permanent buildings having multiple stories and/or adjoined units. The basic embodiment of this design has four oblique quadrilateral panels which form triangular openings along opposite ridges. | 4 |
FIELD OF THE INVENTION
The invention relates to a device for the spatially resolved measurement of changes of physicochemical characteristics of thin layers applied onto, preferably metal-coated, transparent carriers.
The measurement is done by means of an expanded laser beam, which is directed through the transparent layer and onto the metal film at different angles. When using certain angles and a metal film of suitable thickness, surface plasmons will be excited which interact with the incident electromagnetic field, partially extinguishing the reflected radiation.
The angle of incidence at which the reflection-minimum—the so-called SPR minimum—occurs, is dependent on the index of reflection of the medium adjacent to the metal film.
Highly sensitive real time detection of adsorption- and desorption processes which change the reflection indices are thus possible.
BACKGROUND OF THE INVENTION
The importance of sensor based bioanalytical methods and instruments has been increasing the last couple of years in the sectors of biotechnology and medical research as well as in pharmacological research. The main reason lying in the increasing demand of fast analytical methods that yield quantitative data on biomolecular interactions.
Optical affinity sensors deal with these demands in an ideal way, as they are able to detect without delay, in real time, biomolecular binding events without the utilization of interfering labels.
The arising of highly parallel batches for the analysis of complex nucleic acid- or protein-mixtures, as well as the rising use of combinatorial synthesis procedures within the pharmaceutical active substance search, make the high throughput compatibility of following methods of analysis a central criterion. This need could be favorably covered by optical sensors, which can measure many bonding reactions in parallel. In contrast to the devices available today, such sensors would have to be able to analyze the entire image of a sensor array instead of only a few individual measuring points.
Several different state of the art optical detection principles are well-known which can be used for the real time analysis by biomolecular interactions.
Most procedures use the changes of refractive indices due to binding reactions with the sensor surface.
Most common probably the already explained surface plasmon resonance—SPR sensors, which can be implemented apparatively relatively easily.
The shift of the SPR minimum is normally measured spectrally or, more commonly, angularly resolved.
The spectrally resolved detection, which normally is not as sensitive as the angularly resolved one, is advantageously used in cases in which an angularly resolved detection is not apparatively applicable.
One example is the fiber optic SPR (WO 94/16312 A1), in which light from a broadband source is coupled into a gold-coated optical fiber and the shift of the resonance wavelength is measured.
The angularly resolved detection is described, for example, in WO 90/05305. In this apparatus, a metal film is illuminated with convergent light beams, and the angle shift is observed by means of a diode array/lens system-combination.
Such a device demands a relatively large, mechanically very massive measuring head, which makes such an apparatus lavish. A apparativly simpler variant, as described in DE 19817472, only uses two photodiodes to determine the SPR minimum shift, making this apparatus a little bit simpler.
A principally different principle is described by Kooyman et al. (R. P. H. Kooyman, A. T. M. Lenferink, R. G. Eenink and J. Greve (1990) Anal. Chem. one, 63, pp. 83-85). Here the angle of the incident laser beam is varied over time with a scanner mirror and the corresponding change of intensity of the reflected light is detected by means of a photoelectric cell. The system described there supplies good results when measuring few points and is relatively unelaborate.
Other detection principles comprise, for example, the Resonant Mirror (Cush, R., Cronin, J. M., Goddard, N. J., Maule, C. H., Molloy, J. und Stewart, W. J. (1993) Biosensors & Bioelectronics, 8, pp. 347-353), the integrated optical interferometer (DE 4033357), the difference-interferometer (Fattinger, Ch., Koller, H., Schlatter, D. und Wehrli, P. (1993) Biosensors & Bioelectronics, 8, pp. 99-107), the grating coupler (Tiefenthaler, K. (1992) Advances in Biosensors, Vol. 2, pp. 261-289) or the Reflectometric Interference Spectrometer (DE 19615366 A1).
The production of the exchangeable sensor is clearly more complex in all these enumerated techniques than with the SPR, this being one of the reasons, besides others, for them being inferior to the SUPERCHARGER.
All procedures specified above have in common that they do not work spatially resolved and thus cannot cope with multiple analytes.
In past years several methods were therefore developed, which make parallel measuring possible on different parts of the sensor chip.
In this regard, a further development of the above already mentioned grating coupler is described, e.g., in WO 95/03538 or EP 1031828 A1; a spatially resolved reflectrometric interference spectrometer is known from DE 19828547 A1.
Apart from the disadvantage of the complex manufacturing of the exchangeable sensors, these systems also have the disadvantage that they divide the sensor surface into discrete and relatively large parts and the devices therefore become either quite large or exhibit a limited capacity.
As the SPR sensors are technically easier to implement and theoretically allow a nearly arbitrarily small partitioning of the sensor surface, clearly more implementation solutions exist. The first picture-giving SPM (Surface Plasmon Microscope) was developed in 1988 (Knoll, W. and Rothenhaeusler, B. (1988) Nature, 332, pp. 615-617).
In this and other well-known procedure (DE 19829086, as well as Frutos, A. G. and Corn, R. M. (1998) Anal. Chem., July 1, pp 449A-455 A) a widened laser beam is radiated on a metal surface at a fixed angle and the changes of intensity of the picture reflected on a CCD camera is evaluated. The main disadvantage of this method is that only intensity changes of the pixels are recorded and not the angles of the SPR minima.
This results in a clearly worse sensitivity and a strongly reduced dynamic range. In addition, some changes of individual brightness values might be ambiguous under some conditions—it then cannot be determined in which direction the SPR minimum is shifted.
An improvement of the described SPM technology is revealed in DE 3909144. A picture of the sensor surface is recorded using different incidence angles and the SPR minimum angles for up to 5×5 μm small surface sections are determined with downstream image processing. Although quite a high accuracy can be obtained with this procedure in principle, incidence and reflection angles must both be changed for imaging, which is mechanically complex and which can only be realized using a low data acquisition frequency. A two-dimensional fast real time analysis of bonding reactions on the chip surface is therefore not possible with this arrangement.
A spatially resolved SPR sensor with spectral detection is well-known from WO 00/22419. However, it uses mobile hole or slit apertures, in order to successively light up different ranges of the sensor surface, increasing the mechanical complexity, slowing down the data acquisition frequency and setting the size of the individual measuring points to a fixed value from the beginning on.
An angularly resolved SPR equipment with spectral detection is described in WO 99/30135. For the utilization as imaging sensor the use of a mask or a lens array is suggested. The disadvantages of this arrangement closely correspond to those of the sensor mentioned in the preceding section.
A system with mechanical change of the incidence angle and likewise mechanical change of the XY position of the measuring point on the sensor chip is known from WO 00/46589. Unfavorable are, above all, the complex structure and large mobile mechanical components, which entail a low data acquisition frequency.
Moreover, EP 0973023 describes a compact SPR transducer with angle resolved detection. The measuring range and the detector array are here divided into several areas, for which separate SPR signals are recorded. The areas of the individual sensitive regions are determined by the size of the transducers and are thus relatively large. A real high throughput ability might therefore only limits the application as a biosensor.
WO 98/34098 describes a spatially resolved SPR sensor with a complex lens and mirror system for the synchronously detection of the SPR minimum angles for a multiplicity of pixels. A relatively high measuring frequency can be realized using this scheme, but it also is a very complex contraption.
SUMMARY OF THE INVENTION
In summary it can be said that a high resolution SPR transducer with a fast measuring of the SPR minimum angle for each pixel has only been developed in very complex contraptions until today. It is thus the object of the given invention to make available such easily implementable equipment.
This object is achieved by the device for the optical examination of thin layers, comprising a carrier with a surface; a device for the illumination of the surface of the carrier with parallel aligned light under different angles of incidence; a detector for the spatially resolved detection of the intensity of the radiation for different angles of incidence, reflected by the surface of the carrier; and an analysis unit, for the spatially resolved determination of the dependence of the intensity of the reflected light on the incidence angle, on the basis of the spatially resolved acquisition of intensities for different angles of incidence, whereby the detector for acquisition of the reflected radiation does not have to be adjusted for the different angles of incidence of the reflected radiation.
The device for illuminating the surface of the carrier with parallel light comprises preferably a monochromatic light source, such as an LED or a laser. To avoid, respectively to minimize intensity fluctuations, stabilised or controlled lasers and controlled diode lasers or He—Ne lasers in particular are advantageous. Preferably, the intensity fluctuation of the light source should not exceed 0.4% and more preferred not exceed 0.2%. With the preferred stabilized light source, a RMS noise of less than 0.7*10 −3o can be achieved; with the more preferred stabilisation, the RMS noise of the resonance angle can be reduced to values below 0.3*10 −3o .
The carrier comprises for the coupling of the incidence light, for example, a triangular or trapezoidal prism or a plate with individual prisms, whereby the basis of the prism and/or the prisms is either the carrier top side or the surface, respectively, by which the incidence light is reflected, or serves as surface on which a preferably in optical regard flat-parallel plate is put on. In this case reflection takes place from the surface of this flat-parallel plate, which then forms the carrier top side.
The carrier top side is coated with a metal film in devices for the execution of surface plasmon resonance spectroscopy which helps to create a plasmon resonance minimum as sharp as possible. Ag or Au films are particularly suitable, whereby their thickness preferably amounts to about 45 to 55 nm.
In a further setup the gold layer is on a lattice or on a multiplicity of parallel arranged small prisms, respectively. This arrangement has the advantage that it can be realized economically by injection moulding in plastic and the carriers and the prism form a unit, which can be easily replaced.
The detector of the device according to the invention is suitable to detect the reflected radiation of a section of the surface of the carrier over a sufficiently large angle range. The angle range amounts preferably to at least ±1.5° around a mean angle, whereby the mean angle can particularly equal for instance the resonance angle of the plasmon resonance.
The mean angle is adjustable in the embodiment preferred at present, in order to adapt the position of the detector to individual experimental conditions. During the operation of the device according to the invention, i.e. during the spatially resolved acquisition of the radiation reflected by the carrier, the detector however does not any longer need to be adjusted to the changed angle, since the detector surface is laid out sufficiently large to acquire the reflected radiation over the entire angle range.
The device according to the invention thus makes a fast acquisition of the reflected intensity possible for different angles, since a mechanical adjustment of the detector does not have to be made, and thus acceleration forces arising with such movements do not have to be taken under consideration. Furthermore, this leads to a simplified mechanical and optical contraption, which substantially reduces the manufacturing costs of the device according to the invention.
The angle range around a mean angle, detectable by the detector, further preferentially amounts to at least ±2.5°, and particularly preferentially at least ±5°. The acquirable angle range around a mean angle is favorably not larger than ±20°, further preferentially not larger than ±15°, and particularly preferentially not larger than ±10°.
The detector for the spatially resolved acquisition of the intensity of the radiation reflected by the carrier top side, is preferably a photodiode array or a CCD camera. Especially preferred are CMOS cameras which allow for a higher image aquisition frequency.
In addition, the device according to the invention is preferably outfitted as a surface plasmon resonance spectrometer, although other methods of detection, such as brewster angle microscopy and ellipsometry, can be used in principle.
The dependence of the intensity of the reflected light on the angle of incidence can be seized spatially resolved with the device according to invention, whereby same points of the illuminated surface of the carrier or the carrier top side, respectively, are projected onto different points of the detector during the change of the incidence angle.
The angle of incidence is varied by means of a rotating mirror or a scanning mirror, respectively, in the arrangement preferred at present. In this arrangement identical parts of the incidence parallel beam fall onto different points of the surface of the carrier or carrier top side, respectively, due to the change of the incidence angle.
The scanner mirror is preferably a galvoscanner, whose control voltage is sufficient to determine the current incidence angle. In another arrangement of the invention, one part of the light beam reflected by the mirror is reflected directly onto a second detector, whereby the angles of incidence can be determined from the position of this part of the light beam on the second detector. In a further alternative an angle sensor is attached to the axle of the scanning mirror, which directly gives an angle dependent signal. Instead of a scanning mirror which oscillates around a medium angle, a monotonously rotating polygon mirror can be employed as well.
The analysis unit can be, e.g., a computer, preferably with a data storage capability for storing the information on the spatially resolved distribution of the intensity of the light reflected by the surface for different angles; and a data processing unit, which determines, on the basis of the spatially resolved intensity distributions measured using different incident angles, the intensity for different points on the surface of the carrier as a function of the incidence angle. Then at least one characteristic of the layer prepared on the carrier can be determined using angle dependent intensities for different points of the surface by this or another data processing unit. This can be in particular the characteristic layer thickness or the dielectric characteristics of the layer. Details for the determination of the layer thickness or the dielectric characteristics of a layer, respectively, on the basis of the angle dependent distribution of intensity are known to, for example, the specialist in the field of the surface plasmon resonance spectroscopy and do not need to be discussed in detail here.
The device according to the invention is preferably suitable for the described spatially resolved angle dependent intensity measurement and the determination of at least one layer characteristic in a continuous mode, i.e., the angle dependent intensity measurement over the angle range of interest and the following evaluation is done repeatedly.
The angle of incidence is preferentially controlled by the computer of the evaluation unit. The angle range which should be covered is preferably variably adjustable, in order to adapt to the respective experimental task.
Also, the increment between the individual angles, with which a measurement of the intensity takes place, is variable in the preferential set-up. It is intended in a further set-up that the incrementation steps are not equidistant, but can be adapted according to the information content of the individual angle ranges, i.e. the incrementation around the minimum of the plasmon resonance can be chosen smaller than in angle ranges lying outside of the resonance.
In another embodiment the automatic determination of the incrementation is further possible. In an initialization mode the intensity curve is hereby first roughly determined, and on the basis of the determined curve the increment is specified for the individual angle ranges and/or the entire angle range is reduced to a relevant range, for example the determined plasmon resonance angle ±1.25° or ±2.5° or ±5°, respectively. With many applications the expected position of the resonance angle is known and it is then possible to skip the above described initialization mode. As an example, the angle range which is scanned could be ±2.5% around the expected resonance angle.
The data analysis of the light reflected from the sample requires as first step a correction of the image shift, i.e. as with changing scan angle the image of the sample moves over the sensitive area of the camera, each spot on the sample surface has to be ascribed to the corresponding pixels at this angle. In principle this shift can be mathematically calculated and corrected. When lenses are used between sample and light source and/or detector respectively, in the fringe areas distortions of the measured image might occur which are analytically hard to describe. In such cases an experimental determination of the image shift is preferred. Such experimental correction can be achieved for example by projecting onto the camera a sufficiently fine grid which lies on top of the carrier instead of the sample. The well defined positions of the grid are then recorded for each different angle. The thus created angle/pixel matrix allows to unambigously ascribe pixels to sample areas at different angles of incidence. Should it be feasible to describe the image shift between two given angles precise enough by interpolation between these two angles, it is sufficient to store the shifts of these two angles and calculate the data of the remaining angles by interpolation.
Generally, two modes of interaction between detector and data processing unit are possible:
In the first variant the camera processes for each scanned angle all image data to the following data processing unit. This mode produces huge data quantities and is therefore slow.
Other variants include a certain degree of data pre-processing already in the camera. Such pre-processing can for example be achieved by bundling the pixels of certain regions of interests (ROIs). For these ROIs only the average, the minimum and the maximum intensity are processed. In this case the quantity of transferred data is much lower and the data processing speed thus significantly increased.
The aforementioned reduction of data analysis and processing to defined ROIs can be insofar advantageous as the image of the sample contains frequently large areas which do not contribute to the information content of the sample. Such areas are for example the regions between the spots of a microarray.
Insofar as the pixel positions of the ROIs are known for defined angles, for example according to the above described method, the readout of the detector and the image analysis can be reduced to only these pixels which, under angles close to resonance, receive light from the ROIs. Especially CMOS cameras are well suited for such mode of operation.
The procedure or method according to the invention for the analysis of thin layers, is essentially a procedure, in which the layers are illuminated under different incidence angles with parallel light beams in ways so that the light is reflected onto a two-dimensional detector, and with which the layer thickness or another layer characteristic is then computed spatially resolved on the basis of the angle dependent differences in intensities of the reflected light; characterised by the fact that image distortions, due to the change of angle and a detector that does not adapt to these changes of angle, are corrected before determining any layer characteristics. The correction in particular takes place via electronic data processing. Before the determination of the layer characteristics preferentially a correction of the brightness fluctuations, that do not have their source in properties of the sample to be examined, is applied.
This can be, for example, a correction needed due to different intensities of the different parts of the light beam of the incidence light, and/or a correction for the angle dependent transmission function of the entire optical arrangement and/or a correction for local inhomogeneities of the detector for the spatially resolved acquisition of the angle dependent distribution of intensities of the reflected light.
The invention also covers a computer program for the controlling of a device for the execution of the procedure according to the invention.
Further advantages and criteria result from the claims, the description and the designs.
DETAILED DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a schematic view of a device according to invention;
FIG. 2 shows the angle dependence of the intensity of the reflected radiation for different sample positions without any plasmon resonance being present;
FIG. 3 a shows the angle dependence of the intensity of the reflected radiation for different sample positions with plasmon resonance being present;
FIG. 3 b shows a zoomed display of the resonance minimum of the intensity of the reflected radiation for different sample positions; and
FIG. 4 shows the angle dependence of the signal position on the detector for different positions on the sensor chip.
FIG. 5 shows a flow scheme concerning a method for calculating the image shift for different angles of incidence
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention is to be described in more detail hereafter on the basis of an example shown schematically in FIG. 1 . An exemplary optical design of a surface plasmon resonance sensor, or SPR sensor, according to the invention, as well as a path of beams arising during the measuring process are shown. The optical system consists of a preferably monochromatic source of light 1 , preferentially a laser or a laser diode of suitable wavelength, whose radiation is polarized by means of a (not shown) polarization filter parallel to the plane of incidence of the sensor chip 4 , which here serves as a substrate for the SPR.
The diameter of the laser beam is first broadened with a commercial beam expander 11 and steered with a scanner mirror 2 under different angles of incidence onto the entrance surface of a prism 3 .
A subrange of the broadened beam falls under different angles of incidence onto the underside of a sensor chip 4 residing on the prism 3 , which is coated on its top side 5 with a SPR capable gold layer.
The sensor chip 4 is optically connected with the prism 3 by means of immersion oil or a suitable plastic. Optionally, the gold layer can be vapour-deposited directly on the top side of the prism 3 , however the sensitive area is then no longer exchangeable.
The illumination of the sensor chip under different angles of incidence is done in such a manner that the parallel light beams move over the surface during the measurement, however completely illuminating it at any time; a certain point a, b, c of the sensor chip is thus lit up by different parts of the light ray bundle depending on the angle of incidence.
In a preferred arrangement the incidence angle is scanned with a light wave of the length of 660 nm within a range of ±5° around a mean angle of about 75°.
The light reflected by the gold coated surface 5 leaves the prism and falls on an image processing detector 6 , preferably a CCD detector or a photodiode array.
FIG. 2 for example shows the effect of the different intensities of the different parts of the incidence light beam on the intensity of the reflected light from the points a, b, c of the surface 5 , which reaches the detector 6 .
In this case the surface 5 does not exhibit SPR. All curves show the characteristic total reflection edge and otherwise the behavior given by the transmission characteristics of the boundary surfaces. The curves however deviate from each other insofar, that the points a, b, c are illuminated with maximum intensity at different angles.
FIG. 3 a shows how the different incidence intensities described before affect the signal of a plasmon resonance received by the detector.
The actual resonance behavior is shown in curve d, whereby the signal received by the detector 6 of the points a, b, c, has the shape marked by the appropriate letters. By normalization with the curves of the FIG. 2 the actual resonance characteristic d for the respective points a, b, d can be found if necessary.
Making it more difficult is the fact that the points a, b, c of the sensor chip 4 are projected onto different areas i, k of the array 6 depending upon the angle of incidence.
The angle dependent image shift of the signal of the points a, b, c is represented schematically in FIG. 4 . It is therefore necessary to assign by means of an appropriate analysis device and a correction algorithm the individual pixels i, k of the CCD array 6 to certain point a, b, c on the sensor chip surface 5 depending upon the incidence angle (position of the scanner mirror 2 ). The brightness fluctuations of the reflected partial light beams caused by beam inhomogeneities for example, as discussed above, can be corrected at the same time or sequentially.
The effect of the described image-shift and the intensity inhomogeities for the range around the plasmon resonance angle is shown again in FIG. 3 b.
A first pixel i receives reflected light from the resonance minimum first from the point a, then from the point b, and finally from the point c with increasing angle.
Coincidentally, the selected first pixel i for these points has the same intensity with different angles. A second pixel k receives the signals from the points a, b, c after the passage through the resonance minimum. Here a dramatic rise of intensity for the signal of the points a, b, and c is observed.
This example shows that it is therefore of highest importance for the success of the described procedure, to assign those signals acquired by a pixel i, k the correct angle and the correct point a, b, c of the chip surface 5 .
FIG. 5 shows a flow scheme for a method which can be used for such assignment. According to this method, a coordinate grid with high contrast is inserted instead of a sample. The image of this coordinate grid is then recorded for different angles and the spots of the coordinate image are with the help of a discriminator set either to a bright or to a dark value. Thus the coordinate image can be easily analyzed and an unambigously assignment of the sample areas to pixels for different angles of incidence is possible. The image shift is stored as data matrix for different angles of incidence and can later be used for the correct assignment of the pixels when samples are analyzed.
According to the above principles, the intensity of the reflected signal of individual positions a, b, c on the chip surface 5 can be measured spatially resolved as a function of the respective angle.
A SPR curve measured in such a way can be fitted to simulated curves for the increase of the accuracy with the help of the Fresnel theory (see H. Wolter in ,Handbuch der Physik′, ed. S. Flügge, Springer). The incidence angle, at which the intensity of the reflected light becomes a minimum, is the so-called SPR angle.
The position of the scanner mirror 2 in the embodiment preferred at present, needed for the calculation of the SPR angle, is calculated with sufficient accuracy from the control voltage used by the galvoscanner.
Under the condition of good resolution of the used CCD camera and sufficient capacity of the downstream image processing hard- and software, the SPR minimum angle can be determined at the same time for several millions pixels with a frequency of over 10 Hz.
This is sufficient, in order to ensure a fast real time detection of binding reactions at the sensor surface 5 . It is possible to do this without complex and expensive optical components because of the electronic correction of image distortions and intensity fluctuations arising during the angle scans.
It is to be mentioned here that, procedures according to the invention described above with SPR, can also be applied with other, related techniques. These are in particular brewster angle spectrometry and ellipsometry. However, the appropriate measurement setups, easily designed by a specialist with appropriate expertise, are contraptions more complex than SPR devices, and are thus not dealt with in greater detail here.
For the measurement of the interaction, respectively the adsorption, of biological or chemical molecules, the optical detector system described above can be combined with a device for application of liquids or gases. This device is put onto the surface 5 of the chip 4 . Depending upon the intended purpose, a sample can be brought in contact with the entire surface of the sensor chip 4 or a multiplicity of samples independently of each other in contact with different parts of the sensor chip. It is then possible to examine thousands of different samples within a short time.
With certain applications it is useful to bundle the intensities of a pixel population by so-called binning. This is preferred the case if these pixels detect light which is reflected from a uniform sample area. Binning is especially advantageous when the carrier or the sample chip carry a large number of discrete and homogeneous regions, as it is the case on a spotted biochip. The angle-dependent intensity of the so assigned pixels corresponds to the mean signal of the corresponding discrete sample region. Such averaging can also be done in a weighted manner, such that the peripheral areas of a given sample region contribute more or less to the signal. With applications which require said binning of certain regions, it seems to be feasible to restrict the data aquisition to such pixels which receive light from the relevant sample areas. A selective read-out of pre-defined ROIs is especially possible with CMOS cameras. CCD cameras are less suited for this purpose. | Device for the measurement of thickness changes as well as changes of the physicochemical characteristics of thin layers. The system consists of a preferably monochromatic source of light, a scanning mirror, a preferably on one side metallized prism and a photodetector array. The thin layer is irradiated with light at different angles through the prism by means of the scanning mirror. The reflected image of the layer shows with certain incidence angles when choosing a suitable wavelength, polarization and if needed the metal and the film thickness, resonance-caused intensity fluctuations, by which the layer thickness and refractive index can be calculated. | 6 |
REFERENCE TO RELATED APPLICATION
This application is a continuation of application Ser. No. 08/056,192, filed on May 3, 1993, abandoned, which is a continuation of Ser. No. 07/804,791, filed Dec. 9, 1991, now U.S. Pat. No. 5,207,670, which is a continuation-in-part of Ser. No. 538,977, filed Jun. 15, 1990 now U.S. Pat. No. 5,071,417.
BACKGROUND OF THE INVENTION
The technical field of this invention is surgery and, in particular, method and materials for joining living tissues and promoting the healing of small biological structures.
The conventional approach to joining tissue segments following surgery, injury or the like, has been to employ mechanical sutures or staples. While these techniques are often successful, there are a number of limitations inherent in such mechanical approaches. First, the practice of suturing or stapling tissue segments together is limited by the eyesight and the dexterity of the surgeon which can present a severe constraint when anastomosing tiny biological structures. Second, when delicate biological tissues or organs are sutured, even minimal scarring can affect the function of the structure. Finally, suturing can be less than satisfactory, even when properly performed, because of the gaps which are left between the stitches, the inherent weakness of the joint, or the possibility of progressive structural weakening over time.
Various researchers have proposed the use of laser energy to fuse biological tissues together. For example, Yahr et al. in an article in Surgical Forum, pp. 224-226 (1964), described an attempt at laser anastomosis of small arterial segments with a neodymium laser. However, the neodymium laser used by Yahr et al. operated at a wavelength of about 1.06 micrometers was not efficiently absorbed by the tissue, requiring large amounts of energy to effect fusion, while also affecting too large of a tissue volume.
Further research on laser fusion involving various alternative laser sources, such as the carbon dioxide laser emitting laser light at about 10.6 micrometers, the argon laser emitting light at about 0.50 micrometers, and the ruby laser emitting light at about 0.70 micrometers, continued to encounter problems. In particular, the output of carbon dioxide lasers was found to be heavily absorbed by water and typically penetrated into water-laden tissue only to a depth to about 20 micrometers. This penetration depth and the resulting bond induced by carbon dioxide laser fusion was too shallow to provide durable bonding in a physiological environment.
Argon and other visible light laser also produced less than satisfactory effects. The output of argon lasers and the like was found to be heavily absorbed by blood and subject to substantial scattering within the tissue. These effects combined to create a narrow therapeutic "window" between a proper amount of energy necessary for laser fusion and that which induces tissue carbonization, particularly in pigmented tissues and tissues that have a high degree of vascularization. Moreover, argon lasers have been particularly cumbersome devices, requiring large amounts of electricity and cooling water.
Recently, the development of new solid state laser sources have made prospects brighter for efficient, compact laser fusion systems suitable for clinical use. Such systems typically employ rare earth-doped yttrium aluminum garnet (YAG) or yttrium lithium fluoride (YLF) or yttrium-scadium-golilinium-garnet (YSGG) lasers. See, for example, U.S. Pat. Nos. 4,672,969 and 4,854,320 issued to Dew, disclosing the use of a neodymium-doped YAG laser to induce laser fusion of biological materials and to obtain deeper tissue penetration. However, even with such solid state laser sources, the problems of scattering and damage to adjacent tissue remain. The Dew patents disclose the use of computer look-up tables to control the laser dose based on empirical data.
The absorptive properties of biological structures differ considerably from one tissue type to another, as well as from individual to individual, making dosage look-up tables often unreliable. There exists a need for better methods and materials for accurately controlling the formation of anastomotic bonds which avoid thermal damage and achieve optimal results. In particular, non-mechanical suture materials which can take advantage of laser or other high energy light sources to join biological materials together or otherwise make repairs to delicate body tissues would satisfy a long-felt need in the art.
SUMMARY OF THE INVENTION
Materials and methods for photoreactive suturing of biological tissue are disclosed. The suture material includes a structure adapted for positioning at an anastomotic site and has at least a portion of the structure formed by a photoreactive crosslinking agent, such that upon irradiation of the structure the crosslinking agent adheres to the biological material. In one embodiment, the suture material can also include a high tensile strength element which is coated with a laser activatable crosslinking agent or glue. The suture methods can be practiced manually, or with various apparatus, such as endoscopes, catheters or hand-held instruments.
The present invention can employ various "biological glue" materials as crosslinking agents in either solid, liquid, gel or powder form to form a bond to tissue segments and thereby hold them together while natural healing processes occur. The crosslinking agents should be biocompatible and are preferably biodegradable over time in vivo. Examples of such crosslinking agents include collagen, elastin, fibrin, albumin and various other photoreactive polymeric materials.
Various strength enhancing agents can also be incorporated into the suture structure to provide additional tensile support along and across the anastomosis. Such high tensile strength elements can be formed from pre-crosslinked segments of the same material that forms the photoreactive crosslinking agent, or they can be formed from strips or fibers of other natural or synthetic biodegradable materials such as cotton or polyesters, to enhance the strength of the bond.
The present invention permits the creation of anastomoses of biological structures with the optimal use of appropriate laser energy, minimizing the total energy delivered to the site while obtaining maximum bond strength and integrity. The terms "anastomosis" and "anastomotic site" are used herein to broadly encompass the joinder of biological structures, including, for example, incision and wound healing, repair of blood vessels and other tubular structures, sealing of fissures, nerve repairs, reconstructive procedures, and the like.
The present invention is preferably practiced in conjunction with a high energy light source, such as laser, for delivery of a beam of radiation to an anastomotic site, and can also employ a reflectance sensor for measuring light reflected from the site and a controller for monitoring changes in the reflectance of the light from the site and controlling the laser in response to the reflectance changes.
In one embodiment, the laser radiation is delivered through a hand-held instrument via an optical fiber. The instrument can also include one or more additional fibers for the delivery of illumination light or radiation from a laser diode (which can be broadband or white light or radiation from a laser diode) which is reflected and monitored by the reflectance sensor. Reflectance changes during the course of the suturing operation at one or more wavelengths can be monitored (or compared) to provide an indication of the degree of tissue crosslinking and determine when an optimal state of fusion has occurred.
In the present invention, reflective feedback is used to monitor the state of crosslinking of the suture material with the biological material, as well as the degree of fusion or coagulation of the biological structures so as to allow an optimal dose by either manipulation of the energy level or exposure time, or by controlling the sweep of energy across an exposure path. Reflectance changes can also be employed by a control means in the present invention to adjust or terminate laser operation.
Various light sources can be employed, including gas, liquid and solid state laser media. Because the present invention permits the user to carefully monitor the energy dosage, solid state lasers can be utilized instead of the more conventional (and cumbersome) gas lasers. Such solid state laser include optically-pumped (e.g., lamp or diode pumped) laser crystals, diode lasers, and diode pumped optical fibers. Tunable laser sources can also be used to practical advantage in the present invention. In some applications, high intensity flash lamps can also be employed in lieu of a laser source. Since the feedback control systems disclosed herein eliminate (or reduce) the need for look-up tables, a tunable laser source can be used to full advantage by matching the laser output wavelength with the absorptive and/or dimensional characteristics of the biological structures to be repaired or otherwise joined. In one embodiment of the invention, the laser source can be tuned over at least a portion of a wavelength range from about 1.4 micrometers to about 2.5 micrometers to match particular tissue profiles.
In another aspect of the invention, a real-time display means is disclosed which can be incorporated into a surgical microscope or goggles worn by the clinician during the procedure to provide a visual display of the state of tissue coagulation simultaneously with the viewing of the surgical site. The display can reveal reflectance values at one or more specific wavelengths (preferably, chosen for their sensitivity to the onset and optimal state of tissue crosslinking), as well as display a warning of the onset of tissue carbonization.
In one method, according to the invention, a technique for photoreactive suturing of biological structures is disclosed in which laser energy is applied to join together two or more tissue segments via a suture structure that includes a photoreactive crosslinking agent, while the reflectance of light from the irradiated site is monitored. Changes in scattering due to crosslinking of the tissue and crosslinking agent will cause reflectance changes. The reflectance can be monitored in real-time to determine the optimal exposure duration or aid as visual feedback in the timing used in sweeping the energy across the anastomosis during the suturing procedure.
The method can further be enhanced by employing a suturing material which incorporates high tensile strength elements, and/or by coating the entire anastomotic site with a biological glue. The reinforcing strips provide load support across and along the repair line, and preferably are also bonded by the crosslinking agent to the tissue, itself, providing superior bond strength.
The depth of penetration of the laser energy can be controlled in one embodiment by tuning a mid-infrared laser along a range of wavelengths from about 1.4 micrometers to about 2.5 micrometers to adjust the penetration to match the desired weld depth. Tuning can be accomplished, for example, by mechanical or electro-optical variation in the orientation of a birefringent crystal disposed in the laser beam path.
This allows the clinician to select a weld depth appropriate to the size and type of structures to be welded. This feature of the invention can be particularly advantageous with delicate biological structures where accuracy is needed to crosslink only what is necessary for temporary strength, while avoiding thermal denaturing of critical structures that cannot function once scarred. In most instances, the patient's body will metabolize the suture material over time simultaneous with (or following) the natural healing of the repair site by physiological processes.
The invention will next be described in connection with certain illustrated embodiments; however, it should be clear by those skilled in the art that various modifications, additions and subtractions can be made without departing from the spirit or scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic block diagram of a photoreactive suturing system according to the present invention;
FIG. 2 is a perspective view of a clinical system embodying the principles of the invention;
FIG, 3 is a schematic illustration of a suture material incorporating a high tensile strength element according to the invention;
FIG. 4 is a schematic illustration of another suture material according to the invention;
FIG. 5 is a schematic illustration of a yet another suture material according to the invention;
FIG. 6 is a schematic illustration of a further suture material according to the invention;
FIG. 7 is a schematic illustration of a suture material and detachable carrier according to the invention;
FIG. 8. is a schematic illustration of a tubular suture material according to the invention;
FIG. 9 is a schematic illustration of a staple-like suture material according to the invention;
FIG. 10 is a more detailed schematic diagram of a laser source useful in the system of FIG. 1;
FIG. 11 is a partial, cross-sectional view of a laser beam delivery handpiece according to the invention;
FIG. 12 is a front view of the laser delivery handpiece of FIG. 11;
FIG. 13 front view of a surgical instrument incorporating both a suture means and a laser means according to the invention;
FIG. 14 is a more detailed schematic diagram of reflectance monitor for use in the present invention; and
FIG. 15 is a schematic illustration of a clinical eyepiece view showing a "heads-up" display of reflectance measurements according to the invention.
DETAILED DESCRIPTION
In FIG. 1, a schematic block diagram of a photoreactive suturing system 10 is shown, including a laser 12, power supply 14, controller 16 and photoreactive suturing material 36. The system can further include a beamshaping/delivery assembly 20, illumination source 22, reflectance monitor 18, display 24 and tuner 26. In use, the output of laser 12 is delivered, preferably via beamshaping/delivery assembly 20, to an anastomotic site 30 to fuse the suture material 36 on opposite sides of a fissure or cleavage line 32 in a biological material. As the laser beam irradiates exposure zone 34, a crosslinking reaction occurs to fuse the suture material and the biological tissue in the vicinity of the site 30. The degree of crosslinking can be determined by the reflectance monitor 18, which provides electrical signals to controller 16 in order to control the procedure. The reflectance monitor 18 preferably receives light reflected by the site from a broadband or white light illumination source 22. In addition to controlling the laser operation automatically, the reflectance monitor 18 and/or controller 16 can also provide signals to a display 24 to provide visual (and/or audio) feedback to the clinical user, thereby permitting manual control. Tuner 26 can also be employed by the user (or automatically controlled by controller 16) to adjust the wavelength of the annealing radiation beam.
FIG. 2 provides further schematic illustration of the photoreactive suture system 10 in use. The electrical and optical components of the system can be housed in a system cabinet 60 suitable for use in an operating room or other clinical environment. The laser output is delivered to the patient by an optical fiber cable 62 (which can include multiple optical fibers as detailed below) and a handpiece 64. The system is preferably used in conjunction with a surgical microscope (or goggles) 66 which are adapted to provide a "heads-up" display to the user. Display signals from the system cabinet 60 are transmitted to the microscope (or goggles) 66 by cable 68. The laser output can also be delivered to a remote site via an arthroscope, endoscope or catheter and the display features of such an instrument can be similarly adapted to provide the user with data on progress of the crosslinking reaction.
The suture materials of the present invention can take various forms. In the simplest embodiment, the suture material comprises a strip or strand of a photoreactive crosslinking agent, such a collagen fibers, which can be sewn or draped upon a fissure or incision and then crosslinked to the tissue to provide closure. Once in place, the suture material is irradiated with laser or other high intensity light energy to fuse the suture to the anastomotic site.
Alternatively, as shown in FIG. 3, the suture material 36 can include a high tensile strength core element 40 and an outer cross-linkable agent 38 which are likewise used to sew or drape the anastomotic site prior to irradiation and fusion.
In another embodiment, as shown in FIG. 4, a suture material 36A can be employed which is fabricated in a zig-zag strip form and applied directly upon the incision or fissure 32 to close the opening. Again, suture material 36A can include a high tensile strength core element 40 and an outer cross-linkable agent 38.
In further embodiments 36B and 36C, shown in FIGS. 5 and 6, respectively, the suture material can be fabricated as a patch with a high strength element 40 incorporated into the structure, and also including a crosslinking agent 38 to join the suture material to the underlying tissue and thereby effect closure of the anastomotic site 32. In the embodiments of FIGS. 5 and 6, the high strength element 40 can be fabricated, for example, from the same material as the bonding agent 38, but pre-crosslinked to provide the addition resistance to tearing or shearing forces as the wound heals.
The present invention can employ various materials as crosslinking agents in either solid, liquid, gel or powder form to form a bond to tissue segments and thereby hold them together while natural healing processes occur. The crosslinking agents should be biocompatible and are preferably biodegradable over time in vivo. Examples of such crosslinking agents include collagen, elastin, fibrin, albumin and various other photoreactive polymeric materials.
Various strength enhancing agents can also be incorporated into the suture structure to provide additional tensile support along and across the anastomosis. Such high tensile strength elements can be formed from pre-crosslinked segments of the same material that forms the photoreactive crosslinking agent, or they can be formed from strips or fibers of other natural or synthetic biodegradable materials such as polyesters, to enhance the strength of the bond.
In FIG. 7, a detachable carrier 37 is shown for use in applying a zig-zag type strip of crosslinking agent 36 to an anastomotic site 32. In one preferred embodiment, the detachable carrier 37 is substantially transparent to photo-irradiation and can be detached from said crosslinking agent 36 following the bonding of the agent to the biological material.
In FIG. 8, a tubular suture material 36 is shown for repairing a torn blood vessel 31 or other body tube or lumen. The suture material 36 preferably includes a crosslinking agent 38 and reinforcing elements which can be braided, woven or simply matted fibers 40. In use, the suture material is either fitted over the severed lumen (in the case of a tube-shaped suture material) or wrapped around the severed biological structure (e.g., with a strip-like suture material), and then irradiated to crosslink the materials together. In some applications, the tubular suture material 36 of FIG. 8 can be designed to shrink as the crosslinking reaction occurs and thereby more tightly wrap the anastomotic site. In such procedures, it may also be preferable to first dispose a stent 33 or Similar support within the lumen to prevent collapse.
In FIG. 9, a staple structure 37 is shown incorporating a crosslinking agent 36 on each prong such that the staple can be applied to close a wound and then fused in place by application of laser radiation to the crosslinking agent 36. Alternatively, the entire staple can be formed from a crosslinking agent and then irradiated (e.g., such that the exposed prongs are melted into tissue-bonding balls) to fuse the staple in place. (A similar approach can be taken to "knot," or otherwise secure conventionally sewn sutures when a crosslinking agent comprises, or forms part of, the suture thread; in such an application, the surgeon would put the stitches in place and then irradiate the site in order to bond the suture thread to tissue or itself and thereby increase the strength of the closure.)
The present invention can be practiced with a wide variety of laser sources, including both gas and solid state lasers, operating in either continuous wave ("c.w.") or pulsed modes. More specifically, the laser sources can be carbon monoxide, carbon dioxide, argon lasers or various excimer lasers utilizing mixtures of halogen and noble gases, such as argon-flouride, krypton-fluoride, xenon-chloride and xenon-fluoride. Additionally, the laser can be a solid state laser employing a rare, earth-doped Yttrium Aluminum Garnet (YAG) or Yttrium Lithium Fluoride (YLF) or a Yttrium-Scandium-Gadolinium-Garnet (YSGG) laser.
In one preferred embodiment, the laser source is a rare, earth-doped, solid state laser, such as a holmium-doped, erbium-doped or thulium-doped solid state laser of the YAG, YLF or YSGG type which can be operated in a low wattage c.w. or pulsed mode with an output wavelength in the range of about 1.4 to about 2.5 micrometers and a power density of about 0.1 watt/mm 2 to about 1.0 watt/mm 2 . Such laser sources are disclosed in U.S. Pat. No. 4,917,084 issued on Apr. 17, 1990, to the present inventor and incorporated herein by reference.
The absorption of laser energy from such solid state laser sources by biological tissues is relatively high in relation to the absorption of such energy by water, thereby providing an absorption length in the subject's body of about 100 microns or more. Thus, it is possible to operate satisfactorily even with 10-20 micrometers of blood between the handpiece tip and the anastomotic site.
FIG. 10 iS a schematic illustration of laser source 12, including a solid-state laser crystal 41, vacuum chamber 42 and diode pump source 44. The laser crystal 41 is preferably surrounded by a cooling quartz or fused-silica jacket 46 having inlet pipe 48 and an outlet pipe 50 for circulation of liquid nitrogen or other cryogenic coolant. The laser cavity can be formed by input crystal face coating 52 and partially-reflective output mirror 54.
Generally, the laser crystal 41 is excited by optical pumping, that being, irradiation of the crystal with light from the laser diode 44. (The diode 44 can be cooled by a pumped coolant or employ a heatsink). Both ends of the laser crystal 41 are preferably polished flat. The input face of the crystal 41 is preferably finished with a coating 52 for high transmittance at the pump wavelength and high reflectance of the output wavelength. The other end of the crystal 41 preferably includes an antireflective coating 50 for high transmittal of the output wavelength. The entire cavity of the reflector preferably is evacuated to provide thermal insulation and avoid moisture condensation.
For further details on the construction of cryogenic, solid-state lasers, see, for example, an article by Barnes et al., Vol. 190, Society of the Photo-Optical Instrumentation Engineers, pp. 297-304 (1979), NASA/JPL Technical Brief No. NPO-17282/6780 by Hemmati (June, 1988) and above-referenced U.S. Pat. No. 4,917,084, all of which are herein incorporated by reference.
Also shown in FIG. 10 is a tuning element 26 which can include, for example, a birefringent crystal 28 disposed along the beam path 58 at a slight offset from Brewster's angle. The crystal 28 can be tuned electro-optically by application of a voltage, as shown schematically in the figure. Alternatively, the laser wavelength can be tuned mechanically by tilting or rotating the crystal 28 relative to the beam path using techniques well known in the art.
In FIG., 11 a partial, cross-sectional side view of a handpiece 64 is shown, including a casing 70 adapted for gripping by the clinical user and multiple lumens disposed therein. With further reference to FIG. 12 as well, the handpiece serves to deliver laser irradiation suitable for biological tissue fusion via a central optical fiber 72 connected to laser source, as well as one or more additional illumination fibers 74 for the delivery of illumination light and the transmittal of reflected light. The surgical laser delivery fiber 72 is preferable a low, hydroxyl ion content silica fiber. As shown in FIG. 12, the handpiece 64 can deliver illumination light via fibers 74. In one embodiment, these fibers 74 can also be used to collect reflective light and deliver it to a controller. Alternatively, some of the fibers 74 can be devoted entirely to collection of reflected light. The handpiece 64 can further include one or more lens elements 76, as well as a transparent protective cover element or terminal lens 82.
FIG. 13 shows an apparatus 81 for remote application of sutures according to the invention. The apparatus 81 can be incorporated into a catheter, endoscope or arthroscope and disposed adjacent to a remote anastomotic site. As shown, apparatus 81 includes a suture means 85 and a laser means 83. The suture port 85 delivers a photoreactive suture material to the anastomotic site, the suture material comprising a structure with at least a portion of the structure formed by a crosslinking agent such that upon irradiation of said suture means the crosslinking agent adheres to the biological material and thereby provides closure at said anastomotic site. The laser means 83 provides the necessary light energy in the form of laser radiation to effect crosslinking of the suture material at the anastomotic site. The apparatus 81 can also include a viewing port 87, an illumination port 89 and a reflectance sensing port 91 to provide a display and monitoring of the crosslinking process, as described in more detail below.
FIG. 14 is a more detailed schematic diagram of a reflectance monitor 18, including a coupling port 90 for coupling with one or more fibers 76 to receive reflectance signals from the handpiece of FIG. 4 or the apparatus of FIG. 13. The reflectance monitor 18 can further include a focusing lens 92 and first and second beam splitting elements 94 and 96, which serve to divide the reflected light into 3 (or more) different beams for processing.
As shown in FIG. 14, a first beam is transmitted to a first optical filter 98 to detector 102 (providing, for example, measurement of reflected light at wavelengths shorter than 0.7 micrometers). A second portion of the reflected light signal is transmitted by beam splitter 96 through a second optical filter 100 to detector 104 (e.g., providing measurement of light at wavelengths shorter than 1.1 micrometers). Finally, a third portion of the reflected light is transmitted to photodetector 106 (e.g., for measurement of reflected light at wavelengths greater than 1.6 micrometers). Each of the detector elements 102, 104, and 106 generate electrical signals in response to the intensity of light at particular wavelengths.
The detector elements 102, 104 and 106 preferably include synchronous demodulation circuitry and are used in conjunction with a modulated illumination source to suppress any artifacts caused by stray light or the ambient environment. (It should be apparent that other optical arrangements can be employed to obtain multiple wavelength analysis, including the use, for example, of dichroic elements, either as beamsplitters or in conjunction with such beamsplitters, to effectively pass particular wavelengths to specific detector elements. It should also be apparent that more than three discreet wavelengths can be measured, depending upon the particular application.) The signals from the detector elements can then be transmitted to a controller and/or a display element (as shown in FIG. 1).
In the controller, signals from the reflectance monitor are analyzed (as detailed below) to determine the degree of crosslinking which is occurring in the suture material and/or in the biological tissue exposed to the laser radiation. Such analysis can generate control signals which will progressively reduce the laser output energy over time as a particular site experiences cumulative exposure. The control signals can further provide for an automatic shut-off of the laser when the optimal state of crosslinking has been exceeded and/or the onset of carbonization is occurring.
As shown in FIG. 15, the data from the reflectance monitor can also be provided directly to the clinician. In FIG. 15, a simulated view from an eyepiece 110 is shown in which the field of view 112 includes a fissure or cleavage line 114 dividing separate bodies at an anastomotic site. Also shown within the field of view is the suture material 36, a fusion track 116 which has been formed by laser radiation, and a present exposure zone 118. Also displayed within the eyepiece 110 is a "heads-up" display of the reflectance values for the reflectance monitor of FIG. 14, including illuminated warning lights 122 which serve to indicate the reflectance intensity at particular wavelengths or other optical data indicative of the degree of crosslinking and/or tissue fusion.
In use, the apparatus of the present invention can be employed to analyze the degree of crosslinking by comparing the reflectance ratios of a site at two or more wavelengths. Preferably, intensity readings for three or more wavelength ranges are employed in order to accurately assess the degree of crosslinking and to ensure that the optimal state is not exceeded. The particular wavelengths to be monitored will, of course, vary with the particular tissue undergoing treatment. Although the tissue type, (e.g., blood-containing tissue or that which is relatively blood-free) will vary, the general principles of the invention, as disclosed herein, can be readily applied by those skilled in the art to diverse procedures in which the fusion of biological materials is desired.
For example, it is known that carbonization of many tissue types is accompanied by a decrease in visible light reflectance and an increase in infrared reflectance. Thus, the analyzing circuitry of the controller can be constructed to provide a warning (or automatically shut off the laser radiation) when darkening in the visible wavelengths occurs or when the ratio of visible to infrared values falls below a predefined level.
Moreover, when the material to be joined (e.g., aortic tissue) is relatively unpigmented, reliance on changes in the reflectance of visible light can be inaccurate, but infrared reflectance changes (e.g., above 1.1 micrometers) can reliably indicate the degree of crosslinking. (Lack of change in the visible reflectance is one of the reasons that tissues of this type are difficult to crosslink, as no change in the target's visible properties are observed until the tissue is overexposed to laser energy.) Consequently, the analyzing circuitry can monitor infrared reflectively changes (e.g., greater than about 1.0 micrometers) as an indicator of proper crosslinking.
Finally, the reflectance sensor can also be used as a proximity monitor to ensue that the laser is in fact disposed at a proper distance from the anastomic site. By measuring total reflectance (over the entire visible-infrared range or a portion thereof), a sudden drop in the reflectance value will typically be related to incorrect placement of the handpiece. Thus, the analyzing circuitry can sense the changes in reflectance and generate a warning to the user (or automatically shut off the system) until proper placement is achieved. | Materials and methods for photoreactive suturing of biological tissue are disclosed. The suture material includes a structure adapted for positioning at an anastomotic site and has at least a portion of the structure formed by a photoreactive crosslinking agent, such that upon irradiation of the structure the crosslinking agent adheres to the biological material. In one embodiment, the suture material can also include a high tensile strength element which is coated with a laser activatable crosslinking agent or glue. The suture methods can be practiced manually, or with various apparatus, such as endoscopes, catheters or hand-held instruments. | 0 |
FIELD OF THE INVENTION
This invention provides new compounds that have excellent plant fungicide activity. Some of the compounds have also demonstrated insecticidal and miticidal activity. The invention also provides compositions and combination products that contain a compound of the invention as active ingredient, as well as providing fungicidal, miticidal, and insecticidal methods.
There is an acute need for new fungicides, insecticides, and miticides, because target pathogens are rapidly developing resistance to currently used pesticides. Widespread failure of N-substituted azole fungicides to control barley mildew was observed in 1983, and has been attributed to the development of resistance. At least 50 species of fungi have developed resistance to the benzimidazole fungicides. The field performance of DMI (demethylation inhibitor) fungicides, which are now widely relied on to protect cereal crops from powdery mildew, has declined since they were introduced in the 1970's. Even recently introduced fungicides, like the acylalanines, which initially exhibited excellent control of potato late blight and grape downy mildew in the field, have become less effective because of widespread resistance. Similarly, mites and insects are developing resistance to the miticides and insecticides in current use. Resistance to insecticides in arthropods is widespread, with at least 400 species resistant to one or more insecticides. The development of resistance to some of the older insecticides, such as DDT, the carbamates, and the organophosphates, is well known. But resistance has even developed to some of the newer pyrethroid insecticides and miticides. Therefore a need exists for new fungicides, insecticides, and miticides.
SUMMARY OF THE INVENTION
This invention provides compounds of the formula (1): ##STR1## wherein
one or two of A, B, E, or D are N, and the others are CR 1 or A, E, and D are N and B is CR 1 ; where R 1 and R 2 are independently H, halo, (C 1 -C 4 ) alkyl, (C 3 -C 4 ) branched alkyl, (C 1 -C 4 ) alkoxy, halo (C 1 -C 4 ) alkyl, phenyl, or substituted phenyl;
X is O, S, SO, SO 2 , NR 3 , or CR 4 R 5 , where R 3 is H, (C 1 -C 4 ) alkyl, or (C 1 -C 4 ) acyl, and R 4 and R 5 are independently H, (C 1 -C 4 ) acyl, (C 1 -C 4 ) alkyl, (C 2 -C 4 ) alkenyl or -alkynyl, CN, or OH, or R 4 and R 5 combine to form a carbocyclic ring containing four to six carbon atoms;
Y is a bond or an alkylene chain one to six carbon atoms long, optionally including a carbocyclic ring, and optionally including a hetero atom selected from O, NR 3 , S, SO, SO 2 , or SiR 20 R 21 , where R 3 is as defined above and R 20 and R 21 are independently (C 1 -C 4 ) alkyl, (C 3 -C 4 ) branched alkyl, phenyl, or substituted phenyl, and optionally substituted with (C 1 -C 4 ) alkyl, (C 2 -C 4 ) alkenyl or -alkynyl, branched (C 3 -C 7 ) alkyl, C 3 -C 7 ) cycloalkyl or -cycloalkenyl, halo, hydroxy, or acetyl, and
Z is
(a) a C 1 -C 12 saturated or unsaturated hydrocarbon chain, straight chain or branched optionally including a hetero atom selected from O, S, SO, SO 2 , or SiR 20 R 21 , where R 20 and R 21 are as defined above and optionally substituted with halo, halo (C 1 -C 4 ) alkoxy, hydroxy, (C 3 -C 8 ) cycloalkyl or cycloalkenyl, or (C 1 -C 4 ) acyl;
(b) (C 3 -C 8 ) cycloalkyl or cycloalkenyl, optionally substituted with (C 1 -C 4 ) alkyl, (C 1 -C 4 ) alkoxy, halo (C 1 -C 4 ) alkyl, halo (C 1 -C 4 ) alkoxy, halo, hydroxy, or (C 1 -C 4 ) acyl;
(c) a phenyl group of the formula (2) ##STR2## where
R 6 to R 10 are independently H, halo, I, (C 1 -C 10 ) alkyl, (C 3 -C 8 ) alkenyl or -alkynyl, branched (C 3 -C 6 ) alkyl, -alkenyl, or -alkynyl, (C 3 -C 8 ) cycloalkyl or -cycloalkenyl, halo (C 1 -C 7 ) alkyl, (C 1 -C 7 ) alkoxy, (C 1 -C 7 ) alkylthio, halo (C 1 -C 7 ) alkoxy, phenoxy, substituted phenoxy, phenylthio, substituted phenylthio, phenyl, substituted phenyl, NO 2 , acetoxy, OH, CN, SiR 11 R 12 R 13 , OSiR 11 R 12 R 13 , NR 14 R 15 , S(O)R 16 , or SO 2 R 17 where R 11 , R 12 , and R 13 are independently (C 1 -C 4 ) alkyl, (C 3 -C 4 ) branched alkyl, phenyl, or substituted phenyl, R 14 and R 15 are independently H, (C 1 -C 4 ) alkyl, or (C 3 -C 4 ) acyl, and R 16 and R 17 are (C 1 -C 10 ) alkyl, phenyl, or substituted phenyl;
(d) a furyl group of formula (3) ##STR3## where R 18 is H, halo, halomethyl, CN, NO 2 , (C 1 -C 4 ) alkyl, (C 3 -C 4 ) branched alkyl, phenyl, or (C 1 -C 4 ) alkoxy;
(e) a thienyl group of the formula (4) ##STR4## where R 18 is as defined in paragraph (d);
(f) a group of formula (5) or (6) ##STR5## where R 18 is as defined in paragraph (d), J is N or CH, and G is O, NR 19 , or S, provided that if J is not N then G is NR 19 , where R 19 is H, (C 1 -C 4 ) alkyl, (C 1 -C 4 ) acyl, phenylsulfonyl, or substituted phenylsulfonyl;
(g) a group selected from
optionally substituted naphthyl, dihydronaphthyl, tetrahydronaphthyl, and decahydronaphthyl;
optionally substituted pyridyl;
optionally substituted indolyl;
and 1,3-benzodioxolyl;
or an acid addition salt of a compound of formula (1);
provided that the following compounds are excluded:
1) pyrido[2,3-d]pyrimidines of formula (1) wherein X is NR 3 and --Y--Z is benzyl, or X is NR 3 , Y is an alkylene chain containing an O or S atom adjacent to Z, and Z is either unsubstituted phenyl or a substituted phenyl group other than one substituted with
branched (C 3 -C 6 ) alkyl,
halo (C 1 -C 4 ) alkyl,
halo (C 1 -C 4 ) alkoxy,
phenyl,
substituted phenyl,
phenoxy,
substituted phenoxy,
phenylthio,
substituted phenylthio,
SiR 11 R 12 R 13 , or
OSiR 11 R 12 R 13 ;
2) pyrido [3,4-d]pyrimidines of formula (1) wherein X is NR 3 , Z is unsubstituted phenyl, and R 2 is methyl; and
3) pyrido[3,4-d]pyrimidines of formula (1) wherein X is NR 3 and --Y--Z is benzyl or isoamyl.
Proviso (1) excludes compounds that are described as fungicides in Japanese patent application 55108806 of Sankyo. Proviso (2) excludes compounds for which cytokinin activity is reported in Agri. Biol.Chem., 50, 2243-49 (1986). Proviso (3) excludes compounds for which cytokinin activity is reported in Agri. Biol. Chem., 50, 495-97 (1986).
The fungicide combinations of the invention comprise at least 1% by weight of a compound of formula (1), excluding compounds of proviso (1) but including those of provisos (2) and (3), in combination with a second plant fungicide.
The fungicide compositions of the invention comprise a disease inhibiting and phytologically acceptable amount of compound of formula (1), excluding compounds of proviso (1) but including those of provisos (2) and (3), in combination with a phytologically-acceptable carrier. Such compositions may optionally contain additional active ingredients, such as an additional fungicidal, miticidal, or insecticidal ingredient.
The fungicidal method of the invention comprises applying to the locus of a plant pathogen a disease inhibiting and phytologically acceptable amount of a compound of formula (1), excluding compounds of proviso (1) but including those of provisos (2) and (3).
The insecticide and miticide combinations of the invention comprise at least 1% by weight of a compound of formula (1), including compounds of provisos (1) to (3), in combination with a second insecticide or miticide.
The insecticide and miticide compositions of the invention comprise an insect- or mite-inactivating amount of a compound of formula (1), including compounds of provisos (1) to (3), in combination with a carrier. Such compositions may optionally contain additional active ingredients, such as an additional fungicidal, miticidal, or insecticidal ingredient.
The insecticidal or miticidal method of the invention comprises applying to the locus to be protected an insect- or mite-inactivating amount of a compound of formula (1), including compounds of provisos (1) to (3), or of a combination described above.
DETAILED DESCRIPTION OF THE INVENTION
Throughout this document, all temperatures are given in degrees Celsius, and all percentages are weight percentages unless otherwise stated.
The term "halo" refers to a F, Cl, or Br atom.
The term "(C 1 -C 7 ) alkoxy" refers to straight or branched chain alkoxy groups.
The term "(C 1 -C 7 ) alkylthio" refers to straight and branched chain alkylthio groups.
The term "halo (C 1 -C 7 ) alkyl" refers to a (C 1 -C 7 ) alkyl group, straight chain or branched, substituted with one or more halo atoms.
The term "halo (C 1 -C 7 ) alkoxy" refers to a (C 1 -C 7 ) alkoxy group substituted with one or more halo groups.
The term "halo (C 1 -C 4 ) alkylthio" refers to a (C 1 -C 4 ) alkylthio group, straight chain or branched, substituted with one or more halo atoms.
The term "substituted phenyl" refers to phenyl substituted with up to three groups selected from halo, I, (C 1 -C 10 ) alkyl, branched (C 3 -C 6 ) alkyl, halo (C 1 -C 4 ) alkyl, hydroxy (C 1 -C 4 ) alkyl, (C 1 -C 4 ) alkoxy, halo (C 1 -C 4 ) alkoxy, phenoxy, substituted phenoxy, phenyl, substituted phenyl, NO 2 , OH, CN, (C 1 -C 4 ) alkanoyloxy, or benzyloxy.
The terms "substituted naphthyl", "substituted pyridyl" and "substituted indolyl" refer to these ring systems substituted with halo, halo (C 1 -C 4 ) alkyl, CN, NO 2 , (C 1 -C 4 ) alkyl, (C 3 -C 4 ) branched alkyl, phenyl, substituted phenyl, (C 1 -C 4 ) alkoxy, or halo (C 1 -C 4 ) alkoxy.
The term "substituted phenoxy" refers to phenoxy substituted with up to three groups selected from halo, I, (C 1 -C 10 ) alkyl, branched (C 3 -C 6 ) alkyl, halo (C 1 -C 7 ) alkyl, hydroxy (C 1 -C 7 ) alkyl, (C 1 -C 7 ) alkoxy, halo (C 1 -C 7 ) alkoxy, phenoxy, substituted phenoxy, phenyl, substituted phenyl, NO 2 , OH, CN, (C 1 -C 4 ) alkanoyloxy, or benzyloxy.
The term "carbocyclic ring" refers to a saturated or unsaturated carbocyclic ring containing three to seven carbon atoms.
The terms "substituted phenylthio" and "substituted phenyl sulfonyl" refer to such groups substituted with up to three groups selected from halo, I, (C 1 -C 10 ) alkyl, branched (C 3 -C 6 ) alkyl, halo (C 1 -C 7 ) alkyl, hydroxy (C 1 -C 7 ) alkyl, (C 1 -C 7 ) alkoxy, halo (C 1 -C 7 ) alkoxy, phenoxy, substituted phenoxy, phenyl, substituted phenyl, NO 2 , OH, CN, (C 1 -C 4 ) alkanoyloxy, or benzyloxy.
The term "unsaturated hydrocarbon chain" refers to a hydrocarbon chain containing one or two sites of unsaturation.
The term "HPLC" refers to a high-performance liquid chromatography.
COMPOUNDS
Compounds of formula (1) wherein A is N and B, E, and D are CR 1 are pyrido [3,2-d]pyrimidines.
Compounds of formula (1) wherein B is N and A, E, and D are CR 1 are pyrido [4,3-d]pyrimidines.
Compounds of formula (1) wherein E is N and A, B, and D are CR 1 are pyrido[3,4-d]pyrimidines.
Compounds of formula (1) wherein D is N and A, B, and E are CR 1 are pyrido[2,3-d]pyrimidines.
Compounds of formula (1) wherein A and D are N and B and E are CR 1 are pteridines (or pyrazino[2,3-d]pyrimidines.
Compounds of formula (1) wherein B and D are N and A and E are CR 1 are pyrimido[4,5-d]pyrimidines.
Compounds of formula (1) wherein E and D are N and A and B are CR 1 are pyrimido[4,5-c]pyridazines.
Compounds of formula (1) wherein A and E are N and B and D are CR 1 are pyrimido[5,4-d]pyrimidines.
Compounds of formula (1) wherein A and B are N and E and D are CR 1 are pyrimido[5,4-c]pyridazines.
Compounds of formula (1) wherein B and E are N and A and D are CR 1 are pyrimido[4,5-d]pyridazines.
Compounds of formula (1) wherein A, E, and D are N and B is CR 1 are pyrimido[5,4-e]-1,2,4-triazines.
While all of the compounds of the invention are useful fungicides, certain classes are preferred for reasons of greater efficacy or ease of synthesis, viz:
(a) compounds of formula (1) wherein one of A, B, E, and D is N and the rest are CR 1 .
(b) compounds of class (a) wherein D is N and A, B, and E are CR 1 , i.e., pyrido[2,3-d]pyrimidine derivatives;
(c) compounds of formula (1) wherein Z is substituted phenyl;
(d) compounds of formula (1) wherein X is O; and
(e) compounds of class (d) wherein Y is a chain at least two atoms long.
SYNTHESIS
The compounds of this invention are made using well known chemical procedures. The required starting materials are commercially available, or they are readily synthesized using standard procedures.
Synthesis of Compounds Wherein X is O
The compounds of formula (1) wherein X is O are made by condensing a compound of formula (7): ##STR6## where R 2 , A, B, E, and D are as previously defined, and L is a leaving group such as F, Cl, Br, I, NO 2 , 1,2,4-triazol-1-yl, --O--Si(Me) 3 , arylthio, alkylthio, alkylsulfonyl, arylsulfonyl, alkoxy, or arylsulfinyl with an alcohol or phenol of the formula (8):
H--Y--Z (8)
where
Y and Z are as previously defined.
For many of the examples, the reaction was carried out in toluene treated with dry HCl, at room temperature or with gentle heating.
Alternatively, and preferably, the reaction may be carried out in the presence of a strong base, such as sodium hydride, in a non-reactive organic solvent, such as DMF, at a temperature in the range of 0 to 25° C.
Synthesis of Compounds Wherein X is NR 3
The compounds of formula (1) wherein X is NR 3 are prepared by condensing a compound of formula (7) with an amine of the formula (9) ##STR7## where
R 3 , is H or ((C 1 -C 4 ) alkyl, and
Y and Z are as previously defined.
The chloride of formula (7) is allowed to react with an appropriate amine at a wide variety of temperatures (20-180° C.), preferably in the presence of an acid acceptor, such as triethylamine. The reaction may be carried out neat, or in a non-reactive organic solvent. Compounds where R 3 is acyl are prepared from amines where R 3 is H, which were allowed to react with an acylating agent such as acetyl chloride or acetic anhydride. In cases where the starting material of formula (7) is one wherein R 1 or R 2 is Cl, a mixture of products is obtained which are separable using liquid chromatography.
Synthesis of Compounds Wherein X is CH 2
The compounds of formula (1) wherein X is CH 2 can be made using the process described in J. Heterocyclic Chemistry, Vol. 14, p. 1081-1083 (1977) by A. Scoville and F. X. Smith. This process entails preparation of a barbituric acid of the formula (10) ##STR8## which is then hydrolyzed and decarboxylated by dissolving the intermediate in a solution of sodium hydroxide and water, refluxing, then making the solution slightly acidic with hydrochloric acid and again refluxing.
The acid addition salts of compounds of formula (1) are obtained in the usual way.
Accordingly, the invention also provides a process for preparing a compound of formula (1) which comprises
(a) condensing a compound of formula (7) ##STR9## wherein R 1 , R 2 , A, B, E, and D are as previously defined, and L is a leaving group with an alcohol of the formula (8):
HO--Y--Z (8)
wherein Y and Z are as previously defined to produce a compound of formula (1) wherein X is ; or
(b) condensing a compound of formula (7) as defined above with an amine of the formula (9) ##STR10## where R 3 ' is H or (C 1 -C 4 ) alkyl, and Y and Z are as previously defined, to provide a compound of formula (1) where X is NR 3 ; or
(c) acylating a compound of formula (1) wherein X is NR 3 ' to provide a compound of formula (1) wherein X is NR 3 and R 3 is acyl; or
(d) hydrolyzing and decarboxylating a compound of formula (10) ##STR11## to produce a compound of formula (1) wherein X is CH 2 .
Preparation of Pyridopyrimidine, Pyrimidopyrimidine, and Pteridine Starting Materials
4-Hydroxypyridopyrimidine starting materials are commercially available or readily prepared using conventional procedures. For example, useful synthetic procedures are described in
R. K. Robins & G. H. Hitchings, J. Am. Chem. Soc., 77, 2256 (1955);
S. Gabriel & J. Colman, Chem. Ber., 35, 2831 (1902); and
C. C. Price & D. Y. Curtin, J. Am. Chem. Soc., 68, 914 (1946).
4-Hydroxypyrimido[4,5-d]pyrimidines can be prepared using the procedure described in E. C. Taylor, et al., J. Amer. Chem. Soc., 82, 6058 (1960).
4-Hydroxypteridines can be prepared using the procedures described in A. Albert, D. J. Brown and G. Cheesman, J. Chem. Soc., 474 (1951).
4-Hydroxypyrimido[4,5-c]pyridazines can be prepared by the procedures described in J. L. Styles and R. W. Morrison, J. Org. Chem., 50, 346 (1985).
4-Hydroxypyrimido[5,4-d]pyrimidines can be prepared by the procedures described in F. A. Gianturro, P. Gramaccioni, and A. Vaciago, Gazz. Chim. Ital., 99, (1969).
4-Hydroxypyrimido[5,4-c]pyridazines can be prepared by the procedures described in R. N. Castle and H. Murakami, J. Hetero. Chem., 5, 523 (1968).
4-Hydroxypyrimido[4,5-d]pyridazines can be prepared by the procedures described in R. N. Castle, J. Hetero. Chem., 5, 845 (1968).
4-Chloro derivatives of formula (7) wherein L is Cl are prepared by chlorodehydroxylation of the corresponding 4-keto compounds using conventional methods, for example by reaction with POCl 3 .
Intermediates of formula (7) wherein L is 1,2,4-triazol-1-yl, can be prepared, for example, by adding POCl 3 dropwise to a mixture of a 4-hydroxypyridopyrimidine (1 equiv.) and 1,2,4-triazole (3 equiv.) in pyridine at a temperature from 20 to 100° C.
EXAMPLES 1-72
The following examples are compounds actually prepared by the above described general procedures. The melting point is given for each compound. In addition, although the data has not been included, each compound was fully characterized by NMR, IR, mass spectra, and combustion analysis. Specific illustrative preparations for the compounds of Examples follow the tabular listing.
______________________________________EXAMPLENUMBER COMPOUND M.P.______________________________________ 1 4-(4-fluorophenoxy)pyrido[2,3-d]- 142-144° C. pyrimidine 2 4-[2-[4-( .sub.- i-propyl)phenyl]ethyl- 198-200° C. amino]pyrido[2,3-d]pyrimidine 3 4-[2-(4-chlorophenyl)ethoxy]pyrido- 126-128° C. [2,3-d]pyrimidine 4 4-[2-(4-chlorophenyl)ethoxy]pyrido- 86° C. [3,2-d]pyrimidine 5 4-[2-[4-( .sub.- t-butyl)phenyl]ethylamino]- 77-78° C. pyrido[3,2-d]pyrimidine 6 4-(2-chloro-4-fluorophenoxy)pyrido- 181-182° C. [2,3-d]pyrimidine 7 4-[2-(4-ethoxyphenyl)ethoxy]pyrido- 74-75° C. [3,2-d]pyrimidine 8 N-(2-phenylethyl)pyrido[2,3-d]- 252-254° C. pyrimidin-4-amine 9 N-[2-(2-naphthalenyl)ethyl]pyrido- 247-251° C. [2,3-d]pyrimidin-4-amine10 4-[2-(2,4-difluorophenyl)ethoxy]- 84-85° C. pyrido[2,3-d]pyrimidine11 4-[2-(4-ethoxyphenyl)ethoxy]pyrido- 62-64° C. [2,3-d]pyrimidine12 N-[2-[3-(trifluoromethyl)phenyl]- 190-193° C. ethyl]pyrido[2,3-d]pyrimidin-4-amine13 N-(4-phenylbutyl)pyrido[2,3-d]- 179-181° C. pyrimidin-4-amine14 N-(3-phenylpropyl)pyrido[2,3-d]- 195-198° C. pyrimidin-4-amine15 4-(2-phenylethoxy)pyrido[2,3-d]- 101-102° C. pyrimidine16 N-[2-(4-chlorophenyl)ethyl]pyrido- 271-275° C. [2,3-d]pyrimidin-4-amine17 4-[2-(4-methoxy-3-methylphenyl)- 113-114° C. ethoxy]pyrido[2,3-d]pyrimidine18 4-[3-(4-phenoxyphenyl)propoxy]- oil pyrido[2,3-d]pyrimidine19 N-[(4-chlorophenyl)methyl]pyrido- 252-255° C. [2,3-d]pyrimidin-4-amine20 N-[2-(2,6-difluorophenyl)ethyl]- 263-266° C. pyrido[2,3-d]pyrimidin-4-amine21 4-[2-[4-(trimethylsilyl)phenyl]- 90° C. ethoxy]pyrido[2,3-d]pyrimidine22 4-[2-(2-naphthalenyl)ethoxy]pyrido- 108° C. [2,3-d]pyrimidine23 4-[2-(4-methoxyphenyl)ethoxy]- 109-110° C. pyrido[2,3-d]pyrimidine24 4-(4-fluorophenoxy)pyrido[3,4-d]- 212-214° C. pyrimidine25 4-[2-[4-phenylphenyl]ethoxy]pyrido- 124-125° C. [2,3-d]pyrimidine26 4-[2-[4-( .sub.- t-butyl)phenyl]ethoxy]- 59-60° C. pyrido[3,4-d]pyrimidine27 4-[2-[4-( .sub.- t-butyl)phenyl]-ethyl- 209-211° C. amino]pyrido[2,3-d]pyrimidine28 4-[2-[4-( .sub.- i-propyl)phenyl]ethyl- 165-167° C. amino]pyrido[3,4-d]pyrimidine29 4-[2-[4-( .sub.- t-butyl)phenyl]ethoxy]- 55° C. pyrido[3,2-d]pyrimidine30 4-[2-[4-(trifluoromethyl)phenyl]- 65-67° C. ethoxy]pyrido[2,3-d]pyrimidine31 4-(4-fluorophenoxy)pyrido[3,2-d]- 149-151° C. pyrimidine32 4-[2-[4-(trimethylsilyl)phenyl]- 81° C. ethoxy]pyrido[3,4-d]pyrimidine33 4-[2-(4-ethoxyphenyl)ethoxy]pyrido- 87-88° C. [3,4-d]pyrimidine34 N-[2-(4-methoxyphenyl)ethyl]- 260-263° C. pyrido[2,3-d]pyrimidin-4-amine35 N-[2-(4-methoxyphenyl)ethyl]- 153-155° C. pyrido[3,4-d]pyrimidin-4-amine36 4-(2-[1,1'-biphenyl]-4-ylethoxy)- 137-138° C. pyrido[3,4-d]pyrimidine37 N-[2-[4-( .sub.- t-butyl)phenyl]ethyl]- 138-163° C. pyrido[3,4-d]pyrimidin-4-amine38 N-[2-(4-ethoxyphenyl)ethyl]- 174-176° C. pyrido[3,4-d]pyrimidin-4-amine39 N-(4-phenylbutyl)pyrido[3,4-d]- 60-75° C. pyrimidin-4-amine40 N-[2-(4-ethoxyphenyl)ethyl]pyrido- 220-222° C. [2,3-d]pyrimidin-4-amine41 4-[2-[4-( .sub.- t-butyl)phenyl]ethoxy]- 77-79° C. pyrido[2,3-d]pyrimidine42 N-[[3-trifluoromethyl)phenyl]- 202-201° C. methyl]pyrido[2,3-d]pyrimidin-4- amine43 N-[[4-(trifluoromethoxy)phenyl]- 247-249° C. methyl]pyrido[2,3-d]pyrimidin-4- amine44 N-[ 2-(4-methylphenyl)ethyl]pyrido- 260-264° C. [2,3-d]pyrimidin-4-amine45 N-[2-(2-methoxyphenyl)ethyl]pyrido- 158-171° C. [2,3-d]pyrimidin-4-amine46 N-(2-phenylethyl)pyrido[3,4-d]- 134-137° C. pyrimidin-4-amine47 N-[4-(trifluoromethyl)phenyl]pyrido- 283-290° C. [2,3-d]pyrimidin-4-amine48 4-[[2-(4-methoxyphenyl)ethyl]amino]- 120-122° C. pyrido[3,2-d]pyrimidine49 N-(2-phenylethyl)pyrido[3,2-d]pyri- 135-137° C. midin-4-amine50 N-[2-[4-( .sub.- t-butyl)phenyl]ethyl]- 157-158° C. pyrido-[4,3-d]pyrimidin-4-amine51 N-[2-(2-naphthyl)ethyl]pyrido- 140-143° C. [3,2-d]pyrimidin-4-amine52 N-methyl-N-(2-phenylethyl)pyrido- 114-116° C. [2,3-d]pyrimidin-4-amine53 N-methyl-N-[phenylmethyl)pyrido- 99-101° C. [2,3-d]pyrimidin-4-amine54 4-[2-(4-methylphenyl)ethoxy]- 91-92° C. pyrido[2,3-d]pyrimidine55 4-[2-[4-( .sub.- t-butyl)phenyl]ethoxy]- 149° C. pteridine56 4-[2-(4-methylphenyl)ethoxy]pyrido- 74-75° C. [3,4-d]pyrimidine57 4-[2-(biphenyl)ethoxy]pyrido[3,2-d]- 83-84° C. pyrimidine58 4-[2-(4-methoxyphenyl)ethoxy]pyrido- 80-81° C. [3,4-d]pyrimidine59 4-[(4-methylphenyl)methoxy]pyrido- 110-111° C. [2,3-d]pyrimidine60 4-(2-cyclohexylethoxy)pyrido[2,3-d]- 72° C. pyrimidine61 4-[2-(phenyl)ethoxy]pyrido[3,4-d]- 77-78° C. pyrimidine62 4-[2-(4-chlorophenyl)ethoxy]pyrido- 108-109° C. [3,4-d]pyrimidine63 4-(3-phenylpropoxy)pyrido[2,3-d]- 34-36° C. pyrimidine64 4-[(2-phenylethyl)amino]pteridine 159-160° C.65 N-[2-(4-ethylphenyl)ethyl]pyrido- 218-220° C. [2,3-d]pyrimidin-4-amine66 N-(2-ethoxyethyl)pyrido[2,3-d]- N.A. pyrimidin-4-amine67 N-(2-methoxyethyl)pyrido[2,3-d]- 190-193° C. pyrimidin-4-amine68 N-[2-(2-chloro-6-fluorophenyl)- 248-251° C. ethyl]pyrido[2,3-d]pyrimidin-4-amine69 N-[3-(diethylamino)propyl]pyrido- 163-167° C. [2,3-d]pyrimidin-4-amine70 N-[2-[4-( .sub.- t-butyl)phenyl]ethyl]-4- 147° C. pteridinamine71 N-(phenylmethyl)pyrido[2,3-d]- 258-260° C. pyrimidin-4-amine72 4-[2-(2-methyl)ethoxy]pyrido- 128-129° C. [3,4-d]pyrimidine______________________________________
The procedures described in the following detailed examples are representative of the procedures used to prepare the compounds of the other examples.
Preparation 1
Pyrido[3,4-d]pyrimidin-4(3H)one
A mixture of 4 g of 3-amino-pyridine-4-carboxylic acid in 15 mL of formamide was heated in an oil bath to 160-180° C. After one hour the mixture was allowed to cool. Then, the mixture was slurried in 25 mL of water and filtered. The product was recrystallized from water. Yield 3.3 g. M.P. 317° C. (with sublimation).
Preparation 2
Pyrido[3,2-d]pyrimidin-4(3H)one
A mixture of 6.5 g of 3-amino-pyridine-2-carboxylic acid in 9 g of formamide was heated in an oil bath while stirring. The temperature was increased from 130° C. to 180° C. over a two hour period, then the mixture was allowed to cool. The mixture was then diluted with water. The solids were collected and washed with fresh water, then dried. Yield 4.6 g. M.P. 346-347° C.
Preparation 3
4-Chloropyrido[2,3-d]pyrimidine
A mixture of 17.8 g of Pyrido[2,3-d]pyrimidin4(3H)one and 200 mL of POCl 3 was stirred under reflux for one hour. Excess POCl 3 was removed under vacuum, and then CH 2 Cl 2 , ice, and water were added. A black solid dissolved slowly. The organic layer was then separated, washed with aqueous NaHCO 3 , and dried over Na 2 SO 4 . Solvent was then removed under vacuum to leave a yellow solid, which was recrystallized from toluene/hexane. M.P. 137° dec.
Preparation 4
4-[1'-(1,2,4-triazolyl)pyrido[2,3-d]-pyrimidine
A. A mixture of 28.5 g of Pyrido[2,3-d]-pyrimidin-4(3H)one and 40.1 g of 1,2,4-triazole in 500 mL of pyridine was stirred as 71.4 g of 4-chlorophenyl dichlorophosphate was added with modest cooling. The mixture was then stirred at room temperature. Then 2.5 L of CH 2 Cl 2 was added, and the mixture was washed successively with 500 mL of water, 1 L of 2% HCl, and 500 mL of water, then dried over MgSO 4 . Solvent was then evaporated, leaving a yellow solid, which was recrystallized from toluene/hexane to give 9.0 g first crop, M.P. 206-210° C., 5.7 g second crop, M.P. 218-220° C., 1.45 g third crop, M.P. 205-209° C.
B. The title compound was also made by mixing 1.47 g of pyrido[2,3-d]pyrimidin-4(3H)one and 2.07 g of 1,2,4-triazole in 50 mL of pyridine and adding 1.12 mL of POCl 3 while stirring the mixture at room temperature. After stirring the mixture overnight, 500 mL of CH 2 Cl 2 was added, and the mixture was washed successively with 500 mL of 2% HCl and 500 mL of water, and then dried over MgSO 4 . Solvent was evaporated under vacuum to leave 0.4 of yellow solid, which was recrystallized from toluene/hexane. M.P. 217-219° C.
EXAMPLE 2
4-[2-[4-(i-propyl)phenyl]ethylamino]-pyrido[2,3-d]-pyrimidine
A mixture consisting of 1.98 g (.01 mole) of 4-[1'-(1,2,4-triazolyl)]pyrido[2,3-d]pyrimidine, 1.63 g (0.01 mole) of 2-[4-(i-propyl)phenyl]ethylamine, and 50 mL of CHCl 3 was stirred at reflux for two hours. Then 1.01 g (0.01 mole) of triethyl amine was added, and the mixture was refluxed for four hours. After washing the mixture with water, the CHCl 3 layer was dried over MgSO 4 . The CHCl 3 was removed using a vacuum and the product was recrystallized from EtOH/H 2 O. Yield 1.5 g. This product was recrystallized from ethyl acetate. M.P. 200-203° C.
