description stringlengths 2.98k 3.35M | abstract stringlengths 94 10.6k | cpc int64 0 8 |
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BACKGROUND OF THE INVENTION
[0001] This invention relates generally to the field of intraocular lenses (IOL) and, more particularly, to accommodative IOLs.
[0002] The human eye in its simplest terms functions to provide vision by transmitting light through a clear outer portion called the cornea, and focusing the image by way of a crystalline lens onto a retina. The quality of the focused image depends on many factors including the size and shape of the eye, and the transparency of the cornea and the lens.
[0003] When age or disease causes the lens to become less transparent, vision deteriorates because of the diminished light which can be transmitted to the retina. This deficiency in the lens of the eye is medically known as a cataract. An accepted treatment for this condition is surgical removal of the lens and replacement of the lens function by an artificial intraocular lens (IOL).
[0004] In the United States, the majority of cataractous lenses are removed by a surgical technique called phacoemulsification. During this procedure, an opening is made in the anterior capsule and a thin phacoemulsification cutting tip is inserted into the diseased lens and vibrated ultrasonically. The vibrating cutting tip liquifies or emulsifies the lens so that the lens may be aspirated out of the eye. The diseased lens, once removed, is replaced by an artificial lens.
[0005] In the natural lens, bifocality of distance and near vision is provided by a mechanism known as accommodation. The natural lens, early in life, is soft and contained within the capsular bag. The bag is suspended from the ciliary muscle by the zonules. Relaxation of the ciliary muscle tightens the zonules, and stretches the capsular bag. As a result, the natural lens tends to flatten. Tightening of the ciliary muscle relaxes the tension on the zonules, allowing the capsular bag and the natural lens to assume a more rounded shape. In the way, the natural lens can be focus alternatively on near and far objects.
[0006] As the lens ages, it becomes harder and is less able to change shape in reaction to the tightening of the ciliary muscle. This makes it harder for the lens to focus on near objects, a medical condition known as presbyopia. Presbyopia affects nearly all adults over the age of 45 or 50.
[0007] Prior to the present invention, when a cataract or other disease required the removal of the natural lens and replacement with an artificial IOL, the IOL was a monofocal lens, requiring that the patient use a pair of spectacles or contact lenses for near vision. Advanced Medical Optics has been selling a bifocal IOL, the Array lens, for several years, but due to quality of issues, this lens has not been widely accepted.
[0008] Several designs for accommodative IOLs are being studied. For example, several designs manufactured by C&C Vision are currently undergoing clinical trials. See U.S. Pat. Nos. 6,197,059, 5,674,282, 5,496,366 and 5,476,514 (Cumming), the entire contents of which being incorporated herein by reference. The lens described in these patents is a single optic lens having flexible haptics that allows the optic to move forward and backward in reaction to movement of the ciliary muscle. A similar designs are described in U.S. Pat. No. 6,302,911 B1 (Hanna), U.S. Pat. Nos. 6,261,321 B1 and 6,241,777 B1 (both to Kellan), the entire contents of which being incorporated herein by reference. The amount of movement of the optic in these single-lens systems, however, may be insufficient to allow for a useful range of accommodation. In addition, as described in U.S. Pat. Nos. 6,197,059, 5,674,282, 5,496,366 and 5,476,514, the eye must be paralyzed for one to two weeks in order for capsular fibrosis to entrap the lens that thereby provide for a rigid association between the lens and the capsular bag. In addition, the commercial models of these lenses are made from a hydrogel or silicone material. Such materials are not inherently resistive to the formation of posterior capsule opacification (“PCO”). The only treatment for PCO is a capsulotomy using a Nd:YAG laser that vaporizes a portion of the posterior capsule. Such destruction of the posterior capsule may destroy the mechanism of accommodation of these lenses.
[0009] There have been some attempts to make a two-optic accommodative lens system. For example, U.S. Pat. No. 5,275,623 (Sarfarazi), WIPO Publication No. 00/66037 (Glick, et al.) and WO 01/34067 A1 (Bandhauer, et al), the entire contents of which being incorporated herein by reference, all disclose a two-optic lens system with one optic having a positive power and the other optic having a negative power. The optics are connected by a hinge mechanism that reacts to movement of the ciliary muscle to move the optics closer together or further apart, thereby providing accommodation. In order to provide this “zoom lens” effect, movement of the ciliary muscle must be adequately transmitted to the lens system through the capsular bag, and none of these references disclose a mechanism for ensuring that there is a tight connection between the capsular bag and the lens system. In addition, none of these lenses designs have addressed the problem with PCO noted above.
[0010] Prior art accommodative two lens systems using a movable “zoom” lens have inherently limited movement. The maximum sensitivity or movement magnification a (a unitless ratio) is defined as the axial movement of the lens per unit zonule movement and is derived by the following equation:
a=−B/A
where B is the projected distance of the zonule length which is in the order of 1.0 to 2.0 mm; and
A is the axial distance between the middle plane between the dual lens and the anterior surface of the anterior lens where the zonules terminate.
[0011] Practically speaking, because of the lens thickness and dual lens separation requirement, A cannot be less than ˜1 mm. Therefore, α cannot be larger than 2, which defines the limit of the known dual lens accommodative approaches. This limit is too low for the dual optics design to achieve the objective of creating the greater than 2.25 diopters of accommodative amplitude that patients need for normal accommodation, which ideally results in a greater than or equal to 4.
[0012] Secondly, existing dual optics accommodative implants do not manage any necessary change in the base power of the dual optics lens systems. Such changes can result from the inaccuracy of biometry, surgical variations, implant variations and inter-patient capsule variations. Consequently, patients can have refractive error after the implantation and need additional spectacles corrections that are not desired. In addition, potential post implantation capsule reaction and other ocular changes over time can result in the gradual development of refractive errors over time.
[0013] Therefore, a need continues to exist for a safe and stable accommodative intraocular lens that provides accommodation over a broad and useful range and an adjustable base power.
BRIEF SUMMARY OF THE INVENTION
[0014] The present invention improves upon the prior art by providing a two optic accommodative lens system. The present invention also contemplates the use of a cam mechanism to adjust the distance power via adjustment of the dual lens separation when the eye is at distance vision stasis. The cam mechanism allows for distance/base power adjustment as needed.
[0015] Accordingly, one objective of the present invention is to provide a safe and biocompatible intraocular lens system.
[0016] Another objective of the present invention is to provide a safe and biocompatible intraocular lens system that is easily implanted in the posterior chamber.
[0017] Still another objective of the present invention is to provide a safe and biocompatible intraocular lens system that is stable in the posterior chamber.
[0018] Still another objective of the present invention is to provide a safe and biocompatible accommodative lens system.
[0019] Still another objective of the present invention is to provide a safe and biocompatible accommodative lens system having an adjustable base power.
[0020] These and other advantages and objectives of the present invention will become apparent from the detailed description and claims that follow.
BRIEF DESCRIPTION OF THE DRAWING
[0021] FIG. 1A is an enlarged top plan view of the first lens of the lens system of the present invention.
[0022] FIG. 1B is an enlarged elevational view of the first lens of the lens system of the present invention.
[0023] FIG. 2A is an enlarged top plan view of the force transfer ring of the lens system of the present invention.
[0024] FIG. 2B is an enlarged partial cross-sectional view of the force transfer ring of the lens system of the present invention.
[0025] FIG. 3A is an enlarged top plan view of the capsule ring and second lens of the lens system of the present invention.
[0026] FIG. 3B is an enlarged partial cross-sectional view of the capsule ring and second lens of the lens system of the present invention.
[0027] FIG. 4A is an enlarged plan view of the lens system of the present invention shown in its low power, or distance vision state.
[0028] FIG. 4B is an enlarged partial cross-sectional view of the lens system of the present invention shown in its low power, or distance vision state.
[0029] FIG. 5 is an enlarged partial cross-sectional view of the lens system of the present invention in its medium power, or intermediate vision position.
[0030] FIG. 6 is an enlarged partial cross-sectional view of the lens system of the present invention in its high power, or near vision state.
DETAILED DESCRIPTION OF THE INVENTION
[0031] As best seen in FIGS. 1A-1B , first, or anterior lens 100 of the present invention generally includes first optic 110 and attached haptics 120 . Haptics 120 are attached to optic 110 by hinges 101 . Haptics 120 generally encircle optic 110 and contain widened tabs 180 having downward turn edges 104 . Tabs 180 are formed in a vaulted position, as best seen in FIG. 1B so that edge 104 lays in a plane separated from the plane in which optic 110 lays. As best seen in FIGS. 2A-2B , force transfer ring 200 is generally circular having a central bore 140 into which anterior lens 100 fits. Ring 200 contains camming surface 201 that rests on tabs 180 on haptics 120 in the manner described below. Ring 200 further contains outer circumferential rim 203 . As best seen in FIGS. 3A-3B , outer ring 300 is generally circular having a central bore 340 into which ring 200 fits. Ring 300 further contains internal circumferential ledge 301 on which rim 204 rests when ring 200 is fitted within ring 300 . Attached to ring 300 by haptics 420 is second or posterior lens 400 . Lenses 100 and 400 may be made from any suitable material such as a thermoplastic, a silicone, a hydrogel or a soft acrylic and contain any desired additives, such as ultraviolet or blue light blocking chromophores. Lenses 100 and 400 may further have any suitable design, such aspheric, toric, pseudoaccommodative or multifocal. Those skilled in the art will recognize that lenses 100 and 400 need not be implanted at the same time. For example, lens 400 and ring 300 may be implanted in an eye and the eye allowed to recover from the surgical trauma. After waiting such a healing period, bioptric and other physiological measurements may be made sufficient to calculate an accurate prescription for lens 100 , at which time lens 100 and ring 200 may be implanted.
[0032] As best seen in FIGS. 4-6 , lens assembly 500 is assembled within in an eye by first implanting outer ring 300 containing posterior lens 400 within the capsular bag. Anterior lens 100 is then placed within ring 300 in front of posterior lens 400 so that widened tabs 180 are caught under lower rim 302 of circumferential ledge 301 on ring 300 . Ring 200 is then placed within ring 300 so that camming surface 210 rests on tabs 180 of haptics 120 and circumferential rim 203 rests on circumferential ledge 301 . As show in FIG. 4A-4B , lens assembly 500 is at its low power state—distance vision state. This state is achieved via the following sequence. When there is a need to dis-accommodate—to see distance objects, the ciliary muscle relaxes to cause enlargement of the ciliary ring diameter. The enlargement of the ciliary ring pulls the zonules outward in radial directions. Such outward zonule movement causes the anterior and posterior capsule portions to move towards each other. In other words, the capsular bag flattens. Flattening of the capsular bag causes ring 200 and edge 104 on haptic 120 of lens 100 to move toward each other because the anterior capsule portion (not shown) contacts ring 200 at anterior edge 202 , and because the posterior capsule portion (not shown) contacts lens 100 at edge 104 of haptic 120 . The movement stops when circumferential rim 203 rests on circumferential ledge 301 and when distal end 103 of tab 180 meets lower rim 302 . In this position, camming rim 201 presses against tabs 180 at area 102 . Consequently, hinge 101 is in a flexed, tensioned or sprung position. In this dis-accommodative position, the separation between anterior lens 100 and posterior lens 400 together with the respective powers of the two lenses determines the actual power of the lens assembly 500 .
[0033] FIGS. 5-6 , show lens assembly 500 in accommodative positions. As one needs to accommodate—to see near objects, the ciliary muscle contracts causing ciliary ring diameter reduction. This reduction relaxes the holding force of the zonules, no longer flattening the capsule bag. With the capsular bag no longer holding haptics 120 and optic 110 flat, the tension in hinges 101 cause edges 104 to move away from optic 110 , thereby returning lens 110 into its natural vaulted state. Such vaulting moves lens 100 away from lens 400 , thereby causing an increase in lens separations resulting in an overall higher power of dual lens assembly 500 . The leverage ratio is determined by the ratio of the length of haptic 120 from hinge 101 to area 102 , and the length from area 102 to distal end 103 . By design adjustment, a higher ratio can be achieved such that the axial movement of optic 110 is much larger than that of ring 200 . Therefore, the amount of axial movement of optic 110 is not limited to the amount of axial movement of the anterior capsule, so that α>2.25 can be achieved.
[0034] In order to provide power adjustability to lens assembly 500 , as best seen in FIG. 2B , camming surface 201 on ring 200 is not straight, but has an undulating profile, so that the distance between camming surface 201 and anterior edge 202 varies. Rotation of ring 200 causes variable axial movement of optic 110 because camming rim 201 presses against tabs 180 at area 102 , such pressure causing flexure of hinges 101 .
[0035] This description is given for purposes of illustration and explanation. It will be apparent to those skilled in the relevant art that changes and modifications may be made to the invention described above without departing from its scope or spirit. | A two optic accommodative lens system. The present invention also contemplates the use of a cam mechanism to adjust the distance power via adjustment of the dual lens separation when the eye is at distance vision stasis. The cam mechanism allows for distance/base power adjustment as needed. | 0 |
BACKGROUND OF THE INVENTION
The present invention relates to semiconductor matrices which can be used in devices such as solar cells, diodes, electrifiers and transistors and the like and to methods of manufacturing such matrices from elemental semiconductors such as silicon and germanium.
An extremely important use of the semiconductor matrices of the present invention is in a solar cell. Because of the rapid depletion of our natural energy sources, and the associated pollution problems with these sources, solar energy as a source of energy has become highly important. Solar energy is abundantly available in this country and can be utilized without ecological problems.
Electricity can be directly generated from solar energy by the photovoltaic process whereby an electric current is generated when light is allowed to fall upon a rectifying contact or junction such as that contained in a solar cell. Photovoltaic solar cells are an expedient means of utilizing the virtually inexhaustable energy resource, incident solar radiation, to meet the growing worldwide demand for electric power.
However, it is well recognized that except in certain specific instances such as satellite space stations or remote installations away from the utility grid, photovoltaic electric generators are not cost effective at this time. This means that a cost penalty will be paid by an end user to employ power from a photovoltaic source compared to utility power derived from non-renewable fossile or nuclear fuels. For example, the costs of production of solar cells for use in satellites is approximately $20 to $50 per watt. This compares quite unfavorably with $0.50 per watt which is the approximately cost for fossile fuels.
A highly desirable objective is therefore to reduce the cost of power generated from solar radiation by the photovoltaic effect to the point where it becomes cost effective, thereby reducing consumption of and dependence upon non-renewable energy resources.
Reducton of cost can occur in any of several operations in the manufacture of photovoltaic solar cells. The disclosed invention focuses upon a method to reduce the cost of fabricating a semiconductor matrix.
An important factor in the cost of the fabrication of the semiconductor matrix is the manner of depositing the elemental semiconductor which is appropriately doped to form p-n junctions, on the substrate. Prior art methods expend and invest much energy in this process step which greatly increases the energy "payback" time of the resulting cells. That is to say, prior art techniques for manufacturing solar cells require the investment of so much energy that it takes several years to have this energy returned (payed back) as electricity from converted solar energy.
An example of this high energy investment in the deposition of silicon is found in Sirtl (U.S. Pat. No. 4,058,418) which discloses depositing silicon by introducing in a hydrogen stream silicon containing gases decomposable at temperatures at about 1,025° C. and 1,200° C. These high temperatures of course require significant energy investment. Carlson (U.S. Pat. No. 4,064,521) discloses a method of deposition as glow discharge which involves the discharge of electricity through gas at a relatively low pressure in a partially evacuated chamber.
Takagi (U.S. Pat. No. 4,066,527) discloses an ionized-cluster-deposition process which again requires significant expenditures of energy.
Janowiecki (U.S. Pat. No. 4,003,770) discloses producing a sprayed junction by plasma spraying a thin layer of silicon of opposite polarity or type over the initially deposited doped film.
Wakefield (U.S. Pat. No. 3,998,659) discloses forming a fluidized suspension of semiconductor particles which are maintained at a suitably elevated reaction temperature. A semiconductor containing vapor together with a dopant vapor and a vaporized reduction agent are then introduced into the fluidized suspension to effect deposition.
Other conventional techniques disclosed in Fang (U.S. Pat. No. 3,914,856) and Chu (U.S. Pat. No. 4,077,818) are epitaxial vaporation, electron beam evaporation, ion sputtering, thermal decomposition of silane, reduction of trichlorosilane or silicon tetrachloride with hydrogen at temperatures arranging from 900° C. to 1,200° C., or by thermal decomposition of dichlorosilane.
The Austin U.S. Pat. No. 3,990,953 discloses a method for electrodepositing elemental silicon on an electrically conductive cathode body. The patented method is an attempt to achieve a pure form of silicon which would subsequently be used in such applications as a solar cell. The electrodeposition occurs in an electroplating glass vessel with anodes and cathodes of platinum. A power supply is then used to drive the reaction to plate out elemental silicon on the cathode body.
The present invention discloses a method of producing semiconductor matrices by depositing the elemental semiconductor material while greatly reducing the cost and the energy investment required.
SUMMARY OF THE INVENTION
The principal object of the present invention is fabrication of an elemental semiconductor matrix, with back side electrode structural support and p-n junction assemblage in a continuous large area sheet form with the absolute minimum energy investment. One embodiment of the invention is the use of this semiconductor matrix in a photovoltaic solar cell.
The invention represents the first semiconductor device ever created in which the energy consumed in producing the semiconductor layer, in placing the rear electrode, and bonding this assemblage to a metallic structural support is an absolute minimum. The process is also continuous with a product size limited only by available metal rolling mill capacity. This gives the added benefit of eliminating the majority of cell interconnections found in the prior art.
In the practice of the invention a continuous substrate is coated with an appropriate electrical contact which is then coated with a thin film of liquid silicon or germanium containing electrolyte which is in turn contacted with an appropriate metal anode to cause elemental silicon or germanium to be deposited (plated out) on the continuous backing strip.
One exceptionally important embodiment of the invention uses an alkali metal as the anode material. U.S. Pat. No. 3,791,871 issued to L. Rowley teaches the manufacture of a consumable anode alkali metal battery often called the Geisler cell. Although working in an entirely different field and for different purposes than the present invention, Rowley and his co-workers developed a technique of reacting an alkali metal with water to produce electricity without an explosion as would normally be expected with these reactants because of the very high exothemicity of the chemical reactions involved, i.e. approximately 35 kilocalories per mole.
The principle by which the potentially explosive combination of an alkali metal with water is allowed to occur in a controlled and useful fashion is the build-up on the electrode being consumed of a film of reaction products which cause access of the reactants to one another to be diffusion controlled. When the alkali metal, for example sodium, touches water, it is converted to an NaOH, Na X O Y film mixture through which additional OH ions must diffuse to continue their reaction. The rate of diffusion therefore controls the reaction rate. The diffusion of OH ions in turn is controlled by their diffusivity, concentration, and the film thickness, ionic diffusivity in this case obviously including electric field effects.
The overall highly exothermic and kinetically rapid chemical reaction is as follows: Na(s)+H 2 O→NaOH+1/2H 2 ΔG 298 °=-35 kcal.
The present invention utilizes a highly exothermic alkali metal chemical reaction, with a silicon or germanium compound to produce plating at the cathode as a primary product. An extremely important feature of the disclosed invention is the utilization of the by-product electric power produced through the exothermic alkali metal reaction for direct regeneration of the anode material. In this way a semiconductor matrix is fabricated with a total energy input savings, thus far unattainable by prior methods.
A plurality of metal anodes may be used in order to deposit successive layers of appropriately dopsed silicon or germanium. p-n junctions may then be formed by diffusion or ion implantation. The silicon or germanium sheet deposited will be of the amorphous type or may be able to be converted to polycrystalline material by suitable means such as heat treatment.
In the solar cell embodiment, after formation of the p-n junction front contacts are emplaced by thick film paste technology and metallizing sintering heat treatment. The cell is then encapsulated and shipped for use.
The novel features which are believed to be characteristic of the invention, both as to its organization and method of operation, together with further objectives and advantages thereof, will be better understood from the following description considered in connection with the accompanying drawings in which preferred embodiments of the invention are illustrated.
BRIEF DESCRIPTION OF THE DRAWINGS
A detailed description of the invention will be made with the aid of the accompanying drawings wherein:
FIG. 1 is a schematic view of a production line for fabricating a semiconductor matrix;
FIG. 2 is a cross-sectional view of a semiconductor matrix.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a production line for the manufacture of a semiconductor matrix which could be used for solar cells, diodes, electrifiers, transistors and the like. The line begins with a thin metal sheet 10 of sufficient Young's Modulus and appropriate thickness to support its own weight in a half I Beam or channel-like configuration without excessive elastic deformation over the area of the desired semiconductor matrix and yet sufficient elastic limit to be coiled. The metal sheet is preferably steel or aluminum. This sheet is then continuously fed into the reaction system by a roller 12.
If the substrate strip is steel, it should first be coated with aluminum. This aluminum may conveniently be applied with any of the techniques known to those of ordinary skill in the art. However, preferably an aluminum coating can be applied using the techniques of the present invention. In this embodiment, a hopper 14 containing aluminum trichloride electrolyte is used to apply the electrolyte to the surface of the substrate. The substrate coated with electrolyte is then contacted with an alkali metal anode 16 to deposite a layer of aluminum on the substrate.
Strip 10 is then fed into the reaction system by rollers 18 and 20. The rollers are configured in a manner similar to a rolling mill operated with only sufficient force applied to the work piece to cause transport without plastic deformation although some elastic deformation may occur.
Electrolyte liquid is then applied as a thin liquid film to the strip 10 by suitable means which may include spraying, immersion and the like by methods well-known to those with ordinary skill in the art. A preferred embodiment of the electrolyte application system is shown in FIG. 1 as applicators 22 and 24. These applicators can be quartz or metal hoppers extending across the substrate 10 and having a multitude of capillary holes in their bottom through which the electrolyte drains at a rate controlled by liquid head in the hoppers 22 and 24, and the average capillary diameter in the bottom of said hoppers.
The electrolyte liquid is of the general formula MH 4-n X n wherein M is germanium or silicon, X is a halogen such as Cl, I or Br and n is 1, 2, 3 or 4. The electrolyte therefore includes all silicon and germanium halides including those pseudo halides which contain hydrogen as well. It may also contain an appropriate polar solvent.
The forward motion of substrate 10 spreads electrolyte liquid MH 4-n X n over its width uniformly while interfacial tension which is most pronounced at the edges is used to prevent overflow of the electrolyte liquid from the substrate 10.
The electrolyte draining from hopper 22 is preferably highly doped with an n type dopant. This can be accomplished by mixing a phosphorous compound with the silicon or germanium electrolyte solution. Examples of such mixtures would be PBr 3 in SiBr 4 , PB r 3 in GeBr 4 , PCl 3 in SiCl 4 or PCl 3 in GeCl 4 .
A highly doped layer of silicon or germanium is then plated onto the top of strip 10 by an deposition. Anodes 26 and 28 are metal rods or thick sheets of metal which are as wide as strip 10 and a thick in the direction of substrate motion as it is required to achieve the necessary plating thickness. These metal anodes are preferably composed of an alkali metal such as lithium, sodium or potassium. The metal anode 26 is contacted with the electrolyte film at point 30 thereby initiating a chemical reaction. If the alkali metal is sodium and the electrolyte is a pure silicon halide, the reaction is as follows: nNa+MX n →n NaX+M+ΔG(<<o) (1).
NaX is formed as a thin film on the end of anode 26 which is immersed in the electrolyte film. The rate of reaction (1) is then controlled by the diffusion rate of X - ions through the NaX film to the nonreacted anode metal surface. This diffusion rate in turn is controlled electrochemically by several parameters well illucidated in the prior art including the external load resistance and impedence 32 and the cell internal resistance, a function of electrolyte film thickness and chemical composition, interelectrode spacing, substrate velocity and the like. The key to successful operation is as discussed above the NaX thin film which limits the rate of dissolution of sodium so that the energy released by the highly exothermic reaction can be extracted from the system as current in an external load rather than dissipated as heat. Coulombic efficiencies of close to 100 percent are obtainable if the reactor is operated to maximize this parameter.
A thin silicon or germanium film is formed at the cathode 10 in an exactly analogous fashion except that here the diffusion controlled rate limiting process is that of electrons through the product film (M) to the product-electrolyte interface.
Following this first plating operation, substrate 10 with a silicon or germanium doped layer is then fed to a second hopper 24 which is filled with a less highly doped electrolyte solution. The solution however is doped with the same type conductivity as the electrolyte draining from hopper 22. Reducing the solute concentration will achieve this less highly doped electrolyte. For example, if the electrolyte solution in hopper 22 is silicon tetrachloride and phosphoroustrichloride the electrolyte in hopper 24 should be a more dilute solution of the same components. The electrolyte is then coated on substrate 10 in an analogous manner to that previously described for the operation involving hopper 22. The substrate is then fed to a second metal anode 28 which when contacted with the substrate produces an analogous exothermic reaction and as described before, plating a less highly doped silicon or germanium layer onto the carrier.
The carrier 10 is then fed by roller 34 to suction apparatus 36. This suction apparatus 36 removes spent electrolyte containing NaX reaction product and recirculates it so that the alkali metal can be regenerated for further anode use. The substrate is then fed under apparatus 38 which is used to form a p-n junction. The apparatus operates to perform a diffusion or an implantation process which are techniques well-known in the art to provide opposite dopant to form a p-n junction.
The regeneration system will now be described. Anodes 16, 26 and 28 are connected with electrical contacts 40, 42 and 44 respectively through external load 32 to an electrode 46 inside regeneration reaction vessel 48. Brush electrical contacts 50, 52 and 54 contact the strip 10 beneath each anode thereby connecting the cathodes of the system to electrode 56 also housed within regeneration reaction vessel 48. spent electrolyte NaX is vacuumed off the strip 10 by suction apparatus 36 into regeneration reaction vessel 48. The enormous byproduct energy released from the deposition reaction can then be used to run a second deposition in the regeneration vessel 48 thereby plating out regenerated alkali metal on electrode 46. X 2 is liberated as a by product in this reaction and used in direct synthesis of new MH 4-n X n electrolyte or sold on the market.
For convenience, anode 16, which is part of the aluminum deposition reaction, has been shown as part of the regeneration system which includes anodes 26 and 28 from the elemental semiconductor deposition reactions. However, in practice AlX 3 which is present in the spent electrolyte formed from the aluminum deposition reaction should be separated out of the vacuum line so as not to be pumped to reaction vessel 48. If desired an entirely separate regeneration system, not shown, could be fabricated to regenerate the alkali metal of anode 16.
FIG. 2 shows the finished semiconductor matrix with substrate 10 which is coated with layer 58 of highly doped silicon or germanium metal which is further coated with a less highly doped layer 60 of silicon or germanium metal. A third layer 62 contains an opposite type conductivity to the doped layers 58 and 60. Electrical contacts such as illustrated by 64 can then be added to the top of the p-n junction to complete the semiconductor device.
As is well known to those of ordinary skill in the art, the oppositely doped layer 62 which forms the p-n junction may be applied by diffusion or ion implantation means.
One of the important uses of this semiconductor matrix is use in a solar cell. To complete the solar cell, a solar cell grid would be applied to the layer 62 and metallized continuously. Cells would then be cut to appropriate size, leads applied, and environmental protection applied by conventional means.
Due to the continuous process of the present invention large cells limited only by the initial substrate strip size can be fabricated to any length, greatly reducing cost per watt since few interconnections are required. Presently, conventional cells are three inches in diameter, and cells by 1982 are expected to be five inches in diameter which will require larger costs for interconnections for any meaningful power output. | An energy efficient process is disclosed for the continuous production of semiconductor matrices formed from depositing doped silicon or germanium films on metallic sheet substrates. The energy released from such deposition can then be used to regenerate the anode material used in the deposition. | 8 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention is directed to an LED (light emitting diode) assembly with a communication protocol for LED light engine, and to a method of manufacturing the LED assembly, and which is particularly adapted to address issues of color differences between different LEDs within the LED assembly.
[0003] 2. Description of the Background Art
[0004] Traditional light sources are most commonly either incandescent or gas discharge. Each has advantages and disadvantages. Although inexpensive to manufacture, the traditional incandescent bulb suffers from two disadvantages. First, most of the input energy of traditional lighting is wasted as heat or infrared (non-visible) light; only a small amount of the input energy is transferred to visible light. Second, the lifetime of the incandescent bulb is limited and when failure occurs it is catastrophic. Traditional fluorescent bulbs have a longer life, but have significant performance variations across a range of temperatures. At some colder temperatures fluorescent bulbs do not function at all. Halogen light sources are a slight improvement in efficiency and lifetime over incandescent light sources for a marginal increase in cost.
[0005] Traditional sources of lighting can produce exact colors by filtering. The filtering process takes white lighting and removes all the light except the required light of the specified color and therefore further reduces the efficiency of the light source. Traditional lighting also is broadcast in all directions from the source, which may not be advantageous when the goal is to illuminate a small object. Lastly, traditional lighting has a non-linear relationship between brightness and input current. This non-linearity makes it difficult to dim the light source easily.
[0006] LEDs overcome many of the disadvantages of traditional lighting because of their significantly longer lifetime, higher efficiency, and ability to direct the light. The Mean Time Between Failures (MTBF) of typical incandescent light sources is in the order of 10,000 hours. The MTBF of LEDs is on the order of 1-10 million hours. Typically only 5% of the input energy is transferred to visible light for an incandescent light. Similarly, for LEDs about 15% of the input energy is transferred to visible light. The ratio of lumens of light output divided by the watts of input energy is another way to look at the efficiency. Traditional lighting has about 17 lumens/watt, whereas LED based (white) light sources are about 35 lumens/watt. The efficiency improvement equates to lower power consumption or higher light output for similar applied power. Generally, an individual LED produces a low level of light output that is insufficient for usage as a light source. Combining a number of LEDs into an assembly or array allows the array to be a reliable and cost effective replacement for traditional light sources.
[0007] When designed and fabricated, an array of LEDs in an assembly can be electrically interconnected in parallel, in-series, or any combination thereof. Additionally, the LEDs in the assembly can be a single base color or many different colors. By combining several different colors into one assembly, a wide range of specified colors can be displayed by the light engine. These LED light engine assemblies are gaining widespread usage because of their ability to reduce electrical usage, improve maintenance costs, and allow dynamic, custom color projection.
[0008] LED assemblies are also rapidly replacing light bulbs in the Human Safety marketplace. Human Safety applications might include traffic lights, safety beacons on towers, warning lights at rail crossings, emergency egress lighting, aircraft runway lighting, and many more applications. In these applications LED light sources are gaining popularity for two reasons: (1) the increased reliability of LEDs, and (2) the reduced costs and difficulty of the repair and maintenance functions.
[0009] At the present time LED based light engines are in operation for Human Safety Applications in hundreds of thousands locations throughout the world.
[0010] LED lighting is also beneficial in architectural and theatrical applications. The benefit lies not only with the ability to produce an exact and repeatable light for changing moods and emotions but also with the ability to produce these colors dynamically and across a large number of light sources. This practice has been available in theatrical lighting for many years in various forms with tremendous improvement in digital color on demand in the relatively recent past. For architecture, the practical use of color remains limited largely due to the cumbersome use of theatrical grade fixtures in architectural applications. The promise of LED lighting is the ability to accomplish dynamic color in a more useful form factor and in real time for both theater and architectural applications.
[0011] A typical LED assembly includes a number of LEDs installed into a system, and typically all of the LEDs are a single base color. The technology is progressing and new requirements are emerging for the production of a broad spectrum of colors from combinations of two, three, four or more base colors of LEDs. Many assemblies under development include several Red LEDs, several Green LEDs, and several Blue LEDs. Several LEDs are needed of each color, because a single LED does not provide sufficient light for a light engine. Different LED colors are needed so that the different colors can be combined to make a broad spectrum of custom lighting effects.
[0012] A generalized LED assembly 10 is shown in FIG. 1 . The LED assembly 10 includes an LED light source 11 , which in turn includes individual LEDs 12 of different colors represented by the designators—R (red), G (green), and B (blue). The LED assembly 11 includes the LEDs 12 and a support and associated circuitry for driving the LEDs. The associated circuit and support includes an electronic carrier or printed circuit board (not shown) to mechanically hold the LEDs 12 and to provide electrical input to the LEDs 12 , a power supply 13 to convert input power into a usable form for the LEDs 12 , control electronics 14 to turn the LEDs 12 on and off appropriately, perform algorithms on the electronic signal and communicate with other equipment in a larger lighting system, and a lens or diffuser (not shown) to modify the light appearance from several small point sources to a look that is both pleasing to a human and functional for the product.
[0013] LED assemblies do, however, have the following disadvantages recognized by the present inventor. Variations within manufacturing of the optical and electrical output properties are sizeable. Targeted output colors are difficult to achieve because of the manufacturing variations of the LEDs. The optical output varies over the product lifetime; for instance, the output intensity degrades with time. The dominant wavelength is highly dependent on temperature. And, intensity drops with temperature increases.
[0014] Further, for LEDs different semiconductor compounds are used to produce different colors. Each compound will change at a different rate with respect to temperature and long term degradation. This has made the color stability of an array of RGB (Red, Green, Blue) LEDs difficult.
[0015] The fact that LED light output varies proportionately with input current is generally an advantage of LEDs; it becomes a disadvantage when an LED assembly is used as a direct replacement for an incandescent bulb. This is because the control system compensates for the non-linearity of the incandescent bulb and produces nonsensical output with the replacement LED assembly.
[0016] Lighting control systems or consoles address a limited number of light outputs with a limited number of possible color specifications and may require cumbersome hardware to address large lighting systems.
[0017] Temperature variations of the LEDs can occur for two reasons. One source is the outside environment. LED light sources can be installed in controlled temperature environments, examples of which would be home or office buildings. Alternatively, they can be installed in uncontrolled temperature environments where temperature variations are in the range of human habitability and beyond. The second source of temperature variability is the efficacy of the thermal dissipation within the specific system. Optical output properties are related to the die temperature. The die temperature is related to the outside environment, but also the thermal resistance of the entire path from the die to the outside world.
[0018] The dominant wavelength (represented by 1 d ) and the optical intensity exhibit quantifiable changes with these temperature changes. With sufficient temperature variations the change in the dominant wavelength can be discernible by the human eye. At some wavelengths (near the color amber) changes of 2-3 nanometers (nm) are discernible to the human eye; at other wavelengths (near the color red) changes of 20-25 nm are required before the human eye can differentiate a color shift. The intensity change with temperature is discernible as well. Temperature increases of 60° C. can reduce output by approximately 50%.
[0019] The current state of the art partially addresses the issues. The manufacturing variation of the LED optical output is resolved by sorting or binning the LEDs into groupings of similar optical properties. The optical response of an incandescent light has been mimicked in the control software and hardware for the array, see for example U.S. Pat. No. 6,683,419. The initial power output of the LED can also be over-driven, which results in acceptable power outputs over a longer period of time.
[0020] The current state of the art, however, does not resolve the following issues. Exact color generation of a specified color is still not achievable. Binning of the LEDs is not always sufficient to produce an accurate color across all environments because of the wide variations in the LED optical properties within a bin. Temperature variation and time degradation effects on LED output wavelength and intensity are not compensated for.
SUMMARY OF THE INVENTION
[0021] Accordingly, one object of the present invention is to provide a novel LED assembly and novel method of manufacturing the LED assembly that can efficiently and consistently provide a desired color output of the LED assembly.
[0022] The present invention achieves the above and other objects by providing a system including a network and a plurality of light emitting diode (LED) assemblies connected to the network. Each LED assembly includes a unique address. Further, a control unit is connected to the network and is configured to send light control signals to the LED assemblies individually. The light control signals include color information in a universal color coordinate system. The universal color coordinate system can be the CIE color coordinate system and the network can utilize an Ethernet communication protocol.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] A more complete appreciation of the present invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:
[0024] FIG. 1 shows a generalized background LED light assembly;
[0025] FIG. 2 explains LED color specifications on a CIE chromaticity chart;
[0026] FIGS. 3 a and 3 b show processes for uncompensated optical output of an LED assembly;
[0027] FIG. 4 shows a process flow of operations conducted in a method of manufacturing an LED assembly according to the present invention;
[0028] FIG. 5 shows a simplified pictorial of a manufacturing fixture utilized in a method of manufacturing the LED of the present invention;
[0029] FIGS. 6 a , 6 b show an overview of processes for realizing a compensated optical output for an LED assembly of the present invention;
[0030] FIG. 7 shows an LED light engine assembly of a first embodiment of the present invention;
[0031] FIG. 8 shows a more generalized operation of processes performed in manufacturing an LED assembly according to the present invention;
[0032] FIG. 9 shows RGB color specification on a CIE chromaticity chart;
[0033] FIG. 10 shows the effects on rendered color of RGB color specifications on a CIE chromaticity chart;
[0034] FIG. 11 shows a background DMX512 packet format;
[0035] FIG. 12 shows a light system as a further embodiment of the present invention;
[0036] FIG. 13 shows an LED light engine assembly in a further embodiment of the present invention;
[0037] FIG. 14 shows a standard Ethernet frame for communication;
[0038] FIG. 15 shows frame contents that can be utilized in the further embodiment of the present invention; and
[0039] FIG. 16 shows a modification of frame contents that can be utilized in the further embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0040] Referring now to the drawings, wherein like reference numerals designate identical or corresponding parts throughout the several views, features of the present invention are detailed.
[0041] Color output can be specified using the CIE Color Coordinate System. Other appropriate schemes for specifying color can also be utilized. CIE is an abbreviation for “The Commission Internationale de l'Eclairage” and is an international standards development group that first described ways of quantifying color in a standard written in 1931. The CIE Color Coordinate System is an accepted standard for the measurement of a spectral distribution and defines a color using an x coordinate, a y coordinate, and a Y′ coordinate. The CIE Color Coordinate System is a device independent way of describing color and is therefore also described as a universal coordinate system for defining colors, and is shown graphically in FIG. 2 . FIG. 2 shows the CIE Chromaticity Chart with the CIE Color torque. The CIE Color torque shows the x, y, and Y′ coordinates for saturated colors. The x coordinate and the y coordinates are normalized and are represented on a scale of 0 to 1. Both x and y coordinates are unitless and specify the color. Y′ specifies the intensity and is normalized to a unitless number as well.
[0042] Typical Red, Green, and Blue LED color outputs are shown in FIG. 2 . By interconnecting coordinates representing Red, Green, and Blue, a triangle is created. The CIE coordinates within this triangle represent the range of available colors for display. Points outside of the triangle can not be displayed with the given light sources. The center point of the triangle is the CIE coordinate of the max combination of the Red, Green, and Blue light sources and is theoretically White.
[0043] The manufacturing process for the production of LEDs is inconsistent and produces LEDs with a large variability in their output. This variability is shown for Red, Green, and Blue graphically by the span of the ovals (16), (17), and (18) respectively. FIG. 2 also identifies a Target White (15) and shows an additional oval (19) that represents the range of displayed White for combinations of the three color light sources of Red (16), Green (17), and Blue (18).
[0044] FIG. 2 shows the white range (19) of the displayed color without compensation for the many sources of variability of the LEDs. This variability of the individual LEDs includes degradation in output intensity over the LED lifetime, changes in dominant wavelength with temperature, changes in output intensity with temperature, variability within the manufacturing process, and more.
[0045] FIG. 3 a is a simplistic or uncompensated process for producing white light from the output of Red, Green, and Blue LEDs. The process shown in FIG. 3 includes three simultaneous steps S 61 , S 62 , and S 63 in which respectively a maximum output of all of the red LEDs, a maximum output of all the green LEDs, and a maximum output of all the blue LEDs are generated. By performing those steps driving each of the Red, Green, and Blue LEDs to their maximum output, a maximum color output of the Red, Green, and Blue LEDs is generated in step S 64 giving a theoretical white light output. That is, maximally mixing the Red, Green, and Blue, LEDs should provide a white light. However, because of differences between color outputs of individual of the LEDs, such a system has a drawback in that the variations in the color outputs of the Red, Green, and Blue LEDs may not result in a pure white output. The variability of the output from the process of FIG. 3 a is shown on the CIE Chromaticity Chart in FIG. 2 as (19) and may be sufficient to cause a measurable difference of the white light from a theoretical white. The difference may be discernible by the human eye. The additive process of FIG. 3 a does not compensate for LED variability and may produce an inexact white. In addition to being inaccurate the result is inconsistent.
[0046] FIG. 3 b is a similar simplistic or uncompensated process to produce a custom color. In the process of FIG. 3 b , initially each of the Red, Green, and Blue LEDs are each driven at their maximum output in steps S 61 , S 62 , S 63 , as in FIG. 3 a . Then, a scaling is introduced to each of those outputs to produce a desired color. More specifically, step S 71 adjusts Red LEDs drive parameters to obtain a desired Red light output, step S 72 adjusts Green LEDs drive parameters to obtain a desired Green light output, and step S 73 adjusts Blue LEDs drive parameters to achieve a desired Blue light output. Each of steps S 71 , S 72 , and S 73 can achieve the desired scaling by modifying drive parameters such as duty cycle and drive current for each of the respective Red, Green, and Blue LED outputs. The combined output is, ideally, the desired custom color. Unfortunately this simplistic process may also yield unacceptable results. LED variability at each of the three input stimuli induced by a number of factors may yield an inaccurate and inconsistent representation of the target color.
[0047] Single color LED light engine assemblies have been in production for a number of years. The variability associated with the fabrication of single color LEDs and the precise requirements of the Human Safety marketplace, where they have chiefly been implemented, have challenged the LED assembler to produce an accurate output color for the entire system. The LED manufacturers have assisted the assemblers by pre-sorting or binning the LEDs into smaller ranges of variability prior to shipment. The smaller range of LED input stimuli has assisted the assembler in producing a target output color. Acceptable color rendering is still a demanding task because even the bins have a sizeable range of the performance variations.
[0048] The binning operation can become complex quite quickly. An assembly with only Amber LEDs shall be used as an example. The Amber LED arrives from the manufacturer sorted by five flux values which may be identified with the labels V, W, X, Y, and Z. The variation across each flux bin can be ±15% or more. The dominant wave length may vary ±2.5 nm and may be broken into five bins labeled 1, 2, 3, 4, and 5. Five additional bins are created based on Forward Voltage (V f ) values varying ±5% and labeled a, b, c, d, and e. The result of all this sorting is that the Amber LEDs arrive at the assembler sorted into 5*5*5 or 125 possible bin locations. A bin of Amber LEDs might be labeled as a W4e; W specifying its flux range, 4 specifying its dominant wavelength, and an e specifying its Forward Voltage.
[0049] The LED assemblies can be fabricated using recipes of LEDs from the different bins of Amber LEDs. Each recipe contains the acceptable bin code or bin codes for each LED location within the electronic carrier of the LED light engine assembly design. Acceptable recipes are engineered prior to fabrication to an output that is acceptable to the customer's required optical parameters. The acceptable recipes are determined using optical performance calculations and verified experimentally. With a large number of LEDs in the assembly and a large variation of the optical output within a bin, it becomes increasingly difficult to assure the optical output of the entire assembly is acceptable to the customer—even with a recipe.
[0050] There are generally a number of acceptable recipes for each product. Having a number of recipes allows the assembler the flexibility to build the assembly in several different ways to account for inventory variations of the different bins of LEDs. However, even with a number of acceptable recipes for each product design, inventory management of the bin contents in high volume production can be a challenge to the assembler. Conversely, it is sometimes a challenge to find an acceptable recipe of LED bins with an existing inventory of bin quantities.
[0051] The above example used a simple LED assembly with only one color LED. The complexity of the recipes increases multifold when a design involves several different color LEDs and the recipes involve pulling LEDs from bins of several different base colors. In reality, multiple color LED light engine assemblies have been marginally successful. The accuracy issue of a single color becomes multiplied into a larger problem; the end result may be unacceptable color rendering. In summary, binning has allowed volume production of acceptable single color LED light engine assemblies. However, binning for single color assemblies lacks flexibility for manufacturing and can produce light output outside the range of acceptability. Binning becomes difficult or impossible to manage in multiple color LED assemblies and the resulting product is generally unacceptable.
[0052] The process of the present invention addresses such drawbacks by measuring a baseline optical performance of each unique, individual LED light engine assembly at the time of manufacture to quantify the exact color and intensity of the output, as discussed in further detail below. The quantified values of the baseline measurement of the color are then stored within the LED assembly and available to the system for compensation to the driving input parameters to produce an accurate and repeatable output throughout the life of the system.
[0053] The present inventor developed a process shown in FIG. 4 that uses a test system 40 of FIG. 5 . The process of FIG. 4 is performed after assembly of all LEDs and other control electronics but prior to shipment at the manufacturing facility.
[0054] In the process each individual LED assembly 100 is loaded onto a manufacturing test system 40 (see FIG. 5 ) at the beginning of the process, step S 111 (see FIG. 4 ). The test system 40 includes a holder 42 for constraining the LED assembly 100 a fixed distance, d, from an optical measurement instrument 45 . A shield 44 directs the light, and prevents stray light entry to the optical measurement instrument 45 .
[0055] The test system 40 also includes control electronics as well. The control electronics are divided between a customized interface box 41 and the internal circuitry of a customized computer or workstation 46 . The test system 40 control electronics include a measurement device for measuring the current temperature, a control device for controlling the LEDs, a measurement device for measuring voltage, and a device for writing data to a memory of the LED assembly, which can be accommodated in the interface box 41 , the workstation 46 , or on control electronics internal to the LED assembly 100 .
[0056] After loading the LED assembly 100 into the test system 40 , the process directs the control circuitry to drive all of the Red LEDs and only the Red LEDs, step S 112 . The control circuitry for this process can either be internal to the LED assembly 100 or internal to the test system controller workstation 46 . The allRed output is then measured in step S 113 with the optical measurement device 45 , which for example may include a spectrophotometer. The CIE coordinates for the allRed output and the forward voltage at the allRed are measured in step S 113 . Step S 114 is similar to step S 112 except that only all the Green LEDs are driven by the control circuitry. The CIE coordinates of the output for allGreen and the forward voltage for allGreen are measured in step S 115 by the optical measurement device 45 . Process step S 116 is also similar to step S 112 except that only all the Blue LEDs are driven by the control circuitry. Step S 117 measures the allBlue optical output and the allBlue forward voltage. The steps S 112 , S 114 , and S 116 may be easiest to implement if all the Red, Green, and Blue LEDs are driven at 100% maximum input condition. However, because LED flux output is mathematically related to its input current, the processes could be implemented with proportionately lower inputs. All optical measurements are preferably taken after the system has reached a steady state. Alternatively, a varying pulse width can be utilized to drive the LEDs and steady state output performance can be extrapolated from there. Steps S 113 , S 115 , and S 117 could be implemented with any appropriated Color Coordinate System as described below.
[0057] Temperature and/or other relevant environmental data are then measured in step S 118 using a temperature measurement device 47 . The environmental data is measured to indicate the environmental conditions which result in the measured outputs of the LEDs. For example, LED output will vary based on temperature, so it is relevant to know for the measured optical outputs of the Red, Green, and Blue LEDs in steps S 113 , S 115 , and S 117 what the temperature is at the time of measurement. The environmental measurement of step S 118 is then used in a compensation algorithm 24 to control driving of the LEDs, as discussed below with reference to FIG. 6 . The algorithm accommodates the optical output change resulting from intensity changes and dominant wavelength changes with temperature. Future changes away from the baseline environment can be corrected by the below discussed compensation algorithm 24 .
[0058] All of the measured information is then stored internal to the LED assembly 100 in step S 119 . The stored information is represented by the following variables described below, using CIE values (x, y, Y), V f for forward voltage, and T for temperature.
(x r , y r , Y r ′) V fr , (x g , y g , Y g ′) V fg , (x b , y b , Y b ′) V fb , T
[0059] All of the stored information can be written in step S 119 as described or alternatively the stored information could be written to a memory device of the LED assembly immediately after they are acquired in steps S 113 , S 115 , and S 117 . This alternative is shown by the dashed lines in FIG. 4 .
[0060] Additional information about the performance of the unique light engine “as manufactured” can be stored internal to the system in step S 119 , e.g., possibly the date and time of the measurements or the serial number of the product. Storage of these initial measurements external to the system can also be performed. Duplicate data external to the LED assembly could be used in the repair or rework of an assembly or utilized for statistical analysis of the production variability. The process completes in step S 120 by unloading the LED assembly 100 from the test system 100 and proceeding with usage of the LED light engine assembly 100 .
[0061] With the above process, the present invention characterizes and records the LED assembly's specific light output information at the time of manufacture to record baseline color output of the LED assembly, which information is then used in an overall process of generating compensated light output in an LED assembly in FIGS. 6 and 7 . By so doing, an exact baseline of the displayed color can be made available to algorithms for color optimization.
[0062] FIGS. 6 a and 6 b and 7 show an LED assembly of the present invention which stores the data generated by the process in FIG. 4 , and which utilizes such data to generate an enhanced desired light output of the proper color. FIG. 7 shows a structure of an LED assembly 100 including LEDs 105 in LED light 101 and power supply 103 , in the present invention, and FIGS. 6 a and 6 b show control operations performed in that LED assembly 100 .
[0063] As shown in FIG. 7 , the LED assembly 100 of the present invention is similar to that in the background art of FIG. 1 , except the LED assembly 100 of the present invention includes enhanced control electronics 104 including an environmental sensor 106 and memory 109 . The memory 109 stores the data noted in step S 119 in FIG. 4 .
[0064] There are many ways that the information can be stored in the system, but one feature is that the “as manufactured” output information remains available to the optimization algorithms throughout the life of the light engine. The internal method of storing the information can be any of a number of memory devices. A Read Only Memory (ROM), a Programmable Read Only Memory (PROM), an Erasable Programmable Read Only Memory (EPROM), an EEPROM (an Electrically Erasable Programmable Read Only Memory), a Flash EPROMs, etc. can be used, as the memory 109 .
[0065] The control electronics 104 in FIG. 7 performs the operation shown in FIGS. 6 a , 6 b , as now discussed in further detail below.
[0066] A first embodiment of the overall control operation of the LED assembly 100 of the present invention as shown in FIG. 6 a is to utilize the stored baseline light output data of the Red LEDs, Green LEDs, and Blue LEDs that form the LED light 101 in conjunction with the stored environmental data, perform compensations based on the measured output of those lights and based on measured environmental values, and to output a desired light output.
[0067] In the operation, stored values for the allRed response, allGreen response, and allBlue response are retrieved in processes 21 - 23 . Those values correspond to the values stored in step S 119 in FIG. 4 . That retrieved information in processes 21 - 23 can be utilized by compensation and color mixing algorithms to allow a custom color generation to be realized.
[0068] More specifically, the retrieved stored values from processes 21 - 23 are provided to a process 24 that runs a compensation algorithm to predict an output under current environmental conditions based on the retrieved stored values. An output from that compensation algorithm 24 is then provided to a color mixing algorithm 25 . The color mixing algorithm 25 receives as an input a desired light output from a process 30 . Thereby, the color mixing algorithm 25 receives an indication as to a desired light output and can modify the color mixing to achieve that desired light output. The color mixing algorithm 25 then controls driving of parameters for the Red LEDs, Green LEDs, and Blue LEDs in processes 31 - 33 to output light of a desired specification in process 34 .
[0069] The compensation algorithm 24 and color mixing algorithm 25 are the control algorithms to achieve a desired color output and are either hard programmed with electronic circuitry or soft programmed with custom software internal to the control electronics 104 of the LED light engine assembly 100 . The color mixing algorithm 25 adjusts the duty cycle (D) and other parameters of each LED in processes 31 - 33 , effectively modifying the percentages of each base color to customize the color display. The duty cycle can be adjusted using any number of control techniques—including Pulse Frequency Modulation, Pulse Position Modulation, Amplitude Modulation, Phase Shift Modulation, and Pulse Width Modulation (see e.g., U.S. Pat. No. 6,016,038 to Color Kinetics).
[0070] Operating the compensation algorithm 24 and color mixing algorithm 25 in combination with retrieving the stored optical parameters in processes 21 , 22 , and 23 resolves many of the performance issues of LED light engine assemblies. The compensation algorithm 24 can be applied to account for temperature variations in the optical output. Similarly, the lifetime degradation of LEDs can be overcome algorithmically in the compensation algorithm 24 . That is, the compensation algorithm 24 can consider current environmental conditions, aging of the LED, etc., and can compensate the light output of the LEDs for such current conditions. For example light output of LEDs drops with temperature. Therefore, if the current temperature at the LED assembly 100 is higher than when the LEDs were tested, i.e., higher than the temperature stored in step S 119 in FIG. 4 , then the compensation algorithm 24 can control to increase the driving power of each of the LEDs to compensate for the decreased intensity resulting from the increased temperature. Similarly, the compensation algorithm 24 can factor the age of the LEDs and increase the driving current (I) to the LEDs 105 as the LEDs 105 age. The compensation algorithm 24 can perform other compensations based on other environmental conditions, for example humidity, and other factors as needed.
[0071] Further, difficulties of recipes and binning can be accommodated by appropriate application of the color mixing algorithm 25 . The compensation algorithm 24 and color mixing algorithm 25 can provide for calculations of the compensated light rendering process because of an accurate known starting point. That is accomplished in the process of the present invention.
[0072] A specific non-limiting example of specifics of color mixing algorithm 25 that can be implemented in the present invention is as follows.
[0073] The color mixing algorithm 25 begins with the target color specified for display.
Targeted Color Coordinates (x t , y t , Y t ′) (151)
[0074] The CIE Chromaticity coordinates (x, y, Y′) of the spectral input for allRed, allGreen, and allBlue are also known to the algorithm, see steps S 113 , S 115 , S 117 in FIG. 4 .
Measured (x r , y r , Y r ′), (x g , y g , Y g ′), (x b , y b , Y b ′) (152)
[0075] The desired output is the duty cycle of the allRed, allGreen, and allBlue LED assemblies for display of the target color and the driving current.
Find (D r t ′, D g t ′, D b t ′) and I (153)
[0076] The derivation and details for a non-limiting implementation of the color mixing algorithm 25 is as follows.
[0077] First, z need not be given for any of the colors because of the following defining equation.
x+y+z= 1 (154)
z=1− x−y
[0078] Linear proportionality constants (weighting factors) for the relationship between the output intensity and y coordinate for allRed, allGreen, and allBlue are calculated.
m r =( Y r ′/y r ) (155)
m g =( Y g ′/y g )
m b =( Y b ′/y b )
[0079] The proportionality constants are used to calculate the CIE coordinates of the combination of allRed, allGreen, and allBlue—ideally a true white color.
x w = x r m r + x g m g + x b m b m r + m g + m b
y w = y r m r + y g m g + y b m b m r + m g + m b
Y w ′ = Y r ′ + Y g ′ + Y b ′ ( 156 )
[0080] CIE coordinates are converted to Tristimulus values. Tristimulus values are a similar coordinate system for describing the color that is not normalized. The relationship between the 2 coordinate systems is defined by the following equations (157).