EXAMPLE 3
4-[2-(4-chlorophenyl)ethoxy]pyrido[2,3-d]pyrimidine
A mixture consisting of 1.48 g (7.5 mmole) of 4-[1'(1,2,4-triazolyl)-pyrido[2,3-d]pyrimidine, 1.20 g of 2-(4-chlorophenyl)ethanol (7.5 mmole), and 50 mL of toluene which had been treated with dry HCl gas was stirred at room temperature, heated gently for about one and one half hours, then cooled. TLC indicated that the reaction was not complete, so additional alcohol was added and the mixture was warmed. After cooling the mixture, it was diluted with water and made basic with 1.0 N NaOH. The product was extracted from the mixture into toluene, which was then washed with saturated brine, filtered through phase separating paper, and concentrated in vacuo. The oily residue that crystallized was chromatographed (silica gel, CH 2 Cl 2 →70% CH 2 Cl 2 /30% EtOAc). The fractions containing the major product were combined, and the product crystallized. The product was recrystallized from CH 2 Cl 2 /petroleum ether. Yield 1.05 g. M.P. 126-128° C.
EXAMPLE 26
4-[2-[4-(t-butyl)phenyl]ethoxy]pyrido[3,4-d]pyrimidine
To a suspension of 300 mg of 60% NaH in 15 mL of DMF was added 1.33 g of 2-[4-(t-butyl)phenyl]ethanol. The mixture was stirred at room temperature for 30 minutes. The 1.48 g of 4-[1'-(1,2,4-triazolyl)pyrido[3,4-d]pyrimidine was added and the mixture was stirred at room temperature overnight. Solvent was then removed in vacuo, azeotroping with xylene. The residue was diluted with water and the pH was adjusted to neutral by adding dilute HCl. The product was extracted into CH 2 Cl 2 , which was then washed with brine, dried over Na 2 SO 4 , filtered, and concentrated. The residue was adsorbed onto silica gel and chromatographed, eluting with CH 2 Cl 2 to 75/25 CH 2 Cl 2 /EtOAc. Fractions containing the major product were combined to give a thick oil which crystallized from petroleum ether. Yield 1.4 g. M.P. 59-60° C.
EXAMPLE 41
4-[2-[4-(t-butyl)phenyl]ethoxy]pyrido[2,3-d]pyrimidine
A mixture consisting of 1.86 g (0.011 mole) of 4-chloropyrido-[2,3-d]pyrimidine, 2.0 g (0.011 mole) of 2-[4-(t-butyl)phenyl]ethanol, and 40 mL of toluene containing a little HCl gas was stirred at room temperature. The mixture was then cooled, and a yellow solid was collected. This was washed with hexane, then partitioned between 1N NaOH and CH 2 Cl 2 . The CH 2 Cl 2 layer was dried over MgSO 4 , then the solvent was removed under vacuum to leave a yellow solid, which was recrystallized from hexane. Yield 2.5 g. M.P. 77-79° C.
EXAMPLE 50
4-[2-[4-(t-butyl)phenyl]ethylamino]pyrido-[4,3-d]pyrimidine
A mixture consisting of 0.45 g of pyrido-[4,3-d]pyrimidine-4-ol, 0.53 g of 2-[4-(t-butyl)phenyl]ethylamine, about 40 mg of (NH 4 ) 2 SO 4 in 4 mL of hexamethyldisilazane was refluxed for about five hours. The mixture was then cooled and excess disilazane was removed in vacuo. The residue was dissolved in CH 2 Cl 2 , and the solution was washed with water and filtered through phase separating paper. Evaporated the CH 2 Cl 2 and adsorbed the residue onto silica gel, which was applied to a thin silica pad and eluted with CH 2 Cl 2 →50% EtOAc/50% CH 2 Cl 2 EtOAc. Fractions containing the major product were combined and the product which crystallized was recrystallized from hexane/EtOAc. Yield 0.2 g. M.P. 157-158° C.
EXAMPLE 55
4-[2-[4-(t-butyl)phenyl]ethoxy]pteridine
To a suspension of 2 g of 4-hydroxypteridine in 20 mL of CH 2 Cl 2 under nitrogen was added 1.2 g of 25 pyridine. The mixture was cooled to -30° C and over a 15 minute period a solution of 4.82 g of triphenyl phosphite in CH 2 Cl 2 was added simultaneously with addition of chlorine gas. The mixture was stirred for one and one half hours while maintaining the temperature at -15 to -20° C. The mixture was then allowed to warm to 10° C., and a solution of 2.67 g of 2-[4-(t-butyl)phenyl]ethanol in CH 2 Cl 2 was added. The resulting mixture was refluxed for 45 minutes, then cooled and diluted into toluene. The toluene solution was washed with dilute base, then filtered through phase separating paper and concentrated in vacuo. The resulting bluish oil was adsorbed onto silica gel and chromatographed (silica gel, CH 2 Cl 2 →80% CH 2 Cl 2 , 20% EtOAc). Fractions containing the major product were combined. The product was then recrystallized from petroleum ether/CH 2 Cl 2 . Yield 60 mg. M.P. 149° C.
Fungicide Utility
The compounds of the present invention have been found to control fungi, particularly plant pathogens. When employed in the treatment of plant fungal diseases, the compounds are applied to the plants in a disease inhibiting and phytologically acceptable amount. The term "disease inhibiting and phytologically acceptable amount," as used herein, refers to an amount of a compound of the invention which kills or inhibits the plant disease for which control is desired, but is not significantly toxic to the plant. This amount will generally be from about 1 to 1000 ppm, with 10 to 500 ppm being preferred. The exact concentration of compound required varies with the fungal disease to be controlled, the type formulation employed, the method of application, the particular plant species, climate conditions and the like. A suitable application rate is typically in the range from 0.25 to 4 lb/A. The compounds of the invention may also be used to protect stored grain and other non-plant loci from fungal infestation.
Greenhouse Tests
The following experiments were performed in the laboratory to determine the fungicidal efficacy of the compounds of the invention.
This screen was used to evaluate the efficacy of the present compounds against a variety of different organisms that cause plant diseases.
The test compounds were formulated for application by dissolving 50 mg of the compound into 1.25 ml of solvent. The solvent was prepared by mixing 50 ml of "Tween 20" (polyoxyethylene (20) sorbitan monolaurate emulsifier) with 475 ml of acetone and 475 ml of ethanol. The solvent/compound solution was diluted to 125 ml with deionized water. The resulting formulation contains 400 ppm test chemical. Lower concentrations were obtained by serial dilution with the solvent-surfactant mixture.
The formulated test compounds were applied by foliar spray. The following plant pathogens and their corresponding plants were employed.
______________________________________ Designation inPathogen Following Table Host______________________________________Erysiphe qraminis tritici POWD wheat(powdery mildew) MDEWPyricularia oryzae RICE rice(rice blast) BLASPuccinia recondita tritici LEAF wheat(leaf rust) RUSTBotrytis cinerea GRAY grape berries(gray mold) MOLDPseudoperonospora cubensis DOWN squash(downy mildew) MDEWCercospora beticola LEAF sugar beet(leaf spot) SPOTVenturia inaequalis APPL apple seedling(apple scab) SCABSeptoria tritici LEAF wheat(leaf blotch) BLOT______________________________________
The formulated technical compounds were sprayed on all foliar surfaces of the host plants (or cut berry) to past run-off. Single pots of each host plant were placed on raised, revolving pedestals in a fume hood. Test solutions were sprayed on all foliar surfaces. All treatments were allowed to dry and the plants were inoculated with the appropriate pathogens within 2-4 hours.
The following Table presents the activity of typical compounds of the present invention when evaluated in this experiment. The effectiveness of test compounds in controlling disease was rated using the following scale.
0=not tested against specific organism
-=0-19% control at 400 ppm
+=20-89% control at 400 ppm
++=90-100% control at 400 ppm
+++=90-100% control at ppm
______________________________________PLANT PATHOLOGY SCREENEXAMPLE POWD RICE LEAF GRAY DOWNNUMBER MDEW BLAST RUST MOLD MDEW______________________________________ 1 - - - - - 2 - - +++ - +++ 3 + +++ +++ - +++ 4 - ++ + - + 5 +++ +++ +++ + +++ 6 + - - - + 7 + - ++ - +++ 8 - - +++ - +++ 9 - - ++ - +10 ++ - +++ - +++11 ++ - +++ - +++12 - - ++ - +++13 - - +++ - +++14 - - + - +++15 + - +++ - +++16 - - + - -17 +++ +++ +++ - +++18 - ++ +++ - +++19 - - + - -20 - - - - +21 +++ - +++ - +++22 +++ - +++ - +++23 - +++ +++ - +++24 - - - - -25 +++ +++ +++ - +++26 +++ +++ +++ - +++27 - + +++ - +++28 +++ +++ +++ - +++29 ++ ++ ++ - +++30 +++ +++ +++ - +++31 - - - - -32 ++ ++ ++ - ++33 ++ - ++ - ++34 - + ++ - ++35 ++ +++ +++ - +++36 - ++ + - +++37 ++ +++ +++ - +++38 ++ ++ +++ - +++39 +++ ++ +++ - +++40 + + +++ - ++41 +++ +++ +++ - +++43 - - ++ - +44 - - + - ++45 - - ++ - ++46 ++ - ++ - ++47 - - - - ++48 ++ ++ ++ - ++49 + - ++ - ++50 - - ++ - ++51 +++ + +++ - +++52 ++ - ++ - ++53 - - + 0 +54 ++ - ++ 0 ++55 - - + - +++61 ++ ++ ++ - ++65 - - +++ - +++67 - - - 0 ++72 + ++ +++ - +++______________________________________
Combinations
Fungal disease pathogens are known to develop resistance to fungicides. When strains resistant to a fungicide do develop, it becomes necessary to apply larger and larger amounts of the fungicide to obtain desired results. To retard the development of resistance to new fungicides, it is desirable to apply the new fungicides in combination with other fungicides. Use of a combination product also permits the product's spectrum of activity to be adjusted.
Accordingly, another aspect of the invention is a fungicidal combination comprising at least 1% by weight of a compound of formula (1) in combination with a second fungicide.
Contemplated classes of fungicides from which the second fungicide may be selected include:
1) N-substituted azoles, for example propiconazole, triademefon, flusilazol, diniconazole, ethyltrianol, myclobutanil, and prochloraz;
2) pyrimidines, such as fenarimol and nuarimol;
3) morpholines, such as fenpropimorph and tridemorph;
4) piperazines, such as triforine; and
5) pyridines, such as pyrifenox.
Fungicides in these five classes all function by inhibiting sterol biosynthesis. Additional classes of contemplated fungicides, which have other mechanisms of action include:
6) dithiocarbamates, such as maneb and mancozeb;
7) phthalimides, such as captafol;
8) isophthalonitrites, such as chlorothalonil;
9) dicarboximides, such as iprodione;
10) benzimidazoles, such as benomyl and carbendazim;
11) 2-aminopyrimidines, such as ethirimol;
12) carboxamides, such as carboxin;
13) dinitrophenols, such as dinocap; and
14) acylalanines, such as metalaxyl.
The fungicide combinations of the invention contain at least 1%, ordinarily 20 to 80%, and more typically 50 to 75% by weight of a compound of formula (1).
Insecticide and Miticide Utility
The compounds of the invention are also useful for the control of insects and mites. Therefore, the present invention also is directed to a method for inhibiting an insect or mite which comprises applying to a locus of the insect or mite an insect- or mite-inhibiting amount of a compound of formula (1).
The compounds of the invention show activity against a number of insects and mites. More specifically, the compounds show activity against melon aphid, which is a member of the insect order Homoptera. Other members of the Homoptera include leafhoppers, planthoppers, pear pyslla, apple sucker, scale insects, whiteflies, spittle bugs as well as numerous other host specific aphid species. Activity has also been observed against greenhouse thrips, which are members of the order Thysanoptera. The compounds also show activity against Southern armyworm, which is a member of the insect order Lepidoptera. Other typical members of this order are codling moth, cutworm, clothes moth, Indianmeal moth, leaf rollers, corn earworm, European corn borer, cabbage worm, cabbage looper, cotton bollworm, bagworm, eastern tent caterpillar, sod webworm, and fall armyworm.
Representative mite species with which it is contemplated that the present invention can be practiced include those listed below.
__________________________________________________________________________FAMILY SCIENTIFIC NAME COMMON NAME__________________________________________________________________________ACARIDAE Aleurobius farinae Rhizoglyphus echinopus Bulb mite Rhizoglyphus elongatus Rhizoglyphus rhizophagus Rhizoglyphus sagittatae Rhizoglyphus tarsalisERIOPHYIDAE Abacarus farinae Grain rust mite Aceria brachytarsus Acalitus essigi Redberry mite Acera ficus Aceria fraaxinivorus Aceria granati Aceria parapopuli Eriophyes sheldoni Citrus bud mite Aceria tulipae Aculus carnutus Peach silver mite Aculus schlechtendali Apple rust mite Colomerus vitis Grape erineum mite Eriophyes convolvens Eriophyes insidiosus Eriophyes malifoliae Eriophyes padi Eriophyes pruni Epitrimerus pyri Pear leaf blister mite Eriophyes ramosus Eriophyes sheldoni Citrus bud mite Eriophyes ribis Phyllocoptes gracilis Dryberry mite Phyllocoptruta oleivora Citrus rust mite Phytoptus ribis Trisetacus pini Vasates amygdalina Vasates eurynotus Vasates quadripedes Maple bladdergall mite Vasates schlechtendaliEUPODIDAE Penthaleus major Winter grain mite Linopodes spp.NALEPELLIDAE Phylocoptella avellanae Filbert bud mitePENTHALEIDAE Halotydeus destrustorPYEMOTIDAE Pyemotes tritici Straw itch mite Siteroptes cerealiumTARSONEMIDAE Polyphagotarsonemus latus Broad mite Steneotarsonemus pallidus Cyclamen miteTENUIPALPIDAE Brevipalpus californicus Brevipalpus obovatus Privet mite Brevipalpus lewisi Citrus flat mite Dolichotetranychus floridanus Pineapple flase spider mite Tenuipalpes granati Tenuipalpes pacificusTETRANYCHIDAE Bryobia arborea Bryobia practiosa Clover mite Bryobia rubrioculus Brown mite Eotetranychus coryli Eotetranychus hicoriae Pecan deaf scorch mite Eotetranychus lewisi Eotetranychus sexmaculatus Sixspotted spider mite Eotetranychus willametti Eotetranychus banksi Texas citrus mite Oligonychus ilicis Southern red mite Oligonychus pratensis Banks grass mite Oligonychus ununguis Spruce spider mite Panonychus citri Citrus red mite Panonychus ulmi European red mite Paratetranychus modestus Paratetranychus pratensis Paratetranychus viridis Petrobia latens Brown wheat mite Schizotetranychus celarius Bamboo spider mite Schizotetranychus pratensis Tetranychus canadensis Fourspotted spider mite Tetranychus cinnabarinus Carmine spider mite Tetranvchus mcdanieli McDaniel spider mite Tetranychus pacificus Pacific spider mite Tetranychus schoenei Schoene spider mite Tetranychus urticae Twospotted spider mite Tetranychus turkestani Strawberry spider mite Tetranychus desertorum Desert spider mite__________________________________________________________________________
The compounds are useful for reducing populations of insects and mites, and are used in a method of inhibiting an insect or mite population which comprises applying to a locus of the insect or arachnid an effective insect- or mite-inactivating amount of a compound of formula (1). The "locus" of insects or mites is a term used herein to refer to the environment in which the insects or mites live or where their eggs are present, including the air surrounding them, the food they eat, or objects which they contact. For example, plant-ingesting insects or mites can be controlled by applying the active compound to plant parts, which the insects or mites eat, particularly the foliage. It is contemplated that the compounds might also be useful to protect textiles, paper, stored grain, or seeds by applying an active compound to such substance. The term "inhibiting an insect or mite" refers to a decrease in the numbers of living insects or mites; or a decrease in the number of viable insect or mite eggs. The extent of reduction accomplished by a compound depends, of course, upon the application rate of the compound, the particular compound used, and the target insect or mite species. At least an insect-inactivating or mite-inactivating amount should be used. The terms "insect-inactivating amount" and "mite-inactivating amount" are used to describe the amount, which is sufficient to cause a measurable reduction in the treated insect or mite population. Generally an amount in the range from about 1 to about 1000 ppm active compound is used.
In a preferred embodiment, the present invention is directed to a method for inhibiting a mite which comprises applying to a plant an effective mite-inactivating amount of a compound of formula (1) in accordance with the present invention.
MITE/INSECT SCREEN
The compounds of Examples 1-10 were tested for miticidal and insecticidal activity in the following mite/insect screen.
Each test compound was formulated by dissolving the compound in acetone/alcohol (50:50) mixture containing 23 g of "TOXIMUL R" (sulfonate/nonionic emulsifier blend) and 13 g of "TOXIMUL S" (sulfonate/nonionic emulsifier blend) per liter. These mixtures were then diluted with water to give the indicated concentrations.
Twospotted spider mites (Tetranychus urticae Koch) and melon aphids (Aphis gossypii Glover) were introduced on squash cotyledons and allowed to establish on both leaf surfaces. Other plants in the same treatment pot were left uninfested. The leaves were then sprayed with 5 ml of test solution using a DeVilbiss atomizing sprayer at 10 psi. Both surfaces of the leaves were covered until runoff, and then allowed to dry for one hour. Two uninfested leaves were then excised and placed into a Petri dish containing larval southern armyworm (Spodopetra eridania Cramer).
Activity on Southern corn rootworm (Diabrotica undecimpuctata howardi Barber) was evaluated by adding two ml of tap water, a presoaked corn seed, and 15 g of dry sandy soil to a one ounce plastic container. The soil was treated with 1 mL of test solution containing a predetermined concentration of test compound. After six to 12 hours of drying, five 2-3 instar corn rootworm larvae were added to the individual cups, which were then capped and held at 23° C.
After standard exposure periods, percent mortality and phytotoxicity were evaluated. Results for the compounds found to be active are reported in the following table. The remaining compounds showed no activity. The following abbreviations are used in the following table:
CRW refers to corn rootworm
SAW refers to Southern armyworm
SM refers to twospotted spider mites
MA refers to melon aphids.
______________________________________MITE AND INSECT SCREEN SAW SM MAEXAMPLE RATE RESULTS RESULTS RESULTSNUMBER PPM % % %______________________________________ 1 400 0 0 0 2 200 0 0 0 400 80 0 0 3 200 0 0 0 400 0 0 0 4 200 0 0 0 400 0 0 0 5 200 0 100 90 400 0 100 100 6 400 0 0 0 7 200 0 0 90 400 0 0 0 8 200 0 0 0 400 0 0 0 9 200 80 0 0 400 70 0 010 200 0 90 90 200 0 80 100 400 0 100 10011 200 0 100 100 400 0 100 10012 200 0 0 0 400 0 0 013 200 60 0 0 400 0 0 014 200 0 0 50 400 0 0 015 200 0 0 0 400 0 80 8016 200 80 0 0 400 0 0 017 200 0 80 80 400 0 60 8018 200 0 30 80 400 0 90 9019 200 0 0 0 400 0 0 020 200 0 0 0 400 0 0 021 200 70 100 100 400 0 100 6022 200 90 100 100 400 0 60 8023 200 0 0 90 400 0 40 8024 400 0 0 025 200 80 50 60 400 0 0 026 200 0 100 80 400 0 0 027 200 0 0 20 400 0 0 028 200 0 20 30 400 0 0 029 200 0 100 90 400 0 80 8030 200 0 100 100 400 0 100 10031 400 0 0 032 200 60 100 90 400 0 0 033 200 0 0 0 400 0 0 034 200 60 0 0 400 0 0 035 200 0 0 60 400 0 0 036 200 0 0 0 400 0 0 037 200 0 0 0 400 0 0 038 200 20 0 0 400 20 0 039 200 0 80 0 400 0 0 040 200 20 0 0 400 0 0 041 200 0 100 100 400 0 100 10044 200 0 0 0 400 40 0 045 200 0 0 0 400 0 0 046 400 0 0 047 200 0 20 90 400 0 0 048 200 0 80 60 400 0 0 049 200 0 0 0 400 0 0 050 200 0 90 70 400 0 0 051 200 50 80 80 400 40 0 052 200 0 0 0 400 0 100 10053 400 0 0 054 400 0 100 10055 400 0 0 057 200 0 90 90 400 0 80 10061 400 0 0 N.A.64 400 0 0 065 200 90 0 0 400 100 0 067 400 0 0 10068 400 0 0 072 200 0 0 0 400 0 0 0______________________________________
Compositions
The compounds of this invention are applied in the form of compositions which are important embodiments of the invention, and which comprise a compound of this invention and a phytologically-acceptable inert carrier. The compositions are either concentrated formulations which are dispersed in water for application, or are dust or granular formulations which are applied without further treatment. The compositions are prepared according to procedures and formulae which are conventional in the agricultural chemical art, but which are novel and important because of the presence therein of the compounds of this invention. Some description of the formulation of the compositions will be given, however, to assure that agricultural chemists can readily prepare any desired composition.
The dispersions in which the compounds are applied are most often aqueous suspensions or emulsions prepared from concentrated formulations of the compounds. Such water-soluble, water-suspendable or emulsifiable formulations are either solids usually known as wettable powders, or liquids usually known as emulsifiable concentrates or aqueous suspensions. Wettable powders, which may be compacted to form water dispersible granules, comprise an intimate mixture of the active compound, an inert carrier and surfactants. The concentration of the active compound is usually from about 10% to about 90% by weight. The inert carrier is usually chosen from among the attapulgite clays, the montmorillonite clays, the diatomaceous earths, or the purified silicates. Effective surfactants, comprising from about 0.5% to about 10% of the wettable powder, are found among the sulfonated lignins, the condensed naphthalenesulfonates, the naphthalenesulfonates, the alkylbenzenesulfonates, the alkyl sulfates, and non-ionic surfactants such as ethylene oxide adducts of alkyl phenols.
Emulsifiable concentrates of the compounds comprise a convenient concentration of a compound, such as from about 50 to about 500 grams per liter of liquid, equivalent to about 10% to about 50%, dissolved in an inert carrier which is either a water miscible solvent or a mixture of water-immiscible organic solvent and emulsifiers. Useful organic solvents include aromatics, especially the xylenes, and the petroleum fractions, especially the high-boiling naphthalenic and olefinic portions of petroleum such as heavy aromatic naphtha. Other organic solvents may also be used, such as the terpenic solvents including rosin derivatives, aliphatic ketones such as cyclohexanone, and complex alcohols such as 2-ethoxyethanol. Suitable emulsifiers for emulsifiable concentrates are chosen from conventional nonionic surfactants, such as those discussed above.
Aqueous suspensions comprise suspensions of water-insoluble compounds of this invention, dispersed in an aqueous vehicle at a concentration in the range from about 5% to about 50% by weight. Suspensions are prepared by finely grinding the compound, and vigorously mixing it into a vehicle comprised of water and surfactants chosen from the same types discussed above. Inert ingredients, such as inorganic salts and synthetic or natural gums, may also be added, to increase the density and viscosity of the aqueous vehicle. It is often most effective to grind and mix the compound at the same time by preparing the aqueous mixture, and homogenizing it in an implement such as a sand mill, ball mill, or piston-type homogenizer.
The compounds may also be applied as granular compositions, which are particularly useful for applications to the soil. Granular compositions usually contain from about 0.5% to about 10% by weight of the compound, dispersed in an inert carrier which consists entirely or in large part of clay or a similar inexpensive substance. Such compositions are usually prepared by dissolving the compound in a suitable solvent, and applying it to a granular carrier which has been pre-formed to the appropriate particle size, in the range of from about 0.5 to 3 mm. Such compositions may also be formulated by making a dough or paste of the carrier and compound, and crushing and drying to obtain the desired granular particle size.
Dusts containing the compounds are prepared simply by intimately mixing the compound in powdered form with a suitable dusty agricultural carrier, such as kaolin clay, ground volcanic rock and the like. Dusts can suitably contain from about 1% to about 10% of the compound.
It is equally practical, when desirable for any reason, to apply the compound in the form of a solution in an appropriate organic solvent, usually a bland petroleum oil, such as the spray oils, which are widely used in agricultural chemistry.
Insecticides and miticides are generally applied in the form of a dispersion of the active ingredient in a liquid carrier. It is conventional to refer to application rates in terms of the concentration of active ingredient in the carrier. The most widely used carrier is water.
The compounds of the invention can also be applied in the form of an aerosol composition. In such compositions the active compound is dissolved or dispersed in an inert carrier, which is a pressure-generating propellant mixture. The aerosol composition is packaged in a container from which the mixture is dispensed through an atomizing valve. Propellant mixtures comprise either low-boiling halocarbons, which may be mixed with organic solvents, or aqueous suspensions pressurized with inert gases or gaseous hydrocarbons.
The actual amount of compound to be applied to loci of insects and mites is not critical and can readily be determined by those skilled in the art in view of the examples above. In general, concentrations of from 10 ppm to 5000 ppm of compound are expected to provide good control. With many of the compounds, concentrations of from 100 to 1500 ppm will suffice. For field crops, such as soybeans and cotton, a suitable application rate for the compounds is about 0.5 to 1.5 lb/A, typically applied in 50 gal/A of spray formulation containing 1200 to 3600 ppm of compound. For citrus crops, a suitable application rate is from about 100 to 1500 gal/A spray formulation, which is a rate of 100 to 1000 ppm.
The locus to which a compound is applied can be any locus inhabited by an insect or arachnid, for example, vegetable crops, fruit and nut trees, grape vines, and ornamental plants. Inasmuch as many mite species are specific to a particular host, the foregoing list of mite species provides exemplification of the wide range of settings in which the present compounds can be used.
Because of the unique ability of mite eggs to resist toxicant action, repeated applications may be desirable to control newly emerged larvae, as is true of other known acaricides.
The following formulations of compounds of the invention are typical of compositions useful in the practice of the present invention.
______________________________________A. 0.75 Emulsifiable ConcentrateCompound of Example 25 9.38%"TOXIMUL D" 2.50%(nonionic/anionic surfactant blend)"TOXIMUL H" 2.50%(nonionic/anionic surfactant blend)"EXXON 200" 85.62%(naphthalenic solvent)B. 1.5 Emulsifiable ConcentrateCompound of Example 25 18.50%"TOXIMUL D" 2.50%"TOXIMUL H" 2.50%"EXXON 200" 76.50%C. 0.75 Emulsifiable ConcentrateCompound of Example 41 9.38%"TOXIMUL D" 2.50%"TOXIMUL H" 2.50%"EXXON 200" 85.62%D. 1.0 Emulsifiable ConcentrateCompound of Example 41 12.50%N-methylpyrrolidone 25.00%"TOXIMUL D" 2.50%"TOXIMUL H" 2.50%"EXXON 200" 57.50%E. 1.0 Aqueous SuspensionCompound of Example 25 12.00%"PLURONIC P-103" 1.50%(block copolymer of propylene oxideand ethylene oxide, surfactant)"PROXEL GXL" .05%(biocide/preservative)"AF-100" .20%(silicon based antifoam agent)"REAX 88B" 1.00%(lignosulfonate dispersing agent)propylene glycol 10.00%veegum .75%xanthan .25%water 74.25%F. 1.0 Aqueous SuspensionCompound of Example 25 12.50%"MAKON 10" (10 moles ethyleneoxide 1.00%nonylphenol surfactant)"ZEOSYL 200" (silica) 1.00%"AF-100" 0.20%"AGRIWET FR" (surfactant) 3.00%2% xanthan hydrate 10.00%water 72.30%G. 1.0 Aqueous SuspensionCompound of Example 41 12.50%"MAKON 10" 1.50%"ZEOSYL 200" (silica) 1.00%"AF-100" 0.20%"POLYFON H" 0.20%(lignosulfonate dispersing agent)2% xanthan hydrate 10.00%water 74.60%H. Wettable PowderCompound of Example 25 25.80%"POLYFON H" 3.50%"SELLOGEN HR" 5.00%"STEPANOL ME DRY" 1.00%gum arabic 0.50%"HISIL 233" 2.50%Barden clay 61.70%I. Aqueous SuspensionCompound of Example 25 12.40%"TERGITOL 158-7" 5.00%"ZEOSYL 200" 1.00%"AF-100" 0.20%"POLYFON H" 0.50%2% xanthan solution 10.00%tap water 70.90%J. Emulsifiable ConcentrateCompound of Example 25 12.40%"TOXIMUL D" 2.50%"TOXIMUL H" 2.50%"EXXON 200" 82.60%K. Wettable PowderCompound of Example 41 25.80%"SELLOGEN HR" 5.00%"POLYFON H" 4.00%"STEPANOL ME DRY" 2.00%"HISIL 233" 3.00%Barden clay 60.20%L. Emulsifiable ConcentrateCompound of Example 25 6.19%"TOXIMUL H" 3.60%"TOXIMUL D" 0.40%"EXXON 200" 89.81%M. Wettable PowderCompound of Example 25 25.80%"SELLOGEN HR" 5.00%"POLYFON H" 4.00%"STEPANOL ME DRY" 2.00%"HISIL 233" 3.00%Barden clay 60.20%N. Aqueous SuspensionCompound of Example 41 12.40%"TERGITOL 158-7" 5.00%"ZEOSYL 200" 1.00%"POLYFON H" 0.50%"AF-100" 0.20%xanthan solution (2%) 10.00%tap water 70.90%______________________________________ | Fungicidal compositions contain as active ingredient a 4-substituted-pyrido[3,2-d]pyrimidine, -pyrido[4,3-d]pyrimidine, -pyrido[3,4-d]pyrimidine, pyrido[2,3-d]pyrimidine, -pteridine, -pyrimido[4,5-d]pyrimidine, -pyrimido[4,5-c]pyridazine, -pyrimido[5,4-d]pyrimidine, -pyrimido[5,4-c]pyridazine, pyrimido[4,5-d]pyridazine, or -pyrimido[5,4-e]-1,2,4-triazine, for example 4-[2-(4-chlorophenyl)ethoxy]pyrido[2,3-d]pyrimidine. | 2 |
The present application claims priority on European Patent Application 01200180.6, filed on 18 Jan. 2001.
FIELD OF INVENTION
The present invention relates to determining the PVT properties of a hydrocarbon reservoir fluid, where PVT is an acronym used to refer to pressure, volume and temperature. PVT properties are gas-oil ratio, API gravity, viscosity, saturation pressure, formation volume factor, molecular weight, density and oil compressibility.
BACKGROUND OF INVENTION
In order to measure the PVT properties of a hydrocarbon reservoir fluid, a sample of the reservoir fluid is taken and analysed under reservoir pressure and temperature. A brief description of the way in which a PVT analysis is carried out is given in section 3 of the book Contributions in Petroleum Geology and Engineering, Volume 5, Properties of Oils and Natural Gases, K. S. Pederson et al, 1989. Such an analysis can be very accurate, however it takes a long time to be completed.
It is of great importance to know the PVT properties of the reservoir fluid as soon as possible, preferably directly after a well has been drilled. Knowing such information allows for the adjustment of the design of the production and surface equipment to take into account the actual PVT properties.
SUMMARY OF THE INVENTION
Applicant has found that there are empirical relations between the PVT properties and the pressure gradient (dp/dz) in the reservoir, wherein p is the fluid pressure in the reservoir and z the true vertical depth. Because the pressure gradient can be determined directly after completing drilling, the PVT properties can be obtained as early as possible.
Thereto the method of determining at least one of the in situ PVT properties of a hydrocarbon reservoir fluid that is present in a hydrocarbon-bearing formation layer traversed by a borehole according to the present invention comprises the steps of:
a) calculating along the hydrocarbon-bearing formation layer the pressure gradient; and b) determining the in situ PVT property from the pressure gradient using an empirical relation that had been obtained by fitting a curve through previously obtained data points comprising the measured PVT property as a function of the pressure gradient.
BRIEF DESCRIPTION OF DRAWINGS
The method will now be described by way of example with reference to the accompanying drawings in which the examples should not be construed to limit the scope of the invention.
FIG. 1 shows the gas-oil ratio in standard cubic feet per standard barrel on the y-axis as a function of the pressure gradient in psi per foot (at in situ pressure and temperature) on the x-axis;
FIG. 2 shows the API gravity in °API on the y-axis as a function of the pressure gradient in psi per foot (at in situ pressure and temperature) on the x-axis;
FIG. 3 shows the viscosity in centipoise (at in situ pressure and temperature) on the y-axis as a function of the pressure gradient in psi per foot (at in situ pressure and temperature) on the x-axis;
FIG. 4 shows the saturation pressure in psi absolute on the y-axis as a function of the pressure gradient psi per foot (at in situ pressure and temperature) on the x-axis;
FIG. 5 shows the formation volume factor, oil on the y-axis as a function of the pressure gradient in psi per foot (at in situ pressure and temperature) on the x-axis; and
FIG. 6 shows the molecular weight on the y-axis as a function of the pressure gradient psi per foot (at in situ pressure and temperature) on the x-axis.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to the Figures, we will now discuss the method of determining at least one of the in situ PVT properties according to the present invention in reverse order, wherein we start with discussing how the empirical relation is obtained.
The curves shown in FIGS. 1-6 show the empirical relation, line i 1 , that fits the data points i 2 , i 3 and i 4 , where i is the number of the Figure (i=1-6) obtained from samples taken from reservoirs in the same geological area. For the sake of clarity not all data points have been referred to by a reference numeral.
A data point was obtained as follows. At first a well was drilled to the formation layer containing a hydrocarbon reservoir fluid. Then a tool was lowered to the first of a set of locations in that formation layer by means of for example a wireline. The tool comprises a central conduit having an inlet and being provided with a pressure sensor, and a fluid receptacle having an inlet opening into the central conduit. At the first location an exclusive fluid communication was made between the formation and the inlet of the central conduit by extending into the formation a probe having an outlet that is in direct fluid communication with the inlet of the central conduit. Then formation fluid was allowed to enter into the fluid receptacle and the pressure build-up was measured. The required fluid pressure is the pressure at the end of the pressure build-up for that location.
Then the tool was moved to the next location where the pressure-build up was again measured to obtain the fluid pressure for that location, and so on until all the fluid pressures at all locations had been determined. With this the pressure gradient was determined.
Further, at each location a pressure-build no test was conducted, a sample of the hydrocarbon reservoir fluid was taken, and the PVT properties of the sample were measured in a laboratory under reservoir conditions. Each measurement resulted in a data point that was plotted in FIGS. 1-6 .
To get all data points these data were collected and analysed for more wells in the same geological area.
Then for each PVT property a curve was fitted through the data, and surprisingly, the data could be fitted with a considerable accuracy, with a goodness of fit R 2 of greater than 0.9, wherein
R 2 = ( ∑ i = 1 n ( x i - x ) ( y i - y ) ) 2 ∑ i = 1 n ( x i - x ) 2 ∑ i = 1 n ( y i - y ) 2 ,
wherein n is the number of data points, (x 1 , . . . , x n ) is the set of pressure gradients, x is the mean pressure gradient, (y 1 , . . . , y n ) is the set of measurements of the PVT property and y is the mean PVT property. R 2 is the squared value of the correlation coefficient.
The below Table gives the results of the curve fitting.
PVT property
Curve
R 2
Gas oil ratio
(8.6) (dp/dz) −42
0.98
API gravity
65 − (117) (dp/dz)
0.91
Viscosity
(0.0005) exp (24 dp/dz)
0.96
Saturation pressure
(16980) exp (−3.6 dp/dz)
0.72
Formation volume factor
(0.10) (dp/dz) −23
0.97
Molecular weight
(5.2) exp (8.9 dp/dz)
0.98
The correlation can as well be obtained for other PVT properties, such as density and oil compressibility.
We now discuss how a PVT property of an unknown hydrocarbon reservoir fluid that is present in a hydrocarbon-bearing formation layer traversed by a borehole is determined in situ. Suitably, the hydrocarbon-bearing formation layer is in the same geological area.
At first a tool is lowered to the first of a set of locations in that formation layer. The tool comprises a central conduit having an inlet and being provided with a pressure sensor, and a fluid receptacle having an inlet opening into the central conduit. At the first location an exclusive fluid communication is made between the formation and the inlet of the central conduit by extending into the formation a probe having an outlet that is in direct fluid communication with the inlet of the central conduit. Then formation fluid is allowed to enter into the fluid receptacle and the pressure build-up was measured. The required fluid pressure is the pressure at the end of the pressure build-up for that location.
Then the tool is moved to the next location where the pressure-build up is again measured to obtain the fluid pressure for that location, and so on until all the fluid pressures at all locations have been determined. With this the pressure gradient is calculated.
Then the pressure gradient is used with the empirical relation to get the PVT property that is required.
This shows that with the method according to the present invention a good accuracy can be achieved.
In case the hydrocarbon reservoir fluid is a so-called heavy oil that is relatively viscous, it will be difficult to acquire a representative sample of the reservoir fluid. In order to obtain a representative sample, the step of making an exclusive fluid communication further includes activating a heating device arranged near the probe to heat the formation fluid.
Suitably, the probe is associated with a packer pad in an assembly, and the heating device is placed in the packer pad. Alternatively the heating device is arranged on the tool. The heating device may be a device generating microwaves, light waves or infrared waves. The heating device may also be an electrical heater, a chemical heater or a nuclear heater.
So far the present invention has been discussed with reference to an open hole, however, the present invention can as well be applied in a cased hole. In that case, calculating the pressure gradient along the hydrocarbon-bearing formation layer starts with making a plurality of perforation sets through the casing wall into the formation layer. Then the tool is lowered in the cased borehole to the first perforation set. The tool is further provided with an upper and a lower packer arranged at either side of the inlet of the central conduit, wherein the distance between the upper and the lower packer is larger than the height of a perforation set, and wherein the spacing between adjacent perforation sets is at least equal to the length of the longest packer. The packers are set so that the perforation set is straddled between the packers. Then formation fluid is allowed to enter into the fluid receptacle, the pressure build-up is measured, and the fluid pressure is determined. Then the tool is positioned near the next perforation set, and the fluid pressure is measured and so on, until the fluid pressures of a predetermined number of locations have been measured. From these fluid pressures and the true vertical depths of the casing sets, the pressure gradient is calculated. | A method of determining an in situ PVT property of a hydrocarbon reservoir fluid that is present in a hydrocarbon-bearing formation layer traversed by a borehole, which method involves the steps of:
a) calculating along the hydrocarbon-bearing formation layer the pressure gradient; and b) determining the in situ PVT property from the pressure gradient using an empirical relation that had been obtained by fitting a curve ( 11 ) through previously obtained data points ( 12, 13, 14 ) having the measured PVT property as a function of the pressure gradient. | 4 |
CROSS-REFERENCE TO RELATED APPLICATION
The present application is a continuation of application Ser. No. 15/080,506, filed 24 Apr. 2016, which is a continuation-in-part application of application Ser. No. 14/678,644, filed 3 Apr. 2015, which in turn claims the benefit of, and priority to, U.S. Provisional Application No. 61/974,676 filed on 3 Apr. 2014, and U.S. Provisional Application No. 62/137,681 filed on 24 Mar. 2015, all incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates to modular assembly systems. More particularly, the present invention relates to modular assembly systems for office and industrial work stations.
BACKGROUND
Modular building assembly systems have long been available to for the construction and erection of various structures such as office cubicles, industrial work stations, and scaffolding. Such modular building assembly systems usually have some type of standard beam that can be joined to other beams and to which various accessories can be attached. Solid bars, of circular or regular polygonal shape (such as square or hexagonal) may be used, but are inferior to tubes of the same shape because tubes have a better resistance to torsion for the same mass of material than do solid bars. Circular or regular polygons lack an easy point of attachment for accessories and other beams, so more complex shapes are preferred. One such complex shaped beam is a cruciform beam (see U.S. Pat. No. 5,481,842 to Gautreau, FIG. 1). The cruciform beam comprises a center tube surrounded by four angle bars arranged in a square pattern in cross-section and each joined to the center tube with a web or fin, the fins forming a cross when the beam is viewed in cross-section. Accessories can be attached along the cruciform beam by clamping the accessory to one of the angle bars or in a longitudinal groove defined by the spaces between the fins and angle bars. The cruciform beam is relatively strong in resisting buckling when torsion is applied to the beam around an axis orthogonal to the long axis of the cruciform beam because in cross-section, a substantial amount of the beam material is distant from the center longitudinal axis. Such torsion occurs when the cruciform beam spans a space and a load is attached to the beam somewhere in the middle. However, the cruciform beam is not relatively strong when torsion is applied around the long axis of the cruciform beam. Such torsion occurs when a load is cantilevered from the side of the cruciform beam. Since a cruciform beam for a given size and weight does not have good resistance to torsion around its long axis, accessories are usually not cantilevered from the side of the cruciform beam.
What is needed is a modular building system with a beam that has strong resistance to torsion around its long axis.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be described by way of exemplary embodiments, but not limitations, illustrated in the accompanying drawings in which like references denote similar elements, and in which:
The accompanying drawings, which are incorporated into and constitute a part of this specification, illustrate one or more embodiments of the invention and, together with the detailed description, serve to explain the principles and implementations of the invention.
FIG. 1 is a perspective view of a first embodiment of a quad-track beam.
FIG. 2 is a perspective view of a strut nut and a portion of a channel leg.
FIG. 3 is a perspective view of a second embodiment of a quad-track beam.
FIG. 4 a is a top view of a straight configuration quad-track beam.
FIG. 4 b is a top view of a diamond configuration using quad-track beams.
FIG. 4 c is a top view of a cross configuration using quad-track beams.
FIG. 4 d is a top view of a star configuration using quad-track beams.
FIG. 5 a is a top view of a joint in the star configuration.
FIG. 5 b is a top view of a joint in the diamond configuration.
FIG. 6 a is a perspective view of a single channel leg.
FIG. 6 b is a cross-section view of a single channel leg from the top.
FIG. 6 c is a cross-section view of an alternative single channel leg from the top.
FIG. 6 d is a cross-section view of a double channel leg from the top.
FIG. 7 is a perspective view of an application using quad-track beams.
FIG. 8 shows a third embodiment of a quad-track beam.
FIG. 9A shows a fourth embodiment of a quad-track beam in a perspective view.
FIG. 9B shows an exploded perspective view of the fourth embodiment quad-track beam.
FIG. 9C shows the fourth embodiment quad-track beam in a perspective view with components for attaching accessories.
FIG. 10A shows a top view of a first embodiment of a dual quad-track beam assembly.
FIG. 10B shows a perspective view of a dual beam brace bracket.
FIG. 11A shows a perspective view of a second embodiment of a dual quad-track beam assembly.
FIG. 11B shows a top view of the second embodiment of a dual quad-track beam assembly.
FIG. 12 shows a perspective view of a first embodiment of a dual quad-track beam cruciform module.
FIG. 13A shows a perspective view of a second embodiment of a dual quad-track beam cruciform module.
FIG. 13B shows a perspective view of a central mounting plate.
FIG. 14A shows a perspective view of a dual quad-track beam assembly with cantilevered legs attached, forming a first exemplary workstation arrangement.
FIG. 14B shows a top view of the leg mounting plate.
FIG. 15 shows a top view of a second exemplary workstation arrangement using dual quad-track beam assemblies.
FIG. 16 shows a perspective view of an exemplary embodiment of a single-track beam assembly.
FIG. 17 shows a perspective view of an exemplary embodiment of a dual-track beam assembly.
FIG. 18 shows a perspective view of a third exemplary workstation arrangement.
FIG. 19A shows a side view of the third exemplary workstation arrangement with a cable trough and a shelf coupled thereto.
FIG. 19B shows a perspective view of the cable trough of FIG. 19A .
FIG. 20 shows a perspective view of an adjustable end bracket.
FIG. 21 shows a top view of a fourth exemplary workstation arrangement.
FIG. 22 shows a top view of a fifth exemplary workstation arrangement.
FIG. 23 shows a top view of a sixth exemplary workstation arrangement, demonstrating some of the different shaped work surfaces that may be used to create customized workstations for multiple purposes.
DETAILED DESCRIPTION
Before beginning a detailed description of the subject invention, mention of the following is in order. When appropriate, like reference materials and characters are used to designate identical, corresponding, or similar components in different figures. The figures associated with this disclosure typically are not drawn with dimensional accuracy to scale, i.e., such drawings have been drafted with a focus on clarity of viewing and understanding rather than dimensional accuracy.
In the interest of clarity, not all of the routine features of the implementations described herein are shown and described. It will, of course, be appreciated that in the development of any such actual implementation, numerous implementation-specific decisions must be made in order to achieve the developer's specific goals, such as compliance with application and business related constraints, and that these specific goals will vary from one implementation to another and from one developer to another. Moreover, it will be appreciated that such a development effort might be complex and time-consuming, but would nevertheless be a routine undertaking of engineering for those of ordinary skill in the art having the benefit of this disclosure.
Use of directional terms such as “upper,” “lower,” “above,” “below”, “in front of,” “behind,” etc. are intended to describe the positions and/or orientations of various components of the invention relative to one another as shown in the various Figures and are not intended to impose limitations on any position and/or orientation of any embodiment of the invention relative to any reference point external to the reference.
Those skilled in the art will recognize that numerous modifications and changes may be made to the exemplary embodiment(s) without departing from the scope of the claimed invention. It will, of course, be understood that modifications of the invention, in its various aspects, will be apparent to those skilled in the art, some being apparent only after study, others being matters of routine mechanical, chemical and electronic design. No single feature, function or property of the exemplary embodiment(s) is essential. Other embodiments are possible, their specific designs depending upon the particular application. As such, the scope of the invention should not be limited by the particular embodiments herein described but should be defined only by the appended claims and equivalents thereof.
QUAD-TRACK BEAM—FIRST EXEMPLARY EMBODIMENT
FIG. 1 is a perspective view of a first embodiment of a quad-track beam 100 . Typically, the quad-track beam 100 would have an end cap, but this is omitted in FIG. 1 to better illustrate the cross-sectional structure of the first embodiment quad-track beam 100 . The first embodiment quad-track beam 100 has four corner tubes 104 . The corner tubes 104 are much greater in length than in width, typically 20 or more inches in length and one to two inches in width. The corner tubes 104 are arranged in parallel longitudinally and in a rectangular pattern in cross-section. The corner tubes 104 in the first embodiment quad-track beam 100 are made of steel in 12, 14, or 16 gauges, however in other embodiments, other suitable materials may be used. The corner tubes 104 have interior sides 106 that face inward towards the other corner tubes 104 and have exterior sides 107 facing outward.
The first embodiment quad-track beam 100 also has four channel bars 108 . Each of the first embodiment channel bars 108 has two lateral sides 110 and a back side 112 . Collectively, the lateral sides 110 and the back side 112 define a channel bar cavity 114 therein. Each corner tube 104 is coupled to two of the other corner tubes 104 by one of the channel bars 108 with each lateral side 110 of each of the channel bars 108 contacting one of the interior sides 106 of one of the corner tubes 104 . In the first embodiment, the channel bars 108 are made of steel and welded to the corner tubes 104 , but in other embodiments, may be made of other materials and attached in other ways.
FIG. 2 shows a detailed view of one of the channel bars 108 along with a strut-nut 140 . The strut-nut 140 is used to attach an accessory (e.g., the single channel leg 120 in FIG. 1 ) to the first embodiment quad-track beam 100 at the channel bar 108 . Each of the channel bars 108 has channel bar lips 116 that curl in towards each other and then towards the channel bar cavity 114 and the back side 112 of the channel bar 108 . The channel bar cavity 114 has nut-retention foam 118 placed therein. The channel bar 108 is configured to hold the strut-nut 140 against the curled channel bar lips 116 with the nut-retention foam 118 . The channel bar 108 has a space between the channel bar lips 116 that is slightly larger than the width of the strut-nut 140 . The strut-nut 140 can be inserted into the channel bar cavity 114 , pushing back the nut-retention foam 118 . Then the strut-nut 140 can be twisted so that the ends of the longer dimension of the strut-nut 140 slip under the channel bar lips 116 . The strut-nut 140 has a pair of toothed grooves 148 near the ends of its longer dimension that are configured to engage with the channel bar lips 116 . The strut-nut 140 has two rounded corners 142 , diagonally opposed and two angled corners 144 , diagonally opposed. The longer dimension of the strut-nut 140 is configured to be slightly shorter than the interior width of the channel bar cavity 114 . When the strut-nut 140 is twisted clockwise, the rounded corners 142 slide past the interior lateral walls of the channel bar 108 until the angled corners 144 contact the channel bar lateral side 110 , preventing further clockwise rotation of the strut-nut 140 . The strut-nut 140 also has a threaded hole 146 configured to accept a threaded rod, bolt or screw, which is used to attach an accessory (such as the single channel leg 120 ) to the first embodiment quad-track beam 100 .
In the first embodiment, the corner tubes 104 are square in cross-section, but in other embodiments may be rectangular. A rectangular cross-section provides flat corner tube interior sides 106 for joining with the flat lateral sides 110 of the channel bars 108 . The rectangular cross-section provides a flat surface for accommodating accessory parts (e.g., the single channel leg 120 in FIG. 1 ). This allows the accessory parts to have large flat end plates (e.g. the single channel leg end plate 128 in FIG. 1 ) for contacting the corner tubes 104 . Large flat end plates facilitate transmittal of torque from the accessory to the first embodiment quad-track beam 100 . Such torque would occur if the accessory is cantilevered off of the quad-track beam 100 . Any torque placed on the accessory will transmit the torque forces mostly through the leg end plate 128 to the corner tubes 104 and not as much through the hardware (i.e., the bolt, strut-nut 140 , and channel bar lips 116 ) attaching the accessory to the quad-track beam 100 . Torsion transmitted solely through the strut-nut 140 would tend to unseat the strut-nut 140 from one of the channel bar lips 116 and double the stress on the other channel bar lip 116 . This would reduce the torque that could be safely handled by the quad-track beam 100 and accessory combination.
In the first embodiment, the channel bar lips 116 are flush or nearly flush with the exterior sides 107 of the corner tubes 104 . This is to facilitate the coupling of accessories, which is more difficult when the channel bar 108 is recessed. The channel bar lateral sides 110 are just long enough to provide sufficient depth in the channel bar cavity 114 for insertion of a strut-nut 140 . This keeps the channel bar back side 112 close to the exterior of the quad-track beam 100 , as defined by the exterior sides 107 of the adjacent corner tubes 104 . The channel bar back sides 112 bear forces caused by torsion of the quad-track beam 100 about its long axis and will do so more efficiently when they are closer to the exterior of the quad-track beam 100 . In the first embodiment, the channel bar lateral sides 110 in cross-section are no greater in length than the corner tube interior sides 106 with which they are in contact. More specifically, the channel bar lateral sides 110 in cross-section are half or less in length than the corner tube interior sides 106 with which they are in contact. In the first embodiment, the corner tubes 104 are square in cross-section with corner tube interior sides 106 of 1½ inches and the channel bar lateral sides 110 are ¾ inches.
QUAD-TRACK BEAM—SECOND EXEMPLARY EMBODIMENT
FIG. 3 shows a second embodiment of a quad-track beam 156 and a jam nut 168 intended for use therewith. Similar to the first embodiment quad-track beam 100 , the second embodiment quad-track beam 156 has four corner tubes 158 that are rectangular in cross-section and arranged in a rectangular pattern in cross-section. The corner tubes 158 have interior sides 161 that face inward towards the other corner tubes 158 and have exterior sides 159 facing outward. However, instead of channel bars, these four corner tubes 158 are coupled by side plates 162 . In the second embodiment, each side plate 162 is coupled to an adjacent two of the corner tubes 158 to be flush with the exterior sides 159 of the adjacent two corner tubes 158 . In other embodiments, the adjacent corner tubes 158 are nearly flush with the exterior sides 159 of the two adjacent corner tubes 158 , with each of the side plates 162 in cross-section no farther from one of the exterior sides 159 than a half of a length in cross-section of an adjacent one of the interior sides 161 . The side plates 162 bear the torsion forces generated when a torque is applied to the quad-track beam 156 about its long axis. In the second embodiment, the side plates 162 are coupled to the corner tubes 158 by welding, but in other embodiments, may be coupled in other ways. In some embodiments, the second embodiment quad-track beam 156 is extruded as a monolithic piece.
The corner tubes 158 in the second embodiment quad-track beam 156 are made of steel in 12, 14, or 16 gauges. The side plates 162 are made of 14 gauge steel. However in other embodiments, other suitable materials may be used for the corner tubes 158 and side plates 162 . In a cross-section of the second embodiment quad-track beam 156 , the corner tubes 158 are 1½ inches on each side and the side plates 162 are 1½ inches wide. However, in other embodiments, the corner tubes 158 and side plates 162 may have other dimensions.
The side plates 162 of the second embodiment quad-track beam 156 have slots 164 for insertion of the jam nut 168 . The side slots 164 run along the long axis of the side plate 162 , interrupted by side plate webs 166 . The side plate webs 166 bear the forces caused by torsion of the second embodiment quad-track beam 156 about its long axis. The side slots 164 have a width parallel to the long axis of the side plate 162 and a height orthogonal to the width. The width of each of the side slots 164 is at least as wide as the length (largest dimension) of the jam nut 168 . The height of each of the side slots 164 is at least as high as the thickness (smallest dimension) of the jam nut 168 . In the second embodiment, the side slots 164 are 9/16 inch high, which is slightly larger than the ⅜ inch thickness of the jam nut 168 used to attach accessories. In other embodiments, the side slots 164 may have a different height. For example, in some embodiments, the height of the side slots 164 is at least as high as the width of the jam nut 168 intended to be used. This would allow the jam nut 168 to be inserted into one of the side slots 164 while a bolt or threaded rod is inserted into a threaded hole 174 of the jam nut 168 .
Longer side slots 164 and shorter side plate webs 166 will weaken resistance of the second embodiment quad-track beam 156 to torsion about its long axis, and shorter side slot 164 with longer side plate webs 166 will strengthen resistance to torsion. A trade-off must be made between the better torsion resistance of shorter side slots 164 and flexibility in attaching accessories that comes from longer side slots 164 . In the second embodiment, the side slots 164 are 4 inches wide and the side plate webs 166 are 1 inch wide, but other embodiments may have different widths for these features.
The second embodiment quad-track beam 156 has a central cavity 176 defined by the corner tubes 158 and the side plates 162 . The central cavity 176 has a nut-retention foam 160 positioned therein. The nut-retention foam 160 is compressible and resilient. A jam nut 168 to be inserted through one of the side slots 164 compresses the nut-retention foam 160 . The resilience of the nut-retention foam 160 then holds the jam nut 168 in position.
Similar to the strut-nut 140 in the first embodiment, the purpose of the jam nut 168 is to attach accessories to the second embodiment quad-track beam 156 . The jam nut 168 can be inserted into the central cavity 176 , pushing back the nut-retention foam 160 . Then the jam nut 168 can be twisted so that the ends of the longer dimension of the jam nut 168 slip behind the side plate 162 . The jam nut 168 has two rounded corners 170 , diagonally opposed and two angled corners 172 , diagonally opposed. The longer dimension of the jam nut 168 is configured to be slightly shorter than the width of the side plate 162 , where the width refers to the dimension between the corner tubes 158 . When the jam nut 168 is twisted clockwise, the jam nut rounded corners 170 slide past the corner tubes 158 until the angled corners 172 contact the corner tubes 158 , preventing further clockwise rotation of the jam nut 168 . The jam nut 168 also has a threaded hole 174 configured to accept a threaded rod, bolt or screw, which is used to attach an accessory to the second embodiment quad-track beam 156 .
QUAD-TRACK BEAM—THIRD EXEMPLARY EMBODIMENT
FIG. 8 shows a third embodiment of a quad-track beam 230 . Similar to the first embodiment quad-track beam 100 , the third embodiment quad-track beam 230 has four corner tubes 232 arranged in a rectangular pattern in cross-section. However, instead of channel bars, these four corner tubes 232 are coupled by four corner tube webs 238 . The four corner tube webs 238 define a central cavity 240 . The third embodiment quad-track beam 230 is more suitable for manufacturing by extrusion than the first or second embodiments, but all three embodiments may be made by various manufacturing methods without limitation.
The corner tubes 232 each have a corner tube cavity 234 . The corner tubes 232 are each generally rectangular in shape in cross-section with some rounded corners, but in other embodiments may have circular cross-sections or some other suitable shape. The corner tubes 232 each have at least one exterior side 248 and at least one interior side 246 . The corner tubes 232 each have two corner tube lips 236 that each project from one of the interior sides 246 of the corner tube 232 towards an adjacent corner tube 232 . Each two corner tubes 232 , the corner tube web 238 between them and the corner tube lips 236 adjacent this corner tube web 238 , together define a channel cavity 242 .
The channel cavity 242 is “T” shaped to accept a jam nut, similar to the jam nut 168 of the second embodiment. The jam nut is configured to be inserted into the channel cavity 242 with its length axis parallel to the length of the channel cavity 242 , and then turned so that its length axis is parallel to the width of the channel cavity 242 . With a jam nut that has a length that is the same dimension as the width of the channel cavity 242 , the jam nut will jam against the corner tubes 232 . The jam nut can be used to attach an accessory much in the same way as the strut-nut 140 of the first embodiment or the jam nut 168 of the second embodiment.
Each of the four corner tubes 232 has a corner tube neck 244 projecting from the corner tube 232 towards the center of the rectangular pattern of corner tubes 232 . Each corner tube neck 244 connects that corner tube 232 with the two closest corner tube webs 238 . Each corner tube neck 244 is relatively thick to facilitate transmittal of torsion force from an adjacent corner tube 232 to the adjacent corner tube webs 238 without undue bending or deformation of the corner tube neck 244 . If the corner tube neck 244 is too thin, an accessory cantilevered off of the third embodiment quad-track beam 230 and attached with a jam nut in one of the channel cavities 242 would bend the corner tube 232 above the channel cavity 242 back and away from the channel cavity 242 , potentially unseating and releasing the jam nut. To prevent this, each of corner tube necks 244 is at least as thick as half the distance between the adjacent corner tube cavity 234 and the central cavity 240 .
To facilitate transmittal of torque about the long axis of the third embodiment quad-track beam 230 without undue twisting, the corner tube webs 238 are relatively thick and as close to the outer edge of the third embodiment quad-track beam 230 as possible. Each corner tube web 238 is at least as thick as half one of the adjacent corner tube necks 244 . Each corner tube web 238 is at least closer to the outer edges of the third embodiment quad-track beam 230 than to a center of the central cavity 240 . Stated differently, each corner tube web 238 is at least closer to one of the exterior sides 248 one of the corner tubes 232 than to a center of the central cavity 240 .
BASIC ASSEMBLIES AND ACCESSORIES USING QUAD-TRACK BEAMS
FIGS. 4 a -4 d show four basic configurations that can be made with a quad-track beam. The first embodiment quad-track beam 100 is used in FIGS. 4 a -4 d , but second embodiment quad-track beam 156 may be used or any other embodiment of quad-track beam consistent with the teachings herein. FIG. 4 a shows a straight configuration 200 , which is just a single quad-track beam. FIG. 4 b shows a diamond configuration 202 , in which the mitered ends of 4 quad-track beams are joined. FIG. 4 c shows a cross configuration 204 , in which the ends of 4 quad-track beams are joined at a central junction point. FIG. 4 d shows a star configuration 206 , in which is like the diamond configuration 202 except that it has 4 additional side beams, one in each junction between the mitered ends of the quad-track beams in the diamond.
FIG. 5 a shows a star joint 208 in the star configuration 206 . Three first embodiment quad-track beams 100 are joined by a star joint plate 210 . The star joint plate 210 is joined to the channel bar cavities 114 of the quad-track beams 100 with threaded bolts 212 . FIG. 5 b shows a diamond joint 214 in the diamond configuration 202 . Two first embodiment quad-track beams 100 are joined by a diamond joint plate 216 . The diamond joint plate 216 is joined to the channel bar cavities 114 of the quad-track beams 100 with threaded bolts 212 .
One type of accessory that can be joined to a quad-track beam is a channel leg. FIGS. 6 a -6 d show several embodiments of channel legs. FIG. 6 a is a perspective view of a single channel leg 120 and FIG. 6 b is a cross-section view of a single channel leg 120 from the top. The single channel leg 120 has a leg body 126 and a leg end plate 128 . The leg body 126 comprises a “C” type channel. The leg end plate 128 is joined to one end of the leg body 126 and has one or more bolt holes 129 . The bolt holes 129 allow the single channel leg 120 to be attached to a quad-track beam with a threaded bolt and a nut that jams in the quad-track beam, such as a strut-nut 140 or jam nut 168 . The single channel leg 120 has a leg cavity 122 . In some embodiments, such as the embodiment shown in FIG. 6 b , the single channel leg 120 has nut-retention foam 124 positioned therein, which makes it possible to attach other accessories to the single channel leg 120 in the same manner as they are attached to the quad-track beam. However, the single channel leg 120 is not as resistant to torsion about its long axis as is a quad-track beam, so it will not be able to cantilever as much load as a quad-track of similar size. In other embodiments, such as the embodiment shown FIG. 6 a , the single channel leg 120 does not have any nut-retention foam.
FIG. 6 c is a cross-section view of an alternative single channel leg 130 . The alternative single channel leg 130 has a leg channel 132 bracketed by two leg tubes 134 . The leg channel 132 has nut-retention foam 136 positioned therein, but may be omitted in some embodiments. The alternative single channel leg 130 has an end plate (not shown) similar to the leg end plate 128 in FIG. 6 a.
FIG. 6 d is a cross-section view of a double channel leg 180 . The double channel leg 180 has a front channel 182 and a back channel 184 that are joined back-to-back. The double channel leg 180 has an end plate (not shown) similar to the leg end plate 128 in FIG. 6 a . The double channel leg 180 has nut-retention foam 186 positioned therein, but may be omitted in some embodiments.
WORKSTATION ASSEMBLIES USING QUAD-TRACK BEAMS
FIG. 7 shows a first application using quad-track beams. First embodiment quad-track beams 100 are used, but second embodiment quad-track beams 156 or other embodiments of the quad-track beam could be used. A first embodiment quad-track beam 100 is supported by two single channel legs 120 attached thereto. A first side extension 220 and a second side extension 222 are attached to the quad-track beam 100 using gusset plates 224 , threaded bolts 212 and strut-nuts 140 . The first side extension 220 has a single channel leg 120 to support its far end, but the second side extension 222 does not and is cantilevered. Due to the attachment mechanism described herein, the side extensions can be moved laterally after loosening the appropriate threaded bolts 212 . When in the desired position, the threaded bolts 212 are tightened. Other accessories can be attached to the side extensions 220 , 222 such as shelves, bins, computer pedestals and table top work surfaces. A divider 226 is attached to the first embodiment quad-track beam 100 using a gusset plate 224 , threaded bolts 212 and strut-nuts 140 . The divider 226 is shown as cantilevered from the first embodiment quad-track beam 100 , but it could also be supported at the far end by a single channel leg 120 .
QUAD-TRACK BEAM—FOURTH EXEMPLARY EMBODIMENT
FIGS. 9A and 9B show a fourth embodiment of a quad-track beam 230 . FIG. 9A shows the fourth embodiment quad-track beam 260 in a perspective view. FIG. 9B shows an exploded perspective view of the fourth embodiment quad-track beam 260 . The fourth embodiment quad-track beam 260 has four angle bars 264 arranged in parallel lengthwise. The angle bars 264 are arranged in a pattern 270 that is rectangular in cross-section. The rectangular cross-section pattern 270 has four pattern corners 272 . Each of the four angle bars 264 have two legs 266 that join at an angle bar corner edge 268 . The angle bar corner edge 268 of each of the four angle bars 264 is located in a different one of the four pattern corners 272 . The four angle bars 264 are arranged such that there is an inter-bar gap 276 between each leg 266 and an adjacent leg 266 of an adjacent angle bar 264 . The inter-bar gap 276 may serve as a track for attaching accessories or attaching the quad-track beam 260 to other copies of the quad-track beam 260 or to other structures.
The angle bars 264 in the fourth embodiment quad-track beam 260 are made of steel 3/16 inch thick, however in other embodiments, other suitable materials and thicknesses may be used. The angle bars 264 may be a length suitable for constructing workstations. A length of 60 inches is usually suitable, but other lengths may prove to be desirable. The angle bar legs 266 may have a suitable width, such as 1½ inches, but may have other widths. The inter-bar gap 276 may have a suitable width, such as ¾ inches, but may have other widths as well. Length and thickness of the angle bars 264 may be selected based on the situations in which the quad-track beam 260 is intended to be used. Situations that will put more torsion on the quad-track beam 260 may call for thicker angle iron.
In the fourth embodiment quad-track beam 260 , the four angle bars 264 are coupled with one or more beam mount brackets 274 . Typically, there is one beam mount bracket 274 every 30 inches down the length of the quad-track beam 260 , but other spacing may be used. The beam mount bracket 274 is formed in a shape of a rectangular tube. Each of the four corners of the beam mount bracket 274 is nested inside of one of the four angle bars 264 and coupled thereto. The beam mount bracket 274 may be coupled to the four angle bars 264 by welding, by threaded bolts and nuts or some other suitable coupling. In FIG. 9A , the beam mount bracket 274 is shown as coupled to the four angle bars 264 by welding. In FIG. 9B , the beam mount bracket 274 and the four angle bars 264 have bolt holes for facilitating coupling with threaded bolts (not shown).
FIG. 9C shows the fourth embodiment quad-track beam 260 in a perspective view with components for attaching accessories. The fourth embodiment quad-track beam 260 has a central cavity 176 defined by the four angle bars 264 . A block of nut-retention foam 186 is positioned within the cavity. Attachment of accessories to the fourth embodiment quad-track beam 260 is accomplished in a manner very similar to the second embodiment quad-track beam 156 . A jam nut 168 may be inserted into one of the inter-bar gaps 276 and twisted into an orientation perpendicular to the inter-bar gap 276 . A bolt or threaded rod may be inserted into a threaded hole 174 of the jam nut 168 and the bolt be tightened, compressing the accessory and the jam nut 168 against the angle bars 264 . A bolt plate 280 with two jam nut hole 174 may be inserted into one of the inter-bar gaps 276 in a similar manner, but without twisting. Both the jam nut 168 and the bolt plate 280 provide an extent of surface engagement with the angle bars 264 to provide a high amount of resistance to torqueing or lateral movement.
DUAL QUAD-TRACK BEAM ASSEMBLY—FIRST EXEMPLARY EMBODIMENT
FIG. 10A shows a top view of a first embodiment of a dual quad-track beam assembly 262 . The dual quad-track beam assembly 262 provides a stronger base from which to build a work station than just a single quad-track beam and also provides a second row of inter-bar gaps 276 on the same face, which can be convenient for building work stations on both sides of the dual quad-track beam assembly 262 . The dual quad-track beam assembly 262 comprises two of the fourth embodiment quad-track beams 260 coupled together with a plurality of dual beam brace brackets 282 . FIG. 10B shows a perspective view of a dual beam brace bracket 282 . The dual beam brace brackets 282 are coupled to the quad-track beams 260 by welding, bolting or some other suitable coupling. The dual beam brace bracket 282 has bolt holes 278 in its legs for coupling with a quad-track beam 260 and has bolt holes 278 in its back plate for coupling with other dual quad-track beam assemblies 262 or coupling with mounting brackets for accessories.
Bolting of the dual quad-track beam assembly 262 and of the constituent quad-track beams 260 provides a logistical advantage as separate angle bars 264 , beam mount brackets 274 , and dual beam brace brackets 282 can be stored, shipped and moved more conveniently than fully assembled dual quad-track beam assemblies 262 . The dual quad-track beam assembly 262 may be made to any convenient length. A typical configuration would be a dual quad-track beam assembly 262 of 120 inches with dual beam brace brackets 282 at each end and at 30 inch intervals.
DUAL QUAD-TRACK BEAM ASSEMBLY—SECOND EXEMPLARY EMBODIMENT
FIGS. 11A and 11B show views of a second embodiment of a dual quad-track beam assembly 284 . FIG. 11A shows a perspective view of the second embodiment of a dual quad-track beam assembly 284 . FIG. 11B shows a top view of the second embodiment of a dual quad-track beam assembly 284 . The second embodiment dual quad-track beam assembly 284 comprises two quad track beams made of two sets of four angle bars 264 , each arranged as in the fourth embodiment quad-track beam 260 as shown in FIG. 9A , but without the beam mount brackets 274 . Instead, the four angle bars 264 are coupled together by quad-track end plates 286 , one at each end. The quad-track end plates 286 are preferably coupled to the four angle bars 264 by welding, but bolting or some other suitable coupling may be used.
As shown in FIG. 11A , a single quad-track end plate 286 not only couples angle bars 264 of one of the quad-track beams, but both. The quad-track end plates 286 have bolt holes 278 to allow one dual quad-track beam assembly 284 to be coupled to another such assembly and alternatively to allow accessories to be attached. The second embodiment dual quad-track beam assembly 284 has a plurality of stiffeners 288 coupled to the angle bars 264 in the inter-bar gaps 276 , preferably by welding. The stiffeners 288 reinforce the quad-track beam, transmitting compression force and helping maintain the size and integrity of the inter-bar gap 276 when the quad-track beam is under torsion about its long axis.
DUAL QUAD-TRACK BEAM CRUCIFORM MODULE—FIRST EXEMPLARY EMBODIMENT
FIG. 12 shows a perspective view of a first embodiment of a dual quad-track beam cruciform module 292 . The first embodiment dual quad-track beam cruciform module 292 comprises a plurality of dual quad-track beam assemblies coupled in a cruciform shape. The dual quad-track beams assemblies used in the first embodiment dual quad-track beam cruciform module 292 may be either of the first embodiment dual quad-track beam assembly 262 type or of the second embodiment dual quad-track beam assembly 284 type. The plurality of dual quad-track beam assemblies comprises one long dual quad-track beam assembly 298 and two short dual quad-track beam assemblies 300 . The two short dual quad-track beam assemblies 300 are coupled to the long dual quad-track beam 298 using sets of bolts and jam nuts, such as the jam nut 168 shown in FIG. 9C . Each set of bolts and jam nuts are inserted into one of the inter-bar gaps 276 in the long dual quad-track beam 298 .
DUAL QUAD-TRACK BEAM CRUCIFORM MODULE—SECOND EXEMPLARY EMBODIMENT
FIG. 13A shows a perspective view of a second embodiment of a dual quad-track beam cruciform module 294 . The second embodiment dual quad-track beam cruciform module 294 has four dual quad-track beam assemblies, each coupled to a central mounting plate 296 . The dual quad-track beams assemblies used in the first embodiment dual quad-track beam cruciform module 292 may be either of the first embodiment dual quad-track beam assembly 262 type or of the second embodiment dual quad-track beam assembly 284 type. FIG. 13B shows a perspective view of the central mounting plate 296 .
SINGLE-TRACK BEAM ASSEMBLY—EXEMPLARY EMBODIMENT
FIG. 16 shows a perspective view of an exemplary embodiment of a single-track beam assembly 316 . The single-track beam assembly 316 comprises two single-track beams coupled in parallel lengthwise with an inter-beam gap 320 between them. Each of the two single track beams comprises two angle bars 264 coupled in parallel lengthwise and in a pattern that is rectangular in cross-section. The two angle bars 264 are arranged such the corner edge of each of the two angle bars 264 is in a different one of the four pattern corners and such that there is an inter-bar gap 276 between one of the legs 266 of two angle bars 264 and an adjacent one of the legs 266 of a second of the two angle bars 264 . The single-track beam assembly 316 has two end plates 318 , each coupled to one of the ends of the angle bars 264 of both single-track beams. The single-track end plates 318 are preferably coupled to the angle bars 264 by welding, but other couplings may be used.
The single-track beam assembly 316 may be used to provide support for mounting additional accessories to a work station. The single-track beam assembly 316 is not as strong in resisting torsion along its long axis as the quad-track beams, but in situations where no such torsion loads are expected, the single-track beam assembly 316 is a lighter weight alternative. Such situations would include where accessories are only mounted vertically and not cantilevered out sideways.
DUAL-TRACK BEAM ASSEMBLY—EXEMPLARY EMBODIMENT
FIG. 17 shows a perspective view of an exemplary embodiment of a dual-track beam assembly 322 . The dual-track beam assembly 322 has two dual-track beams coupled in parallel lengthwise with an inter-beam gap 320 between them. Each of the two dual track beams comprises two channel bars 326 coupled in parallel lengthwise and in a pattern that is rectangular in cross-section. Each of the two channel bars has two channel bar legs 328 joined to a channel back 330 . The channel back 330 of one of the two channel bars 326 is in two of the four corners of the rectangular pattern and the channel back 330 of other of the two channel bars 326 is in the other two of the four corners of the rectangular pattern. The two channel bars 326 are arranged such that for each channel bar leg 328 there is an inter-bar gap 276 between that leg and an adjacent one of the legs of the other of the two channel bars 326 . The dual-track beam assembly 322 has two dual-track end plates 324 coupled to the ends of the channel bars 326 of both dual-track beams. The dual-track end plate 324 are preferably coupled to the channel bars 326 by welding, but other couplings may be used.
The dual-track beam assembly 322 may be used to provide support for mounting additional accessories to a work station. The dual-track beam assembly 322 is stronger than the single-track beam assembly 316 , but not as strong as the quad-beam assemblies in resisting torsion along its long axis. However, in situations where no such torsion loads are expected, the dual-track beam assembly 322 is an intermediate weight alternative.
DUAL QUAD-TRACK BEAM ASSEMBLY—APPLICATION EXAMPLES
FIG. 14A shows a perspective view of a dual quad-track beam assembly with cantilevered legs 304 attached, forming a first exemplary workstation arrangement 308 . Second embodiment dual quad-track beam assemblies 284 are shown, but first embodiment dual quad-track beam assembly 262 may be used as well. The cantilevered legs 304 couple to the dual quad-track beam assembly 284 , elevating the second embodiment dual quad-track beam assembly 284 to a useful height for when work surfaces and work accessories are attached thereto. The cantilevered legs 304 each have a leg mounting plate 306 with bolt holes 278 therein. FIG. 14B shows a top view of the leg mounting plate 306 . The leg mounting plate 306 is coupled to the second embodiment dual quad-track beam assembly 284 using sets of bolts and jam nuts, such as the jam nut 168 shown in FIG. 9C . Each set of bolts and jam nuts are inserted into one of the inter-bar gaps 276 in the underside of dual quad-track beam assembly 284 . Any of the cantilevered legs 304 can be repositioned along the dual quad-track beam assembly 284 by loosening of the bolts in the leg mounting plate 306 , then sliding the cantilevered leg 304 forward or back along the dual quad-track beam assembly 284 as indicated by the arrows.
FIG. 15 shows a top view of a second exemplary workstation arrangement 310 using dual quad-track beam assemblies 284 . Second embodiment dual quad-track beam assemblies 284 are shown, but first embodiment dual quad-track beam assembly 262 may be used as well. An accessory 312 may be coupled to one of the dual quad-track beam assemblies 284 anywhere there is inter-bar gap 276 available to do so. The accessory 312 is coupled to an accessory mounting 314 . The accessory mounting 314 has bolt holes 278 therein. The accessory mounting 314 couples to the dual quad-track beam assembly 284 using sets of bolts and jam nuts, such as the jam nut 168 shown in FIG. 9C . Each set of bolts and jam nuts are inserted into one of the inter-bar gaps 276 in the topside of dual quad-track beam assembly 284 .
FIG. 18 shows a perspective view of a third exemplary workstation arrangement 332 . This third exemplary workstation arrangement 332 has one or more second embodiment dual quad-track beam assemblies 284 with cantilevered legs 304 attached as in the first exemplary workstation arrangement 308 as shown in FIG. 14A , but also has one or more adjustable accessory brackets 334 and a work surface 336 (shown as transparent to allow view of the adjustable accessory brackets 334 ).
The adjustable accessory brackets 334 each have a bracket tube 338 and a bracket mounting plate 340 . The bracket mounting plate 340 couples to the dual quad-track beam assembly 284 using sets of bolts and jam nuts, such as the jam nut 168 shown in FIG. 9C . The bracket tube 338 is coupled to the bracket mounting plate 340 . A bracket arm 342 is inserted into and slidingly coupled with the bracket tube 338 . Accessories may be mounted to the bracket arm 342 , such as the work surface 336 shown. The bracket arm 342 may be moved within the bracket tube 338 to adjust the height of the accessory. Alternatively, the adjustable accessory bracket 334 may be mounted with the bracket tube 338 pointing sideways rather than vertically, in which case, the lateral position of the accessory is adjusted. The bracket arm 342 may be held in position with a set screw 344 , which may be loosened to reposition the bracket arm 342 and tightened again when in the new position. The set screw 344 may have a hand knob so that the position of the bracket arm 342 can be adjusted without tools.
Bracket arm 342 shown in FIG. 18 has a right angle bend for supporting the work surface 336 , but other bracket arms 342 may not have the right angle bend and may have different ways for connecting with accessories, such as pivot joints.
FIG. 19A shows a side view of the third exemplary workstation arrangement 332 with a cable trough 346 and a shelf 348 coupled thereto. The shelf 348 may be coupled to the dual quad-track beam assembly 284 using sets of bolts and jam nuts. The shelf 348 may be used to hold tools, light fixtures, boxes of parts, etc. FIG. 19B shows a perspective view of the cable trough 346 with a curled lip 350 on either side. The curled lips 350 may clip into the inter-bar gap 276 of the quad-track beams 260 of the dual quad-track beam assembly 284 and engage with the upper edge of one of the angle bar legs 266 (see FIG. 9C ). The cable trough 346 may be used to carry power and communications cables to various workstations.
FIG. 20 shows a perspective view of an adjustable end bracket 352 . The adjustable end bracket 352 has an end bracket back 354 with two bracket tubes 338 attached thereto and two bracket arms 342 positioned within and slidingly coupled to the bracket tubes 338 . Each of the two bracket arms 342 may be held in position with a set screw 344 , which may be loosened to reposition the bracket arm 342 and tightened again when in the new position. The end bracket back 354 has one or more bolt holes 278 matching the bolt holes 278 in a quad-track end plate 286 in a second embodiment dual quad-track beam assembly 284 or dual beam brace bracket 282 in a first embodiment dual quad-track beam assembly 262 , which allows the adjustable end bracket 352 to be coupled to one end of a first embodiment dual quad-track beam assembly 262 or a second embodiment dual quad-track beam assembly 284 .
FIG. 21 shows a top view of a fourth exemplary workstation arrangement 356 . The fourth exemplary workstation arrangement 356 comprises a first embodiment dual quad-track beam cruciform module 292 , although a second embodiment dual quad-track beam cruciform module 294 could be used as well. The dual quad-track beam cruciform module 292 has cantilevered leg 304 coupled to its underside (hidden in this drawing). An end zone work surface 358 is coupled to the end of each of the four arms of the dual quad-track beam cruciform module 292 with a bracket arm 342 held by an adjustable end bracket 352 . Work surface support frame 360 may be coupled to the adjustable bracket arm 342 to help support the end zone work surface 358 . One worker can stand in each space between the end zone work surfaces 358 with the end zone work surface 358 used as collaborative work areas. In FIG. 21 , all four end zone work surfaces 358 are shown as having the same shape, but in other arrangements, each of the end zone work surfaces 358 may have a different shape.
FIG. 22 shows a top view of a fifth exemplary workstation arrangement 362 . The fifth exemplary workstation arrangement 362 comprises a first embodiment dual quad-track beam cruciform module 292 , although a second embodiment dual quad-track beam cruciform module 294 could be used as well. The dual quad-track beam cruciform module 292 has cantilevered legs 304 coupled to its underside (hidden in this drawing). Several work surfaces 364 mounted on work surface support frames 360 are coupled to the dual quad-track beam cruciform module 292 with adjustable accessory brackets 334 . Each of the work surface support frames 360 has bracket arms 342 that sliding couple with the respective adjustable accessory brackets 334 , allowing for adjustment of the height of the work surfaces 364 . Several of the bracket arms 342 have pivots 366 coupling the bracket arm 342 to the respective work surface support frame 360 and work surface 364 , allowing that work surface 364 to be tilted to various angles.
FIG. 23 shows a top view of a sixth exemplary workstation arrangement 368 , demonstrating some of the different shaped work surfaces that may be used to create customized workstations for multiple purposes. The sixth exemplary workstation arrangement 368 comprises two first embodiment dual quad-track beam cruciform modules 292 , although second embodiment dual quad-track beam cruciform module 294 could be used as well or a combination thereof. The dual quad-track beam cruciform modules 292 have cantilevered legs 304 coupled to its underside (hidden in this drawing). Different shaped work surfaces are attached to the dual quad-track beam cruciform modules 292 , including a work surface with circular cutout 370 , a work surface with semi-circular cutout 372 , a work surface with small wing 374 , a work surface with large wings 376 , a work surface with triangular cutout 378 , and an intermediate work surface 380 . The intermediate work surface 380 couples to one of the ends of each of the two dual quad-track beam cruciform modules 292 , joining them together in a single unit. | Embodiments of a multi-track beam for use in modular assembly systems for office and industrial work stations. The embodiments have four corner tubes, bars, or channels arranged in a rectangular pattern in cross-section and connected in ways that provide improved ability to transmit torque along a long axis of the multi-track beam while providing improved resistance to bending under the forces of the torque. Fastening devices such a jam nuts may be inserted into the tracks to secure accessories to the multi-track beam or to other multi-track beams. | 4 |
BACKGROUND
The invention relates to a camshaft adjuster for an internal combustion engine, in which lubrication is performed by means of a lubricant flow.