Y=Y′ x=X /( X+Y+Z ) y=Y /( X+Y+Z ) z=Z /( X+Y+Z ) (157)
[0081] The following general equations can be quickly derived from equations (154) and (157) above.
X Y = x y
Z Y = z y
Z Y = ( 1 - x - y ) y ( 158 )
[0082] The general equations (158) above create the specific equations for the Tristimulus values X, Y, Z for allGreen, allRed, allBlue and the resultant white shown as equations (159). It is important to note that this white may not necessarily appear white. The degree to which it is truly white will depend on how evenly balanced the 3 stimulus colors are around the center coordinates of white (0.333, 0.333, 0.333).
X r = x r Y r ′ y r Y r = Y r ′ Z r = ( 1 - x r - y r ) Y r ′ y r
X g = x g Y g ′ y g Y g = Y g ′ Z g = ( 1 - x g - y g ) Y g ′ y g
X b = x b Y b ′ y b Y b = Y b ′ Z b = ( 1 - x b - y b ) Y b ′ y b
X w = x w Y w ′ y w Y w = Y w ′ Z w = ( 1 - x w - y w ) Y w ′ y w . ( 159 )
[0083] The same equations can be used to convert the given CIE values of the target color to (x t , y t , Y t ′) to Tristimulus values of (X t , Y t , Z t ) as below.
X t = x t Y t ′ y t Y t = Y t ′ Z t = ( 1 - x t - y t ) Y t ′ y t ( 160 )
[0084] Scale Factors (S r , S g , S b ) are required for the transformation matrix M and are calculated from the known values on the right hand side of equation (160) as follows.
[ S r S g S b ] = [ X w Y w Z w ] [ X r Y r Z r X g Y g Z g X b Y b Z b ] - 1 ( 161 ) [ M ] = [ S r X r S r Y r S r Z r S g X g S g Y g S g Z g S b X b S b Y b S b Z b ] ( 162 )
[0085] The [R t G t B t ] for the target color is the amount of Red, Green, and Blue in the target color and could be used to describe the color if an RGB specification system were utilized as follows.
[ R t G t B t ]=[X t Y t Z t ] [M] −1 (163)
[0086] The duty cycle, D, of each of the colors is calculated below. For ease of implementation, one of the three duty cycles for allRed, allBlue, or allGreen is always defined as 100%. The other two duty cycles are scaled to keep similar RGB proportions.
D r t =R t /max( R g ,G t ,B t ) D g t =G t /max( R t ,G t ,B t ) D b t =B t /max(R t ,G t ,B t ) (164)
[0087] Further simplifying for the instance when [S r , S g , S b ]=[1.0, 1.0, 1.0], the instance is relevant when the design requirements state that the combination of allRed, allGreen, and allBlue does not have to be a pure white.
c = x b ( y g - y r ) + x g ( y r - y b ) + x r ( y b - y g )
R t = - y r ⌊ x b ( y t - y g ) + x t ( y g - y b ) + x g ( y b - y t ) ⌋ y t · Y r ′ · c
G t = y g [ x b ( y t - y r ) + x t ( y r - y b ) + x r ( y b - y t ) ] y t · Y g ′ · c
B t = y b [ x t ( y g - y r ) + x g ( y r - y t ) + x r ( y t - y g ) ] y t · Y b ′ · c
D r t = R t / max ( R t , G t , B t )
D g t = G t / max ( R t , G t , B t )
D b t = B t / max ( R t , G t , B t )
[0088] The present equations have only related to the generation of the color and not to the intensity of the color. The target color intensity is expressed by Y t ′. Adjustments for intensity are calculated as follows:
Y total ′=Y r ′+Y g ′+Y b ′
[0089] I ref is the driving current specified by the LED manufacturer and used in the manufacturing testing process to generate the stored values for processes 21 , 22 , and 23 of FIG. 6 .
Case 1: If Y total ′≧Y t ′ then the following equations apply. The duty cycles are downscaled appropriately to account for the intensity.
D r t ′ = Y t ′ Y total ′ D r t
D g t ′ = Y t ′ Y total ′ D g t
D b t ′ = Y t ′ Y total ′ D b t
I = I tested
Case 2: If Y total ′<Y t ′ then the following equations apply. The driving current is upscaled appropriately to accommodate the additional required brightness.
D r t ′ = D r t
D g t ′ = D g t
D b t ′ = D b t
I = Y t ′ Y total ′ I tested
[0092] The targeted color is therefore displayed for both case 1 and case 2 using the duty cycles (D r t ′, D g t ′, D b t ′) and the driving current I.
[0093] FIG. 6 b shows a modification of the embodiment of FIG. 6 a , which can be applied to a device including different colored LEDs of Red LEDs, Blue LEDs, Green LEDs, and Amber LEDs. That is, instead of having a system with only three colors of Red, Blue, and Green, a system can incorporate four colors of Red, Blue, Green, and Amber. In those circumstances the operations shown in FIGS. 3 a , 3 b , and 4 will also perform operations directed to the Amber LEDs similarly as for the Red, Green, and Blue LEDs. As a result, measured optical values stored in memory will also include data for the Amber LEDs, and thus in FIG. 6 b an additional operation of retrieving the all Amber response in process 26 is executed, and then in process 34 the duty cycle and other parameters of the Amber LEDs are also adjusted similarly as for the Red, Green, and Blue LEDs.
[0094] The present invention is not even limited to such an embodiment with four colors, but any number and colors can be used in any desired combination.
[0095] A previous example assembly is now used for the discussion on the present invention. Assume a previous assembly includes several Red LEDS, several Green LEDs, and several Blue LEDs. Additionally, for ease of explanation the combined output from all Red LEDs shall be referred to as the allRed Output. If there is only one Red LED then the output of the Red LED and allRed will be equal. Similarly, the display of all Green LEDs shall be referred to as allGreen and all Blue LEDs as allBlue.
[0096] The process of the present invention allows the generation of an exact, known, starting point or baseline of the color output and internal storage of that known starting point within the system. The light output of a specific LED assembly is initially stored internal to the assembly on an appropriate memory device. This initial point can be utilized by an appropriate compensation algorithm 24 and an appropriate color mixing algorithm 25 at any later point in time to produce a desired color match.
[0097] The process of the present invention involves storing the specific light output description internal to the LED light engine assembly, by the process of FIG. 4 , which is then used for custom color rendering. Then, in operation of the LED assembly 100 the stored data are retrieved in processes 21 , 22 , and 23 of the compensated light process of FIG. 6 . By so doing, an exact baseline of the displayed color can be made available to the compensation algorithm 24 and color mixing algorithm 25 . The processes S 113 , S 115 and S 117 of FIG. 4 generate the CIE coordinates of allRed, allGreen and allBlue, and the processes 21 , 22 and 23 of FIG. 6 utilize the CIE coordinates of allRed, allGreen and allBlue.
[0098] The allocated memory 109 for storing the initial optical performance information can be a dedicated single component. Alternatively, the information can be combined with other system information and added to the storage components that already reside in the system. For instance, the stored output of the manufacturing process of the present invention could be added to the firmware of the control system and stored on the same physical device as the firmware.
[0099] Color specifications in the process of FIG. 4 can be transmitted using the CIE Color Coordinate System. There are other universal color coordinate systems that are device independent that could also be utilized to quantify the light source. The Lab Model uses Lightness (L), an (a) coordinate along a green to red spectrum, and (b) coordinate along a blue to yellow spectrum. The Munsell Color System uses three coordinates of Hue (H), Value (V), and Chroma (C). The present invention does not exclude the usage of any of these universal color coordinate systems, but that the CIE System is believed to be the most effective at communicating an exact color.
[0100] If another coordinate system is used then the measured and stored values would not be exactly the variables listed below
(x r , y r , Y r ′) V f , (x g , y g , Y g ′) V f g , (x b , y b , Y b ′) V b b , T
[0101] Conceptually, they would be similar values describing the color but in a new coordinate system. For instance for an Lab Model they would most likely be
(L r , a r , b r ) V f r , (L g , a g , b b ) V f g , (L b , a b , b b ) V b b , T
[0102] And for the Munsell System they might be
(H r , V r , C r ) V f r , (H g , V g , C g ) V f g , (H b , V b , C b ) V b b , T
[0103] There are a number of different Color Coordinate System standards based around the 3 colors of Red, Green, and Blue. Examples of standard RGB color spaces include ISO RGB, sRGB, ROMM RGB, Adobe RGB, Apple RGB, and video RBG spaces (NTSC, EBU, ITU-R BT.709). But none of these standards are universal, and there may never be a universal RGB standard because the needs of different applications (scanners, digital cameras, monitors, printers) are different. There are also CMYK color standards based on proportions of Cyan, Magenta, Yellow, and Black. The CMYK standards suffer from the same lack of universality disadvantage as the RGB standards. Any of these standards could be used for the color description of the present invention, but the CIE Color Coordinate System may be the preferred implementation because of its more universal acceptance.
[0104] The process described above with respect to FIG. 4 shows obtaining data for a system with up to three colors, and FIG. 6 b shows application for a system with up to four colors. There is no requirement that the system include only these colors but any number of colors can be incorporated. A more generalized process that can be performed in the present invention is shown in FIG. 8 , which essentially achieves the same results as the process of FIG. 4 , but which can be applied to as many colors as desired with different environmental conditions.
[0105] The more generalized process of FIG. 8 has the same goal as the process of FIG. 4 . Step S 131 begins the generalized process by loading the LED light engine assembly 100 into the test system 40 . Step S 132 is the beginning of an “outer loop” iteration function designed to quantify the relevant, baseline optical properties across a number of environments. If only one environment is baselined as in the specific example above, then the number of environments is one and the iteration loop is only performed once. The environments can either be controlled, as in a thermal and humidity test chamber, or uncontrolled, as the LED die temperature at the time of manufacture. Relevant environmental variations might be temperature, humidity, system “on time”, altitude, or any other environmental condition. Step S 133 quantifies the relevant environmental condition either using an environmental sensor, e.g. temperature sensor 47 . Step S 134 begins another “inner loop” iteration function for each base color. In the specific examples, the number of base colors is three or four (Red, Green, Blue, and optionally Amber) and the iteration loop is performed three or four times.
[0106] Step S 135 drives all of the LEDs of a single base color. In general the LEDs are all driven with 100% input current and measured. Other values of inputs could be used with linear, logarithmic, or other appropriate scaling applied in the subsequently executed algorithms. In step S 136 the light output and forward voltage is measured and quantified for the combination of base color and environmental condition being tested. Step S 137 records the measured values of step S 136 to memory 109 . The storage to memory in step S 137 could occur after each measurement is taken or collectively after all measurements have been taken. The “inner loop” iteration function of step S 138 repeats the process for each base color. The “outer loop” iteration function of step S 139 repeats the process for each environmental condition. Each environmental condition for example could be temperature of an ambient temperature value, a hot temperature value, and a cold temperature value. The “inner loop” and “outer loop” functions can be swapped as long as all of the base colors and environments are quantified. Step S 140 concludes the process by removing the LED light engine assembly 100 from the test system 40 . At the conclusion of step S 130 the internal memory 109 now includes baseline optical performance of the specific LED light engine assembly.
[0107] By including the baseline optical performance of the unique LED light engine assembly internal to the control electronics, improvements can be made in the manufacturing, the functioning, and the quality of light output of an LED assembly. Referring to FIG. 7 , each LED light engine assembly has in memory 109 the starting point of the optical output of its installed LEDs 105 under known environmental conditions. Without the stored values generated by the processes 21 , 22 , 23 , 26 of the present invention, an assumed value, like the average optical output of a set of LEDs, would be required for the starting point of the compensation algorithm 24 and the color mixing algorithm 25 . The result of using the generated set of stored values is a considerably improved process for the following reasons: an infinite number of targeted output colors can be rendered by utilizing the known starting point of the unique LED assembly and applying color mixing algorithms; accuracy of the rendered color is improved because the color mixing algorithms begin with the known starting point of optical color performance; repeatability of the target color is improved because compensation for intensity degradation over a product lifetime can be applied from the known starting point; color rendering is more repeatable because compensation to account for wavelength variations and intensity variations with temperature can be applied from the known starting point; recipes and binning can be reduced or eliminated because the LED light engine assembly can perform algorithms to compensate for the manufacturing variations of the individual LEDs.
[0108] The end result is an LED light engine assembly capable of rendering more colors accurately and repeatably while improving costs and manufacturability.
[0109] The features of the embodiment of the present invention noted above are directed to manufacture an LED assembly in which the inputs of the color mixing algorithm 25 utilizes the retrieved stored values 21 - 23 and 26 input into compensation algorithms 24 to predict output.
[0110] However, in a further embodiment of the present invention the input to the color mixing algorithm 25 can be from a different source, and can undergo further compensation prior to the signal being input into the color mixing algorithm 25 .
[0111] Such a further embodiment of the present invention is shown in FIG. 8B .
[0112] In FIG. 8B the color mixing algorithm 25 can receive an input signal from different initial LED spectral response options and after different compensation options.
[0113] As discussed in further detail now, the LED spectral response values are a starting point for an input signal to the color mixing algorithm 25 . The embodiment shown in FIG. 6 b corresponds to the LED spectral response being measured at assembly, noted as 213 in FIG. 7 . That is, the measured at assembly 213 LED spectral response corresponds to the retrieved stored values 21 , 22 , 23 , and 26 in FIG. 6 b . As noted above, utilizing such measured values at assembly requires a pre-testing of the LEDs in the assembly and storing data of different responses of the LEDs. Certainly, simpler options could, however, also be implemented.
[0114] In a simplest process an LED spectral data from a supplier 211 can be utilized. Such data could be the bin data from the LED manufacturer. This is of course the simplest option as it relies on the supplier to provide the relevant data. Of course this option is probably also the least reliable because of the difference in the LEDs even in the binning process as discussed above.
[0115] A further alternative is to provide an average LED spectral data 212 based on experimental data about the LEDs or group of LEDs. Currently, LED technology may not yield an acceptable output of the average data, but even though the variability from any one LED to a next LED may be quite large, the variability of large groups of LEDs diminishes with the size of the groups. With improvements to LED technology and the uses of larger groups of LEDs, the average LED spectral input 212 may yield an acceptable starting LED spectral response.
[0116] After the LED spectral response different compensation options can be utilized.
[0117] The simplest option is no compensation 221 and may be relevant shortly after an LED light engine assembly has been put into service and a temperature is close to a testing temperature. The testing temperature could be the temperature of a supplier testing, average testing, or of the assembly testing depending on the choice of spectral inputs 211 , 212 , and 213 . The no compensation 221 option is the simplest but will not provide the highest level of performance.
[0118] A further compensation option is a time compensation 222 on spectral values to compensate for the effects of time based degradation. That is, LEDs degrade over time as is known, and such time degradation is typically logarithmetic and predictable. Based on the mathematical relationship of degradation in intensity and the usage time of the LED light engine assembly, an LED stimuli can be converted to new predicted LED stimuli at a current time period. As time progresses the intensity of the light output decreases and a typical LED degradation over a first year may be 20%-30%, which is significant enough to warrant a correction. This time compensation option 222 does not provide a temperature compensation.
[0119] A next compensation option is a temperature compensation 223 to correct the effects of temperature based degradation. Temperature has two different effects on LED light output. The first effect is on the light output and is a quadratic relationship in the area of interest. Temperature is an independent variable. An output intensity is a dependent variable of the quadratic equation. The coefficients of the quadratic equation vary with different base color LEDs because a semi-conductor compound is different with each base color. The base color can be determined from the CIE coordinates of the spectral response or from the wavelength by either a look-up table or it can be pre-programmed into electronics. Coefficients of the quadratic equation can then be measured by the semi-conductor manufacturer or assembler and are constant over time and temperature. The result is an algorithm that relates to changes in temperature at the LED light engine to drops in output light intensity. If I is normalized to 1 at room temperature and temperature is expressed as ° C., then a sample equation for a InGaN LED device is:
I=− 0.000004 T 2 .0.029 T+ 1.0477.
[0120] A second effect of temperature that is compensation with the temperature compensation option 223 is on wavelength. A base color can be determined from a wavelength or CIE coordinates by either a look-up table or it can be programmed into electronics. Temperature increases also increase the peak wavelength and increase the breadth of the wavelength response. Wavelength increases linearly with temperature increases in the region of interest. The rate of change, K, can be approximately constant for each base color.
[0121] A further final compensation option which is the most complex but which provides the highest quality results is the time and temperature compensation 224 to correct the spectral input for both time based degradation to output light intensity and temperature related effects described above. The time and temperature compensation 224 option combines the effects of time compensation 222 option and temperature compensation 223 option.
[0122] The output of the compensation option is then provided to the color mixing algorithm 25 . Such options allow providing the most accurate representation of LED stimuli for the starting point for the color mixing algorithm 25 . Utilizing the time and temperature compensation 224 option will yield the most accurate color rendering as it will correct for both time based degradation and temperature induced changes in light output of an LED.
[0123] The above-noted features in the present invention are directed to manufacturing an LED assembly to properly output light. A further feature of the present invention is to insure that a specific desired color of light can be output consistently by an LED light assembly. Such a feature may have particular application for example in architecture, stage, theatrical, live shows, and production lighting. In such applications it may be particularly desirable to insure that light output from an LED light source is of a specific color, and that that specific color is maintained. Such a concept of outputting light of a specific color is often referred to as color rendering.
[0124] Color rendering in modern technology was first accomplished as an additive process of Red, Green, and Blue (RGB). Early rendering produced color by combining appropriate amounts of Red, Green, and Blue to display television images. RGB systems are used for both the generation of color and the specification of color. This is an important distinction. RGB systems are commonly used to create a color, but they are also used to specify a color.
[0125] The prevailing systems to specify color resulted from the usage of the RGB generation systems. When the color is produced as a combination of RGB, the simplest and easiest way to specify the color is the amount of RGB in the target color. The RGB specification systems, out of ease of implementation and response speed, resulted from the RGB generation systems. But RGB specification systems have deficiencies.
[0126] An RGB implementation has a limited range of displayed color. FIG. 9 shows an example RGB color specification on the CIE Chromaticity Chart. All CIE specifiable visible colors are represented by region 56 . RGB specifications are limited to colors that can be represented as a combination of Red, Green, and Blue. The RGB specifiable colors are shown in triangle 54 . Many colors can be represented by the summation of Red, Green, and Blue inside the triangle 54 , but many colors, those outside the triangle, can not. These colors are represented in the surrounding Region Outside of the RGB Specifiable Area 55 . The CIE Specifiable Region 56 is the sum of the RGB Specifiable Triangle 54 and the Region Outside the RGB Specifiable Triangle 55 . The salient point is that with an RGB color specification system the colors in region 55 can not be generated or specified. With an RGB specification, it is as though the colors of region 55 do not exist.
[0127] One further feature in the present invention is to realize a system that allows specifying all such colors in CIE Specifiable Region 56 , as discussed further below.
[0128] Different RGB standards have been developed for different applications. The primary difference between the RGB standards is the definition of the base colors. The Red defined by one system may be a few shades different from the Red of another system—and likewise for Green and Blue. Examples of standard RGB color spaces include ISO RGB, sRGB, ROMM RGB, Adobe RGB, Apple RGB, and video RGB spaces (NTSC, EBU, ITU-R BT.709). It is unlikely that there will ever be a universal RGB standard because the needs of different applications (scanners, digital cameras, monitors, printers, televisions) are different.
[0129] FIG. 10 demonstrates the effect on color rendering of different RGB color specification systems. The RGB Gamut of FIG. 9 is replicated in FIG. 10 and is assumed to be any one of the RGB color specification systems mentioned above. It is labeled RGB Specification System 1 with RGB extents at Standard Red 1 , Standard Green 1 , and Standard Blue 1 . A second RGB Specification System 2 is overlain onto the FIG. 10 with RGB extents at Standard Red 2 , Standard Green 2 , and Standard Blue 2 .
[0130] Because of their basis in a standard Red, standard Green, and standard Blue, custom colors specifications using RGB specifications are only as good as the definition of the standard colors. A custom color specified by RGB System 1 as Red 20%, Green 80% and Blue 0% is shown graphically as 46 and is 20% of the traversal along the line interconnecting Standard Green 1 and Standard Red 1 . A custom color specified in the same manner with RGB System 2 as Red 20%, Green 80% and Blue 0% is shown graphically as 47 and is 20% of the traversal along the line interconnecting Standard Green 2 and Standard Red 2 . Although both colors are specified the same way, the resulting colors 46 and 47 are differentiable because of the different standard Red, Green, and Blue. A custom color of Red 33%, Green 33%, and Blue 33% 48 as specified by RGB System 1 is discernibly different from Red 33%, Green 33% and Blue 33% 49 as specified by RGB System 2 . If RGB System 1 is used by a Cathode Ray Tube (CRT) manufacturer and RGB System 2 is used by a Liquid Crystal Display (LCD) manufacturer (R 20 , G 80 , B 0 ) will be displayed differently on the CRT monitor than the LCD monitor. The target color is not repeatable. The conclusion from FIG. 10 is that the resultant color output is highly dependent on the RGB standard and is not necessarily repeatable.
[0131] The engineering of a color rendering device usually dictates the specific RGB standard. For instance, CRTs for television and computer monitors use a beam splitter to divide white light into its Red, Green, and Blue components. The physics of the beam splitter dictates the CIE Color Coordinate System definition of the Red, Green, and Blue standards for color generation. Liquid Crystal Displays (LCDs) similarly divide each pixel into Red, Green, and Blue sub-pixels. The RGB sub-pixels are created through white light filtering. Similar to CRTs, the design and physics of the filtering process for LCDs mandates the selection of the RGB standards for color generation. The color rendering device design of the beam splitter or the filter, for instance, imposes the RGB standards. Vice-versa, the rendered color output from RGB standards is dependent on the device design.
[0132] The most common communication protocol for architectural, stage, theatrical, live shows, and production lighting is DMX512. The packet structure of DMX512 is shown in FIG. 11 . The protocol allows the transmission of 8 bits (one byte) of information for up to 512 addresses at 250,000 bits/second (bps). The packets also contain header information at the beginning of the packet and trailing check sum information. In a traditional implementation of DMX512, each light source may require several bytes of information for controlling the color wheel location, pan, tilt, dimmer or other relevant control information.
[0133] The 512 addresses available in each packet are fixed. For example, a typical lighting system may be composed of several light sources A, B, C, etc. The first address of the 512 available may be defined to be the 8 bit binary control for the dimmer of light source A. Once this assignment is made, the first address location must continue to be used for the dimmer control of light source A for each and every future packet transmitted. Likewise, the second address, once assigned, must for example be the pan control of light source A for each and every packet. The address locations are physically wired with cabling and additions beyond 512 addresses require the cost and labor of more cables.
[0134] The above mentioned communication protocol was intended for theatrical lighting systems with a finite number of lights each with a color wheel, a dimmer, and possibly pan or tilt capabilities. Extensions of DMX512 currently exist and utilize DMX512 with 8 bit control of each color input—Red, Green, and Blue. To transmit a custom color definition, the color is broken into its constituents—a Red component, a Green component, and a Blue component. Each component is defined on a scale of 0 to 255 with 0 indicating no contribution of that color and 255 indicating a maximum (100%) contribution of the color. After transmission the receiving hardware sums the Red, Green, and Blue components to render a custom color for the user.
[0135] One of the difficulties with an RGB implementation of DMX512 protocol is the definition of a standard RGB color space. With the utilization of a RGB color coordinate system there is a huge potential for miscommunication with lighting consoles from different manufacturers transmitting color specifications to fixtures from other manufacturers. To produce accurate color rendering the sending and receiving hardware must both be communicating with the same RGB standard. With so many RGB standards in existence this may be a formidable task.
[0136] The use of an RGB implementation over DMX512 is not ideal for communication with LED light sources because it requires three bytes of information, as a minimum, for each LED light source. One byte control is also needed for each of RGB. Each light source therefore consumes at least 3 bytes of the available 512 addresses, inferring that an RGB implementation of DMX512 protocol allows for communication with a maximum of 170 LED light sources (512/3=170).
[0137] A further feature of the present invention is a communication protocol capable of transmitting exact color specifications and control information for LED light engine assemblies. The color specifications are capable of specifying any visible color and are not limited to colors that are a sum of Red, Green, and Blue components. The color specifications are repeatable and device independent. The color specification data can be communicated dynamically in real time across existing computer or telecommunications networks. To implement such a system, the LED light engine assemblies each contain a unique address and control hardware and software to render the specified color.
[0138] Computer or telecommunications networks do not generally transmit light control information to LED light engines assemblies. Some early attempts to do such have been marginally successful, but their primary downfall, as recognized by the present inventor, has been defining the color using a color specification of a summation of Red, Green, and Blue components. As discussed above, RGB color specifications are not standardized, repeatable, or device independent. Additionally, RBG color specifications do not address all visible colors. A secondary downfall of early attempts, as recognized by the present inventor, has been the transfer of a limited DMX512 lighting protocol to the computer network rather than adapting a current computer network protocol to LED light engine assemblies.
[0139] In a further feature the present invention develops a protocol for communicating precise color specifications to LED light engine assemblies. Each assembly contains a unique address or name so that it can discern specifications intended for its own use versus specifications intended for other LED light engine assemblies in the lighting system. All colors that are visible to the human eye can be specified using the color specifications. This is in contrast to current systems that only use the sum of Red, Green, and Blue color and that contain only 256 options for a Red component, 256 options for a Green component, and similarly 256 options for a Blue component. The light specifications are conveyed in the data portion of existing computer and telecommunications networks and are transmitted dynamically in real time to the LED light engine assemblies.
[0140] Specific details of a first implementation are now discussed. The present invention is not intended to be limited to this implementation, but the details of the first implementation add to further understanding of the present invention.
[0141] A first implementation utilizes an Ethernet based communication protocol traveling at 10 Million bps or Fast Ethernet traveling at 100 Mbps-40 or 400 times the speed of DMX512. This implementation travels on Ethernet networks as portrayed in FIG. 12 . A number of LED light engine assemblies 10 labeled A-H are connected to an existing topology or network 77 , to which any number of computers or workstations 11 can also be connected. A lighting control console 78 is also attached to the network 77 . The lighting control console 78 can be similar to the consoles of DMX512, a dedicated computer for lighting control, or an existing computer with LED light-specific control hardware and software. The topology or network 77 can be a Bus Topology as shown in FIG. 12 , a Hub and Spoke (Star) Topology, a Wireless System, or other acceptable network topology. The increased data communication rate of Ethernet can provide an advantage in such an implementation of the present invention.
[0142] The addition and interconnection of LED light engine assemblies 10 to any network topology similar to network 77 is also beneficial because of the prevailing use of computers, the internet, cell phone networks, and wired and wireless connectivity in today's society. The protocol of this first implementation is Ethernet based and is intended to operate on Ethernet connectivity systems. Hence, a lighting system using the architecture of the present invention can be easily added to any facility (i.e. office building, conference center, nightclub, theater, home, etc) with an existing Ethernet infrastructure.
[0143] Color specifications in this implementation in the present invention are preferably transmitted using the (x, y, Y′) coordinates of the CIE Color Coordinate System, thereby using a universal color coordinate system, rather than any of the aforementioned RGB standards. Integer or floating point representation of the lighting specification data can be used. Integer representation using 16 bits can be chosen. Floating point requires at least 32 bits and is more costly and less efficient than integer arithmetic. Values can be converted to integers by scaling appropriately at the source and destination.
[0144] There are other universal color coordinate systems that are device independent and that could also be utilized to describe the light output. The Lab Model uses Lightness, an “a” coordinate along a green to red spectrum and a “b” coordinate along a blue to yellow spectrum. The Munsell Color System uses three coordinates of Hue, Value, and Chroma. Any of the aforementioned RGB standards or CMYK standards (Cyan, Magenta, Yellow or Black) could also convey the target light output, but the lack of universality and device dependency of both RGB and CMYK systems compromises the quality of the light output. The present invention is not limited to the usage of a specific color coordinate system, although the CIE System may be the most effective.
[0145] LED light engine assemblies of the current state of the art do not contain an internal address. To implement any communication scheme, each LED light engine assembly must contain an electronic address that is configurable for each assembly. Such an implementation is shown in FIG. 13 in which an electronic address 20 is added for this embodiment of the present invention. In this way, each assembly 10 on the network 77 will have a unique address. The address 20 is how the lighting control console 78 refers to individual of the LED light engines 10 when communicating directives.
[0146] FIG. 13 shows the LED assembly 10 including the configurable address 20 . In addition, as shown in the dashed lines in FIG. 13 the LED assembly can also include the memory 109 such as in the embodiment of FIG. 7 . That is, the LED assembly 10 does not necessarily require the memory 109 storing the premeasured data as noted above, but such a memory 109 can be added to achieve all the benefits of the embodiment discussed above with respect to FIGS. 1-8 in the present specification.
[0147] With DMX512 there is a maximum of 512 addresses and the address locations can not be interchanged from one packet to the next. Communicating with additional address locations using DMX512 requires the addition of extra cabling. The present invention can preferably use an Ethernet-like specification to broadcast color specifications to the LED light engine assemblies 10 .
[0148] FIG. 14 details the structure of an Ethernet Frame communicated over the network topology of FIG. 12 or some similar network topology. There are several different versions of Ethernet, including Ethernet 802.3, Ethernet II, Ethernet 802.2, and Ethernet SNAP, but the frame contents are similar. The 64 bit Preamble field 101 signifies the beginning of a frame and synchronizes the frame with the network. The 48 bit Destination Address field 91 identifies the recipient of the data frame. The 48 bit Source Address field 103 identifies the sender of the data frame. Some of the Ethernet versions use the 16 bit field 104 for specifying the Type and some use it for specifying the Length field. Type fields describe the device specific data to follow. Length fields quantify the size of the data. The Data field 92 contains the information to be transmitted from the source to the destination and can be in the range of 46 to 1500 bytes. The 32 bit Frame Check Sequence 106 verifies the data and allows the recipient to check for the possibility of corruption in the transmission.
[0149] One implementation for light generation would be to use the Ethernet frame as described above—each frame containing a Preamble, a Destination Address, a Source Address, Type or Length control, Data, and a Frame Check Sequence. The minimum amount of data in each packet is 46 bytes of information. Each LED light engine assembly 10 is a destination, containing a configurable destination address 20 . The light output of each LED assembly 10 is controlled by a lighting control console 78 transmitting color specifications. However, the transmitted data for a stationary light source will typically be only 6 bytes-2 bytes (16 bits) each for the (x, y, Y′) CIE coordinates. The additional bytes up to a total of 46 bytes must be padded with zeroes. In this case, there would be 6 bytes of information and 40 bytes of padded zeroes; the inefficiency of which is obvious.
[0150] A modification that can be implemented in this invention modifies the Ethernet Frame for use with a large number of destinations and a small amount of data to be sent to each destination. The various segments of the modified frame of the present invention are as detailed below:
(1) Preamble: as defined in the Ethernet Specifications; (2) Destination Address: a binary series indicating a broadcast message that should be read by all of the light engines; (3) Source Address: the binary location of the source generating the frame; (4) Type or Length: as defined in the Ethernet Specifications; (5) Data: 46 to 1500 bytes of information being sent to a number of different destinations; The data shall include the destination address as well as the control information for the destination, detailed further below; and (6) Frame Check Sequence: as defined in the Ethernet Specifications.
[0157] An example of the communication frame for such an implementation in the present invention can be as follows. First, assume there is an architectural lighting system in a large office building composed of light sources A, B, C, etc., and that all of the light sources are stationary—that is they are not capable of traversing along a rail, panning, or tilting. In that usage a system utilizing a single packet of information 100 as depicted in FIG. 15 can be implemented. The destination address 111 for the light control information is embedded into the body of the data block 105 . The field intended to contain the destination address 111 further contains binary data indicating that it is broadcasting lighting specifications. The indicator of a broadcast packet would signal the light sources to read and evaluate the entire transmitted frame because the data field contains lighting control information. The data field 92 of the Ethernet-like protocol for stationary light fixtures contains data in Light Data Groups 105 , including:
[0158] Destination Address field 111 of the light source to display the specified color;
[0159] CIE x coordinate field 112 of the light specification;
[0160] CIE y coordinate field 113 of the light specification;
[0161] CIE Y′ coordinate field 114 of the light specification.
[0162] The data field 92 contains such information for each destination on the network 77 , as shown in FIG. 15 .
[0163] If each frame can contain 1500 bytes of data and 8 bytes are required to address each light source, then each frame can specify as many as 187 light sources (1500 divided by 8) with accurate, device-independent, and universal color specifications. The next frame can accurately control the same 187 destinations, an entirely new set of 187 destinations or some combination thereof. Therefore, the protocol of the present invention allows a larger number of destination addresses to each receive small amounts of data. This resolves one deficiency of the direct Ethernet connection. By addressing different destinations with each successive frame, the protocol system of the present invention can address an unlimited number of locations. DMX512's inability to address more than 170 locations with a limited (65,536 variations) color specifications is also resolved.
[0164] The protocol can be further generalized for moving light sources, that is light sources with the capability of traversing, panning, or tilting. FIG. 16 shows an example frame for moving light sources. The frame is similar to the frame of FIG. 15 , and hence many of the features are named and numbered identically. FIG. 16 adds a Configuration field 121 , Pan field 122 , and Tilt field 123 . The Configuration field 121 is a binary number that defines the format of the information in the data field, the Pan field 122 indicates a pan of light source, and the Tilt field 123 indicates a tilt of the light source. Systems of stationary lights are relatively easily to control because only the color of light needs to be specified. Moving systems are more complex because in addition to control of target color specifications with (x, y, Y′), some light engines may also require control of pan. In others, only tilt control is added to the target color specification. Or in some instances, pan, tilt and position may need to be controlled but the target color specification may not be required. The Configuration field 121 , therefore, communicates the format of the information in the data field of the frame. The Configuration field 121 , Pan field 122 , and Tilt field 123 could be located within the data block 105 as shown in FIG. 15 , or incorporated into the Type/Length field 104 or elsewhere in the frame.
[0165] It is unlikely that within the network 77 all light specifications will arrive at the LED light engine assembly 10 as CIE coordinates (x, y, Y′). For this reason, in the present invention a conversion algorithm as shown below can be utilized in any light source 10 on the network. The conversion algorithm can transform a target RGB specification in the format (R t , G t , B t ) into CIE coordinates (x t , y t , Y t ′). The process involves making some assumptions about the CIE coordinates of the standard Red 51 , standard Green 52 , and standard Blue 53 of the targeted output. The fact that the assumptions of these values must occur is an inherent weakness specifying color as RGB.
[0166] The conversion algorithm calculates a theoretical white point for the center of the RGB color space and then uses this white point to calculate scale factors (S r , S g , S b ) for the conversion matrix. The conversion matrix [M] is used to perform the conversion from (R t , G t , B t ) of the target color to Tristimulus values (X t , Y t , Z t ) for the target color. The algorithm 130 concludes by using the defining equations 136 to translate the Tristimulus values (X t , Y t , Z t ) to CIE coordinates of the target color (x t , y t , Y t ). Further details of the entire algorithm are as follows.
[0167] The conversion algorithm commences with a targeted color definition specified in an RGB specification system
Given (R t , G t , B t ) (131)
[0168] The CIE Chromaticity coordinates (x, y, Y′) for the Red, Green and Blue of the RGB color specification are also required for the algorithm. If the RGB color specification system is unknown, the CIE values may have to be assumed.
Given or Assumed (x r , y r , Y r ′), (x g , y g , Y g ′), (x b , y b , Y b ′) (132)
z need not be given for any of the colors because of the defining equation.
x+y+z= 1 (133)
z=1− x−y
[0169] Linear proportionality constants (weighting factors) for the relationship between the Output Intensity and y coordinate for the RGB standard Red, Green and Blue are calculated.
m r =( Y r ′/y r )
m g =( Y g ′/y g ) (134)
m b =( Y b ′/y b )
[0170] The proportionality constants are used to calculate the CIE coordinates of the combination of RGB standards Red, Green, and Blue—ideally a true white color.
x w = x r m r + x g m g + x b m b m r + m g + m b
y w = y r m r + y g m g + y b m b m r + m g + m b
Y w ′ = Y r ′ + Y g ′ + Y b ′ ( 135 )
[0171] CIE coordinates are converted to Tristimulus values, which is simply a different coordinate system for describing the color. The relationship between the 2 coordinate systems is defined by the following equations.
Y=Y′ x=X /( X+Y+Z ) y=Y /( X+Y+Z ) z=Z /( X+Y+Z ) (136)
[0172] The following general equations can be quickly derived from equations 31 and 34 above.
x y = X Y
z y = Z Y
Z Y = ( 1 - x - y ) y ( 137 )
[0173] These general equations can then be utilized to create the equations for the Tristimulus values X, Y, Z for the RGB color specifications standard Red, Green and Blue and the resultant white.
X r = x r Y r ′ y r Y r = Y r ′ Z r = ( 1 - x r - y r ) Y r ′ y r
X g = x g Y g ′ y g Y g = Y g ′ Z g = ( 1 - x g - y g ) Y g ′ y g
X b = x b Y b ′ y b Y b = Y b ′ Z b = ( 1 - x b - y b ) Y b ′ y b
X w = x w Y w ′ y w Y w = Y w ′ Z w = ( 1 - x w - y w ) Y w ′ y w ( 138 )
[0174] Scale Factors (S r , S g , S b ) are calculated using the known Tristimulus values for the Red, Green and Blue standards and the calculated white from the following equation.
[ S r S g S b ] = [ X w Y w Z w ] [ X r Y r Z r X g Y g Z g X b Y b Z b ] - 1 ( 139 )
[0175] This results in the transformation matrix below.
[ M ] = [ S r X r S r Y r S r Z r S g X g S g Y g S g Z g S b X b S b Y b S b Z b ] ( 140 )
[0176] The Tristimulus Values for the target color specification are (X t , Y t , Z t )
[X t Y t Z t ]=[R t G t B t ] [M] (141)
[0177] The Tristimulus values of (X t , Y t , Z t ) can then be converted to CIE Coordinates by the defining equations (136).
x t = X t X t + Y t + Z t
y t = Y t X t + Y t + Z t
Y t ′ = Y t ( 142 )
[0178] Completion of the algorithm allows the usage of CIE coordinates (x t , y t , Y t ′) when [R t G t B t ] was specified.
[0179] In summary, this further feature in the present invention has a number of advantages over DMX512 and variations of DMX512. Color specifications are defined with a large number of variations. The clarity of the CIE Color Specification standard versus the ambiguity of RGB Color Standards is employed. The clarity of the CIE specification is because it is independent on the rendering device, is repeatable, and is capable of specifying all colors. A transformation algorithm from RGB to CIE is an important feature of the communication protocol in the event that color specifications are received in RGB format. An almost infinite number of destinations can be addressed with the herein described protocol versus an RGB implementation of DMX512 addressing only 170 with each physical cable. The present invention can use a high speed computer and telecommunications networks in the Million bps speed range or higher versus the 250 Kbps of DMX512. Lastly, the physical hardware of existing networks makes the system cost effective for retrofits and new installations.
[0180] Obviously, numerous additional 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 present invention may be practiced otherwise than as specifically described herein. | A system including LED assemblies, which system can efficiently and consistently provide a desired color output. The system includes a network and a plurality of light emitting diode (LED) assemblies connected to the network. Each LED assembly includes a unique address. Further, a control unit is connected to the network and is configured to send light control signals to the LED assemblies individually. The light control signals include color information in a universal color coordinate system. The universal color coordinate system can be the CIE color coordinate system and the network can utilize an Ethernet communication protocol. | 6 |
BACKGROUND OF THE INVENTION
This invention relates, in general, to drains, and, in particular, to drains for swimming pools.
DESCRIPTION OF THE PRIOR ART
In the prior art various types of pool drains have been proposed. For example, U.S. Pat. No. 2,084,236 to Babb discloses a container for water which has a drain line connected at the bottom, outside surface of the container. The drain line has a valve to open or close the drain line.
U.S. Pat. No. 2,838,768 to Fischett discloses a wading pool which has a detachable plug in the bottom for draining the pool.
U.S. Pat. No. 5,016,296 to Beaumont discloses a wading pool which has a drain in the lower portion of the side of the pool. The drain has a valve which turns on and off the water in the drain.
U.S. Pat. No. 5,103,508 to Counts discloses a water container which has a drain in the side of the container near the bottom which can be controlled remotely from the top of the container.
SUMMARY OF THE INVENTION
The present invention is directed to a drain for a swimming pool. The pool has an opening adjacent a lower surface of the pool and a plug on an inner surface of the pool to close or open the drain. A hose is connected at one end to the opening adjacent a lower surface of the pool and the other end of the hose has a discharge tray connected thereto.
It is an object of the present invention to provide a new and improved drain for a swimming pool.
It is an object of the present invention to provide a new and improved drain for a swimming pool which can be adapted to any type of pool.
It is an object of the present invention to provide a new and improved drain for a swimming pool that will distribute the drain water without damage to lawns or shrubbery.
These and other objects and advantages of the present invention will be fully apparent from the following description, when taken in connection with the annexed drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is perspective view of the present invention attached to a swimming pool.
FIG. 2 is a partial view of a portion of the inside wall of the swimming pool.
FIG. 3 is a perspective view of the discharge tray used with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings in greater detail, FIG. 1 shows the present invention 1 secured to a swimming pool. The pool has outer side walls 1 , a top 3 a bottom 4 , and inner side walls 5 . It should be noted that the pool, as shown in FIG. 1, is merely for illustration purposes and should not be considered the only type of pool that the present invention could be used with. For example, the pool does not need to be circular. The pool could be virtually any shape and size, and made from any conventional swimming pool material.
In the conventional swimming pool it is necessary to provide a drain such as 6 , usually positioned at a lower portion of the pool. The drain is to allow an owner to drain water from the pool if the water is no longer clean. Also, if the owner decides to move the pool, it will be necessary to drain the water from the pool in order to make it light enough to move. However, even a relatively small swimming pool will hold many gallons of water. When this water is drained, it will dump all of the water onto the surface of the lawn or other surface that the pool is on. This will cause a large pool of water to be dumped onto the lawn, which could cause damage to the lawn, or at the very least, leave a pool of water on the lawn until it evaporates.
In order to avoid this problem, the present invention is designed to attach to any conventional swimming pool and to spread any drained water 17 away from the pool in wide dispersal pattern.
In order to drain water from the pool a fitting 11 is placed in the inner wall 5 adjacent the bottom 4 of the pool as shown in FIG. 2 . The fitting 11 has an aperture 12 which is connected to a passageway 18 which leads to a fitting 6 on the outer wall 2 of the pool. The fitting 11 has a plug 14 attached by a lanyard 13 which can be inserted into the aperture 12 in order to keep water in the pool.
A hose or conduit 7 is secured to the outside fitting 6 . As shown the hose 7 is secured to the fitting 6 by a friction fit, however, other means of attachment can be used. For example, a conventional garden hose fitting can be used, and a garden hose can be screwed onto the garden hose fitting in order to secure a garden hose to the pool drain.
The opposite end of the hose 7 is connected to a discharge tray 8 , 9 , 10 which is designed to discharge the water 17 drained from the pool over a wide area. The discharge tray has a fitting 8 which will be connected to the hose 7 in any conventional manner including, but not limited to, a friction fit, or a conventional garden hose fitting.
The fitting 8 , as shown in FIG. 3, has an aperture 16 connected to a passageway 15 which leads from the aperture 16 to the floor 10 of the discharge tray. On opposite sides of the floor 10 are positioned walls 9 which taper away from the fitting 8 , in order to make the discharge tray wider at the remote end and narrower at the end adjacent the fitting 8 .
This tapering of the tray will allow the water 17 drained from the pool to be dispersed over a wide area, which will allow the water to drain from the pool with little or no damage to the lawn or surrounding areas.
Also, it should be noted that the tray 8 , 9 , 10 is shown in the drawings as a single piece, however, this is not critical. The tray can be made in plural pieces which would allow a narrower or wider tray 9 , 10 to be attached to the fitting 8 depending on the size of the pool (and therefore, the amount of water that will be drained from the pool).
In order to use the present invention, the pool owner would first attach the hose 7 to the outside fitting 6 on the pool. Next, he/she would attach the discharge tray 8 , 9 , 10 to the other end of the hose 7 , and position the discharge tray in a position to do a minimum of damage when the water 17 is drained from the pool. The flexibility of the hose 7 will allow the owner to place the discharge tray 8 , 9 , 10 in virtually any position he/she so desires. Next, the plug 14 will be removed from the inside fitting 11 on the inner wall 5 of the pool. This will allow the water, inside the pool, to drain (by gravity) through the aperture 12 , through the passageway 18 into the hose 7 , and finally into and out of the discharge tray 8 , 9 , 10 .
Although the Recyclopool and the method of using the same according to the present invention has been described in the foregoing specification with considerable details, it is to be understood that modifications may be made to the invention which do not exceed the scope of the appended claims and modified forms of the present invention done by others skilled in the art to which the invention pertains will be considered infringements of this invention when those modified forms fall within the claimed scope of this invention. | A drain for a swimming pool. The pool has an opening adjacent a lower surface of the pool and a plug on an inner surface of the pool to close or open the drain. A hose is connected at one end to the opening adjacent a lower surface of the pool and the other end of the hose has a discharge tray connected thereto. | 4 |
FIELD OF INVENTION
This invention relates to conveyor belt weighing systems, and more particularly, to the mechanical structure and its weight-sensitive devices that supports a short section of the belt with its material loading.
BACKGROUND OF INVENTION AND PRIOR ART
The need for accurately measuring both the rate of material weight transported by a conveyor belt as well as the totalized weight that has been transported past the scale has long been recognized. Materials transported by conveyor belts and consequently needing to be measured range from huge flow rates encountered in the mining and aggregate production industries to comparatively miniscule flow rates in the sanitary foods and pharmaceuticals industries. Displayed flow rate is very useful and necessary to afford a plant operator the needed information in order to maximize his production rate by making appropriate changes as needed. Totalized weight is needed in order to provide data on plant yield and productivity over a period of time, such as one shift or one 24-hour day. Both of these data are generally available in currently available belt scales.
A related need for measuring flow rates of materials transported by conveyor belts is in a machine called a weigh belt feeder, where the purpose of this machine is to deliver a flow rate slaved to another requirement, such as feeding granulated coal to the steam boiler of an electric power plant. Here the demand for electric power dictates the coal flow rate. The belt scale plays the role of a flow rate measurement device so that the plant control system has the necessary information to change this flow rate as needed to meet the momentary and changing demand for electric power. Both the need for totalized weight and the need for flow rate require similar components for the belt scale--a mechanical structure equipped with one or more weight measuring devices that supports a short section of the loaded belt and produces a signal indicative of the magnitude of the load, a belt motion measuring device, and an electronic signal processor that combines the weight and motion signals and computes totalized weight, belt speed, and material weight flow rate.
All three sets of components contribute to the accuracy of the entire belt scale. However, it has generally been recognized that the greatest increase in belt scale accuracy requires design improvements of the mechanical structure with its weighing devices. At the same time, simplification of the mechanical structure has also received attention in the prior art as witnessed by U.S. Pat. Nos. 4,260,034, 5,111,896, and 5,296,654. These patents all show belt scales without a structural crossbar member that, if present, would span the conveyor from one side to the other. But simplification and reduction of the belt scale's mechanical structure is normally accompanied by increases in errors of the weighing performance. This mechanical structure and its attendant weighing device or devices will henceforth be called `weighframe` in this patent application. The weighing devices will be referred to as `load cells`. The assembly comprised of one horizontal roll (carry roll) and two inclined (troughed) rolls, and appropriate framework to connect all three rolls is variously called `idler` or `idler assembly` or `three-roll idler`. The particular idler supported by the weighframe is called the weigh idler.
At least two categories of belt scale accuracy are sought in the industrial application of belt scales: (a) highest accuracy for belt scales that are used to determine quantity of goods sold or exchanged; (b) lesser accuracy for belt scales that measure in-plant inventory and production rates. By far the largest number of belt scales are needed in category (b) where simplicity, general purpose usefulness, and low cost are the most important criteria. Accuracy most be preserved and improved if possible, but is not as demanding as in category (a). It is this later category that this invention addresses, both in terms of reducing mechanical structure as well as maintaining greatest possible accuracy while substantially achieving the goals of category (b). factors such as ease of installation, no interferences with existing cross-braces of the conveyor, ease of alignment, no moving parts in the weighing mechanism, long life, and general-purpose application while still maintaining a satisfactory level of accuracy are all important considerations to the user of a belt scale. The manufacturer of belt scales on the other hand has been traditionally concerned with ease of manufacturing, lowest production cost commensurate with intended accuracy, and ability to manufacture in advance of the specific order from a customer. Because conveyor belts are extant in many different widths, and a wide variety of full-scale material loading, a manufacturer has to inventory a very large number of weighframes if the design dictates that each belt width and each belt loading range requires a separate weighframe.
Eliminating the need for a crossbar would greatly enhance the ability to manufacture and stock this equipment in advance of orders for them because belt width would no longer be a defining specification. Furthermore, ability to configure the weight capacity of a belt scale after its manufacture and at the time an order is received is equally important in maintaining flexibility in manufacturing. This later criterion has often been achieved in the past at the time of installing the weighing device, called a load cell, with the appropriate capacity for a particular user's needs. But the former criterion--no crossbar--has been somewhat more elusive in the past. The reason for relatively few belt scale weighframes without crossbars is as stated earlier--accuracy is sacrificed when this particular simplification is adopted. Hence the need for a general purpose belt scale that does not require a crossbar and can be configured for different full-scale belt loading is very obvious, but accuracy must not be compromised if this type of belt scale weighframe is to be successful.
The weighframe cited in U.S. Pat. No. 4,260,034 and shown in FIG. 1 addresses the need for low-cost manufacturing by using a pair of weight sensing load cells as the primary and only connecting link between the idler roll that supports the belt and the conveyor structural members. Therefore, the load cells must sustain not only the vertical downward forces due to the weight of the material transported by the belt, but also the horizontal and lateral forces exerted by the roller axle bearing ends on the load cells. Additionally, the load cells also must sustain twisting forces (called torsion) created by the twisting motion of the longitudinal conveyor supports (called stringers). This twisting action is due to uneven thermal expansion of the stringers caused by the sun during the daytime hours. All these forces generally have non-negligible effects on the load cells, such as output signal changes that are not related to any change in the weight of the material carried by the conveyor belt. Thus errors arise in measuring the weight. An extreme effect of these outside forces and twisting motions is premature failure of the load cells.
The weighing structure of U.S. Pat. No. 5,296,654, shown in FIGS. 2 and 3, is another such attempt at providing a low-cost belt scale without a crossbar to the in-plant inventory market. Here the cantilevered beams labeled 44 to which the strain-gage load sensors are attached must sustain the entire array of forces and torsion loading applied by the idler roll assembly, Similar to the previously cited prior art, these disturbances arise from the horizontal travel of the conveyor belt and its material loading as well as thermal expansion effects. Therefore, the strain-gage load sensors are influenced by disturbance effects not related to or caused by the downward-acting weight of the material on top of the belt. Just as in the previous apparatus, the results are errors in the output signal and, in some instances, premature failure of the sensors themselves. claim 1 in the cited patent specifically refers to measuring only the stresses due to material weight on the belt and isolating the cantilevered beams from " . . . shifting, twisting, and movement of the belt conveying means stringers . . . ". But the structure proposed to solve these problems does not in fact isolate the cantilevered beams and therefore the sensing elements as well from these error-generating forces and motions. Also, the mounting elements required to support the cantilevered beams and to secure them to the conveyor stringers are not at all simple to manufacture because of their multiplicity of direction changes--laterally in from the stringers, then vertically rising, then longitudinally forward, then back down, then forward again to support the idler roll assembly.
Throughout all these direction changes, parallel surfaces between the stringer mounting location and the idler roll assembly support must be maintained at the risk of creating some unwanted torsional twisting of the cantilever beams to which the weight sensors are attached. Also, alignment of the neutral axis plane identified as 42 in FIG. 2 with the top of the carry roll is not correct. The correct alignment is the plane 120 passing slightly above the axle 116 of the carry roll 24 in FIG. 5. Also, there is no provision in this structure for adjusting the vertical height of the carry roll 24 to match the vertical heights of adjacent upstream and downstream carry rolls. This alignment is essential for accurate belt scale weighing. Because there is no such adjustment provision, the installer must place shims between the belt scale marked 38 in FIG. 3 and the conveyor stringers 30. This shimming procedure is tedious and time consuming--not recognized as a user-friendly design.
In summary, the prior art falls short of providing a no-crossbar conveyor belt weighframe that meets the combined user and manufacturer criteria of reliability, accuracy, and manufacturing simplicity.
OBJECTS AND ADVANTAGES
It is an object of this invention to provide a general purpose belt scale weighframe that can be installed on conveyor belts without regard to belt width.
Another object is to create a weighframe that can be easily adapted to any one of a range of full-scale belt loading values after it has been manufactured.
An important object of this invention is to isolate the weight sensing mechanism from the array of forces and torques acting on the weighframe, except for the normal component of the material weight to be weighed by the scale, thereby increasing its weighing accuracy over that of existing no-crossbar weighframes.
Yet another object is to capture and secure the weigh idler roller assembly by the mechanical structure of the weighframe and not by the weight sensing means.
Still another object of the invention is to provide conveniently settable overload stops so that unanticipated large belt loads will not damage the weight sensors.
Another object is to include a convenient means for raising or lowering the idler roller assembly attached to and supported by the scale so as to bring it into close alignment with the adjacent upstream and downstream fixed idler roll assemblies.
Still another object of the invention is to enable the user to align the scale weigh idler with the adjacent idler assemblies by passing a string line underneath the center carry rolls of these three idler assemblies without the line being impeded by any of the scale's component parts.
Another object is to position the three-roll idler assembly so that the axle of the carry roll is nearly in the plane parallel to the conveyor structural support stringers and passing through the hinge line of the scale, thereby reducing errors due to torsional overturning effects.
BRIEF DESCRIPTION OF FIGURES
FIG. 1 is a side view of a prior art no-crossbar weighframe where the weigh idler is entirely secured by two load cells, one on either side of the conveyor.
FIGS. 2 and 3 are taken from a recently patented no-crossbar weighframe where FIG. 2 shows a side view of one cantilever beam with stress sensors and FIG. 3 shows the same weighframe looking back along the conveying direction.