Camshaft adjusters can be roughly classified as follows:
A. Phase adjusters with a control element, that is, a functional unit, which joins in the mass flow or energy flow formed, for example, hydraulically, electrically, or mechanically and rotates with gear elements of the camshaft adjuster.
B. Phase adjusters with a separate setting element, that is, a functional unit, in which the control parameter required for the control method of the control element is formed from the controller output parameter, and a separate control element. Here, there are the following structural forms:
a. Phase adjusters with a co-rotating actuator and a co-rotating control element, for example, a step-up ratio gear, whose adjustment shaft can be advanced by a co-rotating hydraulic motor or centrifugal force motor and can be reset by a spring.
b. Phase adjusters with a co-rotating control element and a stationary, engine-fixed actuator, for example, an electric motor or an electrical or mechanical brake, see also DE 100 38 354 A1, DE 102 05 034 A1, EP 1 043 482 B1.
c. Phase adjusters with a direction-dependent combination of solutions according to a. and b., for example, an engine-fixed brake, in which part of the brake power is used for adjustments toward an advanced position, in order to tension a spring, which allows resetting after the brake is deactivated, see also DE 102 24 446 A1, WO 03-098010, US 2003 0226534, DE 103 17 607 A1.
In systems according to B.a. to B.c., actuators and control elements are connected to each other by an adjustment shaft. The connection can be switchable or non-switchable, detachable or non-detachable, lash-free or with lash, and flexible or stiff. Independent of the structural form, the adjustment energy can be realized in the form of supply through a drive output and/or brake output, as well as with the use of leakage power of the shaft system (e.g., friction) and/or inertia and/or centrifugal force. Braking, advantageously in the adjustment direction of “retarded” can also be realized under the full use or shared use of the friction power of the camshaft. A camshaft adjuster can be equipped with or without mechanical limiting of the adjustment range. As a gear drive in a camshaft adjuster, one-stage or multiple-stage triple-shaft gears and/or multiple links or coupling gears are used, for example, in structural form as a wobble-plate gear, eccentric gear, planetary gear, undulating gear, cam-plate gear, multiple-link or linked gear, or combinations of the individual structural forms in a multiple-stage construction.
For operation of the camshaft adjuster, a lubricant must be fed to lubricating positions, especially bearing positions and/or rolling toothed sections, wherein the lubricant is used for lubricating and/or cooling components of the camshaft adjuster that can move relative to each other. For this purpose, the camshaft adjuster has a lubricant circuit, which can be coupled, for example, with the lubricant circuit of the internal combustion engine.
SUMMARY
The present invention is based on the object of providing a camshaft adjuster with an improved lubricant circuit.
This objective is met by a device according to the invention. Alternative or cumulative solutions for meeting the objective are described in detail below and in the claims.
The invention is based on the idea that for known camshaft adjusters, the flow rate of the lubricant in the camshaft adjuster is determined by the line cross sections, the pumping capacity of a pump in each operating state, the ambient temperature, and the type of lubricant flow being used and the degree of contamination. The selected flow cross sections, in particular, in the region of the supply and discharge, are defined by production-specific needs. In the operation of the camshaft adjuster, the applicant has determined that a gear drive of a camshaft adjuster, under some circumstances, becomes nearly “flooded” with lubricant, in particular,
at high lubricant pressures, if this is provided by the lubricant circuit of the internal combustion engine, and
at a low viscosity of the lubricant, for example, at high rotational speeds under high temperature.
In this way, too much energy is lost in the camshaft adjuster due to churning work to be performed. Under some circumstances, the lubricant becomes greatly foamed. Furthermore, due to the large throughput of the lubricant through the camshaft adjuster, the lubricant pressure of the internal combustion engine can decrease, which can result in degraded lubrication of the other paths of the lubricant circuit. Furthermore, a poorer overall efficiency of the internal combustion engine can be produced due to high hydraulic waste power, which can result in increased fuel consumption.
Therefore, the unpublished application of the applicant with the title “Device for changing the control times of an internal combustion engine” from Dec. 23, 2004 with the internal filing number of the applicant of 4626-10-DE proposes to insert a throttle for the lubricant flow in the camshaft adjuster. Such a throttle can be formed by a tooth gap of a crown gear or by grooves running in the radial direction between individual components of the camshaft adjuster.
On the other hand, in the operation of a camshaft adjuster it has been shown that combustion and contamination residue contained in a lubricant of the engine could lead to temporary or permanent functional disruptions in the adjustment mechanism. This can lead to silting or contamination of a gear drive of the camshaft adjuster. Due to the contaminants, increased wear and also increased waste power can be produced due to the contaminant particles in the functional surfaces for the adjustment of the camshaft adjuster.
If one considers providing a diaphragm or a throttle through targeted shaping of the cross sections of the flow channels in the camshaft adjuster, then this requires a complicated production of the cross sections in the region of the throttles or diaphragms. For example, if a diaphragm is to be provided with a small opening cross section, then this requires a diameter jump to a small diameter in the region of the diaphragm, which can be produced by a drill with a small diameter, which is possible only under increased production requirements and the risk of breakage of the drill for rough conditions of use.
Such complicated production possibilities for a diaphragm or a throttle are avoided according to the invention in that, initially, a flow channel of the camshaft adjuster can be produced without a diaphragm or throttle, for example, with a large and/or constant diameter or ring channel. The flow channel thus can be provided with simple production methods and with safe processing. After production of the flow channel, a flow element is inserted into this channel, wherein this element is constructed separate from the components defining the flow channel. The flow element has contours such that a diaphragm or a throttle is created. The contours of the diaphragm or throttle thus can be produced separately from the other components, wherein, for the spatially limited flow element, separate production methods and/or materials can be used. For one construction of the flow element, advantageously the flow element can have through openings in the interior for the diaphragm or throttles and/or can limit a diaphragm or throttle on one side in the region of inner or outer contours, while another limit of the diaphragm or throttle is guaranteed by a component limiting the flow channel.
Through the use of the flow element, under some circumstances, an exchange of the diaphragm or throttle is enabled, because this is inserted into the flow channel and can be removed from this channel again.
On the other hand, increased variability of the flow relationships is given, because, under some circumstances, for different application purposes of the same camshaft adjuster, for basically the same drilling pattern in the construction of the flow channels, different flow elements can be inserted for adapting to different components of the lubricant circuit or the motor oil circuit.
Furthermore, the invention is based on the knowledge that for flow channels with relatively large flow cross sections, with a rise in temperature of the lubricant, the lubricant flow increases exponentially. In contrast, under use of a flow element in the form of a diaphragm or throttle, the influence of the temperature on the lubricant flow decreases or is nearly eliminated for otherwise unchanged flow conditions.
According to another construction of the invention, the flow element is arranged in the inlet region of the lubricant into the gear drive and/or in the outlet region of the lubricant out of the gear drive, so that throttling can be performed selectively in the region of interest. If throttling is already performed in the inlet region of the lubricant, then increased pressures could be withstood due to the throttling of the gear drive, by which the sealing requirements in the gear drive are not increased unnecessarily.
The flow element is, in particular,
connected with a positive fit to the flow channel, wherein the flow element can engage in suitable recesses or grooves of the components limiting the flow channel,
connected with a friction fit to the flow channel, wherein the flow element is inserted, for example, under an elastic biasing stress, into the flow channel, or
connected with a material fit to the flow channel, for example, by an adhesive,
wherein combinations of a positive-fit, friction-fit, or material-fit connection are also possible.
Flow elements made from plastic or an elastomer have proven to be advantageous with respect to the flow relationships in the region of the surface, the elastic properties, the chemical interaction with the lubricant, and/or the positive-fit, friction-fit, or material-fit connection to the flow channel.
According to one improvement, the flow channel has, in the region, in which the flow element is inserted, a circular ring-shaped cross section. In contrast to throttles or diaphragms, which are formed in the shape of boreholes with circular cross section, the circular ring-shaped cross sections cannot become blocked as easily due to the increased extent in the circumferential direction, because if need be partial circumferential regions can be added.
In another construction of the invention, a circular ring-shaped cross section for a flow channel can be formed between an outer surface of a central screw screwed into the camshaft on the end face and an inner surface fixed to the camshaft, for example, a hollow shaft or a gear element, so that already present components are used for the flow channel and the surfaces limiting the flow channel can be formed by outer and inner contours of the components with relatively large diameters.
Advantageously, in a camshaft adjuster according to the invention, the flow element is pressed elastically in the radial direction and under radial pressure against a boundary of the flow channel, wherein such pressure can be performed on the inside and/or outside in the radial direction.
Due to the reduced flow cross sections, the throttles or diaphragms form areas raising the risk of overriding blockage with contaminant particles or sludge. This condition can be taken into account according to another embodiment of the invention in that a filter element is arranged upstream of the flow element. Here, the filter element can be arranged upstream of or in the camshaft adjuster. For the case that the filter element is arranged in a flow channel of the camshaft adjuster, the filter element can be constructed separate from the throttle or else as an integral element of the flow element. Furthermore it is to be taken into consideration that the filter element similarly generates a throttling effect, so that a throttle or a diaphragm must be dimensioned under consideration of the throttling effect of the filter element.
Advantageously, the diaphragm or throttle is created by a change in cross section perpendicular to the flow direction of the lubricant. For the case of a circular diaphragm, this means that in the region of the diaphragm, the circular diameter is reduced relative to the other flow cross section. For the case of a circular ring-shaped flow cross section, this means that the radial extent of the circular ring is reduced in the region of the diaphragm or throttle.
In an alternative or cumulative construction of the invention, the diaphragm or throttle is created by a change in cross section in the circumferential direction relative to the flow direction of the lubricant. For example, for one circular ring-shaped cross section through the flow element, the flow cross section is divided into individual circle segments, whose total surface area is smaller than the original circular area of the flow cross section. For a circular ring-shaped flow cross section, for example, the flow element can block individual circumferential areas of the circular ring-shaped flow channel.
Furthermore, the invention proposes to connect several flow elements in series or in parallel. Through the use of a series connection for a path of the lubricant, the area for influencing the flow can be increased. In a parallel connection of several flow elements in different flow paths to different lubricating points, through the same or different flow elements, the lubricant flow at the lubricating points can be selectively influenced corresponding to the requirements at the lubricating point, so that lubricating points with increased lubricant demands can be supplied with more lubricant or the inverse.
According to another solution to meet the objective forming the basis of the invention, the flow of lubricant is influenced by a flow element, whose flow properties can be changed during the operation of the internal combustion engine. In this way, the flow element can be constructed as an integral component of the flow channel or as a separate flow element, as described above. By changing the flow properties, a change in the lubricant flow, for example, due to the lubricant heating up can be counteracted. On the other hand, by changing the flow properties of the flow element, it is possible to selectively change the pressure, the velocity, and the lubricant flow in the region of the lubricating point or in the feeding area to this lubricating point, if there is increased or decreased lubricant and/or cooling requirements due to changed operating conditions, so that the individual operating conditions can be better taken into account.
A change in the flow element due to the influence of the flow properties can take place automatically, for example, in the form of a thermocouple or in the form of mechanically self-correcting solutions. The use of an adjustment device for changing the flow element is also possible, wherein this adjustment device is acted upon by a suitable control or regulating device.
In another construction of the camshaft adjuster according to the invention, the flow element can be temporarily closed completely. Such a flow element can be closed completely, for example, when the engine is stopped. Also possible is a repeated closing of the flow element during operation, which can generate pulses in the lubricant, which can, under some circumstances, reinforce a targeted lubrication and cooling effect and which can increase the area covered by the lubricant.
Furthermore, it is possible that the flow properties of the flow element can be changed in a motion-controlled way by rotating the camshaft, the camshaft adjuster, or the gear drive. For example, the centrifugal force of the flow properties of the flow element can be regulated with the rotation of the camshaft. In an alternative construction, in the feeding area between two boreholes of components that can move relative to each other, for example, the cylinder head and the camshaft, by which a lubricant transfer is guaranteed, the transfer cross section can be guaranteed only in select relative positions, while for other relative positions, the transfer cross section is closed partially and/or completely, so that the lubricant can be transferred only intermittently.
Another solution for meeting the objective forming the basis of the invention takes advantage of an already existing hollow cylinder-shaped intermediate space, which is arranged between a central screw and a recess of the camshaft and in which a first partial region of this intermediate space forms a first flow channel, wherein the manufacturing dimensions for the outer diameter of the central screw and the inner diameter of the recess define the gap height of the ring-shaped flow channel. In an outer second partial region of the intermediate space there is a hollow shaft, which forms a second flow channel on the outside and/or inside in the radial direction. Due to the dimensions of the hollow shaft, the second flow channel is equipped with a smaller flow cross section than the first flow channel. An additional throttle or diaphragm is created in such a way that in the transfer cross section between the first flow channel and the second flow channel there is a projection, for example, the central screw, the hollow shaft, or the camshaft, or an additional component, which again reduces the second flow channel in this region and thus creates a throttle or diaphragm. This represents an especially simple realization for a diaphragm or throttle, which uses the already existing components and allows the production of the diaphragm or throttle with small opening cross section with nevertheless large dimensions of the involved components.
For another solution to meet the objective forming the basis of the invention, in the intermediate space named above there is a radial groove in the camshaft. In this case, a diaphragm is created in such a way that the transfer cross section from the first partial region to the radial groove is partially closed by an end face of the hollow shaft similarly arranged in the intermediate space. In this case, the diaphragm can be realized without the necessity of manufacturing small opening cross sections through a borehole of small diameter or the like by shaping the central screw and the recess of the camshaft and also the groove and the hollow shaft.
A multi-functional use of the groove is then given when the groove has an outer dead space in the radial direction, in which particles can be deposited due to a centrifugal force exerted on the lubricant.
Another solution to meet the objective forming the basis of the invention involves the transfer of the lubricant from a cylinder head-fixed component, for example, a camshaft bearing, to the camshaft. For such transfer, the cylinder head-fixed component has at least one outlet opening, from which the lubricant enters into at least one inlet opening of the camshaft. In this case, in a simple way—without the need for manufacturing a throttle or diaphragm with a small borehole diameter, a small groove width, or the like, a throttle or diaphragm can be created in such a way that the inlet opening of the camshaft and the outlet opening of the cylinder head-fixed component do not align with each other, so that the transfer cross section is given by the larger cross section of the inlet opening and the outlet opening, but instead the inlet opening and the outlet opening are arranged offset relative to each other, so that the opening cross section of the diaphragm is given by the only partial overlap of the inlet opening and the outlet opening. Such an offset involves, for example, an offset of the inlet opening and outlet opening in the circumferential direction and/or an axial offset in the direction of the longitudinal axis of the camshaft.
Such a construction is then also possible when the inlet opening or the outlet opening is constructed as a groove running partially or completely in the circumferential direction, while the other opening is constructed as a borehole.
Advantageously, the measures according to the invention are used for a camshaft adjuster in a construction with a wobble plate gear.
Advantageous improvements of the invention emerge from the claims, the description, and the drawings. The advantages named in the introduction of the description for features and combinations of several features are merely examples, without these having to be necessarily realized by embodiments according to the invention. Additional features are to be taken from the drawings—in particular, the illustrated geometries and the relative dimensions of several components to each other, as well as their relative arrangement and effective connection. The combination of features of different embodiments of the invention or of features of different claims is similarly possible deviating from the selected associations of the claims and is suggested with this reference. This also relates to features that are shown in separate drawings or are named in their description. These features can also be combined with features of different claims. Likewise, features listed in the claims can be left out for other embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
Additional features of the invention emerge from the following description and the associated drawings, in which embodiments of the invention are shown schematically. Shown are:
FIG. 1 a schematic diagram of a camshaft adjuster,
FIG. 2 a schematic diagram of a camshaft adjuster with a wobble-plate gear,
FIG. 3 a camshaft adjuster in a schematic diagram with a lubricant circuit,
FIG. 4 a camshaft adjuster in a schematic diagram with a lubricant circuit, in which a filter element is integrated,
FIG. 5 a semi-longitudinal cross-sectional view of a camshaft adjuster with a dead space for the deposition of contaminant particles,
FIG. 6 a schematic diagram of a camshaft adjuster with a lubricant circuit, which is equipped both on the input side and also on the output side with a throttle and a diaphragm,
FIG. 7 a longitudinal cross-sectional view of a camshaft adjuster with guidance of the lubricant into a flow channel,
FIG. 8 a longitudinal cross-sectional view of a camshaft adjuster, in which two diaphragms are connected one after the other in a flow channel,
FIG. 9 a longitudinal cross-sectional view of a camshaft adjuster with a flow element, which is set on a central screw and which forms a diaphragm with an inner casing surface of the camshaft,
FIG. 10 a longitudinal cross-sectional view of a camshaft adjuster with a diaphragm formed between a hollow shaft and a central screw,
FIG. 11 a longitudinal cross-sectional view of a camshaft adjuster with the feeding of a lubricant via a transfer cross section from an outlet opening of the cylinder head to an inlet cross section of the camshaft,
FIG. 12 a longitudinal cross-sectional view of another construction of a lubricant feed to a camshaft and to a camshaft adjuster,
FIG. 13 a longitudinal cross-sectional view of another construction of a lubricant feed to a camshaft and to a camshaft adjuster,
FIG. 14 a longitudinal cross-sectional view of another construction of a lubricant feed to a camshaft and to a camshaft adjuster,
FIG. 15 a longitudinal cross-sectional view of another construction of a lubricant feed to a camshaft and to a camshaft adjuster,
FIG. 16 a longitudinal cross-sectional view of a camshaft adjuster with different examples for an arrangement of diaphragms or throttles for influencing the flow of a lubricant,
FIG. 17 a perspective view of a camshaft adjuster with openings of a housing of the gear drive for passage of the lubricant in the form of droplets, lubricant mist, or sprayed lubricant,
FIG. 18 another perspective view of the camshaft adjuster according to FIG. 17 with other options for openings,
FIG. 19 a view of a camshaft adjuster in the installed state with options for lubrication via droplets, a lubricant mist, and/or sprayed lubricant, and
FIG. 20 a side view of a camshaft adjuster in the installed state with a drop plate, on which droplets of an oil mist settle and drop in the direction of the interior of the camshaft adjuster.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the figures, components that correspond with respect to form and/or function are to some extent provided with the same reference symbols.
FIG. 1 shows in a schematic diagram a camshaft adjuster 1 , in which, in a gear drive 2 , the movements of two input elements, here a drive wheel 3 and an adjustment shaft 4 (also called wobble plate), are superimposed on an output movement of an output element, here a driven shaft 5 locked in rotation with a camshaft or the camshaft 6 directly. The drive wheel 3 is in drive connection with a crankshaft of the internal combustion engine, for example, via a traction element, such as a chain or a belt, or a suitable toothed section, wherein the drive wheel 3 can be formed as a chain or belt wheel.
The adjustment shaft 4 is driven by an electric motor 7 or is in active connection with a brake. The electric motor 7 is supported relative to the surroundings, for example, the cylinder head 8 or another engine-fixed part.
FIG. 2 shows an exemplary construction of a camshaft adjuster 1 with a gear drive 2 with a wobble-plate construction. A housing 9 is locked in rotation with the drive wheel 3 and is sealed in an axial end region by a sealing element 10 relative to the adjustment shaft 4 . In the opposite axial end region, the housing 9 is sealed with a sealing element 11 relative to the cylinder head 8 . An end region of the camshaft 6 projects into an inner space 36 formed by the housing 9 and the cylinder head 8 . Arranged in the inner space are furthermore, an eccentric shaft 13 connected via a coupling 12 to the adjustment shaft 4 , a wobble plate 15 supported by a bearing element 14 , for example, a roller bearing, and a hollow shaft 16 , which is supported by a bearing element 17 , for example, a roller bearing, on the inside in a central recess of the eccentric shaft 13 and carries a driven conical gear wheel 18 . The driven conical gear wheel 18 is supported by a bearing 19 relative to the housing 9 . In the interior, the housing 9 forms a drive conical gear wheel 20 . The wobble plate 15 has suitable toothed sections on opposite end faces. The eccentric shaft 13 with the bearing element 14 and wobble plate rotates about an axis inclined relative to a longitudinal axis 21 - 21 , so that the wobble plate meshes on partial-regions offset in the peripheral direction relative to each other, on one hand, with the drive conical gear wheel 20 and, on the other hand, with the driven conical gear wheel 18 , wherein a step-up or step-down ratio is given between the drive conical gear wheel and driven conical gear wheel. The driven conical gear wheel 18 is locked in rotation with the camshaft 6 .
For the embodiment shown in FIG. 2 , the hollow shaft 16 with the driven conical gear wheel 18 is connected via a central screw 22 , which extends through the hollow shaft 16 , to the camshaft 6 on the end. Lubrication with a lubricant, especially oil, is necessary in the region of the lubricating positions 23 , 24 , which can involve, for example,
the contact surfaces between the drive conical gear wheel 20 and wobble plate 15 ,
the contact surface between the wobble plate 15 and driven conical gear wheel 18 ,
the bearing 19 ,
bearing element 14 , and/or
bearing element 17 .
Here, a continuous, cyclical, pulsing, or intermittent feed and/or forwarding of a lubricant via the lubricant channels is realized. Through the use of a feed recess 25 of the cylinder head 8 , the lubricant is fed to a flow channel 26 of the camshaft 6 , which communicates with a flow channel 27 , which is formed with a hollow cylindrical shape between an inner casing surface 28 of the hollow shaft 16 and an outer casing surface 29 of the central screw 22 . Through the use of radial boreholes 30 of the hollow shaft 16 , the lubricant can emerge from the flow channel 27 outward in the radial direction and can be fed to the lubricating positions.
FIG. 3 shows a schematic lubricant circuit. The lubricant is fed from a reservoir 31 , for example, an oil pan or an oil tank, via a pump 32 , for example, a motor-oil pump, through a filter 33 , in particular, a motor-oil filter, to the supply recess 25 and the flow channel 26 of the camshaft 6 . The lubricant leaves the camshaft adjuster 1 or the housing 9 of the camshaft adjuster via an outlet opening 34 and is fed back into the reservoir 31 .
In contrast to the embodiment according to FIG. 3 , the schematic lubricant circuit according to FIG. 4 has an additional filter element 35 . The filter element 35 is advantageously allocated to the camshaft adjuster 1 and is arranged, for example, after a branch of the lubricant circuit to other components to be lubricated and allocated exclusively to the branch of the lubricant circuit that is used for lubricating the camshaft adjuster. Here, the filter 35 is arranged as close as possible to the installation position of the camshaft adjuster 1 or in the camshaft adjuster itself. The filter element 35 can be used to keep processing residue in the flow channels, which are arranged upstream of the filter element 35 , away from the flow channels of the cylinder head and the camshaft. Furthermore, fabrication residue and contaminant particles in the lubricant can be kept away from the gear drive 2 of the camshaft adjuster 1 . Furthermore, a diaphragm characteristic or a throttle effect of the filter element 35 can be used selectively, in order to influence the pressure, the volume flow, and the velocity of the lubricant. The filter element 35 is advantageously to be implemented in such a way that it cannot become blocked or clogged due to the flow relationships at the maximum contamination to be expected with particles and contaminants during the runtime of the camshaft adjuster. For example, the arrangement in a rising line and/or as a secondary current filter is advantageous.
The filter element 35 can be constructed, e.g., as
a screen, a ring filter, a plug-in filter, a shell filter, filter plates, filter net, or sintered filter.
According to FIG. 5 , lubricant is fed into an inner space 36 of the housing 9 , for example, according to the embodiments described above, wherein, in the inner space 36 , the lubricant comes into contact with the lubricating positions. The inner space 36 is in lubricant connection with a dead space 37 , which is arranged at a position of the inner space 36 farthest removed in the radial direction. A connection of the dead space 37 to the inner space 36 can be formed over a large surface via transfer cross sections or via separate channels, by which lubricant can be fed to and also discharged from the dead space 37 .
For the embodiment shown in FIG. 5 , the dead space 37 is constructed as a surrounding ring channel. A dead space 37 involves, in particular, a space, in which the lubricant moves with minimal velocity or is almost at rest, so that the dead space 37 is not arranged in a direct, maximum flow-through zone of the lubricant. In the dead space 37 , due to the rotation of the housing 9 , the lubricant is exposed to a centrifugal force, by which heavy components and particles suspended in the lubricant are pressed outward and can be deposited on a wall 38 on the outside in the radial direction and are not led back to a lubricating position. It is further possible that the annular dead space 37 is separated in the peripheral direction by intermediate walls, so that, in the peripheral direction, several individual chambers are formed, by means of which it is avoided that in the dead space 37 , the lubricant can move in the peripheral direction relative to the housing 9 . Settling of contaminants is thus realized analogous to a rotating centrifuge.
Dead spaces according to the dead space 37 can be arranged at any position in the gear drive, as well as in the region of the camshaft, by which it can be achieved that important functional surfaces, for example, in the direct neighborhood of the dead spaces, are not “silted up” due to centrifuged contaminants in the gear drive. The centrifugal effect is amplified by an increase in the distance of the dead spaces from the longitudinal axis 21 - 21 .
According to a first construction, the dead space has no additional outflow, so that centrifuged contaminant particles are deposited permanently in the dead space 37 . According to the preferred construction shown in FIG. 5 , the dead space has at least one additional outlet opening 39 , 40 , wherein the outlet opening 39 is oriented in the axial direction and the outlet opening 40 is oriented in the radial direction. Due to the radial centrifugal force and/or the pressure ratios in the dead space 37 in comparison with the surroundings of the camshaft adjuster 1 , the lubricant with deposited contaminant particles moves in the radial direction out of the outlet opening 40 , wherein the feeding of the contaminant particles is supported by the centrifugal effect. Alternatively, feeding through the outlet opening 39 is realized exclusively through the pressure difference in the dead space 37 on one side and in the surroundings of the camshaft adjuster 1 on the other side.
For an alternative construction, contaminants are separated in such a way that the lubricant is guided in a flow channel with a labyrinth-like or zigzag-shape construction. Contaminant separation through such a labyrinth-like contaminant separator touches upon the different inertia of the lubricant and interfering particles in the lubricant. In particular, for high flow rates, a strong deflection of the lubricant flow can lead to the result that the particles are not deflected, but instead are deposited at the borders of the labyrinth. For the case that individual channels of the labyrinth are oriented in the radial direction, deposition in the labyrinth on surfaces on the outside in the radial direction can take place in such channels, as well as similarly in axial channels, due to the centrifugal force described above. An alternative or additional separating effect can be produced when the lubricant is decelerated and accelerated, wherein the lighter lubricant can be accelerated more easily, while contaminant particles remain behind.
In additional to generating the centrifugal effect due to rotation of the housing 9 or other parts of the camshaft adjuster 1 , the centrifugal effect can be generated at least partially in such a way that the flow channels guiding the lubricant are oriented in a circular or spiral construction, so that a deposit can form on the outer boundaries of the flow channels just due to the movement of the lubricant through the curved flow channels.
Deviating from the embodiments shown in FIGS. 3 and 4 for a lubricant circuit, the schematic lubricant circuit shown in FIG. 6 has an input-side diaphragm 41 and also an input-side throttle 42 and an output-side diaphragm 43 and also an output-side throttle 44 . The diaphragms 41 , 43 and throttles 42 , 44 form flow elements for influencing the flow ratios in the lubricant circuit. The flow elements noted above are allocated to a parallel lubricant path, which applies a force exclusively to the camshaft adjuster 1 . Advantageously, the flow elements are arranged close to the camshaft adjuster 1 or are integrated at least partially into this adjuster, the camshaft, or a cylinder head in the region of a bearing position for the camshaft.
Through the use of the diaphragms 41 , 43 and throttles 42 , 44 , the volume flow to the camshaft adjuster is throttled. Additional throttling can be produced through the use of the filter element 35 . Advantageously, the filter element is arranged in the flow direction upstream of the flow elements, so that the flow elements do not become blocked by particles or clogged over the course of time.
In addition to the use of flow elements with constant flow characteristics, a flow element that is continuous or that can be changed in steps can be used. The use of a flow element, whose flow effect is variable
as a function of an engine rotational speed, coupled with a feeding volume of the pump 32 , and/or as a function of the temperature of the camshaft adjuster 1 or the lubricant
is possible, wherein the mentioned changes can be generated automatically in a mechanical way or by a suitable control or regulating device, which acts on the flow element.
The flow element is changed in such a way that, for example, the volume flow of the lubricant is held to a constant value independent of the temperature of the lubricant. It is also possible that the volume flow is increased or decreased due to an effect of the flow element in operating regions, in which there are higher or lower lubricant or cooling requirements.
For the construction of the flow elements in the form of throttles 42 , 44 and diaphragms 41 , 43 , under some circumstances, embodiments are to be used, in which ring gaps or annular cross sections are used instead of boreholes with, for example, a circular cross sectional surface, because, under some circumstances, a borehole can be more easily blocked than a ring gap.
For the embodiment shown in FIG. 7 , lubricant is fed via several boreholes 45 of the camshaft 6 , wherein the boreholes 45 are inclined relative to the longitudinal axis 21 - 21 and the radial orientation. The camshaft 6 has an end-face blind borehole 46 , which transfers with a conical chamfer 47 into a thread for receiving the central screw 22 . The boreholes 45 open into the chamfer 47 . In the end region opposite the chamfer 47 , the boreholes 45 are fed with lubricant from a supply groove of the cylinder head 8 . A groove 48 surrounding in the radial direction is formed with the rectangular geometry shown in the longitudinal section approximately in the center in the borehole 45 .
One part of the lubricant fed to the groove 48 via the borehole 45 and borehole 46 is led via an axial borehole 49 of the camshaft 6 , which opens into the groove 48 , and an axial borehole 50 of the housing 9 with a certain amount of overlap, but offset in the radial direction, in the inner space of the gear drive 2 to the lubricating positions, for example, to the bearing element 17 , the bearing element 14 , the rolling toothed connections of the wobble plate 15 , and/or the bearing 19 .
The other part of the lubricant fed to the groove 48 is led via a flow channel 51 with a circular ring-shaped cross section and formed between the inner casing surface of the hollow shaft 16 and the outer casing surface of the central screw 22 to at least one radial borehole 52 to a lubricating position, for example, the bearing position 17 or in the inner space of the gear drive 2 . The groove 48 is constructed with a radial projection, which extends over the borehole 49 , so that a peripheral, ring-shaped dead space 37 is formed on the outside in the radial direction. Between the boreholes 49 , 50 , a transfer region 53 can be formed in the shape of a recess, a radial groove, or the like, in order to allow transfer between the boreholes 49 , 50 that are offset relative to each other in the radial direction. In the form of the boreholes 49 , 50 that are not aligned with each other, for a partial overlap of the boreholes, a kind of diaphragm can be formed with a small transfer cross section or diaphragm cross section, although the boreholes 49 , 50 can be produced with relatively large diameters and thus with rough tools.
For a construction that otherwise corresponds to FIG. 7 , for the embodiment shown in FIG. 8 , the extent of the hollow shaft 16 in the longitudinal direction lengthens in such a way that the hollow shaft projects into the groove 48 . A diaphragm for transfer of lubricant from the borehole 46 to the groove 48 is formed between a peripheral edge 54 , which is formed by the inner casing surface of the borehole 46 and also a transverse surface 55 defining the groove, and an edge 56 , which is formed by the outer casing surface 57 of the hollow shaft 16 and an end face 58 of the hollow shaft 16 .
For a construction that otherwise corresponds to the embodiments described above, the camshaft 6 according to FIG. 9 has no groove 48 . The boreholes 49 , 50 and the transfer region 53 are also not provided for the embodiment according to FIG. 9 , so that the lubricant is fed from the borehole 46 completely to the flow channel 51 . In the circular ring-shaped flow channel, which is formed in the borehole 46 and which has a rectangular half cross section and which is defined on the inside in the radial direction by the casing surface of the central screw 22 and also by an end face 58 of the hollow shaft 16 , there is a flow element 59 , which can involve a ring made from, for example, plastic or an elastomer, and covered by the central screw 22 . For the embodiment shown in FIG. 9 , the flow element 59 has an approximately T-shaped half longitudinal cross-section, wherein the transverse leg of the T contacts the casing surface of the central screw 22 under elastic pressure on the inside in the radial direction, while the vertical leg of the T extends outward in the radial direction and the end face of this leg forms a ring gap 60 with the borehole 46 , by which a diaphragm is created.
In a modified construction, the flow element 59 can be tensioned outward, for example, in the radial direction against the borehole 46 , wherein, in this case a ring gap 60 is formed between the inner surface of the flow element and the central screw. Also, a positive-fit holding of the flow element 59 , for example, in a suitable groove of the camshaft or the central screw, is conceivable. An arbitrary construction of the contours of the flow element 59 in the region of the ring gap 60 is possible for influencing the flow ratios, for example, with stepped transitions or continuous transitions.
For the embodiment shown in FIG. 10 , the hollow shaft 16 has in the region of the flow channel 51 a radial, peripheral groove 61 , which is defined on the side facing the chamfer 47 by a peripheral, radial projection 62 pointing inwardly in the radial direction. Between the projection 62 and the casing surface of the central screw 22 , a ring gap 63 is formed, which represents a diaphragm. The groove 61 forms a dead space 37 on the outside in the radial direction, because both the ring gap 63 and also the flow channel 51 open into the groove 61 on the inside in the radial direction from the dead space 37 .
The camshaft 6 is supplied with a lubricant from a lubricant gallery of the cylinder head 8 . The transition of the lubricant from the engine-fixed cylinder head 8 to the rotating camshaft 6 is realized usually by known rotary transmitters. This typically involves a ring groove 64 of the outer casing surface of the camshaft 6 . The ring groove 64 is enclosed by a corresponding cylindrical casing surface 65 of the cylinder head 8 , to which a pass borehole 66 oriented in the axial direction toward the ring groove 64 leads out of the lubricant gallery. The pass borehole 66 can pass through the casing surface 65 , as shown in FIG. 11 , in the radial direction or can pass through this surface, for example, tangentially.
A rotary transmitter can be arranged in a radial bearing for the camshaft 6 or on a separate shoulder. For the latter, however, due to the usually larger radial gap, often sealing rings 67 , 68 , for example, a steel sealing ring, cast-iron sealing ring, or plastic sealing ring, are required. In an arrangement of the rotary transmitter in a radial bearing of the camshaft 6 it is to be taken into account that the bearing width is reduced by the width of the ring groove.
In another embodiment, ring grooves can be constructed fixed to the cylinder head, for example, in the bearing, the bearing bridge, or an installed bearing bushing. In the camshaft, no ring grooves 64 are required.
The use of a rotary transmitter described above causes a continuous flow of lubricant from the cylinder head 8 into the camshaft 6 due to the peripheral ring groove and the radial boreholes 69 , which connect the ring groove 64 to the borehole 46 .
For a special construction, the pass borehole 66 and the ring groove 64 are arranged offset relative to each other in the axial direction, by which, in the transfer of the lubricant from the pass borehole 66 to the ring groove 64 , a type of throttle is created, whose opening cross section becomes smaller the greater the offset in the axial direction between the pass borehole 66 and ring groove 64 . A throttle effect can also be achieved for a relatively large diameter of the pass borehole 66 and a larger width of the ring groove 64 , so that no small boreholes or grooves, which are sensitive to contaminants and production, have to be created.
According to another special construction, lubricant is fed via a cyclical lubricant supply. In such a case, the ring groove 64 is left out, so that a lubricant connection between the pass borehole 66 and the boreholes 69 is given only for rotational positions of the camshaft 6 , for which the boreholes 66 , 69 align with each other or overlap. If increased transfer times are desired, then the transition region between the pass borehole 66 and borehole 69 of the cylinder head 8 or the casing surface of the camshaft 6 can have a groove running through a partial extent, so that a transfer from the pass borehole 66 to the borehole 69 is possible as long as these boreholes 66 , 69 are connected to each other by the groove. In addition, through the construction of the width profile of the groove, there can be a variable transfer of the lubricant. Thus, a volume flow and mass flow of the lubricant can be given structurally and cyclically. Furthermore, a pulsing lubricant flow can be realized, which results in fluctuations in pressure that can be used, for example, for better mixing and wetting of the lubricating positions with the lubricant. Furthermore, through pulsing lubricant flows, the risk of blockages can be reduced, for example, for diaphragms or throttles. If such lubricant pulses lead to pulse oscillations in the lubricant cycle, then a non-return valve can be arranged in the lubricant circuit, in particular, in the region of the cylinder head 8 , in the region of the camshaft, and/or in the gear drive.
FIG. 12 shows an embodiment, in which lubricant is fed via a radial blind borehole 70 , an axial, end-face blind borehole 71 of the camshaft opening into the blind borehole 70 , and a pass borehole 72 of the housing 9 . Assembly is simplified when a peripheral ring groove 73 is provided in the transition region between the boreholes 71 of the camshaft and the boreholes 72 of the housing 9 , by which, during assembly, the boreholes 71 , 72 do not have to be aligned coaxial to each other.
FIG. 13 shows an embodiment, which corresponds essentially to the embodiment according to FIG. 9 , wherein, however, no flow element 59 is provided.
FIG. 14 shows an embodiment, in which the ring groove 64 is connected directly to the ring channel 73 via a borehole 74 inclined relative to the longitudinal axis 21 - 21 and the transverse axis.
For the embodiment shown in FIG. 15 , the direct connection of the ring channel 73 and the ring groove 64 is realized via a borehole 75 , which is formed on the end face in the camshaft and which opens into the ring groove 64 and which is drilled through the ring channel 73 .
In addition to the structural measures for constructing the flow cross sections in the cylinder head and also in the camshaft, the flow ratios in the lubricant circuit in the gear drive can be influenced. Here, the supply borehole can be throttled through the use of a throttle or diaphragm. Alternatively or additionally, the throttling of the discharge through a rear-side closing of the gear drive, for example, with a sheet-metal cover, is possible, which forms, together with the adjustment shaft, a ring-shaped gap, in particular, with a gap height in the range from 0.1 to 2 mm.
In addition, it is possible to use bearings in the gear drive, which are equipped with sealing elements. According to FIG. 16 , a ring channel between the hollow shaft 16 and central screw 22 has a ring width in the range from 0.2 to 1 mm. The radial connection boreholes between this flow channel and the inner space of the gear drive advantageously have a diameter between 0.5 and 3 mm. Additional influences or throttles or diaphragms can be realized by setting the axial and/or radial gaps 76 , which can be set structurally and which form flow cross sections or diaphragms or throttles for the lubricant.
According to another construction of a camshaft adjuster 1 , the outer casing surface of the housing 9 has recesses or windows 77 , which can be distributed uniformly or non-uniformly in the peripheral direction, cf. FIG. 17 .
FIG. 18 shows additional options for the arrangement of recesses or openings 78 in the region of one end face of the camshaft adjuster 1 . A transmission of the lubricant via the camshaft can be eliminated if a lubricant is fed through the openings 78 , 77 to the gear drive 2 . For example, the lubricant can be fed via a lubricant injector through the openings 77 , 78 . Such a lubricant injector can be fixed to the cylinder head or arranged on a timing case. In the simplest case, a lubricant injector can involve only one lubricant borehole, from which a fine lubricant stream is discharged and which occurs at a point outside of the gear drive or within the gear drive, for example, through the openings 77 , 78 . In particular, such a point can lie as close as possible to the rotational axis in the interior of the gear drive. Due to the centrifugal force acting on the lubricant in the rotating system, the lubricant is distributed outward to the lubricating positions, for example, to a bearing and/or to the toothed section.
In addition, through the arrangement of the openings 77 , 78 of the gear housing, the lubricant can be sprayed directly onto a toothed section or other lubricating positions. It is also conceivable that the spraying with lubricant is combined with the lubricant supply of other engine components, for example, a chain or a tensioner. It is also conceivable that a point or a surface outside of the gear drive 2 is sprayed with the lubricant. Lubrication is then guaranteed through the rebounding or reflected lubricant or a lubricant mist generated in this way.
According to an alternative construction, a lubricant supply can be realized by the lubricant mist, which is already present in a timing case and which can penetrate into the camshaft adjuster through the openings 77 , 78 .
In another construction of a lubricant supply according to FIG. 20 , outside of the gear drive there is a drop plate 80 , on which the lubricant mist condenses and drips. Alternatively or additionally, special drop lubricant nozzles can be provided, which are oriented selectively in the direction of the openings 77 , 78 .
To reliably guarantee functioning for lubrication with a lubricant mist, mist lubricant droplets, or with a lubricant stream, even at low temperatures of the lubricant or for a cold start, the lubricating positions, for example, slide bearings and/or toothed sections, are to be equipped with emergency-running properties. Such emergency-running properties can be guaranteed, for example
by a coating of the functional partners or by forming lubricant reservoirs.
In particular, the lubricant reservoirs are provided by microscopically or macroscopically small pockets at the lubricating positions, in which lubricant can be stored for a cold start or for low lubricant temperatures. Better emergency-running properties can also be provided, advantageously, when roller bearings are provided at the bearing positions as much as possible.
Furthermore, for lubrication, oil dripping from an oiled traction element (timing chain) can also be used, which passed through an opening of the housing. Under some circumstances, the traction element is lubricated by wobble or spray oiling or by stripping oil from oiled chain tensioners or deflection rails. A part of the oil supplied by the chain can drops above the drive wheel (chain wheel) of the gear drive and can thus be led into openings of the gear drive lying underneath. In addition, it is possible to feed oil through the capillary effect to the gear drive or to drip positions lying above the gear drive. It is also possible that oil is “blown,” for all practical purposes, to the lubricating position, by air currents resulting, e.g., from the drive movement of the control drive or adjustment parts.
LIST OF REFERENCE SYMBOLS
1 Camshaft adjuster
2 Gear Drive
3 Drive wheel
4 Adjustment shaft
5 Driven shaft
6 Camshaft
7 Electric motor
8 Cylinder head
9 Housing
10 Sealing element
11 Sealing element
12 Coupling
13 Eccentric shaft
14 Bearing element
15 Wobble plate
16 Hollow shaft
17 Bearing element
18 Driven conical gear wheel
19 Bearing
20 Drive conical gear wheel
21 Longitudinal axis
22 Central screw
23 Lubricating position
24 Lubricating position
25 Feed recess
26 Flow channel
27 Flow channel
28 Casing surface
29 Casing surface
30 Borehole
31 Reservoir
32 Pump
33 Filter
34 Outlet opening
35 Filter element
36 Inner space
37 Dead space
38 Wall
39 Outlet opening
40 Outlet opening
41 Diaphragm
42 Throttle
43 Diaphragm
44 Throttle
45 Borehole
46 Blind borehole
47 Chamfer
48 Groove
49 Borehole
50 Borehole
51 Flow channel
52 Borehole
53 Transfer region
54 Edge
55 Transverse surface
56 Edge
57 Casing surface
58 End face
59 Flow element
60 Ring gap
61 Groove
62 Projection
63 Ring gap
64 Ring gap
65 Casing surface
66 Pass borehole
67 Sealing ring
68 Sealing ring
69 Borehole
70 Blind borehole
71 Blind borehole
72 Pass borehole
73 Ring channel
74 Borehole
75 Borehole
76 Gap
77 Opening
78 Opening
79 End face
80 Drop plate
81 Intermediate space
82 Sub-region
83 Sub-region
84 Flow channel | Traditional camshaft adjusters are connected to a lubricant circuit of an internal combustion engine. Lubricant flows which are too large flood the drive of the camshaft adjuster, which leads to needless churning losses in the drive and needless losses of the pump capacity of the lubricant for other structural components of the internal combustion engine. According to the invention, a flow element ( 59 ), which includes a throttle element or screen in the flow channel ( 26 ), is used. According to another embodiment of the invention, the throttle element or screen can be used in various ways. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This is a continuation-in-part of U.S. patent application Ser. No. 09/748,411, entitled “ICE MAKER AND METHOD OF MAKING ICE”, filed Dec. 26, 2000, which is a continuation-in-part of U.S. patent application Ser. No. 09/499,011, entitled “ICE MAKER”, filed Feb. 4, 2000, which is a continuation-in-part of U.S. patent application Ser. No. 09/285,283, entitled “ICE MAKER”, filed Apr. 2, 1999, now U.S. Pat. No. 6,082,121.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to freezers, and, more particularly, to ice makers within freezers.
[0004] 2. Description of the Related Art
[0005] The freezer portion of a refrigeration/freezer appliance often includes an ice cube maker which dispenses the ice cubes into a dispenser tray. A mold has a series of cavities, each of which is filled with water. The air surrounding the mold is cooled to a temperature below freezing so that each cavity forms an individual ice cube. As the water freezes, the ice cubes become bonded to the inner surfaces of the mold cavities.
[0006] In order to remove an ice cube from its mold cavity, it is first necessary to break the bond that forms during the freezing process between the ice cube and the inner surface of the mold cavity. In order to break the bond, it is known to heat the mold cavity, thereby melting the ice contacting the mold cavity on the outermost portion of the cube. The ice cube can then be scooped out or otherwise mechanically removed from the mold cavity and placed in the dispenser tray. A problem is that, since the mold cavity is heated and must be cooled down again, the time required to freeze the water is lengthened.
[0007] Another problem is that the heating of the mold increases the operational costs of the ice maker by consuming electrical power. Further, this heating must be offset with additional refrigeration in order to maintain a freezing ambient temperature, thereby consuming additional power. This is especially troublesome in view of government mandates which require freezers to increase their efficiency.
[0008] Yet another problem is that, since the mold cavity is heated, the water at the top, middle of the mold cavity freezes first and the freezing continues in outward directions. In this freezing process, the boundary between the ice and the water tends to push impurities to the outside of the cube. Thus, the impurities become highly visible on the outside of the cube and cause the cube to have an unappealing appearance. Also, the impurities tend to plate out or build up on the mold wall, thereby making ice cube removal more difficult.
[0009] A further problem is that vaporization of the water in the mold cavities causes frost to form on the walls of the freezer. More particularly, in a phenomenon termed “vapor flashing”, vaporization occurs during the melting of the bond between the ice and the mold cavity. Moreover, vaporization adds to the latent load or the water removal load of the refrigerator.
[0010] Yet another problem is that the ice cube must be substantially completely frozen before it is capable of withstanding the stresses imparted by the melting and removal processes. This limits the throughput capacity of the ice maker.
[0011] What is needed in the art is an ice maker which does not require heat in order to remove ice cubes from their cavities, has an increased throughput capacity, allows less evaporation of water within the freezer, eases the separation of the ice cubes from the auger and does not push impurities to the outer surfaces of the ice cubes.
SUMMARY OF THE INVENTION
[0012] The present invention provides a control system and corresponding method of operation which allows ice cubes to be automatically harvested in an efficient manner.
[0013] The invention comprises, in one form thereof a method of making ice in an automatic ice maker, including the steps of: providing a mold including at least one cavity; filling the at least one mold cavity at least partially with water; providing an ice removal device at least partly within the at least one mold cavity; coupling a mechanical drive with the ice removal device; coupling a controller with the drive; measuring a temperature of the mold; measuring an ambient temperature associated with the mold; and controlling operation of the drive using the controller, dependent upon the measured temperature of the mold and the measured ambient temperature.
[0014] The invention comprises, in another form thereof, an ice maker including a mold with at least one cavity for containing water therein for freezing into ice. A mold temperature sensor is positioned in association with a mold and provides an output signal indicative of a temperature of the mold. An ambient temperature sensor provides output signal indicative of an ambient temperature associated with the mold. An ice removal device is at least partly positioned within the at least one mold cavity. The mechanical drive drives the ice removal device. A controller is coupled with each of the mold temperature sensor, the ambient temperature sensor and the drive. The controller controls operation of the drive dependent upon the output signal from the mold temperature sensor and the output signal from the ambient temperature sensor.
[0015] An advantage of the present invention is that ice cubes may automatically be harvested depending upon the temperature of the mold, thereby increasing the throughput rate of the ice maker.
[0016] Another advantage is that the time period necessary for freezing the ice may be calculated without continuously sensing and memorizing the temperature of the mold.
[0017] Yet another advantage is that the time period necessary for freezing the ice may be adjusted automatically based upon changing environmental conditions within the freezer which affect the temperature gradient of the freezing. That provides for better cube quality: no soft cubes, no hollow cubes, no broken cubes.
[0018] A further advantage is that filling of the mold cavity does not occur until the temperature of the mold has decreased to a point where freezing may begin occurring after filling, so no double fills will occur.
[0019] Another advantage is that a frozen or blocked fill tube may be sensed and heat applied thereto for the purpose of clearing the fill tube.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] The above-mentioned and other features and advantages of this invention, and the manner of attaining them, will become more apparent and the invention will be better understood by reference to the following description of an embodiment of the invention taken in conjunction with the accompanying drawings, wherein:
[0021] [0021]FIG. 1 is a schematic illustration of a freezer including an embodiment of an ice maker of the present invention; and
[0022] [0022]FIG. 2 is a flow chart of a method of making ice of the present invention.
[0023] Corresponding reference characters indicate corresponding parts throughout the several views. The exemplification set out herein illustrates one preferred embodiment of the invention, in one form, and such exemplification is not to be construed as limiting the scope of the invention in any manner.
DETAILED DESCRIPTION OF THE INVENTION
[0024] Referring now to the drawings, and more particularly to FIG. 1, there is shown an embodiment of a freezer 10 including an ice maker 12 disposed within a freezer unit 14 . Freezer unit 14 may be, e.g., a side-by-side arranged or vertically stacked freezer unit in a household freezer appliance.
[0025] Ice maker 12 generally includes a mold 16 , an auger 18 , a mechanical drive 20 , a controller 22 , a fill tube 24 , a mold temperature sensor 26 and an ambient temperature sensor 28 . Mold 16 includes at least one mold cavity 30 for containing water therein for freezing into ice. In the embodiment shown, mold 16 includes a single mold cavity 30 with interior walls having a slight draft to allow the ice to be more easily removed therefrom. Auger 18 includes an auger shaft 32 about which a continuous flighting 36 extends from one end to the other. Auger 18 is tapered in a discharge direction to allow easier decoupling from the at least partially frozen ice cube which is formed within mold 16 . For more details of a mold and tapered auger which may be utilized with ice maker 12 of the present invention, reference is hereby made by to U.S. patent application Ser. No. 09/499,011, entitled “Ice Maker”, which is assigned to the assignee of the present invention and incorporated herein by reference. Drive 20 rotatably drives auger 18 within mold 16 . In the embodiment shown, drive 20 is in the form of an electric motor, such as an alternating current or direct current motor, having an output shaft 38 which is coupled with and drives auger 18 . Drive 20 is electrically coupled with controller 22 via line 40 .
[0026] Fill tube 24 is coupled with a water line 42 and receives water from a water source (not shown), such as a common pressurized household water supply line. Fill tube 24 selectively receives water such as by using a control valve 52 for supplying water to cavity 30 within mold 16 . Control valve 52 is coupled with controller 22 via line 54 . Fill tube 24 includes a heater 44 therein which is selectively energized to melt any accumulation of ice which may build up in fill tube 24 during operation. In the embodiment shown, heater 44 is in the form of an electrical wire which is over molded within fill tube 24 , and electric controller 22 via line 46 . For more details for a heated fill tube 24 which may be utilized with the present invention, reference is hereby made to U.S. patent application Ser. No. 09/130,180, entitled “Heater Assembly For a Fluid Conduit With an Internal Heater”, which is assigned to the assignee of the present invention and incorporated herein by reference.
[0027] Mold temperature sensor 26 is positioned in association with mold 16 to sense a temperature of mold 16 . In the embodiment shown, mold temperature sensor 26 is embedded within or carried by a sidewall of mold 16 to thereby sense a temperature of the sidewall and provide an output signal to controller 22 via line 48 . Ambient temperature sensor 28 is positioned in association with mold 16 and provides an output signal indicative of the sensed ambient temperature. Ambient temperature sensor 28 may be mounted to suitable structure within freezer 14 , and is preferably mounted to ice maker 12 . For example, ice maker 12 may include a mounting flange for mounting to a wall within freezer 14 , and ambient temperature sensor 28 may be mounted to the flange of ice maker 12 . Other suitable mounting locations on ice maker 12 which are not in contact with mold 16 are also possible.
[0028] Sensor 29 is used to detect whether or not ice is present within an ice holding tray or bin in freezer unit 14 . Sensor 29 provides an output signal to controller 22 indicative of whether the ice tray is already full.
[0029] Compressor 31 is also coupled with controller 22 and provides an output signal to controller 22 . In particular compressor 31 provides a signal to controller 22 indicating whether compressor 31 is running or not running.
[0030] Controller 22 is used to selectively accuate drive 20 , heater 44 and/or valve 52 . The control of drive 20 , heater 44 and valve 52 is at least in part dependent upon one or more output signals which are outputted from first temperature sensor 26 , second temperature sensor 28 and/or sensor 29 to controller 22 .
[0031] Referring now to FIG. 2, there is shown a flow chart illustrating an embodiment of a method of the present invention for making ice in automatic ice maker 12 shown in FIG. 1. Ice maker 12 generally freezes ice cubes in a batch manner such that ice cubes are sequentially frozen and discharged into a suitable holding tray (not shown). The method described hereinafter corresponds to the logic processes for forming a single ice cube within ice maker 12 . It will be appreciated that the method continues in a looped fashion for making additional ice cubes within ice maker 12 .
[0032] Moreover, the embodiment of the present invention for making ice cubes described hereinafter is assumed to be carried out in software within suitable electronics, and thus may be easily implemented by a person of ordinary skill in the art. It is to be appreciated, however, that the embodiment of the method of the present invention described hereinafter may be carried out in software, firmware and/or hardware, depending upon the particular application.
[0033] After start 60 of the control logic flow chart shown in FIG. 2, a mold temperature Tm and initial ambient temperature Tr are stored in a memory device (block 62 ). Mold temperature sensor 26 outputs a signal via line 48 to controller 22 corresponding to mold temperature Tm; and ambient temperature sensor 28 outputs a signal via line 50 to controller 22 corresponding to initial ambient temperature Tr. Mold temperature Tm and initial ambient temperature Tr may be stored in a non-volatile memory to form a history of stored temperatures over time.
[0034] At block 64 , a maximum mold temperature Tmax is determined using mold temperature sensor 26 . The maximum mold temperature Tmax corresponds to the maximum temperature reached by mold 16 after being filled with water as a result of thermal inertia. Mold 16 is generally at a temperature corresponding the internal temperature within freezer unit 14 prior to an initial fill cycle (i.e., approximately the same as the ambient temperature sensed by ambient temperature sensor 28 ). The water which is injected into mold 16 is at an elevated temperature (e.g., 60° F.). After mold 30 is filled with water from fill tube 24 , the elevated temperature of the water within mold cavity 30 causes the temperature of mold 16 to increase according to the corresponding temperature gradient curve. At some point in time, however, the temperature of mold 16 reaches a maximum level Tmax and then again descends as a result of the colder temperature of the air within freezer unit 14 . Suitable control logic, such as that found in co-pending parent application Ser. No. 09/748,411 can be used to detect the maximum temperature Tmax of mold 16 after being filled with water.
[0035] Blocks 66 , 68 , 70 and 72 basically define a wait state during which heat transfer is allowed to occur for freezing the water into ice within mold cavity 30 . At block 66 , a delay interval of fifteen seconds, or other suitable delay time period, occurs. A counter n, initially set to zero, is incremented by one at block 68 . A total harvest time consisting of the summation of the delay intervals is compared with a minimum time constant Th (block 70 ). Minimum time constant Th corresponds to an empirically determined value of a minimum amount of time necessary for freezing of the water to occur. If the total harvest time is less than the minimum time constant Th (line 72 ), then control loops back to the input side of block 66 and another delay interval occurs. On the other hand, if the total harvest time is greater than or equal to the minimum time constant Th (line 74 ), then a determination is made as to whether the temperature of the mold is approximately the same as the ambient temperature sensed by ambient temperature sensor 28 within freezer 14 .
[0036] More particularly, the temperature of the mold increases above the internal ambient temperature within freezer 14 when water is injected into mold cavity 30 . As the water freezes, the temperature of mold 16 decreases and again approaches the internal ambient temperature within freezer 14 . Constant Tc2 is selected empirically to slightly raise the comparison value of the internal mold temperature Tr in decision block 76 . Since the mold temperature and the internal ambient temperature asymptotically approach each other over time after a fill cycle, it has been found necessary to slightly adjust the ambient temperature Tr by the offset constant Tc2 for the proper determination of whether freezing has occurred. If the mold temperature Tm is greater than the sum of the ambient temperature Tr and the constant Tc2 (line 78 ), control loops back to the input side of block 66 as shown. On the other hand, if the mold temperature Tm is less than or equal to the sum of the ambient temperature Tr and the constant Tc2 (line 80 ), control passes to the next group 82 - 108 for the purpose of determining an additional delay period during which freezing occurs prior to discharging an ice cube using drive 20 controlled by controller 22 .
[0037] To wit, at block 82 the slope V (represented by the temperature fall in degrees per unit of time, e.g., seconds) is calculated using the mathematical expression:
T max− Tm /15 Xn
[0038] Where,
[0039] Tm is the sensed current mold temperature using mold temperature sensor 26 , and the quotient 15 Xn represents in this example the total time for freezing to occur thus far within mold cavity 30 . Of course, the number 15 will vary if the delay interval in block 66 is selected differently. The slope V represents the rate at which freezing occurred within mold cavity 30 . If freezing occurs too rapidly, such as with a high value of the slope V, the outside of an ice cube may freeze while the interior may still remain in a liquid state as water.
[0040] At decision block 84 , slope V of the temperature gradient is compared with a predetermined constant V1. If the slope V is less than the constant V1 (line 86 ), then an additional delay T 1 occurs to ensure that the water is frozen into ice. On the other hand, if the slope V is greater than or equal to the predetermined constant V1 (line 90 ), then the slope V is compared to a further predetermined constant V2. The constant V2 is selected with a value which is greater than the constant V1. If the slope V of the temperature gradient is less than the predetermined constant V2 (line 94 ), then an additional delay time T 2 occurs to ensure that the water is frozen into ice.
[0041] On the other hand, if the slope V is greater than or equal to the predetermined constant V2 (line 98 ), then a determination is made as to whether the maximum mold temperature Tmax is greater than or equal to a predetermined constant Tc3 (decision block 100 ). If the maximum mold temperature Tmax is less than the constant Tc3 (line 102 ), then an additional time delay T 3 occurs to ensure that the water freezes into ice. The value of the time delay T 3 is greater than time delay T 2 , which in turn is greater than time delay T 1 .
[0042] On the other hand, if the maximum mold temperature Tmax is greater than or equal to the constant T 3 , than this in general terms means that the mold warmed too much during the fill cycle and it is necessary to delay for a longer period to ensure that the interior of the ice cube freezes adequately. Thus, if the maximum mold temperature Tmax is greater than or equal to the constant Tc3 (line 106 ), then an additional time delay T 4 occurs to ensure that the water freezes into ice. The value of the additional time delay T 4 is greater than the value of time delay T 3 .
[0043] The output from each of blocks 88 , 96 , 104 and 108 , each with a different time delay period, T 1 , T 2 , T 3 and T 4 , respectively, are inputted in a parallel manner to block 110 , wherein the value of counter N is reset to zero and the value of the maximum mold temperature Tmax is set to zero. At block 112 , controller 22 energizes drive 20 to discharge the ice cube from mold cavity 30 using auger 18 .
[0044] Blocks 114 through 130 relate to the filling cycle of mold cavity 30 within mold 16 . Blocks 114 and 116 generally relate to determining whether the temperature of mold 16 has decreased to an extent allowing adequate freezing of the water to occur during the fill cycle. In block 114 , a current mold temperature Tm 1 and an ambient temperature Tr are sensed using mold temperature sensor 26 and ambient temperature sensor 28 , respectively. The ambient temperature Tr is compared with a constant Ts which is selected to be less than the freezing temperature of water. If the ambient temperature Tr is greater than the constant Ts (line 118 ), then a wait state occurs to the input side of block 114 while the mold continues to cool in freezer 14 . On the other hand, if the value of the ambient temperature Tr is less than or equal to the constant Ts (line 120 ), then the mold has cooled sufficiently and water is injected into mold cavity 30 using fill tube 34 (block 122 ).
[0045] After being filled with water, the temperature Tm 2 of mold 16 is again sensed using mold temperature sensor 26 (block 124 ). The difference of the mold temperature Tm 2 after filling and the mold temperature Tm 1 immediately prior to filling are compared with a predetermined constant Tc 1 (decision block 126 ). If the difference of the mold temperature Tm 2 after filling minus the mold temperature Tm 1 immediately prior to filling is less than the constant Tc 1 (line 128 ), this means that the fill tube 24 has become frozen and water did not enter mold cavity 30 during the fill process of block 122 . Thus, heat is applied to fill tube 24 for thawing ice within fill tube 24 (block 30 ). On the other hand, if the difference of the mold temperature Tm 2 immediately after filling minus the mold temperature Tm 1 immediately prior to filling is greater than or equal to the constant Tc 1 (line 132 ), then control loops back to the input of block 62 at the top of the control logic flow chart.
[0046] From the foregoing description of an embodiment of the method of the present invention for automatically making ice cubes, it will be appreciated that different logic steps may be implemented and/or interchanged and still effect the methodology of the present invention. The control logic effectively determines the amount of time necessary for adequate freezing of an ice cube, adjusts the time necessary using certain input parameters, and ensures that proper filling of water into the ice mold cavity occurs. The structure as well as the method of the present invention therefore combine to provide optimum harvest efficiency with minimum mechanical and electrical control hardware.
[0047] While this invention has been described as having a preferred design, the present invention can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims. | A method of making ice in an automatic ice maker includes the steps of: providing a mold including one cavity; filling the at least one mold cavity at least partially with water; providing an ice removal device at least partly within the at least one mold cavity; coupling a mechanical drive with the ice removal device; coupling a controller with the drive; measuring a temperature of the mold; measuring an ambient temperature associated with the mold; and controlling operation of the drive using the controller, dependent upon the measured temperature of the mold and the measured ambient pressure. | 5 |
[0001] This application claims the benefit of U.S. Provisional Application No. 60/207,770, filed May 30, 2000.
FIELD OF THE INVENTION
[0002] The present invention relates generally to a novel way to store and use cooking appliances normally used on a countertop or those that are often integrated into a cook top or hob. It also relates generally to a novel way to store and use separate cooking utensils normally used on a cook top or hob.
BACKGROUND OF THE INVENTION
[0003] In the art of cooking appliances it is known to build in appliances into the surrounding cabinetry and countertops. These systems generally involve making the cabinetry accommodate the appliance, while leaving an exposed side or surface in an in-use position for the operator. It is also common to provide separate cooking utensils that are to be used on an appliance such as a cook-top hob.
SUMMERY OF THE INVENTION
[0004] A typical kitchen or other workplace today is comprised of many tools that aid in cooking a variety of ways. Pots, pans and other units intended for use in conjunction with a cook top or oven are commonplace and numerous. As such, the storage and retrieval of such devices has become a major concern.
[0005] There are also specialty stand-alone devices that are to be used on a counter top. These include, but are not limited to, countertop grills, griddles, spice racks, food containers such as flour containers, warming plates, can openers, toasters, toaster ovens, mixers, and coffeemakers. For the purpose of this application we will refer to all of the aforementioned as well as any other contemplated devices as food preparation appliances, devices, utensils or tools. The issue with many of these devices is that although their function is desired, they may or may not be used that frequently. And so the problem exists that when they are not in use they are using valuable counter space. The consumer may opt to store the units in cabinetry, however, usually the units are heavy, and constructed (multi-piece) in such a way as to not be conducive to the most efficient form of storage e.g. on their side. So they do not use the cabinetry space efficiently. Again, retrieval of the units when they are to be used is less than optimal.
[0006] There are also built-in appliances (usually cook tops/hobs) that are modular in nature allowing the user to detach a particular unit such as a hob and replace it with another specialty unit such as a grill or griddle. As, previously stated, the storage and retrieval of such devices has become a major concern. The shortcomings of these units parallel those of the tabletop/countertop units.
[0007] To address these issues, many consumers have opted to simply add additional, traditional built-in countertop units throughout the kitchen. This has made it so that these units are readily available and have also addressed the desire for a decentralized cooking zone or kitchen. There has also been a trend towards decentralizing and using these types of appliances in areas other than kitchens. Often warming plates, and other such food related appliances are used in dining rooms, conference rooms and the like. Even patios, decks and other outdoor areas are being outfitted with such appliances like never before. The problem with this approach is that it uses valuable counter/work-surface space for devices that may only be occasionally needed. In many cases this also is undesirable aesthetically. To counter this, manufacturers have resorted to making covers for the units, which is only a marginal improvement in aesthetics, and no improvement as far as regaining workspace.
[0008] This invention addresses all of these concerns and creates a new and novel solution to an old problem. The invention consists of a sleeve, can or tracking system that is capable of receiving and storing and dispensing of a stand alone appliance, or a kitchen utensil that is to be used on another kitchen appliance such as a stovetop/hob.
BRIEF DESCRIPTION OF DRAWINGS
[0009] Referring now to the figures.
[0010] [0010]FIG. 1 is a schematic front elevational view of a typical kitchen arrangement without the invention.
[0011] [0011]FIG. 2 is a schematic top elevational view of the typical kitchen arrangement found in FIG. 1.
[0012] [0012]FIG. 3 is a schematic top elevational view of the typical kitchen arrangement with one embodiment of the invention in place, in an out of use position.
[0013] [0013]FIG. 4 is a schematic top elevational view of the typical kitchen arrangement with one embodiment of the invention in place, in an in use position.
[0014] [0014]FIG. 5 is a schematic front elevational view of the typical kitchen arrangement with one embodiment of the invention in place, in an in use position.
[0015] [0015]FIG. 6 is a schematic sectional view B-B of FIG. 4, which is of the typical kitchen arrangement with one embodiment of the invention in place, showing the appliance in an out of use position.
[0016] [0016]FIG. 7 is a schematic sectional view B-B of FIG. 4 which is of the typical kitchen arrangement with one embodiment of the invention in place, showing the appliance in an in use position.
[0017] [0017]FIG. 8 is a schematic sectional view B-B of FIG. 4, which is essentially the same as FIG. 6, but enlarged to show detail, with one embodiment of the invention in place, showing the appliance in an out of use position.
[0018] [0018]FIG. 9 is a schematic sectional view B-B of FIG. 4 which is essentially the same as FIG. 7, but enlarged to show detail, with one embodiment of the invention in place, showing the appliance in an out of use position.
[0019] [0019]FIG. 10 is a schematic top elevational view of the typical kitchen arrangement showing orientations of the invention in place, in an out of use position.
[0020] [0020]FIG. 11 is a schematic top elevational view of the typical kitchen arrangement showing orientations of the invention in place, in an in use position.
[0021] [0021]FIG. 12 is a schematic sectional of another embodiment of the invention. The sectional view is similar in orientation to section cutting line B-B of FIG. 4, showing the appliance in an out of use position.
[0022] [0022]FIG. 13 is a schematic sectional of another embodiment of the invention. The sectional view is similar to that of FIG. 12 but shows a proposed appliance in an in use position.
[0023] [0023]FIG. 14 is a schematic sectional of another embodiment of the invention. The sectional view is similar in orientation to section cutting line B-B of FIG. 4, showing an appliance carrier in an out of use position.
[0024] [0024]FIG. 15 is a schematic sectional of another embodiment of the invention. The sectional view is similar to that of FIG. 14 but shows a proposed appliance carrier in an in use position.
[0025] [0025]FIG. 16 is a schematic top elevational view of another embodiment of the invention of a typical kitchen arrangement showing orientations of the invention in place, in an out of use position.
[0026] [0026]FIG. 17 is a schematic top elevational view of the typical kitchen arrangement illustrating the embodiment of FIG. 16, in an in use position.
[0027] The following reference characters are used in the drawings to refer to the parts of the present invention. Like reference characters indicate like or corresponding parts in the respective views.
[0028] [0028] 10 countertop/work-surface
[0029] [0029] 12 top face of appliance/utensil or optionally a displaceable cover-plate
[0030] [0030] 14 cooking surface of one proposed appliance
[0031] [0031] 16 cover or downdraft vent cover/opening
[0032] [0032] 18 mounting sleeve/tracking system
[0033] [0033] 20 trim lip
[0034] [0034] 22 fixed guide wheel/guidance surface
[0035] [0035] 24 rear guide wheel/guidance surface
[0036] [0036] 26 pivot point of 24
[0037] [0037] 28 potential sites for clean-out access hatch
[0038] [0038] 30 electrical plug outlet
[0039] [0039] 32 electrical conduit
[0040] [0040] 34 guide rib
[0041] [0041] 36 electrical plug
[0042] [0042] 38 electrical outlet
[0043] [0043] 40 cover plate
[0044] [0044] 42 hinge/pivot point
[0045] [0045] 44 proposed appliance
DETAILED DESCRIPTION OF THE INVENTION
[0046] While the invention will be described in connection with several preferred embodiments, it will be understood that the invention is not limited to these embodiments. On the contrary, the invention includes all alternatives, modifications, and equivalents as may be included within the spirit and scope of the forthcoming claims.
[0047] Referring first to FIGS. 1 - 15 One embodiment of the present invention is illustrated. In the illustrations a kitchen is used to demonstrate the invention. Also, the illustrations use a griddle-appliance to illustrate the basic elements of the invention. Additionally, said appliance is constructed as part of the invention. These three conditions do not have to exist though, any appliance used on a countertop in any type of work place would suffice, such as but not limited to grills, stir fry pans, toasters, pot/pan burners, coffeemakers, as well as others previously mentioned. Likewise, such products could be produced either as part of the invention, or they could be purchased separately from differing manufacturers and simply used in conjunction with the present invention. Referring to FIG. 1 a front view of typical wall of a kitchen is illustrated. Figure two is a top view of figure one. These views are for perspective of an installation lacking the present invention.
[0048] [0048]FIG. 3 is substantially the same top view as FIG. 2, however this represents an installation with one embodiment of the invention in an out of use position. The top face, 12 , of one proposed appliance can be seen. An alternate form is that 12 would represent a cover that could flip up, slide sideways, slide into the sleeve 18 , or move otherwise to enable the appliance to move into a usable position, and yet cover and conceal the appliance when it is in an out-of use position.
[0049] [0049]FIG. 4 is substantially the same top view as FIG. 3; however, the appliance is now in an in-use position. Proposed modes of operations are as follows: the user could press a release catch, button or switch, which would eject the appliance via a biased force a percentage of its vertical length. In the case of a separate cover, this could open simultaneously, or as a separate operation. The user could then simply grasp the appliance, moving it to its in-use position. An alternate to this is to replace the pushbutton catch release with one similar to those commonly found on furniture doors. In this scenario the user would push downward on the appliance, which would release the internal catch similarly allowing the appliance to eject via a biased force a percentage of its vertical length. Again, the user could then simply grasp the appliance, moving it to its in-use position. Alternately, the unit could be moved into its final position (as opposed to a percentage of its length) by the same biased force. So, the unit could be moved into position by a separate motor, spring or other biasing force, on command from a user.
[0050] [0050]FIG. 5 is a front elevational view of FIG. 4 showing one proposed appliance in an in-use position.
[0051] [0051]FIG. 6 is a schematic sectional view along sectional cutting line B-B of FIG. 4, showing the appliance in an out of use position. Item 28 marks two possible locations for a clean out access hatch or door. Access of some kind would be desirable in the event something fell into the sleeve, 18 , and as regular housekeeping of kitchen crumbs and the like.
[0052] [0052]FIG. 7 is a schematic sectional view B-B of FIG. 4, showing the appliance in an out of use position. It is desirable to have the cooking surface 14 , removable from the rest of the appliance to enable it to be cleaned separately. It could be secured to the base unit through a variety of latching arrangements. Additionally, in this way, more then one type of complimentary cooking surface could be used with the same base unit. An example of one such complimentary device is a grilling surface interchangeable with a griddle.
[0053] [0053]FIG. 8 is a schematic sectional view along sectional cutting line B-B of FIG. 4 which is essentially the same as FIG. 6, but enlarged to show detail, with one embodiment of the invention in place, showing the appliance in an out of use position. Guide wheels 22 , and 24 are used to guide the tracking of the appliance vertically, and in this case, the pivot 26 allows the unit to swing into its final in use position. Although guide wheels 22 are referred to as being fixed this only refers to their relative position to the mounting sleeve or can. It may be desirable to bias them laterally with a spring or other means so that manufacturing and environmental tolerances can be compensated for. The same is true for guide wheel 24 and its associated pivot 26 . Guide wheel 24 is tracked by guide rib 34 which could be formed as part of sleeve 18 . Such a sleeve could be formed by commonly known manufacturing processes. Some examples include the stamping/forming of steel, or the injection molding of plastic, or extruded plastic/aluminum. In the illustrations guide wheels are used, however, any of a number of guidance means could be employed. The wheels could be substituted with frictional guide blocks, or an extension drawer-slide assembly, ball bearing or other. Similarly, a wire-form tracking system could be employed. It probably would be appropriate to provide positional switches for disabling the appliance when it is in an out of use position. Such a switch could be a simple pushbutton switch that is tripped into an on position when the appliance is in an in-use position. Another is one that is positonally dependant such as a mercury switch or other form commonly used to avoid fires etc. in appliances such as portable heaters. In the illustration electrical connections are made through electrical conduit 32 , however, it may be desirable to employ other methods of electrical connection. One such method would be to provide conductor interface, attached to the appliance that would only make connection with a mating conductor of the sleeve assembly when the appliance was in its in use position. In this way the cord would be eliminated, and the switching issue would be addressed.
[0054] [0054]FIG. 9 is a schematic sectional view B-B of FIG. 4 which is essentially the same as FIG. 7, but enlarged to show detail, with one embodiment of the invention in place, showing the appliance in an out of use position. Of note is that the cover 16 , has moved into an appropriate position to cover the hole of the sleeve. Such a cover is not a necessity of the invention, however, it provides a finished look and enhances the safety of the user, and keeps debris etc. from entering the sleeve. It should be noted that with an appropriate exhaust fan arrangement the mounting sleeve 16 , could serve as ducting for an exhaust fan. In this case the rectilinear hole of the sleeve may be left open, or the cover 16 may be louvered to allow the appropriate movement of air. It also should be noted that the sleeve itself is not a necessity of the invention, but only serves to fully contain the appliances when stored, or additionally serve as an air-duct. The present illustrations show that the rectilinear hole is covered, in an out of use position, by the top face of the appliance, and then when the appliance is in its in use position by a tail cover 16 . This does not have to be the case though. As previously mentioned, it could be advantageous, in some or all instances, to make the cover as a separate entity that opens in some fashion to allow the appliance to move to its in use position.
[0055] Referring to FIG. 10 a schematic top elevational view showing alternate orientations of the invention in place, in an out of use position can be seen. This view and FIG. 11 simply illustrate that the invention can be used in several alternate positions. Additional positions are possible such as in front of or in back of a countertop installed cook top. The wide variety of positions should be appreciated, especially when the wide variety of counter/worksurface formats such as islands, sinks, etc. are contemplated.
[0056] Referring to FIG. 11 a schematic top elevational view showing the alternate orientations of FIG. 10, in an in use position can be seen.
[0057] Referring to FIG. 12 is a schematic sectional of another embodiment of the invention. The sectional view is similar in orientation to section cutting line B-B of FIG. 4, showing the appliance in an out of use position. The primary difference with this embodiment is that the appliance contemplated is one that only requires vertical movement to transfer it from an out of use position to an in position. Examples of such appliances are toasters, coffeemakers etc. Note that the in FIGS. 12 and 13 the appliance itself 44 , is indicated only generally as a sectioned wall, with a hollow, rectilinear cavity. All applicable contemplated alternatives previously mentioned, such as covers, venting, tracking, and spring/motor biasing are equally applicable to this and all the contemplated embodiments. Also shown is that the unit may be plugged into a standard outlet provided for, preferably, within the cabinet via standard electrical plug 36 , and electrical conduit 32 . This is an alternate electrification method to what is commonly referred to a hard wiring an appliance. Either of these methods of making electrical connections are applicable to all embodiments of the invention where applicable.
[0058] Referring to FIG. 13 is a schematic sectional view similar to that of FIG. 12, but shows a proposed appliance in an in use position. Again, as with previous embodiments, several modes of operation are contemplated for bringing the unit from an out of use position to an in use position.
[0059] Referring to FIG. 14 is a schematic sectional of another embodiment of the invention. The sectional view is similar in orientation to section cutting line A-A of FIG. 3. This embodiment is substantially the same as that of FIGS. 11 and 12 in that predominately vertical movement is contemplated. The primary difference is that instead of moving an integrated appliance, an appliance carrier is disclosed that is capable of accommodating a variety of manufactured appliances. Note that in FIGS. 14 and 15, no appliance is illustrated. An outlet interface indicated generally by 38 , provides a standard outlet, which is suitable for electrifying an appliance that is equipped with a matching plug. In this case, the safety switching scenarios previously set forth could control the electrification of outlet 38 , to prevent the appliance from being powered in an out of use position. This figure also shows one alternate cover form that is applicable to all embodiments of the invention. The cover 40 , includes a pivot 42 , which enable the cover to move into a position allowing the carriage or appliance to move to an in use position.
[0060] Referring to FIG. 15 is a schematic sectional of the embodiment of FIG. 14 but shows a proposed appliance carrier in an in use position. In this view the cover 40 , can be seen in its open position.
[0061] Referring to FIG. 16 is a schematic top elevational view of another embodiment of the invention of a typical kitchen arrangement showing orientations of the invention in place, in an out of use position. The difference between this embodiment and all that have preceded, is that in this scenario non-powered kitchen utensils are contemplated. They are to be used with a separate heating surface. This is made clear by referring to FIG. 17 which is a schematic top elevational view illustrating the embodiment of FIG. 16, in an in use position. Note that the burners are hidden and thus illustrated as hidden lines. As previously described, the utensils can be releasably connected to a carrier so that they may be cleaned at a different location. Additionally, this embodiment shares and contemplates all of the applicable alternatives previously set forth concerning other embodiments.
[0062] Thus, a new and novel product or system for the storage and retrieval of food preparation appliances, devices and other utensils has been described. The system allows the workplace to remain uncluttered, while allowing the consumer ready access to the appliances, devices or utensils when desired. Additionally, the appliances are stored with the cavities in a more efficient manner than is currently available. | A device and method for the storage and retrieval of a variety of cooking utensils is disclosed. The invention may include a sleeve, can or tracking system that is capable of receiving and storing and dispensing a stand alone appliance, or a kitchen utensil that is to be used on another kitchen appliance such as a stovetop/hob. The device may also include a latching system for securing the appliance/appliance carrier or utensil in its stored position. The device may be used with existing appliances and utensils as an appliance/utensil carrier or incorporate its own proprietary appliance(s) or utensil(s). This new and novel product or system for the storage and retrieval of food preparation appliances, allows the workplace to remain uncluttered, and at the same time allows the user ready access to the appliances, devices or utensils when desired. Additionally, the appliances are stored in a more efficient manner than is currently available. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/926,637, filed Apr. 27, 2007, the contents of which are hereby incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] This invention relates to methods of forming superparamagnetic magnetite colloidal nanocrystal clusters and construction of colloidal photonic crystals using these clusters as building blocks.
[0003] Recent advances in colloidal synthesis have enabled the preparation of high quality nanocrystals with controlled size and shape. Focus of synthetic' efforts appear to be shifting to creation of secondary structures of nanocrystals, either by self-assembly or through direct solution growth. Manipulation of the secondary structures of nanocrystals is desired in order to combine the ability to harness the size-dependent properties of individual nanocrystals with the possibility to tune collective properties due to the interactions between the subunits.
[0004] Superparamagnetic nanocrystals have proved to be very promising for biomedical applications as they are not subject to strong magnetic interactions in dispersion. Iron oxide nanocrystals have received the most attention for this purpose because of their biocompatibility and stability in physiological conditions. Several robust approaches have been developed for synthesizing magnetic iron oxide (e.g., γ-Fe 2 O 3 or Fe 3 O 4 ) nanocrystals with tightly controlled size distribution, typically through organometallic processes at elevated temperatures in non-polar solvents. Additional steps of surface modification or lipid encapsulation are usually performed to transfer the hydrophobic nanocrystals from non-polar solvent to water for biomedical applications. The nanocrystals prepared using these methods, with dimensions of order ten nanometers (nm), have a low magnetization per particle so that it is difficult to effectively separate them from solution or control their movement in blood using moderate magnetic fields, thus limiting their usage in some practical applications such as separation and targeted delivery. Increasing the particle size increases the saturation magnetization, but also induces the superparamagnetic-ferromagnetic transition (at a particle size ˜30 nm for Fe 3 O 4 ) so that nanocrystals are no longer dispersible in solution. The strategy of forming clusters of magnetite nanocrystals has the advantage of increasing the magnetization in a controllable manner while retaining the superparamagnetic characteristics.
[0005] Accordingly, what has been needed and heretofore unavailable are superpara-magnetic nanocrystals that overcome the deficiencies of existing configurations so as to eliminate the problem of increasing the particle size producing nanocrystals that are not dispersible in solution. The present invention disclosed herein satisfies these and other needs.
[0006] Besides magnetic separation, these magnetite colloidal nanocrystal clusters also find its application in construct novel solution form photonic crystals. Photonic crystals are spatially periodic dielectric structures displaying photonic bandgaps in which certain optical modes can not exist. They have attracted much attention because of their important optoelectronic applications where manipulation of photons is required, for example, as photonic components intended for telecommunications, lasers, and sensors. Among these applications, a highly desirable feature is to have a tunable bandgap, which can be conveniently controlled by external stimuli. Although considerable efforts have been devoted along this direction by changing the refractive indices of the materials, the lattice constants or spatial symmetry of the crystals, the tunability has been typically limited to tens of nanometers in diffraction wavelength. A known system was developed from fabricated colloidal photonic crystals using charged polystyrene microspheres containing superparamagnetic nanoparticles. Changes in diffraction wavelength above one hundred nanometers can be achieved by imposition of magnetic fields.
SUMMARY OF THE INVENTION
[0007] The present invention is directed to a chemical synthetic method for the production of monodisperse colloidal nanocrystal clusters (CNCs) of magnetite (Fe 3 O 4 ). The size of the clusters can be controlled from about thirty nanometers (nm) to about three hundred nm by using a high-temperature hydrolysis process. The combination of superpara-magnetic property, high magnetization per particle, monodispersity, and high water dispersibility makes the CNCs ideal candidates for various important biomedical applications such as drug delivery, bioseparation, and magnetic resonance imaging. Each cluster is composed of many single magnetite crystallites of about ten nm, thus retaining the superparamagnetic properties at room temperature. The use of a surfactant in synthesis renders the clusters highly water dispersible. The CNCs show strong responses to external magnetic field due to their much higher magnetization per particle than that of individual magnetite “nanodots,” which are defined herein as isolated particles each of which has a single crystalline domain. A “cluster” is defined herein as particles that are composed of many single crystallites.
[0008] Previously reported superparamagnetic iron oxide nanocrystals have typical dimensions of order ten nm. Due to their low magnetization per particle, it has been difficult to effectively separate them or control their movement in solution using moderate magnetic fields, thus limiting their usage in some practical applications. Increasing the particle size increases the saturation magnetization, but also induces the superpara-magnetic-ferromagnetic transition (at a particle size about thirty nm for Fe 3 O 4 ) so that particles are no longer dispersible in solution. The strategy of forming clusters of magnetite nanocrystals has the advantage of increasing the magnetization in a controllable manner while retaining the superparamagnetic characteristics.
[0009] This invention also describes a magnetically tunable photonic crystal system by assembling highly charged superparamagnetic Fe 3 O 4 colloidal nanocrystal clusters (CNCs) in aqueous solution. Stabilized by the balance of attractive (magnetic) and repulsive (electrostatic) forces, the colloids form ordered structures along the direction of the external magnetic field with a regular interparticle spacing on the order of hundreds of nanometers. As a result, the solutions strongly diffract visible light. This novel photonic crystal system has several remarkable merits. Since the interparticle spacing is determined by the relative strengths of electrostatic repulsions and magnetic attractions, one can conveniently tune the diffraction wavelength throughout the entire visible spectrum by changing the strength of the external field. The optical response has also been found sensitive to both the size of the colloids and the ionic strength of the solution. Due to the high refractive index of iron oxide, strong diffraction is realized at a low volume fraction of particles (˜0.06%). In addition, a relatively weak magnetic field (˜100-400 Gauss) is sufficient to induce the ordering of CNCs as a result of the high magnetic moment possessed by each particle. The optical response of the solutions to the variation of magnetic field is found to be fast, fully reversible, and compatible with miniaturization, suggesting great potential for uses in sensors, optical switches, and color displays. The concentration of stray electrolytes also has a strong effect on the optical response of the solution as it changes the strength of the interparticle electrostatic repulsion. Other factors including the size, size distribution and concentration of the colloids have also been examined to optimize the diffraction intensity and tuning range.
[0010] Tunable photonic structures have also been formed in alkanol solutions by assembling silica coated Fe 3 O 4 CNC colloids using magnetic fields. Surface modification of Fe 3 O 4 CNCs with silica shells allows their dispersion in nonaqueous alkanol solutions. Both electrostatic and solvation forces contribute to the interparticle repulsion which counters the magnetically induced attractive force during the assembly of Fe 3 O 4 @SiO 2 colloids in alkanol solutions. The system reported here shows important features such as a fast, reversible and tunable optical response to external magnetic fields, high stability, and convenient control of the working diffraction range by changing the silica shell thickness. The ability to assemble the magnetic particles in nonaqueous solutions allows the fabrication of field-responsive polymer composite films for potential applications as displays or sensors.
[0011] Other features and advantages of the present invention will become more apparent from the following detailed description of the invention, when taken in conjunction with the accompanying exemplary drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIGS. 1 a - 1 f are transmission electron microscopy (TEM) images of Fe 3 O 4 nanocrystal clusters in the present invention.
[0013] FIGS. 2 a - 2 c are high-resolution and high magnification TEM images of secondary structures for isolated colloidal nanocrystal clusters in the present invention.
[0014] FIG. 2 d is the selected area diffraction of an isolated colloidal nanocrystal cluster.
[0015] FIG. 3 shows X-ray diffraction patterns confirming the secondary structure of magnetite colloidal nanocrystal clusters of the present invention and magnetite nanodots as a reference.
[0016] FIG. 4 is a XAS spectrum at Fe L edge of Fe 3 O 4 colloidal nanocrystal clusters and referential spectra for Fe 3 O 4 , γ-Fe 2 O 3 , α-Fe 2 O 3 .
[0017] FIGS. 5 a - 5 c show hysteresis loops of colloidal nanocrystal clusters of the present invention, wherein mass magnetization (M) is plotted as a function of applied external field.
[0018] FIGS. 6 a - 6 c show the aqueous dispersion of colloidal nanocrystal clusters of the present invention on a glass substrate.
[0019] FIGS. 6 d - 6 f show photos of a CNC aqueous dispersion in a vial with or without magnetic field applied.
[0020] FIGS. 7 a - 7 b show the digital photos and reflectance spectra, respectively, of an aqueous solution of CNCs made in the present invention in response to a varying magnetic field at normal incidence.
[0021] FIG. 8 shows the dependence of the tuning range of diffraction spectra of the colloidal photonic crystals, represented by the vertical bars, and the wavelength of maximum diffraction intensity, represented by the solid squares, on the size of CNCs.
[0022] FIGS. 9 a - 9 c show modulated optical responses of Fe 3 O 4 colloidal photonic crystals in a periodic magnetic field of different frequencies.
[0023] FIGS. 10 a - 10 e show TEM images of Fe 3 O 4 colloidal nanocrystal clusters coated with silica layers of various thickness (Fe 3 O 4 @SiO 2 ).
[0024] FIG. 11 shows reflection spectra of Fe 3 O 4 @SiO 2 in ethanol solution in response to an external magnetic field with varying strength.
[0025] FIG. 12 shows reflection spectra of Fe 3 O 4 @SiO 2 colloids in various alkanol solvents in response to a defined magnetic field.
[0026] FIG. 13 a shows fabrication procedure of a field-responsive PDMS composite embedded with droplets of EG solution of Fe 3 O 4 @SiO 2 colloid.
[0027] FIG. 13 b shows magnetically induced color change of a flexible PDMS film with EG solution of Fe 3 O 4 @SiO 2 colloids.
DETAILED DESCRIPTION OF THE INVENTION
[0028] The present invention is directed to superparamagnetic magnetite colloidal nanocrystal clusters (CNC) and methods of their production. Highly water soluble magnetite (Fe 3 O 4 ) CNCs are synthesized by a high temperature hydrolysis reaction using a precursor, a surfactant, a precipitation agent and a polar solvent. A NaOH/DEG stock solution was prepared by dissolving NaOH (50 mmol) in DEG (20 ml); this solution was heated at 120° C. for one hour under nitrogen, and cooled down and kept at 70° C. In a typical synthesis, a mixture of PAA (4 mmol), FeCl 3 (0.4 mmol) and DEG (17 ml) was heated to 220° C. in a nitrogen atmosphere for at least 30 min under vigorous stirring, forming a transparent light-yellow solution. A NaOH/DEG stock solution (1.75 ml) was injected rapidly into the above hot mixture, and the temperature dropped to about 210° C. instantly. The reaction solution slowly turned black after about two minutes and eventually slightly turbid. The resulting mixture' was further heated for 1 h to yield 93-nm magnetite clusters. The amount of NaOH/DEG solution determines the size of the CNCs. For example, 1.6, 1.65, 1.7, 1.8, 1.85 ml of stock solutions lead to the formation of CNCs with average sizes of 31, 53, 71, 141, 174 nm, respectively. The final products were washed with the mixture of de-ionized (DI) water and ethanol several times and then dispersed in DI water.
[0029] The method of the present invention for forming colloidal nanocrystal clusters includes precursors chosen from iron salts including, but not limited to, iron (II) chloride, iron (III) chloride, iron (II) sulfate, iron (III) sulfate, iron (II) nitrate, iron (III) nitrate, iron (II) fluoride, iron (III) fluoride, iron (II) bromide, iron (III) bromide, iron (II) iodide, iron (III) iodide, iron (II) sulfide, iron (III) sulfide, iron (II) selenide, iron (III) selenide, iron (II) telluride, iron (III) telluride, iron (II) acetate, iron (III) acetate, iron (II) oxalate, iron (III) oxalate, iron (II) citrate, iron (III) citrate, iron (II) phosphate, iron (III) phosphate. Other transition metals such as cobalt, nickel, and manganese can be incorporated into the synthesis by adding the corresponding salts so that the final products are iron based complex oxides. Suitable surfactants for use in the method of the present invention can be chosen from a wide range of polyelectrolytes such as, but not limited to those containing carboxylic acid groups including polyacrylic acid and polymethacrylic acid. Suitable polar solvents for use in the method of the present invention include, but are not limited to, ethylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol and polyethylene glycols.
[0030] In the method of the present invention, the precipitation of the colloidal nanocrystal clusters can be initiated by adding bases such as hydroxides, carbonates, bicarbonates, phosphates, hydrogen phosphate, dihydrogen phosphates of group 1 and 2, ammonium (for example, NaOH, KOH, Na 2 CO 3 , K 2 CO 3 ), ammonia, as well as group 1 salts of carbanions, amides and hydrides. The reaction to form the colloidal nanocrystal clusters of the present invention can be carried out at a temperature between room temperature and the boiling point of the solvents. In one embodiment, the temperature for synthesis is controlled between about 100° C. to about 320° C. In accordance with the present invention, the size of the clusters can be controlled from approximately thirty (30) nm to approximately three hundred (300) nm.
[0031] In one embodiment of the present invention, highly water soluble magnetite (Fe 3 O 4 ) CNCs are synthesized by using a high temperature hydrolysis reaction with polyacrylic acid (PAA) as the surfactant. Iron (III) chloride (FeCl 3 ) is used as a precursor, and diethylene glycol, (DEG, a polyhydric alcohol with a boiling point of 244-245° C.) is used as a polar solvent. PAA was selected as the surfactant for the strong coordination of carboxylate groups with iron cations on the magnetite surface. An additional advantage of using PAA is that the uncoordinated carboxylate groups on the polymer chains extend to aqueous solution, conferring upon the particles a high degree of dispersibility in water. Introduction of sodium hydroxide (NaOH) into the hot mixture of DEG, FeCl 3 and PAA produces water molecules and also increases the alkalinity of the reaction system, with both results favoring the hydrolysis of Fe 3+ . Under the reductive atmosphere provided by DEG at high temperature, Fe(OH) 3 partially transforms to Fe(OH) 2 , finally leading to the formation of Fe 3 O 4 particles through dehydration. These Fe 3 O 4 nanocrystals spontaneously aggregate to form flower-like three-dimensional clusters, as shown in the representative transmission electron microscopy (TEM) images in FIGS. 1 a - 1 f . The average sizes of the CNCs in FIGS. 1 a - 1 f , obtained by measuring about 150 clusters for each sample, are 31 nm, 53 nm, 71 nm, 93 nm, 141 nm, and 174 nm respectively, wherein all scale bars are 200 nm. Close inspection of these images confirms that these monodisperse colloids are consisted of small subunits.
[0032] The size of the CNCs can be precisely controlled from ˜30 nm to ˜300 nm by simply increasing the amount of NaOH while keeping all other parameters fixed ( FIG. 1 ). This size tunability might be the result of slight differences in H 2 O concentration and alkalinity caused by varying NaOH additions. Higher H 2 O concentration and relatively stronger alkalinity could accelerate the hydrolysis of Fe 3+ , promoting the formation of larger oxide clusters. The growth of CNCs follows the well-documented two-stage growth model where primary nanocrystals nucleate first in a supersaturated solution and then aggregate into larger secondary particles.
[0033] The secondary structure of CNCs can be observed more clearly in FIGS. 2 a - 2 c for isolated clusters of ˜31 nm, ˜93 nm, and ˜174 nm, respectively. Lattice fringes were recorded for a small cluster with diameter of 31 nm, as shown in the high-resolution TEM (HRTEM) image in FIG. 2 a . It's clear that the cluster is composed of small subcrystals of 6-8 nm size and of the same crystal orientation. Measuring the distance between two adjacent planes in a specific direction gives a value of 0.482 nm, which corresponds to the lattice spacing of (111) planes of cubic magnetite. The fact that subcrystals crystallographically align with adjacent ones can be understood as the result of oriented attachment and subsequent high temperature sintering during the synthesis. FIGS. 2 b and 2 c show the secondary structures of CNCs of much larger size. FIG. 2 d shows selected-area electron diffraction (SAED) pattern recorded on an isolated cluster of ˜174 nm, which reveals a single-crystal-like diffraction where diffraction spots are seen to have widened into narrow arcs, indicating slight misalignments among the subcrystals.
[0034] XRD measurements also confirm the secondary structure of magnetite CNCs. FIG. 3 shows the diffraction patterns with almost identical broadenings for clusters of different sizes of 53-nm, 93-nm, and 174-nm and 8-nm magnetite nanodots, wherein peak positions and intensities recorded in the literature for bulk magnetite samples are indicated by the vertical bars. Calculations using Debye-Scherrer formula for the strongest peak (311) give grain sizes of 9.73, 9.65 and 10.83 nm for CNCs of size 53, 93 and 174 nm, respectively, implying that the subcrystals do not grow significantly with the increasing size of CNCs. Consistently, the peak shape and broadening in XRD patterns of CNCs are comparable to that of 8-nm isolated nanodots. We also confirmed the composition of iron oxide being magnetite by combining the XRD results with the X-ray absorption spectroscopy (XAS) measurements in FIG. 4 .
[0035] The unique and complex structure allows CNCs to retain superparamagnetic behavior at room temperature even though their size exceeds 30 nm. FIGS. 5 a and 5 b show hysteresis loops of 93-nm CNCs measured at 300° K. and 2° K., respectively. FIG. 5 c is a comparison of hysteresis loops of 53-nm, 93-nm, 174-nm CNCs and a reference sample of 8-nm nanodots and the insert depicts the magnetic moment (μ) per cluster (or dot) plotted in a logarithmic graph. The clusters show no remanence or coercivity at 300° K., corresponding to superparamagnetic behavior. At 2° K., thermal energy is insufficient to induce moment randomization so that the clusters show typical ferromagnetic hysteresis loops with a remanence of 12.6 emu/g and a coercivity of 140 Oe.
[0036] To evaluate the magnetic response of CNCs to an external field, the mass magnetization (σ) was measured at 300° K. by cycling the field between −20 kOe and 20 kOe. FIG. 5 c shows that all the CNCs, as the reference sample of 8-nm Fe 3 O 4 nanodots, are superparamagnetic at room temperature, i.e., 300° K. The saturation magnetization (σ s ) was determined to be 63.5 emu/g, 56.7 emu/g, 30.9 emu/g, 21.2 emu/g for 174-nm, 93-nm, 53-nm CNCs and 8-nm particles, respectively. The values for large clusters are close but decrease noticeably for small particles, which may be attributed to a surface related effect such as surface disorder or surface spin canting. The magnetic moment of an individual grain (μ) can be determined by the Langevin paramagnetic function: M(x)=Nμ(cothx−(1/x)).
[0037] The CNCs are highly water soluble even after washing with the mixture of ethanol and water for three times, thanks to the robust surface coating of PAA. The method of the present invention included the ability to visualize their magnetic responses in an optical microscope by observing a thin layer of aqueous dispersion of CNCs on a glass substrate.
[0038] FIGS. 6 a - 6 c show optical dark-field images of a thin layer of CNC aqueous dispersion on a glass substrate, without magnetic field, with magnetic field, and after the applied magnetic field is removed, respectively. The bright region at the lower-left corner in each image represents the dried CNCs.
[0039] As shown in FIG. 6 b , the initially well-dispersed CNCs shown in FIG. 6 a forms chain-line structures when a magnetic field was applied. The chain-like structures are disassembled immediately upon removing the external field, as seen in FIG. 6 c , displaying a typical superparamagnetic behavior. FIGS. 6 d - 6 f show photos of a CNC aqueous dispersion in a vial without magnetic field, with magnetic field, and after the applied magnetic field is removed, respectively. If a CNC solution is subjected to a strong magnetic field, the particles can be completely separated from the solution within minutes, as shown in FIGS. 6 d and 6 e . A slight agitation will bring the CNCs back into the original solution if the magnetic field is removed as shown in FIG. 6 f.
[0040] The present invention is further directed to a method for constructing colloidal photonic crystals out of the polyacrylate capped superparamagnetic magnetite (Fe 3 O 4 ) colloidal nanocrystal clusters (CNCs) with tunable size from about thirty to about three hundred nm using a high-temperature hydrolysis process. The colloidal photonic crystals show highly tunable diffractions covering the whole visible region owing to the highly charged polyacrylate covered surfaces and the strong magnetic responses of the magnetite CNCs. Such a system, with the advantages of simple and inexpensive to synthesize, wide and reversible tunability, and instant response to external magnetic field, opens the door to many critical applications including as active components in optical micro-electromechanical (MEMS) systems.
[0041] Uniform magnetite CNC building blocks were synthesized by hydrolyzing FeCl 3 with NaOH at about 220° C. in a diethylene glycol (DEG) solution containing the surfactant of polyacrylic acid (FAA), which is described in the last section. These CNCs retain the superparamagnetic behavior at room temperature and show much stronger response to the external magnetic field than individual nanodots. Polyacrylate binds to the particle surface through the strong coordination of carboxylate groups with iron cations, while the uncoordinated carboxylate groups on the polymer chains extend to aqueous solution and render the particles highly charged surfaces.
[0042] These Fe 3 O 4 CNCs can readily self-assemble into colloidal crystals in deionized water upon application of a magnetic field; after removing the extra surfactants and decreasing the ionic strength through repeated centrifugation. FIGS. 7 a and 7 b show the digital photos and reflectance spectra, respectively, of an aqueous solution of CNCs (approximately 10.2 mg/ml) in response to a varying magnetic field at normal incidence. The colloidal photonic crystals, shown in FIG. 7 a , with magnetically tunable diffractions covering the whole visible spectra have been fabricated from superparamagnetic magnetite 120-nm CNCs. The magnetic field has been increased from 87.8 to 352 Gauss by moving a NdFeB magnet towards the sample (3.7-2.0 cm) with step size of 0.1 cm. As shown in FIG. 7 a , the color of the aqueous solution of CNCs changes from red (in the vial 710) to blue (in the vial 720) as the magnetic filed increases. As shown in FIG. 7 b , the diffraction peak resulting from the close pack (111) planes accordingly blue shifts under increasing magnetic filed as, for example, the peak 730 shifts to the peak 740. The peak frequency gradually shifts from about 750 nm to below 450 nm. As the magnet moves away from the sample, the diffraction peak reversibly red shifts. A rapid response (<<1 s) of the diffraction to the change in the magnetic field is observed. The interplanar spacing decreases from 274 to 169 nm as the strength of magnetic field increases, as estimated by using the Bragg's Law (λ=2nd sin θ), where λ is the diffraction wavelength, n is the refractive index of water, d is the lattice plane spacing, and θ=90° is the Bragg angle.
[0043] The three-dimensional order of the formed colloidal crystals is the result of the balance between the interparticle electrostatic repulsive force and the magnetic forces. The as synthesized CNCs without cleaning show no diffractions even when the magnetic field is so strong that they are separated from the solution. Their optical response to the magnetic field increases with the number of cleaning cycles which reduce the ionic strength of the solution and increases the Debye-Hiickel screening length and therefore the electrostatic repulsion ξ-potential measurement of a sample cleaned five times gave a typical value of −51 mV, demonstrating their highly charged surface characteristics. Unlike the previously reported case for superparamagnetic polystyrene spheres, the CNCs do not form colloidal crystal in the absence of a magnetic field.
[0044] Since CNCs are composed of pure Fe 3 O 4 , their response to the external magnetic field is much stronger than that of the similarly sized polystyrene beads doped with iron oxide nanoparticles. The application of magnetic field results in additional magnetic packing forces, magnetic dipole-dipole repulsive and attractive forces. The magnetic packing force is exerted on every cluster and attracts them towards the maximum of local magnetic gradient. The repulsive and attractive forces are perpendicular and parallel to the magnetic field, respectively. For example, a 120-nm cluster shows a magnetic moment μ about 6.319×10 −14 emu in a 235 Gauss magnetic field, and experiences a magnetic packing force(F m =∇(μB)) of 1.26×10 −11 dyn in a 200 Gauss·cm −1 gradient. With a 197.4 nm nearest-neighbor spacing d derived from the diffraction peak position, the interparticle repulsive force F mr =3(μ 2 /d 4 ) and the attractive force F ma =6(μ 2 /d 4 ) are estimated to be 9.91×10 −7 and 1.98×10 −6 dyn respectively. These values, which are negligible when the magnetic moment per particle is small, are now comparable to that of the interparticle electrostatic repulsive forces. It is also worth noting that the magnetic field required for inducing the ordering of the particles in the current system is ten times less than the previously reported value due to the much stronger magnetic moment of the Fe 3 O 4 CNCs. The broad tunability and rapid responses of the current system may benefit from the large contribution of the magnetic forces in determining the crystal structure and the lattice constant.
[0045] The tuning range of the diffraction wavelength is found to relate to the average size of the CNCs. In general, crystals of large-size clusters (˜160-180 nm) preferably diffract red light in a relatively weak magnetic field, and their ordered structures become unstable when the magnetic field is too strong. Small-size clusters (˜60-100 nm) form ordered structures only when the magnetic field is sufficiently strong and the crystals preferably diffract blue light. As demonstrated by the example in FIG. 7 b , the medium-size clusters can form stable colloidal crystals in a magnetic field with tunable diffractions covering the whole visible spectrum. To clearly reveal such size dependence, FIG. 8 plots the tuning range of colloidal photonic crystals, represented by the vertical bars, and the wavelength of maximum diffraction intensity, represented by the solid squares, against the size of CNCs. For each sample, the position of maximum diffraction intensity is determined by the polynomial fitting of the curve consisted of all peak values of the reflectance spectra, and the tuning range is obtained by including all the diffractions whose intensity is above 30% of the maximum value. FIG. 8 indicates that the diffraction with maximum intensity red-shifts as the size increases approximately in a linear fashion, which agrees with our visual observations.
[0046] The optical responses of these photonic crystals are rapid and fully reversible. To characterize the response time, we recorded changes in the reflection spectrum of a magnetic colloidal photonic crystal in the presence of a periodically on-off magnetic field with a controllable switching frequency. FIG. 9 a shows the reflection spectra of a 70 nm Fe 3 O 4 colloidal photonic crystals in a periodic magnetic field with a frequency of 0.5 Hz with spectra integration time of 200 msec. They demonstrate that the switch of diffraction at ˜470 nm between on and off states can be achieved with the same frequency as the external field. FIGS. 9 b and 9 c show the variation of peak intensity at 470 nm in response to electromagnetic fields at higher frequencies such as 1 and 2 Hz with integration time of 100 msec. As shown in FIGS. 9 b and 9 c , the diffraction intensity shows periodic modulations which closely match the profile of external field, displaying clear on/off states with the corresponding frequency. No gradual transition from longer wavelengths to the final shorter wavelength was observed during the development of the spectra, indicating that the ordered structures form within the first 200 msec upon the application of magnetic field. During the rest of the ‘on’ stage, the order of the crystals further improves as the remaining particles rearrange their positions. The diffraction peak disappears completely within 100-200 msec after the magnetic field is off, which is much faster than the time needed for development of translational order under a magnetic field.
[0047] Further modifications and improvements may additionally be made to the superparamagnetic magnetite colloidal nanocrystal clusters and methods of production disclosed herein without departing from the scope of the present invention. Accordingly, it is not intended that the invention be limited by the embodiments disclosed herein.
[0048] The present invention is further directed to a method of fabricating magnetically responsive photonic structures that can operate in nonaqueous solutions. Unlike the previously reported polyelectrolyte-grafted CNCs which are only dispersible in water, the modification of the particle surface with a layer of silica allows their dispersion in various nonaqueous organic solvents such as alkanols. Interestingly, upon application of an external magnetic field, the modified particles in these nonaqueous solvents can also assemble into ordered structures and diffract light. Given the expected diminished role for electrostatic forces for silica coated particles in alkanols, it is natural to suspect that other repulsive forces must be present to counter the magnetic attractive force and yield the observed persistence of ordering. The photonic response of the solutions to external fields suggests a rough range for this force and allows us to identify it with effects already observed in the literature. As well as allowing us to study fundamental details of interparticle forces, forming tunable photonic structures in nonaqueous solvents provides a number of advantages over the water-based approach for practical applications. For example, solvents with low volatility can now be used as dispersion media for improved long-term stability and ease of processing. The use of nonaqueous solvents also addresses the issue in the previous system where trace amount of ions released from environment such as glass containers may gradually alter the system's photonic response. While maintaining the merits of our earlier work with aqueous colloids such as a fast and reversible response, the modification with silica layer also provides a convenient method for extending the diffraction wavelength beyond the visible range. Our synthetic procedure currently can produce Fe 3 O 4 CNCs with sizes below 300 nm, which limit the maximum diffraction wavelength to below ˜800 nm. The size limitation can be conveniently overcome by coating a layer of silica whose thickness can be precisely controlled by using the facile sol-gel processes. The silica coating also makes it possible to link a large variety of ligands to the particle surface through the well-developed silane chemistry for further enhancing the compatibility between the particles and solvents.
[0049] FIGS. 10 a - 10 e show TEM images of Fe 3 O 4 colloidal nanocrystal clusters coated with silica layers of various thickness of 16.5, 25, 37, 56, and 70.5 nm, respectively, where the CNCs have a similar core size of ˜110 nm. Fe 3 O 4 @SiO 2 colloids were synthesized as follows. Fe 3 O 4 CNCs were synthesized using a high-temperature hydrolysis reaction reported previously. Fe 3 O 4 @SiO 2 core/shell colloids were prepared through a modified Stöber process. Typically, an aqueous solution (3 mL) containing Fe 3 O 4 CNCs (−25 mg) was mixed with ethyl alcohol (20 mL), ammonium hydroxide (28%, 1 mL) aqueous solution by vigorous stirring using mechanical stirrer. TEOS (0.1 mL) was injected to the solution in every 20 min till the total amount of TEOS reaches 0.9 mL. At the end of every cycle, reflection spectra of reaction solution were measured under magnetic field (622 Gauss) to monitor the thickness of silica layer. After obtaining the desired size, the Fe 3 O 4 @SiO 2 colloids were collected by magnetic separation, washed by ethanol for three times, and finally dispersed in ethanol (3 mL).
[0050] Fe 3 O 4 @SiO 2 core-shell particles can be dispersed in a number of alkanol solvents and show a tunable optical response in the presence of an external magnetic field. The diffraction peak blue-shifts as the distance decreases from 4.3 to 1.9 cm with step size of 0.2 cm.
[0051] FIG. 11 shows the typical reflection spectra of an ethanol solution of 170-nm (overall diameter with 114 nm in core size and 28 nm in shell thickness) Fe 3 O 4 @SiO 2 as a function of the external magnetic field strength, achieved by changing the magnet-sample distance. The diffraction intensity increases steadily with increasing external field strength until reaching a saturation value. Further increasing the strength of the magnetic field does not significantly change the peak position and the peak intensity drops only slightly. The contour of the peaks therefore shows a skewed profile. From the reflection spectra, one can estimate an average value for interparticle spacings along the magnetic field using Bragg's law, λ=2nd sin θ, as well as a surface-to-surface distance, d s-s , by subtracting the colloid diameter.
[0052] For the Fe 3 O 4 @SiO 2 dispersions in ethanol, besides the electrostatic force, another repulsive force, “solvation force,” must be considered besides the reduced electrostatic force when discussing the interactions in the framework of Derjaguin-Landau-Verwey-Overbeek (DLVO) theory. It has been widely accepted that for an ethanol dispersion of silica, a wetting film of solvent formed on the silica surface through the hydrogen bonds can significantly stabilize the system. When the solvation layers of two nearby particles overlap, a strong disjoining pressure appears to prevent the particles from coming together. While the electrostatic force still remains effective at larger separations, the solvation force may dominate the interparticle repulsions at small separations, making it possible to counter the induced magnetic attractive force and assemble the particles into ordered structures. The combined effect of these two repulsive forces leads to the skewed dependence profile of the diffraction to the changes in the strength of magnetic field. By calculating the spacing from the shortest diffraction wavelength, we estimate the thickness of the solvation layer to be ˜20.4 nm which is close to the value reported in literature. The solvation force is also present in aqueous systems, however, its contribution to the overall repulsive interaction might be negligible in comparison to the strong electrostatic force resulted from high surface charges.
[0053] Alkanol solutions of Fe 3 O 4 @SiO 2 colloids show significant long-term stability in photonic activity. In the previous aqueous Fe 3 O 4 CNC system, slow release of ions from the environment or from the particles into the solution may eventually alter the photonic properties including both diffraction intensity and wavelength. The system reported here was able to display consistent photonic response after storage for several months, owing to the lower ionic strength of the alkanol solutions and the predominantly non-electrostatic contribution to interparticle repulsion.
[0054] The diffraction spectra of the Fe 3 O 4 @SiO 2 colloids can be modified by changing the thickness of the silica shell. To avoid the homogeneous nucleation of small silica particles, TEOS was added to the reaction slowly and continuously during the synthesis. Interestingly, the Fe 3 O 4 @SiO 2 colloids show an optical response to external magnetic field even in the original reaction solution (12.5% water, 4.2% NH 4 OH solution, and 83.3% ethanol), providing a convenient way to monitor the growth of silica layers around the Fe 3 O 4 cores. The detection method is fast in comparison to other measurement techniques such as dynamic light scattering or TEM imaging. FIGS. 10 a - 10 e show TEM measurements which confirm the increasing thickness of the silica shell from ˜16 to ˜70 nm. While the average diameter of the Fe 3 O 4 CNCs is below 180 nm as limited by the synthesis procedure, silica coating allows to increasing the effective particle size in a controlled manner so that the diffraction wavelength of the photonic crystals can be extended into the near-IR region.
[0055] Silanol surface makes the Fe 3 O 4 @SiO 2 colloids compatible with many alkanol solvents besides ethanol. FIG. 12 shows the reflection spectra of 170-nm Fe 3 O 4 @SiO 2 colloids in various alkanol solvents in response to a same magnetic field of 622 Gauss. The applied magnetic field is strong enough to drive the neighboring particles close to “hard contact” so that the intensity of the diffraction is around the maximum value. In this case, the thickness of solvation layer (d′=(d−d colloid )/2) in each solvent can be estimated from the calculated lattice spacing (d)
[0056] The ability to assemble magnetic colloids into ordered structures in nonaqueous solvents represents a significant step towards the practical applications of these tunable photonic structures. The method of the present invention provides the ability to embed alkanol solutions of Fe 3 O 4 @SiO 2 colloids in a polydimethylsiloxane (PDMS) matrix in the form of liquid droplets, thus producing solid composite materials with field responsive optical properties. Similar operations have been extremely difficult using aqueous solutions due to the high polarity of water. In a typical process, Fe 3 O 4 @SiO 2 colloids are dispersed in a nonvolatile alkanol solvent such as EG, DEG, and glycerol, and then mixed with PDMS prepolymer and curing agent using mechanical stirring. Thanks to the high viscosity of prepolymer (3900 cp), EG solution of Fe 3 O 4 @SiO 2 forms very stable emulsion-like droplets with an average diameter of ˜5 μm. The stability of droplets is also believed to benefit from the close match between the densities of the glycol and the PDMS matrix. Curing the mixture at room temperature for ˜24 hours (or at 60° C. for 2 hours) produces a dark brown silicone gel, which displays color change property when placed under a varying magnetic field.
[0057] EG droplets remain intact during the curing process. Direct observation of the droplets using optical microscope has been difficult due to the close match between the refractive indices of EG (1.431) and PDMS (1.430). FIG. 13 a shows fabrication procedure of s field-responsive PDMS composite embedded with droplets of EG solution of Fe 3 O 4 @SiO 2 colloids and an optical microscopy graph of the droplets under a vertically aligned external magnetic field. The assembly of Fe 3 O 4 @SiO 2 colloids in the droplets under the magnetic field leads to the diffraction of green light. As shown in FIG. 13 a , the droplets change color and show significantly increased contrast against the PDMS matrix under a vertically aligned magnetic field, and therefore can be easily observed and imaged. Careful inspection reveals that the droplets contain many bright spots, each of which represents a chain of Fe 3 O 4 @SiO 2 particles assembled along the magnetic field. FIG. 13 b shows magnetically induced color change of a flexible PDMS film with EG solution of Fe 3 O 4 @SiO 2 colloids. As shown in FIG. 13 b , the composite film retains the flexibility of the PDMS matrix and can be folded into various shapes while still displaying magnetically induced colors. The material is also very stable, wherein no apparent degradations in optical or mechanical properties were observed after storing the samples for month. | Monodisperse colloidal nanocrystal clusters of magnetite (Fe 3 O 4 ) with tunable sizes from about thirty to about three hundred nanometers have been synthesized using a high-temperature hydrolysis process. The colloidal nanocrystal clusters are capped with polyelectrolytes, and highly water soluble. Each cluster is composed of many single magnetite crystallites, thus retaining the superparamagnetic behavior at room temperature. The combination of superparamagnetic property, high magnetization, and high water dispersibility makes the colloidal nanocrystal clusters ideal candidates for various important biomedical applications such as drug delivery and bioseparation. The present invention is further directed to methods for forming colloidal photonic crystals from both aqueous and nonaqueous solutions of the superparamagnetic colloidal nanocrystal clusters with an external magnetic field applied thereto. The diffraction of the photonic crystals can be tuned from near infrared to visible and further ultraviolet spectral region by varying the external magnetic field. | 2 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to Norwegian Patent Application No. 20100144 filed 29 Jan. 2010 which is incorporated by reference herein.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable
THE NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT
[0003] Not Applicable
REFERENCE TO A SEQUENCE LISTING SUBMITTED ON COMPACT DISC
[0004] Not Applicable
BACKGROUND OF THE INVENTION
[0005] The invention concerns a device for concentrating material located on or directly below a water surface. The material may comprise oil pollution or some other type of pollution, floating waste or live or dead organic material. The device is towed on the water surface, for example in the open sea or on a lake or, alternatively, the water with the material may flow through the device, for example by virtue of the device covering the surface of a portion of a river. More particularly, the invention concerns a device provided with at least two consecutive guide elements in the flow direction of the water.
[0006] Hereinafter, the invention will be referred to in context of concentrating material located on or directly below a water surface. Such material may comprise, but is not restricted to, pollution consisting of oil floating on a water surface, chemicals, a solid in a particulate form and loose objects. A solid in a particulate form may be dust, or it may be an absorbent containing, per se, pollution. Loose objects may be waste, such as small and large bits of plastic, objects such as e.g. cans, jugs and ropes, or they may be natural objects such as e.g. driftwood. The invention may also be used for concentrating live or dead biological material, e.g. seaweed, kelp, algae and crustaceans, for example hill and Calanus finmarchicus , when being present naturally, or when being introduced so as to be present on or directly below the water surface.
[0007] Oil pollution on a water surface is distinguished by a relatively small amount of oil forming a large and relatively thin oil slick. This renders collection of the pollution difficult, insofar as the collection must be carried out over a large area. The oil slick pollution may be broken into smaller oil slicks, which renders the collection even more difficult.
[0008] It is know within the art to use booms in order to restrict the adverse effect of oil pollution on a water surface and in order to collect the pollution. Booms are distinguished by being provided with a buoyancy body and a skirt. The buoyancy body forms a barrier across the water, and the skirt, which is weighed down by a suitable weight, forms a barrier beneath the water. In order to be able to follow the motions of the waves, the buoyancy body and the skirt may be comprised of elastic material, for example a plastic material. Further, the buoyancy body may be inflatable. The advantage thereof is that the boom assumes little space, relatively speaking, during storage, transport and deployment, whilst assuming its full volume during use.
[0009] Booms may be used in several ways. One object may be to prevent a beach area from becoming soiled by oil pollution. The boom then forms a barrier between e.g. the oil slick and the beach area. Another object may be to prevent dispersion by disposing the boom around an oil slick, after which the oil slick is collected by means of suitable equipment. A boom may also be towed through an oil slick in order for the oil to become concentrated in a portion of the boom, thus making it easier to collect the oil with, for example, so-called skimmers or pumps. For such towing, one and preferably two vessels may be used to tow the boom behind the free end portion thereof. Patent publication WO 02/12636 describes the manner in which a boom may concentrate an oil spill and discloses a solution to how it may be collected. Patent publication WO 2004/035937 discloses the manner in which a boom may be towed by two vessels through an oil spill area.
[0010] It is known in the art for booms, especially in the collection portion thereof, to be provided with an impervious bottom. Booms of this type are referred to as an oil trawl. Further, it is known for a net to be used instead of an impervious bottom. Booms of this type are referred to as V-booms or net booms.
[0011] There are several disadvantages associated with the known types of booms, and the degree of effectiveness varies relative to the purpose thereof. They are restricted in terms of the size of wave height they can operate within before the oil is carried past the boom. During stowing oil and water up against the boom, the boom will belch, i.e. oil is forced down into the water near the boom and then is carried underneath the skirt and past the boom. Towing of the boom is carried out at low speed, and generally two towing vessels must coordinate their movements in order for the boom to maintain its shape which, when seen from above, assumes a horseshoe-shape or a U-shape.
[0012] Upon towing the known booms, which mainly form a U-shape, the sides of the boom are referred to as arms, and the area between the free end portions of the arms are referred to as the front opening of the boom. Among other things, the collection efficiency of the boom, and the size of the area across which the boom can collect, depends on the width of the front opening and the tow speed of the vessel or vessels. It is also known for the portions of the boom comprising the arms of the boom, which are substantially parallel, to contribute insignificantly to the collection of the oil.
[0013] Besides the wave height, it is also known for the tow speed to be limited by the deep-draught of the skirt. At the longitudinal portion, which comprises the bottom portion or collection portion of a U-shaped, towed boom, a significant water resistance will be present, and the water resistance increases with the deep-draught of the skirt. This water resistance will also produce a stowing pressure in front of the front opening of the boom. Given that the water with the pollution will deflect and pass on the outside of the boom, the stowing pressure has a blocking effect on pollution which, desirably, is to enter into the boom. In order to counteract this effect, it is known to have, within the collection portion of the boom, an opening through which water and pollution may discharge from the boom. It is also known to be preferable to place collection equipment in this opening in the collection portion owing to the fact that the pollution will be most concentrated in this portion. Upon using too high a tow speed, water and pollution will be forced down along the bottom portion of the boom's skirt and cause the boom to belch.
[0014] Thus, there is a need for a device that is capable of covering a relatively large area, and which can concentrate the pollution in a manner allowing the pollution to be collected using technology known per se. Further, there is a need for a device that is capable of being operated in the open sea using, preferably, one vessel, and which can be towed at a relatively high speed.
BRIEF SUMMARY OF THE INVENTION
[0015] The object of the invention is to remedy or to reduce at least one of the disadvantages of the prior art, or at least to provide a useful alternative to the prior art.
[0016] The object is achieved by virtue of features disclosed in the following description and in the subsequent claims.
[0017] In a first aspect, the invention concerns a device for concentration of material on or directly below a water surface, wherein the device is provided with a front opening, with buoyancy bodies and with guide elements structured for guiding the material towards a collection portion, and wherein the device is structured for admitting water through the device in the flow direction of the water by virtue of the device, in a portion thereof, being provided with at least two consecutive guide elements in the flow direction of the water.
[0018] The guide element may be fixed to a form element. The form element may be comprised of a net. In one embodiment, the form element may be of a triangular shape. In an alternative embodiment, the form element may be comprised of lines fixed to the guide elements so as to allow the device, when in its position of use, to assume a triangular shape, as viewed from above.
[0019] The guide element may be comprised of a buoyancy body, a skirt and a weight rope. A longitudinal direction of the guide element may form an angle of between 0° and 90° with respect to a width direction of the front opening. This implies that the front opening forms an imaginary base line, wherein the angle between the imaginary base line and the longitudinal direction of the guide element is measured as an internal angle in a triangle where the guide element forms a side in the triangle.
[0020] At least two guide elements may be substantially parallel. In an alternative embodiment, the perpendicular distance between two neighbouring guide elements may be smaller at the collection end of the guide elements than at the front end of the guide elements. Using the same number of guide elements and the same front opening, the device of this embodiment will have a shorter distance between the front opening of the device and the end portion of the device, as compared to the embodiment where the guide elements are substantially parallel. In a further alternative embodiment, the perpendicular distance between two neighbouring guide elements may be larger at the collection end of the guide elements than at the front end of the guide elements. Using the same number of guide elements and the same front opening, the device of this embodiment will have a larger distance between the front opening of the device and the end portion of the device, as compared to the embodiment where the guide elements are substantially parallel.
[0021] The collection portion of the device may be comprised of a mid-portion. Collected material, which is guided along the guide element until the material passes the collection end of the guide element, undergoes enhanced concentration from two sides in the mid-portion of the device. The collection portion of the device forms a channel in the device, wherein the channel extends from the front opening of the device onto the end portion of the device. Two and two collection ends of the guide elements may form an opening in the mid-portion of the device. When two and two guide elements are arranged symmetrically about the mid-portion of the device, as viewed from above, the distance between the collection ends of the guide elements will correspond to the width of the collection portion.
[0022] The front opening of the device may be provided with spacers structured for towing behind a vessel. The spacer may be comprised of a door. This door may be a trawl door, a seismic deflector or some other form of door known in the art. This has the advantage of allowing the device to be operated by one vessel.
[0023] In a second aspect, the invention concerns a method of concentrating material located on or directly below a water surface by guiding the material through a device as described hereinbefore. The device may be towed on a water surface by means of at least one vessel.
[0024] In an alternative method, a front line of the device is fixed to the banks of a river so as to allow river water to flow through and past the device.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] Hereinafter, an example of a preferred embodiment is described and is depicted on the accompanying drawings, where:
[0026] FIG. 1 schematically shows the invention, as viewed from above, wherein some of the elements are shown at different scales;
[0027] FIG. 2 shows the invention depicted in FIG. 1 , wherein the device is further provided with a collection device;
[0028] FIG. 3A-C shows a cut-through section of a guide element and the position of the guide element at different water flow velocities through the device; and
[0029] FIG. 4 shows the invention depicted when used to collect material in a river course.
DETAILED DESCRIPTION OF THE INVENTION
[0030] In the drawings, reference numeral 1 denotes a device according to the invention. The device is provided with several guide elements 12 and outer guide elements 18 , 18 ′ fixed to a form element 3 . In the figures, the form element 3 is depicted as a net.
[0031] A front line 32 , at the end portions 34 , 34 ′ thereof, is fixed to a door 94 , 94 ′. The doors 94 , 94 ′ are connected to a vessel 9 with tow lines 92 , 92 ′. The vessel 9 moves along a water surface 8 and in a direction denoted by a solid arrow. Upon movement of the vessel 9 , the doors 94 , 94 ′, which are of a type known per se, will move out to the side of the vessel 9 when being pulled by the tow lines 92 , 92 ′. The tow lines 92 , 92 ′ are comprised of a type known per se and may be comprised of ropes or metal wire. The doors 94 , 94 ′ will stretch out the front line 32 between themselves, whereby the front line 32 will assume a curved shape, as viewed from above and depicted in FIGS. 1 and 2 . During towing, the end portions 34 , 34 ′ of the front line will define a front opening 2 of the device 1 . By virtue of the vessel 9 towing the device 1 in the direction marked with a solid arrow, the water in the water surface 8 and a material 4 located on or directly below the water surface 8 , will move in a direction relative to the device, as denoted with an open arrow in the figures.
[0032] The guide elements 12 , 18 , 18 ′ are fixed to the net 3 in such a way that the longitudinal direction of the guide elements 12 , 18 , 18 ′ is oblique relative to the pulling direction of the device 1 . The guide elements 12 , 18 , 18 ′, at the front ends 120 thereof, are fixed to the net 3 substantially at the front line 32 . Collection ends 121 of the guide elements 12 end freely in a collection portion 14 . The collection portion 14 extends from the front line 32 onto an end portion 16 . The collection ends 121 of the outer guide elements 18 , 18 ′ may meet in the end portion 16 of the device 1 . In an alternative embodiment, the collection ends 121 of the outer guide elements 18 , 18 ′ may be terminated somewhat apart from each other, whereby an opening 5 is formed between the collection ends 121 , as shown in FIG. 2 . In this opening, the device 1 may be provided with a collection unit 52 of a type known per se, for example a so-called skimmer or an oil trawl. The collection unit 52 may be provided with a fluid connection 54 of a type known per se, which is structured to bring collected material 4 to a collection craft, for example the vessel 9 .
[0033] Material 4 located on or directly below the water surface 8 , and between the doors 94 , 94 ′ in the front opening 2 , will encounter one of the guide elements 12 , 18 , 18 ′. Due to the relative movement between the device 1 and the water, the material 4 , or parts of the material 4 , will be guided along the guide elements 12 , 18 , 18 ′ in the direction of the collection portion 14 . Some of the material 4 will move underneath the guide elements 12 , 18 , 18 ′. The material 4 moving underneath the outer guide elements 18 , 18 ′ will then be inaccessible for further concentration but may be further concentrated by repeating the sweep across the area using the device 1 . The material 4 moving underneath one of the guide elements 12 will float up to the water surface 8 and then encounter the following guide element 12 and thereafter be guided towards the collection portion 14 . From FIGS. 1 and 2 , the skilled person will appreciate that this may be repeated several times. The material 4 will be further concentrated in the collection portion 14 , which forms a channel between the front line 32 and the end portion 16 of the device. The material 4 being guided to the end portion 16 of the device will be significantly more concentrated than at the front opening 2 and suitable for collecting with equipment known per se, for example pumps or skimmers.
[0034] As shown in FIGS. 1 and 2 , the device 1 is provided with several guide elements 12 , which mainly have parallel longitudinal axes. The number of guide elements is determined by the desired perpendicular distance between the guide elements 12 , by the width of the front opening 2 , and by the angle α which is formed between the guide elements 12 and the front opening 2 . In FIGS. 1 and 2 , this angle is ca. 75°. This angle may be an angle in the region from of 70°, inclusive, to 80°, inclusive, but not limited to this angular region. It is up to the skilled person to determine which angle is optimum, insofar as the optimum angle may depend on which type of material 4 is desirable to concentrate further, for example oil or drifting seaweed. The optimum angle may also depend on the assumed wave height and assumed towing speed. As depicted in FIGS. 1 and 2 , the angle is given as an internal angle measured from a base line extending between the doors 94 , 94 ′. An angle of 0° will therefore correspond to a direction being parallel to the base line.
[0035] As shown in FIGS. 3A-C , the guide element 12 is comprised of a lengthy buoyancy body 122 of a type known per se, and which is provided with a skirt 124 . The skirt 124 is cloth-shaped and surrounds a portion of the buoyancy body 122 . The skirt is provided with a lengthy weight in the form of a weight rope 126 of a type known per se. The weight rope 126 may be fixed to the skirt 124 at the outside of the skirt 124 . In an alternative embodiment, the skirt 124 may surround a portion of the weight rope 126 . The skirt 124 is fixed to the net 3 with a lashing 128 , as shown in FIGS. 3A-C . Alternatively, the skirt 124 may be fixed to the net 3 with a seam. In its position of use, when the device 1 is at rest relative to the water, the skirt 124 will be suspended down into the water from the buoyancy body 122 so as to allow the weight rope 126 to be located substantially below the buoyancy body 122 , as shown in FIG. 3A . The net 3 will be submerged in the water and be kept floating by the guide elements 12 . The distance from the net 3 to the water surface 8 is determined by the deep-draught of the skirt 124 .
[0036] The FIGS. 3A-C show the mutual positions of the buoyancy body 122 , the skirt 124 and the weight rope 126 at increasing towing speeds for the device 1 . The movement of the water relative to the device 1 is shown with an open arrow. At a towing speed between 0 and 2 knots, as shown in FIG. 3A , the weight rope 126 will be located substantially below the buoyancy body 122 . At a towing speed between 2 and 4 knots, as shown in FIG. 3B , the weight rope 126 will be located substantially sidelong the buoyancy body 122 and in a direction against the water flow. The net 3 will be lifted closer to the water surface 8 . At a towing speed between 4 and 6 knots, as shown in FIG. 3C , the weight rope 126 will be located completely sidelong the buoyancy body 122 and in vicinity of the water surface 8 in a direction against the water flow. The net 3 will be lifted close to the water surface 8 . The advantage thereof is that the towing resistance of the device 1 is reduced at higher towing speeds owing to the fact that the deep-draught of the skirt 124 is reduced. Insofar as the material 4 is allowed to pass beneath one or several guide elements 12 prior to being concentrated in the collection portion 14 , the deep-draught of the skirt 124 may be reduced without expending too much of the collective capacity of the device 1 to concentrate the material 4 located on or directly below the water surface 8 .
[0037] With respect other known solutions, the device 1 has a larger capacity for concentrating material 4 located on or directly below the water surface 8 . For this purpose, it is advantageous that the front opening of the device 1 can be made very wide. It is known from gathering of seismic data to use doors 94 , 94 ′ forming a front opening from 1000 to 1400 meters. In principle, the front opening 2 of the device 1 may be made equally wide. The capacity also depends on the speed of the towing. Thus, it is advantageous that the deep-draught of the skirt 124 decreases at increasing towing speeds. Given that the structure of the device 1 is flexible and simultaneously is kept in position by the extended form element 3 , the device 1 may also be used for larger wave heights than when using traditional booms.
[0038] The skilled person will appreciate that the device 1 may be stored and transported on board a vessel 9 in the same manner as that of the trawls and trawl bags used for fishing. Alternatively, the device 1 may be stored and transported on board a vessel 9 in the same manner as for equipment intended for carrying out seismic surveys offshore. Deployment and retrieval of the device 1 may therefore be carried out in a manner known per se.
[0039] In an alternative embodiment, as shown in FIG. 4 , the device 1 may be comprised of substantially half of the device shown in FIG. 1 . This implies that the net 3 is of a triangular shape with an associated guide elements 12 extending substantially in one longitudinal direction only. Then the collection portion 14 will comprise a side edge of the device 1 , and the device 1 includes only one outer guide element 18 . Such an embodiment may prove advantageous in context of concentrating material in a river 6 . The front portion 2 may extend across a surface portion of the width of the river 6 , possibly across the entire width of the river 6 . With its end portions 34 , 34 ′, the front line 32 of the net is fixed at each river bank 62 , 62 ′. The river water will flow past the device 1 , and the device 1 will guide the material 4 , which is located on or directly below the water surface, inward to the one river bank 62 where the material 4 may be collected in a manner known per se. This also has the advantage of the flow velocity being lower along the river bank 62 than in the midst of a river 6 , which makes it easier to collect the material 4 along the river bank 62 .
[0040] In an alternative embodiment (not shown), the guide elements 12 , 18 , 18 ′ are comprised of narrow-spaced buoyant balls of a type known per se. In this embodiment, the buoyant balls may be attached both to the lower side and the upper side of the net 3 , whereby the buoyant balls also comprise the skirt 124 of a guide element, and no weight rope 126 is used.
[0041] In a further alternative embodiment (not shown), the guide element 12 is comprised of a thick buoyant rope fixed to the net 3 . The skilled person will also know that such a buoyant rope may comprise a part of the mesh thread of the net 3 .
[0042] The foregoing description details certain preferred embodiments of the present invention and describes the best mode contemplated. It will be appreciated, however, that changes may be made in the details of construction and the configuration of components without departing from the spirit and scope of the disclosure. Therefore, the description provided herein is to be considered exemplary, rather than limiting, and the true scope of the invention is that defined by the following claims and the full range of equivalency to which each element thereof is entitled. | A device for concentration of material on a water surface, wherein the device forms a front opening and is provided with buoyancy bodies and guide elements structured for guiding the material towards a collection portion, wherein the device is structured for admitting water through the device in the flow direction of the water, and wherein the device, in a portion thereof, is provided with at least two consecutive guide elements in the flow direction of the water. | 4 |
This work was in part supported by a grant from the National Institutes of Health (GM42798 and CA13038).
FIELD OF INVENTION
The present invention relates to new taxoids possessing strong reversing activities for drug-resistance associated with anticancer agents, the preparation of these reversal agents, and pharmaceutical compositions thereof.
BACKGROUND OF THE INVENTION
Clinical drug resistance is a serious obstacle in any cancer chemotherapy. Although the cause of this drug resistance is complex, it has been shown that multi-drug resistance (MDR) observed in tumor models is the major cause of the clinical drug resistance, at least for several types of common cancers including breast cancer Sikic B. I. "Modulation of Multidrug Resistance: At the Threshold", J. Clin. Oncol., 1993, 11, 1629-1635!. Multi-drug resistance (MDR) is defined as cross-resistance to various structurally different cytotoxic (antitumor) agents, which is caused by increased outward transport of these agents through the plasma membrane by the action of P-glycoprotein as described by Sikic, B. I. in "Modulation of Multidrug Resistance: At the Threshold", J, Clin. Oncol., 11, 1629-1635, 1993. In other words, P-glycoprotein is over-expressed (mdr1 gene) in MDR cancer cells, which binds to cytotoxic (antitumor) agents and pumps them out. Several "reversal agents", i.e., MDR modulators, have been found such as cyclosporin A (immunodepressant) and verapamil (antihypertensive). Although these agents were not specially designed nor developed for the modulation of MDR, combined therapy with MDR-related antitumor agents with a modulator indeed shrinks tumors and prolongs life span in animal models. Modified versions of these agents, i.e., cyclosporin D (SDZ PSC 833) and dexverapamil, have been developed, which have recently shown some promising results in human clinical trails as discussed by Sikic, B. I. in "Modulation of Multidrug Resistance: At the Threshold", J. Clin. Oncol., 11, 1629-1635, 1993; and in Anti-Cancer Drugs, 5, Supplement 1, pp 58-73 1995; featuring "1st International Conference on Reversal of Multidrug Resistance in Cancer". It appears that the reversal agents also referred to as MDR modulators bind to P-glycoprotein and increase the accumulation and retention of anticancer drugs, thereby providing a biochemical and/or pharmacological basis for their action.
Cells that express mdr1 are found to be cross-resistant to anthracyclines, vinca alkaloids, podophyllotoxins, and taxanes. Among these drugs, it has been shown that Taxol® (paclitaxel) demonstrates highest degree of cross-resistance in MDR cells. Taxol® and Taxotere® (docetaxel) are currently considered among the most exciting drugs in cancer chemotherapy as more specifically described in "Taxane Anticancer Agents: Basic Science and Current Status", by George, G. I.; Chen, T. T.; Ojima, I.; Vyas, D. M. (EDs.), ACS Symp Ser. 583, American Chemical Society, Washington, D.C., 1995. Taxol® and Taxotere® possesses high cytotoxicity and strong antitumor activity against different cancers which have not been effectively treated by existing anticancer drugs. In 1992 FDA approval was obtained for Taxol® for the treatment of advanced ovarian cancer and in 1994 for treatment of metastatic breast cancer. FDA approval was also obtained for Taxotere® for the treatment of breast cancer in 1996. However, clinical drug resistance has already been observed and will become a difficult problem to overcome when the usage of these drugs increases. Such drug resistance has been a serious problem for the use of anthracyclines such as daunorubicin, doxorubicin, and idarubicin, vinca alkaloids such as vincristine, vinblastine, navelbine, podophyllotoxins such as etoposide and teniposide, and dactinomycin. Consequently, it is extremely important to discover and develop efficient reversal agents for MDR so that clinical oncologists can continue treatment of cancer patients with available anticancer drugs, including Taxol® and Taxotere®.
Kobayashi et al. recently reported that non-crytotoxic taxanes 1-4 isolated from the Japanese yew. Taxus cuspidata Sieb et Zucc, show strong effects on the accumulation of vincristine in MDR cells which are better than those of verapamil in "Taxuspines A˜C, New Taxoids from Japanese Yew Taxus Cuspidata Inhibiting Drug Transport Activity of P-Glycoprotein in Multidrug-resistant Cells", Kobayashi, J. et al. Tetrahedron, 25, 7401-7416, 1994. ##STR2##
During our research on the development of new taxoid antitumor agents and their photoaffinity labels, we synthesized SB-T-5101. SB-T-5101 binds to microtubules as expected, but it has also been found that this compound binds to P-glycoprotein in Taxol-resistant cells (T1 cells) as well as vinblastine-resistant cells which are also cross-resistant to Taxol (V1 cells): SB-T-5101 binds to both mdr 1a (major) and mdr 1b (minor) in T1 cells, but it only binds to mdr 1b in V1 cells as shown by Ojima, I., et al. in "A New Paclitaxel Photoaffinity Analog with a 3-(4-benzoylphenyl)propanoyl Probe for Characterization of Drug-Binding Sites on Tubulin and P-Glycoprotein." J. Med. Chem. 38, 3891-3894, 1995. It should be noted that SB-T-5101 does not bind to other proteins, and thus no photoaffinity labeling is observed for non-drug resistant J7 (parent) cells. ##STR3##
Accordingly, it is an objective of the present invention to develop new and efficient reversal agents for multi-drug resistance (MDR) in cancer cells and tumors based on the taxoid skeleton.
It is a further object of the present invention to develop reversal agents which will prevent multidrug resistance associated with the use of anthracyclines, Taxol®, Taxotere®, vinblastine and vincristine.
SUMMARY OF THE INVENTION
The present invention which addresses the needs of the prior art, provides compound of the formula (I). ##STR4## wherein R 1 , R 2 or R 3 represents a radical of the formula R 4 --(A) k --(R 5 ) m --(B) n or R 7 ;
R 4 is a substituted or unsubstituted alkyl, alkenyl, aryl, heteroaryl or alicyclic radical;
A is an oxygen, sulfur, or --NR 6 -- radical in which R 6 is a hydrogen or R 4 ;
R 5 is a substituted or unsubstituted alkylidene, alkenylidene, alkynylidene radical;
B is a carbonyl, --OC(O)-- or --NR 6 -- radical;
k, m, and n are numbers selected from 0 and 1, however, k, m, and n are not 0 at the same time;
R 7 is a hydroxy protecting group, an acyl, carbomoyl, N-substituted carbamoyl or N, N-disubstituted carbamoyl radical or a hydrogen;
wherein R 1 , R 2 , and R 3 are not R 7 at the same time and R 1 , R 2 and R 3 are not H at the same time;
Y is a hydrogen, a hydroxyl, or R 1 O-- radical wherein R1 is defined above;
Z is a hydroxyl radical;
Y and Z can be connected to form a cyclic structure.
Compounds of the formula I are useful as reversal agents for drug-resistance in cancer chemotherapy.
In a preferred embodiment in formula I, whenever R 1 is R 7 , R 7 is not H.
The new taxoids for formula (I) are synthesized by the modification of naturally occurring 10 -deacetylbaccatin III (II) and 14β-hydroxyl-10-deacetylbaccatin III (III). ##STR5##
In another embodiment R 1 represents a radical of the formula R 4# --(A) k --(R 5 ) m --(B) n , wherein R 4# is an aryl or heteroaryl radical substituted by one or more hydrophobic groups, cycloalkyl, cycloalkenyl, polycycloalkyl, polycycloalkenyl, polycyclic aryl, or polycyclic heteroaryl radical.
R 4 represents a straight chain or branched alkyl radical containing 1 to 10 carbon atoms, a straight chain or branched alkenyl radical containing 2 to 10 carbon atoms, or a straight chain or branched alkenyl radical containing 2 to 20 carbon atoms, a cycloalkyl radical containing 3 to 10 carbon atoms, a heterocycloalkyl radical containing 3 to 10 carbon atoms, a cycloalkenyl radical containing 3 to 10 carbon atoms, a heterocycloalkenyl radical containing 3 to 10 carbon atoms, a polycycloalkyl radical containing 6 to 20 carbon atoms, an aryl radical containing 6 to 20 carbons, a heteroaryl radical containing 3 to 20 carbon atoms; these radicals being optionally substituted with one or more halogen, hydroxyl, alkoxy, aryloxy, heteroaryloxy, amino, alkylamino, dialkylamino, mercapto, alkylthio, arylthio, heteroarylthio, cyano, carboxyl, alkoxycarbonyl the alkyl portion of which containing 1 to 15 carbon atoms, aryloxycarbonyl the aryl portion of which containing 6 to 20 carbon atoms, or heteroaryloxycarbonyl the heteroaryl portion of which containing 3 to 15 carbon atoms;
R 5 is a straight chain or branched alkylidene, alkenylidene, alkynylidene radical containing 1 to 15 carbons;
R 6 is a hydrogen or R 4 ;
R 7 is a hydroxy protecting group, an acyl radical containing 1 to 20 carbons, carbamoyl group, N-substituted carbamoyl radical containing 1 to 20 carbons, or N,N-disubstituted carbamoyl radical containing 2 to 40 carbon.
R 4 can also be an alkyl radical selected from methyl, ethyl, propyl, isopropyl, butyl, isobutyl, tert-butyl, pentyl, isopentyl, neopentyl, hexyl, heptyl, octyl, nonyl, decyl, cyclohexylmethyl, cyclohexylethyl, benzyl, phenylethyl, cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl, cyclooctyl, and adamantyl,
or an alkenyl radical selected from ethenyl, propenyl, butenyl, pentenyl, hexenyl, heptenyl, octenyl, nonenyl, decenyl, 2-phenylethenyl, 2-furylethenyl, 2-pyrrolylethenyl, 2-pyridylethenyl, 2-thienylethyl,
or an an unsubstituted or substituted alkynyl radical selected from ethynyl, propynyl, butynyl, pentynyl, hexynyl, heptynyl, octynyl, nonynyl, decynyl,
or an aryl radical selected from phenyl tolyl, methoxyphenyl dimethoxyphenyl, fluorophenyl, trifluoromethylphenyl, chlorophenyl, dimethylaminophenyl, chlorophenyl, acetylphenyl, pivaloylphenyl, benzoylphenyl, methoxylcarbonylphenyl, tert-butoxycarbonylphenyl, naphthyl, methoxynaphthyl, chloronaphthyl, acetylnaphthyl, benzoylnaphthyl, anthracenyl, phenanthrenyl,
or a heteroaryl radical selected from furyl, pyrrolyl, pyridyl, thienyl, benzofuryl, benzopyrrolyl, benzothienyl, quinolinyl, indolyl, N-acetylindolyl, N-methylindolyl, N-allylindolyl,
or a cycloalkenyl radical selected from cyclopropyl, cyclopentenyl, cyclohexenyl and cycloheptenyl,
or a heterocycloalkyl selected from oxiranyl, pyrrolidinyl, piperidinyl, morpholinyl, tetrahydrofuryl, and tettrahydropyranyl,
or a heterocycloalkenyl radical selected from dihydrofuryl, dihydropyrrolyl, dihydropiranyl, dihydropyridyl;
R 6 is a hydrogen or R 4 .
(A) k --(R 5 ) m --(B) n is an α-, β-, or ω-hydroxyalkanoic acid residue, α-, β-, or ω-mercaptoalkanoic acid residue, or α-, β-, or ω-amino acid residue, wherein k=n=1
or ω-hydroxyalkyl, ω-mercaptoalkyl, or ω-aminoalkyl residue, wherein k=1 and n=0.
R 4 can also be selected from benzoylphenyl, naphthyl, phenoxylphenyl, methoxyphenyl, ethoxyphenyl, isopropoxyphenyl, tert-butoxyphenyl, anthracenyl, phenathrenyl, isopropylphenyl, tert-butylphenyl, trimethylsilylphenyl;
(A) k --(R 5 ) m --(B) n is a hydroxyalkanoic acid residue selected from hydroxyacetyl, hydroxypropyl, and hydroxybutyl,
or a mercaptoalkanoic acid residue selected from mercaptoacetyl, mercaptopropanoyl, mercaptobutanoyl,
or an amino acid residue selected from, glycinyl, alanyl, β-alanyl, 4-aminobutanoyl, valyl, leucyl, isoleucyl, methionyl, phenylalanyl, tryptophanyl.
R 7 is also a hydroxyl protecting group selected from methoxylmethyl (MOM), methoxyethyl (MEM), 1-ethoxyethyl (EE), benzyloxymethyl, (β-trimethylsilylethoxyl)methyl, tettrahydropyranyl, 2,2,2-trichloroethoxylcarbonyl (troc), benzyloxycarbonyl (Cbz), tert-butoxycarbonyl (t-Boc), 9-fluorenylmethoxycarbonyl (Fmoc), 2,2,2-trichloroethoxymethyl, trimethylsilyl, triethylsilyl (TES), tripropylsilyl, dimethylethylsilyl, (tert-butyl)dimethylsilyl (TBS), diethylmethylsilyl, dimethylphenylsilyl and diphenylmethylsilyl,
or an acyl radical selected from acetyl, chloroacetyl, dichloroacetyl, trichloroacetyl, trifluoroacetyl, propanoyl, butanoyl, pentanoyl, hexanoyl, heptanoyl, cyclohexanecarbonyl, octanoyl, nonanoyl, decanoyl, undecanoyl, dodecanoyl, benzoyl, phenylacetyl, naphthalenecarbonyl, indoleacetyl, cyclopropanecarbonyl, fluorobenzoyl, chlorobenzoyl, azidobencyol, 2-propenoyl, 2-butenoyl, 2-methyl-1-propenoyl, 2-methyl-2-butenoyl, 3-methyl-2-butenoyl readical,
or an N-substituted or N,N-disubstituted carbamoyl radical selected from N-methylcarbamoyl, N-ethylcarbamoyl, N-propylcarbamoyl, N-isopropylcarbamoyl, N-butylcarbamoyl, N-pentylcarbamoyl, N-hexylcarbamoyl, N,N-diemthylcarbamoyl, N,N-diethylcarbamoyl, N,N-dipropylcarbamoyl, N,N-dibutylcarbamoyl, pyrrolidine-N-carbonyl, piperidine-N-carbonyl, morpholine-N-carbonyl.
Y and Z are connected to form a carbonate, thiocarbonate, sulfate, sufite, ketal, or acetal.
R 1 , R 2 or R 3 is selected from 3-(benzolyphenyl)-2-propenoyl, 3-naphthyl-2-propenoyl, 3-biphenyl-2-propenoyl, 3-(phenoxyphenyl)-2-propenoyl, 3-(methoxyphenyl)-2-propenoyl, 3-(ethoxyphenyl)-2-propenoyl, 3-(isopropoxyphenyl)-2-propenoyl, 3-(tert-butoxyphenyl)-2-propenoyl, 3-(isopropylphenyl)-2-propenoyl, 3-(tert-butylphenyl)-2-propenoyl, 3-(trimethylsilylphenyl)-2-propenoyl, 3-anthracenyl-2-propenoyl, 3-phenanthrenyl-2-propenoyl, (benzoylphenyl)acetyl, naphthylacetyl, indoeacetyl, (N-acetyl)indoleacetyl, 3-(benzoylphenyl)propanoyl, 3-naphthylpropanoyl, 3-(biphenyl)propanoyl, 3-(phenoxyphenyl)propanoyl, 3-(methoxyphenyl)propanoyl, 3-(ethoxyphenyl)propanoyl, 3-(isopropoxyphenyl)propanoyl, 3-tert-butoxyphenyl)propanoyl, 3-(isopropylphenyl)propanoyl, 3-(tert-butylphenyl)propanoyl, 3-(trimethylsilylphenyl)propanoyl, 4-(benzoylphenyl)butanoyl, 4-naphthylbutanoyl, 5-(benzoylphenyl)pentanoyl, 5-naphthylpentanoyl, 6-(benzoylphenyl)hexanoyl, 6-naphthylhexanoyl, 3-(anthracenyl)propanoyl, 4-(anthracenyl)butanoyl, 5-(anthracenyl)pentanoyl, 6-(anthracenyl)hexanoyl, 3-(phenanthrenyl)propanoyl, 4-(phenanthrenyl)butanoyl, 5-(phenanthrenyl)pentanoyl, 6-(phenanthrenyl)hexanoyl, (benzoylphenyl)methyl, naphthylmethyl, 2-(benzoylphenyl)ethyl, 3-(benzoylphenyl)propyl, 3-naphthylpropyl, 4-(benzoylphenyl)butyl, 4-naphthylbutyl, 5-(benzoylphenyl)pentyl, 5-naphthylpentyl, 6-(benzoylphenyl)hexyl, 6-naphthylhexyl, 3-(anthracenyl)propyl, 4-(anthracenyl)butyl, 5-(anthracenyl)pentyl, 6-(anthracenyl)hexyl, 3-(phenanthrenyl)propyl, 4-(phenanthrenyl)butyl, 5-(phenanthrenyl)pentyl, 6-(phenanthrenyl)hexyl.
Y is an R 1 O radical;
R 1 is selected from 3-(benzoylphenyl)-2-propenoyl, 3-naphthyl-2-propenoyl, 3-biphenyl-2-propenoyl, 3-(phenoxyphenyl)-2-propenoyl, 3-(methoxyphenyl)-2-propenoyl, 3-(ethoxyphenyl)-2-propenoyl, 3-(isopropoxyphenyl)-2-propenoyl 3-(tert-butoxyphenyl)-2-propenoyl, 3-(isopropylphenyl)-2-propenoyl, 3-(tert-butylphenyl)-2-propenoyl, 3-(trimethylsilylphenyl)-2-propenoyl, 3-anthracenyl-2-propenoyl, 3-phenanthrenyl-2-propenoyl, (benzoylphenyl)acetyl, naphthylacetyl, indoleacetyl, (N-acetyl)indoleacetyl, 3-(benzoylphenyl)propanoyl, 3-naphthylpropanoyl, 3-(biphenyl)propanoyl, 3-(phenoxyphenyl)propanoyl, 3-(methoxyphenyl)propanoyl, 3-(ethoxyphenyl)propanoyl, 3-(isopropoxyphenyl)propanoyl, 3-(tert-butoxyphenyl)propanoyl, 3-(isopropylphenyl)propanoyl, 3-(tert-butylphenyl)propanoyl, 3-(trimethylsilylphenyl)propanoyl, 4-(benzoylphenyl)butanoyl, 4-naphthylbutanoyl, 5-(benzoylphenyl)pentanoyl, 5-naphthylpentanoyl, 6-(benzoylphenyl)hexanoyl, 6-naphthylhexanoyl, 3-(anthracenyl)propanoyl, 4-(anthracenyl)butanoyl, 5-(anthracenyl)pentanoyl, 6-(anthracenyl)hexanoyl, 3-(phenanthrenyl)propanoyl, 4-(phenanthrenyl)butanoyl, 5-(phenanthrenyl)pentanoyl, 6-(phenanthrenyl)hexanoyl, (benzoylphenyl)methyl, naphthylmethyl, 2-(benzoylphenyl)ethyl, 3-(benzoylphenyl)propyl, 3-naphthylpropyl, 4-(benzoylphenyl)butyl, 4-naphthylbutyl, 5-(benzoylphenyl)pentyl, 5-naphthylpentyl, 6-(benzoylphenyl)hexyl, 6-naphthylhexyl, 3-(anthracenyl)propyl, 4-(anthracenyl)butyl, 5-(anthracenyl)pentyl, 6-(anthracenyl)hexyl, 3-(phenanthrenyl)propyl, 4-(phenanthrenyl)butyl, 5-(phenanthrenyl)pentyl, 6-(phenanthrenyl)hexyl;
Z is a hydroxyl radical.
R 1 , R 2 or R 3 is selected from 3-(4-benzoylphenyl)-2-propenoyl, 3-(4-benzoylphenyl)propanoyl, 3-(2-naphthyl)-2-propenoyl, and 3-(2-naphthyl)propanoyl.
R 1 , R 2 or R 3 is selected from 3-(4-benzoylphenyl)-2-propenoyl, 3-(4-benzoylphenyl)propanoyl, 3-(2-naphthyl)-2-propenoyl, and 3-(2-naphthyl)propanoyl;
Y and Z are connected to form a carbonate, thiocarbonate, sulfate, sufite, ketal, or acetal.
R 1 and R 2 are selected from 3-(4-benzoylphenyl)-2-propenoyl, 3-(4-benzoylphenyl)propanoyl, 3-(2-naphthyl)-2-propenoyl, and 3-(2-naphthyl)propanoyl;
R 3 is a hydrogen or an acetyl radical;
Y is a hydrogen;
Z is a hydroxyl radical.
R 1 and R 2 are selected from 3-(4-benzoylphenyl)-2-propenoyl, 3-(4-benzoylphenyl)propanoyl, 3-(2-naphthyl)-2-propenoyl, and 3-(2-naphthyl)propanoyl;
R 3 is a hydrogen or an acetyl radical;
Y and Z are connected to form a carbonate, thiocarbonate, sulfate, sufite, ketal, or acetal.
R 1 and R 3 are selected from 3-(4-benzoylphenyl)-2-propenoyl, 3-(4-benzoylphenyl)propanoyl, 3-(2-naphthyl)-2-propenoyl, and 3-(2-naphthyl)propanoyl;
R 2 is a hydrogen or an acetyl radical;
Y is a hydrogen;
Z is a hydroxyl radical
R 2 and R 3 are selected from 3-(4-benzoylphenyl-2-propenoyl, 3-(4-benzoylphenyl)propanoyl, 3-(2-naphthyl)-2-propenoyl, and 3-(2-naphthyl)propanoyl;
R 1 is a hydrogen or an acetyl radical;
Y is a hydrogen;
Z is a hydroxyl radical.
R 1 , R 2 and R 3 are selected from 3-(4-benzoylphenyl)-2-propenoyl, 3-(4-benzoylphenyl)propanoyl, 3-(2-naphthyl)-2-propenoyl, and 3-(2-naphthyl)propanoyl;
Y is a hydrogen;
Z is a hydroxyl radical
The new taxoids of the present invention have shown strong drug-resistance reversal activity when used as a pharmaceutical composition with antrarydins, Taxol®, Taxotere®, vinblastine and vincristine.
Methods for treating tumors which include administrating to a patient an effective amount of paclitaxel or doxorubicin with an effective amount of drug-resistance reversal compound of of the formula I are also encompassed by the present invention. The multi-drug resistance agents of the present invention have been found to be particularly useful when treating tumors selected from the group consisting of leukemia, melanoma, breast, non-small cell lung, ovarian, renal and colon cancers.
For a better understanding of the present invention, together with other and further objects, reference is made to the following description and its scope will be pointed out in the appended claims.
DETAILED DESCRIPTION OF THE INVENTION
New taxoids of the formula (I) hereinabove are useful as reversal agents for drug-resistance in cancer chemotherapy. These taxoids posses strong reversing activities against drug-resistant cancer cells to convert them to drug-sensitive cancer cells so that coadministration of an anticancer agent with a reversal agent of the present invention provides an efficient treatment for such drug-resistant tumors. ##STR6##
The new taxoids of formula I are synthesized by the modification of naturally occurring 10-deacetylbaccatin III (II) and 14β-hydroxyl-10-deacetylbaccatin III (III) through transformations illustrated in SCHEMES 1-12. ##STR7##
As Scheme 1 above illustrates, 10-deacetylbaccatin III (II) is readily converted to 7-TES-10-deacetylbaccatin III (IV) (TES=triethylsilyl) in high yield following the literature procedure described by Ojima, I. et al., in "New and Efficient Approaches to the Semisynthesis of Taxol and Its C-13 Side Chain Analogs by Means of β-Lactam Synthon Method," Tetrahedron, 48, 6985-7012 1992 and; Mangatal, L. et al., in "Application of the Vicinal Oxyamination Reaction with Asymmetric Induction to the Hemisynthesis of Taxol and Analogues," Tetrahedron, 45, 4177-4190, 1989, the content of which is incorporated herein by reference as is set forth in full. The C-10 hydroxyl group is modified by reacting with R 4 --(A) k --(R 5 ) m --(B) n --X, typically in the presence of a base such as 4-dimethylaminopyridine (DMAP), lithium hexamethyldisilazide (LiHMDS), lithium diisopropylamide (LDA) to give compound VII. R 4 , R 5 , A, B, k, m, and n defined above. X represents a halogen, hydroxyl, acyloxy, tosyloxy, mesyloxy, trifluoromethansulfonyl oxy, N-oxysuccinimide, and other leaving groups, which will be eliminated after the modification.
The R 4 --(A) k --(R 5 ) m --(B) n --X modifiers have typically carboxylic acid, acid chloride, alkyl halide, carboxylic anhydride, or activated ester terminus. Triethylsilyl group at C-7 is readily removed by HF/pyridine to afford VIII. The C-7 position is easily modified by R 7 --X, in which R 7 and X are defined above, typically in the presence of a base such as 4-dimethylaminopyridine (DMAP), lithium hexamethyldisilazide (LiHMDS), lithium diisopropylamide (LDA) to yield X. This modification is specific to the C-7 position because of the substantial difference in the reactivity of the C-7 and C-13 hydroxyl groups in that the C-7 hydroxyl is much more reactive than the C-13 hydroxyl group. The hydroxyl group at C-1 does not have appreciable reactivity with alkylating and acylating agents. The C-13 position of VII is also readily modified with R 7 --X, followed by deprotection with HF/pyridine to give IX. ##STR8##
As Scheme 2 above illustrates, 7-TES-10-deacetylbaccatin III(IV) is readily modified at C-10 by reacting with R 7 --X in the presence of a base to give XI. The compound XI reacts with R 4 --(A) k --(R 5 ) m --(B) n --X as defined above to afford XII, which is readily desilylated at C-7 to give XIII. The C-7 desilylation of XII followed by modification with R 4' --(A') k --(R 5' ) m --(B') n --X at the C-7 position affords XV which has two hydrophobic tethers at C-7 and C-13. R 4' , R 5' , A', and B' simply indicate that each of these components is selected from R 4 , R 5 , A, and B defined above, but R 4' --(A') k --(R 5' ) m --(B') n moiety is not necessarily the same as R 4 --(A) k --(R 5 ) m --(B) n in this molecule. The desilylated C-7 position of compound XIII can be easily modified with R 7* --X to give XIV. R 7* is selected from R 7 defined above, but R 7* is not necessarily the same as R 7 in this molecule. ##STR9##
As Scheme 3 above shows, the baccatin derivative XI is deprotected at C-7 to give XVI, which is easily modified at C-13 with R 7* --X to afford XVII wherein R 7* --X is as defined above. Then, XVII is readily converted to XVIII through the coupling reaction with R 4 --(A) k --(R 5 ) m --(B) n --X. The baccatin derivative XI can also be desilylated at C-7 by HF/pyridine to give XVI', which reacts with R 4 --(A) k --(R 5 ) m --(B) n --X to afford XVIII'. This taxoid XVIII' is derived to XVIII with modification at C-13 with R 7* --X. ##STR10##
As Scheme 4 above shows, the C-13 position of VII is easily modified with R 4' --(A') k --(R 5' ) m --(B') n --X wherein R 4' , R 5' , A', and B' are as defined above to give XIX. Desilylation of XIX affords XX which has two hydrophobic tethers at C-10 and C-13. Modification of the C-7 position of XX with R 7 --X yields XXI. ##STR11##
As Scheme 5 above illustrates, the C-7 position of VII can be selectively modified with R 4' --(A') k --(R 5' ) m --(B') n --X to give XXII. Further modification of the C-13 position of XXII with R 7 --X affords XXIII. ##STR12##
As Scheme 6 above shows, the C-7 position of XIII is readily modified with R 4' --(A') k --(R 5' ) m --(B') n --X in the presence of a base to give XXIV which has two hydrophobic tethers at C-7 and C-13. ##STR13##
As Scheme 7 above indicates, the C-7 position of XX can easily be modified with R 4" --(A") n --(R 5" ) m --(B") n --X to give XXV which has three hydrophobic tethers at C-7, C-10, and C-13. R 4" , R 5" , A", and B" are selected from R 4 , R 5 , A, and B defined above, but R 4 --(A) k --(R 5 ) m --(B) n , R 4' --(A') k --(R 5' ) m --(B') n , and R 4" --(A") n --(R 5" ) m --(B")n are not necessarily the same group in this molecule. ##STR14##
For the syntheses of taxoid I bearing R 4 --(A) k --(R 5 ) m --(B) n or R 7 at C-7, the intermediates XXVI and XXVII can be prepared by directly modifying the C-7 hydroxyl group of 10-deacetylbaccatin III (II) with R 4 --(A) k --(R 5 ) m --(B) n --X or R 7 --X in the presence of a base as shown in Scheme 8 above, wherein the base can be DMAP, LiHMDS and LDA. Further modifications at C-10 and C-13 of compounds XXVI and XXVII can be carried out in the same manner as those shown in Schemes 1-7 shown above. ##STR15##
Scheme 9 above shows that 14β-hydroxyl-10-deacetylbaccatin III (III) is readily derivatized to key synthetic intermediates by the reaction with hydroxyl protecting groups such as triethylsilyl (TES) and 2,2,2-trichloroethoxycarbonyl chloride (troc-Cl) to give XXVIII and XXIX, following the literature procedure described by Kant, J. et al. in, "Synthesis and Antitumor Properties of Novel 14-β-Hydroxytaxol and Related Analogues", Bioorg. Med. Chem Lett. 1994, 1565 1994, and Ojima, I. et al. in "Structure-Activity Relationships of New Taxoids Derived from 14β-hydroxyl-10-deacetylbaccatin III", J. Med. Chem. 37, 1408-1410, 1994 which are incorporated herein by reference as if set forth in full. troc-Cl refers to 2,2,2-trichloroethoxylcarbonyl. As usual, the base can be pyridine, triethylamine, or imidazole.