FIG. 4, from the current invention, shows an isometric view of one of two load beams mounted on one of two conveyor stringers and securing one end of the backbone of the weigh idler.
FIG. 5 shows the relationship between a belt loaded with material, the idler rolls supporting the belt, an end view of one load beam, and the best location for the plane through the weighframe's hinge line.
FIG. 6 shows a side view of the FIG. 4 load beam, exposing details including the cutting of the load beam to render it compliant in the weighing direction, placement of a load cell, mounting members that also provide vertical alignment adjustment, overload stop bolt, and means for attaching the idler backbone to the load beam.
FIG. 7 shows the means for securing the weigh idler backbone to the load beam; also some alternative shapes for the retainer block.
FIG. 8 is an abstract view of the load beam in FIG. 6 to illustrate the array of forces, torques, and twisting motions that the load beam experiences in conveyor weighing applications, also, its essential similarity to a C-shaped structure. FIG. 8 alternative three-piece load beam design instead of a single-piece design.
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 2 and 3 show the relative arrangement of a prior art weighframe used to weigh material being transported by a troughing-idler belt conveyor. Although these figures show only the weigh idler 20 supporting the belt and its load, it can readily be understood that the entire conveyor is comprised of idlers like the one shown supported by the weighframe. FIG. 5 also provides a picture of the weighing idler and its rolls supporting the belt and the material being transported. The other regularly-spaced idlers, mounted on the parallel stringers 30 comprising the conveyor's structure, are spaced vertically so that the belt 114 substantially forms a straight line from the belt's tail pulley to its discharge pulley. It can also be readily understood that the weight of the belt and its material loading 110, 112 carried by these discretely spaced idlers is thereby transferred through them to the conveyor stringers. Furthermore, an industrial-grade belt of this nature can be expected to have imperfections, tears, and other protrusions that cause and create forces and torques applied to the idler rolls in addition to the readily understood downward force due to the weight of the belt and its material loading. These additional forces, torques, and twisting motions are discussed in some detail in the context of FIG. 8. Suffice it to say at this point that a conveyor belt scale weighframe must have the capability to substantially respond only to the weight-induced forces--responses to these other forces are errors in the measured weight and flow rate.
This invention suggests a structure and spatial arrangement of that structure so as to minimize these error responses. This structure has two principal attributes that make it very attractive to the supplier-manufacturer of belt scales: a) it is a two-piece design consisting of two load beams, one load beam independently mounted on each of the conveyor's stringers, with no crossbar connecting the two halves of the weighframe; b) the full-scale weight capacity can easily be selected after the load beams have been manufactured by choosing the appropriate load cell weighing capacity at the time a customer places an order for a belt scale. Additional attributes that make this weighframe very attractive to the user that are at the heart of this invention are: c) means for isolating error-generating forces, torques, and twisting motions from the weight sensing means so that only the weight-created downward forces can cause the load cells to respond; d) correct spatial arrangement between the weighframe hinge line and the weigh idler carry roll so as to minimize and substantially eliminate errors induced by over-turning forces; e) convenient means for raising or lowering the weigh idler supported by the two load beams so as to bring about vertical alignment with upstream and downstream idlers.
FIG. 4 shows one-half of a weighframe comprised of two load beams supporting and securing the right-hand end of its weigh idler. A one-piece load beam 54 made from a piece of tubing must be cut along 60 so that its upper half 56 would be reasonably free to bend about its hinge line 62. A force measuring means located between 56 and 58 prevents the upper and lower portions from bending together under loaded belt conditions. It is easily understood that element 54 could be fabricated of two pieces joined together at one end so that the cut line 60 would not be necessary to achieve essentially the same objective as the one-piece element 54 shown in FIG. 4. The lower portion 58 is rigidly secured to the conveyor stringer 30 by means of mounting bolts 64 extending through holes in mounting plates 68 and adjustment nuts 66. The mounting plates are welded or otherwise fastened to stringer 30. Thus each load beam is connected and thereby secured to the conveyor.
As shown in FIG. 5, the weight of material 110, 112 on top of belt 114 is transferred to support rolls 22, 24 and to the idler backbone 34 via support brackets 26a, 26b, which in turn transfers the weight to the outboard ends of the load beam upper portion 56. Lines 78 represent a multiplicity of shims so that the vertical height relationship between the hinge line 62 and the weigh idler carry roll 24 and its axle 116 can be correctly established and thereby substantially eliminate errors due to belt-induced overturning torque acting on the weigh idler carry roll. Because of the rising angles of the troughing rolls 22 and the material 112 carried by these two rolls, the hinge line 62 optimally lies in a plane parallel to stringers 30 and passing slightly above the carry roll axle 116, shown as line 120.
FIG. 6 shows a side view of the load beam and its attachment to the weigh idler backbone 34 and to its mounting plate 68. Nuts 66 capture the load beam at any desired vertical height. Rotating all the nuts in on e direction raises the entire load beam assembly and the attached weigh idler. Alternatively, rotating all the nuts in the opposite direction lowers the load beam relative to the conveyor stringers, thereby permitting simple, fast, and reliable height adjustment of the weigh idler to ensure that the belt will travel across the weighframe and its weigh idler without deforming the belt in either an upward or downward direction. Either type of belt deformation at the weigh idler would cause inaccuracy in the weighing of the material transported by the conveyor belt. The weigh idler backbone 34 is secured to the load beam upper portion 56 by threaded bolt 74. When nut 76 is tightened, backbone 34 is drawn up against V-block 72 by a cylindrical retainer block 70a. Thus the weight of the material pulls down on portion 56 through bolt 74 and nut 76. FIG. 7 shows an alternative shape for the retainer block; namely, a parallelogram 70b. Still other shapes for the retainer block are envisioned, such as a sphere.
As previously mentioned, 56 would collapse against 58 under loaded belt conditions were it not for the load cell 80 and force and torque isolator 86 situated between upper and lower portions 56 and 58. (`Force and torque isolator` is henceforth abbreviated to "Force Isolator`.) Holes 82 in the base of the load cell are used to secure it to the load beam's lower portion 58. Force isolator 86 is screwed or otherwise attached to the upper portion of the load cell and is adjusted so that it bears against the underside of load beam portion 56, thereby transferring the belt loading from upper portion 56 through member 86 and onto the top of the load cell. Nut 88 locks isolator 86 to the load cell and thus prevents the isolator from inadvertently turning loose. With the lower end of the force isolator attached to the load cell and its upper end simply touching the underside of the load beam, the only force component that can be transmitted to the upper face of the load cell is the downward-acting weight of the loaded belt--the one and only force that an ideal weighframe is intended to measure. Item 86 is called a `force and torque isolator` because it isolates all extraneous forces and twisting deflections from the load cell. If it were not for this force isolator, significantly larger weighing errors would occur. Further discussion regarding the function of the force isolator is presented in the context of FIG. 8. Overload stop bolt 90 is adjusted to an allowable gap 94 the prevent excessive compressive displacement of the load cell. Locking nut 92 prevents the stop bolt adjustment from changing inadvertently.
FIG. 8 shows an abstract side view of the load beam of FIG. 6. This figure illustrates that the load beam described in this invention is essentially a C-shaped frame with a designed-in line of flexibility 100 that corresponds to line 62 in FIG. 6 and that stiffness is provided by a load cell 80 and a force isolator 86 interposed between upper portion 96 and lower portion 98, and not by the structural rigidity of the C-frame itself Also illustrated here is the mechanism whereby a load cell 80 of a specific load capacity can be shifted along the length of the load beam in order to select the correct proportion of the material load to be applied to the load cell. Three specific mounting locations for this single load cell are all designated 84, each being a distance L1 away from the load beam's hinge line. It is to be understood that the length L1 is a variable that, as shown in FIG. 8, can take on any one of three values. The length L2 remains fixed. Note that the length L2 remains fixed. Note that the load cell force is related to the material load by the ratio L2/L1, and that changing the load cell position changes the proportion of the material weight. This variability in load cell installation position provides a second means of setting up the weighframe for a customer's belt conveyor load range after the load beams have been manufactured. Elsewhere it was mentioned that this same objective could be accomplished by selecting the appropriate load cell weight capacity. Both methods have a place in the manufacture and marketing of belt scales.
FIG. 8 also shows the array of forces and torques applied to the upper and lower portions of the load beams containing the load cells. For example, force Fy 132 is caused by the material load on the belt and is therefore the force to be measured by the belt scale, Ty 140 is a disturbance torque about the y-axis in line with the force Fy. Similarly, Fz 134 and Tz 142 are a disturbance force and a torque about the transverse z-axis; Fx 130, Tx1 136, and Tx2 138 are disturbances in and about the x-axis, in the direction of belt travel. The disturbance torques Tx1 and Tx2 are better understood as twisting deflections of the upper and lower members of the load beam. These two twisting disturbances are especially troublesome in a no-crossbar weighframe because they are frequently present in sufficient magnitude to cause weighing errors. Tx1 arises when the weigh idler backbone deflects due to the material load on top of the belt; Tx2 occurs when the sun heats the conveyor stringers non-uniformly and one or both stringers respond by twisting. If the present invention would have its load cell rigidly secured to both top and bottom members 96 and 98, the load cell itself would suffer internal bending or twisting deflection between its top and bottom members. Similarly, the inventions pictured in FIGS. 1, 2, and 3 experience this twisting deflection of their weight sensors; and weight sensing devices operate most accurately when they are strained only along their primary measurement axis.
The present invention described herein introduces an additional component, the force and torque isolator, to prevent these unavoidable disturbance forces and torques from being transmitted to the load cell, except for the disturbance torque Tz 142. But this transverse disturbance torque can be reduced to an insignificant level if shim stack 78 is properly used. As an example, if either Tx1 or Tx2 are present, the contact point of force isolator 86 acts as a pivot point for these disturbance deflections. Therefore it is not possible for the twist to act on the load cell itself Similarly, a disturbance force Fx cannot be transmitted across the force isolator contact point to the top of the load cell. However, the force Fy 132 to be sensed and measured by the load cell most certainly does cross the force isolator contact point boundary and acts on the load cell.
From the foregoing description it can be understood that the primary purpose of the load beams is to restrain and secure the weigh idler in all directions of response to the vagaries of the force and torque disturbances at work except in and along the principal axis of the load cell, which is arranged so as to measure the downward-acting forces due to the weight of the material being carried by the conveyor belt.
FIG. 9 shows an alternative method of constructing a load beam. Instead of a single piece of tubing, this figure shows two separate pieces 146 and 148 with a flexible connecting link 150. Hinge line 152 takes the place of hinge line 62 in the one-piece load beam.
SUMMARY AND CONCLUSIONS
From the previous description the reader can readily understand that a general purpose belt scale weighframe without a crossbar but with the numerous and special features described herein combines the best interests of both the manufacturer and user. The special feature called the force and torque isolator is an especially necessary and vital component to enable a no-crossbar design to work with expectation of satisfactory accuracy. While the specifics of this invention have been carefully stated and illustrated, these specific renditions should not be construed as limitations to the scope of this invention. For example, the force isolator is shown to be attached to the top of the load cell and is only in touch contact with the top portion of the load beam. But the force isolator can also be attached securely to the top portion of the load beam and in touch contact with the top of the load cell. Similarly, the base of the load cell could be attached to the top rather than the bottom of the load beam with the force isolator in touch contact with the bottom portion of the load beam. Accordingly, the scope of this invention should be determined not by the illustrated embodiment, but by the accompanying claims. | A general purpose belt scale for measuring the weight of material being transported on a conveyor belt includes a pair of load beams, each having a load cell in combination with a force and torque isolator mechanism that isolates the load cell from disturbance forces and torques that would increase the measurement errors. Absence of a crossbar enables the two independent load beams to fit a wide variety of belt widths. Selection of the capacity of the load cells after the weighing application has been determined completes the general applicability of the belt scale for both belt width and load weighing requirements. An alternative embodiment of a selectable mounting location for the load cell within each load beam allows the weight capacity of the belt scale to be varied without changing the load cell's weight capacity. The hinge axis of each load beam is preferably matched to a plane passing just slightly above the carry roll axle; and provisions for this matching in the field at installation are provided for in the invention. Additionally, a threaded mounting bolt and nut arrangement enables simple height adjustment so that the weigh idler carry roll can be matched with adjacent idler carry rolls at the time of field installation. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to dielectric ceramics and dielectric resonators for use in such high-frequency ranges as microwave and millimeter-wave frequencies.
2. Description of the Prior Art
Recently, dielectric ceramics have been widely used in dielectric resonators and filters in microwave and millimeter-wave frequencies at wavelengths of several centimeters or less (hereinafter referred to as microwave in general). It is required that a dielectric material for use in such applications have a high unloaded Q (Qu) value and dielectric constant ε r , and that the temperature coefficient at resonant frequency τ f be variable as desired.
Various materials appropriate for use in such applications have been conventionally reported, among which ZrTiO 4 ceramics are included. Also included in such materials are ZrO 2 --SnO 2 --TiO 2 ceramics, the ZrO 2 --SnO 2 --TiO 2 --MgO ceramic suggested in Japanese Laid-Open Patent No. 62-132769 and the ZrO 2 --SnO 2 --TiO 2 --CoO--Nb 2 0 5 ceramic in No. 2-192460 are known, for example.
However, although ZrTiO 4 ceramics have a high dielectric constant of 45, the temperature coefficient at resonant frequency is high in the positive side at 54 ppm/°C., and the temperature coefficient is significantly varied by the heating history during sintering. ZrO 2 --SnO 2 --TiO 2 ceramic system achieved a low temperature coefficient at resonant frequency nearly zero, but the heating history problems didn't solved satisfactory.
In addition, conventional materials have such problems that the dielectric constant and unloaded Q value are low, and that the temperature coefficient at resonant frequency cannot be varied as desired.
Moreover, although the product of resonant frequency (f)×Qu value is generally regarded as being constant in a given material, when f is lowered (that is, an element is enlarged), actually, the product fQu is reduced (decreased). Therefore, there is a strong demand for a dielectric element for microwave applications such as a dielectric resonator for a base station of mobile radio communication system used in a relatively low frequency range with a higher unloaded Q value. Furthermore, because dielectric resonators used in the relatively low frequency ranges are very bulky, reduction in size is highly demanded.
SUMMARY OF THE INVENTION
The object of the present invention is to provide ZrTiO 4 and ZrO 2 --SnO 2 --TiO 2 dielectric ceramics with less variation of temperature coefficient at their resonant frequency due to heating history during sintering.
It is another object of the invention to provide dielectric ceramics that have a high unloaded Q value and high dielectric constant, and have a temperature coefficient at resonant frequency which is variable as desired.
It is still another object of the invention to provide TE 01 δ-mode dielectric resonators having a high unloaded Q value in a frequency range of 0.8 to 5 GHz with a compact size.
The subject of the invention is to achieve one of these objects or to achieve more than two objects at the same time.
The invention relates to a dielectric ceramic comprising as the main component a complex oxide formed of both Zr and Ti, at least one component selected from the group (A) consisting of Mg, Co, Zn, Ni and Mn and at least one component selected from the group (B) consisting of Nb and Ta.
The invention also relates to a dielectric ceramic composition expressed by (a):
xZrO.sub.2 --yTiO.sub.2 --zA.sub.(1+w)/3 Nb.sub.(2-w)/3 O.sub.2(a)
wherein A denotes at least one component selected from the group (A) consisting of Mg, Co, Zn, Ni and Mn,
x, y and z denote molar fractions ranging from 0.10 to 0.60, 0.20 to 0.60 and 0.01 to 0.70, respectively, and have the relation represented by Formula (α):
x+y+z=1 (α)
and w denotes a value of 0 to 1.50.
The invention also relates to a dielectric ceramic composition expressed by Formula (b):
xZrO.sub.2 --yTiO.sub.2 --zA.sub.(l+w)/3 Ta.sub.(2-w)/3 O.sub.2(b)
wherein A denotes at least one component selected from the group (A) consisting of Mg, Co, Zn, Ni and Mn,
x, y and z denote molar fractions ranging from 0.10 to 0.60, 0.10 to 0.60 and 0.01 to 0.80, respectively, and have the relation represented by Formula (α):
x+y+z=1 (α)
and w denotes a value of 0 to 1.00.
The invention also relates to a dielectric ceramic in which the main component comprises a ZrTiO 4 phase substituted with at least one component selected from the group (A) consisting of Mg, Co, Zn, Ni and Mn and at least one component selected from the group (B) consisting of Nb and Ta, or the main component crystallographically comprises a ZrTiO 4 phase substituted with at least one component selected from the group (A) consisting of Mg, Co, Zn, Ni and Mn and at least one component selected from the group (B) consisting of Nb and Ta.
The invention also relates to a dielectric ceramic in which the main component comprises a ZrTiO 4 phase substituted with at least one component selected from the group (A) consisting of Mg, Co, Zn, Ni and Mn and at least one component selected from the group (B) consisting of Nb and Ta, or the main component crystallographically comprises a ZrTiO 4 phase substituted with at least one component selected from the group (A) consisting of Mg, Co, Zn, Ni and Mn and at least one component selected from the group (B) consisting of Nb and Ta, wherein the molar fraction ratio of the total amount of the group (A) components to the total amount of the group (B) components ranges from 0.5 to 1.0.
The invention also relates to a TE 01 δ-mode dielectric resonator comprising a dielectric ceramic which comprises as the main component a complex oxide formed of both Zr and Ti, at least one component selected from the group (A) consisting of Mg, Co, Zn, Ni and Mn and at least one component selected from the group (B) consisting of Nb and Ta.
The invention also relates to a TE 01 δ-mode dielectric resonator comprising a dielectric ceramic expressed by Formula (a):
xZrO.sub.2 --yTiO.sub.2 --zA.sub.(1+w)/3 Nb.sub.(2-w)/3 0.sub.2(a)
wherein A denotes at least one component selected from the group (A) consisting of Mg, Co, Zn, Ni and Mn,
x, y and z denote molar fractions ranging from 0.10 to 0.60, 0.20 to 0.60 and 0.01 to 0.70, respectively, and have the relation represented by Formula (α):
x+y+z=1 (α)
and w denotes a value of 0 to 1.50.
The invention also relates to a TE 01 δ-mode dielectric resonator comprising a dielectric ceramic expressed by Formula (b):
xZrO.sub.2 --yTiO.sub.2 --zA.sub.(1+w)/3 Ta.sub.2-w)/3 O.sub.2(b)
wherein A denotes at least one component selected from the group (A) consisting of Mg, Co, Zn, Ni and Mn,
x, y and z denote molar fractions ranging from 0.10 to 0.60, 0.10 to 0.60 and 0.01 to 0.80, respectively, and have the relation represented by Formula (α):
x+y+z=1 (α)
and w denotes a value of 0 to 1.00.
The invention also relates to a TE 01 δ-mode dielectric resonator in which the main component comprises a ZrTiO 4 phase substituted with at least one component selected from the group (A) consisting of Mg, Co, Zn, Ni and Mn and at least one component selected from the group (B) consisting of Nb and Ta, or the main component crystallographically comprises a ZrTiO 4 phase substituted with at least one component selected from the group (A) consisting of Mg, Co, Zn, Ni and Mn and at least one component selected from the group (B) consisting of Nb and Ta.
The invention also relates to a TE 01 δ-mode dielectric resonator in which the main component comprises a ZrTiO 4 phase substituted with at least one component selected from the group (A) consisting of Mg, Co, Zn, Ni and Mn and at least one component selected from the group (B) consisting of Nb and Ta, or the main component crystallographically comprises a ZrTiO 4 phase substituted with at least one component selected from the group (A) consisting of Mg, Co, Zn, Ni and Mn and at least one component selected from the group (B) consisting of Nb and Ta, wherein the molar fraction ratio of the total amount of the group (A) components to the total amount of the group (B) components ranges from 0.5 to 1.0.
DETAILED DESCRIPTION OF THE INVENTION
Any compound such as oxide, carbonate, hydroxide, alkoxide of the component elements described above may be used as an initial material of the dielectric ceramic according to the present invention.
As blending methods of powdery raw materials, wet blending for mixing the materials with water or organic solvent in a ball mill and dry blending for mixing them by a mixer or a ball mill, etc. without using any solvent are generally known, and any of these methods may be employed. Alternatively, the alkoxide method and coprecipitation method may be used depending on the initial materials. This means that various known methods applicable to manufacture of dielectric ceramics can be employed. Because the process is thus comparatively uncomplicated, and a homogeneous mixture can be easily obtained, it is desirable to employ the wet blending method for mixing them in a ball mill by using a solvent, and a dispersing agent may be additionally used for increasing the dispersing property of powders, or pH adjustment may be performed.
Although calcination of the mixture is not required, the sintering time can be reduced by calcination. Although the calcination temperature depends on the particular compositions, it is generally in the order of 2 to 8 hrs at about 800° to 1250° C,
As milling method of the calcined material or mixture, any such method of using a ball mill, high-speed rotor mill, media agitating mill and jet mill may be employed.
For molding, press molding is generally carried out to obtain a desired shape. Although not specifically limited, pressure used in the press molding is generally in a range of approximately 0.5 to 1.5 ton/cm 2 .
Although the sintering is not specifically limited, as it depends on the particular compositions and dimensions of the moldings, it is generally desirable to perform firing at a temperature of approximately 400° to 700° C. for about 1 to 100 hrs in order to remove binders, then, at approximately 1300° to 1650° C. for about 1 to 10 hrs.
EXAMPLE 1
As initial materials, ZrO 2 , TiO 2 , MgO, CoO, ZnO, NiO, Nb 2 0 5 and MnCO 3 of high chemical purity were used, weighed so as to make a predetermined compositions as shown in Table 1 at the end of this specification, and wet-blended with ethanol by using a ball mill. The volume ratio between the powders and ethanol was approximately 2:3. The mixture was removed from the ball mill, dried, and calcined for 2 hours at 1000° C. in the air. The calcination product was wet-milled in the ball mill with ethanol. After the milled slurry was removed from the ball mill and dried, the powders were mixed with 8% by weight of polyvinyl alcohol solution of 6% in concentration added thereto as a binder, homogenized, and granulated by sieving through 32 mesh screen. The granulated powders were molded into a disk of 7 mm in diameter and approximately 3 mm in thickness by using molds and an oil hydraulic press at a molding pressure of 1.3 ton/cm 2 . The molding was placed in a magnesia vessel of high purity, kept in the air at a temperature of 600° C. for 4 hrs to remove binders, then retained in the air at 1500° C. for 24 hrs for sintering, and quenched (taken out of a furnace and air-cooled) or slowly cooled (at a cooling rate of 20° C./hr) thereafter, and dielectric ceramics were obtained.
The resonant frequency was obtained from measurement by the dielectric rod resonator method. The temperature coefficient at resonant frequency τ f was obtained in a range between -25 and 85° C.
Compositions of dielectric ceramics thus produced are shown in Table 1, and cooling conditions after sintering and temperature coefficients at resonant frequency (ppm/°C.) in Table 2. In Table 1 and Table 2, those with an asterisk are comparison examples.
As recognized from the results shown in Table 2, in dielectric ceramics of sample Nos. 3 to 10 variation of temperature coefficient at resonant frequency due to the heating history during sintering of ZrTiO 4 and ZrO 2 --SnO 2 --TiO 2 ceramics are reduced. In addition, similar effects were confirmed in dielectric ceramics with 0.5mol % of at least one compound of Al 2 O 3 , SiO 2 , BaCO 3 , SrCO 3 , La 2 O 3 and Sm 2 O 3 added to those of sample Nos. 3 to 10. Other components may be added as far as the objects of the invention are not adversely affected.
According to the first aspect of the invention, variation of temperature coefficient at resonant frequency due to the heating history during sintering of ZrTiO 4 and ZrO 2 --SnO 2 --TiO 2 ceramics can be reduced.
EXAMPLE 2
As initial materials, ZrO 2 , TiO 2 , MgO, CoO, ZnO, NiO, MnCO 3 and Nb 2 O 5 of high chemical purity were used, weighed so as to make a predetermined composition as shown in Table 3, and wet-blended with ethanol by using a ball mill. The volume ratio between the powders and ethanol was approximately 2:3. The mixture was removed from the ball mill, dried, and calcined for 2 to 8 hrs at a temperature of 800° to 1250° C. in the air. The calcination product was wet-milled in the ball mill with ethanol. After the milled slurry was removed from the ball mill and dried, the powders were mixed with 8% by weight of polyvinyl alcohol solution of 6% in concentration added thereto as a binder, homogenized, and granulated by sieving them through 32 mesh screen. The granulated powders were molded into a disk of 7 mm in diameter and approximately 3 mm in thickness by using molds and an oil hydraulic press at a molding pressure of 1.3 ton/cm 2 . The molding was placed in a magnesia vessel of high purity, kept in the air at a temperature of 400° to 700° C. for 4 to 8 hrs to remove binders, and retained thereafter in the air at a temperature of 1300° to 1650° C. for one to 100 hrs for sintering, and dielectric ceramics were obtained. The resonant frequency, unloaded Q (Qu) value and dielectric constant ε r were obtained by measurement with the dielectric rod resonator method. The temperature coefficient at resonant frequency τ f was obtained in a range between -5 and 85° C. The resonant frequency was within a range of 5 to 10 GHz.
The dielectric constants, temperature coefficients at resonant frequency (ppm/°C.) and unloaded Q values obtained in such manner are shown in Table 3. In Table 3, those with an asterisk are comparison examples.
As is obvious from the results shown in Table 3, in dielectric ceramic compositions within a composition range of the second aspect of the invention, the dielectric constant is kept at a high value at microwave frequencies, while a high unloaded Q value is provided.
On the contrary, when x is higher than 0.6, the unloaded Q value is significantly reduced as observed in sample Nos. 54 to 56 (Tables 3-2 and 3--3),and 123 (Table 3-6). In addition, when x is below 0.10, the unloaded Q value is reduced as shown in sample Nos. 60, 61 (Table 3--3) and 126 (Table 3-7), and the objects of the invention cannot readily be achieved.
As recognized in sample Nos. 26 to 29 (Table 3-1) and 116 (Table 3-6), since the unloaded Q value is significantly reduced, when y is higher than 0.60, and the unloaded Q value is excessively low, as seen in sample Nos. 15 to 18 (Table 3-1) and 114 (Table 3-6), when y is below 0.20, the objects of the invention cannot readily be achieved.
When z is higher than 0.70, the unloaded Q value is reduced as observed in sample Nos. 30 to 33 (Table 3-1) and No. 117 (Table 3-6); and the temperature coefficient at resonant frequency is excessively high and the unloaded Q value is significantly reduced as in sample No. 36 (Table 3-2) when z is below 0.01, the objects of the invention cannot readily be achieved. Additionally, although the unloaded Q value can be improved by increasing w to a higher value than 0, however, when w exceeds 1.50, the unloaded Q value is reduced as shown in sample Nos. 93 to 96 (Tables 3-4 and 3-5) and 133 (Table 3-7). However, even in the case of sample No. 133, its properties were better than those of conventional dielectric ceramics.
Incidentally, it was confirmed within the composition range of the example that the unloaded Q value was improved by using A, which is at least one element selected from Mg, Co, Zn, Ni and Mn, and Nb oxide that were calcined beforehand at a temperature of 800° to 1200° C.
Moreover, it was confirmed within the composition range of the example that the degree of sintering was improved by slightly adding an additive, and the properties were not significantly inferior. For example, although the sintering temperature was reduced by approximately 50° C., when 0.08 wt. % of Al 2 O 3 was added to sample No. 105 (Table 3-5), and was reduced by approximately 25° C., when 0.08 wt. % of SiO 2 was added, the properties were not changed significantly in either case. Moreover, even in the case of dielectric ceramic with 0.1 mol % of at least one compound of BaCO b 3, SrCO 3 , La 2 O 3 and Sm 2 O 3 added thereto, the properties were not significantly changed. Other components may be added as far as the objects of the invention are not adversely affected.
EXAMPLE 3
As initial materials, ZrO 2 , TiO 2 , MgO, CoO, ZnO, NiO, MnCO 3 and Ta 2 O 5 of high chemical purity were used, weighed so as to make a predetermined composition as shown in Table 4 and wet-blended with ethanol by using a ball mill. The volume ratio between the powders and ethanol was approximately 2:3. The mixture was removed from the ball mill, dried, and calcined for 2 to 8 hrs at a temperature of 900° to 1250° C. in the air. The calcination product was wet-milled in the ball mill with ethanol. After the milled slurry was removed from the ball mill and dried, the powders were mixed with 8% by weight of polyvinyl alcohol solution of 6% in concentration added thereto as a binder, homogenized, and granulated by sieving through 32 mesh screen. The granulated powders were molded into a disk of 7 mm in diameter and approximately 3 mm in thickness by using molds and an oil hydraulic press at a molding pressure of 1.3 ton/cm 2 . The molding was placed in a magnesia vessel of high purity, kept in the air at a temperature of 400° to 700° C. for 4 to 8 hrs for removing binders, and succeedingly retained in the air at a temperature of 1300° to 1650° C. for 1 to 100 hrs for sintering, and dielectric ceramics were obtained.
The resonant frequency, unloaded Q (Qu ) value and dielectric constant ε r were obtained from measurement by the dielectric rod resonator method. The temperature coefficient at resonant frequency τ f was obtained in a range between -25° and 85° C. The resonant frequency was within a range of 5 to 10 GHz.
The dielectric constants, temperature coefficients at resonant frequency (ppm/°C.) and unloaded Q values obtained in such manner are shown in Table 4. In Table 4those with an asterisk are comparison examples outside the range of the invention.
As obviously recognized from a result shown in Table 4, in dielectric ceramic compositions within a composition range of the third aspect of the invention, the dielectric constant is kept at a high value at microwave frequencies, while providing a high unloaded Q value.
Within the composition range of the invention, when x is higher than 0.60, because the unloaded Q value is significantly reduced as shown in sample No. 152 (Table 4-1), the objects of the invention cannot readily be achieved. Also, when x is below 0.10, since the unloaded Q value is reduced as in sample No. 155 (Table 4-2), the objects of the invention cannot easily be fulfilled.
The unloaded Q value is significantly reduced as seen in sample No. 138 (Table 4-1), when y is higher than 0.60; and the unloaded Q value is too low as in sample No. 134 (Table 4-1), when y is below 0.10 as well, the objects of the invention cannot readily be achieved.
The unloaded Q value is reduced as observed in sample No. 139 (Table 4-1), when z is higher than 0.80; and it is significantly reduced as in sample No. 141 (Table 4-1), when z is lower than 0.01, thus, the objects of the invention cannot readily be achieved.
In addition, although the unloaded Q value can be improved by increasing w to a higher value than 0, the objects of the invention cannot be attained, because the unloaded Q value is significantly reduced, when w is higher than 1.00, as recognized in sample No. 168 (Table 4-2).
Incidentally, it was confirmed within the composition range of the example that the unloaded Q value was superior when powdery oxide of A, which is at least one element selected from Mg, Co, Zn, Ni and Mn, and powdery oxide of Ta calcined beforehand at a temperature of 800° to 1200° C. was used.
Moreover, it was confirmed within the composition range of the invention that the degree of sintering could be enhanced by slightly adding an additive, and the properties were not significantly inferior. For example, although the sintering temperature was reduced by approximately 100° C. when 0.08 wt. % of Al 2 O 3 was added to sample No. 151 (Table 4-1); and it was reduced by approximately 50° C. when 0.08 wt. % of SiO 2 was added, the properties were not changed significantly in either case. Furthermore, even in the case of dielectric ceramics with 0.1 mol % of at least one compound of BaCO 3 , SrCO 3 , La 2 O 3 and Sm 2 O 3 added thereto, the properties were not significantly reduced. Other components may be added as far as the objects of the invention are not adversely affected.
Additionally, a ZrTiO 4 phase or one recognized as being crystallographically a ZrTiO 4 phase was confirmed by powder X-ray diffraction of a dielectric ceramic within the composition range of Examples 1 to 3 of the invention. It was further confirmed in composition analysis by a local X-ray diffractometer of a fracture surface and polished surface of dielectric ceramic having, as the main component, a ZrTiO 4 phase or crystallographically a ZrTiO 4 phase that all components of Zr, Ti, A and B wherein A is at least one component selected from the group (A) consisting of Mg, Co, Zn, Ni and Mn, and B is at least one component selected from the group (B) consisting of Nb and Ta, were present in a single grain, and their composition ratio was consistent with the composition ratio between other grains that constitute the main phase in the same dielectric ceramic. It was also confirmed that all components A and B blended were present in a single grain. Moreover, it was confirmed that a dielectric ceramic with components Zr, Ti, A and B present in a single grain showed a higher lattice constant in comparison with a ZrTiO 4 ceramic not containing A and B obtained under the same sintering conditions. Accordingly, it was confirmed that components A and B are substituted in the ZrTiO 4 phase or the crystallographically ZrTiO 4 phase.
Such dielectric ceramic specifically showed a high unloaded Q value, high dielectric constant, and was superior in thermo-stability at resonant frequency, and the unloaded Q value was even higher, when the molar fraction ratio of component A to component B was 0.5 or more and 1.0 or less.
It would be appreciated that dielectric ceramics according to the fourth and fifth aspects of the invention are capable of maintaining the dielectric constant at a high value at microwave frequencies, while providing a high unloaded Q value, and are superior in thermo-stability at resonant frequency.
EXAMPLE 1
As initial materials, ZrO 2 , TiO 2 , MgO, CoO, ZnO, NiO, MnCO 3 and Nb 2 O 5 of high chemical purity were used, weighed so as to make a predetermined composition as shown in Table 5, and wet-blended with ethanol by using a ball mill. The volume ratio between the powders and ethanol was approximately 2:3. The mixture was removed from the ball mill, dried, and calcined for 2 to 8 hours at a temperature of 900° to 1250° C. in the air. The calcination product was wet-milled in the ball mill with ethanol. After the milled slurry was removed from the ball mill and dried, the powders were mixed with 10% by weight of polyvinyl alcohol solution of 6% in concentration added thereto as a binder, homogenized, and granulated by sieving them through 32 mesh screen. The granulated powders were molded into cylinders of 16, 35 and 70 mm in diameter by using molds and an oil hydraulic press at a molding pressure of 1 ton/cm 2 . The ratio between diameter and thickness of the molding was arranged to be approximately 2:1. The moldings were placed in a magnesia vessel of high purity, kept in the air at a temperature of 400° to 700° C. for 2 to 100 hrs to remove binders, and then retained in the air at a temperature of 1300° to 1650° C. for 1 to 100 hrs for sintering, and dielectric ceramics were obtained. The dielectric ceramic was placed in the center of a cylindrical cavity made of copper with silver plating (10 μm thick), and a dielectric resonator utilizing TE 01 δ-mode resonance of the dielectric by electromagnetic wave emitted from an antenna placed in a side surface of the cavity was constructed. The inner dimensions of the cylindrical copper cavity were about four times larger than the diameter and thickness of the dielectric ceramic, respectively, and the thickness was 5 mm. The resonant frequency and Qu value were obtained by measurement with a vector network analyzer. In the case of a molding with a diameter of 16 mm, the resonant frequencies were 2 to 5 GHz, 35 mm, 1 to 2.5 GHz, and 70 mm, 0.6 to 1.5 GHz.
The resonant frequencies (f) and products f×Qu value obtained in such manner are shown in Table 5. In Table 5, those with an asterisk are comparison examples outside the range of the invention.
As evidently seen from a result shown in Table 5, the TE 01 δ-mode dielectric resonator according to the seventh aspect of the invention has a high unloaded Q value in microwave frequency range and a significantly high unloaded Q value in a relatively low frequency range.
In addition, the volume of dielectric ceramic at resonant frequency of 0.8 GHz is approximately 113 cc in ZrO 2 --SnO 2 --TiO 2 ceramic (ε r =37.0) and 200 cc in Ba(Mg 1/3 Ta 2/3 )O 3 ceramic (ε r = 24.0), for example, while the volume of sample No. 177 (Table 5-1) of the invention, for example, is about 83 cc. As the volume of TE 01 δ-mode dielectric resonator corresponds to that of the dielectric ceramic, the TE 01 δ-mode dielectric resonator according to the seventh aspect of the invention comes to be significantly compact in a relatively low frequency range. Moreover, since the dielectric ceramic is reduced in size and weight as compared with conventional ones, material and manufacturing costs for such a dielectric resonator are reduced.
EXAMPLE 5
As initial materials, ZrO 2 , TiO 2 , MgO, CoO, ZnO, NiO, MnCO 3 and Ta 2 O 5 of high chemical purity were used, weighed so as to make a predetermined composition as shown in Table 6 and wet-blended with ethanol by using a ball mill. The volume ratio between the powders and ethanol was approximately 2:3. The mixture was removed from the ball mill, dried, and calcined for 2 to 8 hours at a temperature of 900° to 1250° C. in the air. The calcination product was wet-milled in the ball mill with ethanol. After the milled slurry was removed from the ball mill and dried, the powders were mixed with 8% by weight of polyvinyl alcohol solution of 6% in concentration added thereto as a binder, homogenized, and granulated by sieving them through 32 mesh screen. The granulated powders were molded into disks of 7, 16, 42 and 70 mm in diameter by using molds and an oil hydraulic press at a molding pressure of 1.3 ton/cm 2 . The ratio between diameter and thickness of the molding was arranged to be approximately 2:1. The moldings were placed in a magnesia vessel of high purity, and kept in the air at a temperature of 1300° to 1650° C. for 1 to 100 hrs for sintering, and dielectric ceramics were obtained. The dielectric ceramic was placed in the center of a cylindrical cavity made of copper with silver plating (10 μm thick), and a dielectric resonator utilizing TE 01 δ-mode resonance of the dielectric by electromagnetic wave emitted from an antenna placed in a side surface of the cavity was constructed. The inner dimensions of the cylindrical copper cavity were about four times larger than the diameter and thickness of the dielectric ceramic, respectively, and the thickness was 5 mm. The resonant frequency and Qu value were obtained by measurement with a vector network analyzer. In the case of a molding with a diameter of 7 mm, the resonant frequencies were 8 to 9 GHz, 16 mm, 3 to 4 GHz, 42 mm, 1 to 2 GHz, and 70 mm, 0.6 to 0.9 GHz .
The values of the resonant frequencies (f) and products f×Qu obtained in such manner are shown in Table 6. In Table 6, those with an asterisk are comparison examples outside the range of the invention.
As is evident from the results shown in Table 6, the TE 01 δ-mode dielectric resonator according to the eighth aspect of the invention has a high unloaded Q value in microwave frequency range and a significantly high unloaded Q value in a relatively low frequency range.
In addition, the volume of dielectric ceramic at resonant frequency of 0.8 GHz is approximately 113 cc in ZrO 2 --SnO 2 --TiO 2 ceramic (ε r= 37.0), and about 200 cc in Ba(Mg 1/3 Ta 2/3 )O 3 ceramic (ε r= 24.0), for example, while the volume of sample No. 211 of the invention, for example, is about 98 cc. As the volume of TE 01 δ-mode dielectric resonator corresponds to that of dielectric ceramic, the TE 01 δ-mode dielectric resonator according to the eighth aspect of the invention comes to be significantly compact in a relatively low frequency range. Moreover, since the dielectric ceramic is reduced in size and weight as compared with conventional ones, the material and manufacturing costs of such a dielectric resonator are reduced.
Although a dielectric ceramic of cylindrical shape is used in Examples 4 and 5, it is not limited to such shape, and it was confirmed by the inventors that the TE 01 δ-mode dielectric resonator having an equivalent or higher unloaded Q value can be constructed by using, for example, an annular dielectric ceramic as well.
As shown in Example 1, because a dielectric ceramic having, as the main component, a complex oxide formed of Zr, Ti, at least one component selected from the group (A) consisting of Mg, Co, Zn, Ni and Mn and at least one component selected from the group (B) consisting of Nb and Ta reduces variation of temperature coefficient at resonant frequency due to the heating history during sintering of ZrTiO 4 and ZrO 2 --SnO 2 --TiO 2 ceramics, the TE 01 δ-mode dielectric resonator comprising such dielectric ceramic, that is, the TE 01 δ-mode dielectric resonator according to the sixth aspect of the invention is useful.
Also, the existence of the ZrTiO 4 phase or crystallographically ZrTiO 4 phase was confirmed by powder X-ray diffraction in the dielectric ceramics of Examples 1 to 5 of the invention. Moreover, it was confirmed in composition analysis by a local X-ray diffractometer of a fracture surface and polished surface of dielectric ceramic having, as the main component, ZrTiO 4 phase or crystallographically ZrTiO 4 phase that all components Zr, Ti, A and B, wherein A is at least one component selected from the group (A) consisting of Mg, Co, Zn, Ni and Mn, and B is at least one component selected from the group (B) consisting of Nb and Ta, were present in a single grain, and their composition ratio agreed with that of other grains that constitute the main phase in the same dielectric ceramic. It was also confirmed that all components A and B blended were present in a single grain. It was further confirmed that a dielectric ceramic with components Zr, Ti, A and B present in a single grain showed a higher lattice constant in comparison with ZrTiO 4 ceramic obtained in the same sintering condition. Accordingly, it was confirmed that components A and B are substituted in the ZrTiO 4 phase or crystallographically ZrTiO 4 phase.
Such dielectric ceramic specifically showed a high unloaded Q value and high dielectric constant, and was superior in thermo-stability at resonant frequency, and the unloaded Q value was even higher, when the A:B molar fraction ratio was 0.5 or more and 1.0 or less. In other words, the TE 01 δ-mode dielectric resonators according to the ninth and tenth aspects of the invention have a high unloaded Q value, while maintaining the dielectric constant at a high value at microwave frequencies, and are superior in thermo-stability at resonant frequency.
Especially, in the dielectric ceramic compositions according to the invention, above all sample Nos. 43 to 53, 62 to 92, 97 to 113 and 112 are specifically superior as compositions in which the dielectric constant and unloaded Q value are high, the temperature coefficient at resonant frequency is low, and niobium which is less expensive than tantalum is used. In addition, as dielectric resonators, sample Nos. 117, 180, 183, 186 to 188, 194 and 195 are particularly superior in such aspect that niobium which costs less than tantalum is used.
According to the dielectric ceramic of the invention, variation of temperature coefficient at resonant frequency due to heat history during sintering of ZrTiO 4 and ZrO 2 --SnO 2 --TiO 2 ceramics can be reduced, a high unloaded Q value is provided, and the temperature coefficient at resonant frequency can be changed as desired without reducing the dielectric constant. In other words, a dielectric ceramic having the temperature coefficient of desired value can be obtained by changing the content of the components of dielectric ceramic composition.
Furthermore, according to the structure of the TE 01 δ-mode dielectric resonator of the invention, a dielectric resonator having a high unloaded Q value in a frequency range of 0.8 to 5 GHz with a compact size can be achieved.
TABLE 1__________________________________________________________________________ Composition (molar fraction)Sample NO. Zr Ti Mg Co Zn Ni Mn Nb Ta Sn__________________________________________________________________________*1, *2 0.50 0.50 0 0 0 0 0 0 0 03, 4 0.35 0.50 0.05 0 0 0 0 0.10 0 05, 6 0.35 0.50 0 0.05 0 0 0 0.10 0 07, 8 0.35 0.50 0.01 0.01 0.01 0.01 0.01 0.10 0 09, 10 0.35 0.50 0.01 0.01 0.01 0.01 0.01 0.05 0.05 0*11, *12 0.40 0.50 0 0 0 0 0 0 0 0.10*13, *14 0.32 0.50 0 0.03 0 0 0 0.05 0 0.10__________________________________________________________________________
TABLE 2______________________________________Sample Cooling conditionNo. after sintering τ.sub.f (ppm/°C.)______________________________________*1 Quenching 53.7*2 Slow cooling 64.33 Quenching 3.54 Slow cooling 3.85 Quenching 5.26 Slow cooling 3.97 Quenching 4.98 Slow cooling 4.89 Quenching 0.510 Slow cooling 0.9*11 Quenching -8.7*12 Slow cooling 1.2*13 Quenching -24.5*14 Slow cooling -16.3______________________________________
TABLE 3-1______________________________________Sam- Compositionple (molar fraction) (Value)No. A x y z w εr τf Qu______________________________________*15 Mg 0.400 0.150 0.450 0 30.2 -85.2 950*16 Co 0.400 0.150 0.450 0 29.8 -70.5 850*17 Zn 0.400 0.150 0.450 0 30.0 -88.6 980*18 Ni 0.400 0.150 0.450 0 30.5 -69.5 850 19 Mg 0.200 0.200 0.600 0 30.0 -48.5 9000 20 Co 0.200 0.200 0.600 0 28.6 -35.6 9300 21 Ni 0.200 0.200 0.600 0 28.0 -30.8 8200 22 Mg 0.450 0.200 0.350 0 31.8 -50.0 5200 23 Co 0.450 0.200 0.350 0 32.6 -28.9 5700 24 Mg 0.200 0.600 0.200 0 57.5 47.5 5500 25 Zn 0.200 0.600 0.200 0 55.5 40.0 6200*26 Mg 0.150 0.700 0.150 0 74.5 189.5 520*27 Co 0.150 0.700 0.150 0 98.8 255.6 210*28 Zn 0.150 0.700 0.150 0 71.5 162.6 630*29 Ni 0.150 0.700 0.150 0 75.5 320.6 190*30 Mg 0.150 0.120 0.730 0 28.0 -85.0 1200*31 Co 0.150 0.120 0.730 0 24.5 -65.8 1000*32 Zn 0.150 0.120 0.730 0 26.9 -88.9 800*33 Ni 0.150 0.120 0.730 0 23.6 -56.7 900 34 Mg 0.100 0.200 0.700 0 33.8 -8.5 9800______________________________________
TABLE 3-2______________________________________Sam- Compositionple (molar fraction) (Value)No. A x y z w εr τf Qu______________________________________35 Ni 0.100 0.200 0.700 0 26.8 -5.6 9500*36 0.550 0.450 0 0 45.8 250.8 180037 Mg 0.490 0.500 0.010 0 44.5 42.5 380038 Co 0.490 0.500 0.010 0 44.3 42.0 360039 Zn 0.490 0.500 0.010 0 43.8 45.9 330040 Ni 0.490 0.500 0.010 0 44.5 46.5 340041 Mg 0.300 0.300 0.400 0 37.5 -32.0 700042 Co 0.300 0.300 0.400 0 38.6 -20.3 560043 Mg 0.400 0.400 0.200 0 42.0 0 960044 Co 0.400 0.400 0.200 0 43.2 12.6 850045 Zn 0.400 0.400 0.200 0 42.0 -5.9 890046 Mg 0.340 0.520 0.140 0 42.6 5.5 750047 Co 0.340 0.520 0.140 0 44.3 8.3 560048 Zn 0.340 0.520 0.140 0 42.9 -3.6 740049 Ni 0.340 0.520 0.140 0 42.4 13.9 480050 Mg 0.450 0.450 0.100 0 41.0 6.5 520051 Co 0.450 0.450 0.100 0 42.6 9.8 490052 Mg 0.400 0.500 0.100 0 41.4 -1.2 860053 Co 0.400 0.500 0.100 0 43.5 -3.6 9300*54 Mg 0.650 0.200 0.100 0 35.8 59.7 1400______________________________________
TABLE 3-3______________________________________Sam- Compositionple (molar fraction) (Value)No. A x y z w εr τf Qu______________________________________*55 Co 0.650 0.200 0.100 0 29.6 21.3 580*56 Zn 0.650 0.200 0.100 0 23.2 36.5 86057 Mg 0.600 0.300 0.100 0 40.2 45.7 480058 Mg 0.100 0.400 0.500 0 64.5 49.8 400059 Ni 0.100 0.400 0.500 0 53.6 48.6 4500*60 Mg 0.050 0.500 0.450 0 82.9 153.2 980*61 Co 0.050 0.500 0.450 0 86.9 213.5 23062 Mg 0.450 0.350 0.200 0 41.5 -9.8 490063 Zn 0.450 0.350 0.200 0 41.3 -21.3 520064 Ni 0.450 0.350 0.200 0 42.5 -3.9 490065 Mg 0.350 0.450 0.200 0 43.5 12.5 600066 Co 0.350 0.450 0.200 0 45.6 26.9 510067 Zn 0.350 0.450 0.200 0 42.5 3.6 580068 Ni 0.350 0.450 0.200 0 42.9 30.6 480069 Mg 0.350 0.450 0.200 0.01 43.5 12.5 635070 Co 0.350 0.450 0.200 0.01 45.6 26.9 530071 Zn 0.350 0.450 0.200 0.01 42.5 3.6 590072 Ni 0.350 0.450 0.200 0.01 42.9 30.6 510073 Mg 0.350 0.450 0.200 0.05 43.1 10.8 670074 Co 0.350 0.450 0.200 0.05 45.1 22.6 5600______________________________________
TABLE 3-4______________________________________Sam- Compositionple (molar fraction) (Value)No. A x y z w εr τf Qu______________________________________75 Zn 0.350 0.450 0.200 0.05 41.9 2.8 620076 Ni 0.350 0.450 0.200 0.05 41.6 25.8 550077 Mg 0.350 0.450 0.200 0.20 42.6 7.5 680078 Co 0.350 0.450 0.200 0.20 44.0 20.3 590079 Zn 0.350 0.450 0.200 0.20 40.3 1.8 650080 Ni 0.350 0.450 0.200 0.20 41.2 18.6 570081 Mg 0.350 0.450 0.200 0.50 42.3 1.2 802082 Co 0.350 0.450 0.200 0.50 42.3 11.9 630083 Zn 0.350 0.450 0.200 0.50 38.0 -1.3 660084 Ni 0.350 0.450 0.200 0.50 40.2 13.5 590085 Mg 0.350 0.450 0.200 1.00 39.8 -3.5 720086 Co 0.350 0.450 0.200 1.00 39.0 5.3 710087 Zn 0.350 0.450 0.200 1.00 35.0 -5.8 730088 Ni 0.350 0.450 0.200 1.00 36.7 4.8 630089 Mg 0.350 0.450 0.200 1.50 37.4 -6.8 640090 Co 0.350 0.450 0.200 1.50 36.5 3.2 690091 Zn 0.350 0.450 0.200 1.50 32.1 -9.8 720092 Ni 0.350 0.450 0.200 1.50 32.6 0.9 6000*93 Mg 0.350 0.450 0.200 1.80 33.5 -12.2 1350*94 Co 0.350 0.450 0.200 1.80 32.6 -5.6 1200______________________________________
TABLE 3-5__________________________________________________________________________ Composition (molar fraction) (Value)Sample No. A x y z w εr τf Qu__________________________________________________________________________*95 Zn 0.350 0.450 0.200 1.80 29.6 -15.6 1400*96 Ni 0.350 0.450 0.200 1.80 29.6 -5.9 850 97 Mg.sub.1/2 Co.sub.1/2 0.340 0.520 0.140 0 43.8 6.1 6900 98 Mg.sub.2/3 Co.sub.1/3 0.340 0.520 0.140 0 43.4 5.7 7200 99 Mg.sub.1/2 Zn.sub.1/2 0.340 0.520 0.140 0 42.8 0.5 7200100 Mg.sub.1/3 Co.sub.1/3 Ni.sub.1/3 0.340 0.520 0.140 0 42.9 8.5 6900101 Mg.sub.1/4 Co.sub.1/4 0.340 0.520 0.140 0 43.0 12.0 5900 Zn.sub.1/4 Ni.sub.1/4102 Mg.sub.1/2 Co.sub.1/2 0.340 0.520 0.140 1.00 43.2 2.6 7100103 Mg.sub.1/3 Co.sub.1/3 Ni.sub.1/3 0.340 0.520 0.140 1.00 40.5 5.2 7600104 Mg.sub.1/4 Co.sub.1/4 0.340 0.520 0.140 1.00 41.2 2.6 6800 Zn.sub.1/4 Ni.sub.1/4105 Mg.sub.39/40 0.340 0.520 0.140 0.02 42.7 5.4 8500 Mn.sub.1/40106 Mg.sub.443/500 0.338 0.517 0.145 0.08 42.6 5.4 8300 Mn.sub.57/500107 Mg.sub.361/500 0.334 0.511 0.155 0.23 42.5 5.3 8200 Mn.sub.139/500108 Mg.sub.113/200 0.328 0.502 0.170 0.41 42.4 5.1 7900 Mn.sub.87/200__________________________________________________________________________
TABLE 3-6__________________________________________________________________________ Composition (molar fraction) (Value)Sample No. A x y z w εr τf Qu__________________________________________________________________________109 Co.sub.487/500 0.340 0.519 0.141 0.02 44.2 8.1 6400 Mn.sub.13/500110 Zn.sub.487/500 0.340 0.519 0.141 0.02 42.5 -3.5 8100 Mn.sub.13/500111 Ni.sub.487/500 0.340 0.519 0.141 0.02 42.3 9.8 6200 Mn.sub.13/500112 Mg.sub.1983/2000 0.350 0.449 0.201 1.01 39.8 -3.8 7600 Mn.sub.17/2000113 Co.sub.1983/2000 0.350 0.449 0.201 1.01 39.2 5.0 7500 Mn.sub.17/2000*114 Mn 0.400 0.050 0.550 0 27.5 -50.2 320115 Mn 0.200 0.600 0.200 0 60.4 49.5 3200*116 Mn 0.150 0.700 0.150 0 78.3 210.9 280*117 Mn 0.100 0.080 0.820 0 20.9 -52.3 1200118 Mn 0.490 0.500 0.010 0 44.7 44.5 3500119 Mn 0.350 0.350 0.300 0 34.8 -23.8 4800120 Mn 0.400 0.400 0.200 0 37.3 -9.8 4700121 Mn 0.300 0.500 0.200 0 46.4 20.5 4500122 Mn 0.400 0.500 0.100 0 43.8 0.9 6300*123 Mn 0.650 0.250 0.100 0 30.4 -15.6 360124 Mn 0.600 0.300 0.100 0 33.1 4.3 4500__________________________________________________________________________
TABLE 3-7______________________________________Sam- Compositionple (molar fraction) (Value)No. A x y z w εr τf Qu______________________________________ 125 Mn 0.100 0.400 0.500 0 48.7 48.6 3600*126 Mn 0.050 0.450 0.500 0 75.2 183.2 240 127 Mn 0.450 0.350 0.200 0 35.5 -15.6 3900 128 Mn 0.330 0.470 0.200 0 43.5 3.5 5300 129 Mn 0.330 0.470 0.200 0.01 43.5 3.5 5500 130 Mn 0.330 0.470 0.200 0.10 43.5 3.4 5500 131 Mn 0.330 0.470 0.200 0.50 43.8 3.9 5800 132 Mn 0.330 0.470 0.200 1.00 43.9 3.9 6000 133 Mn 0.330 0.470 0.200 2.00 45.1 5.2 5000______________________________________
TABLE 4-1__________________________________________________________________________ CompositionSample (molar fraction) (Value)No. A x y z w εr τf Qu__________________________________________________________________________*134 Mg 0.400 0.050 0.550 0 29.8 -77.5 950135 Mg 0.300 0.100 0.600 0 31.0 -48.5 7500136 Mg 0.500 0.100 0.400 0 30.2 -43.5 6400137 Mg 0.200 0.600 0.200 0 58.9 48.2 4100*138 Mg 0.150 0.700 0.150 0 70.3 177.9 680*139 Mg 0.100 0.080 0.820 0 27.9 -56.3 1000140 Mg 0.100 0.100 0.800 0 31.5 -12.5 13500*141 0.550 0.450 0 0 45.8 250.8 1800142 Mg 0.490 0.500 0.010 0 44.8 455 3900143 Mg 0.350 0.350 0.300 0 36.1 -26.5 7800144 Mg 0.400 0.400 0.200 0 38.8 -14.8 6700145 Mg 0.300 0.500 0.200 0 45.5 16.1 8200146 Mg 0.400 0.500 0.100 0 42.5 0 8600147 Co 0.400 0.500 0.100 0 43.5 3.5 8200148 Zn 0.400 0.500 0.100 0 43.5 -3.5 7900149 Ni 0.400 0.500 0.100 0 40.9 1.0 7600150 Mn 0.400 0.500 0.100 0 43.8 4.5 6900151 Mg.sub.1/5 Co.sub.1/5 Zn.sub.1/5 0.400 0.500 0.100 0 42.9 0.7 8900 Ni.sub.1/5 Mn.sub.1/5*152 Mg 0.650 0.250 0.100 0 32.3 -4.5 950153 Mg 0.600 0.300 0.100 0 40.1 5.5 4500__________________________________________________________________________
TABLE 4-2__________________________________________________________________________ Composition (molar fraction) (Value)Sample No.A x y z w εr τf Qu__________________________________________________________________________154 Mg 0.100 0.400 0.500 0 62.8 49.8 3600*155 Mg 0.050 0.450 0.500 0 73.4 135.0 780156 Mg 0.450 0.350 0.200 0 41.5 -9.8 4900157 Mg 0.330 0.470 0.200 0 42.1 -1.0 8700158 Mg 0.330 0.470 0.200 0.01 42.1 -0.8 8800159 Mg 0.330 0.470 0.200 0.05 41.8 -0.5 8950160 Mg 0.330 0.470 0.200 0.20 41.0 0 9200161 Co 0.330 0.470 0.200 0.20 40.5 4.6 8900162 Zn 0.330 0.470 0.200 0.20 40.2 -1.3 8700163 Ni 0.330 0.470 0.200 0.20 38.4 6.0 7300164 Mn 0.330 0.470 0.200 0.20 42.9 3.5 6300165 Mg.sub.1/5 Co.sub.1/5 Zn.sub.1/5 0.330 0.470 0.200 0.20 41.8 0.9 9500Ni.sub.1/5 Mn.sub.1/5166 Mg 0.330 0.470 0.200 0.50 40.0 1.2 9830167 Mg 0.330 0.470 0.200 1.00 37.8 4.5 9950*168 Mg 0.330 0.470 0.200 1.10 32.1 8.9 1800__________________________________________________________________________
TABLE 5-1______________________________________Sam- Compositionple (molar fraction) (Value) f fQuNo. A x y z w (G) (G)______________________________________*169 0.410 0.590 0 0 3.82 40000*170 0.410 0.590 0 0 1.65 25000*171 0.410 0.590 0 0 0.79 8500 172 Mg 0.340 0.520 0.140 0 3.85 58500 173 Mg 0.340 0.520 0.140 0 1.69 51000 174 Mg 0.340 0.520 0.140 0 0.80 35300 175 Mg.sub.39/40 0.340 0.520 0.140 0.02 3.84 60200Mn.sub.1/40 176 Mg.sub.39/40 0.340 0.520 0.140 0.02 1.68 56100Mn.sub.1/40 177 Mg.sub.39/40 0.340 0.520 0.140 0.02 0.81 48700Mn.sub.1/40 178 Mg 0.350 0.450 0.200 1.00 3.95 60000 179 Mg 0.350 0.450 0.200 1.00 1.72 54200 180 Mg 0.350 0.450 0.200 1.00 0.90 46300 181 Mg.sub.1983/2000 0.350 0.449 0.201 1.01 394 60000Mn.sub.17/2000 182 Mg.sub.1983/2000 0.350 0.449 0.201 1.01 1.72 56800Mn.sub.17/2000 183 Mg.sub.1983/2000 0.350 0.449 0.201 1.01 0.91 52500Mn.sub.17/2000______________________________________
TABLE 5-2______________________________________ CompositionSample (molar fraction) (Value) f fQuNo. A x y z w (G) (G)______________________________________184 Co.sub.1983/2000 0.350 0.449 0.201 1.01 3.90 56000 Mn.sub.17/2000185 Co.sub.1983/2000 0.350 0.449 0.201 1.01 1.69 51200 Mn.sub.17/2000186 Co.sub.1983/2000 0.350 0.449 0.201 1.01 0.87 47200 Mn.sub.17/2000187 Zn.sub.1983/2000 0.350 0.449 0.201 1.01 0.88 46500 Mn.sub.17/2000188 Ni.sub.1983/2000 0.350 0.449 0.201 1.01 0.85 48000 Mn.sub.17/2000189 Mn 0.400 0.500 0.100 0 3.83 51000190 Mn 0.400 0.500 0.100 0 1.62 45000191 Mn 0.400 0.500 0.100 0 0.79 35200192 Mn 0.400 0.500 0.100 1.00 3.81 54100193 Mn 0.400 0.500 0.100 1.00 1.62 45300194 Mn 0.400 0.500 0.100 1.00 0.76 38100195 Mg.sub.1/5 Co.sub.1/5 0.400 0.500 0.100 0 0.79 54200 Zn.sub.1/5 Ni.sub.1/5 Mn.sub.1/5______________________________________
TABLE 6__________________________________________________________________________Sam- Composition SnO.sub.2ple (molar fraction) (Value) molar f fQuNo. A x y z w (%) (G) (G)__________________________________________________________________________*196 0.400 0.500 0 0 0.10 9.002 55000*197 0.400 0.500 0 0 0.10 4.036 27100*198 0.400 0.500 0 0 0.10 1.524 15300 199 0.400 0.500 0 0 0.10 0.900 10200 200 Mg 0.330 0.470 0.200 0 0 8.519 74100 201 Mg 0.330 0.470 0.200 0 0 3.884 51800 202 Mg 0.330 0.470 0.200 0 0 1.502 28100 203 Mg 0.330 0.470 0.200 0 0 0.788 25400 204 Mg 0.330 0.470 0.200 0.20 0 8.598 76200 205 Mg 0.330 0.470 0.200 0.20 0 3.942 57200 206 Mg 0.330 0.470 0.200 0.20 0 1.511 31500 207 Mg 0.330 0.470 0.200 0.20 0 0.812 26900 208 Mg.sub.1/5 Co.sub.1/5 Zn.sub.1/5 0.330 0.470 0.200 0.20 0 8.622 81900 Ni.sub.1/5 Mn.sub.1/5 209 Mg.sub.1/5 Co.sub.1/5 Zn.sub.1/5 0.330 0.470 0.200 0.20 0 4.098 63500 Ni.sub.1/5 Mn.sub.1/5 210 Mg.sub.1/5 Co.sub.1/5 Zn.sub.1/5 0.330 0.470 0.200 0.20 0 1.763 56200 Ni.sub.1/5 Mn.sub.1/5 211 Mg.sub.1/5 Co.sub.1/5 Zn.sub.1/5 0.330 0.470 0.200 0.20 0 0.903 48100 Ni.sub.1/5 Mn.sub.1/5__________________________________________________________________________ | The invention provides a dielectric ceramic including as the main component a complex oxide formed of both Zr and Ti, at least one component selected from the group (A) consisting of {Mg, Co, Zn, Ni and Mn} and at least one component selected from the group (B) consisting of {Nb and Ta} and a TE 01 δ-mode dielectric resonator including the dielectric ceramic, and also the invention provides a dielectric ceramic composition expressed by Formula (a):