The protected baccatins, XXVIII and XXIX, are further reacted with phosgene in toluene or chloroformates such as methyl chloroformate and troc-Cl in the presence of a base to give baccatin-1,4-carbonates, XXX and XXXI, respectively as shown in Scheme 10 below. Deprotections of the C-7 TES group of XXX with HF/pyridine and troc groups at C-7 and C-10 of XXXI with Zn in acetic acid (AcOH)/methanol afford 14β-hydroxyl-10-deacetylbaccatin-1,14-carbonated (XXXII), respectively, in high yields as shown in Scheme 10. ##STR16##
Because of a higher reactivity of the C-14hydroxyl group in comparison with the sterically hindered C-13 hydroxyl group, the selective modification of XXIX at C-14 is possible using R 4 --(A) k --(R5) m --(B) n --X or R 7 --X in the presence of a base, affording XXXIII and XXXIV as shown in Scheme 10 above. The 7,10-ditroc-14-modified baccatins, XXXIII and XXXIV, are readily deprotected by treatment with Zn in acetic acid/methanol to give XXXV and XXXVI, respectively as illustrated in Scheme 11 below. ##STR17##
As Scheme 11 shows, the synthetic intermediates XXVIII, XXIX, XXXII, XXXV, and XXXVI, thus obtained, are converted to taxoids I in the same manner as that used for the taxoids I derived from 10-deacetylbaccatin III (II) illustrated in Schemes 1-7. R 1' is selected from R 1 defined above, but R 1' is to necessarily the same as R 1 in this molecule. For the cyclic structure at C-1 and C-14 position, 1,14-carbonate is shown as an example. The cyclic structure can also be cyclic sulfonate (X,Y═O--SO2--O), cyclic sulfinate (X,Y═O--SO--O), acetal (X, Y═O--CHR--O), ketal (X, Y═O--CRR'--O) or thiocarbonate (O--C(S)--O), which are easily prepared from vicinal cis-diols.
The hydroxyl protecting group includes methoxylmethyl (MOM), methoxyethyl (MEM), 1-ethyoxyethyl (EE), benzyloxymethyl, (b-trimethylsilylethoxyl)methyl, tetrahydropyranyl, 2,2,2-trichloroethoxylcarbonyl (Troc), benzyloxycarbonyl (CBZ), tert-butoxycarbonyl (t-BOC), 9-fluorenylmethoxycarbonyl (Fmoc), 2,2,2-trichloroethoxymethyl, trimethylsilyl, triethylsilyl, tripropylsilyl, dimethylethylsilyl, dimethyl(t-butyl)silyl, diethylmethylsilyl, diethylmethylsilyl, dimethylphenylsilyl and diphenylmethylsilyl radical.
The hydroxyl protecting groups can then be removed by using the standard procedures which are generally know to those skilled in the art to give the desired baccatin derivatives. For example, EE and triethylsilyl groups can be removed with 0.5N HCl at room temperature for 12-36 hours, TIPS and TBDMS groups can be removed by treating with fluoride ion in a non-protic organic solvent, and Troc group can be removed with zinc and acetic acid in methanol at 60° C. for 1 hour without disturbing the other functional groups and the skeleton of the taxoids.
The compounds of the invention can be formulated in pharmaceutical preparations or formulated in the form of pharmaceutically acceptable salts thereof, particularly as nontoxic pharmaceutically acceptable acid addition salts or acceptable basic salts. These salts can be prepared from the compounds of the invention according to conventional chemical methods.
Normally, the salts are prepared by reacting free base or acid with stoichiometric amounts or with an excess thereof of the desired salt forming inorganic or organic acid in a suitable solvent or various combination of solvents. As an example, the free base can be dissolved in an aqueous solution of the appropriate acid and the salt recovered by standard techniques, for example, by evaporation of the solution. Alternatively, the free base can be dissolved in an organic solvent such as a lower alkanol, an ether, an alkyl ester, or mixtures thereof, for example, methanol, ethanol, ether, ethyl acetate, an ethyl acetate-ether solution, and the like, whereafter it is treated with the appropriate acid to form the corresponding salt. The salt is recovered by standard recovery techniques, for example, by filtration of the desired salt on spontaneous separation from the solution or it can be precipitated by the addition of a solvent in which the salt is insoluble and recovered therefrom.
Due to their MDR reversing activity, the taxane compounds of the invention can be utilized in the treatment of cancers together with anticancer agents such as paclitaxel, docetaxel, doxorubicin, vinblastine, and vincristine. The new compounds are administrable in the form of tablets, pills, powder mixtures, capsules, injectables, solutions, suppositories, emulsions, dispersions, food premix, and in other suitable forms. The pharmaceutical preparation which contains the compound is conveniently admixed with a nontoxic pharmaceutical organic carrier, usually about 0.01 mg. up to 2500 mg. or higher per dosage unit, preferably from about 50 to about 500 mg. Typical of pharmaceutically acceptable carriers are, for example, manitol, urea, dextrans, lactose, potato and maize starches, magnesium stearate, talc, vegetable oils, polyalkylene glycols, ethyl cellulose, poly(vinylpyrrolidone), calcium carbonate, ethyl oleats, isopropyl myristate, benzyl benzoate, sodium carbonate, gelatin, potassium carbonate, silicic acid, and other conventionally employed acceptable carriers. The pharmaceutical preparation may also contain nontoxic auxiliary substances such as emulsifying, preserving, wetting agents, and the like as for example, sorbitan monolaurate, triethanolamne oleate, polyoxyethylene monostearate, glyceryl tripalmitate, dioctyl sodium sulfosuccinate, and the like.
The compounds of the invention can also be freeze dried and, if desired, combined with other pharmaceutically acceptable excipients to prepare formulations suitable for parenteral, injectable administration. For such administration, the formulation can be reconstituted in water (normal, saline), or a mixture of water and an organic solvent, such as propylene glycol, ethanol, and the like.
The dose administered, whether a single dose, multiple does, or a daily dose, will, of course, vary with the particular compound of the invention employed because of the varying potency of the compound, the chosen route of administration, the size of the recipient and the nature of the patient's condition. The dosage administered is not subject to definite bounds, but it will usually be an effective amount, or the equivalent on a molar basis of the physiologically active free form produced from a dosage formulation upon the metabolic release of the active drug to achieve its desired pharmacological and physiological effects.
The following non-limiting examples are illustrative of the present invention. It should be noted that various changes would be made in the above examples and processes therein without departing from the scope of the present invention. For this reason, it is intended that the illustrative embodiments of the present application should be interpreted as being illustrative and not limiting in any sense.
EXAMPLE 1
Preparation of 7-Triethylsilyl-10-deacetylbaccatin III (IV)
To a stirred solution of 10-deacetylbaccatin III (2 mmol. 1.088 g) in dry pyridine (100 mL) was added dropwise previously distilled chlorotriethylsilane (40 mmol, 6 mL). After stirring the reaction mixture at room temperature for 24 h, pyridine was evaporated under reduced pressure and the crude was purified by column chromatography using ethyl acetate/hexane (1:1) as eluent, affording 1.018 g of 7-TES-10-deacetylbaccatin III (IV) as a white solid (78%).
Identification data for compound IV are shown as follows: 1 H NMR (300 MHz, CDCl 3 ) δ 0.49 (m, 6H), 0.87 (t, 7.9 Hz, 9H), 1.02 (s, 6H), 1.67 (s, 3H), 1.84 (m, 1H), 2.02 (s, 3H), 2.22 (s, 5H), 2.41 (m, 1H), 3.88 (d, 6.8 Hz, 3H), 4.10 (d, 8.4 Hz, 1H), 4.25 (d, 8.4 Hz, 1H), 4.34 (dd, 10.9 and 6.7 Hz, 1H), 4.81 (m, 1H), 4.89 (dd, 9.5 and 0.9 Hz, 1H), 5.11 (s, 1H), 5.54 (d, 7 Hz, 1H), 7.41 (t, 7.6 Hz, 2H), 7.54 (t, 7.1 Hz, 1H), 8.04 (d, 7.3 Hz, 2H); 13 C NMR (75 MHz, CDCl 3 ) δ 5.16, 6.73, 9.92, 15.13, 19.53, 22.58, 26.63, 37.23, 38.69, 46.99, 67.82, 72.94, 74.66, 74.85, 76.55, 84.27, 128.57, 129.33, 130.05, 133.57, 135.05, 141.81, 167.01, 170.75, 210.33.
EXAMPLE 2
Preparation of 7-triethylsilylbaccatin III (XIa)
To a stirred solution of IV prepared as in Example 1 (200 mg, 0.303 mmol) in dry THF (8 mL) lithium hexamethyldisilazide (LiHMDS) (370 μL, 0.37 mmol) was added dropwise at -40° C. After stirring for 10 min, freshly distilled acetyl chloride (0.703 mmol, 50 μL) was added dropwise and the reaction mixture was stirred for another 40 min at -40° C. The solvent was evaporated under reduced pressure and the crude product was purified by column chromatography on silica gel using ethyl acetate/hexane (1:1) as the eluant, providing 7-TES-bacccatin III (XIa) as a white solid (203 mg, 95% yield). Compound XIa is a specie of compound XI.
Identification data for compound XIa are shown as follows: 1 H NMR (300 MHz, CDCl 3 ) δ 0.56 (m, 6H), 0.91 (t, 7.9, 9H), 1.02 (s, 3H), 1.17 (s, 3H), 1.66 (s, 3H), 1.85 (m, 1H, 2.15 (s, 6H), 2.27 (s, 5H), 2.51 (m, 1H), 3.86 (d, 7 Hz, 1H), 4.12 (d, 8.2 Hz, 1H), 4.28 (d, 8.2 Hz, 1H), 4.47 (dd, 10.3-6.7 Hz, 1H), 4.81 (m, 1H), 4.93 (d, 9.5 Hz, 1H), 5.61 (d, 7 Hz, 1H), 6.44 (s, 1H), 7.45 (t, 7.6 Hz, 2H), 7.56 (t, 7.1 Hz, 1H), 8.08 (d, 7.3 Hz, 2H); 13 C NMR (63 MHz, CDCl 3 ) δ5.22, 6.71, 9.89, 14.91, 20.04, 20.91, 22.62, 26.74, 37.17, 38.23, 42.72, 47.20, 58.58, 67.83, 72.30, 74.67, 75.75, 76.48, 78.66, 80.76, 84.17, 128.54, 129.33, 130.04, 132.05, 133.57, 144.02, 169.35, 170.67, 202.23.
EXAMPLE 3
Preparation of baccatin III (XVI'a)
To a solution of 7-TES-baccatin III (290 mg, 0.414 mmol) in (1:1) pyridine/acetonitrile (30 mL) 70% hydrogen fluoride in pyridine (2.9 mL) was added dropwise at 0° C. Then the ice bath was removed and the mixture was allowed to stir at room temperature for 4 h. The reaction was quenched with saturated ammonium chloride solution (10 mL). The reaction mixture was extracted with ethyl acetate and the combined organic layers were washed with brine, dried over magnesium sulfate, filtered and concentrated in vacuo. Purification of the crude product by column chromatography on silica gel with ethyl acetate/hexane (2:1) as the eluant gave baccatin III (XVI'a) as a white solid (176 mg, 73% yield).
Identification data for compound XVI'a are shown as follows: 1 H NMR (300 MHz, CDCl 3 ) δ 0.96 (s, 6H), 1.53 (s, 3H), 1.70 (t, 2.65 Hz, 1H), 1.91 (s, 3H), 2.09 (s, 3H), 2.14 (s, 3H), 2.37 (m, 1H), 3.73 (d, 6.83 Hz, 1H), 4.02 (d, 8 Hz, 1H), 4.15 (d, 8 Hz, 1H), 4.33 (dd, 6.87+10 Hz, 1H), 4.72 (br s, 1H), 4.85 (d, 9.19 Hz, 1H), 5.48 (d, 6.92 Hz, 1H), 6.19 (s, 1H), 7.35 (m, 2H), 7.48 (m, 1H), 7.95 (m, 2H); 13 C NMR (75 MHz, CDCl 3 ) δ 9.42 14.09, 15.41, 20.78, 20.93, 22.38, 26.81, 35.57, 38.94, 42.60, 46.18, 58.48, 60.34, 67.48, 72.15, 74.99, 76.30, 78.84, 80.57, 84.39, 128.54, 129.44, 129,97, 131.34, 133.50, 146.91, 166.79, 170.48, 171.23, 204.24.
EXAMPLE 4
Preparation of 7-triethylsilyl-13-acetylbaccatin III (XVIa)
To a solution of 7-triethylsilyl-10-deacetylbaccatin III (200 mg, 0.3003 mmol) and dimethylaminopyridine (DMAP) (222 mg, 1.82 mmol) in dry dichloromethane (10 mL) acetic anhydride (2.3 mL, 24.4 mmol) was added slowly with stirring. After stirring at room temperature for 2 h, the reaction mixture was treated with a saturated aqueous solution of sodium bicarbonate (10 mL) and stirred for another 20 min. The reaction mixture was then extracted with dichloromethane (3×20 mL). The combined organic layers were washed with brine (25 mL) and dried over magnesium sulfate. The solvent was evaporated and the crude product was purified by column chromatography on silica gel with ethyl acetate/hexane (1:3, then 1:2) as the eluant to give 7-TES-13-Ac-baccatin III (XVIa) as a white solid (184 mg, 82% yield).
Identification data for compound XVIa are shown as follows: 1 H NMR (300 MHz, CDCl 3 ) δ 0.50 (m, 6H), 0.84 (t, 7.82 Hz, 9H), 1.07 (s, 3H), 1.12 (s, 3H), 1.56 (s, 3H), 1.80 (m, 1H), 1.95 (s, 3H), 2.09 (s, 3H), 2.11 (s, 3H), 2.12 (m, 2H), 2.25 (s, 3H), 2.44 (m, 1H), 3.74 (d, 6.92 Hz, 1H), 4.06 (d, 8.43 Hz, 1H), 4.21 (d, 8.43 Hz, 1H), 4.39 (m, 1H), 4.86 (d, 8.68 Hz, 1H), 5.57 (d, 7 Hz, 2H), 6.05 (t, 8.56 Hz, 1H), 6.37 (s, 1H), 7.38 (t, 7.5 Hz, 2H), 7.51 (t, 7.34 Hz, 1H), 7.98 (d, 7.38 Hz, 2H).
All compounds XVIIa-c are species of compound XVII. They are prepared as described herein.
EXAMPLE 5
Preparation of 13-acetylbaccatin III (XVIIa)
To a solution of 7-TES-13-Ac-baccatin III (184 mg, 0.247 mmol) in a 1:1 mixture of pyridine and acetonitrile (14 mL) a solution of 70% hydrogen fluoride in pyridine (1 mL) with stirring was added dropwise at 0° C. After stirring for 15 h at room temperature, the reaction was quenched with a saturated solution of ammonium chloride (10 mL) and ethyl acetate (10 mL) added. The aqueous layer was extracted with ethyl acetate (3×20 mL), then the combined organic layers were dried over magnesium sulfate and concentrated in vacuo. Purification of the crude product by column chromatography on silica gel with ethyl acetate/hexane (1:1, then 2:1) as the eluant gave 13-acetylbaccatin III (XVIIa) as a white solid (126 mg, 81% yield).
Identification data for XVIIa are set forth as follows: 1 H NMR (250 MHz, CDCl 3 ) δ 1.08 (s, 3H), 1.18 (s, 3H), 1.62 (s, 3H), 1.86 (m, 4H), 2.16 (s, 3H), 2.19 (s, 3H), 2.22 (m, 2H), 2.28 (s, 3H), 2.5 (m, 2H), 3.78 (d, 6.95 Hz, 1H), 4.12 (d, 8.38 Hz, 1H), 4.25 (d, 8.38 Hz, 1H), 4.38 (m, 1H), 4.92 (d, 7.94 Hz, 2H), 5.61 (d, 7.05 Hz, 1H), 6.13 (t, 8.06 Hz, 1H), 6.26 (s, 1H), 7.38 (t, 7.5 Hz, 2H), 7.51 (t, 7.34 Hz, 1H), 7.98 (d, 7.38 Hz, 2H); 13 C NMR (62.5 MHz, CDCl 3 ) δ 9.40, 14.96, 20.75, 20.92, 22.41, 26.53, 35.50, 35.67, 42.92, 45.74, 58.42, 69.62, 72.01, 74.86, 75.59, 76.26, 78.92, 80.91, 84.27, 93.07, 128.53, 129.14, 129.90, 142.68, 166.71, 169.66, 170.09, 171,10, 203.64.
EXAMPLE 6
Preparation of 7- N-carbobenzyloxyglycinyl!baccatin III (XVIIb)
To a solution of baccatin III (130 mg, 0.22 mmol), N-Cbz-glycine (69 mg, 0.33 mmol) and DMAP (14 mg, 0.11 mmol) in dry dichloromethane (10 mL) was added dicyclohexyl carbodiimide (DCC) (91 mg, 0.443 mmol) with stirring. After stirring for 3.5 h at room temperature, the white precipitate was filtrated off and the filtrate evaporated in vacuo. The crude product was purified by column chromatography on silica gel with ethyl acetate/hexane (1:1) as the eluant, giving 7-(N-Cbz-Gly)baccatin III (XVIIb) as a white solid (149 mg, 86% yield).
Identification data for XVIIb are set forth as follows: 1 H NMR (250 MHz, CDCl 3 ) δ 1.09 (s, 3H), 1.15 (s, 3H), 1.75 (s, 3H), 1.85 (m, 1H), 2.05 (s, 3H), 2.18 (s, 3H), 2.25 (s, 5H), 2.55 (m, 1H), 2.7 (d, 1H, OH), 3.8 (dd, 1H), 3.9-4.35 (m, 4 H), 4.85 (m, 1H), 4.95 (d, 1H), 5.1 (dd, 2H), 5.5 (m, 1H), 5.6 (d, 1H), 5.7 (dd, 1H), 6.15 (s, 1H), 7.28 (m, 5H), 7.42 (t, 2H), 7.55 (t, 1H), 8.1 (d, 2H); 13 C NMR (60 MHz, CDCl 3 ) δ 10.59, 15.21, 20.04, 20.86, 22.43, 24.86, 25.51, 26.53, 33.14, 33.82, 38.50, 42.66, 43.00, 47.36, 49.05, 56.08, 66.87, 67.59, 72.16, 74.22, 76.22, 78.48, 80.40, 83.82, 128.00, 128.02, 128.40, 128.56, 129.21, 129.99, 130.93, 133.61, 136.38, 145.29, 156.70, 166.82, 169.49, 169.76, 170.54, 202.28.
EXAMPLE 7
Preparation of 7-triethylsilyl-10- N-carbobenzyloxyglycinyl!-10 -deacetylbaccatin III (XVIIc)
To a solution of 7-TES-10-deacetylbaccatin III (20 mg, 0.030 mmol) in dry tetrahydrofuran THF (1 ML) LiHMDS was added dropwise (0.08 mmol, 80 μL) at -40° C. After stirring for 5 min, a solution of N-Cbz-glycinyloxysuccinimide (0.036 mmol), 11 mg) in dry THF (1 mL) was added at -40° C. The reaction mixture was stirred for 1 h with the temperature allowed to raise to 0° C., then quenched with a saturated solution of ammonium chloride (10 mL). The aqueous layer was extracted with ethyl acetate (3×15 mL) and the combined organic layers were concentrated in vacuo. The crude product was purified by column chromatography on silica gel with ethyl acetate/hexane (1.2, then 1:1) as the eluant, giving XVIIc as a white solid (14 mg, 77% conversion yield).
Identification data for XVIIc are listed as follows: 1 H NMR (CDCl 3 , 250 MHz) δ 0.58 (q, 6H), 0.91 (t, 9H), 1.0 (s, 3H), 1.13 (s, 3H), 1.26 (m, 1H), 1.66 (s, 3H), 1.86 (m, 1H), 2.15 (s, 3H), 2.26 (br s, 5H), 2.52 (m, 1H), 3.85 (d, 6.96 Hz, 1H), 4.12 (m, 3H), 4.28 (t, 8.28 Hz, 1H), 4.47 (m, 1H), 4.80 (m, 1H), 4.94 l(d, 8.27 Hz, 1H), 5.10 (s, 2H), 5.37 (m, 1H), 5.60 (d, 6.94 Hz, 1H), 6.49 (s, 1H), 7.33 (m, 5H), 7.45 (t, 2H), 7.58 (t, 1H), 8.08 (d, 2H); 13 C NMR (CDCl 3 , 62.5 MHz) δ 5.31, 6.77, 9.94, 15.03, 20.11, 22.64, 26.68, 37.20, 38.34, 42.67, 42.87, 47.23, 58.70, 67.14, 67.84, 72.39, 74.66, 76.59, 78.68, 68.80, 80.77, 84.16, 128.11, 128.15, 128.20, 128.53, 128.60, 129.37, 130.08, 132.06; 133.63, 136.13, 144.78, 156.70, 167.05, 168.37, 170.72, 201.93.
Compounds XVIII'a-d are species of compound XVIII'. They are prepared as described hereinbelow.
EXAMPLE 8
Synthesis of 7- 3-(2-naphthyl)-2-propenoyl!baccatin III (XVIII'a) (SB-RA-30011)
To a stirred solution of dry benzene (5 mL) 3-(2-naphthyl)-2-propenoic acid (0.746 mmol, 148 mg) and thionyl chloride (440 mg, 3.671 mmol) were added. After refluxing the mixture for 2.5 h, the solvent was evaporated in vacuo to give a yellowish solid. The solid was dissolved in 3 mL dry dichloromethane and slowly added to a stirred solution of 7-TES-baccatin III (96 mg, 0.163 mmol), 4-dimethylaminopyridine (DMAP) (0.163 mmol, 20 mg) and triethylamine (84 mg, 0.817 mmol) in dry methylene chloride (3 mL). After stirring for 19 h, the reaction mixture was washed with brine (10 mL), saturated sodium bicarbonate (2×15 mL) and brine again (2×15 mL). The organic phase was dried over magnesium sulfate, filtered and concentrated in vacuo. Purification of the crude product by column chromatography on silica gel using ethyl acetate/hexane (1:1) as the eluant were gave XVIII'a as a slightly yellow solid (68 mg, 54% yield).
Identification data for compound XVIII'a are shown as follows: mp 184°-186° C., α! D 22 -64.8° (c 0.54, CH 2 Cl 2 ); IR (KBr disk) 3489, 2945, 1719, 1635, 1438, 1371, 1236, 1164, 1109, 1069, 1018, 979, 912, 851, 816, 710 cm -1 ; 1 H NMR (300 MHz, CDCl 3 ) δ 1.02 (s, 3H), 1.10 (s, 3H), 1.85 (s, 4H), 2 (s, 3H), 2.10 (s, 3H), 2.25 (s, 5H), 2.68 (m, 1H), 4.02 (d, 6.78 Hz, 1H), 4.13 (d, 8.3 Hz, 1H), 4.29 (d, 8.3 Hz, 1H), 4.81 (m, 1H), 4.97 (d, 8.9 Hz, 1H), 5.62 (d, 6.93 Hz, 1H), 5.69 (dd, 7.39+10.13 Hz, 1H), 6.35 (s, 1H), 6.40 (d, 16 Hz, 1H), 7.39-7.88 (m, 11H), 8.06 (d, 7.38 Hz, 2H); 13 C NMR (75 MHz, CDCl 3 ) δ 10.87, 15.15, 20.16, 20.62, 22.53, 26.62, 33.48, 38.63, 42.80, 47.41, 56.37, 67.82, 71.95, 74.51, 75.73, 76.37, 78.63, 80.68, 84.09, 118.34, 123.87, 126.54, 127.05, 127.70, 128.45, 128.54, 128.60, 129.37, 129.86, 130.06, 131.73, 132.14, 133.27, 133.62, 134.16, 144.80, 165.82, 166.94, 168.62, 170.64, 202.70. Anal. Calcd. for C 44 H 46 O 12 : C, 68.92; H, 6.05. Found: C, 69.09; H, 6.25.
EXAMPLE 9
7- 3-(2-Naphthyl)propanoyl!baccatin III (XVIII'b) (SB-RA-30021)
3(2-naphtyl)propanoic acid 2 (116 mg, 0.583 mmol) and thionyl chloride (340 mg, 2.86 mmol) were added to a stirred solution of dry benzene (5 mL). After refluxing the mixture for 2.5 h, the solvent was evaporated in vacuo to give a yellowish solid. The solid was dissolved in 3 mL dry methylene chloride and slowly added to a stirred solution of baccatin III (120 mg, 0.204 mmol), DMAP (25 mg, 0.204 mmol) and triethylamine (82 mg, 0.816 mmol) in dry methylene chloride (3 mL). After stirring for 14 h, the reaction mixture was washed with brine (10 mL), saturated sodium bicarbonate (10 mL) and brine again (2×10 mL). The organic layer was dried over magnesium sulfate, filtered and concentrated in vacuo. Purification of the crude product by column chromatography on silica gel with ethyl acetate/hexane (1:1) as the eluant gave XVIII'b as a white solid (104 mg, 66% yield).
Identification data for XVIII'b are set forth as follows: mp 222°-223° C., α! D 22 -77° (c 0.87, CH 2 Cl 2 ); IR (KBr disk) 3419, 2950, 1718, 1375, 1243, 1066 cm -1 , 1 H NMR (300 MHz, CDCl 3 ) δ 1.01 (s, 3H), 1.07 (s, 3H), 1.67 (m, 1H), 1.72 (s, 3H), 2.05 (s, 3H), 2.13 (s, 3H), 2.22 (s, 5H), 2.45 (m, 1H), 2.63 (m, 1H), 2.72 (m, 1H), 3.02 (m, 2H), 3.81 (d, 6.89 Hz, 1H), 4.02 (d, 8.3 Hz, 1H), 4.24 (d, 8.3 Hz, 1H), 4.78 (t, 8.21 Hz, 1H), 4.87 (d, 8.39 Hz, 1H), 5.58 (m, 2H), 6.25 (s, 1H), 7.23-7.73 (m, 10H), 8.04 (d, 7.4 Hz, 2H); 13 C NMR (75 MHz, CDCl 3 ) δ 10.76, 14.18, 15.21, 20.15, 20.83, 21, 22.53, 26.66, 30.62, 33.33, 35.57, 38.61, 42.82, 47.44, 56.22, 60.40, 67.85, 71.65, 74.47, 75.92, 76.33, 78.63, 80.68, 83.99, 125.21, 125.89, 126.35, 127.15, 127.46, 127.58, 127.91, 128.63, 129.37, 130.09, 131.62, 132.12, 133.65, 138.39, 144.79, 166.96, 169, 170.64, 172.12, 202.43. Anal. Calcd. for C 44 H 48 O 12 : C, 68.57; H, 6.40. Found: C, 68.74; H, 6.29.
EXAMPLE 10
7- 4-Benzoylcinnamoyl!baccatin III (XVIII'c) (SB-RA-31011)
To a stirring solution of baccatin III (37 mg, 0.063 mmol) and DMAP (46 mg, 0.378 mmol) in dry dichloromethane (3 mL) a solution of 4-benzoylcinnamyl chloride (48 mg, 0.189 mmol) in dry dichloromethane (2 mL) was slowly added. After stirring for 3 h, the reaction was quenched with a saturated solution of ammonium chloride (10 mL) and extracted with dichloromethane (3×15 mL). The organic layer was washed with a saturated solution of sodium bicarbonate (10 mL) and dried over magnesium sulfate, filtered and concentrated in vacuo. Purification of the crude product by column chromatography on silica gel with ethyl acetate/hexane (1:3, then 1:1) as the eluant gave XVIII'c as a white solid (25 mg, 50% yield).
Identification data for XVIII'c are given as follows: mp 165°-168° C. α! D 20 -70.6° (c 0.016, CH 2 Cl 2 ); IR (KBr disk) 3518, 3068, 2968, 1723, 1652, 1601, 1371, 1314, 1238, 1162, 1069, 1019, 983, 707 cm -1 ; 1 H NMR (250 MHz, CDCl 3 ) δ 1.07 (s, 3H), 1.14 (s, 3H), 1.71 (m, 1H), 1.87 (s, 3H), 2.07 (s, 3H), 2.14 (s, 3H), 2.29 (m, 5H), 2.71 (m, 1H), 4.04 (d, 6.86 Hz, 1H), 4.17 (d, 8.3 Hz, 1H), 4.33 (d, 8.3 Hz, 1H), 4.86 (m, 1H), 5.00 (d, 8.81 Hz, 1H), 5.70 (m, 2H), 6.36 (s, 1H), 6.44 (d, 16 Hz, 1H), 7.45-7.81 (m, 13H), 8.10 (d, 7.33 Hz, 2H); 13 C NMR (60 MHz, CDCl 3 ) δ 10.83, 15.19, 20.12, 20.67, 22.54, 26.61, 33.41, 38.50, 42.77, 44.32, 47.37, 56.29, 67.84, 72.16, 74.39, 75.70, 76.34, 78.62, 80.61, 83.98, 120.64, 127.99, 128.35, 128.62, 129.28, 129.96, 130.07, 130.45, 131.68, 132.58, 133.68, 137.34, 138.46, 143.20, 144.79, 165.38, 166.96, 168.70, 170.67, 196.55, 202.63. Anal. Calcd. for C 47 H 48 O 13 ; C, 68.77; H, 5.89. Found: C, 68.54; H, 5.84.
EXAMPLE 11
7- 3-(4-Benzoylphenyl)propanoyl!baccatin III (XVIII'd) (SB-RA-31021)
A solution of 3-(4-benzoylphenyl)propanoic acid (60 mg, 0.234 mmol) in neat thionyl chloride was stirred for 16 hours. Thereafter, thionyl chloride was evaporated on a rotary evaporator and the resulting yellow oil was dried under vacuum for 1 hour. The residual oil was dissolved in dry dichloromethane (1.5 mL) and slowly added to the stirred solution of baccatin III (80 mg, 0.136 mmol) and DMAP (20 mg, 0.164 mmol) in dry dichloromethane (1.5 mL). After stirring for 21 hours, the reaction was quenched with a saturated solution of ammonium chloride (10 mL) and extracted with dichloromethane (3×15 mL). The organic layer was washed with brine (20 mL) and dried over magnesium sulfate, filtered and concentrated in vacuo. Purification of the crude product by column chromatography on silica gel with ethyl acetate/hexane (1:1) then (3:2) as the eluant gave XVIII'd (86 mg, 79% yield) as a white solid.
Identification data for compound XVIII'd are provided as follows: 1 H NMR (250 MHz, CDCl 3 ) δ 1.05 (s, 3H), 1.11 (s, 3H), 1.71 (m, 1H), 1.76 (s, 3H), 2.08 (s, 3H), 2.16 (s, 3H), 2.26 (m, 5H), 2.5-2.73 (m, 3H), 2.99 (m, 2H), 3.97 (d, 6.78 Hz, 1H), 4.12 (d, 8.3 Hz, 1H), 4.28 (d, 8.3 Hz, 1H), 4.84 (t, 7.66 Hz, 1H), 4.93 (d, 8.73 Hz, 1H), 5.61 (m, 2H), 6.26 (s, 1H), 7.3 (d, 8.11 Hz, 2H), 7.44 (m, 4H), 7.55 (m, 2H), 7.72 (m, 4H), 8.04 (d, 7.2 Hz, 2H); 13 C NMR (62.5 MHz, CDCl 3 ) δ 10.67, 15.17, 20.06, 20.81, 22.45, 26.54, 30.36, 33.25, 35.11, 38.52, 42.7, 47.34, 56.05, 67.66, 71.7, 74.31, 75.84, 76.23, 78.5, 80.48, 83.84, 128.16, 128.25, 128.56, 129.24, 129.88, 130, 130.31, 131.31, 132.18, 133.6, 135.37, 137.73, 144.94, 146.05, 166.84, 169.03, 170.59, 171.72, 196.55, 202.39.
EXAMPLE 12
7-(2-Benzoylcinnamoyl)-13-acetylbaccatin III (XVIIIa) (SB-RA-31012)
To a stirring solution of 13-acetylbaccatin III (50 mg, 0.079 mmol) and DMAP (58 mg, 0.477 mmol) in dry dichloromethane (3 mL) a solution of 4-benzoylcinnamyl chloride (60 mg, 0.238 mmol) in dry dichloromethane (2 mL) was slowly added. After stirring for 6.5 hours, the reaction mixture was quenched with a saturated solution of ammonium chloride (10 mL) and extracted with dichloromethane (3×15 mL). The organic layer was washed with a saturated solution of sodium bicarbonate (20 mL) and dried over magnesium sulfate, filtered and concentrated in vacuo. Purification of the crude product by column chromatography on silic gel with ethyl acetate/hexane (1:3, then 1:1) as the eluant gave XVIIIa as a white solid (26 mg, 38% yield).
Identification data for compound XVIIIa are set forth as follows: mp 158°-161° C. α! D 20 -57.6° (c 1.7, CH 2 Cl 2 ); IR (KBr disk) 3491, 3021, 2949, 1724, 1659, 1603, 1449, 1372, 1273, 1239, 1161, 1069, 1019, 983, 708 cm -1 ; 1 H NMR (250 MHz, CDCl 3 ) δ 1.17 (s, 3H), 1.20 (s, 3H), 1.67 (s, 1H), 1.87 (s, 3H), 2.00 (m, 4H), 2.07 (s, 3H), 2.20 (s+m, 5H), 2.35 (s, 3H), 2.71 (m, 1H), 4.00 (d, 6.58 Hz, 1H), 4.18 (d, 8.35 Hz, 1H), 4.33 (d, 8.35 Hz, 1H), 4.99 (d, 9.67 Hz, 1H), 5.70 (m, 2H), 6.17 (t, 7.8 Hz, 1H), 6.36 (s, 1H), 6.44 (d, 16 Hz, 1H), 7.45-7.81 (m, 13H), 8.10 (d, 7.33 Hz, 2H); 13 C NMR (62.5 MHz, CDCl 3 ) δ 10.89, 14.77, 20.63, 20.71, 21.23, 22.47, 26.35, 33.4, 35.57, 43.11, 47.14, 56.21, 69.54, 71.95, 74.46, 75.21, 76.32, 78.80, 80.84, 83.94, 120.58, 128, 128.35, 128.67, 129.15, 129.97, 130.05, 130.46, 132.57, 133.78, 137.37, 138.4, 138.52, 141.48, 143.29, 165.33, 166.95, 168.65, 169.57, 170.21, 195.95, 202.28. Anal. Calcd, for C 49 H 50 O 14 : C, 68.20,H, 5.84. Found C, 68.18,H, 5.88.
EXAMPLE 13
7- 3-(2-Naphtyl)propanoyl!-13-acetylbaccatin III (XVIIIb) (SB-RA-30012)
A solution of 3-(2-naphtyl)propanoyl chloride (0.334 mmol, 66 mg) in dry dichloromethane (2 mL) was slowly added to a solution of 13-acetylbaccatin III (70 mg, 0.111 mmol) and DMAP (81 mg, 0.668 mmol) in dry dichloromethane (3 mL). After stirring for 2 hours, the reaction was quenched with a saturated solution of ammonium chloride (10 mL) and extracted with dichloromethane (3×15 mL). The organic layer was washed with a saturated solution of sodium bicarbonate (20 mL) and dried over magnesium sulfate, filtered and concentrated in vacuo. Purification of the crude product by column chromatography on silica gel with ethyl acetate/hexane (1:3, then 1:1) as the eluant, followed by recrystallization in ethyl acetate/hexane gave XVIIIb as a white solid (49 mg, 54% yield).
Identification data for XVIIIb are provided as follows: mp 181°-184° C.; α! D 20 -56.25° (c 0.16, CH 2 Cl 2 ); IR (KBr disk) 3460, 2954, 1747, 1722, 1633, 1436, 1371, 1314, 1236, 1149, 1065, 1022, 980, 713 cm -1 ; 1 H NMR (250 MHz, CDCl 3 ) δ 1.20 (s, 6H), 1.69 (s, 1H), 1.90 (s, 3H), 1.97 (m, 1H), 2.02 (s, 3H), 2.05 (s, 3H), 2.24 (m, 5H), 2.35 (s, 3H), 2.73 (m, 1H), 4.02 (d, 7 Hz, 1H), 4.19 (d, 8.06 Hz, 1H), 4.34 (d, 8.06 Hz, 1H), 5.01 (d, 8.62 Hz, 1H), 5.72 (m, 2H), 6.17 (t, 8.25 Hz, 1H), 6.40 (s, 1H), 6.46 (d, 16 Hz, 1H), 7.45-7.93 (m, 11H), 8.09 (d, 7.59 Hz, 2H); 13 C NMR (60 MHz, CDCl 3 ) δ 10.91, 14.77, 20.59, 20.70, 21.23, 22.47, 26.35, 33.44, 35.55, 43.10, 47.13, 56.26, 69.55, 71.69, 74.51, 75.18, 76.33, 78.82, 80.85, 84, 87.21, 118.3, 123.87, 126.55, 127.07, 127.71, 128.46, 128.55, 128.65, 129.17, 129.92, 130.04, 132.13, 132.62, 133.25, 134.16, 141.44, 144.83, 165.73, 166.94, 168.55, 169.49, 170.22, 202.36. Anal. Calcd. for C 46 H 48 O 13 ; C, 68.13; H, 5.98. Found: C, 68.50; H, 6.09
EXAMPLE 14
10- (4-Benzoyl)cinnamoyl!-10-deacetylbaccatin III (VIIIa) (SB-RA-4001)
To a solution of 7-TES-10-deacetylbaccatin III (144 mg, 0.218 mmol) in dry THF (5 mL) at -40° C. lithium hexamethyldisilazide (LiHMDS) (260 μL, 0.26 mmol) was added dropwise. After stirring for 5 min, 4-benzoylcinnamoyloxysuccinimide (78 mg, 0.24 mmol) in dry THF (4 mL) was added dropwise at -40° C. and the reaction mixture was stirred for another 30 min. The mixture was then warmed up to room temperature and quenched with 1M ammonium chloride (15 mL). The aqueous phase was extracted with dichloromethane and the organic layer was dried over magnesium sulfate, filtered and concentrated in vacuo. The crude product was purified by column chromatography on silica gel using ethyl acetate/hexane (1:1) as the eluant, giving 106 mg of a white solid. This solid was dissolved in 10 ml pyridine/acetonitrile (1:1) and the solution was cooled down to 0° C. Hydrogen fluoride (70% in pyridine, 1 mL) was added dropwise, then the ice bath was removed and the reaction mixture was allowed to stir at room temperature for 4 h. The reaction was quenched with saturated ammonium chloride solution (5 mL), the solution was extracted with ethyl acetate and the organic layer was washed with brine, dried over magnesium sulfate, filtered and concentrated in vacuo. Purification of the crude product by column chromatography on silica gel with ethyl acetate/hexane (1:1) as the eluant gave VIIIa as a white solid (57 mg, 34% yield).
Identification data for compound VIIIa are shown as follows: mp 250°-252° C.; α! D 20 -68.2° (c 0.44, CHCl 3 ); IR (KBr disk) 3425, 2950, 1721, 1662, 1639, 1560, 1445, 1400, 1317, 1274, 1166, 1110, 1024, 749, 700 cm -1 ; 1 H NMR (300 MHz, CDCl 3 -CD 3 OD) δ 1.03 (s, 3H), 1.07 (s, 3H), 1.58 (s, 3H), 1.77 (m, 1H), 1.98 (s, 3H), 2.19 (s, 5H), 2.45 (m, 1H), 3.81 (d, 6.95 Hz, 1H), 4.37 (d, 6.80 Hz, 1H), 4.40 (d, 6.80 Hz, 1H), 4.74 (t, 7.84 Hz, 1H), 4.91 (d, 8.38 Hz, 1H), 5.53 (d, 7 Hz, 1H), 6.40 (s, 1H), 6.58 (d, 16 Hz, 1H), 7.34-7.73 (m, 13H), 7.99 (d, 7.35 Hz, 2H); 13 C NMR (75 MHz, CDCl 3 -CD 3 OD) δ 9.42, 15.32, 20.99, 22.32, 26.86, 35.69, 38.69, 42.61, 46.44, 58.55, 60.43, 67.26, 71.86, 75.00, 76.40, 78.87, 80.72, 84.49, 119.55, 121.55, 128.03, 128.14, 128.34, 128.51, 129.42, 129.93, 130.47, 131.27, 132.71, 133.53, 137.11, 137.88, 138.85, 144.86, 147.26, 166.26, 166.94, 170.76, 196.16, 204.13. Anal. Calcd. for C 45 H 46 O 12 ; C, 69.40; H, 5.95. Found: C, 69.25; H, 5.86
Compounds XIVa-c are species of compound XIV. They are prepared as described hereinbelow.
EXAMPLE 15
13-(4-Benzoylcinnamoyl)-7,10-bis(2,2,2-trichloroethoxycarbonyl)baccatin III (XIVa) (SB-RA-1101)
To a magnetically stirred solution of 7,10-ditroc-baccatin III (100 mg, 0.11 mmol), which was readily prepared by the reaction of 10-deacetylbaccatin III (II) with 2,2,2-trichloroethyl chloroformate (troc-Cl) in pyridine, were added DMAP (14 mg, 0.11 mmol), 4-benzoylcimmamic acid (73 mg, 0.22 mmol), and dicyclohexylcarbodiimide (DCC) (454 mg, 2.20 mmol). All three of the latter compounds were added in toluene (10 mL) at room temperature. After 4 hours, TLC analysis showed no starting material. The mixture was concentrated and the dicyclohexylurea (DCU) and excess DCC were removed by passing through a silica gel column using hexane/EtOAc (1/1) as the eluant, which gave crude product. Purification of the crude product by column chromatography on silica gel using hexane/EtOAc (1:1) as the eluant afforded XIVa (105 mg, 83%) as a white solid.
Identification data for compound XIVa are given as follows: mp 179°-181° C. α! D -24.3° (c 0.54, CHCl 3 ); IR (CDCl 3 ) 3319, 3248, 2919, 2837, 1768, 1702, 1619, 1578, 1531, 1443, 1378, 1308, 1267, 1243, 1167, 1085, 985, 932, 697 cm -1 ; 1 H NMR (250 MHz, CDCl 3 ) δ 1.28 (s, 3H), 1.88 (s, 3H), 2.15 (s, 3H), 2.22 (m, 1H), 2.31 (s, 3H), 2.48 (m, 1H), 2.66 (m, 1H), 3.47 (m, 2H), 3.75 (m, 2H), 3.97 (d, J=7.2 Hz, 1H), 4.14 (m, 3H), 4.33 (d, J=8.1 Hz, 1H), 4.55 (d, J=11.8 Hz, 1H), 4.78 (s, 1H), 4.92 (d, J=11.8 Hz, 1H), 5.00 (d, J=8.1 Hz, 1H), 5.60 (m, 1H), 5.70 (d, J=6.5 Hz, 1H), 6.62 (d, J=16.0 Hz, 1H), 6.80 (s, 2H), 6.86 (m, 3H), 7.53 (m, 7H), 7.68 (m, 2H), 7.79 (m, 4H), 7.87 (d, J=7.2 Hz, 1H), 8.06 (d, J=7.5 Hz, 1H), 13 C NMR (63 MHz, CDCl 3 ) δ 9.8, 14.2, 14.4, 15.0, 20.1, 20.3, 21.0, 22.6, 24.8, 25.5, 26.3, 26.5, 33.8, 36.0, 36.5, 36.9, 37.0, 42.7, 46.5, 46.7, 49.3, 53.4, 57.6, 57.7, 60.4, 69.9, 70.2, 71.9, 72.1, 74.6, 75.9, 78.9, 81.0, 84.1, 116.9, 126.3, 126.6, 126.9, 127.1, 127.6, 127.9, 128.3, 128.5, 128.7, 129.2, 130.0, 133.7, 135.5, 135.7, 139.1, 139.2, 146.1, 146.7, 153.3, 153.5, 165.1, 169.5, 172.4, 200.6. Anal. Calcd. for C 51 H 50 C 16 O 15 ; C, 54.91; H, 4.52. Found: C, 54.88; H, 4.57.
EXAMPLE 16
13- 3-(2-Naphthyl)prop-2-enoyl!-7,10-bis(2,2,2-trichloroethoxycarbonyl)baccatin III (XIVb)
To a magnetically stirred solution of 7,10-ditroc-baccatin III (100 mg, 0.11 mmol) in dry toluene (10 mL) were added acid 3-(2-naphthyl)prop-2-enoic acid (44 mg, 0.22 mmol), DMAP (14 mg, 0.11 mmol), and DCC (454 mg, 2.20 mmol) at room temperature under N2. After stirring for 4 h, TLC analysis showed no starting material. The solvent was removed on a rotary evaporator and the residue was prepurified using silica gel chromatography with hexane/EtOAc (1:1) as the eluant to remove the excess DCC and DCU. Further purification of the crude product using hexane/EtOAc (3:1) as the eluant afforded XIVb (100 mg, 83%) as a white solid.
Identification data for compound XIVb are listed as follows: mp 171°-173° C.; α! 20 D -63.2° (c 0.19, CHCl 3 ); IR (CDCl 3 ) 3060, 2958, 1760, 1719, 1631, 1449, 1431, 1379, 1249, 1161, 1149, 1108, 1061, 979, 814, 720, 703 cm -1 ; 1 H NMR (250 MHz, CDCl 3 ) δ 1.22 (s, 3H), 1.73 (s, 1H), 1.89 (s, 3H), 2.19 (s, 3H), 2.09 (m, 1H), 2.26 (m, 1H), 2.33 (s, 3H), 2.51 (dd, J=9.1, 15.5 Hz, 1H), 2.69 (m, 1H), 4.00 (d, J=6.9 Hz, 1H), 4.19 (d, J=8.6 Hz, 1H), 4.33 (d, J=8.6 Hz, 1H), 4.33 (d, J=8.6 Hz, 1H), 4.62 (d, J=11.8 Hz, 1H), 4.79 (s, 2H), 4.94 (d, J=11.8 Hz, 1H), 5.02 (d, J=8.9 Hz, 1H), 5.64 (dd, J=7.3, 10.7 Hz, 1H), 5.72 (d, J=6.9 Hz, 1H), 6.23 (m, 1H), 6.32 (s, 1H), 6.63 (d, J=16.0 Hz, 1H), 7.47 (m, 2H), 7.58 (m, 3H), 7.71 (d, J=8.5 Hz, 1H), 7.89 (m, 3H), 8.05 (m, 4H); 13 C NMR (63 MHz, CDCl 3 ) δ 10.7, 15.4, 20.5, 22.6, 26.4, 33.4, 36.1, 42.9, 47.2, 56.3, 69.9, 74.1, 76.3, 76.6, 77.1, 77.4, 78.8, 79.3, 80.7, 83.6, 94.2, 116.9, 123.1, 127.0, 127.7, 127.8, 128.7, 129.0, 130.0, 130.6, 131.3, 131.8, 133.3, 133.8, 134.5, 143.4, 146.9, 153.3, 165.8, 166.8, 170.0, 200.8. Anal. Calcd. for C 48 H 46 C 16 O 15 ; C, 54.31; H, 4.56. Found: C, 54.27; H, 4.61.
EXAMPLE 17
13- 3-(2-Naphthyl)prop-2-enoyl!-10-deacetylbaccatin III (XIVc) (SB-RA-2001)
Activated zinc (0.45 g, 6.80 mmol) dust was added to a solution of XIVb (98 mg, 0.100 mol) in AcOH (1.5 mL) and MeOH (1.5 mL). The zinc dust was activated by washing with 10% HCl followed by rinsing with water until the washings became neutral. The zinc was then washed with ether and dried under vacuum overnight. The mixture was heated at 70° C. for 75 min. The reaction mixture was diluted with 100 mL of ethyl acetate and filtered. The filtrate was washed with aqueous saturated NaHCO3, water, and dried over MgSO4. After evaporation of the solvent, purification of the crude product by column chromatography on silica gel using hexane/EtOAc (1:1) as the eluant afforded XIVc (65 mg, 80%) as a white solid.
Identification data for compound XIVc are listed as follows: mp 189°-192° C.; α! 20 D -32.5° (c 0.40, CHCl 3 ); IR (CDCl 3 ) 3448, 2919, 1702, 1631, 1455, 1443, 1367, 1308, 1267, 1243, 1161, 1108, 1067, 1020, 967 cm -1 ; 1 H NMR (250 MHz, CDCl 3 ) δ 1.15 (s, 3H), 1.26 (s, 3H), 1.70 (m, 2H), 1.79 (s, 3H), 1.93 (m, 1H), 2.09 (s, 3H), 2.24 (m, 1H), 2.30 (s, 3H), 2.46 (dd, J=9.2, 16.0 Hz, 1H), 2.65 (m, 1H), 4.02 (d, J=7.0 Hz, 1H), 4.26 (m, 3H), 4.99 (d, J=8.3 Hz, 1H), 5.71 (d, J=7.0 Hz, 1H), 6.19 (m, 1H), 6.61 (d, J=16.0 Hz, 1H), 7.51 (m, 4H), 7.70 (d, J=9.2 Hz, 1H), 7.89 (m, 2H), 8.03 (m, 3H); 13 C NMR (63 MHz, CDCl 3 ) δ: 9.8, 15.1, 20.2, 22.6, 26.5, 36.5, 37.1, 42.9, 46.8, 57.7, 70.3, 72.1, 74.7, 76.6, 79.0, 81.0, 84.1, 117.1, 123.1, 126.4, 127.6, 127.8, 128.6, 128.9, 129.2, 130.0, 130.5, 131.4, 133.3, 133.7, 134.4, 135.8, 139.3, 143.9, 146.6, 166.3, 166.9, 211.5. Anal. Calcd. for C 42 H 46 O 10 : C, 70.97; H, 6.52. Found: C, 71.01; H, 6.55.
EXAMPLES 18-23
In a manner similar to the syntheses of modified baccatins (taxoids) described above, taxoids of the type XVIII' and XXII were synthesized in good yields as described below. Compounds XVIII'a-c and XXIIa-c are species of compounds XVIII' and XXII, respectively.
To a stirring solution of 7-TES-baccatin III in THF (0.015M) was added 1.2 equivalents of LiHMDS at -40° C. After the mixture was stirred for 5 min, a solution of the N-hydroxysuccinimide ester of 3-(4-benzoylphenyl)propanoic acid or 3-(2-naphtyl)prop-2-enoic acid in THF (1.2 equiv, 1 mL) was added dropwise at -40° C. with stirring. The mixture was warmed to -20° C. over the preiod of 30 min and then the reaction was quenched with saturated aqueous ammonium chloride. The aqueous layer was extracted with ethyl acetate and the combined organic layers were dried over magnesium sulfate, filtered and concentrated in vacuo. Purification of the crude product by flash chromatography on silica gel (eluant: hexane/EtOAc=1/1) afforded the corresponding 10-acyl-7-TES 10-deacetylbaccatin III as a white solid.
To a stirring solution of 10-acyl-7-TES 10-deacetylbaccatin III (0.011M), thus obtained, in a 1:1 mixture of pyridine and acetonitrile was added HF/pyridine (70/30) (1 mL/16 mg of the substrate) at 0° C. After stirring at room temperature for 16 h, the reaction was quenched with saturated aqueous ammonium chloride and extracted with ethyl acetate. The combined organic layers were washed with saturated aqueous copper sulfate and water, then dried over magnesium sulfate, filtered and concentrated in vacuo. Purification of the crude by flash chromatography on silica gel (eluant: hexane/EtOAc=1/2) afforded the corresponding 10-acyl-10-deacetylbaccatin III as a white solid.
To a stirring solution of 10-acyl-10-deacetylbaccatin III (0.015-0.02M), DMAP (0.2 equiv.) and 3-(2-naphtyl)propanoic acid, 3-(4-benzoylphenyl)propanoic acid or Cbz-glycine (1.2 equiv.) in dichloromethane was added. dicyclohexylcarbodiimide (DCC) (1.5 equiv.) at room temperature. After stirring for 16 hours, 1 equivalent of DCC was added. After 17-25 hours, the solvent was evaporated in vacuo. Purification of the crude by flash chromatography on silica gel (eluant: hexane/EtOAc=1/1) afforded the 10-acyl-7-acyl-10-deacetylbaccatin III as a white solid.
7-(N-Carbobenzoxyglycinyl)baccatin III (XVIII'a)
Identification data for Compound XVIII'a obtained in 82% yield are set forth as follows; 1 H NMR (250 MHz, CDCl 3 ) δ 1.09 (s, 3H), 1.15 (s, 3H), 1.75 (s, 3H), 1.85 (m, 1H), 2.05 (s, 3H), 2.18 (s, 3H), 2.25 (s, 5H), 2.55 (m, 1H), 2.7 (d, 1H, OH), 3.8 (dd, 1H), 3.9-4.35 (m, 4H), 4.85 (m, 1H), 4.95 (d, 1H), 5.1 (dd, 2H), 5.5 (m, 1H), 5.6 (d, 1H), 5.7 (dd, 1H), 6.15 (s, 1H), 7.28 (m, 5H), 7.42 (t, 2H), 7.55 (t, 1H), 8.1 (d, 2H); 13 C NMR (62.5 MHz, CDCl 3 ) δ 10.59, 15.21, 20.04, 20.86, 22.43, 24.86, 25.51, 26.53, 33.14, 33.82, 38.50, 42.66, 43.00, 47.36, 49.05, 56.08, 66.87, 67.59, 72.16, 74.22, 76.22, 78.48, 80.40, 83.82, 128.00, 128.02, 128.40, 128.56, 129.21, 129.99, 130.93, 133.61, 136.38, 145.29, 156.70, 166.82, 169.49, 169.76, 170.54, 202.28.
7-(Naphthalene-2-carbonyl)baccatin III (XVIII'b) (SB-RA-30001)
Identification data for Compound XVIII'b obtained in 58% yield are as follows: mp 251°-252° C.; α! 20 D -56.25° (c 0.16, CH 2 Cl 2 ); IR (KBr disk) 3469, 2993, 1728, 1640, 1406, 1286, 1240, 1023, 714 cm -1 ; 1 H NMR (250 MHz, CDCl 3 ) δ 1.07 (s, 3H), 1.17 (s, 3H), 1.91 (s, 3H), 1.99 (s, 4H), 2.18 (s, 3H), 2.32 (s, 5H), 2.84 (m, 1H), 4.12 (d, 6.9 Hz, 1H), 4.22 (d, 8.3 Hz, 1H), 4.36 (d, 8.3 Hz, 1H), 4.86 (m, 1H), 5.04 (d, 8.7 Hz, 1H), 5.71 (d, 6.9 Hz, 1H), 5.86 (m, 1H), 6.47 (s, 1H), 7.46-7.64 (m, 5H), 7.82-7.98 (m, 4H), 8.12 (d, 2H), 8.48 (s, 1H); 13 C NMR (62.5 MHz, CDCl 3 ) δ 11.01, 15.21, 20.16, 20.45, 22.56, 26.60, 33.45, 38.53, 42.77, 47.24, 56.47, 67.88, 72.45, 74.50, 75.48, 76.39, 78.71, 80.64, 84.03, 125.49, 126.31, 127.55, 127.69, 127.83, 128.02, 128.64, 129.31, 1299.55, 130.10, 131.29, 131.87, 132.43, 133.70, 135.52, 144.79, 165.51, 167.04, 168.42, 170.69, 202.95. Anal. Calcd. for C 42 H 44 O 12 : C, 68.10; H, 5.99. Found: C, 68.27; H, 5.83.
7-(Naphthalene-2-carbonylglycyl)baccatin III (XVIII'c) (SB-RA-3201)
A methanol (0.02M) solution of 7-(N-carbobenzoxyglycinyl)baccatin III (XVIII'a), obtained as described above was subjected to hydrogenolysis in the presence of 10% Pd-C (150 weight %) at ambient temperature and pressure for 4.5 hours. The solution was filtered through a pad of celite to remove the catalyst and concentrated in vacuo to afford a white solid. The resulting solid was dissolved in ethyl acetate (0.02M) and naphthalene-2-carbonyl chloride (1.6 equiv) was added. After vigorous stirring for 10 minutes, a saturated aqueous sodium bicarbonate was added. The mixture was stirred for another 10 minutes, then diluted with ethyl acetate washed with brine, and extracted with ethyl acetate. The combined organic layers were dried over magnesium sulfate, filtered and concentrated in vacuo. Purification of the crude product by flash chromatography on silica gel (eluant: hexane/EtOAc=1//1 then 1/2) afforded XVIII'c as a white solid (71%).
Identification data for compound XVIII'c are set forth as follows: mp 165°-168° C.; α! 20 D -78° (c 2.18, CH 2 Cl 2 ); IR (KBr disk) 3428, 2969, 1734, 1656, 1538, 1452, 1379, 1248, 1069, 1020, 980, 718 cm -1 ; 1 H NMR (250 MHz, CDCl 3 ) δ 1.07 (s, 3H), 1.13 (s, 3H), 1.79 (s, 3H), 1.87 (m, 1H), 2.09 (s, 3H), 2.18 (s, 3H), 2.27 (s, 3H), 2.30 (m, 2H), 2.65 (m, 1H), 4.0 (d, 6.8 Hz, 1H), 4.12 (d, 8.3 Hz, 1H), 4.18-4.40 (m, 2H), 4.84 (m, 1H), 4.96 (d, 8.8 Hz, 1H), 5.61 (d, 6.9 Hz, 1H), 5.72 (m, 1H), 6.23 (s, 1H), 7.10 (t, 5.4 Hz, 1H), 7.43-7.59 (m, 5H), 7.85-7.98 (m, 4H), 8.08 (d, 2H), 8.42 (s, 1H); 13 C NMR (62.5 MHz, CDCl 3 ) δ 10.77, 15.31, 20.12, 21.04, 22.51, 26.62, 33.19, 38.51, 42.06, 42.76, 47.44, 56.26, 67.78, 72.62, 74.23, 76.23 78.55, 80.52, 83.84, 123.75, 126.62, 127.59, 127.73, 128.34, 128.62, 129.0, 129.18, 130.04, 131.09, 131.41, 132.68, 133.70, 134.80, 145.24, 166.94, 167.50, 169.23, 170.29, 170.70, 202.45. Anal. Calcd. for C 44 H 47 NO 13 : C, 66.24; H, 5.94; N, 1.76. Found: C, 66.46; H, 5.84; N, 1.75.
7,10-Bis 3-(2-naphthyl)prop-2-enoyl!-10-deacetylbaccatin III (XXIIa) (SB-RA-4101)
Identification data for compound XXIIa is as follows: mp 176°-179° C.; α! 20 D -50° (c 0.5, CH 2 Cl 2 ); IR (KBr disk) 3422, 2940, 1718, 1631, 1363, 1256, 1163, 1018, 988, 711 cm -1 ; 1 H NMR (250 MHz, CDCl 3 ) δ 1.15 (s, 3H), 1.28 (s, 3H), 1.94 (m, 4H), 2.22 (s, 3H), 2.34 (s, 3H), 2.37 (m, 2H), 2.83 (m, 1H), 4.13 (d, 6.8 Hz, 1H), 4.23 (d, 8.34 Hz, 1H), 4.37 (d, 8.34 Hz, 1H), 4.90 (t, 7.73 Hz, 1H), 5.05 (d, 8.86 Hz, 1H), 5.75 (m, 2H), 6.53 (d, 15.8 Hz, 1H), 6.55 (d, 16 Hz, 1H), 6.63 (s, 1H), 7.40-8.2 (m, 21H); 13 C NMR (63 MHz, CDCl 3 ) δ 10.95, 15.25, 20.45, 22.57, 24.91, 25.57, 26.74, 33.48, 33.88, 38.59, 42.83, 47.37, 56.50, 67.88, 72.26, 74.55, 75.82, 76.42, 78.76, 80.70, 84.11, 117.37, 118.41, 123.41, 123.90, 126.49, 127.04, 127.13, 127.64, 127.68, 128.35, 128.44, 128.49, 128.64, 129.34, 129.96, 130.10, 131.69, 131.81, 132.25, 133.10, 133.28, 133.68, 134.13, 136.16, 145.04, 145.22, 145.72, 149.57, 164.89, 165.95, 167.01, 170.72, 202.95. Anal. Calcd. for C 55 H 52 O 12 : C, 72.99; H, 5.79. Found: C, 72.82; H, 5.69.
7,10-Bis 3-(4-benzoylphenyl)prop-2-enoyl!-10-deacetylbaccatin III (XXIIb) (SB-RA-4102)
Identification data for compound XXIIb is set forth as follows: mp 132°-135° C.; α! 20 D -54.7° (c 0.53, CH 2 Cl 2 ); IR (KBr disk) 3444, 2946, 1738, 1651, 1605, 1372, 1278, 1068, 984, 703 cm -1 ; 1 H NMR (250 MHz, CDCl 3 ) δ 1.04 (s, 3H), 1.11 (s, 3H), 1.78 (s, 3H), 1.89 (m, 1H), 2.10 (s, 3H), 2.29 (m, 5H), 2.48-3.12 (m, 9H), 3.99 (d, 6.8 Hz, 1H), 4.14 (d, 8.3 Hz, 1H), 4.31 (d, 8.3 Hz, 1H), 4.85 (t, 7.9 Hz, 1H), 4.95 (d, 8.74 Hz, 1H), 5.65 (m, 2H), 6.31 (s, 1H), 7.28-7.77 (m, 22H), 8.10 (d, 7.3 Hz, 2H); 13 C NMR (63 MHz, CDCl 3 ) δ 10.72, 15.25, 20.18, 22.51, 24.89, 25.56, 26.62, 30.39, 30.85, 33.32, 33.88, 35.12, 38.50, 42.72, 7.38, 49.13, 56.17, 67.76, 71.70, 74.31, 76.00, 76.28, 78.58, 80.55, 84.89, 128.18, 128.24, 128.59, 129.90, 130.05, 130.34, 130.45, 131.27, 132.18, 132.30, 133.67, 135.47, 137.65, 137.77, 145.09, 145.29, 146.00, 166.93, 170.64, 170.96, 171.70, 196.37, 196.42, 202.34. Anal. Calcd. for C 61 H 60 O 14 : C, 72.03; H, 5.95. Found: C, 71.88; H, 5.71.
7- 3-(2-Naphthyl)prop-2-enoyl!-10- 3-(4-benzoylphenyl)propanoyl!-10-deacetylbaccatin III (XXIIc) (SB-RA-4302)
Identification data for compound XXIIc is as follows: mp 135°-136° C.; α! 20 D -57.4° (c 1.01, CH 2 Cl 2 ); IR (KBr disk) 3469, 2928, 1724, 1653, 1604, 1447, 1369, 1276, 1152, 1067, 980, 704 cm -1 ; 1 H NMR (250 MHz, CDCl 3 ) δ 1.04 (s, 3H), 1.14 (s, 3H), 1.91 (m, 4H), 2.16 (s, 3H), 2.29 (m, 2H), 2.31 (s, 3H), 2.69-2.93 (m, 5H), 4.07 (d, 6.9 Hz, 1H), 4.20 (d, 8.3 Hz, 1H), 4.36 (d, 8.3 Hz, 1H), 4.86 (t, 6.6 Hz, 1H), 5.02 (d, 8.8 Hz, 1H), 5.71 (m, 2H), 6.46 (s, 1H), 6.48 (d, 15.8 Hz, 1H), 7.11 (d, 8.2 Hz, 2H), 7.46-7.94 (m, 18H), 8.12 (d, 7.3 Hz, 2H); 13 C NMR (63 MHz, CDCl 3 ) δ 10.92, 15.21, 20.28, 22.55, 24.91, 25.59, 26.65, 30.78, 33.51, 33.90, 35.04, 38.57, 42.77, 47.37, 49.22, 56.46, 67.89, 71.9, 74.49, 75.80, 78.69, 80.73, 84.08, 118.44, 123.73, 126.62, 127.11, 127.47, 127.74, 128.14, 128.21, 128.26, 128.53, 128.58, 128.65, 129.34, 129.89, 130.11, 130.28, 131.70, 132.19, 132.25, 133.29, 133.70, 134.19, 135.54, 137.77, 144.81, 145.04, 145.44, 165.79, 167.02, 170.25, 170.67, 196.38, 202.78. Anal. Calcd. for C 58 H 56 O 13 : C, 72.49; H, 5.87. Found: C, 72.36; H, 5.90.
EXAMPLES 24-26
7-Triethylsilyl-14-(6-phenyl hexanoyl)-10-deacetylbaccatin III (7-TES-XXXVa)
DCC (2.1 equivalents) was added to a solution of 7-triethylsilyl-14-hydroxy-10-deacetybaccatin III (0.026M), dimethylaminopyridine (0.2 equivalents) and 6-phenylhexanoic acid (1.1 equivalents) in dichloromethane at room temperature. After stirring for 48 h, the solvent was evaporated in vacuo. Purification by radial chromatography using hexane/EtOAc as the eluant afforded 7-TES-XXXva as a white solid (95% yield).
Identification data for compound 7-TES-XXXVa is shown as follows: 1 H NMR (250 MHz, CDCl 3 ) δ 0.56 (m, 6H), 0.95 (t, 9H), 1.05 (s, 3H), 1.14 (s, 3H), 1.41 (m, 6H), 1.71 (s, 3H), 1.92 (m, 1H), 2.11 (s, 3H), 2.37 (s, 3H), 2.45 (m, 3H), 2.61 (t, 7.5 Hz, 2H), 3.95 (d, 7.1 Hz, 1H), 4.22 (d, 8.34 Hz, 1H), 4.28 (d, 8.34 Hz, 1H), 4.42 (m, 1H), 4.65 (m, 1H), 4.97 (d, 8.5 Hz, 1H), 5.20 (s, 1H), 5.36 (d, 5.3 Hz, 1H), 5.79 (d, 7.2 Hz, 1H), 7.08-7.29 (m, 5H), 7.42-7.53 (m, 3H), 8.05 (d, 2H); 13 C NMR (62.5 MHz, CDCl 3 ) δ 5.16, 6.75, 9.86, 15.06, 20.60, 22.45, 24.83, 26.24, 28.36, 30.77, 34.21, 35.68, 37.21, 42.72, 46.47, 58.21, 72.89, 73.50, 74.50, 75.10, 76.40, 76.61, 77.43, 80.47, 84.16, 125.66, 125.75, 128.27, 128.48, 129.33, 130.12, 133.42, 136.18, 138.72, 142.15, 142.41, 165.76, 171.11, 173.67, 209.74.
14-(6-Phenyl hexanoyl)-10-deacetylbaccatin III (XXXVa)
To a solution of 7-TES-XXXVa (0.009M) in a (1:1) mixture of pyridine and acetonitrile was added HF/pyridine (70:30) (1 mL/8 mg of starting material) at 0° C. After stirring at room temperature for 16 hours, the reaction was quenched with a saturated solution of ammonium chloride and extracted with ethyl acetate. The combined organic layers were washed with a saturated solution of copper sulfate and water, then dried over magnesium sulfate, filtered and concentrated in vacuo. Purification of the crude product by chromatography on silica gel (hexane/EtOAc=1/2) afforded XXXVa as a white solid (72% yield).
Identification data for compound XXXva is shown as follows: 1 H NMR (250 MHz, CDCl 3 ) δ 1.05 (s, 3H), 1.14 (m, 5H), 1.43 (m, 4H), 1.75 (s, 3H), 1.84 (m, 1H), 2.08 (s, 3H), 2.34 (m, 2H), 2.37 (s, 3H), 2.45 (m, 2H), 2.56 (m, 1H), 2.75 (s, 1H), 3.20 (br s, 1H), 3.98 (d, 7.1 Hz, 1H), 4.27 (m, 3H), 4.64 (m, 1H), 4.98 (d, 9.1 Hz, 1H), 5.28 (s, 1H), 5.35 (d, 5.3 Hz, 1H), 5.80 (d, 7.2 Hz, 1H), 7.08-7.29 (m, 5H), 7.39-7.56 (m, 3H), 8.04 (d, 2H); 13 C NMR (62.5 MHz, CDCl 3 ) δ 9.69, 14.98, 20.77, 22.44, 24.68, 26.07, 28.34, 30.74, 34.21, 35.39, 36.84, 42.62, 46.36, 57.95, 71.93, 73.47, 74.79, 75.02, 76.42, 76.61, 77.55, 80.55, 84.11, 125.74, 128.27, 128.50, 129.24, 130.10, 133.47, 135.89, 139.06, 142.15, 165.77, 171.08, 173.70, 211.07,
14-(6Phenyl hexanoyl) 7,13-diacetyl baccatin III (7,10-Ac2-XXXVa)
Acetic anhydride (30 equivalents) was added to a solution of XXXVa (0.026M) and DMAP (6 equivalents) in dichloromethane. After stirring at room temperature for 3 h, the reaction was quenched with a saturated solution of ammonium chloride and extracted with dichloromethane. The combined organic layers were dried over magnesium sulfate, filtered and concentrated in vacuo. Purification of the crude by chromatography on silica gel (hexane/EtOAc=1/3) afforded 7,10-Ac2-XXXVa as a white solid (87% yield).
Identification data for compound 7,10-ALZ XXXVa is set forth as follows: mp 191°-193° C.; 1 H NMR (250 MHz, CDCl 3 ) δ 1.11 (m, 2H), 1.21 (s, 3H), 1.22 (s, 3H), 1.42 (m, 4H), 1.84 (s, 4H), 1.98 (s, 3H), 2.03 (s, 3H), 2.08 (m, 2H), 2.15 (s, 3H), 2.17 (s, 3H), 2.43 (t, 2H), 2.51 (s, 4H), 2.70 (s, 1H), 3.99 (d, 6.7 Hz, 1H), 4.22 (d, 8.0 Hz, 1H), 4.29 (d, 8.0 Hz, 1H), 4.97 (d, 8.8 Hz, 1H), 5.51 (m, 2H), 5.84 (d, 6.8 Hz, 1H), 6.13 (m, 1H), 6.28 (s, 1H), 7.07-7.26 (m, 5H), 7.39-7.56 (m, 3H), 8.06 (d, 2H); 13 C NMR (62.5 MHz, CDCl 3 ) δ 10.63, 14.92, 20.64, 20.86, 21.03, 21.61, 22.36, 24.53, 25.74, 28.38, 30.77, 33.30, 33.94, 35.38, 43.21, 46.57, 56.32, 70.99, 71.23, 72.93, 75.16, 76.14, 76.82, 80.54, 83.89, 125.68, 128.21, 128.39, 128.97, 130.24, 133.46, 134.09, 137.80, 142.14, 165.62, 168.76, 170.19, 170.32, 170.76, 171.62, 201.34.
EXAMPLE 27
Cytotoxicity Evaluation
Taxoids, thus synthesized, were evaluated for their cytotoxicity against human tumor cell line, A2780 (ovarian carcinoma), A2780-DX5 (ovarian carcinoma resistant to doxorubicin), MCF7 (mammary carcinoma) or MCF7-R (mammary carcinoma cells resistant to doxorubicin), after 72 hours drug exposure according to the methods of Skehon, et al., "J. Nat. Cancer Inst. 82, 1107, 1990". The results are shown in Table 1. The cytotoxicities of paclitaxel, docetaxel and doxorubicin are also listed for comparison. Lower numbers indicate higher potency. The data represent the means values of at least three separate experiments. Lower numbers indicate stronger cytotoxicity. As Table 1 shows, the taxoids of this invention possess about 1,000 times less cytotocity than paclitaxel against ovarian and breast cancer cells. Low cytotocitiy is preferred for ideal MDR reversal agents.
TABLE 1______________________________________ A2780.sup.a A2780-DX5.sup.a MCF7.sup.a MCF7-R.sup.aTaxoid (ovarian) (ovarian) (breast) (breast)______________________________________Paclitaxel 2.7 547 1.7 850Doxorubicin 5.0 357 17 1,890SB-RA-110 >10,000 >10,000 >10,000 >10,000SB-RA-2001 2,600 3,800 2,000 5,000SB-RA-30001 -- -- 5,300 11,000SB-RA-30011 6,300 6,800 4,700 8,000SB-RA-30012 -- -- >10,000 >10,000SB-RA-30021 5,700 5,300 4,900 5,000SB-RA-31011 -- -- 11,000 >10,000SB-RA-31012 -- -- >10,000 >10,000SB-RA-4001 8,000 10,000 8,500 >10,000SB-RA-4102 -- -- >10,000 >10,000______________________________________ .sup.a The concentration of compound which inhibit 50% (IC50, nM) of the growth of human tumor cell line.
Assessment of cytotoxicity, i.e., cell growth inhibition, was determined according to the methods of Skehan, et al. as discussed in J. Nat. Cancer Inst. 82, 1107, 1990. Briefly, cells were plated between 400 and 1200 cells/well in 96 well plates and incubated at 37° C. for 15-18 h prior to drug addition to allow attachment of cells. Compounds tested were solubilized in 100% DMSO and further diluted in RPMI-1640 containing 10 mM HEPES. Each cell line was treated with 10 concentrations of compounds (5 log range). After a 72 h incubation, 100 mL of ice-cold 50% TCA was added to each well and incubated for 1 h at 4° C. Plates were then washed 5 times with tap water to remove TCA, low-molecular-weight metabolites and serum proteins. Sulforhodamine B (SRB) (0.4%, 50 mL) was added to each well. Following a 5 minute incubation at room temperature, plates were rinsed 5 times with 0.1% acetic acid and air dried. Bound dye was solubilized with 10 mM Tris Base (pH 10.5) for 5 min on a gyratory shaker. Optical density was measured at 570 nm.
EXAMPLE 28
Activity of Taxoids as MDR Agents
Taxoids, thus synthesized, were evaluated in combination with either paclitaxel or doxorubicin for their cytostatic activity against the drug-resistant breast cancer cells MCF7-R. As shown in Example 27, these taxoids only possess weak cytotoxicity (>2 μM level IC 50 values) against drug-sensitive and drug-resistant cancer cells. However, these taxoids when used in combination with paclitaxel at 1 or 3 μM concentration decreased the IC 50 of paclitaxel 20˜100-fold, i.e, from 860 to 42˜1.6, a reduction of 95˜99.8% as shown in TABLE 1. For the IC 50 vaues, the lower number indicates stronger cytotoxicity and for the % IC 50 reduction, a larger number shows higher MDR reversal activity. Similarly, the taxoid reversal agents (1 μM SB-RA-30011) enhanced the tumor growth inhibitory activity of doxorubicin by 92% as shown in Table 2.
Consequently, in the presence of these taxoids, paclitaxel and doxorubicin can recover their excellent inhibitory activities against the drug-resistant cancer cells MCF7-R (paclitaxel and doxorubicin possess only weak cytotoxicity, i.e., IC 50 =860 nM and 1,890 nM, respectively, against MCF7-R as shown in TABLEs 1 and 2). It has been proven in these laboratories that the observed remarkable enhancement of paclitaxel's cytotoxicity of against MCF7-R is ascribed to the market increase in the uptake of paclitaxel in MCF7-R cancer cells in the presence of these taxoid reversal agents using a radiolabeled paclitaxel. These results clearly show that these taxoids possess outstanding MDR reversal activity.
TABLE 2______________________________________Taxoid IC.sub.50 (nM) % IC.sub.50 reduction______________________________________Paclitaxel 860 --Doxorubicin 1,890 --SB-RA-30001 + Paclitaxel.sup.a 21 97.5SB-RA-30011 + Paclitaxel.sup.a 36 96SB-RA-30011 + Doxorubicin.sup.a 160 92SB-RA-30012 + Paclitaxel.sup.a 5.8 99.3SB-RA-30021 + Paclitaxel.sup.a 33 96SB-RA-31011 + Paclitaxel.sup.a 1.6 99.8SB-RA-31012 + Paclitaxel.sup.a 2.6 99.7SB-RA-4001 + Paclitaxel.sup.a 42 95SB-RA-4102 + Paclitaxel.sup.a 2.7 99.7______________________________________ .sup.a Treatment consists of concurrent exposure of MCF7R cells to paclitaxel (or doxorubicin) in the presence or absence of the taxoid reversing agent (1 μM) for 72 h in vitro. | The present invention is directed to novel taxoids possessing strong reversing activities for drug-resistance associated with anti-cancer agents, the preparation of these reversal agents and pharmaceutical compositions thereof. The new taxoids of the present invention have the formula (I). ##STR1## | 2 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. application Ser. No. 09/284,906, filed on Jul. 2, 1999, which is the National Stage of International Application No. PCT/US97/19210, filed on Oct. 24, 1997, which claims the benefit under 35 U.S.C. 119(e) of U.S. Provisional Application No. 60/029,112, filed on Oct. 24, 1996.
SUMMARY OF THE INVENTION
The syntheses of several didemnin derivatives, including didemnin M (1) as well as pyroglutaminyl didemnin B (2), have been performed. Didemnin M, one of the most active of the didemnins, contains pyroglutamate, glutamine, lactyl, and proline groups in its side chain, while pyroglutaminyl didemnin B contains only a pyroglutaminyl unit in addition to the lactyl and prolyl residues. Glutaminyl derivatives (3-5) were also synthesized in the process of producing didemnin M.
The retrosynthetic disconnections which formed the basis of a plan for preparation of the side chain of didemnin M are shown in Equation 1. Disconnection of the ester function between lactic acid and L-glutamine would give two units: a dipeptide, unit 7, comprised of pyroglutamate and glutamine; and unit 8, comprised of lactic acid and proline.
A mixed anhydride from L-pyroglutamic acid 9 and pivaloyl chloride was coupled with L-glutamine t-butyl ester 10 followed by acidic workup to yield L-pyroglutamyl-L-glutamine 7 (Equation 2). This dipeptide was purified by reversed phase HPLC using a gradient system of acetonitrile/H 2 O.
The synthesis of compound 8 began with protection of (S)-ethyl lactate, 11, as the benzyloxy derivative 12. Hydrolysis provided the acid 13 which was coupled with L-proline phenacyl ester to afford compound 14. Treatment with a solution of zinc in acetic acid afforded 8 (Scheme I).
Didemnin M was synthesized by a three step scheme involving a coupling reaction of benzyllactylproline, 8, with didemnin A to give the protected derivative 15 followed by hydrogenation to yield didemnin B. The final step involved coupling of the pyroglutaminylglutamine unit, 7, with didemnin B. This was carried out using a variety of techniques with the most efficient being the mixed anhydride method (Scheme II). Purification was performed using HPLC with an acetonitrile/H 2 O gradient system.
A second approach toward the synthesis of didemnin M involved protecting L-glutamine, 16, as the benzyloxycarbonyl derivative, 17, followed by coupling with didemnin B using DCC. During this coupling procedure, two glutaminyl derivatives were produced, 18, bore a glutaminyl residue at only the lactyl residue while the second, 19, contained two glutaminyl residues, one on the lactyl unit and the second on the isostatine unit. These derivatives were separated via reversed phase HPLC, then hydrogenated to provide the deprotected compounds 3 and 4 (Scheme III).
A different attempt at deprotection of the benzyloxycarbonyl derivative 18 provided yet another glutaminyl didemnin analogue. This analogue was formed upon treatment of 18 with hydrogen bromide in acetic acid. It appears as though an acetyl unit was added to the isostatine residue to provide compound 5 (Equation 3). These two compounds appear to be easily separable by reversed phase HPLC. This deprotection technique also proved to be useful with the dibenzyloxycarbonylglutaminyl derivative of didemnin B, 19.
Pyroglutamic acid was protected as the benzyloxycarbonyl derivative (20) which was then coupled with glutaminyldidemnin B (3) using DCC to provide the protected form of didemnin M (21). Deprotection via hydrogenation afforded didemnin M (1) (Scheme IV). Purification via reversed phase HPLC provided the desired compound.
Another interesting analogue of didemnin is pyroglutaminyldidemnin B (2). The synthesis of 2 was accomplished by coupling 20 to didemnin B using EDC to provide Cbz-pyroglutaminyl didemnin B 22. Removal of the protecting group was accomplished using hydrogenation in the presence of a palladium catalyst to afford 2. Purification via reversed phase HPLC, using an acetonitrile/water gradient system, provided the pure compound (Equation 4).