xZrO.sub.2 --yTiO.sub.2 --zA.sub.(1+w)/3 Nb.sub.(2-w)/3 O.sub.2(a)
wherein A denotes at least one component selected from the group (A) consisting of {Mg, Co, Zn, Ni and Mn},
x, y and z denote molar fractions ranging from 0.10 to 0.60, 0.20 to 0.60 and 0.01 to 0.70, respectively, and have the relation represented by Formula (α):
x+y+z=1 (α)
and w denotes a value of 0 to 1.50, and a TE 01 δ-mode dielectric resonator in which using the dielectric ceramic. | 2 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 14/455,156 filed on Aug. 8, 2014, entitled “MODULE SPECIFIC TRACING IN A SHARED MODULE ENVIRONMENT,” which issued as U.S. Pat. No. 9,292,416 on Mar. 22, 2016, which claims the benefit of and priority to U.S. Provisional Patent Application Ser. No. 61/873,773 filed on Sep. 4, 2013 and entitled “MODULE SPECIFIC TRACING IN A SHARED MODULE ENVIRONMENT,” the entirety of each of which are incorporated herein by reference.
BACKGROUND
Application tracing is one mechanism to understand and monitor an application. Tracing is a mechanism to collect data while the application executes. In some uses, application tracing may be used for monitoring the ongoing performance of an application. In other uses, application tracing may be used by a developer to understand an application, identify any problems, and improve the application.
In many computer languages and communities, some code may be distributed as modules, libraries, or other reusable components. These modules may be distributed as source code, intermediate code, executable code, or some other form, but may all share the characteristic that the modules may be reused by other programmers in many different applications.
SUMMARY
A module-specific tracing mechanism may trace the usage of a module on behalf of the module developer. The module may be used by multiple application developers, and the tracing system may collect and summarize data for the module in each of the different applications. The data may include usage data as well as performance data. Usage data may include anonymized data for each time the module may be invoked and called, and performance data may include the processing time, memory consumption, and other metrics. The module-specific tracing may be enabled or disabled by an application developer.
A tracing system may trace applications and their modules, and may make module-specific data available through various interfaces. The tracing system may collect tracer data while an application executes, and may preprocess the data into application-specific and module-specific databases. An analysis engine may further analyze and process these databases to create application-specific views and module-specific views into the data. The application-specific views may be intended for a developer of the application, while the module-specific views may have a public version accessible to everybody and a module developer version that may contain additional details that may be useful to the module developer.
A database of module performance may be generated by adding tracing components to applications, as well as by adding tracing components to modules themselves. Modules may be reusable code that may be made available for reuse across multiple applications. When tracing is performed on an application level, the data collected from each module may be summarized in module-specific databases. The module-specific databases may be public databases that may assist application developers in selecting modules for various tasks. The module-specific databases may include usage and performance data, as well as stability and robustness metrics, error logs, and analyses of similar modules. The database may be accessed through links in module description pages and repositories, as well as through a website or other repository.
This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings,
FIG. 1 is a diagram illustration of an embodiment showing a system for tracing applications and modules.
FIG. 2 is a diagram illustration of an embodiment showing a network environment with devices that may collect and view application and module trace data.
FIG. 3 is a diagram illustration of an example embodiment showing a user interface for module trace data.
FIG. 4 is a diagram illustration of an embodiment showing an example trace coverage graph.
FIG. 5 is a diagram illustration of an embodiment showing an example module topology graph.
FIG. 6 is a flowchart illustration of an embodiment showing a method for creating applications.
FIG. 7 is a flowchart illustration of an embodiment showing a method for application execution with module tracing.
FIG. 8 is a flowchart illustration of an embodiment showing a method for application execution with application tracing.
FIG. 9 is a flowchart illustration of an embodiment showing a method for preprocessing tracer data.
FIG. 10 is a flowchart illustration of an embodiment showing a method for processing module trace data.
FIG. 11 is a flowchart illustration of an embodiment showing a method for processing requests for module data.
DETAILED DESCRIPTION
Module Specific Tracing System
A tracing system may collect data about modules that may be incorporated into multiple applications. The modules may be shared sets of code that may be distributed among developers, and the developers may select various modules to incorporate into their applications.
Some of the modules may incorporate a tracing mechanism, which may trace the operations of the module and store tracer data. The tracer data may include usage data, which may describe the number of uses, timestamps for uses, conditions under which the module was used, and other usage data. The tracer data may also include performance data, such as the amount of time taken to execute, amount of computational resources, memory resources, network resources, or other resources consumed during execution.
The module specific tracing system may consolidate the raw data for the module developer and for other users. Some embodiments may include a detailed view of the data for module developers and a less detailed view for other users. Module developers may use the tracer data to identify portions of the module that may be executing poorly or have some other issue. The other users may examine the module tracing data to determine a general notion of performance of the module and may use the tracing data as part of the criteria for comparing and selecting one module over another.
In one use scenario, a module developer may incorporate a tracing mechanism in the module. The tracing mechanism may operate within the confines of the module and only trace code within the module. In many cases, the tracing mechanism may be able to gather some metadata about the environment in which the module was executed.
The tracing mechanism may gather tracing data while the module executes in an application. The tracing mechanism may transmit the tracing data to a database for analysis. In many cases, the application developer may have an option to turn off the tracing mechanism or set various options for the tracing mechanism, even though the tracing mechanism may have been initially incorporated and configured by the module developer.
In the use scenario, the tracing mechanism may gather usage and performance data that the module developer may use to improve the module. These tracer data may help the module developer understand which portions of the module are used more frequently than others, which may help the module developer prioritize improving the most used portions. The tracer data may also help identify code that is less reliable than other code, and the data may be used to generate robustness or fragility measurements of individual functions.
In another use scenario, an application developer may access the module specific data to gauge whether or not to use the module in a particular application. The developer may have identified several modules that may serve a particular purpose, and then may use the tracer data as one metric to select between the modules. The application developer may investigate the module's reliability and robustness by viewing the performance and usage data.
Tracing System for Application and Module Tracing
A tracing system may provide tracing for applications and modules using similar techniques and mechanisms yet with some differences. The tracing system may gather tracing data while an application executes, and that data may be shared with the application developer, the module developer, and a wider audience of potential module users. In some cases, the wider audience may be public at large.
Each of the three audiences may have different uses for the tracer data and different security concerns. The application developer may view the application as a trade secret, and may not wish certain tracer information be shared outside of the team developing the application. The module developer may wish to collect data on how the module performed, but may not wish for some details of the operations be disclosed to the general public. The public at large may include developers who may be building their own applications, and these developers may wish to view the module specific data to determine whether or not the module is suited for their use.
The application developer may request tracing be performed on their application. Such tracing data may include tracing information that may be proprietary, such as the values of data elements handled by the application, the application architecture and function, source code of the application, and other information. Because the application developer may consider this as secret or proprietary, such information may be processed and stored in a database that may be separate from the data that may be shared with the module developer and the public at large.
The data collected for each module may be collected when the application is executed. As such, module-specific data collection may be a subset of the available data because the module-specific data may be shared with a module developer who may be another party other than the application development team. In some cases, the module developer may be a third party who may create and disseminate a module without knowing who may use the module in their application.
The module-specific data may be collected as part of executing an application, but only those subsets of data that the application developer may permit to be collected may actually be collected. In many cases, the application developer may have a set of configuration settings that may enable or disable certain types of data to be collected. In some cases, certain data elements may not be collected at all for module-specific tracing.
In some cases, an application developer may disable or not install application-level tracing but may permit a module developer to collect tracer data as a module executes within the application. In such situations, an application may execute without tracing, but when the module is executed, the tracing may occur only within the module. Such module-specific tracing may be processed and made available to the module developer and, in some cases, a wider audience. In such cases, the module-specific tracing may be much more limited in scope than if the application developer had enabled tracing for the entire application.
When an application developer enables tracing for an entire application and permits tracing for individual modules, the application developer may be able to view a complete set of the data relating to each module, with a subset of the data being transmitted and processed in the module-specific manner. In such a situation, the application developer may have access to a superset of data for a specific module than the module developer would be able to access.
Module Database with Tracing Options
A module database may use tracing data to decorate descriptions of modules. The module database may list various modules that may be incorporated into applications. The decorations may include performance and usage data, as well as summaries and other data that may be useful for evaluating modules and comparing modules against each other.
The module database may be constructed by analyzing tracer data gathered while an application executes a module. A tracer may gather performance and usage data for the module during execution, and these data may be aggregated, summarized, and displayed for a user to browse.
The tracer data may include actual usage of the module by third parties, as well as the manners in which the module was incorporated into various applications. The application developers may select and use a module but may only exercise a subset of the module's functionality. In many cases, a module may have many different functions, methods, objects, or other components, yet an application developer may use one a small subset of the components.
The third party usage may be gathered when the application is used by an end user. For example, an application may consist of an app that runs on a mobile device along with a backend component that executes on a server in a datacenter. The end user may exercise the application in many different manners, some of which may exercise the module and some which may not.
The usage data may reflect the popularity and usefulness of the various components of the module. When these data may be presented to the module developer or to other application developers, the data may be arranged as a popularity score or percentage.
The usage data may be tracked over time to determine which applications continue to use the module and which modules are being included and removed from various applications. In many cases, an application developer may select a module, use the module for a short period of time, then switch to another module. In such a situation, the application developer made a conscious decision to switch from one module to another, indicating the application developer's preference for the second module over the first. This preference may be valuable to another application developer who may be considering the use of the first module.
The performance data for the various functions or components within the module may be used to develop a reliability or robustness metric for each function. The reliability or robustness metric may be an indicator of how fragile a function may be, and may be useful for an application developer when selecting specific functions for incorporation in their application. The reliability or robustness metric may be based on the variance of performance metrics or other factors.
The module database may include graphical or other indicators of the architecture of the module. In many cases, a module may include several other modules, each of which may be invoked when an application executes. Such complex interactions may not be readily apparent from reading the source code or from other sources. The graphical representation of the module may give an application developer a visual indication of the complexity of the module and the various dependencies.
The module database may roll up or aggregate various metrics about the dependencies of a module to generate data for a given module. The various use and performance data of the modules may be apportioned to the various modules that actually perform the underlying functions. For example, a module may call a second module to perform certain tasks, and one of those tasks may be performed by a third module. In such a case, the first module's function may be displayed along with the second and third module's functions and the data collected from each of the dependencies.
Throughout this specification and claims, the term “module” is used to define a group of reusable code that may be incorporated into an application. A module may be known as a ‘library’, ‘subroutine’, or some other notion. For the purposes of this specification and claims, these terms are considered synonymous.
The “module” may be code that is arranged in a way that multiple applications may access the code, even though the applications may have no connection with each other. In general, a “module” may be code that is configured to be reused. In some cases, a module may be reused within the scope of a large application, while in other cases, the module may be shared to other application developers who may use the module in disparate and unconnected applications.
Many programming languages and paradigms have a notion of a “module” or library, where the module may have a defined interface through which an application may invoke and use the module. Some paradigms may allow a programmer to incorporate a module in a static manner, such that the module code does not further change after the application is written and deployed. Some paradigms may allow for dynamic libraries, which may be loaded and invoked at runtime or even after execution has begun. The dynamic libraries may be updated and changed after the application may have been distributed, yet the manner of invoking the libraries or modules may remain the same.
Modules may be distributed in source code, intermediate code, executable code, or in some other form. In some cases, modules may be services that may be invoked through an application programming interface.
Throughout this specification and claims, the terms “profiler”, “tracer”, and “instrumentation” are used interchangeably. These terms refer to any mechanism that may collect data when an application is executed. In a classic definition, “instrumentation” may refer to stubs, hooks, or other data collection mechanisms that may be inserted into executable code and thereby change the executable code, whereas “profiler” or “tracer” may classically refer to data collection mechanisms that may not change the executable code. The use of any of these terms and their derivatives may implicate or imply the other. For example, data collection using a “tracer” may be performed using non-contact data collection in the classic sense of a “tracer” as well as data collection using the classic definition of “instrumentation” where the executable code may be changed. Similarly, data collected through “instrumentation” may include data collection using non-contact data collection mechanisms.
Further, data collected through “profiling”, “tracing”, and “instrumentation” may include any type of data that may be collected, including performance related data such as processing times, throughput, performance counters, and the like. The collected data may include function names, parameters passed, memory object names and contents, messages passed, message contents, registry settings, register contents, error flags, interrupts, or any other parameter or other collectable data regarding an application being traced.
Throughout this specification and claims, the term “execution environment” may be used to refer to any type of supporting software used to execute an application. An example of an execution environment is an operating system. In some illustrations, an “execution environment” may be shown separately from an operating system. This may be to illustrate a virtual machine, such as a process virtual machine, that provides various support functions for an application. In other embodiments, a virtual machine may be a system virtual machine that may include its own internal operating system and may simulate an entire computer system. Throughout this specification and claims, the term “execution environment” includes operating systems and other systems that may or may not have readily identifiable “virtual machines” or other supporting software.
Throughout this specification and claims, the term “application” is used to refer to any combination of software and hardware products that may perform a desired function. In some cases, an application may be a single software program that operates with a hardware platform. Some applications may use multiple software components, each of which may be written in a different language or may execute within different hardware or software execution environments. In some cases, such applications may be dispersed across multiple devices and may use software and hardware components that may be connected by a network or other communications system.
Throughout this specification, like reference numbers signify the same elements throughout the description of the figures.
In the specification and claims, references to “a processor” include multiple processors. In some cases, a process that may be performed by “a processor” may be actually performed by multiple processors on the same device or on different devices. For the purposes of this specification and claims, any reference to “a processor” shall include multiple processors which may be on the same device or different devices, unless expressly specified otherwise.
When elements are referred to as being “connected” or “coupled,” the elements can be directly connected or coupled together or one or more intervening elements may also be present. In contrast, when elements are referred to as being “directly connected” or “directly coupled,” there are no intervening elements present.
The subject matter may be embodied as devices, systems, methods, and/or computer program products. Accordingly, some or all of the subject matter may be embodied in hardware and/or in software (including firmware, resident software, micro-code, state machines, gate arrays, etc.) Furthermore, the subject matter may take the form of a computer program product on a computer-usable or computer-readable storage medium having computer-usable or computer-readable program code embodied in the medium for use by or in connection with an instruction execution system. In the context of this document, a computer-usable or computer-readable medium may be any medium that can contain, store, communicate, propagate, or transport the program for use by or in connection with the instruction execution system, apparatus, or device.
The computer-usable or computer-readable medium may be, for example but not limited to, an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, device, or propagation medium. By way of example, and not limitation, computer readable media may comprise computer storage media and communication media.
Computer storage media includes volatile and nonvolatile, removable and non-removable media implemented in any method or technology for storage of information such as computer readable instructions, data structures, program modules or other data. Computer storage media includes, but is not limited to, RAM, ROM, EEPROM, flash memory or other memory technology, CD-ROM, digital versatile disks (DVD) or other optical storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other medium which can be used to store the desired information and which can accessed by an instruction execution system. Note that the computer-usable or computer-readable medium could be paper or another suitable medium upon which the program is printed, as the program can be electronically captured, via, for instance, optical scanning of the paper or other medium, then compiled, interpreted, of otherwise processed in a suitable manner, if necessary, and then stored in a computer memory.
When the subject matter is embodied in the general context of computer-executable instructions, the embodiment may comprise program modules, executed by one or more systems, computers, or other devices. Generally, program modules include routines, programs, objects, components, data structures, etc. that perform particular tasks or implement particular abstract data types. Typically, the functionality of the program modules may be combined or distributed as desired in various embodiments.
FIG. 1 is an illustration of an example embodiment 100 showing a tracer data collection system. Embodiment 100 may be an overview of a process that collects tracer data from an application. The tracer data may fall into application-specific or module-specific classifications, and may be handled differently based on the classification.
A tracer may be incorporated into individual modules or an application as a whole. The tracer output may be used to populate a module database, which may be used by application developers to evaluate, compare, and select modules for their application. The module database may include records for each module for which the tracing system has gathered data.
In some use cases, a module developer may incorporate a tracing mechanism into a module. In such a case, each time the module is incorporated into an application and executed, the embedded tracer may collect data for that module. Unless the tracer is configured otherwise, the tracer may gather data for that module but not for the remainder of the application.
The tracer data may be accessed in multiple manners. Module developers may access tracer data for their modules and view more detailed tracer data than the general public, which may have access to a subset of the tracer data for the module. Application developers may access application-specific data, which may be more detailed than the data available to the module developers or the general public.
As described above, the three classes of audiences may have different uses of the data and different security concerns. For the application developer, the application may be a proprietary project that may include trade secrets or other information that the application developer may not wish to share. This application-specific data may include, for example, the control and sequence of the application, data types handled by the application, the raw data processed by the application, and other information that may be proprietary. As such, the application-specific data may be stored in a separate database than module-specific data and access to the application-specific data may be limited to authorized users.
In many cases, the module developer may have created and distributed a module so that application developers may reuse the module. Module developers may be commercial software companies as well as open source software developers. Such developers may desire to see their modules in use, either for commercial purposes or for the satisfaction of contributing to the community.
The tracer data that may be collected from an application but made available to the module developers may be sanitized, anonymized, or otherwise scrubbed to remove proprietary information from the data. Such operations may limit the application-specific information in the module traces, but may enable the module developer to have access to the module specific data.
A module developer may access module-specific data to monitor the deployment and use of the module, as well as to identify performance issues with the module. The module-specific data may also be made available to a wider audience, such as the general public. The general public may make use of the module-specific data to compare and select modules.
A module developer 102 may contribute modules 104 , which may be used by an application developer 106 to build an application 108 . A tracing module 110 may be incorporated into individual modules 104 or into the application 108 . When a tracing module 110 is incorporated into one or more modules 104 , those modules may be traced. When a tracing module 110 is incorporated into the application 108 , all of the application 108 may be traced, including any modules included in the application 108 .
The application 108 may be executed in an execution environment 112 . During execution, a tracer 114 may gather data, which may be passed to a preprocessor 116 . In many cases, the tracer 114 may gather data and transmit those data to the preprocessor 116 on a periodic basis.
The preprocessor 116 may perform lightweight analyses, formatting, or other processing, then store application-specific data in an application database 118 and module-specific data in various module databases 120 . In many cases, the module databases 120 may be configured with a separate database for each module that may be traced.
An analysis engine 122 may perform further analysis of the stored data to produce analyzed application data 124 or analyzed module data 126 , respectively. The analysis engine 122 may perform many different types of analyses, including analyzing historical data, summarizing usage and performance statistics, graphing and charting data, and other analyses. In some cases, the analysis engine 122 may perform analyses on demand, meaning that some analyses may be performed when the analyzed data may be requested. In other cases, the analysis engine 122 may perform analyses ahead of time so that the analyzed data may be readily available when requested.
A module developer 102 may have private access 130 to the analyzed module data 128 . The module developer's private access of the module-specific data may include details about performance and usage. In contrast, an application developer 106 may have public access 132 to the analyzed module data 128 , which may contain fewer details and only a subset of the data available through the private access 130 of the module developer 102 .
The public access 132 may include summaries of the tracer data collected for the module, including performance and usage statistics. An example of such a user interface may be found later in this specification.