Dehydrodidemnin B was synthesized by first coupling Boc-L-proline (23) to didemnin A using EDC as the coupling agent. The Boc protecting group was removed upon treatment with acid and the resulting compound (25) was coupled with pyruvic acid to provide dehydrodidemnin B (Scheme V). The compound was purified via reversed phase HPLC using a gradient system of acetonitrile/H 2 O.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a 1 H NMR spectrum of O-Benzyldidemnin B (15).
FIG. 2 is a LRFAB mass spectrum of O-Benzyldidemnin B (15).
FIG. 3 is a RPHPLC trace of Didemnin B.
FIG. 4 is a 1 H NMR spectrum of Didemnin B.
FIG. 5 is a LRFAB mass spectrum of O-Benzyldidemnin B (15).
FIG. 6 is a RPHPLC trace of Didemnin M (1).
FIG. 7 is a 1 H NMR spectrum of Didemnin M (1).
FIG. 8 is a LRFAB mass spectrum of Didemnin M (1).
FIG. 9 is a RPHPLC trace of Benzyloxycarbonyl-L-Glutaminyldidemnin B (18).
FIG. 10 is a 1 H NMR spectrum of Benzyloxycarbonyl-L-Glutaminyldidemnin B (18).
FIG. 11 is a LRFAB mass spectrum of Benzyloxycarbonyl-L-Glutaminyldidemnin B (18).
FIG. 12 is a RPHPLC trace of (Benzyloxycarbonyl-L-Glutaminy) 2 .Didemnin M B(19).
FIG. 13 is a 1 H NMR spectrum of (Benzyloxycarbonyl-L-Glutaminy) 2 .Didemnin M B(19).
FIG. 14 is a LRFAB mass spectrum of (Benzyloxy-carbonyl-L-Glutaminy) 2 .Didemnin M B(19).
FIG. 15 is a RPHPLC trace of Glutaminyldidemnin B (3).
FIG. 16 is a 1 H NMR spectrum of Glutaminyldidemnin B (3).
FIG. 17 is a LRFAB mass spectrum of Glutaminyldidemnin B (3).
FIG. 18 is a LRFAB mass spectrum of Diglutaminyldidemnin B (4).
FIG. 19 is a RPHPLC trace of Benzyloxycarbonyldidemnin M (21).
FIG. 20 is a 1 H NMR spectrum of Benzyloxycarbonyldidemnin M (21).
FIG. 21 is a LRFAB mass spectrum of Benzyloxycarbonyldidemnin M (21).
FIG. 22 is a LRFAB mass spectrum of Benzyloxycarbony-L-Pyroglutaminyldidemnin B (22).
FIG. 23 is a RPHPLC trace of Pyroglutaminyldidemnin B (23).
FIG. 24 is a 1 H NMR spectrum of Pyroglutaminyldidemnin B (23).
FIG. 25 is a LRFAB mass spectrum of Pyroglutaminyldidemnin B (23).
FIG. 26 is a LRFAB mass spectrum of Prolydidemnin A (25).
FIG. 27 is a RPHPLC trace of Dehydrodidemnin B.
FIG. 28 is a 1 H NMR spectrum of Dehydrodidemnin B.
FIG. 29 is a LRFAB mass spectrum of Dehydrodidemnin B.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
General Experimental Procedures. 1 H NMR spectra were recorded on Varian XL-200, General Electric QE-300, Varian XL-400, and General Electric QN-500 spectrometers. 1 H Chemical shifts are referenced in CDCl 3 and methanol-d 4 to residual CHCl 3 (7.26 ppm) and CD 2 HOD (3.34 ppm). Electron impact (EI) mass spectra were recorded on a Finnigan MAT CH-5 DF spectrometer. High resolution (HRFAB) and fast atom bombardment (PAB) mass spectra were recorded on a VG ZAB-SE mass spectrometer operating in the FAB mode using magic bullet matrix. 27 Microanalytical results were obtained from the School of Chemical Sciences Microanalytical Laboratory. Infrared (IR) spectra were obtained on an IR/32 FTIR spectrophotometer. Solid samples were analyzed as chloroform solutions in sodium chloride cells. Liquids or oils were analyzed as neat films between sodium chloride plates.
Optical rotations (in degrees) were measured with a DIP 360 or a DIP 370 digital polarimeter with an Na lamp (589 nm) using a 5×0.35-cm (1.0 mL) cell. Melting points were determined on a capillary melting point apparatus and are not corrected. Normal phase column chromatography was performed using Merck-kieselgel silica gel (70-230 mesh). Fuji-Davison C18 gel (100-200 mesh) was used for reversed phase column chromatography. All solvents were spectral grade. Analytical thin layer chromatography was performed on precoated plates (Merck, F-254 indicator). These plates were developed by various methods including exposure to ninhydrin, iodine, and UV light (254 nm). HPLC was performed with a Waters 990 instrument and an Econosil C 18 column (Alltech/Applied Science) and a Phenomenex C 18 column.
THF was distilled from sodium benzophenone ketyl and CH 2 Cl 2 from P 2 O 5 . Dimethylformamide (DMF), triethylamine (Et 3 N), and N-methylmorpholine (NMM) were distilled from calcium hydride and stored over KOH pellets. Pyridine was distilled from KOH and stored over molecular sieves. Other solvents used in reactions were reagent grade without purification. Di-tert-butyl dicarbonate [(Boc) 2 O], dicyclohexylcarbodiimide (DCC), 1-(3-dimethylaminopropyl)-3-ethylcarbodiimide hydrochloride (EDCI), dimethylaminopyridine (DMAP), 1-hydroxybenzotriazole (HOBT), L-glutamine, L-pyroglutamine, and L-proline were obtained from the Aldrich Chemical Company. All reactions requiring anhydrous conditions were performed under an atmosphere of nitrogen.
Pyroglutaminylglutamine (7). Pyroglutamic acid (0.11 g, 0.84 mmol) was dissolved in DMF (2.09 mL) and the solution was cooled to −20° C. N-Methylmorpholine (0.19 mL) and pivaloyl chloride (0.10 mL) were added to the solution and stirring continued at −20° C. for 5 h. At this time, a solution of glutamine t-butyl ester (0.20 g, 0.84 mmol) in DMF (0.42 mL) and N-methylmorpholine (92 mL) was added dropwise. Stirring was continued for 48 h, and the solution was allowed to warm to room temperature, then poured into H 2 O and extracted with EtOAc. The EtOAc layer was washed with 1N HCl and H 2 O, then dried (Na 2 SO 4 ), and the solvent was carefully removed below 40° C. A white solid was isolated. Recrystallization from ether/petroleum ether provided 7 as a white crystalline material (0.17 g, 79%); FABMS 258.1 (M+H); HRFABMS calcd for C 10 H 15 N 3 O 5 (M+H) 258.1090, found 258.1091.
Ethyl (S)-O-Benzyllactate (12). To a solution of ethyl (S)-lactate (2.36 g, 20.0 mmol) in THF (7.80 mL) was added sodium hydride (60% dispersion, 0.94 g, 24.0 mmol) portionwise, with cooling. Benzyl bromide (2.60 mL, 22.0 mmol) was then added via a dropping funnel. The reaction was allowed to stand at room temperature for 24 h. Ethyl acetate (70 mL) was slowly added to the reaction mixture, followed by water, to destroy the excess sodium hydride. The solution was then evaporated to dryness and the oily residue was partitioned between ether (30 mL) and water (60 mL). The ether layer was washed with aqueous sodium bicarbonate (5 mL) and brine. The solution was dried over sodium sulfate and the solvent evaporated to give an oily residue which crystallized overnight. Recrystallization of the crude product gave the compound as a white crystalline material (3.01 g, 72%); FABMS m/z 209.1 (M+H), 181.2 (M-C 2 H 4 ).
O-Benzyllactic acid (13). To a cold solution of 12 (0.31 g, 1.49 mmol) in THF (14.9 mL) was added, dropwise, a cold 0.2 M lithium hydroxide solution (14.9 mL) during 10-min. Stirring continued for 3 h at ambient temperature, then the solution was concentrated to half its volume and washed with ether (2×15 mL). The combined ether layers were extracted with saturated NaHCO 3 (10 mL), and the aqueous layers were combined and acidified to pH 4 with 1 N potassium hydrogen sulfate. The acidified aqueous layer was extracted with ether (3×50 mL) and the combined ether extracts were dried (Na 2 SO 4 ), filtered, and concentrated under reduced pressure, providing the corresponding acid an oil, which was used directly in the next step (0.21 g, 80%); 1 H NMR (500 MHz, CDCl 3 ) δ1.46 (3H, d), 4.05 (1H, q), 4.55 (2H, dd), 7.31 (5H, s), 11.36 (1H, s); FABMS 219.0 (M+K), 203.1 (M+Na), 181.2 (M+H); HRFABMS calcd for C 10 H 12 NaO 3 (M+Na) 203.0684, found 203.0686; m/z calcd for C 10 H 13 O 3 (M+H) 181.0865, found 181.0864.
Boc-L-Proline Phenacyl Ester. Boc-proline (1.00 g, 4.65 mmol) was dissolved in ethyl acetate (29.4 mL), triethylamine (0.46 g, 0.63 mL) and phenacyl bromide (0.93 g, 4.68 mmol) were added and, within a few minutes, a precipitate formed. The mixture was stirred overnight, water and ether were added and the two layers separated. The organic layer was washed with 0.1N HCl, saturated sodium bicarbonate, and brine, then dried over MgSO 4 . Evaporation of the solvent provided the desired compound (1.27 g, 83%); FABMS 334.2 (M+H), 234.1 (M+2H-Boc), 667.3 (2M+H); HRFABMS calcd for C 18 H 23 NO 5 (M+H) 334.1654, found 334.1665.
L-Proline phenacyl ester. Boc-L-proline phenacyl ester (0.29 g, 0.87 mmol) was dissolved in EtOAc (25 mL) and a steady current of HCl was passed through the solution for approximately 40 min, when TLC analysis showed the deprotection to be complete. The solvent was evaporated to provide a white crystalline material. Recrystallization from petroleum ether gave clear crystals (0.19 g, 94%); FABMS 234.2 (M+H), 467.2 (2M+H); HRFABMS calcd for C 13 H 16 NO 3 (M+H) 234.1130, found 234.1129.
L-O-Benzyllactyl-proline Phenacyl Ester (14). Proline phenacyl ester (0.19 g, 0.83 mmol) in CH 2 Cl 2 , DMAP (0.10 g, 0.83 mmol) and DCC (0.19 g, 0.96 mmol) were added at 0° C. to a solution of 13 (0.15 g, 0.83 mmol). The solution was allowed to warm to room temperature and stirred for 12 h. Dicyclohexylurea was filtered and washed with ethyl acetate. The filtrate and washings were combined and washed with 10% citric acid, 5% sodium bicarbonate and water, dried over MgSO 4 and concentrated. The crude residue was purified by flash chromatography eluting with hexane and ethyl acetate (4:1) to obtain the product (0.19 g, 57%) as an orange oil; FABMS 396.2 (M+H); HRFABMS calcd for C 23 H 26 NO 5 (M+H) 396.1811, found 396.1812.
L-O-Benzyllactyl-proline (8). Compound 14 (0.19 g, 0.48 mmol) was treated with Zn (0.96 g) in AcOH/H 2 O (70:30), the mixture was allowed to stir at rt overnight, Zn was filtered off using celite, and the solution was partitioned between ether and water. The organic layer was separated and dried over Na 2 SO 4 to afford the desired compound (0.11 g, 86%); FABMS 278.1 (M+H).
O-Benzyldidemnin B (15). L-O-Benzyllactyl-proline (33.0 mg, 0.13 mmol) in DMF (3 mL), DMAP (0.6 mg) and DCC (26.0 mg, 0.13 mmol) were added at 0° C. to a solution of didemnin A (39.7 mg, 0.42 mmol). The solution was allowed to warm to room temperature and stirred for 12 h, dicyclohexylurea was filtered and washed with ethyl acetate. The filtrate and washings were combined and washed with 10% citric acid, 5% sodium bicarbonate and water, and the extracts were dried over MgSO 4 and concentrated. The crude residue was purified by reversed phase HPLC using a gradient system of acetonitrile/H 2 O to provide the compound as a yellow powder (40.5 mg, 80%); 1 H NMR (500 MHz, CDCl 3 ), see Supplementary Material, S-1; FABMS 1241.2 (M+K), 1226.1 (M+Na), 1203.1 (M+H), see Supplementary Material, S-2; HRFABMS calcd for C 64 H 96 N 7 O 15 (M+H) 1202.6964, found 1202.6964.
Didemnin B. Protected didemnin B (15, 40.5 mg, 33.7 mmol) was dissolved in isopropyl alcohol (5 mL), palladium on carbon (10%) catalyst (37.4 mg) was added and the solution was hydrogenated at room temperature and atmospheric pressure for 3 h, when TLC showed the reaction to be complete. The catalyst was filtered over celite and the solvent was evaporated to provide the desired compound as a white powder. Reversed phase HPLC (acetonitrile/H 2 O gradient system) revealed the compound to be pure, see Supplementary Material, S-3 (32.1 mg, 86%); 1 H NMR (500 MHz, CDCl 3 ), see Supplementary Material, S-4; FABMS 1134.5 (M+Na), 1112.5 (M+H), Supplementary Material, S-5; HRFABMS calcd for C 57 H 90 N 7 O 15 (M+H) 1112.6495, found 1112.6491.
Pyroglutaminyl-glutaminyl-didemnin B [Didemnin M (1)]. Pyroglutaminylglutamine (3.42 mg, 14.4 μmol) was dissolved in DMF (36.0 μL) and the solution was cooled to −20° C. N-Methylmorpholine (3.27 μL) and pivaloyl chloride (1.72 μL) were added to the solution and stirring continued at −20° C. for 5 h, when a solution of didemnin B (16.0 mg, 14.4 μmol) in CH 2 Cl 2 (7.23 μL) and N-methylmorpholine (1.59 μL) was added dropwise. Stirring continued for 48 h, then the solution was allowed to warm to room temperature, and the mixture was poured into H 2 O and extracted with EtOAc. The EtOAc layer was washed with 1N HCl and H 2 O, dried (Na 2 SO 4 ), and solvent was carefully removed below 40° C. Reversed phase HPLC using a gradient system of acetonitrile/H 2 O afforded the desired compound, see Supplementary Material, S-6 (8.1 mg, 79%); 1 H NMR (500 MHz, CDCl 3 ), see Supplementary Material, S-7; FABMS m/z 1389.5 (M+K), 1374.5 (M+Na), 1351.6 (M+H), see Supplementary Material, S-8; HRFABMS m/z calcd for C 67 H 103 N 10 O 19 (M+H) 1351.7401, found 1351.7406.
N-Benzyloxycarbonyl-L-glutamine (17). Glutamine (1.84 g, 12.62 mmol) was dissolved in 1 N NaOH (12.58 mL) and the solution was cooled to 0° C. and stirred for 30 min, when Na 2 CO 3 (3.30 g) and benzyl chloroformate (4.38 mL) in dioxane (19.30 mL) were gradually added, in equal portions. Stirring continued at 0° C. for 1 h, then the solution was allowed to stir overnight at room temperature and was extracted with ethyl ether (2×20 mL). The aqueous solution was acidified with 2N HCl to pH 5 and extracted with ethyl acetate (3×50 mL), which was dried over sodium sulfate, and evaporated to give an oil which crystallized overnight. Recrystallization of the crude product gave a white crystalline material (3.07 g, 87%); FABMS 319.1 (M+K), 281.1 (M+H).
N-Benzyloxycarbonyl-L-glutaminyl-didemnin B (18). To a solution of Cbz-glutamine (0.14 g, 0.55 mmol) in dry DMF (2.50 mL), DMAP (0.6 mg) and DCC (20.6 mg, 0.11 mmol) were added at 20° C. with stirring. Stirring continued at room temperature for 2 h and a solution of didemnin B (23.0 mg, 20.6 μmol) in DMF (2.50 mL) was added with stirring. The solution was stirred at room temperature for 24 h, diluted with CH 2 Cl 2 and washed with 5% NaHCO 3 and water to neutral pH. The solution was dried (Na 2 SO 4 ) and evaporated to give a white solid which was purified by reversed phase HPLC using a gradient system of acetonitrile/water, see Supplementary Material, S-9 (51.3 mg, 34%); 1 H NMR (500 MHz, CDCl 3 ), see Supplementary Material, S-10; FABMS 1374.6 (M+H), see Supplementary Material, S-11; HRFABMS calcd for C 70 H 104 N 9 O 19 (M+H) 1374.7448, found 1374.7446. A second derivative was also obtained from HPLC purification (see Supplementary Material, S-12) and was found to be di-(benzyloxycarbonyl)glutaminyl-didemnin B (36.0 mg, 20%); 1 H NMR (500 MHz, CDCl 3 ), see Supplementary Material, S-13, FABMS 1637.2 (M+H), see Supplementary Material, S-14; HRFABMS calcd for C 83 H 118 N 11 O 23 (M+H) 1636.8402, found 1636.8401.
Glutaminyl-didemnin B (3). Compound 18 (25.1 mg, 18.2 μmol) was dissolved in isopropyl alcohol (1.00 mL) and 10% Pd/C catalyst (0.99 mg) was added. The solution was hydrogenated for 3 h. The catalyst was removed by filtration over celite and solvent was removed to afford 3 which was purified by reversed phase HPLC using a gradient system of acetonitrile/water (see Supplementary Material, S-15) (19.6 mg, 87%); 1 H NMR (500 MHz, CDCl 3 ), see Supplementary Material, S-16; FABMS 1278.5 (M+K), 1262.6 (M+Na), 1240.7 (M+H), see Supplementary Material, S-17; HRFABMS calcd for C 62 H 106 N 11 O 9 (M+H) 1240.7081, found 1240.7076.
Glutaminyl-glutaminyl-didemnin B (4). The procedure was identical to that described above for 3. Compound 4 was also prepared by treatment of 19 with hydrogen bromide in acetic acid; FABMS 1368.7 (M+H), see Supplementary Material, S-18; HRFABMS calcd for C 67 H 106 N 11 O 19 (M+H) 1368.7666, found 1368.7680.
N-Benzyloxycarbonyl-L-pyroglutamine (20). L-Pyroglutamine (2.02 g, 13.83 mmol) was dissolved in 1 N NaOH (13.84 mL) and the solution was cooled to 0° C. After 30 min stirring, Na 2 CO 3 (3.63 g) and benzyl chloroformate (4.82 mL) in dioxane (21.23 mL) were gradually added, in equal portions. Stirring was continued at 0° C. for 1 h, then the solution was stirred overnight at room temperature and extracted with ethyl ether (2×20 mL). The aqueous solution was acidified with 2N HCl to pH 5, extracted with ethyl acetate (3×50 mL), dried over sodium sulfate, and evaporated to give an oil which crystallized overnight. Recrystallization of the crude product gave white crystalline material (2.86 g, 87%); FABMS 240.1 (M+H).
L-(N-Benzyloxycarbonyl-pyroglutaminyl)-L-glutaminyl-didemnin B (21). To a solution of Cbz-pyroglutamine (10.2 mg, 38.7 μmol) in dry DMF (0.18 mL), DMAP (0.22 mg) and DCC (7.59 mg, 7.74 μmol) were added at 20° C. with stirring. Stirring continued at room temperature for 2 h and a solution of didemnin B (9.60 mg, 7.74 μmol) in DMF (2.50 mL) was added with stirring. The solution was stirred at room temperature for 24 h. The solution was diluted with CH 2 Cl 2 and washed with 5% NaHCO 3 and water to neutral pH. The solution was dried (Na 2 SO 4 ) and solvent evaporated to give 21 as a white solid. The compound was purified by reversed phase HPLC using a gradient system of acetonitrile/water (see Supplementary Material, S-19) (5.19 mg, 46%); 1 H NMR (500 MHz, CDCl 3 ), see Supplementary Material, S-20; FABMS 1524.2 (M+K), 1509.1 (M+Na), 1485.8 (M+H), see Supplementary Material, S-21; HRFABMS calcd for C 75 H 109 N 10 O 21 (M+H) 1485.7769, found 1485.7765.
L-Pyroglutaminyl-L-glutaminyl-didemnin B [Didemnin M (1)]. Compound 21 (2.12 mg, 1.40 μmol) was dissolved in isopropyl alcohol (1.00 mL) and 10% Pd/C catalyst (9.90 μg) was added. The solution was hydrogenated for 3 h, catalyst was removed by filtration over celite and solvent was removed to afford the desired compound. The compound was purified by reversed phase HPLC using a gradient system of acetonitrile/water (see Supplementary Material, S-6) (1.66 mg, 88%); 1 H NMR (500 MHz, CDCl 3 ), see Supplementary Material, S-7; FABMS 1389.5 (M+K), 1374.5 (M+Na), 1351.6 (M+H), see Supplementary Material S-8; HRFABMS calcd for C 67 H 103 N 10 O 19 (M+H) 1351.740.1, found 1351.7406.
N-Benzyloxycarbonyl-L-pyroglutaminyl-didemnin B (22). DMAP (0.48 mg) and EDC (16.5 mg, 88.0 μmol) were added at 20° C. with stirring to compound 20 (0.11 g, 0.44 mmol) in dry CH 2 Cl 2 (2.00 mL). Stirring continued at room temperature for 2 h and a solution of didemnin B (9.20 mg, 8.24 μmol) in CH 2 Cl 2 (2.00 mL) was added with stirring. The solution was stirred at room temperature for 24 h, diluted with CH 2 Cl 2 and washed with 5% NaHCO 3 and water to neutral pH. The solution was dried (Na 2 SO 4 ) and the solvent evaporated to give the compound as a white solid. The compound was purified by reversed phase HPLC using a gradient system of acetonitrile/water (5.70 mg, 52%); FABMS 1356.7 (M+H), see Supplementary Material, S-22; HRFABMS calcd for C 70 H 102 N 9 O 18 (M+H) 1356.7343, found 1356.7335.
L-Pyroglutaminyl-didemnin B (2). Compound 22 (5.70 mg, 4.28 μmol) was dissolved in isopropyl alcohol (0.5 mL) and 10% Pd/C catalyst (0.25 mg) was added. The solution was hydrogenated for 5 h, catalyst was removed by filtration, and the solvent was removed to afford 22, which was purified by reversed phase HPLC using a gradient system of acetonitrile/water, see Supplementary Material, S-23 (4.28 mg, 82%); 1 H NMR (500 MHz, CDCl 3 ), see Supplementary Material, S-24; FABMS 1223.7 (M+H), see Supplementary Material, S-25; HRFABMS calcd for C 62 H 95 N 8 O 17 (M+H) 1223.6815, found 1223.6811.
Boc-L-prolyl-didemnin A (24). DMAP (0.75 mg) and EDC (11.5 mg, 60.0 mmol) were added at 20° C. with stirring to Boc-L-proline (23) (25.0 mg, 0.12 mmol) in dry CH 2 Cl 2 (2.00 mL). Stirring continued at room temperature for 2 h and a solution of didemnin B (44.4 mg, 40.0 mmol) in CH 2 Cl 2 (2.00 mL) was added with stirring. The solution was stirred at room temperature for 24 h. The solution was diluted with CH 2 Cl 2 and washed with 5% NaHCO 3 solution and water to neutral pH. The solution was dried (Na 2 SO 4 ) and the solvent evaporated to give the compound as a white solid (17.5 mg, 42%); FABMS 1140.6. (M+H), 1040.6 (M+2H-Boc).
L-Prolyl-didemnin B (25). Compound 24 (15.1 mg, 13.2 μmol) was dissolved in 5N HCl in ethyl acetate. After 3 h stirring at room temperature, TLC analysis showed the deprotection to be complete. The solvent was evaporated to provide a white crystalline material (12.5 mg, 91%); FABMS 1040.6 (M+H), see Supplementary Material, S-26.
Dehydrodidemnin B. DMAP (0.16 mg) and DCC (2.62 mg, 12.8 μmol) were added at 20° C. with stirring to a solution of pyruvic acid (2.61 mg, 29.7 μmol) in dry DMF (0.10 mL). Stirring continued at room temperature for 2 h and a solution of prolyl-didemnin A (10.3 mg, 9.90 μmol) in DMF (0.40 mL) was added with stirring. The solution was stirred at room temperature for 24 h, diluted with CH 2 Cl 2 and washed with 5% NaHCO 3 solution and water to neutral pH, then dried (Na 2 SO 4 ) and the solvent evaporated to give the product as a white solid. The compound was purified by reversed phase HPLC using a gradient system of acetonitrile/water (see Supplementary Material, S-27) to give a white powdery substance; 1 H NMR (500 MHz, CDCl 3 ), see Supplementary Material, S-28; FABMS 1110.6 (M+H), see Supplementary Material, S-29; HRFABMS calcd for C 57 H 88 N 7 O 15 (M+H) 1110.6338, found 1110.6334.
TABLE I
Antiviral Activities of Didemnins a (# - New Compounds)
HSV/CV-1
Activ-
Compound
ng/mL
Cytotoxocity b
ity c
#
Gln-Didemnin B
100
16
?
50
16
?
20
16
?
10
0
+++
#
Cbz-Gln-Didemnin B (161)
100
0
+
50
0
+
20
0
+
10
0
−
Didemnin M (5)
100
16
?
50
16
?
20
0
+++
10
0
+
#
pGlu-Didemnin B (39)
100
16
?
50
16
?
20
0
+++
10
0
+
#
Cbz-pGlu-Didemnin B (145)
100
0
+
50
0
+
20
0
+
10
0
−
#
Gln[GlnIst 2 ]-Didemnin B (160)
100
0
+++
50
0
+
20
0
+
10
0
+
#
Cbz-Gln[Cbz-GlnIst 2 ]DB (162)
100
0
+++
50
0
+
20
0
+
10
0
+
O-Bu-Didemnin B (140)
100
16
?
50
9
+
20
8
+
10
0
+
Didemnin (B) (2)
100
16
?
50
0
+++
20
0
+++
10
0
+
Dehydrodidemnin B (6)
100
16
?
50
16
?
20
0
+++
10
0
+
Didemnin A (1)
100
0
+
50
0
+
20
0
+
10
0
−
FOOTNOTES:
a Performed by Dr. G. R. Wilson in this laboratory;
b 0 (least toxic) to 16 (toxic);
c +++ = complete inhibition; ++ = strong inhibition; + = moderate inhibition; − = no inhibition.
TABLE III
T/C (% of Control, Life Extension) vs. P388
Murine Leukemia in Mice
T/C
Dose, mg/kg
#Gln-DB
185
1
171
0.05
152
0.025
TABLE II
Cytotoxicity of Didemnins a # = New Compounds
Dose (ng/mL)
250
25
2.5
0.25
IC 50
Compounds
Inhibition (%)
(ng/mL)
#
Gln-Didemnin B (141)
100
100
100
94
0.1
#
PGlu-Didemnin B (39)
100
100
100
94
0.1
Dehydrodidemnin B (6)
100
100
100
95
0.2
Didemnin M (6)
100
100
100
94
0.8
Didemnin B (2)
100
100
40
0
7
O-Bu-didemlnin B (140)
100
97
0
NT b
10
Prolyl-didemnin A (43)
100
99
40
30
12
#
Cbz-Gln-didemnin B (161)
100
87
0
0
25
#
(Cbz-Gln) 2 -didemnin
99
87
0
0
50
B (162)
#
(Gln) 2 -didemnin B (160)
100
87
0
0
50
#
Cbz-pGlu-didemnin
100
70
0
0
50
B (145)
Didemnin A (1)
100
70
0
0
75
Boc-Pro-didemnin A (158)
100
55
0
0
85
a Performed by Dr. G. R. Wilson in this laboratory.
b NT = not tested.
TABLE III
T/C (% of Control, Life Extension) vs. P388
Murine Leukemia in Mice
T/C
Dose, mg/Kg
#Gln-DB
185
1
171
0.05
152
0.025 | Disclosed are semi-synthetic methods for the preparation of Didemnin Analogs. The compounds of this type are illustrated in Formula (I). | 2 |
BRIEF DESCRIPTION OF THE INVENTION
This invention relates to a variable venturi type carburetor, especially to a variable venturi type carburetor which is not provided with any oil damper within a suction piston thereof.
From the point of view of reducing harmful contaminants, such as carbon monoxide (CO), hydrocarbon (HC) and nitrogen oxides (NO x ), contained in exhaust gas emitted from an internal combustion engine mounted in a vehicle and reducing fuel consumption of the engine, the importance of the operating characteristics of a carburetor is increasing.
BACKGROUND OF THE INVENTION
Known carburetors are classified into two types, a fixed venturi type and a variable venturi type. Variable venturi type carburetors have been mainly mounted on a specially designed car such as a sports car. Variable venturi type carburetors have the advantages of: (a) good transient response which takes place when the supply of the mixture is changed, and; (b) good continuity of operating characteristics between the idling condition and the running condition of the engine, because the variable venturi type carburetors are not divided into a slow system and a main system. Consequently, to reduce harmful contaminants in exhaust gas, reduce fuel consumption of an engine and increase the driveability of a vehicle, variable venturi type carburetors are also utilized in regular type automobiles.
As is well known in the art, a variable venturi type carburetor is provided with a suction piston movable in a direction perpendicular to an air flow, in accordance with changes in the air flow, so as to vary the area of venturi opening formed between the bottom end of the suction piston and the wall of the carburetor body facing the bottom end of the suction piston, for maintaining the speed of the air flow passing through the venturi opening substantially constant. However, in a conventional variable venturi type carburetor, a suction piston may cause a vertical oscillation due to the slow oscillation of the intake vacuum of the engine when the engine is operated at low speed. In addition, when the throttle valve disposed in the carburetor is opened suddenly (when the engine is increasingly accelerated), the suction piston may suddenly displace upward and may fluctuate widely on both sides of the predetermined position, and as a result, the air fuel ratio may become lean.
To obviate the above-mentioned problems, a conventional variable carburetor has an oil damper installed within a piston rod for guiding the suction piston. However, the oil stored in the oil damper of the variable venturi type carburetor may be lost with the passage of time during which the variable venturi type carburetor is used. If damping oil is not supplied adequately, the carburetor may cause a wide fluctuation of the suction piston or a slow oscillation of the suction piston as a variable venturi type carburetor having no oil damper disposed therein does. As a result, the operating characteristics of a vehicle, such as the acceleration ability and driveability, are degraded.
The viscosity of damping oil stored in the oil damper must be adequately adjusted. If damping oil having a high viscosity is used, the suction piston is prevented from quick movement. As a result, the air fuel ratio is enriched, harmful contaminants contained in exhaust gas are increased and fuel consumption is increased. On the other hand, if damping oil having a low viscosity is used, the damping effect of the oil damper is decreased. In addition, it should be noted that the viscosity of oil varies as ambient temperature is varied. Therefore, in summer, the problem caused by using oil having a low viscosity may occur, and in winter, the problem caused by using oil having a high viscosity may occur. As is apparent from the above discussion, an oil damper is troublesome because it requires the maintenance and adjustment of the quality and quantity of oil at a predetermined level.
SUMMARY OF THE INVENTION
The principle object of the present invention is to provide a variable venturi type carburetor which can obviate the above-mentioned problems associated with an oil damper installed in the variable venturi type carburetor.
Another object of the present invention is to provide a variable venturi type carburetor which has a specially shaped venturi opening instead of a rectangular venturi opening of a conventional variable venturi carburetor and which can prevent fluctuation due to resonance and wide fluctuation from occurring without using an oil damper disposed therein.
A further object of the present invention is to provide a variable venturi type carburetor which can be easily maintained.
Other features and advantages of the present invention will become apparent from the description set forth below with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 and 2 are schematic illustrations which are used for the explanation of the present invention;
FIG. 3 is a diagram which shows the relationship between the displacement of the suction piston and the area of the venturi opening in a variable venturi carburetor according to the present invention;
FIG. 4 is a sectioned elevational view which shows a first embodiment of the present invention;
FIG. 5 is a side view of the apparatus shown in FIG. 4;
FIG. 6 is a side view which shows a suction piston installed in the apparatus shown in FIG. 4;
FIG. 7 is a side view which shows a suction piston of a second embodiment according to the present invention;
FIG. 8 is a side view which shows a suction piston of a third embodiment according to the present invention;
FIG. 9 is a diagram which shows the relationships between the air flow Ga and the pressure variation ΔP 2 /Δx of a conventional carburetor and of the apparatus shown in FIGS. 4 through 6, and;
FIGS. 10 and 11 are side views, each of which shows a suction piston of a fourth or fifth embodiment according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Principle of the Present Invention
Prior to the explanation of embodiments according to the present invention, the theoretical background of the present invention will be explained. A variable venturi type carburetor has a suction piston movably disposed within a suction chamber. The suction piston has a hole therein for communicating the venturi opening with the inside of the suction chamber and the suction chamber has a spring disposed therein for urging the suction piston. Therefore, the variable venturi type carburetor is divided into two models, which are, (1) a pneumatic system model shown in FIG. 1 and (2) a spring system model shown in FIG. 2.
(1) Pneumatic System Model (FIG. 1)
Pressure acting on a suction piston 2 installed in a suction chamber 1 is designated by P 1 , the cross sectional area of the suction piston 2 is designated by A 1 , pressure acting on the surface, facing the venturi opening, of the suction piston 2 is designated by P 2 and the cross sectional area of the suction piston is designated by A 2 . When the forces acting on the suction piston 2 are balanced, the pressures P 1 and P 2 acting on the suction piston 2 are equal to each other and P 1 equals P 2 . When the suction piston 2 is displaced a small distance Δx from the balanced condition by an external force, the variations of the pressures P 1 and P 2 may be designated as ΔP 1 and ΔP 2 , and the following equation of the balanced force obtained
ΔP.sub.2 =ΔP.sub.1 +ΔP.sub.r +ΔP.sub.f (1)
wherein,
ΔP r designates the variation of the pressure caused by the viscosity of air passing through the hole, and is expressed as
ΔP.sub.r =128 μL/πd.sup.4 Q,
and;
ΔP f designates the variation of the pressure caused by the force of inertia of air passing through the hole, and is expressed as
ΔP.sub.f =4Lρ/πd.sup.4 ·dQ/dt
wherein,
Q designates an air flow passing through the hole, and is expressed as
Q=V/E·dP.sub.1 /dt-A.sub.1 dx/dt;
μ designates the coefficient of viscosity of air;
ρ designates the density of air;
L designates the length of the hole;
d designates the diameter of the hole;
V designates the volume of the suction chamber, and;
E designates the bulk modulus of air.
The force f acting on the suction piston 2 is expressed by the following equation.
f=A.sub.2 P.sub.2 -A.sub.1 P.sub.1 (2)
According to the required operating characteristics of the variable venturi carburetor, the pressure variation ΔP 2 at the venturi opening is expressed by the following equation when the suction piston 2 is displaced a small distance Δx from the balanced condition.
ΔP.sub.2 /Δx=C (3)
wherein, C is constant.
(2) Spring System Model (FIG. 2)
The equation of motion concerning the spring system model shown in FIG. 2 is expressed by the following equation, wherein m is the mass of the suction piston 2 and k is the coefficient of the spring 3, but the damped factor is neglected.
f=m d.sup.2 x/dt.sup.2 +kx (4)
To study the stability of the variable venturi carburetor, a characteristic equation is established using the above-mentioned equations (1) through (4), and a criterion of the stability of the variable venturi carburetor is obtained, which is given by the following equation.
A.sub.1 E/V>ΔP.sub.2 /Δx (5)
(When an equation ΔP 1 =E/VA 1 ·Δx, which expresses the increase of the pressure due to the compression of gas, is substituted into equation (5), the following equation (6) is obtained.
ΔP.sub.1 /Δx>ΔP.sub.2 /Δx (6)
It will be understood from the equation (5) that, when the ratio between the pressure variation ΔP 2 of the pressure P 2 at the venturi opening and the small displacement Δx of the suction piston 2 is selected to be smaller than a predetermined value which is given by the equation (5), the fluctuation of the suction piston due to resonance can be prevented from occurring. In addition, when the operating characteristics of the variable venturi type carburetor are taken into consideration, it can be concluded that the variation ΔS of the cross sectional area S of the venturi opening due to the small displacement Δx of the suction piston should be small.
Consequently, when a conventional variable venturi carburetor which has a rectangular venturi opening is used to satisfy the above-mentioned criterion, the venturi opening should be shaped into a slender rectangle having its long sides along the displacing direction of the suction piston. This will result in the variation of the cross sectional area of the venturi opening due to the small displacement Δx of the suction piston being small. However, such a variable venturi carburetor which has a slender rectangular venturi opening must have a large suction piston stroke, so that the maximum air flow, which is determined by the required performance of the carburetor, is supplied through the venturi opening. As a result, such variable venturi carburetor can not be actually used.
The inventors of the present invention have conducted research to find a shape of the venturi opening which can satisfy the above-mentioned criterion and provide a sufficiently large maximum air flow, and which can be actually used in a variable venturi carburetor. Referring to FIG. 3, a displacement of the suction piston is designated by x, and the area of the venturi opening corresponding to the displacement x is designated by S(x). When the suction piston is displaced a small distance Δx and the variation ratio is a constant α, the condition is given by the following equation (7).
[S(x+Δx)-S(x)]/S(x)=α (7)
The integral of the equation (7) is
S=S.sub.o e.sup.αx (8)
wherein, S o is the area of the venturi opening at x=0.
The side shape f(x) of the venturi opening is obtained when the equation (8) is differentiated.
f(x)=αS.sub.o e.sup.αx (9)
It is concluded, in view of the above discussion, that when the end surface of the venturi opening is formed in an exponential curve of the displacement of the suction piston, the pressure variation ΔP 2 at the venturi opening can be maintained lower than a predetermined value. Consequently, fluctuation of the suction piston due to resonance can be prevented from occurring and a sufficiently large cross sectional area of the venturi opening can be obtained.
Embodiment
An embodiment of the present invention in accordance with the above discussion will now be explained with reference to FIGS. 4 through 6.
A carburetor body 10 is provided with a chamber case 12 and a suction chamber 14 is formed within the chamber case 12. The chamber case 12 has a guide 13 formed therein in one body. The guide 13 has a rod 18 movably inserted therein and the rod 18 is fixed to a suction piston 16. The suction piston 16 is held by the chamber case 12, so that the suction piston 16 can move within the chamber case 12, and the suction piston 16 has labyrinth packings 16a formed thereon. The wall of the suction piston 16, which wall faces to a venturi opening 28, has a hole 16b formed therein. The upper wall of the carburetor body 10 has a hole 10a formed therein, which hole 10a communicates the inside of the carburetor body 10 with an atmospheric pressure chamber 20 formed at a space between the suction piston 16 and the carburetor body 10. A metering rod 22 is fixed to the bottom end of the suction piston 16 so that the metering rod 22 can be inserted into a well 24 connected to the lower wall of the carburetor body 10. Fuel supplied to the well 24 through an inlet pipe 27 is measured and supplied into the venturi opening 28 through a clearance formed between the metering rod 22 and a metering jet 26 formed at an inlet of the well 24. A throttle valve 30 is disposed at a position downstream of the venturi opening 28 and an air horn 32 for supplying air is disposed at a position upstream of the venturi opening 28. The suction chamber 14 has a spring 34 therein for urging the suction piston 16.
The construction mentioned above is similar to that of a conventional variable venturi type carburetor. The variable venturi type carburetor according to the present invention shown in FIGS. 4 through 6 has a flat projection 36 formed on the lower wall of the carburetor body 10, and also, has a pair of partitions 38 and 38' fixed to the bottom end of the suction piston 16. The end surface f(x) of each partition 38 or 38' is formed in an exponential curve f(x)=αS o e.sup.αx at a distance x measured from the bottom end. As a result, the area of the venturi opening 28, which is formed by the bottom end of the suction piston 16, the projection 36 formed on the carburetor body 10 and the pair of partitions 38 and 38', is also an exponential function of the distance x. The variation ratio ΔS/S is constant when the ratio is defined by the area variation ΔS of the venturi opening in accordance with the small displacement Δx to the area S of the venturi opening.
If the throttle valve 30 is suddenly opened while the suction piston 16 has had a predetermined displacement in accordance with the air flow passing through the venturi opening 28, so that the forces acting on the suction piston 16 due to the pressure and the spring 34 have been balanced, the vacuum pressure P 2 in the venturi opening 28 is raised. The raised vacuum pressure P 2 is transmitted into the suction chamber 14 through the hole 16b. As a result, the force acting in the atmospheric pressure chamber 20 and that acting in the suction chamber 14 become unbalanced, and the suction piston 16 begins to displace upward against the urging force of the spring 34. When the suction piston 16 begins to displace upward, the vacuum pressure in the venturi opening is lowered and a force acting on the bottom end of the suction piston 16, for raising the suction piston 16, is generated. On the other hand, the air in the suction chamber 14 is compressed when the suction piston 16 is raised and the suction piston 16 is forced back due to the air cushion effect.
The area of the venturi opening 28 is so selected that the variable venturi carburetor can satisfy the equation (6), that is (ΔP 1 /Δx)>ΔP 2 /Δx, and as is apparent from FIG. 4, A 1 >A 2 . The force acting on the suction piston 16 due to the pressure increase ΔP 2 when the suction piston 16 is raised upward is equal to ΔP 2 ×A 2 . The force acting on the suction piston 16 due to the air cushion effect of the suction chamber 14 caused by the displacement of the suction piston 16 is equal to ΔP 1 ×A 1 . Consequently, the force acting on the suction piston due to the air cushion effect ΔP 1 ×A 1 is larger than that due to the pressure increase ΔP 2 ×A 2 . Therefore, the suction piston 16 does not generate the fluctuation due to resonance and wide fluctuation.
The test data obtained by the variable venturi type carburetor according to the present invention shown in FIGS. 4 through 6 (in which, the constants expressed in the equation (9) are selected to be 0.1≦α≦0.3, 1.0≦S o ≦60 (mm 2 )) and by that of a conventional type having a slender venturi opening (the width of which is not less than 8 mm) and no oil damper disposed therein are illustrated in FIG. 9. In FIG. 9, the data are plotted on a graph with the air flow in weight Ga g/s as the ordinate and the pressure variation ΔP 2 /Δx, defined by the ratio of the pressure increase ΔP 2 to the small displacement Δx of the suction piston, as the abscissa. The curve A shows the operating characteristics of the present invention. From the curve A it is seen that the pressure variation ΔP 2 /Δx is almost constant for all the air flow Ga. Fluctuation of the suction piston 16 could not be observed. On the other hand, the curve B shows the operating characteristics of the conventional carburetor. From the curve B, it is seen that the pressure variation ΔP 2 /ΔX is steeply increased at the closed position of the suction piston where the air flow Ga is small. Fluctuation of the suction piston was observed. This fluctuation is caused by the fact that the pressure variation ΔP 2 /Δx exists within a range which is above the limit of the fluctuation expressed by ΔP 2 /Δx=A 1 E/V.
The variable venturi type carburetor shown in FIGS. 4 through 6 can prevent the fluctuation of the suction piston without using an oil damper which causes various problems.
The suction piston 16 shown in FIG. 7 is provided with a pair of partitions 38a and 38'a, each of which has an end surface of an arc shape instead of those of 38 and 38' of the exponential curve. It is easier to manufacture the partition 38a or 38'a than the partition 38 or 38'. The suction piston 16 shown in FIG. 8 is provided with a pair of partitions 38b and 38'b, each of which has an inclined end surface. It is easier to manufacture the partition 38b and 38'b than the partitions 38 and 38'. It has been confirmed by tests that, when the suction piston shown in FIGS. 7 and 8 are so designed that the pressure variation ΔP 2 /Δx is smaller than the limit of the fluctuation A 1 E/V, the fluctuation of the suction piston due to resonance and wide fluctuation can be prevented. (Tests were effected for the suction piston shown in FIG. 7 in a range of R/3≦R≦D, 10≦S o ≦60 (mm 2 ), and for the suction piston shown in FIG. 8 in a range of 80°≦θ≦140°, 10≦S o ≦60 (mm 2 )).
A variable venturi carburetor shown in FIG. 10 comprises a suction piston 16 having a flat bottom end and a pair of partitions 40 and 40' disposed on a wall of a carburetor body 10 facing the bottom end of the suction piston 16. The end surface of each partition is formed in an exponential curve f(x)=αS o e.sup.αx at a distance measured from the wall of the carburetor body 10. The ends surfaces are so disposed that each end surface is opposite the other end surface. The variable venturi type carburetor shown in FIG. 10 does not cause fluctuation of the suction piston. The end surface of the partition 40 or 40' shown in FIG. 10 can also be formed in an arc shape similar to that shown in FIG. 7, and can be formed in an inclined shape (shown in FIG. 11) similar to that shown in FIG. 8.
The present invention can prevent fluctuation due to resonance and wide fluctuation of the suction piston without an oil damper being disposed in a carburetor, and the variable venturi type carburetor is simple in construction and is easy to maintain and adjust. | Disclosed is a variable venturi type carburetor which is provided with a suction piston movable in a direction perpendicular to an air flow, in accordance with changes in the air flow, so as to vary the area of a venturi opening formed between the bottom end of the suction piston and a wall of the carburetor body facing the bottom end of the suction piston, for maintaining the speed of the air flow passing through the venturi opening substantially constant. The suction piston has a hole formed therein communicating the venturi opening with a suction chamber in which the suction piston is moved. The carburetor has a spring for urging the suction piston, but does not have any oil damper within the suction chamber. The shape of the venturi opening is so arranged that the increase of the area of the venturi opening in accordance with the displacement of the suction piston is gradually increased. As a result, fluctuation due to the resonance and wide fluctuation caused during the transient response of the suction piston do not occur. | 8 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates to an electronic apparatus for cooling a semiconductor element therein, with using a liquid cooling system.
[0002] The semiconductor element generates heat during the operation thereof, which is used in an electronic apparatus, such as a computer, etc.
[0003] In particular, with the semiconductor in recent year, the heat-generation comes up much more, due to the demands on high processing speed and high capacity or performances thereof. In general, the semiconductor element looses the function of as the semiconductor element, remarkably, when exceeding over a predetermined level in temperature thereof, and therefore it is necessary to make compulsive cooling, in particular, on the semiconductor having a large amount of heat generation thereof.
[0004] As a method for cooling down the semiconductor of the electronic apparatus, for example, there are already known methods of applying the heat conduction, applying an air cooling, with using a heat pipe, and applying a liquid cooling, etc.
[0005] Among of those, cooling applying a liquid cooling is most effective for the semiconductor element having large heat-generation.
[0006] Such the cooling method applying the liquid cooling is described, in more details thereof, for example, Japanese Patent Laying-Open Nos. Hei 5-335454 (1993), Hei 6-97338 (1994), Hei 6-125188 (1994), Hei 10-213370 (1998), etc.
[0007] However, those conventional technologies are limited in the use thereof only in a filed of a large-scaled computer.
[0008] This is because the liquid cooling system comes to be large in the scale due to the fact that it needs a large number of parts for exclusive use of cooling, such as a pump, a piping system, a radiator, etc., and it is difficult to maintain the reliability in respect of applying the liquid into cooling thereof.
[0009] Also, another one reason thereof is the fact that such the semiconductor element is not used in the field other than the large-scaled computer, which has a large heat-generation so that the liquid cooling is needed therein.
[0010] Technology of applying the liquid cooling into a small-sized electronic apparatus is disclosed in Japanese Patent Laying-Open No. Hei 6-266474 (1994). In this prior art, a heat-receiving jacket attached on the semiconductor element and a radiator disposed apart from it are connected through flexible tubes, thereby cooling down it with an aid of the liquid flowing therein.
[0011] However, as was mentioned previously, an amount of heat-generation comes up every year, in particular, of the semiconductor elements, etc., which are used in the electronic apparatuses, such as, a personal computer, a home server, a projector, a media storage, etc., and for treating with it, but a compulsive cooling is not sufficient enough, with using the natural air cooling or a fan, or a cooling of using the heat pipe therein.
[0012] Then, attention was paid onto the technology described in Japanese Patent Laying-open No. Hei 6-6266474 (1994), and with this, it is possible to receive the liquid cooling system within an inside of a case of a personal computer, by using the case itself of the computer to be a heat radiation plate, which is made of a metal material having good heat conductivity.
[0013] However, installation of the liquid cooling system into such the computer causes a new problem.
[0014] That is, due to the fact that only a small amount of the liquid is held within the liquid cooling system, and further that the operating temperature thereof is relatively high, etc., corrosion is promoted on the parts or elements in contact with the liquid, which are made of a metal material, such as, the heat-receiving jacket and the radiator, since the liquid is degraded in quality thereof even if the corrosive ion flow out in a very small amount thereof, in particular, from the parts or element of an organic material (i.e., the parts or element made of synthetic resin).
[0015] If causing water leakage due to the corrosion, it results into an important problem of stopping the function of that electronic apparatus; therefore, it is indispensable to make a treatment of measure of anti-corrosion on the parts or element, to be in contact with the cooling water.
[0016] Further, a treatment of measure of anti-corrosion due to a liquid is already known, for example, in Japanese Patent Laying-Open No. 2003-185321 (2003).
BRIEF SUMMARY OF THE INVENTION
[0017] An object, according to the present invention, is to provide a liquid cooling system enabling to maintain corrosion resistance for a long time period (for example, from 5 to 10 years), and also an electronic apparatus using the same therein.
[0018] According to the present invention, the object mentioned above is accomplished by a liquid cooling system, comprising: a pump for supplying a cooling liquid; a heat-receiving jacket, being supplied with said cooling liquid, for receiving heat from an electronic parts; a radiator, being supplied with said cooling liquid passing through said heat-receiving jacket, for radiation heat therefrom; and flow passages for circulating said cooling liquid in a route passing through said radiator back to said pump, wherein: an ion exchange bag, having a bag enclosing an ion exchange resin therein, is disposed in a part of said route.
[0019] Also, according to the present invention, the object mentioned above is accomplished with the liquid cooling system, as mentioned above, wherein: the ion exchange bag, having the bag enclosing the ion exchange resin therein, is held within a container, and said ion exchange holder being exchangeable with the ion exchange bag is provided in said container.
[0020] And also, according to the present invention, the object mentioned above is accomplished with the liquid cooling system, as mentioned above, wherein: said ion exchange bag or said ion exchange holder are disposed within an inside or a downstream of said radiator, and also in one of parts building up the liquid cooling system in an upstream of said heat-receiving jacket.
[0021] Further, according to the present invention, the object mentioned above is accomplished with an electronic apparatus, comprising: a heat-generation element mounted on a substrate; a heat-receiving jacket, being thermally connected to said heat-generation element; a heat radiation jacket for radiating heat of a heated liquid supplied from said heat-receiving jacket; a pump for circulating the liquid to those jackets; and a piping for connecting said pump and said both jackets, wherein: an ion exchange bag, having a bag enclosing ion exchange resin therein, is provided on way of said piping.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0022] Those and other objects, features and advantages of the present invention will become more readily apparent from the following detailed description when taken in conjunction with the accompanying drawings wherein:
[0023] FIG. 1 is a perspective view of a personal computer of notebook type, applying a cooling system therein, according to the present invention;
[0024] FIG. 2 is a block diagram of the personal computer of notebook type, applying the cooling system therein, also according to the present invention;
[0025] FIG. 3 is a graph for showing change in a halogen ion concentration with the passage of time, with using an ion exchange bag therein;
[0026] FIG. 4 is a view for showing an example of the ion exchange bag, according to the present invention;
[0027] FIG. 5 is a view for showing the structure of a tank, applying the ion exchange bag according to the present invention therein;
[0028] FIG. 6 is a view for showing the ion exchange bag, according to one embodiment of the present invention;
[0029] FIG. 7 is a view for showing the ion exchange bag, according to other embodiment of the present invention;
[0030] FIG. 8 is a view for showing an ion exchange holder, according to one embodiment of the present invention;
[0031] FIG. 9 is a view for showing the structure of a tank, using the ion exchange holder therein, which is shown in FIG. 8 mentioned above;
[0032] FIG. 10 is a view for showing the ion exchange holder, according to other embodiment of the present invention;
[0033] FIG. 12 is a view for showing the structure of pipe arrangement with using therein the ion exchange bag, according to one embodiment of the present invention;
[0034] FIG. 13 is also a view for showing the structure of pipe arrangement with using the ion exchange bag therein, according to one embodiment of the present invention;
[0035] FIG. 14 is also a view for showing the structure of pipe arrangement with using the ion exchange bag therein, according to one embodiment of the present invention;
[0036] FIG. 15 is a view for showing the structure of a tank using the ion exchange bag or the ion exchange holder therein, according to one embodiment of the present invention; and
[0037] FIG. 16 is a view for showing the structure of a tank using the ion exchange bag or the ion exchange holder therein, according to one embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0038] Hereinafter, explanation will be made on the embodiments according to the present invention, by referring to the drawings attached herewith.
[0039] FIG. 1 is a perspective view of a personal computer of notebook type, with using the cooling system according to the present invention therein.
[0040] However, though will be explained about upon the notebook type personal computer most familiar with, hereinafter, however the present should not be restricted only to such the notebook type personal computer, but is also applicable to other electronic apparatuses, reaching up to so-called a desktop type personal computer and a server.
[0041] In FIG. 1 , a semiconductor element 6 installed within a main housing 7 is connected with a heat-receiving jacket 2 , within an inside of which is formed a flow passage for a cooling liquid. In the main housing 7 is also provided a pump 5 . On a rear surface of a housing 8 of a display device, there are provided a heat radiation pipe 4 and a tank 5 . The pump 1 , the heat-receiving jacket 2 , the heat radiation pipe 4 and the tank 5 are connected to builds up a closed-loop through connector pipes 3 , as shown in the figure, and within an inside of those is filled up with a cooling liquid 10 (will be described by referring to FIG. 2 ). Within the tank 5 is provided an ion exchange bag 9 . Between the main housing 7 and the display device housing 8 , the piping is connected by using flexible tubes 3 ′.
[0042] FIG. 2 is a view for showing the liquid cooling system of the notebook type personal computer, which is shown in FIG. 1 mentioned above, according to the first embodiment, but in the form of a block diagram thereof.
[0043] In this FIG. 2 , the ion exchange bag 9 is made from a bag having water permeability, and being formed rod-like in the shape thereof and containing the ion exchange resin therein. For the purpose of suppressing thermal degradation of the ion exchange resin, it is preferable to dispose the ion exchange bag within an inside of the radiator, being low in temperature thereof, or in the downstream thereof, and also within the constituent parts of the liquid cooling system in the upstream of the heat-receiving jacket.
[0044] The conventional ion exchanger is built up with filling the ion exchange resin into a cylindrical container, so that the cooling water passes through this ion exchange resin, to be treated with the ion exchange with high efficiency thereof, thereby improving the liquid quality of the cooling liquid. This structure is applied into the liquid cooling system for the large-scaled computer, for example. In a small-sized computer, because of application of a small-sized motor therein, it is impossible to use an ion exchanger of such the water-conducting type having a large pressure loss therein.
[0045] According to the present invention, a dipping type ion exchange bag 9 is applied therein, wherein ions within the cooling liquid are adsorbed due to diffusion. The corrosive ions flow out from the organic materials used within, such as, the pump 1 , the tank 5 , the flexible tubes 3 ′, etc.
[0046] FIG. 3 is a graph for showing change in a halogen ion concentration with using ion exchange bag in the small-sized liquid cooling system, with respect to the passage of time.
[0047] In this FIG. 3 , 1 cc of the ion exchange bag tested can adsorb all 300 ppm of chlorine ion within 50 cc of the cooling liquid during a time period of 100 hours. With this system, an amount of chlorine ions flowing out for five (5) years is equal to 300 ppm or less than that.
[0048] From this, it is apparent that adsorption velocity due to diffusion of the ion exchange resin within the ion exchange bag is sufficiently swift with respect to the flow-out velocity of the ions. Accordingly, the dipping-type ion exchange bag can be an effective means for corrosion control in the small-sided liquid cooling system.
[heading-0049] [Embodiment 1]
[0050] FIG. 4 is a view for showing an example of the ion exchange bag 9 mentioned above therein.
[0051] In this FIG. 4 , the ion exchange bag is made up with an ion exchange resin 11 , mixing up a positive ion (i.e., a cation) exchange rein for adsorbing the positive ions and a negative (i.e., an anion) ion exchange resin for adsorbing the negative ions, and a water-permeable bag 12 , which contains the ion exchange resins therein and is formed to be rod-like in the shape thereof.
[0052] In other words, like a teabag of green tea or black tea enclosing the tea leaves by the water-permeable cloth or paper, it also encloses the ion exchange resins by the water-permeable cloth or paper, and it is bonded on the periphery thereof, or welded through heating (in FIG. 4 , being indicted by a white outlined portion surrounding the ion exchange resin 11 ).
[0053] This ion exchange bag 9 is effective for ion adsorbing within the cooling water, if putting it into the tank, for example, since almost of the cooling liquid circulating around passes through the ion exchange bag 9 .
[0054] However, the ion exchange bag 9 floats up to the surface within the tank if only put into the tank, therefore it is preferable to fix the ion exchange bag 9 at a predetermined position within an inside of the tank.
[0055] However, in a case where the ions flowing out is only the positive one (i.e., the cation), such as, a metal ion or the like, the ion exchange bag may be made up with only the positive ion exchange resin. Also, in a case where the ion flowing out is only the negative ion (i.e., the anion), such as, halogen ion or the like, the ion exchange bag may be made up with only the negative ion exchange resin.
[0056] For the small-sized liquid cooling system of being equal or less than 1 litter, it is preferable that the ion exchange bag contains therein the ion exchange resin being equal or less than 10 cc in the volume. The water-permeable bag is sealed up through, such as, the thermo-welding, etc. The water-permeable bag is made from mesh or non-woven fabric, on which treated with a water permeability processing, then it comes into the cooling liquid swiftly; therefore it sinks down, but without remaining a bubble within the bag.
[0057] With this, the corrosive ions within the cooling liquid can permeate through the water-permeable bag together with the cooling liquid, thereby being adsorbed by the ion exchange resin within the bag. An amount of the ion exchange resin to be filled up within the bag is determined by paying the consideration upon the expansion of the cooling liquid when it is frozen. Also, sizes of a small cavity of the mesh or the non-woven fabric are determined, so that the cracking ion exchange resin cannot passes therethrough. This cracking ion exchange resin comes to be a reason of causing a trouble within the pump, if it reached to the movable portion thereof, for example.
EXAMPLE 2
[0058] FIG. 5 is a view for showing the condition, in a case where the ion exchange bag is located at the predetermined position within the tank.
[0059] In this FIG. 5 , surrounding the ion exchange bag is provided a partition plate 13 .
[0060] With this, the ion exchange bag 9 will not comes up to the surface if a gaseous layer remains in an inside thereof, thereby enabling to adsorb the corrosive ions within the cooling liquid. Also, with provision of the partition plate 13 at the central portion of the tank 5 , it is possible to hold the ion exchange bag 9 within the cooling liquid if the cooling system is used in any posture thereof. For this reason, the corrosive ions within the cooling liquid can pass through the water-permeable bag together with the cooling liquid, to be adsorbed by the ion exchange resin within the bag.
EXAMPLE 3
[0061] FIG. 6 is a view for showing other embodiment of the ion exchange bag therein.
[0062] In this FIG. 6 , the water-permeable bag 12 , having a hole 14 for use of fixing thereof, can be holed within the liquid, but without floating up when a gaseous layer is formed within the bag because of the low water-permeability thereof. For this reason, the corrosive ions within the cooling liquid can pass through the water-permeable bag together with the cooling liquid, to be adsorbed by the ion exchange resin within the bag.
EXAMPLE 4
[0063] FIG. 7 is a view for showing further other embodiment of the ion exchange bag therein.
[0064] In this FIG. 7 , the water-permeable bag 12 , having a weight 15 for use of prevention of floating, can be held within the liquid, but without floating up even if a gaseous layer is formed therein because of the low water-permeability thereof. In the case of using the anti-floating weight 15 thereon, the ion exchange bag can be held within the liquid when the cooling system is used in any posture thereof. For this reason, the corrosive ions within the cooling liquid can pass through the water-permeable bag together with the cooling liquid, to be adsorbed by the ion exchange resin within the bag. In a case where the tank is made of a metal, such as, iron, the weight 15 can be attached, easily if making it from a permanent magnet.
[heading-0065] [Embodiment 5]
[0066] FIG. 8 is a view for showing an example of an ion exchange holder 16 therein.
[0067] In this FIG. 8 , the ion exchange holder 16 has the ion exchange bag 9 , a part for holing that ion exchange bag 9 therein, and a part 18 to be fixed onto a part of cooling parts (such as, the tank). The part for holding the ion exchange bag 9 therein is made of a metal mesh, for example, and the part 18 to be fixed onto the cooling part is a flange, for example.
[0068] However, the flange has a function of sealing up therethrough, with using such as, packing or an “0” ring, for example. The ion exchange holder 16 has an advantage that the ion exchange bag can be exchanged, easily, when the capacity of adsorbing the corrosive ions is reduced down due to the degradation of the ion exchange resin. Also, using of the holder in common with, as a water supply opening, brings about an advantage that the water can be supply in addition, easily when the cooling liquid is lowered down in the amount thereof.
[0069] FIG. 9 is a view for showing an example, in which the ion exchange holder 16 is installed in the tank 5 .
[0070] In this FIG. 9 , further if the ion exchange holder 16 is located in the vicinity of the center of the tank, the ion exchange holder can be held within the cooling liquid if the cooling system is used in any posture thereof. For this reason, the corrosive ions within the cooling liquid can pass through the water-permeable bag together with the cooling water, thereby being adsorbed by the ion exchange resin within the bag.
EXAMPLE 6
[0071] FIG. 10 is a view for showing other embodiment of the ion exchange holder 16 therein.
[0072] In this FIG. 10 , the water-permeable bag 12 attached with the anti-floating weight 15 is fixed on a fixing part 18 , such as, the flange, etc., with using the fixing hole 14 . The ion exchange bag 14 is soft, therefore the ion exchange bag can be held within the cooling liquid even if the cooling system is used in any posture thereof. For this reason, the corrosive ions within the cooling liquid can pass through the water-permeable bag together with the cooling liquid, to be adsorbed by the ion exchange resin within the bag.
EXAMPLE 7
[0073] FIG. 11 is a view for showing other embodiment of the ion exchange holder 16 , therein.
[0074] In this FIG. 11 , with using a plural pieces of ion exchange bags, each being thin in the shape thereof, the contacting area between the ion exchange resin and the cooling liquid can be increased up; therefore it is possible to adsorb the corrosive ions in an earlier stage. In a case there is a necessity of adsorbing the corrosive ions in the earlier stage in this manner, it is effective to adopt the structure of increasing up the contacting area between the ion exchange resin and the cooling water, with using the ion exchange bags in the plural number thereof, and/or a below-like ion exchange bag, for example.
EXAMPLE 8
[0075] FIG. 12 is a view for showing an embodiment, in which the ion exchange holder 16 is inserted into a container having a connect opening thereof.
[0076] In this FIG. 12 , the ion exchange holder 15 is attached onto the container 19 having the connect opening between the conduit 3 . The ion exchange holder 16 does not block the flow passage of the cooling liquid, therefore there is caused no such the pressure loss within the ion exchange holder 16 . The ion exchange holder 16 can be replaced with the ion exchange bag 9 , easily, when the capacity of adsorbing the ions falls down due to the degradation of the ion exchange resin.
EXAMPLE 9
[0077] FIG. 13 is a view for showing an embodiment, in which the ion exchange holder 16 and the container having the connect opening with the conduit are formed into a one body.
[0078] In this FIG. 13 , if it is not necessary to replace the ion exchange bag 9 , the ion exchange holder 16 and the container having the connect opening with the conduit may be formed into a one body, as is shown in the present embodiment. Those ion exchange holders 16 show a large effect, in particular, when they are positioned in an upstream of the heat-receiving jacket, for example, being made of the material in need of corrosion control thereof, since it can adsorb those ions, easily.
EXAMPLE 10
[0079] FIG. 14 shows an example of building up the container 19 with using a conduit 20 having a small capillary in a part thereof and also a cover 21 . This container can be manufacture through the drawing process, easily, thereby obtaining a low cost thereof.
EXAMPLE 11
[0080] FIG. 15 is a view for showing the ion exchange bag 9 or the ion exchange holder 16 , being disposed within the tank.
[0081] In this FIG. 15 , around the periphery of the ion exchange bag 9 is provided a partition plate 13 . The cooling liquid flows into an inside of the tank from a discharge opening 5 b , and is stayed or accumulated within the partition plate. The cooling liquid accumulted within the partition plate drips down from a drip opening 13 a opened in the partition plate, gradually. Due to the flow of the cooling liquid dripping therefrom, the corrosive ions within the cooling liquid are adsorbed on the ion exchange resin within the ion exchange bag 9 or the ion exchange holder 16 , with superior or high efficiency. In a case where a flow rate of circulation is large, the cooling liquid flowing into the tank 5 overflows from an overflow opening 13 b formed in the partition plate.
EXAMPLE 12
[0082] FIG. 16 shows an example, in which the drip opening 13 a of the partition plate and the ion exchange bag 9 or the ion exchange holder 16 are disposed in series.
[0083] In this FIG. 16 , with this, it is possible to let the cooling liquid to penetrate within the ion exchange bag 9 or the ion exchange holder 16 , with using the pump head of the cooling liquid accumulated within the partition plate 13 , thereby enabling to adsorb the corrosive ions within the cooling liquid, further effectively. In this so-called a dripping method, the more effective, the higher the pump head of the cooling liquid is.
[0084] Thought the embodiments of the ion exchange bag and the ion exchange holder, mentioned in the above, are explained of being applied into only the notebook-type personal computer, in the above, however the present invention can be also applied in the liquid cooling system, being applicable into other electronic apparatuses, such as, the projector, the media storage, and the server, etc., for example.
[0085] As was fully explained in the above, according to the present invention, it is possible to provide the liquid cooling system or an electronic apparatus using the same therein, enabling to maintain the corrosion resistance for a long time period (from 5 to 10 years) suitable for the electronic apparatus, which has the heat-generation body therein, such as, the semiconductor element, being microminiaturized and very thin in the thickness and also having a large amount of heat-generation thereof.
[0086] The present invention may be embodied in other specific forms without departing from the spirit or essential feature or characteristics thereof. The present embodiment(s) is/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 by the forgoing description and range of equivalency of the claims are therefore to be embraces therein. | A liquid cooling system for use in an electronic apparatus, being super small-sized and thin in the shape and being suitable for cooling a heat-generation part, such as, a semiconductor element having large amount of heat generation, for example, with maintaining the corrosion resistance thereof for a long time period, comprises: a pump for supplying a cooling liquid; a heat-receiving jacket, being supplied with the cooling liquid, for receiving heat from an electronic parts; a radiator, being supplied with the cooling liquid passing through the heat-receiving jacket, for radiation heat; and flow passages for circulating the cooling liquid in a route passing through the radiator back to said pump, wherein an ion exchange bag, having an ion exchange resin and a bag enclosing it therein, is disposed in a part of the constituent parts of the liquid cooling system, and/or the ion exchange bag is exchangeable. | 7 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Application No. 61/032,598, filed Feb. 29, 2008, the entire disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates to precipitation-hardenable stainless steel alloys and in particular to a method of making such alloys to reduce the size and distribution of inclusions that adversely affect the fatigue resistance and fracture toughness provided by such alloys.
[0004] 2. Description of the Related Art
[0005] U.S. Pat. No. 5,681,528 and U.S. Pat. No. 5,855,844 describe high-strength, notch-ductile, precipitation-hardening stainless steels. Those alloys are used for structural applications in the aerospace industry and in many additional non-aerospace uses. Testing of the known alloys by the aerospace industry has indicated that the fatigue life provided by the alloys, while considered to be acceptable, leaves something to be desired. Fatigue life is a very important parameter for the design of aerospace structural members. Improved fatigue life would allow for either product weight savings or longer design service life for structural components. It is desired to provide improved fatigue-strength relative to the known alloys, while still maintaining the excellent combination of strength, toughness, and corrosion resistance that the known alloys provide.
[0006] The abovementioned fatigue testing has demonstrated that the majority of fatigue failures initiate at large second phase inclusions, which are present in the material as a result of the alloy composition and processing. The alloy according to the present invention is designed to provide strength and toughness that are equivalent to the known alloy, but without the resultant large second phase inclusions that adversely affect the fatigue resistance of the known alloy.
SUMMARY OF THE INVENTION
[0007] The improvement in fatigue life desired for the known precipitation hardenable, stainless steel alloys is achieved to a large degree by the alloy in accordance with the present invention. The alloy according to this invention is a precipitation hardening Cr—Ni—Ti—Mo martensitic stainless steel alloy that provides a unique combination of corrosion resistance, fatigue resistance, strength, and toughness.
[0008] The broad, intermediate, and preferred compositional ranges of the precipitation hardening, martensitic stainless steel of the present invention are as follows, in weight percent:
[0000] Broad Intermediate Preferred C 0.03 max 0.02 max 0.015 max Mn 1.0 max 0.25 max 0.10 max Si 0.75 max 0.25 max 0.10 max P 0.040 max 0.015 max 0.010 max S 0.020 max 0.010 max 0.005 max Cr 10-13 10.5-12.5 11.0-12.0 Ni 10.5-11.6 10.75-11.25 10.85-11.25 Ti 1.5-1.8 1.5-1.7 1.5-1.7 Mo 0.25-1.5 0.75-1.25 0.9-1.1 Cu 0.95 max 0.50 max 0.25 max Al 0.25 max 0.050 max 0.025 max Nb 0.3 max 0.050 max 0.025 max B 0.010 max 0.001-0.005 0.0015-0.0035 N 0.030 max 0.015 max 0.010 max
The balance of the alloy is essentially iron except for the usual impurities found in commercial grades of such steels and minor amounts of additional elements which may vary from a few thousandths of a percent up to larger amounts that do not objectionably detract from the desired combination of properties provided by this alloy. The alloy according to this invention is further characterized by a plurality of non-strengthening, calcium-based inclusions that are sparsely dispersed in the matrix steel.
[0009] In accordance with another aspect of the present invention, there is provided a method of making a high strength, high toughness, precipitation-hardenable stainless steel alloy. The method includes the step of melting a precipitation-hardenable stainless steel alloy having the weight percent composition set forth above. The method further includes the step of adding calcium to the molten alloy in an amount sufficient to combine with available sulfur and oxygen in the molten alloy to form calcium base inclusions that are removable from said alloy. The method also includes the steps of processing the alloy to remove at least a portion of the inclusions from the alloy and then solidifying the refined alloy, whereby the solidified alloy contains a sparse dispersion of such inclusions in the alloy matrix.
[0010] The foregoing tabulation is provided as a convenient summary and is not intended thereby to restrict the lower and upper values of the ranges of the individual elements of the alloy of this invention for use in combination with each other, or to restrict the ranges of the elements for use solely in combination with each other. Thus, one or more of the element ranges of the broad composition can be used with one or more of the other ranges for the remaining elements in the preferred composition. In addition, a minimum or maximum for an element of one preferred embodiment can be used with the maximum or minimum for that element from another preferred embodiment. Throughout this application percent (%) means percent by weight unless otherwise indicated. The term “inclusion” encompasses secondary particles and phases such as sulfides, oxides, oxysulfides, carbides, nitrides, and carbonitrides.
DETAILED DESCRIPTION
[0011] In the alloy according to the present invention, the unique combination of strength, notch toughness, and stress-corrosion cracking resistance is achieved by balancing the elements chromium, nickel, titanium, and molybdenum. At least about 10%, better yet at least about 10.5%, and preferably at least about 11.0% chromium is present in the alloy to provide corrosion resistance commensurate with that of a conventional stainless steel under oxidizing conditions. At least about 10.5%, better yet at least about 10.75%, and preferably at least about 10.85% nickel is present in the alloy because it benefits the notch toughness of the alloy. At least about 1.5% titanium is present in the alloy to benefit the strength of the alloy through the precipitation of a nickel-titanium-rich phase during aging. At least about 0.25%, better yet at least about 0.75%, and preferably at least about 0.9% molybdenum is also present in the alloy because it contributes to the alloy's notch toughness. Molybdenum also benefits the alloy's corrosion resistance in reducing media and in environments which promote pitting attack and stress-corrosion cracking.
[0012] When chromium, nickel, titanium, and/or molybdenum are not properly balanced, the alloy's ability to transform fully to a martensitic structure using conventional processing techniques is inhibited. Furthermore, improper balancing of chromium, nickel, titanium, and molybdenum in this alloy impairs the alloy's ability to remain substantially fully martensitic when solution treated and age-hardened. Under such conditions the strength provided by the alloy is significantly reduced. Therefore, chromium, nickel, titanium, and molybdenum present in this alloy are restricted. More particularly, chromium is limited to not more than about 13%, better yet to not more than about 12.5%, and preferably to not more than about 12.0% and nickel is limited to not more than about 11.6% and preferably to not more than about 11.25%. Titanium is restricted to not more than about 1.8% and preferably to not more than about 1.7% and molybdenum is restricted to not more than about 1.5%, better yet to not more than about 1.25%, and preferably to not more than about 1.1%.
[0013] Sulfur in this alloy tends to combine with manganese and/or titanium to form manganese sulfides (MnS) and/or titanium sulfides (TiS) which adversely affect the fracture toughness, notch toughness, and notch tensile strength of the alloy. A product form of this alloy having a large cross-section, i.e., >0.7 in 2 (>4 cm 2 ), does not undergo sufficient thermomechanical processing to homogenize the alloy and neutralize the adverse effect of the sulfide inclusions. A small addition of calcium is preferably made to the alloy to benefit the fatigue strength of the alloy by combining with sulfur to facilitate the removal of sulfur from the alloy. In the known alloy, small additions of cerium, lanthanum, and/or other rare earth metals are used to benefit the toughness and fracture toughness properties, especially in large section sizes. However, although the use of such rare earth treatment benefits the toughness of the alloy, it has now been found that remnants of such rare earth inclusions may also serve as crack initiation sites that adversely affect the fatigue strength of the alloy. Therefore, rare earth additions are not used in the present alloy so as to avoid the presence of the rare earth inclusions. Rare earth metals including cerium, lanthanum, yttrium, etc. are restricted such that the combined amounts of such elements are not more than about 0.001%. Preferably, the alloy contains not more than about 0.0008%, and better yet not more than 0.0007% of such elements.
[0014] The elimination of the rare earth treatment would have been expected to adversely affect the fracture toughness of the alloy, especially in larger section sizes. However, it has been found that the use of the calcium treatment instead of the rare earth treatment not only benefits the fatigue strength of the alloy, but does not adversely affect the combination of toughness and fracture toughness provided by this alloy. Therefore, it is believed that the alloy according to the present invention provides strength and toughness equivalent to the known alloys.
[0015] Additional elements such as boron, aluminum, niobium, manganese, and silicon may be present in controlled amounts to benefit other desirable properties provided by this alloy. More specifically, up to about 0.010% boron, better yet up to about 0.005% boron, and preferably up to about 0.0035% boron can be present in the alloy to benefit the hot workability of the alloy. In order to provide the desired effect, at least about 0.001% and preferably at least about 0.0015% boron is present in the alloy.
[0016] Aluminum and/or niobium can be present in the alloy to benefit the yield and ultimate tensile strengths. More particularly, up to about 0.25%, better yet up to about 0.10%, still better up to about 0.050%, and preferably up to about 0.025% aluminum can be present in the alloy. Also, up to about 0.3%, better yet up to about 0.10%, still better up to about 0.050%, and preferably up to about 0.025% niobium can be present in the alloy. Although higher yield and ultimate tensile strengths are obtainable when aluminum and/or niobium are present in this alloy, the increased strength is developed at the expense of notch toughness. Therefore, when optimum notch toughness is desired, aluminum and niobium are restricted to the usual residual levels.
[0017] Up to about 1.0%, better yet up to about 0.5%, still better up to about 0.25%, and preferably up to about 0.10% manganese and/or up to about 0.75%, better yet up to about 0.5%, still better up to about 0.25%, and preferably up to about 0.10% silicon can be present in the alloy as residuals from scrap sources or deoxidizing additions. Such additions are beneficial when the alloy is not vacuum melted. Manganese and/or silicon are preferably kept at low levels because of their deleterious effects on toughness, corrosion resistance, and the austenite-martensite phase balance in the matrix material.
[0018] The balance of the alloy is essentially iron apart from the usual impurities found in commercial grades of alloys intended for similar service or use. The levels of such elements are controlled so as not to adversely affect the desired properties.
[0019] In particular, too much carbon and/or nitrogen impair the corrosion resistance and deleteriously affect the toughness and fatigue strength provided by this alloy. Accordingly, not more than about 0.03%, better yet not more than about 0.02%, and preferably not more than about 0.015% carbon is present in the alloy. Also, not more than about 0.030%, better yet not more than about 0.015%, and preferably not more than about 0.010% nitrogen is present in the alloy. When carbon and/or nitrogen are present in larger amounts, the carbon and/or nitrogen combines with titanium to form titanium-rich non-metallic inclusions, such as titanium carbonitrides. That reaction inhibits the formation of the nickel-titanium-rich phase which is a primary factor in the high strength provided by this alloy. Moreover, such carbonitrides serve as crack-initiation sites and adversely affect the fracture toughness and fatigue resistance provided by the alloy.
[0020] Phosphorus is maintained at a low level because of its deleterious effect on toughness and corrosion resistance. Accordingly, not more than about 0.040%, better yet not more than about 0.015%, and preferably not more than about 0.010% phosphorus is present in the alloy.
[0021] Not more than about 0.020%, better yet not more than about 0.010%, and preferably not more than about 0.005% sulfur is present in the alloy. Larger amounts of sulfur promote the formation of titanium-rich non-metallic inclusions which, like carbon and nitrogen, inhibit the desired strengthening effect of the titanium and serve as crack-initiation sites that adversely affect the fracture toughness and fatigue resistance provided by the alloy. Also, greater amounts of sulfur deleteriously affect the hot workability and corrosion resistance of this alloy and impair its toughness, particularly in a transverse direction. Oxygen is limited to not more than about 25 parts per million (ppm). Tramp elements such as lead, bismuth, antimony, arsenic, tellurium, selenium, tin, germanium, and gallium are limited to about 0.003% max. each, better yet to not more than about 0.002% each, and preferably to not more than about 0.001% each.
[0022] Too much copper deleteriously affects the notch toughness, ductility, and strength of this alloy. Therefore, the alloy contains not more than about 0.95%, better yet not more than about 0.75%, still better, not more than about 0.50%, and preferably not more than about 0.25% copper.
[0023] The method according to the present invention is preferably carried out by vacuum induction melting (VIM) the constituent elements as described above. Preferably, VIM is followed by vacuum arc remelting (VAR), but other practices can be used. The preferred method of providing calcium in this alloy is through the addition of a nickel-calcium compound during VIM. The nickel-calcium compound, such as the Ni-Cal® alloy sold by Chemalloy Co. Inc., is added in an amount effective to combine with available phosphorus, sulfur, and oxygen. Other techniques for adding calcium may also be used. For example, capsules of elemental calcium or calcium master alloys can be added to the melt. It is believed that a slag containing calcium or a calcium compound may also be used. The chemical reactions result in the formation of secondary phase inclusions such as calcium sulfides, calcium oxides, and calcium oxysulfides that can be readily removed during primary or secondary melting. It is believed that any residual calcium-based inclusions are sparsely dispersed in the alloy matrix material upon solidification. It is expected that after VAR the alloy contains less than about 0.001% calcium and not more than about 0.001% sulfur. The inclusions are generally smaller in major cross-sectional size than the rare-earth-based inclusions and Ti-rich non-metallic inclusions that are present in the known alloys. It is also believed that the size distribution of the calcium-based inclusions is about 0.5 μm to about 3.00 μm in major cross-sectional dimension, when such inclusions are present. The very small size and sparse dispersion of Ca-based inclusions benefits the strength, toughness, and fatigue resistance provided by the alloy.
[0024] This alloy can be made using powder metallurgy techniques, if desired. Although the alloy of the present invention can be hot or cold worked, cold working enhances the mechanical strength of the alloy.
[0025] The precipitation hardening alloy of the present invention is solution annealed and then age hardened to develop the desired high strength and hardness. The solution annealing temperature should be high enough to dissolve essentially all of the undesired precipitates into the alloy matrix material. However, if the solution annealing temperature is too high, it will impair the fracture toughness of the alloy by promoting excessive grain growth. Typically, the alloy of the present invention is solution annealed at about 1700° F.-1900° F. (927° C.-1038° C.) for about 1 hour and then quenched.
[0026] When desired, this alloy can also be subjected to a deep chill treatment after it is quenched, to further develop the high strength of the alloy. The deep chill treatment cools the alloy to a temperature sufficiently below the martensite finish temperature to ensure the completion of the martensite transformation. Typically, a deep chill treatment consists of cooling the alloy to below about −100° F. (−73° C.) for about 1 to 8 hours. The need for a deep chill treatment will be affected, at least in part, by the martensite finish (MF) temperature of the alloy. If the MF temperature is sufficiently high, the transformation to a martensitic structure will proceed without the need for a deep chill treatment. In addition, the need for a deep chill treatment may also depend on the cross-sectional size of the piece being manufactured. As the size of the piece increases, segregation in the alloy becomes more significant and the use of a deep chill treatment becomes more beneficial. Further, the length of time that the piece is chilled may need to be increased for large pieces in order to ensure that the transformation to martensite is completed. For example, it has been found that in a piece having a large cross-sectional area as described above, a deep chill treatment lasting about 8 hours is preferred for developing the high strength that is characteristic of this alloy.
[0027] The alloy of the present invention is age hardened in accordance with techniques used for the known precipitation hardening, stainless steel alloys, as are known to those skilled in the art. For example, the alloys are aged at a temperature between about 900° F. (482° C.) and about 1150° F. (621° C.) for about 4 to 8 hours. The specific aging conditions used are selected by considering that: (1) the ultimate tensile strength of the alloy decreases as the aging temperature increases; and (2) the time required to age harden the alloy to a desired strength level increases as the aging temperature decreases.
[0028] The terms and expressions that have been employed herein are used as terms of description and not of limitation. There is no intention in the use of such terms and expressions to exclude any equivalents of the features described or any portions thereof. It is recognized, however, that various modifications are possible within the scope of the invention claimed. | A process for making a precipitation hardenable stainless steel alloy is described. The process includes the step of melting a martensitic steel alloy having the following composition in weight percent, about
Carbon 0.03 max. Manganese 1.0 max. Silicon 0.75 max. Phosphorus 0.040 max. Sulfur 0.020 max. Chromium 10-13 Nickel 10.5-11.6 Titanium 1.5-1.8 Molybdenum 0.25-1.5 Copper 0.95 max. Aluminum 0.25 max. Niobium 0.3 max. Boron 0.010 max. Nitrogen 0.030 max.
and the balance being iron and usual impurities. The process also includes the step of adding calcium to the alloy while molten. The calcium combines with available sulfur and oxygen to form calcium base inclusions selected from the group consisting of calcium sulfides, calcium oxides, calcium oxysulfides, and combinations thereof. In a further step, the alloy is processed to remove at least a portion of the calcium base inclusions. The alloy is then solidified. As a result of the process, the alloy has a matrix containing a sparse dispersion of said calcium-based inclusions and substantially no rare-earth base inclusions. | 2 |
BACKGROUND OF THE INVENTION
[0001] The subject matter disclosed herein relates to turbine systems, and more particularly to turbine bucket shroud arrangements, as well as a method of controlling turbine bucket interaction with an adjacent turbine bucket.
[0002] Turbine systems employ a number of rotating components or assemblies, such as compressor stages and turbine stages that rotate at high speed when the turbine is in operation, for example. In general, a stage includes a plurality of free-floating blades that extend radially outward from a central hub. Some blades include a shroud that limits vibration within a stage and provides sealing to increase efficiency of the overall system. The shroud is typically positioned at a tip portion of the blade, a mid-portion of the blade or at both the mid portion and the tip portion of the blade. The shrouds are designed such that the free-floating blades interlock to form an integral rotating member during operation.
[0003] Prior to rotation of the free-floating blades, a gap between contact surfaces of the shrouds is present. The distance of the gap determines how early an interlock of the shrouds occurs upon startup of the turbine system. Too large of a gap inefficiently delays the locking speed, which may result in resonance, for example. Too small of a gap results in undesirable effects at high speed operation of the turbine system. Such effects include lower damping effectiveness and flutter margin, as well as high stresses imposed on the turbine bucket due to increased transfer of forces between the contacting shrouds, for example. Therefore, current efforts to beneficially reduce the gap to provide an early interlock to address potential low speed aeromechanics issues are mitigated by the detrimental effects on tip shroud life that occur at steady state operating conditions.
BRIEF DESCRIPTION OF THE INVENTION
[0004] According to one aspect of the invention, a turbine bucket shroud arrangement for a turbine system includes a contact region of a tip shroud, wherein the contact region is in close proximity to an adjacent tip shroud. Also included is a negative thermal expansion material disposed proximate the contact region, the contact region comprising a first volume during a startup condition and a shutdown condition of the turbine system and a second volume during a steady state condition of the turbine system, wherein the second volume is less than the first volume.
[0005] According to another aspect of the invention, a method of controlling turbine bucket interaction with an adjacent turbine bucket is provided. The method includes reducing a gap disposed between a contact region of a tip shroud and an adjacent tip shroud by depositing a negative thermal expansion material proximate the contact region. Also included is engaging the contact region of the tip shroud with the adjacent tip shroud during a startup operating condition and a shutdown operating condition. Further included is decreasing a volume of the contact region during increased temperature operating conditions upon contraction of the negative thermal expansion material, wherein decreasing the volume reduces tip shroud contact forces and stresses during a steady state operating condition.
[0006] These and other advantages and features will become more apparent from the following description taken in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The subject matter, which 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 features, and advantages of the invention are apparent from the following detailed description taken in conjunction with the accompanying drawings in which:
[0008] FIG. 1 is a schematic view of a turbine system;
[0009] FIG. 2 is a partial perspective view of a turbine stage of the turbine system;
[0010] FIG. 3 is a top plan view of a turbine bucket shroud arrangement having a contact region;
[0011] FIG. 4 is an enlarged top plan view of the contact region of FIG. 3 ;
[0012] FIG. 5 is a schematic view of the contact region comprising a composition;
[0013] FIG. 6 is a schematic view of a plurality of layers of the composition; and
[0014] FIG. 7 is a flow diagram illustrating a method of controlling turbine bucket interaction with an adjacent turbine bucket.
[0015] The detailed description explains embodiments of the invention, together with advantages and features, by way of example with reference to the drawings.
DETAILED DESCRIPTION OF THE INVENTION
[0016] Referring to FIG. 1 , a turbine system, shown in the form of a gas turbine engine, constructed in accordance with an exemplary embodiment of the present invention, is indicated generally at 10 . The turbine system 10 includes a compressor 12 and a plurality of combustor assemblies arranged in a can annular array, one of which is indicated at 14 . As shown, the combustor assembly 14 includes an endcover assembly 16 that seals, and at least partially defines, a combustion chamber 18 . A plurality of nozzles 20 - 22 are supported by the endcover assembly 16 and extend into the combustion chamber 18 . The nozzles 20 - 22 receive fuel through a common fuel inlet (not shown) and compressed air from the compressor 12 . The fuel and compressed air are passed into the combustion chamber 18 and ignited to form a high temperature, high pressure combustion product or air stream that is used to drive a turbine 24 . The turbine 24 includes a plurality of stages 26 - 28 that are operationally connected to the compressor 12 through a compressor/turbine shaft 30 (also referred to as a rotor).
[0017] In operation, air flows into the compressor 12 and is compressed into a high pressure gas. The high pressure gas is supplied to the combustor assembly 14 and mixed with fuel, for example process gas and/or synthetic gas (syngas), in the combustion chamber 18 . The fuel/air or combustible mixture ignites to form a high pressure, high temperature combustion gas stream. Alternatively, the combustor assembly 14 can combust fuels that include, but are not limited to, natural gas and/or fuel oil. In any event, the combustor assembly 14 channels the combustion gas stream to the turbine 24 which converts thermal energy to mechanical, rotational energy.
[0018] At this point, it should be understood that each of the plurality of stages 26 - 28 is similarly formed, thus reference will be made to FIG. 2 in describing stage 26 constructed in accordance with an exemplary embodiment of the present invention with an understanding that the remaining stages, i.e., stages 27 and 28 , have corresponding structure. Also, it should be understood that the present invention could be employed in stages in the compressor 12 or other rotating assemblies that require wear and/or impact resistant surfaces. In any event, the stage 26 is shown to include a plurality of rotating members, such as an airfoil 32 , which each extend radially outward from a central hub 34 having an axial centerline 35 . The airfoil 32 is rotatable about the axial centerline 35 of the central hub 34 and includes a base portion 36 and a tip portion 38 .
[0019] A tip shroud 50 covers the tip portion 38 of the airfoil 32 . The tip shroud 50 is designed to receive, or nest with, tip shrouds on adjacent rotating members in order to form a continuous ring that extends circumferentially about the stage 26 . The continuous ring creates an outer flow path boundary that reduces gas path air leakage over top portions (not separately labeled) of the stage 26 , so as to increase stage efficiency and overall turbine performance. In the exemplary embodiment shown, during high or operational speeds, adjacent airfoils interlock through the tip shroud 50 of each respective airfoil by virtue of centrifugal forces and thermal loads created by the operation of the turbine 24 .
[0020] Referring now to FIGS. 3 and 4 , the tip shroud 50 is illustrated in greater detail and is in close proximity with an adjacent tip shroud 52 . The tip shroud 50 includes a contact region 54 configured to engage the adjacent tip shroud 52 during operation of the turbine system 10 . Specifically, the contact region 54 engages an adjacent contact region 56 of the adjacent tip shroud 52 . A gap 58 is present between the tip shroud 50 and the adjacent tip shroud 52 , and more particularly between the contact region 54 and the adjacent contact region 56 . The gap 58 is present prior to startup of the turbine system 10 . The gap 58 is dimensionally selected based on a desirable early interlock of the tip shroud 50 and the adjacent tip shroud 52 upon operation of the turbine system 10 and rotation of the airfoil 32 . Subsequent to interlock of the tip shroud 50 and the adjacent tip shroud 52 , the operating environment increases in temperature, thereby resulting in thermal expansion of most components within the turbine 24 .
[0021] To alleviate the stresses imposed by potential expansion of already contacted components, at least one of the contact region 54 and the adjacent contact region 56 , but typically both the contact region 54 and the adjacent contact region 56 , include a negative thermal expansion material 60 . The negative thermal expansion material 60 is defined by having a negative coefficient of thermal expansion, such that the material contracts in response to increased temperature exposure, rather than expanding. It is to be appreciated that any material having a negative coefficient of thermal expansion may be suitable for inclusion with the contact region 54 and the adjacent contact region 56 . Examples of such materials include zircon, zirconium tungstate and A 2 (MO 4 ) 3 compounds. Forming at least a portion of the contact region 54 and the adjacent contact region 56 with the negative thermal expansion material 60 advantageously allows for the gap 58 to be dimensionally reduced to facilitate an early interlock between the tip shroud 50 and the adjacent tip shroud 52 , while also reducing the contact forces associated with interaction between the tip shroud 50 and the adjacent tip shroud 52 , thereby reducing stresses imposed on various portions of the tip shroud 50 , the adjacent tip shroud 52 and the airfoil 32 attached thereto. The stress reduction is achieved by maintaining an interlock, but contracting the negative thermal expansion material 60 . In other words, the contact region 54 comprises a first volume during a startup condition of the turbine system 10 and a smaller, second volume during a steady state operating condition of the turbine system 10 .
[0022] Referring now to FIGS. 5 and 6 , the contact region 54 is schematically illustrated in greater detail. The tip shroud 50 includes a base metal region 62 that is coated or integrally formed with the contact region 54 . The contact region 54 is formed of one or more composition layers that typically include a fraction of the negative thermal expansion material 60 and a fraction of a wear resistant material. As noted above, the contact region 54 may include a single composition layer ( FIG. 5 ) or a plurality of composition layers ( FIG. 6 ). In an embodiment having a plurality of composition layers 72 , it is to be appreciated that distinct volume and/or weight fractions of the negative thermal expansion material 60 may be present in the plurality of composition layers 72 , such as a first layer 64 , a second layer 68 and a third layer 70 , as shown. In one embodiment, the fraction of the negative thermal expansion material 60 progressively increases in each layer, relative to moving away from the base metal region 62 . Specifically, the first layer 64 may include a lower fraction of the negative thermal expansion material 60 than the second layer 68 , with the second layer 68 having a lower fraction than the third layer 70 . Gradually transitioning the inclusion of the negative thermal expansion material 60 from the base metal region 62 reduces thermal fight at the interface between the contact region 54 and the base metal region 62 of the tip shroud 50 . It is to be appreciated that each of the plurality of composition layers 72 may vary in thickness from one another and may comprise the negative thermal expansion material 60 in a fraction ranging from about 0% to about 100%.
[0023] The contact region 54 , whether a single layer or the plurality of composition layers 72 , may be deposited or integrated with the tip shroud 50 in a number of application processes. Examples of such processes include brazing, welding, laser cladding, cold spraying and a plasma transferred arc (PTA) process. The preceding list is merely illustrative and is not intended to be limiting of numerous other suitable application procedures.
[0024] As illustrated in the flow diagram of FIG. 7 , and with reference to FIGS. 1-6 , a method of controlling turbine bucket interaction with an adjacent turbine bucket 100 is also provided. The turbine system 10 , as well as the tip shroud 50 and the contact region 54 , have been previously described and specific structural components need not be described in further detail. The method of controlling turbine bucket interaction with an adjacent turbine bucket 100 includes reducing a gap between a contact region of a tip shroud and an adjacent tip shroud by depositing a negative thermal expansion material proximate the contact region 102 . The contact region is engaged with the adjacent tip shroud during a startup operating condition 104 . A volume of the contact region is decreased during increased temperature operating conditions upon contraction of the negative thermal expansion material 106 .
[0025] While the invention has been described in detail in connection with only a limited number of embodiments, it should be readily understood that the invention is not limited to such disclosed embodiments. Rather, the invention can be modified to incorporate any number of variations, alterations, substitutions or equivalent arrangements not heretofore described, but which are commensurate with the spirit and scope of the invention. Additionally, while various embodiments of the invention have been described, it is to be understood that aspects of the invention may include only some of the described embodiments. Accordingly, the invention is not to be seen as limited by the foregoing description, but is only limited by the scope of the appended claims. | A turbine bucket shroud arrangement for a turbine system includes a contact region of a tip shroud, wherein the contact region is in close proximity to an adjacent tip shroud. Also included is a negative thermal expansion material disposed proximate the contact region, the contact region comprising a first volume during a startup condition and a shutdown condition of the turbine system and a second volume during a steady state condition of the turbine system, wherein the second volume is less than the first volume. | 5 |
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application is related to application No. _/_,_, entitled “System for Selecting and Playing Songs in a Playback Device with a Limited User Interface,” (Atty. Docket No. 17002-020800); and application No. _/_,_, entitled “Automatic Hierarchical Categorization of Music by Metadata,” (Atty. Docket No. 17002-022500), all filed Jan. 5, 2001, the disclosures of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] Today, portable consumer electronic devices are more powerful than ever. For example, small, portable music playback devices can store hundreds, even thousands, of compressed songs and can play back the songs at high quality. With the capacity for so many songs, a playback device can store many songs from different albums, artists, styles of music, etc.
[0003] As users desire to store more songs on the portable music player different storage media are being used. A hard disk drive (HDD) has many benefits in terms of capacity, access time, cost. However, HDDs consume power and quickly drain batteries used in a portable music player.
[0004] Accordingly, HDDs have power saving modes, such as the STANDBY mode and the SLEEP mode. In both the STANDBY and SLEEP modes the motor is turned off and the disk spins down. Additionally, is SLEEP mode most of the electronic subsystems of the HDD are powered down to save additional power. However, to recover from SLEEP mode the drive must be reset which adds additional time to the recover. Typical recovery times are several seconds to transition from a power-saving mode to the IDLE mode.
[0005] In the IDLE mode the HDD is ready to transfer data and the disk is spinning. During reading or writing the HDD is in the ACTIVE mode.
[0006] Some HDDs automatically transition to a power saving mode from the IDLE mode if no read or write requests are received during a set time interval, e.g., 30 seconds.
[0007] Additionally, jitter is a problem when reading data from an HDD in portable device because the device is subject to jarring or bumping which causes glitches. Further, when the disk is spinning noise and vibration is present which may be noticeable to a listener.
[0008] Accordingly, techniques for extending battery life and reducing jitter and noise in portable music players are being actively developed.
SUMMARY OF THE INVENTION
[0009] According to one aspect of the present invention, battery life is extended in a portable music player using an HDD to store audio tracks by transitioning the HDD to a power-saving mode when the a track is stored in the play buffer.
[0010] According to another aspect of the invention, the HDD is transitioned out of the power-saving mode when the buffer reaches a low threshold level so that a next audio track can be read from the HDD to the buffer before the present track is through playing.
[0011] According to another aspect of the invention, the HDD is not transitioned to the power-saving mode if the battery voltage is below a critical level to avoid a large current drain on the batteries occurring when the HDD transitions from the power-saving mode.
[0012] Other features and advantages of the invention will be apparent in view of the following detailed description and appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] [0013]FIG. 1 is a block diagram of a system for implementing an embodiment of the invention;
[0014] [0014]FIG. 2 is a state diagram depicting the transitions between modes of the HDD; and
[0015] FIGS. 3 A- 3 D are schematic diagrams depicting a buffer at various points in time.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0016] An embodiment of the invention implemented in the Nomad® Jukebox portable music player will now be described by way of example, not limitation. The principles of the invention are broadly applicable to portable music players in general.
[0017] [0017]FIG. 1 is a block diagram of a system 10 including a hard-disk drive (HDD) 12 and interface 14 , central processing unit 16 , a buffer 18 , system memory 20 , and audio subsystem 22 connected to bus 24 . As is well-known in the art, the buffer 18 may be a part of the system memory 20 and various components may be integrated on a single chip or be part of chip set.
[0018] In a preferred embodiment the act described are implemented under control of the CPU which executes program code stored in the system memory. The program code can be stored in any computer readable medium including magnetic storage, CD ROM, optical media, or digital data encoded on an electromagnetic signal.
[0019] The CPU executes software to implement a power management system. As described above, the HDD may be in the IDLE, STANDBY, or SLEEP states. In the IDLE state the disk is spinning and data may be read from the disk. In the presently described embodiment, the data is compressed digital music, for example, music encoded in the MP3 format.
[0020] In the STANDBY and SLEEP states the disk is not spinning and the states differ by the amount of power consumed, the time required to transition back to IDLE, and the amount of power required to transition back to IDLE. SLEEP mode consumes less power but has a longer recovery time.
[0021] Typical power consumption numbers for an HDD used in the Nomad® Jukebox are:
[0022] spin-up (from standby or sleep)-900 mA max
[0023] active mode-460 mA
[0024] idle mode-170 mA
[0025] standby mode-56 mA
[0026] sleep mode-20 mA
[0027] In the presently described embodiment, in response to a user request to play a track or a list of tracks, a block track data is transferred to the buffer until the buffer is full. In the presently described embodiment the buffer is implemented in system memory and may vary in sized depending on how much of system memory is used for other purposes. As depicted in FIG. 2, when the block is loaded into the buffer the HDD transitions from the IDLE mode to the SLEEP mode. The track data is then played from the buffer, that is, the track data is transferred from the buffer to the audio subsystem where the digital music data is transformed into an audio output signal utilizing techniques known in the art.
[0028] When the buffer data remaining to be played reaches a low threshold level the HDD transitions from the SLEEP mode to the IDLE mode. An exemplary buffer management system for triggering this transition is depicted in FIG. 3.
[0029] Referring to FIG. 2 FIGS. 3 A-D, a first block is read from the HDD and stored in the buffer as depicted in FIG. 3A. Data is read from the storage location as depicted by the READ pointer and a subsequent writing of data will commence at the location indicated by the WRITE pointer. Subsequent to reading data from the disk the HDD transitions to the SLEEP mode.
[0030] As depicted in FIG. 3B and FIG. 2, when the READ pointer reaches a threshold value the software causes the HDD to transition to the IDLE mode from the SLEEP mode. This threshold can be set as a number of addresses from the beginning of the block because the amount of data read from the buffer translates as a known duration of audio. The threshold is set to take into account amount of time required to spin-up the disk to the IDLE mode and to read the next track into the buffer.
[0031] As depicted in FIG. 3C, when the read pointer is reaching the end of the first block the second block is being stored in the buffer and the HDD transitions to the SLEEP mode again.
[0032] Finally, as depicted in FIG. 3D, the READ pointer is positioned to read block 2 and the HDD is again in SLEEP mode.
[0033] If the portable music player is being powered by an external supply then STANDBY mode may be utilized instead of SLEEP mode since a faster transition to IDLE may be more important then lowest power drain. Alternatively, STANDBY mode can also be utilized when using battery power albeit with a large current drain on the batteries.
[0034] As set forth above, a large current drain on the batteries occurs during spin-up. If the battery is low this power drain could cause the voltage output from the battery to drop to a low value that could cause the system to crash.
[0035] Accordingly, in one embodiment of the invention, if the voltage reading from the batteries indicates that battery life is very low then HDD is not put into SLEEP mode between disk reads to avoid the large current drain required to spin the disk back up to IDLE.
[0036] The invention has now been described with reference to the preferred embodiments. Alternatives and substitutions will now be apparent to persons of skill in the art. For example, alternative buffer management techniques can be utilized to trigger the transitions to the power-saving mode. Further, in the embodiment described, a single track is read from the buffer between spin-downs. However, depending on the size of the buffer and characteristics of the HDD different size blocks of audio data may be stored in the buffer between spin downs. Accordingly, it is not intended to limit the invention except as provided by the appended claims. | A technique for extending battery life and reducing noise in a portable music player storing tracks on a hard drive reads a track from the disk to a buffer and plays the track from the buffer while the disk is spun down to a power-saving state. Noise and vibration is also reduced when the disk is spun down. | 6 |
[0001] This invention relates to compounds. More specifically, the invention relates to compounds useful as inhibitors of the Wnt signalling pathway. Specifically, inhibitors of Porcupine (Porcn) are contemplated by the invention. In addition the invention contemplates processes to prepare the compounds and uses of the compounds.
[0002] The compounds of the invention may therefore be used in treating conditions mediated by the Wnt signalling pathway, for example secreted Wnt ligand mediated diseases which may be treated by inhibition of porcupine; treating cancer, sarcoma, melanoma, skin cancer, haematological tumors, lymphoma, carcinoma, and leukemia; or enhancing the effectiveness of an anti-cancer treatment.
BACKGROUND
[0003] The Wnt genes encode a large and highly conserved family of secreted growth factors. During normal development, transcription of Wnt family genes is tightly regulated both temporally and spatially. To date, 19 Wnt proteins have been discovered in humans. All of the Wnt proteins are 38- to 43-kDa cysteine-rich glycoproteins. Wnts have a range of roles during development, governing cell fate, migration, proliferation and death. These include body axis formation in zebrafish and xenopus, wing and eye development in drosophila and brain development in mice (Parr, et al. (1994) Curr. Opinion Genetics & Devel. 4:523-528, McMahon A P, Bradley A (1990) Cell 62: 1073-1085). In adults the role of Wnts is thought to be linked to maintaining tissue homeostasis with aberrant signalling implicated in a variety of cancers.
[0004] Wnt-mediated signalling occurs through binding of Wnt ligand to frizzled (Fzd) proteins, seven-transmembrane receptors. These receptors contain an N-terminal cysteine rich domain (CRD) which serves as the Wnt binding domain. Binding is stabilised by low-density-lipoprotein receptor-related proteins 5 and 6 (Lrp5 and Lrp6) (He, et al. (2004) Dev April; 131(8):1663-77). Fizzled ligation by Wnt is known to activate at least three different signalling pathways including the “canonical” β-catenin pathway, “non-canonical” planar cell polarity (PCP) and calcium pathways. Wnt signalling is further regulated by alternative receptors, including Ror2, secreted antagonists, such as WIF-1 (Hsieh, et al. (1999) Nature April 1; 398(6726):431-6) and alternative Wnt receptors, such as Dickkopf (DKK) (Niehrs C (2006) Oncogene December 4; 25(57):7469-81).
[0005] When inactive, β-Catenin is rapidly turned over by a conglomeration of several proteins known as the “destruction complex”. The complex consists of Axin, adenomatous polyposis coli (APC), casein kinase (CK)-1a and glycogen synthasekinase (GSK)-3β (Hamada, et al. (1999) Science 12; 283(5408):1739-42). In this state, β-catenin is phosphorylated on serine-threonine on the amino terminus leading to ubiquitination (Behrens, et al. (1998) Science 280: 596-599). In the canonical pathway of Wnt activation, Wnt-ligated Fzd binds to and activates cytoplasmic Dishevelled (Dvl) (Chen, et al. (2003) Science 301:1391-94). Wnt-ligated Lrp5 and Lrp6 directly bind to cytoplasmic Axin, inhibiting its function as a destruction complex stabiliser (Zeng, et al. (2008) Dev. 135, 367-375). These associations lead to a destabilisation of the destruction complex and cytosolic accumulation of β-catenin. Stabilisation and accumulation of β-catenin leads to nuclear translocation where it complexes with T cell factor/lymphoid enhancer factor (TCF/LEF) high mobility group transcription factors and promotes transcription of target genes such as Cyclin D1, p21 and cMyc.
[0006] Oncogenic mutations in the β-catenin gene CTNNb1 exclusively affect specific serine and threonine and surrounding residues vital for targeted degradation by APC (Hart, et al. (1999) Curr. Biol. 9:207-210). This interaction is especially apparent in colorectal cancer, where the majority of tumours present with APC mutations and an increased proportion of the remainder express CTNNb1 mutations (Iwao, et al. (1998) Cancer Res Mar. 1, 1998 58; 1021).
[0007] Many recent studies have investigated compounds targeting β-catenin or other downstream Wnt pathway proteins. Recent research suggests that modulating Wnt-Wnt receptor interaction at the cell surface is effective in reducing cell oncogenicity. This has been shown in systems with tumourgenicity driven by Wnt ligand overexpression (Liu, et al. (2013) PNAS 10; 110(50):20224-9) and where Wnt expression is driven by downstream pathway activation (Vincan et al., Differentiation 2005; 73: 142-153). Vincan et al transfected non-functional Frd7 receptor into a SK-CO-1 cell line with a homozygous APC mutation driving Wnt pathway activation. These cells demonstrated modulated morphology and reduced tumour-forming efficiency compared to parental cells in a xenograft model. This data suggests that modulating Wnt ligand-mediated signalling may have a beneficial effect even in malignancies with downstream Wnt pathway mutations.
[0008] The described invention is proposed to inhibit Wnt-mediated signalling. This includes paracrine signalling in the tissues surrounding tumours and autocrine and paracrine signalling in cancer cells.
[0009] Wnt proteins undergo post-translational modification, shown in several mutation experiments to be vital for effective protein trafficking and secretion (Tang, et al. (2012) Dev. Biol 364, 32-41, Takada, R. et al (2006) Dev. Cell 11, 791-801). Palmitoylation of Wnt proteins occurs at several conserved amino acids (C77, S209) and is performed by porcupine, an O-acetyltransferase, in the endoplasmic reticulum. Mutations in porcupine have been shown to be the cause of developmental disorders, including focal dermal hypoplasia, through impaired Wnt pathway signalling (Grzeschik, et al. (2007) Nat. Genet, 39 pp. 833-835). The dependence of Wnt ligand signalling on porcupine and the body of evidence linking Wnt pathway signalling to cancer has led to porcupine being identified as a potential anti-cancer target.
[0010] US 2014/0038922 discloses compounds that inhibit the Wnt signalling pathway and the use of these compounds in the treatment of Wnt signalling-related diseases. Similarly, WO 2012/003189 and WO 2010/101849 disclose compounds and methods for modulating Wnt signalling pathway.
[0011] An aim of the present invention is to provide alternative or improved Wnt signalling modulators. For example, an aim of the present invention is to provide alternative or improved Wnt signalling inhibitors, optionally inhibitors of porcupine.
[0012] Furthermore, it is an aim of certain embodiments of this invention to provide new compounds for use in: Wnt mediated diseases, such as secreted Wnt ligand mediated diseases which may be treated by inhibition of porcupine; treating cancer, sarcoma, melanoma, skin cancer, haematological tumors, lymphoma, carcinoma, and leukemia; or enhancing the effectiveness of an anti-cancer treatment.
[0013] It is an aim of certain embodiments of this invention to provide new cancer treatments. In particular, it is an aim of certain embodiments of this invention to provide compounds which have comparable activity to existing treatments, ideally they should have better activity. Certain embodiments of the invention also aim to provide improved solubility compared to prior art compounds and existing therapies. It is particularly attractive for certain compounds of the invention to provide better activity and better solubility over known compounds.
[0014] It is an aim of certain embodiments of this invention to provide compounds which exhibit reduced cytotoxicity relative to prior art compounds and existing therapies.
[0015] Another aim of certain embodiments of this invention is to provide compounds having a convenient pharmacokinetic profile and a suitable duration of action following dosing. A further aim of certain embodiments of this invention is to provide compounds in which the metabolised fragment or fragments of the drug after absorption are GRAS (Generally Regarded As Safe).
[0016] Certain embodiments of the present invention satisfy some or all of the above aims.
BRIEF SUMMARY OF THE DISCLOSURE
[0017] In accordance with the present invention there is provided a compound of formula (I):
[0000]
[0000] wherein
het 1 represents a 8 or 9 membered bicyclic heterocyclic ring system comprising a 5 membered ring and 1, 2, 3 or 4 heteroatoms selected from N, O or S, wherein the 8 or 9 membered bicyclic heterocyclic ring system is unsubstituted or substituted, and when substituted the ring system is substituted with 1, 2, or 3 groups independently selected at each occurrence from: halo, C 1-4 alkyl, C 1-4 haloalkyl, —OR A2 , —NR A2 R B2 , —CN, —SO 2 R A2 , and C 3-6 cycloalkyl;
het 2 is a 5 or 6 membered heterocyclic ring which may be unsubstituted or substituted, and when substituted the ring is substituted with 1, 2 or 3 groups independently selected at each occurrence from: halo, C 1-4 alkyl, C 1-4 haloalkyl, —OR A1 , —NR A1 R B1 , —CN, —NO 2 , —NR A1 C(O)R B1 , —C(O)NR A1 R B1 , —NR A1 SO 2 R B1 , —SO 2 NR A1 R B1 , —SO 2 R A1 , —C(O)R A1 , —C(O)OR A1 and C 3-6 cycloalkyl;
het 3 is a 6 membered heterocyclic ring which may be unsubstituted or substituted, and when substituted the ring is substituted with 1, 2 or 3 groups independently selected at each occurrence from: halo, C 1-4 alkyl, C 1-4 haloalkyl, —OR A1 , —NR A1 R B1 , —CN, —NO 2 , —NR A1 C(O)R B1 , —C(O)NR A1 R B1 , —NR A1 SO 2 R B1 , —SO 2 NR A1 R B1 , —SO 2 R A1 , —C(O)R A1 , —C(O)OR A1 and C 3-6 cycloalkyl;
R 1 and R 2 are independently selected at each occurrence from: H, halo, C 1-4 alkyl, C 1-4 haloalkyl, —OR A3 , —NR A3 R B3 and C 3-6 cycloalkyl;
R 3 is selected from: H, C 1-4 alkyl, C 1-4 haloalkyl, and C 3-6 cycloalkyl;
R 4 is independently selected at each occurrence from: halo, C 1-4 alkyl, C 1-4 haloalkyl, —CN, —OR A4 , —NR A4 R B4 , —SO 2 R A4 , C 3-6 cycloalkyl and C 3-6 halocycloalkyl;
m is selected from, 1, 2 or 3;
n is selected from 0, 1 or 2; and
R A1 , R B1 , R A2 , R B2 , R A3 , R B3 , R A4 and R B4 are at each occurrence independently selected from: H, C 1-4 alkyl, C 1-4 haloalkyl.
[0018] The invention also provides pharmaceutically acceptable salts of compounds of the invention. Accordingly, there is provided compounds of formula (I) and pharmaceutically acceptable salts thereof.
[0019] In an embodiment the compound according to formula (I) is a compound according to formulae (IIa) or (IIb):
[0000]
[0020] Het 2 may be represented by an aromatic, saturated or unsaturated 5 or 6 membered heterocyclic ring which is unsubstituted or substituted.
[0021] Het 2 may be represented by a ring selected from unsubstituted or substituted: pyrazole, imidazole, pyridine, pyrazine, pyrimidine, pyridazine, pyran, tetrahydropyran, dihydropyran, piperidine, piperazine, morpholine, thiomorpholine, oxazine, dioxine, dioxane, thiazine, oxathiane and dithiane.
[0022] Preferably, het 2 may be represented by unsubstituted or substituted: pyrazole, imidazole, pyridine, tetrahydropyran, dihydropyran, piperidine, piperazine and morpholine.
[0023] Optionally, het 2 is represented by an unsubstituted or substituted pyridine.
[0024] Het 2 may be unsubstituted or substituted with 1, 2, or 3 groups selected from: halo, C 1-4 alkyl, C 1-4 haloalkyl, —OR A1 , —NR A1 R B1 , —CN, and C 3-6 cycloalkyl. Preferably, het 2 may be unsubstituted or substituted with 1, 2, or 3 groups selected from: halo, C 1-4 alkyl, —OR A1 , and C 1-4 haloalkyl, wherein R A1 is H, methyl, or trifluoromethyl.
[0025] In a preferred embodiment het 2 is unsubstituted or substituted with 1 or 2 groups selected from: fluoro, chloro, methyl, ethyl, trifluoromethyl, trifluoroethyl, —CN and —OCF 3 . In a particularly preferred embodiment het 2 is unsubstituted or substituted with 1 or 2 groups selected from methyl and trifluoromethyl.
[0026] Preferably, het 2 is unsubstituted or substituted with 1 or 2 groups. More preferably, het 2 is unsubstituted or substituted with 1 group.
[0027] Het 2 may be unsubstituted pyridine, unsubstituted pyrazole, unsubstituted tetrahydropyran, unsubstituted dihydropyran, unsubstituted piperidine, unsubstituted piperazine and unsubstituted morpholine, methylpyridine, dimethylpyridine, ethylpyridine, iso-propylpyridine, tert-butylpyridine, trifluoromethylpyridine, methoxypyridine, ethyoxypyridine, aminopyridine, N-methyl-aminopyridine, N,N-dimethyl-aminopyridine, nitropyridine, cyanopyridine, methyltetrahydropyran, dimethyltetrahydropyran, ethyltetrahydropyran, iso-propyltetrahydropyran, tert-butyltetrahydropyran, trifluoromethyltetrahydropyran, methoxytetrahydropyran, ethyoxytetrahydropyran, aminotetrahydropyran, N-methyl-aminotetrahydropyran, N,N-dimethyl-aminotetrahydropyran, nitrotetrahydropyran, cyanotetrahydropyran, methyldihydropyran, dimethyldihydropyran, ethyldihydropyran, iso-propyldihydropyran, tert-butyldihydropyran, trifluoromethyldihydropyran, methoxydihydropyran, ethyoxydihydropyran, aminodihydropyran, N-methyl-aminodihydropyran, N,N-dimethyl-aminodihydropyran, nitrodihydropyran, cyanodihydropyran, methylpiperidine, dimethylpiperidine, ethylpiperidine, iso-propylpiperidine, tert-butylpiperidine, trifluoromethylpiperidine, methoxypiperidine, ethyoxypiperidine, aminopiperidine, N-methyl-aminopiperidine, N,N-dimethyl-aminopiperidine, nitropiperidine, cyanopiperidine, methylpiperazine, dimethylpiperazine, ethylpiperazine, iso-propylpiperazine, tert-butylpiperazine, trifluoromethylpiperazine, methoxypiperazine, ethyoxypiperazine, aminopiperazine, N-methyl-aminopiperazine, N,N-dimethyl-aminopiperazine, nitropiperazine, cyanopiperazine, methylmorpholine, dimethylmorpholine, ethylmorpholine, iso-propylmorpholine, tert-butylmorpholine, trifluoromethylmorpholine, methoxymorpholine, ethyoxymorpholine, aminomorpholine, N-methyl-aminomorpholine, N,N-dimethyl-aminomorpholine, nitromorpholine, cyanomorpholine, methylpyrazole, dimethylpyrazole, ethylpyrazole, iso-propylpyrazole, tert-butylpyrazole, trifluoromethylpyrazole, methoxypyrazole, ethyoxypyrazole, aminopyrazole, N-methyl-aminopyrazole, N,N-dimethyl-aminopyrazole, nitropyrazole, or cyanopyrazole.
[0028] Het 3 may be represented by an aromatic, saturated or unsaturated 6 membered heterocyclic ring which is unsubstituted or substituted and comprises at least one nitrogen atom. Preferably the ring is aromatic or saturated. Optionally, het 3 is not pyridine.
[0029] Het 3 may be represented by an aromatic, saturated or unsaturated 6 membered heterocyclic ring which is unsubstituted or substituted and comprises 2 heteroatoms, preferably the ring is aromatic or saturated. In a preferred embodiment het 3 is represented by an aromatic, saturated or unsaturated 6 membered heterocyclic ring which is unsubstituted or substituted and comprises 2 nitrogen atoms, preferably the ring is aromatic or saturated.
[0030] Het 3 may be represented by a ring selected from unsubstituted or substituted: pyrimidine, pyrazine, pyridazine, piperazine, dioxine, dioxane, morpholine and thiomorpholine.
[0031] Preferably, het 3 may be represented by a ring selected from pyrimidine, pyrazine, pyridazine or piperazine.
[0032] Preferably, het 3 may be represented by a ring selected from pyrimidine, pyrazine or pyridazine.
[0033] Optionally, het 3 is represented by a ring selected from unsubstituted or substituted: pyrimidine and pyrazine. Preferably, het 3 is represented by a ring selected from unsubstituted or substituted pyrazine.
[0034] Het 3 may be unsubstituted or substituted with 1, 2, or 3 groups selected from: halo, C 1-4 alkyl, C 1-4 haloalkyl, —OR A1 , —NR A1 R B1 , —CN, —C(O)R A1 , —C(O)OR A1 and C 3-6 cycloalkyl. Preferably, het 3 may be unsubstituted or substituted with 1, 2, or 3 groups selected from: halo, C 1-4 alkyl, C 1-4 haloalkyl, —OR A1 , —C(O)R A1 and —C(O)OR A1 , wherein R A1 is H, methyl, tert-butyl or trifluoromethyl.
[0035] In a particular preferred embodiment het 3 is unsubstituted or substituted with 1 or 2 groups selected from: fluoro, chloro, methyl, ethyl, trifluoromethyl, trifluoroethyl, —OCF 3 , —C(O)Me, —C(O)OMe, —C(O)Et and —C(O)O t Bu.
[0036] Preferably, het 3 is unsubstituted or substituted with 1 or 2 groups. More preferably, het 3 is unsubstituted or substituted with 1 group.
[0037] In an embodiment het 2 is represented by an aromatic, saturated or unsaturated 6 membered heterocyclic ring which is unsubstituted or substituted, and het 3 is represented by an aromatic, saturated or unsaturated 6 membered heterocyclic ring which is unsubstituted or substituted and comprises 2 heteroatoms.
[0038] In an embodiment het 2 is represented by a ring selected from unsubstituted or substituted: pyridine, pyrazole, imidazole, pyrazine, pyrimidine, pyridazine, pyran, tetrahydropyran, dihydropyran, piperidine, piperazine, morpholine, thiomorpholine, oxazine, dioxine, dioxane, thiazine, oxathiane and dithiane; and het 3 is represented by a ring selected from unsubstituted or substituted: pyrimidine, pyrazine, pyridazine, piperazine, dioxine, dioxane, morpholine and thiomorpholine.
[0039] Preferably, het 2 is represented by a ring selected from unsubstituted or substituted: pyridine, pyrazole, imidazole, tetrahydropyran, dihydropyran, piperidine, piperazine and morpholine; and het 3 is represented by a ring selected from unsubstituted or substituted: pyrimidine, pyrazine, pyridazine and piperazine.
[0040] Het 1 represents a substituted or unsubstituted 8 or 9 membered bicyclic heteroaryl group comprising a 5 membered ring and comprising 1, 2, 3 or 4 heteroatoms selected from N, O or S. Het 1 represents a substituted or unsubstituted 9 membered bicyclic heteroaryl group comprising a 5 membered ring and a 6 membered ring, wherein the 5 membered ring comprises 1 or 2 N atoms and the 6-membered ring comprises 1 or 2 N atoms.
[0041] Het 1 may represent a group selected from unsubstituted or substituted: indolizine, indole, isoindole, benzofuran, isobenzofuran, benzothiophene, isobenzothiophene, benzothiazole, benzoxazole, benzisothiazole, benzisoxazole, imidazopyridine, imidazopyrimidine, indazole, azaindazole, purine, azaindole, and azaisoindole.
[0042] Het 1 may represent a group selected from unsubstituted or substituted: indolizine, indole, isoindole, benzofuran, isobenzofuran, benzothiophene, isobenzothiophene, benzothiazole, benzoxazole, benzisothiazole, benzisoxazole, imidazopyridine, imidazopyrimidine, indazole, azaindazole, purine, pyrrolopyrimidine, pyrazolopyrimidine, pyrazolopyridine, azaindole, and azaisoindole.
[0043] Het 1 represents a group selected from unsubstituted or substituted: indolizine, indole, isoindole, benzofuran, isobenzofuran, benzothiophene, isobenzothiophene, benzothiazole, benzoxazole, benzisothiazole, benzisoxazole, purine, pyrrolopyrimidine, pyrazolopyrimidine, pyrazolopyridine, azaindole, and azaisoindole.
[0044] Het 1 may represent a group selected from unsubstituted or substituted: imidazopyridine, imidazopyrimidine, azaindazole, purine, pyrrolopyrimidine, pyrazolopyrimidine, pyrazolopyridine, azaindole, and azaisoindole.
[0045] Optionally, het 1 may represent a group selected from unsubstituted or substituted: indolizine
[0046] Preferably het 1 represents an unsubstituted or substituted pyrrolopyrimidine or azaindole. Preferably het 1 represents an unsubstituted or substituted azaindole.
[0047] When het 1 represents azaindole, the azaindole may be 5-azaindole, 6-azaindole or 7-azaindole, preferably 7-azaindole.
[0048] Het 1 may be unsubstituted or substituted with 1, 2, or 3 groups (preferably 1 or 2) selected from: halo, C 1-4 alkyl, C 1-4 haloalkyl, —OR A2 , —NR A2 R B2 and —CN. Het 1 may be unsubstituted or substituted with 1 or 2 groups selected from: chloro, fluoro, methyl, ethyl, trifluoromethyl, trifluoroethyl, —OCF 3 , —OH, —OMe, —OEt, —NH 2 , —NHMe, —NMe 2 and —CN. Preferably, Het 1 may be unsubstituted or substituted with 1 or 2 methyl groups.
[0049] In an embodiment het 1 represents a group selected from unsubstituted or substituted: indolizine, indole, isoindole, benzofuran, isobenzofuran, benzothiophene, isobenzothiophene, benzothiazole, benzoxazole, benzisothiazole, benzisoxazole, imidazopyridine, imidazopyrimidine, indazole, azaindazole, purine, azaindole, and azaisoindole; het 2 is represented by an aromatic, saturated or unsaturated 6 membered heterocyclic ring which is unsubstituted or substituted; and het 3 is represented by an aromatic, saturated or unsaturated 6 membered heterocyclic ring which is unsubstituted or substituted and comprises 2 heteroatoms.
[0050] In an embodiment het 1 represents a group selected from unsubstituted or substituted: indolizine, indole, isoindole, benzofuran, isobenzofuran, benzothiophene, isobenzothiophene, benzothiazole, benzoxazole, benzisothiazole, benzisoxazole, imidazopyridine, imidazopyrimidine, indazole, azaindazole, purine, pyrrolopyrimidine, pyrazolopyrimidine, azaindole, and azaisoindole; het 2 is represented by an aromatic, saturated or unsaturated 6 membered heterocyclic ring which is unsubstituted or substituted; and het 3 is represented by an aromatic, saturated or unsaturated 6 membered heterocyclic ring which is unsubstituted or substituted and comprises 2 heteroatoms.
[0051] In an embodiment het 1 represents a group selected from unsubstituted or substituted: indolizine, indole, isoindole, benzofuran, isobenzofuran, benzothiophene, isobenzothiophene, benzothiazole, benzoxazole, benzisothiazole, benzisoxazole, imidazopyridine, imidazopyrimidine, indazole, azaindazole, purine, azaindole, and azaisoindole; het 2 is represented by a ring selected from unsubstituted or substituted: pyrazole, imidazole, pyridine, pyrazine, pyrimidine, pyridazine, pyran, tetrahydropyran, dihydropyran, piperidine, piperazine, morpholine, thiomorpholine, oxazine, dioxine, dioxane, thiazine, oxathiane and dithiane; het 2 is represented by unsubstituted or substituted pyridine; and het 3 is represented by a ring selected from unsubstituted or substituted: pyrimidine, pyrazine, pyridazine, piperazine, dioxine, dioxane, morpholine and thiomorpholine.
[0052] In an embodiment het 1 represents a group selected from unsubstituted or substituted: indolizine, indole, isoindole, benzofuran, isobenzofuran, benzothiophene, isobenzothiophene, benzothiazole, benzoxazole, benzisothiazole, benzisoxazole, imidazopyridine, imidazopyrimidine, indazole, azaindazole, purine, pyrrolopyrimidine, pyrazolopyrimidine, azaindole, and azaisoindole; het 2 is represented by a ring selected from unsubstituted or substituted: pyrazole, imidazole, pyridine, pyrazine, pyrimidine, pyridazine, pyran, tetrahydropyran, dihydropyran, piperidine, piperazine, morpholine, thiomorpholine, oxazine, dioxine, dioxane, thiazine, oxathiane and dithiane; het 2 is represented by unsubstituted or substituted pyridine; and het 3 is represented by a ring selected from unsubstituted or substituted: pyrimidine, pyrazine, pyridazine, piperazine, dioxine, dioxane, morpholine and thiomorpholine.
[0053] Optionally, het 1 represents a group selected from unsubstituted or substituted: indolizine, indole, isoindole, benzofuran, isobenzofuran, benzothiophene, isobenzothiophene, benzothiazole, benzoxazole, benzisothiazole, benzisoxazole, imidazopyridine, imidazopyrimidine, indazole, azaindazole, purine, azaindole, and azaisoindole; het 2 is represented by a ring selected from unsubstituted or substituted: pyrazole, imidazole, pyridine, tetrahydropyran, dihydropyran, piperidine, piperazine and morpholine; and het 3 is represented by a ring selected from unsubstituted or substituted: pyrimidine, pyrazine, pyridazine and piperazine.
[0054] Optionally, het 1 represents a group selected from unsubstituted or substituted: indolizine, indole, isoindole, benzofuran, isobenzofuran, benzothiophene, isobenzothiophene, benzothiazole, benzoxazole, benzisothiazole, benzisoxazole, imidazopyridine, imidazopyrimidine, indazole, azaindazole, purine, pyrrolopyrimidine, pyrazolopyrimidine, azaindole, and azaisoindole; het 2 is represented by a ring selected from unsubstituted or substituted: pyrazole, imidazole, pyridine, tetrahydropyran, dihydropyran, piperidine, piperazine and morpholine; and het 3 is represented by a ring selected from unsubstituted or substituted: pyrimidine, pyrazine, pyridazine and piperazine.
[0055] In an embodiment m is 1 or 2. In a preferred embodiment m is 1.
[0056] In an embodiment the compound according to formula (I) is a compound according to formula (III):
[0000]
[0057] In an embodiment the compound according to formula (I) is a compound according to formulae (IIIa) or (IIIb):
[0000]
[0058] In an embodiment the compound according to formula (I) is a compound according to formulae (IVa) or (IVb):
[0000]
[0059] In an embodiment the compound according to formula (I) is a compound according to formulae (Va) or (Vb):
[0000]
[0060] In an embodiment het 1 represents an unsubstituted or substituted azaindole; het 2 is represented by an aromatic, saturated or unsaturated 6 membered heterocyclic ring which is unsubstituted or substituted, and het 3 is represented by an aromatic, saturated or unsaturated 6 membered heterocyclic ring which is unsubstituted or substituted and comprises 2 heteroatoms.
[0061] In an embodiment het 1 represents an unsubstituted or substituted azaindole; het 2 is represented by a ring selected from unsubstituted or substituted: pyrazole, imidazole, pyridine, pyrazine, pyrimidine, pyridazine, pyran, tetrahydropyran, dihydropyran, piperidine, piperazine, morpholine, thiomorpholine, oxazine, dioxine, dioxane, thiazine, oxathiane and dithiane; and het 3 is represented by a ring selected from unsubstituted or substituted: pyrimidine, pyrazine, pyridazine, piperazine, dioxine, dioxane, morpholine and thiomorpholine.
[0062] Optionally, het 1 represents an unsubstituted or substituted azaindole; het 2 is represented by a ring selected from unsubstituted or substituted: pyrazole, imidazole, pyridine, tetrahydropyran, dihydropyran, piperidine, piperazine and morpholine; and het 3 is represented by a ring selected from unsubstituted or substituted: pyrimidine, pyrazine, pyridazine and piperazine.
[0063] In a preferred embodiment het 1 represents an unsubstituted or substituted: azaindole; het 2 is represented by an unsubstituted or substituted pyridine; and het 3 is represented by a ring selected from unsubstituted or substituted: pyrimidine, and pyrazine.
[0064] In an embodiment the compound according to formula (I) is a compound according to formula (VI):
[0000]
[0065] In an embodiment the compound according to formula (I) is a compound according to formulae (VIa) or (VIb):
[0000]
[0066] R 1 and R 2 may be independently selected at each occurrence from: H, halo, C 1-4 alkyl, C 1-4 haloalkyl, —OR A3 and —NR A3 R B3 . R 1 and R 2 may be independently selected at each occurrence from: H, chloro, fluoro, methyl, ethyl, trifluoromethyl, trifluoroethyl, —OCF 3 , —OH, —OMe, —OEt, —NH 2 , —NHMe, and —NMe 2 . Preferably, R 1 and R 2 are H.
[0067] In an embodiment m is 1 and R 1 and R 2 are H. In an alternative embodiment m is 2 and R 1 and R 2 are H. In an alternative embodiment m is 1 and R 1 is Me R 2 are H.
[0068] R 3 is optionally H or methyl.
[0069] R 4 is optionally selected at each occurrence from: halo, C 1-4 alkyl, C 1-4 haloalkyl, —CN, —OR A4 and —NR A4 R B4 . R 4 may be independently selected at each occurrence from: H, chloro, fluoro, methyl, ethyl, trifluoromethyl, trifluoroethyl, —OCF 3 , —OH, —OMe, —OEt, —NH 2 , —NHMe, and —NMe 2 .
[0070] R A1 , R B1 , R A2 , R B2 , R A3 , R B3 , R A4 and R B4 are at each occurrence independently selected from: H, methyl, ethyl and —OCF 3 .
[0071] In a preferred embodiment the compound of formula (I) is a compound according to formulae (IIa), (IIIa), (IVa), (Va) or (VIa).
[0072] In a preferred embodiment n is 0.
[0073] The compound according to the invention may be selected from a group consisting of:
[0000]
[0074] The compound according to the invention may also be selected from a group consisting of:
[0000]
[0075] The compound according to the invention may also be selected from a group consisting of:
[0000]
[0076] In accordance with another aspect, the present invention provides a compound of the present invention for use as a medicament.
[0077] In accordance with another aspect, the present invention provides a pharmaceutical formulation comprising a compound of the present invention and a pharmaceutically acceptable excipient.
[0078] In an embodiment the pharmaceutical composition may be a combination product comprising an additional pharmaceutically active agent. The additional pharmaceutically active agent may be an anti-tumor agent described below.
[0079] In accordance with another aspect, there is provided a compound of the present invention for use in the modulation of Wnt signalling. Optionally, the Wnt signalling is modulated by the inhibition of porcupine (Porcn). Modulation of Wnt signalling may include inhibition of paracrine signalling in the tissues surrounding tumours and autocrine and paracrine signalling in cancer cells
[0080] In accordance with another aspect, there is provided a compound of the present invention for use in the treatment of a condition which can be modulated by inhibition of Porcn using a compound of the present invention. A compound of formula (I) may be for use in the treatment of a condition treatable by the inhibition of Porcn.
[0081] Porcn inhibition is relevant for the treatment of many different diseases associated with increased Wnt signalling. In embodiments the condition treatable by the modulation of Wnt signalling or the inhibition of Porcn may be selected from: cancer, sarcoma, melanoma, skin cancer, haematological tumors, lymphoma, carcinoma, and leukemia. Specific cancers, sarcomas, melanomas, skin cancers, haematological tumors, lymphoma, carcinoma and leukemia treatable by the modulation of Wnt signalling or the inhibition of Porcn may be selected from: esophageal squamous cell carcinoma, gastric cancer, glioblastomas, astrocytomas; retinoblastoma, osteosarcoma, chondosarcoma, Ewing's sarcoma, rabdomysarcoma, Wilm's tumor, basal cell carcinoma, non-small cell lung cancer, brain tumour, hormone refractory prostate cancer, prostate cancer, metastatic breast cancer, breast cancer, metastatic pancreatic cancer, pancreatic cancer, colorectal cancer, cervical cancer, head and neck squamous cell carcinoma and cancer of the head and neck.
[0082] Porcn inhibition is also relevant for the treatment of a condition treatable by the inhibition of Wnt ligand secretion selected from: skin fibrosis, idiopathic pulmonary fibrosis, renal interstitial fibrosis, liver fibrosis, proteinuria, kidney graft rejection, osteoarthritis, Parkinsons's disease, cystoid macular edema, uveitis associated cystoid macular edema, retinopathy, diabetic retinopathy and retinopathy of prematurity.
[0083] The invention contemplates methods of treating the above mentioned conditions and contemplates compounds of the invention for use in a method of treatment of the above mentioned conditions.
[0084] In an aspect of the invention, a compound of the invention may be for use in the treatment of a condition selected from: cancer, sarcoma, melanoma, skin cancer, haematological tumors, lymphoma, carcinoma, and leukemia. Specific cancer, sarcoma, melanoma, skin cancer, haematological tumors, lymphoma, carcinoma, and leukemia that may be treated by the compound of the invention may be selected from: esophageal squamous cell carcinoma, gastric cancer, glioblastomas, astrocytomas; retinoblastoma, osteosarcoma, chondosarcoma, Ewing's sarcoma, rabdomysarcoma, Wilm's tumor, basal cell carcinoma, non-small cell lung cancer, brain tumour, hormone refractory prostate cancer, prostate cancer, metastatic breast cancer, breast cancer, metastatic pancreatic cancer, pancreatic cancer, colorectal cancer, cervical cancer, head and neck squamous cell carcinoma and cancer of the head and neck.
[0085] The compound of the invention also may be for use in the treatment of a condition selected from: skin fibrosis, idiopathic pulmonary fibrosis, renal interstitial fibrosis, liver fibrosis, proteinuria, kidney graft rejection, osteoarthritis, Parkinsons's disease, cystoid macular edema, uveitis associated cystoid macular edema, retinopathy, diabetic retinopathy and retinopathy of prematurity.
[0086] In an aspect of the invention there is provided a method of treatment of a condition which is modulated by Wnt signalling, wherein the method comprises administering a therapeutic amount of a compound of the invention, to a patient in need thereof. In an embodiment of the invention there is provided a method of treatment of a condition which is modulated by Porcn.
[0087] The method of treatment may be a method of treating a condition treatable by the modulation of Wnt signalling or Porcn. These conditions are described above in relation to conditions treatable by the inhibition of Porcn.
[0088] In an aspect of the invention there is provided a method of treatment of a condition selected from: cancer, sarcoma, melanoma, skin cancer, haematological tumors, lymphoma, carcinoma, and leukemia, wherein the method comprises administering a therapeutic amount of a compound of the invention, to a patient in need thereof. Specific cancer, sarcoma, melanoma, skin cancer, haematological tumors, lymphoma, carcinoma, and leukemia that may be treated by the method of treatment may be selected from: esophageal squamous cell carcinoma, gastric cancer, glioblastomas, astrocytomas; retinoblastoma, osteosarcoma, chondosarcoma, Ewing's sarcoma, rabdomysarcoma, Wilm's tumor, basal cell carcinoma, non-small cell lung cancer, brain tumour, hormone refractory prostate cancer, prostate cancer, metastatic breast cancer, breast cancer, metastatic pancreatic cancer, pancreatic cancer, colorectal cancer, cervical cancer, head and neck squamous cell carcinoma and cancer of the head and neck.
[0089] The method of treatment also may be the treatment of a condition selected from: skin fibrosis, idiopathic pulmonary fibrosis, renal interstitial fibrosis, liver fibrosis, proteinuria, kidney graft rejection, osteoarthritis, Parkinson's disease, cystoid macular edema, uveitis associated cystoid macular edema, retinopathy, diabetic retinopathy and retinopathy of prematurity.
[0090] In an aspect of the invention there is provided a use of a compound of the invention in the manufacture of a medicament for the treatment of a condition which is modulated by Porcn. The condition may be any of the conditions mentioned above.
[0091] Aberrant Wnt signalling may be associated with a condition selected from: non small cell lung cancer (NSCLC); chronic lymphocytic leukemia (CLL); gastric cancer; head and neck squamous cell carcinoma (HNSCC); colorectal cancer; ovarian cancer; basal cell carcinoma (BCC); breast cancer; bladder cancer; mesothelioma colorectal; prostate cancer; non-small cell lung cancer; lung cancer; osteosarcoma; Frz overexpression; has been associated with cancers such as prostate; colorectal; ovarian cancer; gastric; overexpression of Wnt signaling pathway components such as dishevelled; prostate cancer; breast cancer; mesothelioma; cervical; Frat-1 overexpression; pancreatic cancer; esophageal cancer; cervical cancer; breast cancer; and gastric cancer; Axin loss of function (LOF); hepatocellular cancer; medulloblastoma; gastric cancer; colorectal cancer; intestinal carcinoid; ovarian cancer; pulmonary adenocarcinoma; endometrial cancer; hepatocellular; hepatoblastoma; medulloblastoma; pancreatic cancer; thyroid cancer; prostate cancer; melanoma; pilomatricoma; Wilms' tumor; pancreatoblastomas; liposarcomas; juvenile nasopharyngeal angiofibromas; desmoid; synovial sarcoma; melanoma; leukemia; multiple myeloma; brain tumors, such as gliomas, astrocytomas, meningiomas, schwannomas, pituitary tumors, primitive neuroectodermal tumors (PNET), medulloblastomas, craniopharyngioma, pineal region tumors, and non cancerous neurofibromatoses;
[0092] Inhibition of Wnt signaling with the Wnt antagonists of the present invention may be therapeutic in the treatment of disorders resulting from dysfunctional hematopoieses, such as leukemias and various blood related cancers, such as acute, chronic, lymphoid and myelogenous leukemias, myelodysplastic syndrome and myeloproliferative disorders. These include myeloma, lymphoma (e.g., Hodgkin's and non-Hodgkin's) chronic and nonprogressive anemia, progressive and symptomatic blood cell deficiencies, polycythemia vera, essential or primary thrombocythemia, idiopathic myelofibrosis, chronic myelomonocytic leukemia (CMML), mantle cell lymphoma, cutaneous T-cell lymphoma, and Waldenstrom macro globinemia.
[0093] Other disorders associated with aberrant Wnt signaling, include but are not limited to osteoporosis, osteoarthritis, polycystic kidney disease, diabetes, schizophrenia, vascular disease, cardiac disease, non-oncogenic proliferative diseases, and neurodegenerative diseases such as Alzheimer's disease.
[0094] Aberrant Wnt signalling may be associated with a cancer selected from: brain; lung; colon; epidermoid; squamous cell; bladder; gastric; pancreatic; breast; head and neck; renal; kidney; liver; ovarian; prostate; uterine; oesophageal; testicular; gynaecological; thyroid; melanoma; acute myeloid leukemia; chronic myelogenous leukemia; MCL Kaposi's sarcoma;
[0095] Aberrant Wnt signalling may be associated with an inflammatory disease selected from: multiple sclerosis; rheumatoid arthritis; systemic lupus; inflammatory bowel disease; osteoarthritis; Alzheimer's;
DETAILED DESCRIPTION
[0096] Given below are definitions of terms used in this application. Any term not defined herein takes the normal meaning as the skilled person would understand the term.
[0097] The term “halo” refers to one of the halogens, group 17 of the periodic table. In particular the term refers to fluorine, chlorine, bromine and iodine. Preferably, the term refers to fluorine or chlorine.
[0098] The term “C 1-4 alkyl” refers to a linear or branched hydrocarbon chain containing 1, 2, 3, 4, 5 or 6 carbon atoms, for example methyl, ethyl, n-propyl, iso-propyl, n-butyl, sec-butyl, tert-butyl, n-pentyl and n-hexyl. Alkylene groups may likewise be linear or branched and may have two places of attachment to the remainder of the molecule. Furthermore, an alkylene group may, for example, correspond to one of those alkyl groups listed in this paragraph. The alkyl and alkylene groups may be unsubstituted or substituted by one or more substituents. Possible substituents are described below. Substituents for the alkyl group may be halogen, e.g. fluorine, chlorine, bromine and iodine, OH, C 1-6 alkoxy.
[0099] The term “C 1-4 alkoxy” refers to an alkyl group which is attached to a molecule via oxygen. This includes moieties where the alkyl part may be linear or branched and may contain 1, 2, 3, 4, 5 or 6 carbon atoms, for example methyl, ethyl, n-propyl, iso-propyl, n-butyl, sec-butyl, tert-butyl, n-pentyl and n-hexyl. Therefore, the alkoxy group may be methoxy, ethoxy, n-propoxy, iso-propoxy, n-butoxy, sec-butoxy, tert-butoxy, n-pentoxy and n-hexoxy. The alkyl part of the alkoxy group may be unsubstituted or substituted by one or more substituents. Possible substituents are described below. Substituents for the alkyl group may be halogen, e.g. fluorine, chlorine, bromine and iodine, OH, C 1-6 alkoxy.
[0100] The term “C 1-4 haloalkyl” refers to a hydrocarbon chain substituted with at least one halogen atom independently chosen at each occurrence, for example fluorine, chlorine, bromine and iodine. The halogen atom may be present at any position on the hydrocarbon chain. For example, C 1-6 haloalkyl may refer to chloromethyl, fluoromethyl, trifluoromethyl, chloroethyl e.g. 1-chloromethyl and 2-chloroethyl, trichloroethyl e.g. 1,2,2-trichloroethyl, 2,2,2-trichloroethyl, fluoroethyl e.g. 1-fluoromethyl and 2-fluoroethyl, trifluoroethyl e.g. 1,2,2-trifluoroethyl and 2,2,2-trifluoroethyl, chloropropyl, trichloropropyl, fluoropropyl, trifluoropropyl.
[0101] The term “C 2-6 alkenyl” refers to a branched or linear hydrocarbon chain containing at least one double bond and having 2, 3, 4, 5 or 6 carbon atoms. The double bond(s) may be present as the E or Z isomer. The double bond may be at any possible position of the hydrocarbon chain. For example, the “C 2-6 alkenyl” may be ethenyl, propenyl, butenyl, butadienyl, pentenyl, pentadienyl, hexenyl and hexadienyl.
[0102] The term “C 2-6 alkynyl” refers to a branched or linear hydrocarbon chain containing at least one triple bond and having 2, 3, 4, 5 or 6 carbon atoms. The triple bond may be at any possible position of the hydrocarbon chain. For example, the “C 2-6 alkynyl” may be ethynyl, propynyl, butynyl, pentynyl and hexynyl.
[0103] The term “C 1-6 heteroalkyl” refers to a branched or linear hydrocarbon chain containing 1, 2, 3, 4, 5, or 6 carbon atoms and at least one heteroatom selected from N, O and S positioned between any carbon in the chain or at an end of the chain. For example, the hydrocarbon chain may contain one or two heteroatoms. The C 1-6 heteroalkyl may be bonded to the rest of the molecule through a carbon or a heteroatom. For example, the “C 1-6 heteroalkyl” may be C 1-6 N-alkyl, C 1-6 N,N-alkyl, or C 1-6 O-alkyl.
[0104] The term “carbocyclic” refers to a saturated or unsaturated carbon containing ring system. A “carbocyclic” system may be monocyclic or a fused polycyclic ring system, for example, bicyclic or tricyclic. A “carbocyclic” moiety may contain from 3 to 14 carbon atoms, for example, 3 to 8 carbon atoms in a monocyclic system and 7 to 14 carbon atoms in a polycyclic system. “Carbocyclic” encompasses cycloalkyl moieties, cycloalkenyl moieties, aryl ring systems and fused ring systems including an aromatic portion.
[0105] The term “heterocyclic” refers to a saturated or unsaturated ring system containing at least one heteroatom selected from N, O or S. A “heterocyclic” system may contain 1, 2, 3 or 4 heteroatoms, for example 1 or 2. A “heterocyclic” system may be monocyclic or a fused polycyclic ring system, for example, bicyclic or tricyclic. A “heterocyclic” moiety may contain from 3 to 14 carbon atoms, for example, 3 to 8 carbon atoms in a monocyclic system and 7 to 14 carbon atoms in a polycyclic system. “Heterocyclic” encompasses heterocycloalkyl moieties, heterocycloalkenyl moieties and heteroaromatic moieties. For example, the heterocyclic group may be: oxirane, aziridine, azetidine, oxetane, tetrahydrofuran, pyrrolidine, imidazolidine, succinimide, pyrazolidine, oxazolidine, isoxazolidine, thiazolidine, isothiazolidine, piperidine, morpholine, thiomorpholine, piperazine, and tetrahydropyran.
[0106] The term “C 3-6 cycloalkyl” refers to a saturated hydrocarbon ring system containing 3, 4, 5, 6, 7 or 8 carbon atoms. For example, the “C 3-6 cycloalkyl” may be cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl and cyclooctyl.
[0107] The term “C 3-6 cycloalkenyl” refers to an unsaturated hydrocarbon ring system containing 3, 4, 5, 6, 7 or 8 carbon atoms that is not aromatic. The ring may contain more than one double bond provided that the ring system is not aromatic. For example, the “C 3-6 cycloalkyl” may be cyclopropenyl, cyclobutenyl, cyclopentenyl, cyclopentadienyl, cyclohexenyl, cyclohexadienly, cycloheptenyl, cycloheptadiene, cyclooctenyl and cycloatadienyl.
[0108] The term “C 3-6 heterocycloalkyl” refers to a saturated hydrocarbon ring system containing 3, 4, 5, 6, 7 or 8 carbon atoms and at least one heteroatom within the ring selected from N, O and S. For example there may be 1, 2 or 3 heteroatoms, optionally 1 or 2. The “C 3-6 heterocycloalkyl” may be bonded to the rest of the molecule through any carbon atom or heteroatom. The “C 3-6 heterocycloalkyl” may have one or more, e.g. one or two, bonds to the rest of the molecule: these bonds may be through any of the atoms in the ring. For example, the “C 3-6 heterocycloalkyl” may be oxirane, aziridine, azetidine, oxetane, tetrahydrofuran, pyrrolidine, imidazolidine, succinimide, pyrazolidine, oxazolidine, isoxazolidine, thiazolidine, isothiazolidine, piperidine, morpholine, thiomorpholine, piperazine, and tetrahydropyran.
[0109] The term “C 3-6 heterocycloalkenyl” refers to an unsaturated hydrocarbon ring system, that is not aromatic, containing 3, 4, 5, 6, 7 or 8 carbon atoms and at least one heteroatom within the ring selected from N, O and S. For example there may be 1, 2 or 3 heteroatoms, optionally 1 or 2. The “C 3-6 heterocycloalkenyl” may be bonded to the rest of the molecule through any carbon atom or heteroatom. The “C 3-6 heterocycloalkenyl” may have one or more, e.g. one or two, bonds to the rest of the molecule: these bonds may be through any of the atoms in the ring. For example, the “C 3-6 heterocycloalkyl” may be tetrahydropyridine, dihydropyran, dihydrofuran, pyrroline.
[0110] The term “aromatic” when applied to a substituent as a whole means a single ring or polycyclic ring system with 4n+2 electrons in a conjugated τ system within the ring or ring system where all atoms contributing to the conjugated τ system are in the same plane.
[0111] The term “aryl” refers to an aromatic hydrocarbon ring system. The ring system has 4n+2 electrons in a conjugated τ system within a ring where all atoms contributing to the conjugated τ system are in the same plane. For example, the “aryl” may be phenyl and naphthyl. The aryl system itself may be substituted with other groups.
[0112] The term “heteroaryl” refers to an aromatic hydrocarbon ring system with at least one heteroatom within a single ring or within a fused ring system, selected from O, N and S. The ring or ring system has 4n+2 electrons in a conjugated τ system where all atoms contributing to the conjugated τ system are in the same plane. For example, the “heteroaryl” may be imidazole, thiene, furane, thianthrene, pyrrol, benzimidazole, pyrazole, pyrazine, pyridine, pyrimidine and indole.
[0113] The term “alkaryl” refers to an aryl group, as defined above, bonded to a C 1-4 alkyl, where the C 1-4 alkyl group provides attachment to the remainder of the molecule.
[0114] The term “alkheteroaryl” refers to a heteroaryl group, as defined above, bonded to a C 1-4 alkyl, where the alkyl group provides attachment to the remainder of the molecule.
[0115] The term “halogen” herein includes reference to F, Cl, Br and I. Halogen may be Cl. Halogen may be F.
[0116] A bond terminating in a “ ” represents that the bond is connected to another atom that is not shown in the structure. A bond terminating inside a cyclic structure and not terminating at an atom of the ring structure represents that the bond may be connected to any of the atoms in the ring structure where allowed by valency.
[0117] Where a moiety is substituted, it may be substituted at any point on the moiety where chemically possible and consistent with atomic valency requirements. The moiety may be substituted by one or more substituents, e.g. 1, 2, 3 or 4 substituents; optionally there are 1 or 2 substituents on a group. Where there are two or more substituents, the substituents may be the same or different. The substituent(s) may be selected from: OH, NHR, amidino, guanidino, hydroxyguanidino, formamidino, isothioureido, ureido, mercapto, C(O)H, acyl, acyloxy, carboxy, sulfo, sulfamoyl, carbamoyl, cyano, azo, nitro, halo, C 1-6 alkyl, C 1-6 alkoxy, C 1-6 haloalkyl, C 3-8 cycloalkyl, C 2-6 alkenyl, C 2-6 alkynyl, aryl, heteroaryl or alkaryl. Where the group to be substituted is an alkyl group the substituent may be ═O. R may be selected from H, C 1-6 alkyl, C 3-8 cycloalkyl, phenyl, benzyl or phenethyl group, e.g. R is H or C 1-3 alkyl. Where the moiety is substituted with two or more substituents and two of the substituents are adjacent the adjacent substituents may form a C 4-8 ring along with the atoms of the moiety on which the substituents are substituted, wherein the C 4-8 ring is a saturated or unsaturated hydrocarbon ring with 4, 5, 6, 7, or 8 carbon atoms or a saturated or unsaturated hydrocarbon ring with 4, 5, 6, 7, or 8 carbon atoms and 1, 2 or 3 heteroatoms.
[0118] Substituents are only present at positions where they are chemically possible, the person skilled in the art being able to decide (either experimentally or theoretically) without inappropriate effort which substitutions are chemically possible and which are not.
[0119] Ortho, meta and para substitution are well understood terms in the art. For the absence of doubt, “ortho” substitution is a substitution pattern where adjacent carbons possess a substituent, whether a simple group, for example the fluoro group in the example below, or other portions of the molecule, as indicated by the bond ending in “ ”.
[0000]
[0120] “Meta” substitution is a substitution pattern where two substituents are on carbons one carbon removed from each other, i.e with a single carbon atom between the substituted carbons. In other words there is a substituent on the second atom away from the atom with another substituent. For example the groups below are meta substituted.
[0000]
[0121] “Para” substitution is a substitution pattern where two substituents are on carbons two carbons removed from each other, i.e with two carbon atoms between the substituted carbons. In other words there is a substituent on the third atom away from the atom with another substituent. For example the groups below are para substituted.
[0000]
[0122] By “acyl” is meant an organic radical derived from, for example, an organic acid by the removal of the hydroxyl group, e.g. a radical having the formula R—C(O)—, where R may be selected from H, C 1-6 alkyl, C 3-8 cycloalkyl, phenyl, benzyl or phenethyl group, eg R is H or C 1-3 alkyl. In one embodiment acyl is alkyl-carbonyl. Examples of acyl groups include, but are not limited to, formyl, acetyl, propionyl and butyryl. A particular acyl group is acetyl.
[0123] Throughout the description the disclosure of a compound also encompasses pharmaceutically acceptable salts, solvates and stereoisomers thereof. Where a compound has a stereocentre, both (R) and (S) stereoisomers are contemplated by the invention, equally mixtures of stereoisomers or a racemic mixture are completed by the present application. Where a compound of the invention has two or more stereocentres any combination of (R) and (S) stereoisomers is contemplated. The combination of (R) and (S) stereoisomers may result in a diastereomeric mixture or a single diastereoisomer. The compounds of the invention may be present as a single stereoisomer or may be mixtures of stereoisomers, for example racemic mixtures and other enantiomeric mixtures, and diasteroemeric mixtures. Where the mixture is a mixture of enantiomers the enantiomeric excess may be any of those disclosed above. Where the compound is a single stereoisomer the compounds may still contain other diasteroisomers or enantiomers as impurities. Hence a single stereoisomer does not necessarily have an enantiomeric excess (e.e.) or diastereomeric excess (d.e.) of 100% but could have an e.e. or d.e. of about at least 85%
[0124] The invention contemplates pharmaceutically acceptable salts of the compounds of the invention. These may include the acid addition and base salts of the compounds. These may be acid addition and base salts of the compounds. In addition the invention contemplates solvates of the compounds. These may be hydrates or other solvated forms of the compound.
[0125] Suitable acid addition salts are formed from acids which form non-toxic salts. Examples include the acetate, aspartate, benzoate, besylate, bicarbonate/carbonate, bisulfate/sulfate, borate, camsylate, citrate, edisylate, esylate, formate, fumarate, gluceptate, gluconate, glucuronate, hexafluorophosphate, hibenzate, hydrochloride/chloride, hydrobromide/bromide, hydroiodide/iodide, isethionate, lactate, malate, maleate, malonate, mesylate, methylsulfate, naphthylate, 1,5-naphthalenedisulfonate, 2-napsylate, nicotinate, nitrate, orotate, oxalate, palmitate, pamoate, phosphate/hydrogen phosphate/dihydrogen phosphate, saccharate, stearate, succinate, tartrate, tosylate and trifluoroacetate salts.
[0126] Suitable base salts are formed from bases which form non-toxic salts. Examples include the aluminium, arginine, benzathine, calcium, choline, diethylamine, diolamine, glycine, lysine, magnesium, meglumine, olamine, potassium, sodium, tromethamine and zinc salts. Hemisalts of acids and bases may also be formed, for example, hemisulfate and hemicalcium salts. For a review on suitable salts, see “Handbook of Pharmaceutical Salts: Properties, Selection, and Use” by Stahl and Wermuth (Wiley-VCH, Weinheim, Germany, 2002).
[0127] Pharmaceutically acceptable salts of compounds of formula (I) may be prepared by one or more of three methods:
[0000] (i) by reacting the compound of the invention with the desired acid or base;
(ii) by removing an acid- or base-labile protecting group from a suitable precursor of the compound of the invention or by ring-opening a suitable cyclic precursor, for example, a lactone or lactam, using the desired acid or base; or
(iii) by converting one salt of the compound of the invention to another by reaction with an appropriate acid or base or by means of a suitable ion exchange column.
[0128] All three reactions are typically carried out in solution. The resulting salt may precipitate out and be collected by filtration or may be recovered by evaporation of the solvent. The degree of ionisation in the resulting salt may vary from completely ionised to almost non-ionised.
[0129] The compounds of the invention may exist in both unsolvated and solvated forms. The term ‘solvate’ is used herein to describe a molecular complex comprising the compound of the invention and a stoichiometric amount of one or more pharmaceutically acceptable solvent molecules, for example, ethanol. The term ‘hydrate’ is employed when said solvent is water.
[0130] Included within the scope of the invention are complexes such as clathrates, drug-host inclusion complexes wherein, in contrast to the aforementioned solvates, the drug and host are present in stoichiometric or non-stoichiometric amounts. Also included are complexes of the drug containing two or more organic and/or inorganic components which may be in stoichiometric or non-stoichiometric amounts. The resulting complexes may be ionised, partially ionised, or non-ionised. For a review of such complexes, see J Pharm Sci, 64 (8), 1269-1288 by Haleblian (August 1975).
[0131] Hereinafter all references to compounds of any formula include references to salts, solvates and complexes thereof and to solvates and complexes of salts thereof.
[0132] The compounds of the invention include compounds of a number of formula as herein defined, including all polymorphs and crystal habits thereof, prodrugs and isomers thereof (including optical, geometric and tautomeric isomers) as hereinafter defined and isotopically-labelled compounds of the invention.
[0133] The present invention also includes all pharmaceutically acceptable isotopically-labelled compounds of the invention wherein one or more atoms are replaced by atoms having the same atomic number, but an atomic mass or mass number different from the atomic mass or mass number most commonly found in nature.
[0134] Examples of isotopes suitable for inclusion in the compounds of the invention include isotopes of hydrogen, such as 2 H and 3 H, carbon, such as 11 C, 13 C and 14 C, chlorine, such as 36 Cl, fluorine, such as 18 F, iodine, such as 123 I and 125 I, nitrogen, such as 13 N and 15 N, oxygen, such as 15 O, 17 O and 18 O, phosphorus, such as 32 P, and sulphur, such as 35 S.
[0135] Certain isotopically-labelled compounds, for example, those incorporating a radioactive isotope, are useful in drug and/or substrate tissue distribution studies. The radioactive isotopes tritium, i.e. 3 H, and carbon-14, i.e. 14 C, are particularly useful for this purpose in view of their ease of incorporation and ready means of detection.
[0136] Substitution with heavier isotopes such as deuterium, i.e. 2 H, may afford certain therapeutic advantages resulting from greater metabolic stability, for example, increased in vivo half-life or reduced dosage requirements, and hence may be preferred in some circumstances.
[0137] Before purification, the compounds of the present invention may exist as a mixture of enantiomers depending on the synthetic procedure used. The enantiomers can be separated by conventional techniques known in the art. Thus the invention covers individual enantiomers as well as mixtures thereof.
[0138] For some of the steps of the process of preparation of the compounds of the invention, it may be necessary to protect potential reactive functions that are not wished to react, and to cleave said protecting groups in consequence. In such a case, any compatible protecting radical can be used. In particular methods of protection and deprotection such as those described by T. W. GREENE (Protective Groups in Organic Synthesis, A. Wiley-Interscience Publication, 1981) or by P. J. Kocienski (Protecting groups, Georg Thieme Verlag, 1994), can be used. All of the above reactions and the preparations of novel starting materials used in the preceding methods are conventional and appropriate reagents and reaction conditions for their performance or preparation as well as procedures for isolating the desired products will be well-known to those skilled in the art with reference to literature precedents and the examples and preparations hereto.
[0139] Also, the compounds of the present invention as well as intermediates for the preparation thereof can be purified according to various well-known methods, such as for example crystallization or chromatography.
[0140] One or more compounds of the invention may be combined with one or more pharmaceutical agents, for example anti-viral agents, chemotherapeutics, anti-cancer agents, immune enhancers, immunosuppressants, anti-tumour vaccines, anti-viral vaccines, cytokine therapy, or tyrosine kinase inhibitors, for the treatment of conditions modulated by the inhibition of Porcn, for example cancer, sarcoma, melanoma, skin cancer, haematological tumors, lymphoma, carcinoma, leukemia, central nervous system disorders, inflammation and immunological diseases
[0141] The method of treatment or the compound for use in the treatment of cancer, sarcoma, melanoma, skin cancer, haematological tumors, lymphoma, carcinoma, leukemia, central nervous system disorders, inflammation and immunological diseases as defined hereinbefore may be applied as a sole therapy or be a combination therapy with an additional active agent.
[0142] The method of treatment or the compound for use in the treatment of cancer, sarcoma, melanoma, skin cancer, haematological tumors, lymphoma, carcinoma, leukemia, and central nervous system disorders may involve, in addition to the compound of the invention, conventional surgery or radiotherapy or chemotherapy. Such chemotherapy may include one or more of the following categories of anti-tumor agents:
[0000] (i) antiproliferative/antineoplastic drugs and combinations thereof, such as alkylating agents (for example cis-platin, oxaliplatin, carboplatin, cyclophosphamide, nitrogen mustard, uracil mustard, bendamustin, melphalan, chlorambucil, chlormethine, busulphan, temozolamide, nitrosoureas, ifosamide, melphalan, pipobroman, triethylene-melamine, triethylenethiophoporamine, carmustine, lomustine, stroptozocin and dacarbazine); antimetabolites (for example gemcitabine and antifolates such as fluoropyrimidines like 5-fluorouracil and tegafur, raltitrexed, methotrexate, pemetrexed, cytosine arabinoside, floxuridine, cytarabine, 6-mercaptopurine, 6-thioguanine, fludarabine phosphate, pentostatine, and gemcitabine and hydroxyurea); antibiotics (for example anthracyclines like adriamycin, bleomycin, doxorubicin, daunomycin, epirubicin, idarubicin, mitomycin-C, dactinomycin and mithramycin); antimitotic agents (for example vinca alkaloids like vincristine, vinblastine, vindesine and vinorelbine and taxoids like taxol and taxotere and polokinase inhibitors); proteasome inhibitors, for example carfilzomib and bortezomib; interferon therapy; and topoisomerase inhibitors (for example epipodophyllotoxins like etoposide and teniposide, amsacrine, topotecan, mitoxantrone and camptothecin); bleomcin, dactinomycin, daunorubicin, doxorubicin, epirubicin, idarubicin, ara-C, paclitaxel (Taxol™), nabpaclitaxel, docetaxel, mithramycin, deoxyco-formycin, mitomycin-C, L-asparaginase, interferons (especially IFN-a), etoposide, and teniposide;
(ii) cytostatic agents such as antiestrogens (for example tamoxifen, fulvestrant, toremifene, raloxifene, droloxifene and iodoxyfene), antiandrogens (for example bicalutamide, flutamide, nilutamide and cyproterone acetate), LHRH antagonists or LHRH agonists (for example goserelin, leuprorelin and buserelin), progestogens (for example megestrol acetate), aromatase inhibitors (for example as anastrozole, letrozole, vorazole and exemestane) and inhibitors of 5α-reductase such as finasteride; and navelbene, CPT-II, anastrazole, letrazole, capecitabine, reloxafme, cyclophosphamide, ifosamide, and droloxafine;
(iii) anti-invasion agents, for example dasatinib and bosutinib (SKI-606), and metalloproteinase inhibitors, inhibitors of urokinase plasminogen activator receptor function or antibodies to Heparanase;
(iv) inhibitors of growth factor function: for example such inhibitors include growth factor antibodies and growth factor receptor antibodies, for example the anti-erbB2 antibody trastuzumab [Herceptin™], the anti-EGFR antibody panitumumab, the anti-erbB1 antibody cetuximab, tyrosine kinase inhibitors, for example inhibitors of the epidermal growth factor family (for example EGFR family tyrosine kinase inhibitors such as gefitinib, erlotinib, 6-acrylamido-N-(3-chloro-4-fluorophenyl)-7-(3-morpholinopropoxy)-quinazolin-4-amine (CI 1033), erbB2 tyrosine kinase inhibitors such as lapatinib) and antibodies to costimulatory molecules such as CTLA-4, 4-IBB and PD-I, or antibodies to cytokines (IL-10, TGF-beta); inhibitors of the hepatocyte growth factor family; inhibitors of the insulin growth factor family; modulators of protein regulators of cell apoptosis (for example Bcl-2 inhibitors); inhibitors of the platelet-derived growth factor family such as imatinib and/or nilotinib (AMN107); inhibitors of serine/threonine kinases (for example Ras/Raf signalling inhibitors such as farnesyl transferase inhibitors, for example sorafenib, tipifarnib and lonafarnib), inhibitors of cell signalling through MEK and/or AKT kinases, c-kit inhibitors, abl kinase inhibitors, PI3 kinase inhibitors, Plt3 kinase inhibitors, CSF-1R kinase inhibitors, IGF receptor, kinase inhibitors; aurora kinase inhibitors and cyclin dependent kinase inhibitors such as CDK2 and/or CDK4 inhibitors; and CCR2, CCR4 or CCR6 modulator;
(v) antiangiogenic agents such as those which inhibit the effects of vascular endothelial growth factor, [for example the anti-vascular endothelial cell growth factor antibody bevacizumab (Avastin™); thalidomide; lenalidomide; and for example, a VEGF receptor tyrosine kinase inhibitor such as vandetanib, vatalanib, sunitinib, axitinib and pazopanib;
(vi) gene therapy approaches, including for example approaches to replace aberrant genes such as aberrant p53 or aberrant BRCA1 or BRCA2;
(vii) immunotherapy approaches, including for example antibody therapy such as alemtuzumab, rituximab, ibritumomab tiuxetan (Zevalin®) and ofatumumab; interferons such as interferon α; interleukins such as IL-2 (aldesleukin); interleukin inhibitors for example IRAK4 inhibitors; cancer vaccines including prophylactic and treatment vaccines such as HPV vaccines, for example Gardasil, Cervarix, Oncophage and Sipuleucel-T (Provenge); gp100; dendritic cell-based vaccines (such as Ad.p53 DC); and toll-like receptor modulators for example TLR-7 or TLR-9 agonists; and
(viii) cytotoxic agents for example fludaribine (fludara), cladribine, pentostatin (Nipent™);
(ix) steroids such as corticosteroids, including glucocorticoids and mineralocorticoids, for example aclometasone, aclometasone dipropionate, aldosterone, amcinonide, beclomethasone, beclomethasone dipropionate, betamethasone, betamethasone dipropionate, betamethasone sodium phosphate, betamethasone valerate, budesonide, clobetasone, clobetasone butyrate, clobetasol propionate, cloprednol, cortisone, cortisone acetate, cortivazol, deoxycortone, desonide, desoximetasone, dexamethasone, dexamethasone sodium phosphate, dexamethasone isonicotinate, difluorocortolone, fluclorolone, flumethasone, flunisolide, fluocinolone, fluocinolone acetonide, fluocinonide, fluocortin butyl, fluorocortisone, fluorocortolone, fluocortolone caproate, fluocortolone pivalate, fluorometholone, fluprednidene, fluprednidene acetate, flurandrenolone, fluticasone, fluticasone propionate, halcinonide, hydrocortisone, hydrocortisone acetate, hydrocortisone butyrate, hydrocortisone aceponate, hydrocortisone buteprate, hydrocortisone valerate, icomethasone, icomethasone enbutate, meprednisone, methylprednisolone, mometasone paramethasone, mometasone furoate monohydrate, prednicarbate, prednisolone, prednisone, tixocortol, tixocortol pivalate, triamcinolone, triamcinolone acetonide, triamcinolone alcohol and their respective pharmaceutically acceptable derivatives. A combination of steroids may be used, for example a combination of two or more steroids mentioned in this paragraph;
(x) targeted therapies, for example PI3Kd inhibitors, for example idelalisib and perifosine; PD-1, PD-L1, PD-L2 and CTL4-A modulators, antibodies and vaccines; IDO inhibitors (such as indoximod); anti-PD-1 monoclonal antibodies (such as MK-3475 and nivolumab); anti-PDL1 monoclonal antibodies (such as MEDI-4736 and RG-7446); anti-PDL2 monoclonal antibodies; and anti-CTLA-4 antibodies (such as ipilimumab);
(xi) anti-viral agents such as nucleotide reverse transcriptase inhibitors (for example, zidovudine, didanosine, zalcitabine, stavudine, lamivudine, abacavir, adefovir diprovoxil, lobucavir, BCH-10652, emitricitabine, beta-L-FD4 (also called 3′-dicleoxy-5-fluoro-cytidine), (−)-beta-D-2,6-diamino-purine dioxolane, and lodenasine), non-nucleoside reverse transcriptase inhibitors (for example, nevirapine, delaviradine, efavirenz, PNU-142721, AG-1549, MKC-442 (1-ethoxy-methyl)-5-(1-methylethyl)-6-(phenylmehtyl)-(2,4(1H,3H)pyrimidineone), and (+)-alanolide A and B) and protease inhibitors (for example, saquinavir, ritonavir, indinavir, nelfinavir, amprenavir, lasinavir, DMP-450, BMS-2322623, ABT-378 and AG-1 549);
(xii) chimeric antigen receptors, anticancer vaccines and arginase inhibitors.
[0143] The method of treatment or the compound for use in the treatment of inflammation and immunological diseases may involve, in addition to the compound of the invention, additional active agents. The additional active agents may be one or more active agents used to treat the condition being treated by the compound of the invention and additional active agent. The additional active agents may include one or more of the following active agents: —
[0000] (i) steroids such as corticosteroids, including glucocorticoids and mineralocorticoids, for example aclometasone, aclometasone dipropionate, aldosterone, amcinonide, beclomethasone, beclomethasone dipropionate, betamethasone, betamethasone dipropionate, betamethasone sodium phosphate, betamethasone valerate, budesonide, clobetasone, clobetasone butyrate, clobetasol propionate, cloprednol, cortisone, cortisone acetate, cortivazol, deoxycortone, desonide, desoximetasone, dexamethasone, dexamethasone sodium phosphate, dexamethasone isonicotinate, difluorocortolone, fluclorolone, flumethasone, flunisolide, fluocinolone, fluocinolone acetonide, fluocinonide, fluocortin butyl, fluorocortisone, fluorocortolone, fluocortolone caproate, fluocortolone pivalate, fluorometholone, fluprednidene, fluprednidene acetate, flurandrenolone, fluticasone, fluticasone propionate, halcinonide, hydrocortisone, hydrocortisone acetate, hydrocortisone butyrate, hydrocortisone aceponate, hydrocortisone buteprate, hydrocortisone valerate, icomethasone, icomethasone enbutate, meprednisone, methylprednisolone, mometasone paramethasone, mometasone furoate monohydrate, prednicarbate, prednisolone, prednisone, tixocortol, tixocortol pivalate, triamcinolone, triamcinolone acetonide, triamcinolone alcohol and their respective pharmaceutically acceptable derivatives. A combination of steroids may be used, for example a combination of two or more steroids mentioned in this paragraph;
(ii) TNF inhibitors for example etanercept; monoclonal antibodies (e.g. infliximab (Remicade), adalimumab (Humira), certolizumab pegol (Cimzia), golimumab (Simponi)); fusion proteins (e.g. etanercept (Enbrel)); and 5-HT 2A agonists (e.g. 2,5-dimethoxy-4-iodoamphetamine, TCB-2, lysergic acid diethylamide (LSD), lysergic acid dimethylazetidide);
(iii) anti-inflammatory drugs, for example non-steroidal anti-inflammatory drugs;
(iv) dihydrofolate reductase inhibitors/antifolates, for example methotrexate, trimethoprim, brodimoprim, tetroxoprim, iclaprim, pemetrexed, ralitrexed and pralatrexate; and
(v) immunosuppressants for example cyclosporins, tacrolimus, sirolimus pimecrolimus, angiotensin II inhibitors (e.g. Valsartan, Telmisartan, Losartan, Irbesatan, Azilsartan, Olmesartan, Candesartan, Eprosartan) and ACE inhibitors e.g. sulfhydryl-containing agents (e.g. Captopril, Zofenopril), dicarboxylate-containing agents (e.g. Enalapril, Ramipril, Quinapril, Perindopril, Lisinopril, Benazepril, Imidapril, Zofenopril, Trandolapril), phosphate-containing agents (e.g. Fosinopril), casokinins, lactokinins and lactotripeptides.
[0144] Such combination treatment may be achieved by way of the simultaneous, sequential or separate dosing of the individual components of the treatment. Such combination products employ the compounds of this invention within a therapeutically effective dosage range described hereinbefore and the other pharmaceutically-active agent within its approved dosage range.
[0145] Compounds of the invention may exist in a single crystal form or in a mixture of crystal forms or they may be amorphous. Thus, compounds of the invention intended for pharmaceutical use may be administered as crystalline or amorphous products. They may be obtained, for example, as solid plugs, powders, or films by methods such as precipitation, crystallization, freeze drying, or spray drying, or evaporative drying. Microwave or radio frequency drying may be used for this purpose.
[0146] For the above-mentioned compounds of the invention the dosage administered will, of course, vary with the compound employed, the mode of administration, the treatment desired and the disorder indicated. For example, if the compound of the invention is administered orally, then the daily dosage of the compound of the invention may be in the range from 0.01 micrograms per kilogram body weight (pg/kg) to 100 milligrams per kilogram body weight (mg/kg).
[0147] A compound of the invention, or pharmaceutically acceptable salt thereof, may be used on their own but will generally be administered in the form of a pharmaceutical composition in which the compounds of the invention, or pharmaceutically acceptable salt thereof, is in association with a pharmaceutically acceptable adjuvant, diluent or carrier. Conventional procedures for the selection and preparation of suitable pharmaceutical formulations are described in, for example, “Pharmaceuticals—The Science of Dosage Form Designs”, M. E. Aulton, Churchill Livingstone, 1988.
[0148] Depending on the mode of administration of the compounds of the invention, the pharmaceutical composition which is used to administer the compounds of the invention will preferably comprise from 0.05 to 99% w (percent by weight) compounds of the invention, more preferably from 0.05 to 80% w compounds of the invention, still more preferably from 0.10 to 70% w compounds of the invention, and even more preferably from 0.10 to 50% w compounds of the invention, all percentages by weight being based on total composition.
[0149] The pharmaceutical compositions may be administered topically (e.g. to the skin) in the form, e.g., of creams, gels, lotions, solutions, suspensions, or systemically, e.g. by oral administration in the form of tablets, capsules, syrups, powders or granules; or by parenteral administration in the form of a sterile solution, suspension or emulsion for injection (including intravenous, subcutaneous, intramuscular, intravascular or infusion); by rectal administration in the form of suppositories; or by inhalation in the form of an aerosol.
[0150] For oral administration the compounds of the invention may be admixed with an adjuvant or a carrier, for example, lactose, saccharose, sorbitol, mannitol; a starch, for example, potato starch, corn starch or amylopectin; a cellulose derivative; a binder, for example, gelatine or polyvinylpyrrolidone; and/or a lubricant, for example, magnesium stearate, calcium stearate, polyethylene glycol, a wax, paraffin, and the like, and then compressed into tablets. If coated tablets are required, the cores, prepared as described above, may be coated with a concentrated sugar solution which may contain, for example, gum arabic, gelatine, talcum and titanium dioxide. Alternatively, the tablet may be coated with a suitable polymer dissolved in a readily volatile organic solvent.
[0151] For the preparation of soft gelatine capsules, the compounds of the invention may be admixed with, for example, a vegetable oil or polyethylene glycol. Hard gelatine capsules may contain granules of the compound using either the above-mentioned excipients for tablets. Also liquid or semisolid formulations of the compound of the invention may be filled into hard gelatine capsules. Liquid preparations for oral application may be in the form of syrups or suspensions, for example, solutions containing the compound of the invention, the balance being sugar and a mixture of ethanol, water, glycerol and propylene glycol. Optionally such liquid preparations may contain colouring agents, flavouring agents, sweetening agents (such as saccharine), preservative agents and/or carboxymethylcellulose as a thickening agent or other excipients known to those skilled in art.
[0152] For intravenous (parenteral) administration the compounds of the invention may be administered as a sterile aqueous or oily solution.
[0153] The size of the dose for therapeutic purposes of compounds of the invention will naturally vary according to the nature and severity of the conditions, the age and sex of the animal or patient and the route of administration, according to well-known principles of medicine.
[0154] Dosage levels, dose frequency, and treatment durations of compounds of the invention are expected to differ depending on the formulation and clinical indication, age, and co-morbid medical conditions of the patient. The standard duration of treatment with compounds of the invention is expected to vary between one and seven days for most clinical indications. It may be necessary to extend the duration of treatment beyond seven days in instances of recurrent infections or infections associated with tissues or implanted materials to which there is poor blood supply including bones/joints, respiratory tract, endocardium, and dental tissues.
[0155] Throughout the description and claims of this specification, the words “comprise” and “contain” and variations of them mean “including but not limited to”, and they are not intended to (and do not) exclude other moieties, additives, components, integers or steps. Throughout the description and claims of this specification, the singular encompasses the plural unless the context otherwise requires. In particular, where the indefinite article is used, the specification is to be understood as contemplating plurality as well as singularity, unless the context requires otherwise.
[0156] Features, integers, characteristics, compounds, chemical moieties or groups described in conjunction with a particular aspect, embodiment or example of the invention are to be understood to be applicable to any other aspect, embodiment or example described herein unless incompatible therewith. All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive. The invention is not restricted to the details of any foregoing embodiments. The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.
[0157] The reader's attention is directed to all papers and documents which are filed concurrently with or previous to this specification in connection with this application and which are open to public inspection with this specification, and the contents of all such papers and documents are incorporated herein by reference.
EXAMPLES AND SYNTHESIS
[0158] Solvents, reagents and starting materials were purchased from commercial vendors and used as received unless otherwise described. All reactions were performed at room temperature unless otherwise stated. Compound identity and purity confirmations were performed by LCMS UV using a Waters Acquity SQ Detector 2 (ACQ-SQD2#LCA081). The diode array detector wavelength was 254 nM and the MS was in positive and negative electrospray mode (m/z: 150-800). A 2 μL aliquot was injected onto a guard column (0.2 μm×2 mm filters) and UPLC column (C18, 50×2.1 mm, <2 μm) in sequence maintained at 40° C. The samples were eluted at a flow rate of 0.6 mL/min with a mobile phase system composed of A (0.1% (v/v) Formic Acid in Water) and B (0.1% (v/v) Formic Acid in Acetonitrile) according to the gradients outlined in Table 1 below. Retention times RT are reported in minutes.
[0000]
TABLE 1
Time (min)
% A
% B
Method 1
0
95
5
1.1
95
5
6.1
5
95
7
5
95
7.5
95
5
8
95
5
Method 2
0
95
5
0.3
95
5
2
5
95
2.6
95
5
3
95
5
[0159] NMR was also used to characterise final compounds. NMR spectra were obtained on a Bruker AVIII 400 Nanobay with 5 mm BBFO probe. Optionally, compound Rf values on silica thin layer chromatography (TLC) plates were measured.
[0160] Compound purification was performed by flash column chromatography on silica or by preparative LCMS. LCMS purification was performed using a Waters 3100 Mass detector in positive and negative electrospray mode (m/z: 150-800) with a Waters 2489 UV/Vis detector. Samples were eluted at a flow rate of 20 mL/min on a XBridge™ prep C18 5 μM OBD 19×100 mm column with a mobile phase system composed of A (0.1% (v/v) Formic Acid in Water) and B (0.1% (v/v) Formic Acid in Acetonitrile) according to the gradient outlined in Table 2 below.
[0000]
TABLE 2
Time (min)
% A
% B
0
90
10
1.5
90
10
11.7
5
95
13.7
5
95
14
90
90
15
90
90
[0161] Chemical names in this document were generated using Elemental Structure to Name Conversion by Dotmatics Scientific Software. Starting materials were purchased from commercial sources or synthesised according to literature procedures.
[0162] The compounds of the invention may be synthesised by analogy with the following reaction routes:
[0000]
[0163] Compounds of the invention could be prepared by analogy with the following route
Biaryl alpha-chloroacetamide: Synthesis A
[0164]
Intermediate 1: 4-(2-methyl-4-pyridyl)-1H-pyrrolo[2,3-b]pyridine
[0165]
[0166] 4-Bromo-7-azaindole (247 mg, 1.25 mmol) and sodium carbonate (352 mg, 3.32 mmol) were dissolved in a mixture of ethyl acetate (8 mL) and water (2 mL). Nitrogen was bubbled through the solution for 10 mins, after which (2-methyl-4-pyridinyl)boronic acid (235 mg, 1.72 mmol) and [1,1′-bis(diphenylphosphino)ferrocene]Palladium(II) chloride dichloromethane complex (102.38 mg, 0.13 mmol) were added and the. The reaction was heated in the MW at 100° C. for 2 hrs. LCMS shows incomplete reaction. A further 30 mg of Catalyst and 100 mg of boronic acid were added and the reaction was heated at 100° C. for 30 mins. The reaction was filtered through a celite plug washing with EtOAc. The mixture was diluted with sat NH 4 Cl solution, the layers separated and the aqueous phase extracted twice with EtOAc. The combined organic extracts were dried over Na 2 SO 4 and reduced in vacuo. The crude material was loaded onto a 10 g SCX cartridge and eluted with MeOH and then 1M NH 3 in MeOH. The ammonia layer was reduced in vacuo to afford 4-(2-methyl-4-pyridyl)-1H-pyrrolo[2,3-b]pyridine (280 mg, 1.34 mmol, 106.74% yield) as a brown solid.
[0167] MS Method 2: RT: 0.79 min, ES + m/z 210.1 [M+H] +
[0168] 1 H NMR (400 MHz, CDCl 3 ) δ/ppm: 10.39-10.50 (bs, 1H), 8.96-8.71 (1H, d, J=5.1 Hz, 1H), 8.44-8.47 (d, J=4.9 Hz, 1H), 7.43-7.55 (m, 3H), 7.21-7.25 (1H, d, J=4.9 Hz, 1H), 6.71-6.74 (d, J=3.2 Hz, 1H), 2.79 (s, 3H)
Biaryl alpha-chloroacetamide: Synthesis A—Step 1
Intermediate 2: 5-pyrazin-2-ylpyridin-2-amine
[0169]
[0170] A microwave vial with stirrer bar was charged with 2-aminopyridine-5-boronic acid pinacol ester (0.95 g, 4.3 mmol) iodopyrazine (777 mg, 3.77 mmol), sodium carbonate (1.20 g, 11.32 mmol) Toluene (5 mL) Water (5 mL) Ethanol (5 mL) and degassed for 10 mins.
[0171] Tetrakis(triphenylphosphine)palladium(0) (436 mg, 0.38 mmol) was then added and the vial sealed then irradiated at 100° C. for 1 hr. Analysis showed completion so the reaction mixture was concentrated to dryness, then the residue was suspended in DCM and 1M aqueous HCl was then added. The phases were separated and the aqueous phase was basified with 10% aqueous NaOH until pH-12, The aqueous layer was re-extracted with EtOAc several times, dried over sodium sulphate, filtered and concentrated. The resulting solid was triturated with diethyl ether and then filtered giving 5-pyrazin-2-ylpyridin-2-amine (355 mg, 1.65 mmol, 43.702% yield) as a pink powder.
[0172] MS Method 2: RT 0.45 min, ES + m/z 172.9 [M+H] +
[0173] 1 H NMR (400 MHz, DMSO) δ/ppm: 9.08 (s, 1H), 8.71-8.73 (d, J=1.9 Hz, 1H), 8.58-8.6 (m, 1H), 8.45-8.47 (d, J=2.5 Hz, 1H), 8.10-8.14 (dd, J=8.7, 2.5 Hz, 1H), 6.54-6.57 (d, J=8.7 Hz, 1H), 6.41-6.47 (bs, 2H)
Biaryl alpha-chloroacetamide: Synthesis A—Step 2
Intermediate 3: 2-chloro-N-(5-pyrazin-2-yl-2-pyridyl)acetamide
[0174]
[0175] To a pink suspension of 5-pyrazin-2-ylpyridin-2-amine (355 mg, 2.06 mmol), THF (1.5 mL) and N,N-diisopropylethylamine (0.72 mL, 4.12 mmol) was added drop-wise chloroacetyl chloride (0.16 mL, 2.06 mmol) at room temperature. The suspension turned black and a large exotherm was given off. Analysis of the reaction after 30 mins showed that it was complete. The reaction was diluted with methanol and then concentrated. The resulting residue was purified by flash column chromatography (12 g SiO 2 , 30-100% EtOAc in heptane, then 0-20% MeOH in EtOAc) affording an off white/brown solid 2-chloro-N-(5-pyrazin-2-yl-2-pyridyl)acetamide (194 mg, 0.78 mmol, 37.84% yield).
[0176] MS Method 2: RT 1.10 min, ES + m/z 249 [M+H] +
[0177] 1 H NMR (400 MHz, CDCl 3 ) δ/ppm: 8.96-8.99 (d, J=1.5 Hz, 1H), 8.91-8.93 (m, 1H), 8.85-8.89 (bs, 1H), 8.58-8.61 (m, 1H), 8.48-8.50 (d, J=2.5 Hz, 1H), 8.27-8.35 (m, 2H), 4.17 (s, 2H)
Example 1: 2-[4-(2-methyl-4-pyridyl)pyrrolo[2,3-b]pyridin-1-yl]-N-(5-pyrazin-2-yl-2-pyridyl)acetamide
[0178]
[0179] To a solution of 4-(2-methyl-4-pyridyl)-1H-pyrrolo[2,3-b]pyridine (230 mg, 1.1 mmol) in DMF (6 mL) at 0° C. was added sodium hydride, (60% dispersed in mineral oil) (61 mg, 1.54 mmol). The reaction was stirred at 0° C. for 1 hour, after which 2-chloro-N-(5-pyrazin-2-yl-2-pyridyl)acetamide (475 mg, 1.91 mmol) was added in one portion. The reaction was warmed to room temperature and left to stir overnight. LCMS indicates incomplete reaction. The reaction was again cooled to 0° C., and NaH (50 mg) was added. After stirring for 1 hour, chloroacetamide (75 mg) was added and the reaction was warmed to room temperature and stirred over the weekend. The reaction was diluted with water and the aqueous phase extracted three times with EtOAc. The combined organic extracts were dried over Na 2 SO 4 and reduced in vacuo. The crude material purified by flash column chromatography (40 g SiO 2 0 to 100% EtOAc in heptane, followed by 0 to 10% MeOH in EtOAc), however the material was still not
[0180] The semi-pure material was dry loaded onto silica and purified again by flash column chromatography (12 g SiO 2 , 50% to 100% EtOAc in heptane, followed by 0 to 5% MeOH in EtOAc) to afford 2-[4-(2-methyl-4-pyridyl)pyrrolo[2,3-b]pyridin-1-yl]-N-(5-pyrazin-2-yl-2-pyridyl)acetamide (58 mg, 0.14 mmol, 12.52% yield) as a tan solid.
[0181] MS Method 1: RT: 2.43 min, ES + m/z 422.1 [M+H] +
[0182] 1 H NMR (400 MHz, DMSO) δ/ppm: 12.27 (s, 1H), 9.31-9.33 (d, J=1.5 Hz, 1H), 9.14-9.16 (d, J=1.9 Hz, 1H), 8.72-8.74 (m, 1H), 8.61-8.65 (m, 2H), 8.51-8.55 (dd, J=8.7, 2.6 Hz, 1H), 8.35-8.37 (d, J=4.9 Hz, 1H), 8.12-8.17 (d, J=8.7 Hz, 1H), 7.73-7.76 (d, J=3.7 Hz, 1H), 7.66 (s, 1H), 7.58-7.61 (d, J=5.0 Hz, 1H), 7.34-7.37 (d, J=5.0 Hz, 1H), 6.75-6.77 (d, J=3.5 Hz, 1H), 5.35 (s, 2H), 2.61 (s, 3H).
Example 2
[0183] The following compound was prepared by analogy with General Scheme 1 substituting 4-Bromo-7-azaindole with the appropriate 5,6-fused bromo-heteroaryl.
[0000]
LCMS RT
m/z
STRUCTURE
STRUCTURE NAME
(min)
MIM
2-[6-methyl-4-(2-methyl-4- pyridyl)pyrrolo[2,3- d]pyrimidin-7-yl]-N-(5- pyrazin-2-yl-2- pyridyl)acetamide
2.41 (Method 1)
436.47
[0000]
[0184] Further compounds of the invention could be prepared by analogy with the following route
Intermediate 4: 2-(4-chloropyrrolo[2,3-d]pyrimidin-7-yl)-N-(5-pyrazin-2-yl-2-pyridyl)acetamide
[0185]
[0186] 6-Chloro-7-deazapurine (139 mg, 0.91 mmol) was dissolved in DMF (2.5 mL) and the solution was cooled to 0° C. NaH (60% dispersed in mineral oil) (54.3 mg, 1.36 mmol) was added and the reaction was stirred at 0° C. for 45 mins. The reaction was warmed to room temperature and left to stir for 15 mins, after which the reaction was again cooled to 0° C. and 2-chloro-N-(5-pyrazin-2-yl-2-pyridyl)acetamide (337 mg, 1.36 mmol) was added. The reaction was warmed to room temperature and left to stir for 16 hours. LCMS showed completion of reaction. The reaction was quenched by the addition of water and extracted three times with EtOAc. Combined organic extracts were dried over Na 2 SO 4 and reduced in vacuo. The product was deposited on silica and purified by flash column chromatography (12 g column, 0 to 100% EtOAc in Heptane then 0 to 10% MeOH in EtOAc) to furnish the product 2-(4-chloropyrrolo[2,3-d]pyrimidin-7-yl)-N-(5-pyrazin-2-yl-2-pyridyl)acetamide (240 mg, 0.60 mmol, 66% yield) as a tan solid.
[0187] MS Method 2: RT 3.11 min, ES + m/z 366 [M+H] +
[0188] 1 H NMR (400 MHz, d 6 -DMSO) δ/ppm: 11.3 (s, 1H), 9.32 (d, 1H, J=1.6 Hz), 9.14 (dd, 1H, J=2.5, 0.8 Hz), 8.71 (dd, 1H, J=2.5, 1.6 Hz), 8.64 (dd, 1H, J=2.5 Hz), 8.52 (dd, 1H, J=8.8, 2.5 Hz), 8.11 (d, 1H, J=8.8 Hz), 7.96 (s, 1H), 7.81 (d, 1H, J=3.6 Hz), 6.71 (d, 1H, J=3.6 Hz), 5.34 (s, 2H).
Example 3: 2-[4-(2-methyl-4-pyridyl)pyrrolo[2,3-d]pyrimidin-7-yl]-N-(5-pyrazin-2-yl-2-pyridyl)acetamide
[0189]
[0190] In a 2.0-5.0 mL microwave vial 2-(4-chloropyrrolo[2,3-d]pyrimidin-7-yl)-N-(5-pyrazin-2-yl-2-pyridyl)acetamide (110 mg, 0.27 mmol) and sodium carbonate (58 mg, 0.55 mmol) were suspended in 1,4-dioxane (2.5 mL) and water (0.5 mL). Nitrogen was bubbled through the solution for 10 mins, after which (2-methyl-4-pyridinyl)boronic acid (49 mg, 0.36 mmol) and tetrakis(triphenylphosphine)palladium (0) (32 mg, 0.02 mmol) were added. The vial was capped and the reaction was heated by microwave irradiation at 120° C. for 1 hour. The reaction was observed to be complete by LCMS. The reaction was diluted with sat. NaHCO 3 and extracted three times with EtOAc. Combined organic extracts were dried over Na 2 SO 4 and reduced in vacuo. The product was dry loaded onto silica and purified by flash column chromatography to afford 2-[4-(2-methyl-4-pyridyl)pyrrolo[2,3-d]pyrimidin-7-yl]-N-(5-pyrazin-2-yl-2-pyridyl)acetamide (29 mg, 0.07 mmol, 25% yield) as a grey solid.
[0191] MS Method 1: RT 2.30 min, ES + m/z 423 [M+H] +
[0192] 1 H NMR (400 MHz, d 6 -DMSO) δ/ppm: 11.3 (s, 1H), 9.32 (d, 1H, J=1.5 Hz), 9.15 (dd, 1H, J=2.4, 0.6 Hz), 8.93 (s, 1H), 8.73 (dd, 1H, J=2.5, 1.5 Hz), 8.69 (d, 1H, J=5.2 Hz), 8.64 (d, 1H, J=2.5 Hz), 8.53 (dd, 1H, J=8.8, 2.5 Hz), 8.13 (d, 1H, J=8.8 Hz), 8.00 (bs, 1H), 7.94 (dd, 1H, J=5.2, 1.5 Hz), 7.85 (d, 1H, J=3.8 Hz), 7.08 (s, 1H, J=3.8 Hz), 5.38 (s, 2H), 2.64 (s, 3H).
Example 4
[0193] The following compounds were prepared by analogy with General Scheme 2 substituting 6-Chloro-7-deazapurine with the appropriate 5,6-fused chloro heteroaryl and (2-methyl-4-pyridinyl)boronic acid with the appropriate heteroaryl boronic acid.
[0000]
LCMS RT
m/z
Structure
STRUCTURE NAME
(min)
MIM
2-[4-(2-methyl-4- pyridyl)pyrazolo[3,4- b]pyridin-1-yl]-N-(5- pyrazin-2-yl-2- pyridyl)acetamide
2.31 (Method 1)
422.44
2-[4-(2-methyl-4- pyridyl)pyrrolo[2,3- c]pyridin-1-yl]-N-(5- pyrazin-2-yl-2- pyridyl)acetamide
1.92 (Method 1)
421.45
2-[4-(2-methylpyrazol-3- yl)pyrazolo[3,4-b]pyridin-1- yl]-N-(5-pyrazin-2-yl-2- pyridyl)acetamide
2.85 (Method 1)
411.42
2-[4-(2-methylpyrazol-3- yl)pyrrolo[3,2-c]pyridin-1- yl]-N-(5-pyrazin-2-yl-2- pyridyl)acetamide
0.99 (Method 2)
410.43
2-[4-(2-methylpyrazol-3- yl)pyrrolo[2,3-c]pyridin-1- yl]-N-(5-pyrazin-2-yl-2- pyridyl)acetamide
2.32 (Method 1)
410.43
2-[4-(2-methylpyrazol-3- yl)pyrrolo[2,3-d]pyrimidin- 7-yl]-N-(5-pyrazin-2-yl-2- pyridyl)acetamide
2.88 (Method 1)
411.42
2-[4-(2-methyl-4- pyridyl)pyrrolo[3,2- c]pyridin-1-yl]-N-(5- pyrazin-2-yl-2- pyridyl)acetamide
2.21 (Method 1)
421.45
N-(5-pyrazin-2-yl-2- pyridyl)-2-[4-[2- (trifluoromethyl)-4- pyridyl]pyrrolo[2,3- d]pyrimidin-7-yl]acetamide
3.56 (Method 1)
476.41
2-[5-cyano-4-(2-methyl-4- pyridyl)pyrrolo[2,3- b]pyridin-1-yl]-N-(5- pyrazin-2-yl-2- pyridyl)acetamide
2.60 (Method 1)
446.46
2-[2-methyl-4-(2-methyl-4- pyridyl)pyrrolo[2,3- d]pyrimidin-7-yl]-N-(5- pyrazin-2-yl-2- pyridyl)acetamide
2.41 (Method 1)
436.47
2-[2-amino-4-(2-methyl-4- pyridyl)pyrrolo[2,3- d]pyrimidin-7-yl]-N-(5- pyrazin-2-yl-2- pyridyl)acetamide
2.24 (Method 1)
437.46
2-[2-chloro-4-(2-methyl-4- pyridyl)pyrrolo[2,3- d]pyrimidin-7-yl]-N-(5- pyrazin-2-yl-2- pyridyl)acetamide
1.20 (Method 2)
456.89
2-[5-(2-methyl-4- pyridyl)pyrrolo[2,3- b]pyridin-1-yl]-N-(5- pyrazin-2-yl-2- pyridyl)acetamide
2.41 (Method 1)
421.45
2-[5-(2-methyl-4- pyridyl)pyrazolo[3,4- b]pyridin-1-yl]-N-(5- pyrazin-2-yl-2- pyridyl)acetamide
2.25 (Method 1)
422.44
2-[4-(2-methyl-4- pyridyl)imidazo[4,5- c]pyridin-1-yl]-N-(5- pyrazin-2-yl-2- pyridyl)acetamide
2.24 (Method 1)
422.44
[0000]
[0194] Further compounds of the invention could be prepared by analogy with the following route
Intermediate 5: N-(6-bromo-3-pyridyl)-2-chloro-acetamide
[0195]
[0196] 5-amino-2-bromopyridine (1.44 g, 8.32 mmol) and DIPEA (2.23 mL, 12.5 mmol) were dissolved in DMF (40 mL). Chloroacetyl chloride (0.7 mL, 8.74 mmol) was added dropwise and the reaction was left to stir at room temperature for 16 hours. LCMS showed that the reaction had completed. The reaction was quenched by the addition of water and extracted three times with EtOAc. Combined organic extracts were dried over Na2SO4 and reduced in vacuo. The crude product was deposited onto silica and purified by flash column chromatography (80 g column, 0 to 100% EtOAc in Heptane) to furnish N-(6-bromo-3-pyridyl)-2-chloro-acetamide (1.52 g, 6.09 mmol, 73% yield) as a yellow solid.
[0197] MS Method 2: RT 1.25 min, ES + m/z 250 [M+H] +
[0198] 1 H NMR (400 MHz, CDCl 3 ) δ/ppm: 8.45 (d, 1H, J=2.8 Hz), 8.40 (bs, 1H), 8.05 (dd, 1H, J=8.6, 2.8 Hz), 7.48 (d, 1H, J=8.6 Hz), 4.22 (s, 2H).
Intermediate 6: N-(6-bromo-3-pyridyl)-2-[4-(2-methyl-4-pyridyl)pyrrolo[2,3-b]pyridine-1-yl]acetamide
[0199]
[0200] 4-(2-methyl-4-pyridyl)-1H-pyrrolo[2,3-b]pyridine (163 mg, 0.78 mmol) was dissolved in DMF (5 mL) and cooled to 0° C. NaH (60% dispersed in mineral oil) (38 mg, 0.93 mmol) was added and the reaction was stirred at 0° C. for 45 mins. The reaction was warmed to room temperature and stirred for 15 mins, after which the reaction was cooled to 0° C. and N-(6-bromo-3-pyridyl)-2-chloro-acetamide (243 mg, 0.97 mmol) was added. The reaction was warmed to room temperature and left to stir for 16 hours. LCMS indicates a small amount of starting material remaining but mainly formation of desired product. The reaction was quenched by the addition of water and extracted three times with EtOAc. Combined organic extracts were reduced in vacuo. The crude product was deposited onto silica and the purified by flash column chromatography (12 g column, 0 to 100% EtOAc in Heptane then 0 to 10% MeOH in EtOAc) to afford N-(6-bromo-3-pyridyl)-2-[4-(2-methyl-4-pyridyl)pyrrolo[2,3-b]pyridine-1-yl]acetamide (230 mg, 0.54 mmol, 70% yield).
[0201] MS Method 2: RT 1.13 min, ES + m/z 423 [M+H] +
[0202] 1 H NMR (400 MHz, d 6 -DMSO) δ/ppm:10.83 (s, 1H), 8.63-8.61 (m, 2H), 8.35 (d, 1H, J=5.0 Hz), 7.98 (dd, 1H, J=8.7, 2.8 Hz), 7.72 (d, 1H, J=3.6 Hz), 7.52 (bs, 1H), 7.62 (dd, 1H, J=8.7, 0.4 Hz), 7.58 (dd, 1H, J=5.0, 1.5 Hz), 7.35 (d, 1H, J=4.9 Hz), 6.75 (d, 1H, J=3.6 Hz), 5.26 (s, 2H), 2.60 (s, 3H).
Example 5: 2-[4-(2-methyl-4-pyridyl)pyrrolo[2,3-b]pyridin-1-yl]-N-(6-pyrazin-2-yl-3-pyridyl)acetamide
[0203]
[0204] In a 2.0-5.0 mL microwave vial N-(6-bromo-3-pyridyl)-2-[4-(2-methyl-4-pyridyl)pyrrolo[2,3-b]pyridine-1-yl]acetamide (75 mg, 0.18 mmol) and (tributylstannyl)pyrazine (78 mg, 0.21 mmol) were dissolved in DMF (2.5 mL). Nitrogen was bubbled though the solution for 10 mins, after which tetrakis(triphenylphosphine)palladium (0) (21 mg, 0.02 mmol) was added, the vial was capped and the reaction mixture was heated by microwave irradiation at 120° C. for 7 hours. LCMS indicated formation of desired product with a small amount of starting material remaining. The reaction was diluted with sat. NaHCO 3 solution and extracted three times with EtOAc. Combined organic extracts were reduced in vacuo. The crude product was deposited onto silica and purified by flash column chromatography (12 g column, 0 to 100% EtOAc in Heptane then 0 to 10% MeOH in EtOAc) to give 2-[4-(2-methyl-4-pyridyl)pyrrolo[2,3-b]pyridin-1-yl]-N-(6-pyrazin-2-yl-3-pyridyl)acetamide (7.0 mg, 0.02 mmol, 10% yield) as a white solid.
[0205] MS Method 1: RT 2.36 min, ES + m/z 422 [M+H] +
[0206] 1 H NMR (400 MHz, d 6 -DMSO) δ/ppm: 10.94 (s, 1H), 9.49 (d, 1H, J=1.4 Hz), 8.93 (d, 1H, J=2.4 Hz), 8.71 (dd, 1H, J=2.4, 1.5 Hz), 8.67 (d, 1H, J=2.5 Hz), 8.63 (d, 1H, J=5.1 Hz), 8.37 (d, 1H, J=5.1 Hz), 8.34 (d, 1H, J=8.6 Hz), 8.25 (dd, 1H, J=8.6, 2.5 Hz), 7.76 (d, 1H, J=3.7 Hz), 7.66 (bs, 1H), 7.59 (d, 1H, J=5.2 Hz), 7.36 (d, 1H, J=4.9 Hz), 6.77 (d, 1H, J=3.7 Hz), 5.32 (s, 2H), 2.60 (s, 3H).
Example 6
[0207] The following compounds were prepared by analogy with General Scheme 3 using the appropriate 5,6-fused chloro heteroaryl and heteroaryl boronic acid.
[0000]
LCMS RT
m/z
Structure
STRUCTURE NAME
(min)
MIM
2-[4-(2-methyl-4- pyridyl)pyrrolo[2,3- d]pyrimidin-7-yl]-N-(6- pyrazin-2-yl-3- pyridyl)acetamide
2.28 (Method 1)
422.44
2-[4-(2-methyl-4- pyridyl)pyrazolo[3,4- b]pyridin-1-yl]-N-(6-pyrazin- 2-yl-3-pyridyl)acetamide
2.28 (Method 1)
422.44
2-[4-(2-methyl-4- pyridyl)pyrazolo[3,4- d]pyrimidin-1-yl]-N-(6- pyrazin-2-yl-3- pyridyl)acetamide
2.34 (Method 1)
423.43
[0000]
Intermediate 7: 4-chloro-1-tetrahydropyran-2-yl-pyrazolo[3,4-d]pyrimidine
[0208]
[0209] 4-chloro-1H-pyrazolo[3,4-d]pyrimidine (678 mg, 4.39 mmol) and p-toluenesolfonic acid monohydrate (16 mg, 0.09 mmol) were suspended in ethyl acetate (25 mL), 3,4-Dihydro-2H-pyran was added and the reaction mixture was heated under reflux for 3 hours. Once all suspended solids had gone into solution, the solvent was removed in vacuo and the crude product deposited onto silica. The product was purified by flash column chromatography (12 g column, 0 to 100% EtOAc in Heptane) to furnish 4-chloro-1-tetrahydropyran-2-yl-pyrazolo[3,4-d]pyrimidine (840 mg, 3.52 mmol, 80% yield) as a pink solid.
[0210] 1 H NMR (400 MHz, CDCl 3 ) δ/ppm: 8.80 (s, 1H), 8.22 (s, 1H), 6.05 (dd, 1H, J=10.4, 2.5 Hz), 4.15-4.10 (m, 1H), 3.85-3.77 (m, 1H), 2.68-2.57 (m, 1H), 2.21-2.12 (m, 1H), 2.03-1.95 (m, 1H), 1.95-1.77 (m, 2H), 1.69-1.63 (m, 1H).
Intermediate 8: 4-(2-methyl-4-pyridyl)-1-tetrahydropyran-2-yl-pyrazolo[3,4-d]pyrimidine
[0211]
[0212] In a 10-20 mL microwave vial 4-chloro-1-tetrahydropyran-2-yl-pyrazolo[3,4-d]pyrimidine (153 mg, 0.64 mmol) and sodium carbonate (135 mg, 1.28 mmol) were suspended in 1,4-dioxane (4 mL) and water (1 mL). Nitrogen was bubbled through the solution for 5 mins, after which (2-methyl-4-pyridinyl)boronic acid (105 mg, 0.77 mmol) and [1,1′-bis(diphenylphosphino)ferrocene]dichloropalladium (11). CH 2 Cl 2 (52 mg, 0.06 mmol) were added the vial was capped and the reaction was heated under microwave irradiation at 120° C. for 1 hour. LCMS showed that the reaction had completed. The reaction was quenched by the addition of sat. NaHCO 3 and extracted three times with EtOAc. Combined organic extracts were reduced in vacuo and deposited onto silica. The crude product was purified by flash column chromatography (12 g column, 0 to 100% EtOAc in Heptane then 0 to 5% MeOH in EtOAc) to furnish 4-(2-methyl-4-pyridyl)-1-tetrahydropyran-2-yl-pyrazolo[3,4-d]pyrimidine (130 mg, 0.44 mmol, 69% yield) as an orange oil.
[0213] MS Method 2: RT 1.16 min, ES + m/z 296 [M+H] +
[0214] 1 H NMR (400 MHz, CDCl 3 ) δ/ppm: 9.16 (s, 1H), 8.78 (dd, 1H, J=5.2, 0.6 Hz), 8.43 (s, 1H), 7.92 (bs, 1H), 7.81 (ddd, 1H, J=5.2, 1.7, 0.6 Hz), 6.17 (dd, 1H, J=10.4, 2.6 Hz), 4.20-4.14 (m, 1H), 3.90-3.82 (m, 1H), 2.74 (s, 3H), 2.72-2.63 (m, 1H), 2.24-2.15 (m, 1H), 2.07-2.00 (m, 1H), 1.87-1.65 (m, 3H).
Intermediate 9: 4-(2-methyl-4-pyridyl)-1H-pyrazolo[3,4-d]pyrimidine
[0215]
[0216] 4-(2-methyl-4-pyridyl)-1-tetrahydropyran-2-yl-pyrazolo[3,4-d]pyrimidine (320 mg, 1.08 mmol) was suspended in 4M HCl in 1,4-dioxane solution (10 mL, 40 mmol). The reaction was stirred at room temperature for 16 hours. LCMS showed that the reaction had completed. The reaction was quenched by addition of sat. NaHCO 3 and extracted three times with EtOAc. Combined organic extracts were reduced in vacuo and deposited onto silica. The product was purified on by flash column chromatography (12 g column, 0 to 100% EtOAc in Heptane) to afford 4-(2-methyl-4-pyridyl)-1H-pyrazolo[3,4-d]pyrimidine (55 mg, 0.26 mmol, 24% yield) as a yellow solid.
[0217] MS Method 2: RT 0.74 min, ES + m/z 210 [M+H] +
[0218] 1 H NMR (400 MHz, d 6 -DMSO) δ/ppm: 14.35 (bs, 1H), 9.13 (s, 1H), 8.84 (s, 1H), 8.72 (d, 1H, J=5.3 Hz), 8.10 (bs, 1H), 8.04 (d, 1H, J=5.3), 2.66 (s, 3H).
Example 7: 2-[4-(2-methyl-4-pyridyl)pyrazolo[3,4-d]pyrimidin-1-yl]-N-(5-pyrazin-2-yl-2-pyridyl)acetamide
[0219]
[0220] 4-(2-methyl-4-pyridyl)-1H-pyrazolo[3,4-d]pyrimidine (122 mg, 0.58 mmol) was dissolved in DMF (5 mL) and cooled to 0° C. NaH (60% dispersed in mineral oil) (28 mg, 0.69 mmol) was added and the reaction was stirred at 0° C. for 45 mins. The reaction was warmed to room temperature and left to stir for 15 mins. The reaction was cooled to 0° C. and 2-chloro-N-(5-pyrazin-2-yl-2-pyridyl)acetamide (186 mg, 0.75 mmol) was added. The reaction was warmed to room temperature and stirred for 3 days. LCMS showed the reaction had completed. The reaction was quenched by the addition of water and extracted three times with EtOAc. Combined organic extracts were reduced in vacuo and deposited onto silica. The product was purified by flash column chromatography (25 g column, 0 to 100% EtOAc in Heptane then 0 to 10% MeOH in EtOAc) to furnish 2-[4-(2-methyl-4-pyridyl)pyrazolo[3,4-d]pyrimidin-1-yl]-N-(5-pyrazin-2-yl-2-pyridyl)acetamide (15 mg, 0.04 mmol, 6% yield) as a white solid.
[0221] MS Method 2: RT 1.08 min, ES + m/z 424 [M+H] +
[0222] 1 H NMR (400 MHz, d 6 -DMSO) δ/ppm: 11.4 (s, 1H), 9.32 (d, 1H, J=1.5 Hz), 9.18 (s, 1H), 9.15 (d, 1H, J=2.6 Hz), 8.94 (s, 1H), 8.75-8.72 (m, 2H), 8.64 (d, 1H, J=2.5 Hz), 8.53 (dd, 1H, J=8.8, 2.5 Hz), 8.12 (s, 1H), 8.11 (d, 1H, J=5.8 Hz), 8.08 (d, 1H, J=5.2 Hz), 5.58 (s, 2H), 2.67 (s, 3H).
Example 8
[0223] The following compounds were prepared by analogy with General Scheme 4 using the appropriate 5,6-fused chloro heteroaryl and heteroaryl boronic acid.
[0000]
LCMS RT
m/z
Structure
STRUCTURE NAME
(min)
MIM
2-[6-(2-methyl-4- pyridyl)purin-9-yl]-N-(5- pyrazin-2-yl-2-pyridyl- acetamide
2.27 (Method 1)
423.43
2-[4-(2-methylpyrazol-3- yl)pyrazolo[3,4- d]pyrimidin-1-yl]-N-(5- pyrazin-2-yl-2- pyridyl)acetamide
2.90 (Method 1)
412.41
[0000]
[0224] Further compounds of the invention could be prepared by analogy with the following route
Intermediate 9: 4-chloropyrrolo[2,3-b]pyridine-1-yl)-triisopropylsilane
[0225]
[0226] 4-Chloro-1H-pyrrolo[2,3-b]pyridine (1.05 g, 6.88 mmol) was dissolved in THF (50 mL) and cooled to 0° C. NaH (60% dispersed in mineral oil) (1.5 g, 10.3 mmol) was added and the reaction was stirred at 0° C. for 1 hour. Triisopropylsilyl chloride (2.38 g, 12.4 mmol) was added and the reaction was heated under reflux overnight. TLC (8:2 Heptane/EtOAc) showed consumption of SM (Rf 0.4) and formation of new product spot (0.9). The reaction was quenched with water and extracted three times with EtOAc. Combined organic extracts were reduced in vacuo and deposited onto silica. The product was purified by flash column chromatography (40 g column, 0 to 20% EtOAc in Heptane) to give (4-chloropyrrolo[2,3-b]pyridine-1-yl)-triisopropylsilane (2.1 g, 6.88 mmol, 100% yield).
[0227] 1 H NMR (400 MHz, CDCl 3 ) δ/ppm: 8.21 (d, 1H, J=5.4 Hz, 7.39 (d, 1H, J=3.5 Hz), 7.12 (d, 1H, J=5.4 Hz), 6.74 (dd, 1H, J=3.5 Hz), 1.93 (hept, 3H, J=7.2 Hz), 1.19 (d, 18H, J=7.2 Hz).
Intermediate 10: (4-chloro-5-fluoro-pyrrolo[2,3-b]pyridine-1-yl)-triisopropylsilane
[0228]
[0229] 4-chloropyrrolo[2,3-b]pyridine-1-yl)-triisopropylsilane (290 mg, 0.94 mmol) was dissolved in THF (8 mL) and cooled to −78° C. A solution of s-BuLi was added dropwise and the reaction was stirred at −78° C. for 30 mins. A solution of N-fluorobenzenesulfonimide (830 mg, 2.63 mmol) in THF (3 mL) was added and the reaction was stirred at −78° C. for 1 hour. LCMS was inconclusive as neither starting material nor product can be observed. The reaction was quenched at −78° C. by addition of sat. NH 4 Cl solution and then slowly warmed to room temperature. The reaction mixture was extracted three times with EtOAc and the combined organic extracts were dried over Na 2 SO 4 and reduced in vacuo. The crude product was deposited onto silica and the product purified by flash column chromatography (12 g column, 0 to 20% EtOAc in Heptane) to give (4-chloro-5-fluoro-pyrrolo[2,3-b]pyridine-1-yl)-triisopropylsilane (180 mg, 0.55 mmol, 59% yield) as a white solid.
[0230] 1 H NMR (400 MHz, CDCl 3 ) δ/ppm: 8.18 (d, 1H, J=2.0 Hz), 7.41 (d, 1H, J=3.5 Hz), 6.68 (d, 1H, J=3.5 Hz), 1.86 (hept, 3H, J=7.6 Hz), 1.14 (d, 18H, J=7.6 Hz).
Intermediate 11: [5-fluoro-4-(2-methyl-4-pyridyl)pyrrolo[2,3-b]pyridine-1-yl-triisopropylsilane
[0231]
[0232] In a 2.0-5.0 mL microwave vial (4-chloro-5-fluoro-pyrrolo[2,3-b]pyridine-1-yl)-triisopropylsilane (180 mg, 0.55 mmol) and potassium phosphate tribasic (233 mg, 1.10 mmol) were suspended in 1,4-dioxane (4 mL) and water (1 mL). Nitrogen was bubbled through the solution for 10 mins, after which 2-methylpyridine-4-boronic acid (180 mg, 1.31 mmol), tricyclohexylphosphine (15 mg, 0.06 mmol) and tris(dibenzylideneacetone)dipalladium (0) (34 mg, 0.04 mmol) were added. The vial was capped and reaction was heated by microwave irradiation at 120° C. for 1 hour. LCMS indicated completion of reaction. The reaction was diluted with sat. NaHCO 3 and extracted three times with EtOAc. Combined organic extracts were reduced in vacuo and deposited onto silica. The crude product was purified by flash column chromatography (12 g, 0 to 50% EtOAc in Heptane) to furnish [5-fluoro-4-(2-methyl-4-pyridyl)pyrrolo[2,3-b]pyridine-1-yl-triisopropylsilane (136 mg, 0.35 mmol, 64% yield) as a colourless oil.
[0233] MS Method 2: RT 2.48 min, ES + m/z 384 [M+H] +
[0234] 1 H NMR (400 MHz, CDCl 3 ) δ/ppm: 8.66 (d, 1H, J=5.2 Hz), 8.24 (d, 1H, J=2.9 Hz), 7.50 (bs, 1H), 7.44-7.41 (m, 2H), 6.59 (d, 1H, J=3.6 Hz), 2.68 (s, 3H), 1.87 (hept, 3H, J=7.7 Hz), 1.16 (d, 18H, J 15=7.7 Hz).
Intermediate 12: 5-fluoro-4-(2-methyl-4-pyridyl)-1H-pyrrolo[2,3-b]pyridine
[0235]
[0236] [5-fluoro-4-(2-methyl-4-pyridyl)pyrrolo[2,3-b]pyridine-1-yl-triisopropylsilane (136 mg, 0.35 mmol) was dissolved in THF (3.5 mL) and a 1M solution of tetrabutylammonium fluoride in THF (0.43 mL, 0.43 mmol) was added. The reaction was stirred at room temperature for 2 hours, after which the reaction was observed to be complete by LCMS. The reaction was diluted with water and extracted three times with EtOAc. Combined organic extracts were dried over Na 2 SO 4 and reduced in vacuo to yield 5-fluoro-4-(2-methyl-4-pyridyl)-1H-pyrrolo[2,3-b]pyridine (80 mg, 0.35 mmol, 80% yield) as a yellow solid.
[0237] MS Method 2: RT 0.90 min, ES + m/z 228 [M+H] +
[0238] 1 H NMR (400 MHz, CDCl 3 ) δ/ppm: 9.41 (bs, 1H), 8.69 (d, 1H, J=5.2 Hz), 8.32 (d, 1H, J=3.1 Hz), 7.50 (bs, 1H), 7.47 (dd, 1H, J=3.5, 2.5 Hz), 7.44 (d, 1H, J=3.1 Hz), 6.56 (dd, 1H, J=3.5, 2.0 Hz), 2.69 (s, 3H).
Example 9: 2-[5-fluoro-4-(2-methyl-4-pyridyl)pyrrolo[2,3-b]pyridin-1-yl]-N-(5-pyrazin-2-yl-2-pyridyl)acetamide
[0239]
[0240] 5-fluoro-4-(2-methyl-4-pyridyl)-1H-pyrrolo[2,3-b]pyridine (80 mg, 0.35 mmol) was dissolved in DMF (4 mL) and cooled to 0° C. NaH (60% dispersed in mineral oil) (17 mg, 0.42 mmol) was added and the reaction was stirred at 0° C. for 45 mins, after which the reaction was warmed to room temperature and stirred for 15 mins. The reaction was cooled to 0° C. and 2-chloro-N-(5-pyrazin-2-yl-2-pyridyl)acetamide (114 mg, 0.46 mmol) was added. The reaction was warmed to room temperature and left to stir for 16 hours. LCMS showed a small amount of starting material remaining and also formation of desired product. The reaction was quenched by the addition of water and extracted three times with EtOAc. Combined organic extracts were reduced in vacuo and deposited onto silica. The product was purified by flash column chromatography (12 g column, 0 to 100% EtOAc in Heptane then 0-10% MeOH in EtOAc). The purified product was then purified by prep HPLC to give the purified product 2-[5-fluoro-4-(2-methyl-4-pyridyl)pyrrolo[2,3-b]pyridin-1-yl]-N-(5-pyrazin-2-yl-2-pyridyl)acetamide (10 mg, 0.03 mmol, 6% yield).
[0241] MS Method 1: RT 2.58 min, ES + m/z 440 [M+H] +
[0242] 1 H NMR (400 MHz, d 6 -DMSO) δ/ppm: 11.28 (s, 1H), 9.32 (d, 1H, J=1.5 Hz), 9.15 (dd, 1H, J=2.5, 0.7 Hz), 8.73 (dd, 1H, J=2.5, 1.5 Hz), 8.66 (d, 1H, J=5.2 Hz), 8.64 (d, 1H, J=2.5 Hz), 8.53 (dd, 1H, J=8.8, 2.5 Hz), 8.38 (d, 1H, J=2.9 Hz), 8.14 (d, 1H, J=8.8 Hz), 7.79 (d, 1H, J=3.5 Hz), 7.56 (s, 1H), 7.49 (d, 1H, J=5.2 Hz), 6.56 (d, 1H, J=3.5 Hz), 5.34 (s, 2H), 2.60 (s, 3H).
Example 10
[0243] The following compound was prepared by analogy with General Scheme 5 using the appropriate 5,6-fused chloro heteroaryl.
[0000]
LCMS RT
m/z
Structure
STRUCTURE NAME
(min)
MIM
2-[5-methyl-4-(2-methyl-4- pyridyl)pyrrolo[2,3- b]pyridin-1-yl]-N-(5- pyrazin-2-yl-2- pyridyl)acetamide
2.50 (Method 1)
435.45
[0000]
[0244] Further compounds of the invention could be prepared by analogy with the following route
Intermediate 13: 2-(4-chloropyrrolo[2,3-b]pyridin-1-yl)-N-(5-pyrazin-2-yl-2-pyridyl)acetamide
[0245]
[0246] 2-chloro-N-(5-pyrazin-2-yl-2-pyridyl)acetamide (708 mg, 2.85 mmol) and potassium carbonate (1132 mg, 8.19 mmol) were added to a solution of 4-chloro-1H-pyrrolo[2,3-b]pyridin (250 mg, 1.64 mmol) in DMF (70 mL), the reaction mixture was heated to 60° C. overnight. LCMS analysis demonstrated the formation of the desired product. The reaction mixture was concentrated to dryness, the resulting residue taken up in DCM and sodium bicarbonate was added. The phases were separated and the aqueous extracted with DCM. The combined organic layers were washed with brine, dried over sodium sulphate and solvent was removed under reduced pressure. The crude residue was purified by column chromatography (40 g SiO 2 , 0-10% MeOH in DCM) like fractions were combined and solvent removed under reduced pressure to yield 2-(4-chloropyrrolo[2,3-b]pyridin-1-yl)-N-(5-pyrazin-2-yl-2-pyridyl)acetamide (350 mg, 0.96 mmol, 59% yield) as a cream solid.
[0247] MS Method 1: RT 3.52 min, ES + m/z 365.1/367.0 [M+H] +
[0248] 1 H NMR (400 MHz, CDCl 3 ) δ/ppm: 9.00-9.02 (d, J=1.5 Hz, 1H), 8.90-8.93 (m, 1H), 8.64-8.67 (m, 1H), 8.55-8.57 (d, J=2.4 Hz, 1H), 8.30-8.39 (m, 3H), 7.40-7.43 (d, J=3.6 Hz, 1H), 7.23-7.25 (d, J=5.3 Hz, 1H), 6.74-6.76 (d, J=3.6 Hz, 1H), 5.23 (s, 2H).
Example 11: 2-[4-(1-piperidyl)pyrrolo[2,3-b]pyridin-1-yl]-N-(5-pyrazin-2-yl-2-pyridyl)acetamide
[0249]
[0250] Triethylamine (0.19 mL, 1.37 mmol) and piperidine (0.14 mL, 1.37 mmol) were added to a solution of 2-(4-chloropyrrolo[2,3-b]pyridin-1-yl)-N-(5-pyrazin-2-yl-2-pyridyl)acetamide (100 mg, 0.27 mmol) in NMP (2 mL). The reaction was subjected to microwave radiation at 180° C. for 4 hrs. LCMS analysis demonstrated the reaction had formed the desired product ion. Brine and DCM were added to the reaction mixture, and the layers separated. The aqueous was extracted with DCM (×3), the combined organic layers were dried over sodium sulphate and solvent removed under reduced pressure. The crude residue was purified by column chromatography (0-10% MeOH in DCM) like fractions were combined and solvent removed under reduced pressure. The crude residue was taken up in DMSO:MeCN:H2O (8:1:1) and purified by reverse phase preparative HPLC (eluting with H 2 O and MeCN plus 0.1% formic acid). Like fraction were combined and passed through an SCX cartridge, the cartridge was eluted with MeOH and then NH 3 /MeOH. The NH 3 /MeOH fractions were combined and solvent removed under reduced pressure to yield 2-[4-(1-piperidyl)pyrrolo[2,3-b]pyridin-1-yl]-N-(5-pyrazin-2-yl-2-pyridyl)acetamide (3 mg, 0.0073 mmol, 2.6% yield) as a colourless solid.
[0251] MS Method 1: RT 2.81 min, ES + m/z 414.1[M+H] +
[0252] 1 H NMR (400 MHz, D6-DMSO) δ/ppm: 11.13 (bs, 1H), 9.30-9.32 (d, J=1.5 Hz, 1H), 9.12-9.14 (m, 1H), 8.71-8.74 (m, 1H), 8.63-8.64 (d, J=2.6 Hz, 1H), 8.50-8.54 (dd, J=2.6, 8.9 Hz, 1H), 8.11-8.16 (d, J=8.7 Hz, 1H), 7.91-7.94 (d, J=5.5 Hz, 1H), 7.33-7.35 (d, J=3.5 Hz, 1H), 6.48-6.50 (d, J=3.7 Hz, 1H), 6.44-6.47 (d, J=5.5 Hz, 1H), 5.19 (s, 2H), 3.40-3.46 (m, 4H), 1.62-1.71 (m, 6H).
Example 12
[0253] The following compounds were prepared using the method described in general scheme 6, replacing piperidine with the appropriate saturated amine.
[0000]
LCMS RT
m/z
Structure
STRUCTURE NAME
(min)
MIM
2-[4-(3,5-dimethylpiperazin-1- yl)pyrrolo[2,3-b]pyridin-1-yl]- N-(5-pyrazin-2-yl-2- pyridyl)acetamide
1.83 (Method 1)
443.1
2-[4-(4-methylpiperazin-1- yl)pyrrolo[2,3-b]pyridin-1-yl]- N-(5-pyrazin-2-yl-2- pyridyl)acetamide
1.64 (Method 1)
429.1
[0254] Dual-Cell β-Catenin Reporter Assay
[0255] Mouse L cells transfected to constitutively produce biologically active murine Wnt-3a, referred to as L-Wnt cells, were purchased from the American Type Culture Collection, ATCC, Manassas, Va. (ATCC). These cells were cultured in DMEM supplemented with 10% FCS (Gibco/Invitrogen, Carlsbad, Calif.), 1% geneticin and 1% sodium pyruvate (Sigma) at 37° C. with 5% CO 2 . The cells were seeded into 96 well plates and treated with serial dilutions of compound diluted to 0.1% DMSO concentration. After 24 hours, cell supernatants were transferred to a 96 well plate previously seeded with Leading Light® Wnt Reporter Cells, stably transfected with a luciferase gene under control of Wnt pathway response elements. After a further 24 hours, cells are treated with One-glo luciferase assay system (Promega, Madison, Wis.) and the luminescent signal read by envision. The IC 50 of the compound is determined as the concentration that reduces the induced luciferase signal to 50% of the DMSO control.
[0256] The results of the in vitro biological data for certain compounds of the invention are given in the table below. The table shows a group for each compound based on the IC50 value of each compound as “+”, “++” and “+++”. The category “+” refers to compounds with an IC50 of >5 nM. The category “++” refers to compounds with an IC50 of 1 nM to 5 nM. The category “+++” refers to compounds with an IC50 of <1 nM.
[0000]
ID No.
Compound Name
IC50 (nM)
1
2-[5-methyl-4-(2-methyl-4-pyridyl)pyrrolo[2,3-b]pyridin-1-yl]-N-(5-
***
pyrazin-2-yl-2-pyridyl)acetamide
2
2-[5-fluoro-4-(2-methyl-4-pyridyl)pyrrolo[2,3-b]pyridin-1-yl]-N-(5-
***
pyrazin-2-yl-2-pyridyl)acetamide
3
2-[5-(2-methyl-4-pyridyl)pyrazolo[3,4-b]pyridin-1-yl]-N-(5-pyrazin-
***
2-yl-2-pyridyl)acetamide
4
2-[4-(2-methylpyrazol-3-yl)pyrrolo[3,2-c]pyridin-1-yl]-N-(5-pyrazin-
**
2-yl-2-pyridyl)acetamide
5
2-[5-(2-methyl-4-pyridyl)pyrrolo[2,3-b]pyridin-1-yl]-N-(5-pyrazin-2-
***
yl-2-pyridyl)acetamide
6
2-[4-(2-methylpyrazol-3-yl)pyrazolo[3,4-b]pyridin-1-yl]-N-(5-
*
pyrazin-2-yl-2-pyridyl)acetamide
7
2-[4-(2-methylpyrazol-3-yl)pyrrolo[2,3-c]pyridin-1-yl]-N-(5-pyrazin-
**
2-yl-2-pyridyl)acetamide
8
2-[2-amino-4-(2-methyl-4-pyridyl)pyrrolo[2,3-d]pyrimidin-7-yl]-N-
***
(5-pyrazin-2-yl-2-pyridyl)acetamide
9
2-[5-cyano-4-(2-methyl-4-pyridyl)pyrrolo[2,3-b]pyridin-1-yl]-N-(5-
***
pyrazin-2-yl-2-pyridyl)acetamide
10
2-[2-methyl-4-(2-methyl-4-pyridyl)pyrrolo[2,3-d]pyrimidin-7-yl]-N-
***
(5-pyrazin-2-yl-2-pyridyl)acetamide
11
2-[4-(2-methylpyrazol-3-yl)pyrazolo[3,4-d]pyrimidin-1-yl]-N-(5-
***
pyrazin-2-yl-2-pyridyl)acetamide
12
2-[2-chloro-4-(2-methyl-4-pyridyl)pyrrolo[2,3-d]pyrimidin-7-yl]-N-
***
(5-pyrazin-2-yl-2-pyridyl)acetamide
13
2-[6-methyl-4-(2-methyl-4-pyridyl)pyrrolo[2,3-d]pyrimidin-7-yl]-N-
*
(5-pyrazin-2-yl-2-pyridyl)acetamide
14
2-[4-(2-methyl-4-pyridyl)pyrazolo[3,4-d]pyrimidin-1-yl]-N-(6-
**
pyrazin-2-yl-3-pyridyl)acetamide
15
2-[4-(2-methyl-4-pyridyl)pyrazolo[3,4-b]pyridin-1-yl]-N-(6-pyrazin-
**
2-yl-3-pyridyl)acetamide
16
2-[4-(2-methyl-4-pyridyl)pyrrolo[2,3-d]pyrimidin-7-yl]-N-(6-pyrazin-
*
2-yl-3-pyridyl)acetamide
17
2-[4-(2-methyl-4-pyridyl)pyrrolo[2,3-b]pyridin-1-yl]-N-(6-pyrazin-2-
**
yl-3-pyridyl)acetamide
18
2-[4-(2-methylpyrazol-3-yl)pyrrolo[2,3-d]pyrimidin-7-yl]-N-(5-
**
pyrazin-2-yl-2-pyridyl)acetamide
19
2-[6-(2-methyl-4-pyridyl)purin-9-yl]-N-(5-pyrazin-2-yl-2-
*
pyridyl)acetamide
20
2-[4-(2-methyl-4-pyridyl)imidazo[4,5-c]pyridin-1-yl]-N-(5-pyrazin-
**
2-yl-2-pyridyl)acetamide
21
N-(5-pyrazin-2-yl-2-pyridyl)-2-[4-[2-(trifluoromethyl)-4-
***
pyridyl]pyrrolo[2,3-d]pyrimidin-7-yl]acetamide
22
2-[4-(2-methyl-4-pyridyl)pyrazolo[3,4-d]pyrimidin-1-yl]-N-(5-
***
pyrazin-2-yl-2-pyridyl)acetamide
23
2-[4-(2-methyl-4-pyridyl)pyrrolo[3,2-c]pyridin-1-yl]-N-(5-pyrazin-2-
***
yl-2-pyridyl)acetamide
24
2-[4-(2-methyl-4-pyridyl)pyrrolo[2,3-c]pyridin-1-yl]-N-(5-pyrazin-2-
***
yl-2-pyridyl)acetamide
25
2-[4-(2-methyl-4-pyridyl)pyrazolo[3,4-b]pyridin-1-yl]-N-(5-pyrazin-
***
2-yl-2-pyridyl)acetamide
26
2-[4-(2-methyl-4-pyridyl)pyrrolo[2,3-d]pyrimidin-7-yl]-N-(5-pyrazin-
***
2-yl-2-pyridyl)acetamide
27
2-[4-(2-methyl-4-pyridyl)pyrrolo[2,3-b]pyridin-1-yl]-N-(5-pyrazin-2-
***
yl-2-pyridyl)acetamide
28
2-[4-(4-methylpiperazin-1-yl)pyrrolo[2,3-b]pyridin-1-yl]-N-(5-
*
pyrazin-2-yl-2-pyridyl)acetamide
29
2-[4-(3,5-dimethylpiperazin-1-yl)pyrrolo[2,3-b]pyridin-1-yl]-N-(5-
*
pyrazin-2-yl-2-pyridyl)acetamide
30
2-[4-(1-piperidyl)pyrrolo[2,3-b]pyridin-1-yl]-N-(5-pyrazin-2-yl-2-
nv
pyridyl)acetamide
31
2-[4-(2-methylpyrazol-3-yl)pyrrolo[2,3-b]pyridin-1-yl]-N-(5-pyrazin-
***
2-yl-2-pyridyl)acetamide
[0257] Specific IC 50 values for a selection of compounds of the invention are given below.
[0000]
IC50
ID no.
Compound
(nM)
27
2-[4-(2-methyl-4-pyridyl)pyrrolo[2,3-b]pyridin-1-yl]-
0.67
N-(5-pyrazin-2-yl-2-pyridyl)acetamide
3
2-[5-(2-methyl-4-pyridyl)pyrazolo[3,4-b]pyridin-
0.36
1-yl]-N-(5-pyrazin-2-yl-2-pyridyl)acetamide
10
2-[2-methyl-4-(2-methyl-4-pyridyl)pyrrolo[2,3
0.32
-d]pyrimidin-7-yl]-N-(5-pyrazin-2-yl-2-pyridyl)acetamide
23
2-[4-(2-methyl-4-pyridyl)pyrrolo[3,2-c]pyridin-1-
0.43
yl]-N-(5-pyrazin-2-yl-2-pyridyl)acetamide
31
2-[4-(2-methylpyrazol-3-yl)pyrrolo[2,3-b]pyridin-
0.89
1-yl]-N-(5-pyrazin-2-yl-2-pyridyl)acetamide
[0258] Specificity Immunoprecipitation
[0259] L-Wnt cells can be assessed by treatment with alkanyl-palmitate and several concentrations of compound. After 24 hours cell lysates could be washed in PBS (SOURCE) and collected in ice cold lysis buffer (LYSIS BUFFER). Dynabeads (SOURCE) can be incubated with anti-wnt-3a antibody (Abcam) for 20 minutes and incubated with lysates for an hour. Beads can be isolated by magnet and the unbound faction retained. Click chemistry can be performed on samples using Click-iT® protein buffer kit (Life technologies), following the protocol provided, to conjugate biotin to alkanyl palmitate. Elutes can be separated from the samples by magnet and the resulting samples boiled for 20 minutes to dissociate the conjugates. Beads can be removed and the elutes and unbound fraction can be run by polyacrylamide gel electrophoresis, transferred to a membrane and stained for biotin using streptavidin-horseradish peroxidase and for total Wnt by specific antibody.
[0260] Cell Death Assay
[0261] Cells in growth media (DMEM, 10% FCS) can be treated with a serial dilution of compound diluted to 0.1% DMSO for 72 hours. Viable cell number was measured by the ability to reduce resazurin to resorufin which was detected by fluorescence emission at 590 nm.
[0262] Foci Formation Assay
[0263] Capan-2 cells can be seeded onto 6 well plates in standard growth media and treated with serial dilutions of compound. Cell media was changed every four days with fresh compound added. After ten days' growth, cells can be fixed on methanol and treated with crystal violet to visualize. Area covered by cell colonies was detected by Operetta and analysed using Columbus software. | Disclosed are compounds useful as inhibitors of the Wnt signalling pathway. Specifically, inhibitors of Porcupine (Porcn) are contemplated by the invention. In addition, the invention contemplates processes to prepare the compounds and uses of the compounds. The compounds of the invention may therefore be used in treating conditions mediated by the Wnt signalling pathway, for example, in treating cancer, sarcoma, melanoma, skin cancer, haematological tumors, lymphoma, carcinoma, and leukemia; or enhancing the effectiveness of an anti-cancer treatment. | 2 |
BACKGROUND OF THE INVENTION
During transfer of liquid or gas from a subsea pipeline or other installation at great ocean depths to a floating structure by riser devices, high loads must be endured thereby due to currents, waves, or motions of the structure. Furthermore, rather strong internal wear caused by the flowing fluids, as well as external corrosion, will tend to shorten the useful lives of the riser devices.
In Norwegian Pat. No. 136 243 an articulated riser device is suggested which comprises fluid conducting lines which are rigidly connected to a part which is connected to similar parts by means of universal joints. Such a riser device is not a very stable structure and will experience relatively large horizontal and vertical motions due to comparably small forces, and the device will thus be subjected to oscillations which entail danger for subsequent fatigue and failure of the parts of the structure.
Internal wear from the conveyed fluid and external corrosion have lately turned out to be more extensive than previously assumed, and maintenance requirements are therefore constantly being made more stringent. Thus, the previously known riser devices will have to be replaced relatively often. This entails considerable expenditures, while time consuming replacement work leads to large production losses.
The object of the present invention is to provide a riser device of the type mentioned by way of introduction, which device eliminates, or to a large extend reduces the noted drawbacks and deficiencies. A detailed understanding of the invention will be obtained by reference to the following discussing taken in conjunction with the accompanying drawings.
DESCRIPTION OF THE DRAWINGS
FIG. 1 schematically depicts a riser device according to the invention in elevation.
FIG. 2 and FIG. 3 illustrate some of the forces acting on a device according to FIG. 1 in two different positions.
FIG. 4 schematically shows in elevation an alternative embodiment of the invention for reaching greater depths.
FIG. 5 shows some of the parts of the inventive riser device in greater detail.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The riser device, in the following called riser 1, comprises separate members 4, 5 and 6 is arranged so that the different constituent members 4, 5 and 6 will assume a pronounced zigzag form as shown in FIG. 1. The upper end portion of the upper member 4 is movably attached to a floating structure 7 by means of a flexible joint 9 and a preferably remotely controlled hydraulic coupling 11, while the lower end portion of the lower member 6 is similarly movably attached to a subsea pipeline 13 or the like on the ocean floor 8 by means of a flexible joint 10 and a preferably hydraulic coupling 12. The middle or third member 5 of the system connects the two members 4 and 6 together by means of flexible joints 14 and 15.
In order to reduce the oscillation amplitudes that may occur in the pipeline as a result of varying external forces, the upper portion riser 1 is made self-stabilizing by furnishing the upper member 4 with a weight means 2 in its lower portion, this weight means subjecting the system to a downwardly directed force acting primarily in the area where members 4 and 5 are interconnected. Furthermore, the lower member 6 is furnished in its upper portion with a buoyancy means, such as a chamber 3 which can contain a variable amount of a lighter-than-water substance such as air, and this buoyancy means provides the system with an upwardly directed force substantially in the area where members 5 and 6 are interconnected.
The upper member 4 of the riser acts like a suspended pendulum depending from the floating structure 7. The lower member 6 acts like a standing pendulum which is attached to the ocean floor and is held in upwardly directed position by the action of the buoyancy means. The middle member 5 acts like a strut pushing the two pendulums 4 and 6 out from their equilibrium positions. As is well known, a pendulum which is brought out from its equilibrium position will tend to act against this position with a force, and it is this principle that here has been used in order to stabilize the riser 1.
The downwardly directed action of the weight means 2 may also be distributed along the length of the member 4, for instance by forming part of the structure. Likewise, the upwardly directed action from the single buoyancy means 3 may be replaced by several buoyancy bodies placed on the member 4. In order to obtain the desired cooperation between a suspended and a standing pendulum, the riser 1 must consist of at least three members 4, 5, 6, and this is thus a preferred embodiment.
The stabilizing principle is shown in an example in FIG. 2. Here, the riser 1 is illustrated as a suspended pendulum 4, a standing pendulum 6 and a strut 5 which pushes these out from their equilibrium positions G and H. In this example, the members 4, 5, 6 are assumed to have a weight equalling their buoyancy. The weight means 2 is represented by the downwardly directed force P and the buoyancy means 3 by the upwardly directed force B. For simplicity, the members 4 and 6 have been made equally long. The force P may be split into a component force Q which acts in the longitudinal direction of the member 4, and a component force R which acts in the longitudinal direction of the member 5. The force B may be split into the force C acting in the longitudinal direction of the member 6 and the force D acting in the longitudinal direction of the member 5. The force components Q and C will constantly act perpendicular by perpendicularly to the pendulum orbits and will have no influence on the motions. The two other components R and D tend to accelerate the pendulums toward their equilibrium positions G and H. The condition for equilibrium, when other forces are not present, is that R and D are equal and opposite. FIG. 2 shows the system in equilibrium.
If the system is given a displacement, the relationship between the components will change, but always in such a way that there will be a resultant force acting towards the equilibrium position of the system. This is shown in an example in FIG. 3, where the system is subjected to an external force S giving a displacement towards the right to a new equilibrium position. The suspended pendulum will move towards its equilibrium position G while the standing pendulum will move away from its equilibrium position H. The component forces R and D will change to R 1 and D 1 in such a way that R 1 will be smaller than D 1 , and the resultant will act along the strut 5 against the external force S and will try to bring the system back to its natural equilibrium position. The longer out from its natural equilibrium position the system is brought, the larger the resultant will be. If the member 4 is brought past the point G, R 1 and D 1 will act in the same direction.
If P and B are increased to, say, P 2 and B 2 as shown in FIGS. 2 and 3, the components R and D and the resultant of these will increase in the same proportion. When applied to the riser 1, this means that the system may be made stiffer or softer by varying the magnitude of P and B, so that it will take a larger or smaller force, respectively, to bring the system a given distance out from its natural equilibrium position. The length of the members of the riser will be decisive for the water depth at which these may be installed while concurrently maintaining the desired stabilizing effect.
For greater depths the riser may be extended by introducing more members as shown in FIG. 4. Here, the same principle is utilized by alternatingly employing suspended and standing pendulums with rigid struts in between.
In the arrangement of a riser as shown in FIG. 4 with more than three members, the total length of these must be adjusted to the ocean depth at hand so that the above-mentioned zigzag form is maintained. The form of the members 4 and 5 remains unchanged, while the member 6 must be equipped with a weight means 19 at its lower end portion in order for the stabilizing effect to be maintained. The member 20 is made like member 5, while member 21 is equipped with a buoyancy means in the form of a chamber 3a at its upper portion.
Further members may be connected in a similar manner in order to extend the riser 1.
The riser 1 may be released from its attachment 12 on the ocean floor and be pulled into the floating structure 7 through the shaft 22 by means of a crane or the like, as shown in FIG. 1.
In order that this work may easily be done with a riser according to the invention in three parts, the two lower riser members 5 and 6 must be lowered, say, by reducing the buoyancy of the chamber 3. Thereby, the upper member 4 will assume a generally vertical position and may be pulled into the shaft 22. When the upper member has been pulled in, the middle member 5 must also be vertical in order to be pulled into the shaft. This may be assured by making the total length of the two lower riser members 5 and 6 equal or less than the distance between the bottom and the floating structure. Alternatively, the body 7 may be raised sufficiently for the riser 1 to assume a straight vertical position for retraction.
Inside the shaft the riser may be disassembled and new parts quickly exchanged. This is possible by the subdivision of the riser into sections 23 which may be connected by means of quick connect couplings 24 and 25 as shown in FIG. 5. The fluid pipe 16 is connected together by means of couplings 25 and the structural struts 17 by means of couplings 24. | The present invention relates to a riser device which extends from an underwater installation up to a structure situated near the water's surface, and which comprises at least three rigid, elongate members each having associated therewith at least one fluid flow line. The elongate members are interconnected by means of universal joints and have sufficient lengths that the total length of the riser device will exceed the distance between the underwater installation and the structure. | 1 |
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