An application developer 106 may have private access 126 to the analyzed application data 124 . This access may include extensive data regarding the performance of the application as a whole, including the performance of the various modules. In some cases, the application developer 106 may be able to access more data or a different set of data than a module developer 104 . For example, an application developer 106 may be able to access parameter values passed to a module, where the parameter values may be proprietary and not available to the module developer 104 .
The application developer 106 may have control over which types of data may be made available to the module databases 120 . For example, the application developer 106 may fully turn off any sharing of the module-specific data, but such data may still be collected, stored, and made available through the private access 126 of the application developer 106 .
The application developer 106 may place various limits on the data that may be shared in the module databases. For example, the application developer 106 may permit usage statistics to be collected, but may not permit values of variables to be collected. The application developer 106 may establish that the data may be obfuscated or anonymized prior to being included in the module databases 120 .
FIG. 2 is a diagram of an embodiment 200 showing components that may collect data when an application executes and present various user interfaces showing the collected data. The example of embodiment 200 is merely one example of a multi-device system that may generate and view tracer data. Other architectures may include single device and multiple device architectures.
The architecture of embodiment 200 includes a device 202 on which the tracer data may be collected, as well as several other devices for storing and processing different elements of the collected data. A client device may present and view the collected data. In other embodiments, some or all of the functions illustrated may be combined into one or more devices.
The diagram of FIG. 2 illustrates functional components of a system. In some cases, the component may be a hardware component, a software component, or a combination of hardware and software. Some of the components may be application level software, while other components may be execution environment level components. In some cases, the connection of one component to another may be a close connection where two or more components are operating on a single hardware platform. In other cases, the connections may be made over network connections spanning long distances. Each embodiment may use different hardware, software, and interconnection architectures to achieve the functions described.
Embodiment 200 illustrates a device 202 that may have a hardware platform 204 and various software components. The device 202 as illustrated represents a conventional computing device, although other embodiments may have different configurations, architectures, or components.
In many embodiments, the device 202 may be a server computer. In some embodiments, the device 202 may still also be a desktop computer, laptop computer, netbook computer, tablet or slate computer, wireless handset, cellular telephone, game console or any other type of computing device.
The hardware platform 204 may include a processor 208 , random access memory 210 , and nonvolatile storage 212 . The hardware platform 204 may also include a user interface 214 and network interface 216 .
The random access memory 210 may be storage that contains data objects and executable code that can be quickly accessed by the processors 208 . In many embodiments, the random access memory 210 may have a high-speed bus connecting the memory 210 to the processors 208 .
The nonvolatile storage 212 may be storage that persists after the device 202 is shut down. The nonvolatile storage 212 may be any type of storage device, including hard disk, solid state memory devices, magnetic tape, optical storage, or other type of storage. The nonvolatile storage 212 may be read only or read/write capable. In some embodiments, the nonvolatile storage 212 may be cloud based, network storage, or other storage that may be accessed over a network connection.
The user interface 214 may be any type of hardware capable of displaying output and receiving input from a user. In many cases, the output display may be a graphical display monitor, although output devices may include lights and other visual output, audio output, kinetic actuator output, as well as other output devices. Conventional input devices may include keyboards and pointing devices such as a mouse, stylus, trackball, or other pointing device. Other input devices may include various sensors, including biometric input devices, audio and video input devices, and other sensors.
The network interface 216 may be any type of connection to another computer. In many embodiments, the network interface 216 may be a wired Ethernet connection. Other embodiments may include wired or wireless connections over various communication protocols.
The software components 206 may include an operating system 218 on which various software components and services may operate. Depending on the embodiment, the application 222 may be executed in an operating system 218 or in an execution environment 220 . An execution environment 220 may have memory management, process scheduling, and other components that may manage application execution in a similar manner to an operating system 218 .
A tracing gatherer 224 may work with either the operating system 218 or execution environment 220 . The tracing gatherer 224 may include a tracer 226 and a communications manager 228 . The tracer 226 may monitor the operations of the application 222 , while the communications manager 228 may transmit the tracer data to a preprocessor system 240 .
The tracer 226 and communications manager 228 may be components of a tracer that may be included in the application 222 . The application 222 may have a tracer 230 which may trace the entire application 222 , including all of the modules 234 . When a module developer wishes to trace their module, a tracer 236 may be included in the specific module 234 to be traced.
The application 222 may include a tracer configuration 232 which may define different parameters for the tracer. In some cases, the tracer configuration 232 may define which data elements may be collected, the precision of the data being collected, which data elements may be shared with module developers, and other items. In some cases, the tracer configuration 232 may define one configuration for one module and a different configuration for another module.
The communications manager 228 may package and transmit tracer data to a preprocessor system 240 , which may be accessed over a network 238 . The preprocessor system 240 may have a hardware platform 242 , which may be similar to the hardware platform 204 , and on which a preprocessor 244 may operate.
The preprocessor 244 may receive tracer data and perform some preliminary processing prior to storing the data in the application database server 246 or the module database server 254 . In many cases, the preprocessor 244 may be designed to handle a high volume of tracer data.
The application database server 246 may have a hardware platform 248 , which may be similar to the hardware platform 204 , on which two databases may operate. An application database 250 may contain application-specific tracer data in raw or preprocessed form. An analyzed application database 252 may contain analyzed application data that may be ready for viewing by an application developer.
The module database server 254 may have a hardware platform 256 , which may be similar to the hardware platform 204 , on which two databases may operate. A module database 258 may contain module-specific tracer data in raw or preprocessed form. An analyzed module database 260 may contain analyzed module data that may be ready for viewing by a module developer or a third party.
An analysis system 262 may have a hardware platform 264 , which may be similar to the hardware platform 204 , on which an analysis engine 266 may execute. The analysis engine 266 may perform various analyses of the application tracer data or module tracer data. The analyses may include summarizing the data, combining the tracer data with other data sources, visualizing the data, or other operations on the data.
An access portal system 268 may have a hardware platform 270 , which may be similar to the hardware platform 204 , on which an access portal 272 may execute. The access portal 272 may be a web service or other application that may gather data from the analyzed application database 252 or the analyzed module database 260 for display on a client system 274 . The access portal 272 may include authentication systems, user account and login systems, billing and accounting systems, and other functions.
The client system 274 may have a hardware platform 276 , which may be similar to the hardware platform 204 , on which a browser 278 may execute. The browser 278 may be used to access the access portal 272 and generate a user interface 280 . The user interface 280 may be different based on the user and the user's credentials. For example, application developers may be able to view application data for their applications, as well as the module database for third party or general consumption. Similarly, a module developer may be able to see detailed module-specific data for their modules but not for other modules or for applications. A third party may be able to view module information permitted for general consumption but not be able to access application data or detailed module-specific data.
FIG. 3 is an example embodiment 300 showing a user interface for module trace data. Embodiment 300 is a user interface 302 that may be an example of a publically available module-specific user interface for a module named CONFIG.
The user interface 302 may represent the type of data that may be publically available after being gathered from a tracer. The tracer may be a module-specific tracer or may be an application-level tracer. The type of data illustrated in the example of embodiment 300 may be merely illustrative as possible types of data and possible methods for aggregating and displaying the data. Other embodiments may have different types of data and mechanisms for communicating the data.
A name 304 may identify the module as CONFIG. A set of summarized ratings 306 may give a user a high level summary of the module's reliability, popularity, and how the module is trending. Reliability may be a metric derived from usage and performance data that may reflect the robustness or fragility of the module as a whole.
Popularity may be a metric that reflects the community's usage of the module. In some cases, the popularity may reflect the module's popularity in comparison to the community as a whole, in comparison to comparable modules, or in some other context.
A trending indicator may indicate if the module is increasing or decreasing in overall popularity and robustness. If the module is being used less and less or if the subsequent releases of the module are poorer performing than previous releases, the trend indicator may be down. Conversely, if the module is gaining users and each release of the module increases reliability, the trend may be upwards.
The reliability, popularity, and trending indicators are merely three examples of high level summary indicators that may be useful for a user interface describing a particular module.
A set of dataset information 308 may display the quantity of data that may underlie the displayed data. In the example, the number of datasets analyzed may be 252,000 and the number of applications using the module may be 15,000. These numbers may lend credibility to the overall data, giving the views confidence that the performance and usage data are based on a statistically significant population of data.
A set of function-specific data 310 may show observations for individual functions within a module. Many modules may include multiple functions, objects, or other components, each of which may be called or invoked individually. In the example, lines 314 , 316 , 318 , and 320 may illustrate summary data for config.foo, config.bar, config.baz, and config.qux, respectively.
The type of function-specific data may include a use percentage, which may indicate which of the functions are used the most. In the case of config.qux, the use percentage may be 0, which may occur when no trace data exists for the function. In one example of an analysis routine, the source code for the config module may be read to identify each of the available functions. The list of functions may be compared with the tracer data to generate some of the function specific data 310 .
An error rate may be determined for each function, as well as the CPU consumption and memory consumption. The resource consumption of CPU and memory may be given as a mean with a standard deviation. The standard deviation may be one metric of a function's stability or reliance. A reliability score for the function may also be included. The reliability score may be determined using an algorithm or heuristic that may capture the variance in resource consumption.
A graph of usage trends 320 may be one mechanism that shows usage of the function over time. In the case of the graph of usage trends 320 , the top portion 322 of the graph may show new applications that add the module, while the bottom portion 324 may show applications that no longer use the module.
In some cases, a module may be added to an application during an initial phase, then removed later when an application developer elects to change out the module for another one. This usage pattern is one mechanism that may indicate that the second module may be better suited for the application that the current module. When a tracing system can capture or infer such behavior, the desirability of the second module may be strongly indicated and the undesirability of the first module may also be strongly indicated. These types of patterns may be very valuable feedback that may be passed to the module developer who may investigate and improve their module, as well as an application developer who may be searching for a module.
The graph may be interactive, and an example interactive box 326 may be placed on the user interface when a user hovers or clicks on one of the bars in the graph. The interactive box 326 may show underlying data for the selected bar.
A coverage graph 328 may visually illustrate the components of the module for which trace data exists. An example of a coverage graph may be found later in this specification.
Similarly, a module topology graph 330 may visually illustrate the links between the current module and other modules that the current module may call. An example of a module topology graph may be found later in this specification.
A competing modules area 332 may list similar or competitive modules to the current module. The modules listed may have hot links, buttons, or other mechanisms that may cause the user interface to change to that module. The competing modules may include indicators showing the relative strength of the other modules, the module's trends, or some other indicators.
FIG. 4 is an example diagram of an embodiment 400 showing a trace coverage graph. The graph 402 may show various functions or components of a module as the nodes of the graph. The edges of the graph may reflect the connections or sequences of execution of the nodes, and may be drawn to reflect amount of data that were used to generate the coverage graph.
In many embodiments, each of the nodes of graph 402 may be labeled with references to the executable code represented by each of the nodes. For the sake of simplicity in the figure, such labels have been removed.
In the example of embodiment 400 , nodes 404 , 406 , 408 , and 410 may be connected with thick, heavy lines. Such lines may indicate that a large amount of trace data may be present for that sequence of execution. In contrast, the sequence of node 404 , 412 , 414 , and 416 may have much less supporting data. In the case of nodes 418 , 420 , 422 , and 424 , the dashed lines may indicate that no trace data may be available. In such a case, the code associated with nodes 418 , 420 , 422 , and 424 may never have been exercised by an application.
The graph 402 may be an interactive graph. As an example of an interaction, a user may hover, click, select, or otherwise indicate node 404 and an interactive component 426 may be displayed. The interactive component 426 may display additional underlying data about the node.
FIG. 5 is an example diagram of an embodiment 500 showing a module topology graph. The graph 502 may show a module and its dependencies, which may be other modules that may be included or called from the base module. The nodes of the graph may reflect the base module and its dependencies. The edges of the graph may reflect the connections or function calls to the dependent modules.
The graph 502 may be a visual image of the call structure of a module, and may be used to give a user a graphical view of the complexity and dependencies of a module.
A module config 504 may be illustrated as a shaded or highlighted node. This node may represent the base node for the graph. The nodes 506 , 508 , 510 , 510 , 512 , 514 , 516 , and 518 may represent modules alpha, beta, gamma, delta, epsilon, zeta, and eta, respectively. The interconnections illustrate the function calls or other dependencies between modules.
In the example of embodiment 500 , the module config 504 is shown to call node 510 , module gamma, which in turn calls node 514 , module epsilon. Module epsilon, node 514 , calls modules zeta and eta, as represented by nodes 516 and 518 . This structure may communicate to a viewer how module eta on node 518 relates to module config 514 .
FIG. 6 is a flowchart illustration of an embodiment 600 showing a method for creating applications. Embodiment 600 illustrates a general method that an application developer may use to create an application that includes one or more modules or libraries.
A developer may begin coding an application block 602 . While coding, the developer may identify a function in block 604 that may prompt a search in block 606 for modules that may perform the function. From the list of candidate modules in block 606 , the developer may evaluate each candidate in block 608 .
The developer may examine the module-specific trace data in block 610 for each of the candidate modules. An example of such data may be found in the user interface of embodiment 300 . From these data, the developer may be able to select an appropriate module in block 612 and incorporate the module into the application in block 614 .
If the module developer has added tracing in block 616 , the application developer may be able to configure various tracing parameters for the module in block 618 . The tracing parameters may allow the application developer to select different options for the tracer.
The tracing parameters may be configured in many different manners to allow the application developer to control how the module may be traced. The module tracing may be requested by a module developer to address specific goals that the module developer may have, yet the application developer may have the final approval and control over how the module tracing may occur. In many cases, the application developer may be able to completely disable tracing for the module, as well as to limit or expand some of the parameters that a tracer may collect.
The tracing frequency may be part of the tracer configuration. In many embodiments, tracing may consume processing and memory resources. As such, the tracing may be performed on a sampling basis or may have other architectures that limit the amount of resources consumed by tracing.
The application developer may be incented to permit tracing for the module because the module tracing data may be fed back to the module developer to help improve the module, as well as to further populate a public database for the module. At this point, the application developer may have already accessed the public database in block 610 and may wish to give back to the community by permitting the module tracing.
If the application developer identifies another function that may be implemented in a module in block 620 , the process may return to block 604 , otherwise the process may continue to block 622 .
In block 622 , the application developer may wish to add application specific tracing. If so, a tracing module may be added in block 624 and the application specific tracing may be configured in block 626 .
The application developer may compile the code in block 628 and execute the code in block 630 .
FIG. 7 is a flowchart illustration of an embodiment 700 showing a method for executing applications with module tracing.
Other embodiments may use different sequencing, additional or fewer steps, and different nomenclature or terminology to accomplish similar functions. In some embodiments, various operations or set of operations may be performed in parallel with other operations, either in a synchronous or asynchronous manner. The steps selected here were chosen to illustrate some principles of operations in a simplified form.
Embodiment 700 illustrates how an application may be executed with module-specific tracing. The module-specific tracing may occur only when the module executes and may not operate when other portions of the application execute.
An application may be received in block 702 and begin execution in block 704 . During execution, a module may be encountered in block 706 . The module may be loaded in block 708 and begin execution in block 710 .
If the module includes tracing in block 712 , tracing may be turned on in block 714 . The tracing may be performed by a separate thread or process, or may be incorporated into a single thread with the module itself. If the tracing is not included in the module, the tracing may not be turned on.
While the module executes in block 716 , the module tracer operations in block 718 may be performed. The module tracer may collect tracing data in block 720 and send the tracer data to a preprocessor in block 722 . In many embodiments, the tracer data may be sent to the preprocessor on a periodic basis, such as every second, every several seconds, every minute, or some other frequency.
The module processing may continue in block 724 by looping back to block 716 . When the module is complete in block 724 , processing may continue to block 726 . When another module is encountered in block 726 , the process may loop back to block 706 . When processing is complete, the application may end in block 728 .
FIG. 8 is a flowchart illustration of an embodiment 800 showing a method for executing applications with both application and module tracing.
Other embodiments may use different sequencing, additional or fewer steps, and different nomenclature or terminology to accomplish similar functions. In some embodiments, various operations or set of operations may be performed in parallel with other operations, either in a synchronous or asynchronous manner. The steps selected here were chosen to illustrate some principles of operations in a simplified form.
Embodiment 800 illustrates how an application may be executed with application-specific and module-specific tracing. Application-specific tracing may occur while the application executes, and module-specific tracing may occur while various modules execute. Embodiment 800 may be compared to embodiment 700 where module-specific tracing may occur without application-specific tracing.
An application may be received in block 802 and begin execution in block 804 . When the application includes tracing in block 806 , application tracing may begin in block 808 . The operations of the tracer may be illustrated in block 810 .
The application may be executed in block 814 . While the application executes in block 814 , the tracer may collect application-specific tracer data in block 812 .
When the application encounters a module in block 816 , the module may be executed in block 818 . While the module executes in block 818 , the tracer may collect tracer data in block 820 .
During the tracer operations of block 810 , the tracer may send tracer data to a preprocessor in block 822 . The tracer data may be transmitted on a periodic basis, for example.
As more code is to be executed in block 824 , the process may loop back to block 814 , otherwise the application may end in block 826 .
FIG. 9 is a flowchart illustration of an embodiment 900 showing a method for preprocessing tracer data. Embodiment 900 may be performed to gather tracer data and dispatch the data to the appropriate databases. The data may be further processed and analyzed by an analysis engine once the data are in the databases.
Other embodiments may use different sequencing, additional or fewer steps, and different nomenclature or terminology to accomplish similar functions. In some embodiments, various operations or set of operations may be performed in parallel with other operations, either in a synchronous or asynchronous manner. The steps selected here were chosen to illustrate some principles of operations in a simplified form.
Embodiment 900 is one example of a preprocessor. In many embodiments, the preprocessor may handle large volumes of data. Consequently, the preprocessor may perform a limited amount of analysis and may operate in a lightweight fashion. The operations of embodiment 900 may be performed on each packet or message sent from a tracer.
The trace data may be received in block 902 . In many cases, the trace data may come in a packet, message, or other form that may contain a group of observations, metadata, and other information gathered by a tracer.
If the trace data is application trace data in block 904 , the module-specific data may be extracted in block 906 , anonymized in block 908 , and sent to a module preprocessor in block 910 . If the trace data is module trace data in block 904 , the trace data is sent to the module preprocessor.
The extraction and anonymizing of module-specific data in blocks 906 and 908 may remove data that may identify the application, data handled by the application, or other information that may relate to the application. These data may, in some cases, be considered proprietary and therefore are removed prior to being added to the module database.
The operations of a module preprocessor are illustrated in block 912 . An initial analysis of the module-specific data may be performed in block 914 . The new data may be aggregated into existing module data in block 916 , and the module database may be updated in block 918 . The data in the module database may be further processed by an analysis engine to generate data viewable by the module developer as well as a wider audience, which may include the general public.
The application-specific data may be processed an application preprocessor as illustrated in block 920 . An application preprocessor may perform initial analysis on the application data in block 922 , aggregate the new data into existing application data in block 924 , and update the application database in block 926 .
FIG. 10 is a flowchart illustration of an embodiment 1000 showing a method for analyzing tracer data. Embodiment 1000 may be performed by an analysis engine to incorporate module trace data into an analyzed module database. From the analyzed module database, the data may be presented to a user with a user interface such as the user interface of embodiment 300 .
Other embodiments may use different sequencing, additional or fewer steps, and different nomenclature or terminology to accomplish similar functions. In some embodiments, various operations or set of operations may be performed in parallel with other operations, either in a synchronous or asynchronous manner. The steps selected here were chosen to illustrate some principles of operations in a simplified form.
Preprocessed trace data may be received in block 1002 . The module metadata may be extracted from the data in block 1004 .
If the module is not in the analyzed module database in block 1006 , a process may be executed to add the module to the database beginning in block 1008 .
In block 1008 , an entry in the analyzed module database may be created. The source code for the module may be retrieved in block 1010 and parsed in block 1012 to locate the exported functions and other objects.
For each of the exported functions or other available objects in block 1014 , the function or object may be added to the analyzed trace database in block 1016 . The process may continue at block 1018 .
If the module is in the database in block 1006 , module level data elements may be extracted from the data in block 1018 and the analyzed module database may be updated in block 1020 .
The functions or other objects in the data may be identified in block 1022 . For each function in block 1024 , the statistics relating to the function may be updated in block 1026 and the statistics used to update the analyzed module database in block 1028 .
Any statistics for the module as a whole may be updated in block 1030 and the updates may be published in the analyzed module database in block 1032 .
FIG. 11 is a flowchart illustration of an embodiment 1100 showing a method for servicing requests for data from analyzed trace data. Embodiment 1100 may be performed by a portal server in response to a request from a client device.
Other embodiments may use different sequencing, additional or fewer steps, and different nomenclature or terminology to accomplish similar functions. In some embodiments, various operations or set of operations may be performed in parallel with other operations, either in a synchronous or asynchronous manner. The steps selected here were chosen to illustrate some principles of operations in a simplified form.
A request may be received in block 1102 for summary data for a particular module. If the user is not an authenticated user in block 1104 , the general data for the module may be retrieved in block 1106 and transmitted to the user in block 1108 . If the user is an authenticated user in block 1104 , the module developer data may be retrieved in block 1110 and transmitted in block 1108 .
In the example of embodiment 1100 , the notion of the data being delivered as a ‘page’ may refer to an example the delivery of the data in the form of a web page. Some embodiments may transmit the data in other manners to be rendered or presented to a user in a user interface.
The foregoing description of the subject matter has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the subject matter to the precise form disclosed, and other modifications and variations may be possible in light of the above teachings. The embodiment was chosen and described in order to best explain the principles of the invention and its practical application to thereby enable others skilled in the art to best utilize the invention in various embodiments and various modifications as are suited to the particular use contemplated. It is intended that the appended claims be construed to include other alternative embodiments except insofar as limited by the prior art. | Visualizing execution of an application in a trace coverage graph includes receiving module trace data gathered during execution of an executable module. The module trace data includes data representing sequences of execution between individual executable components. A trace coverage graph is generated and displayed from the module trace data. The trace coverage graph includes graph nodes that each correspond to a different executable component. The trace coverage graph also includes graph edges that each visually connects two of the graph nodes. Each graph edge visually indicates an amount of trace data present for the sequence of execution between the graph nodes that are connected by the graph edge. Thicker graph edges represent the presence of a larger amount of trace data, and thinner graph edges represent the presence of a lesser amount of trace data. | 6 |
BACKGROUND
Proposals for an electronic compass, to avoid drawbacks of the conventional needle compass, have been known for many years but have seen little practical application.
The present invention is believed to provide an electronic compass that, because it is simple, inexpensive and reliable, should find widespread application. The invention also provides, more generally, a sensitive, inexpensive approach to detection or interaction with magnetic flux.
SUMMARY OF THE INVENTION
According to one aspect of the invention, a flux concentrator made of two similar reeds is vibrated to break a closed flux path infinitesimally and at an irreqular rate to produce an irreqular modulation of the flux that can be readily detected by a pickup coil playing to earphones or a simple amplifier and loudspeaker.
In the prior art of electronic compasses with vibrating flux concentrators, it has been suggested that the vibrating element should be driven near or at its natural mechanical frequency. I have discovered, for present purposes, the converse is true. An extremely inexpensive and accurate device can be achieved using a flux concentrator that is mechanically tapped so as to vibrate non-coherently. The term "non-coherent" as used here is intended to imply that energy is dispersed over numerous mechanical frequencies, a condition that can be called "noisy". While the term is not intended to exclude energy present at the fundamental frequency, or its simple harmonics, it does imply that much of the energy is spread over other frequencies so as to give the overall effect of noise to the ear.
According to one aspect of my invention I have, in a sense, discovered that "cheaper is better" for a class of products which previously may have been thought to require precision. I can use inexpensive, loosely fitted parts made without close tolerances and inexpensive entertainment electronic components to achieve the desired effect.
Another aspect of the invention is a sonic device for detecting the boundary or null regions of a magnetic field, by generating sonic noise from ambient flux, and employing the ear to discriminate between presence and absence of such noise. Leakage currents from the drive of the flux concentrator are a clear tone, amply swamped by sonic noise.
These and numerous other advantageous features are employed in the achievement of the preferred compass.
Another aspect of the invention, more generally, is that of breaking a closed magnetic circuit non-coherently so as to efficiently generate electronic noise in the infinitesimal temporary gaps thus formed and lost, which may find use not only in compasses and magnetometers, but also in certain classes of amplifiers and current generators where a vibratory motion of a flux concentrator may be employed.
Still another aspect of the invention is the use of simple piezoelectric or electromagnetic drive systems for the excitation of the sensing elements.
Various features of this invention are given in the claims which are incorporated here by reference.
DESCRIPTION OF PREFERRED EMBODIMENTS
The preferred embodiments will be described with reference to the figures.
FIG. 1 is a side view of an embodiment of an electronic compass;
FIG. 2 is a plan view of the embodiment of FIG. 1; and
FIG. 3 is a plan view of the piezoelectric transducer employed in the embodiment of FIGS. 1 and 2.
FIG. 4 is a plan view and
FIG. 5 is a side view, partly in section, of another embodiment which has an electromagnetic driver.
Referring now to FIGS. 1 and 2, two elongated flux-concentrating reeds 12, 14, are aligned along axis A in a slightly overlapping relationship. Each reed is formed of magnetic metal (M5 Silicon Steel) of length, L, 11/4 inch; width, W, 1/8 inch; and thickness, t, 0.010 inch. The length of overlap, L OL , is 1/64 inch.
The elements are loosely mounted on posts 16,18 at their remote ends in a manner which biases them into light contact in the region of overlap when the compass is not energized.
A pickup coil 20 surrounds the region of overlap. It is connected, via amplifier 22, to speaker 24. The interior of the coil restrains the reeds from lateral motion.
Post 18, mounting the end of reed 14, is secured to fixed frame 26 while post 16, mounting the end of reed 16, is secured to the margin of piezoelectric transducer 28, which in turn is secured to the frame.
In the operating breadboard design, which these figures represent, the piezoelectric transducer and 2.8 Khz oscillator 30 are taken from an inexpensive piezoelectric alerting device (Sonalert®, SNP 4 from P. R. Mallory & Son). The pickup coil 20 is the 1000 ohm winding of an output transformer from an inexpensive transistor radio, with armature removed. The amplifier 22 and speaker arrangement, 24, are taken from a portable cassette player (Model 892 from Lennox Sound).
Referring to FIG. 3, the piezoelectric crystal is of disc form with electrodes provided to enable excitation and feedback to the oscillator. In known manner, the piezoelectric disc and a brass substrate to which it is secured, are caused to vibrate between concave and convex, dished shapes, with excursions in the direction normal to its plane. A hammer 32 is formed on the piezoelectric transducer in a region of greatest excursion, arranged to contact the underside of reed 12 adjacent the region of overlap, to repeatedly strike the reed 12. Whereas the piezoelectric transducer and feedback controlled oscillator per se form a highly resonant electro-mechanical system, the loosely mounted reeds form a relatively non-resonant, untuned system, comparable to cymbals, say.
Because of this construction the transducer taps the reed intermittently and irregularly, because reed 12 continually changes its position relative to the transducer at the time of contact with the hammer. The second reed 14 is jangled through its loose contact with the first reed, its loose constraints preventing it from damping the first reed excessively as well as allowing it to participate in the disorderly motion.
The reeds, thus excited, can be heard to make a slight tinny sound and the intermittent contact between them makes a slight rustling sound. If the reeds are in a magnetic path, the output of the coil, played to the speaker, sounds roughly like noise.
When a very slight flux is present, noise from the loud speaker is heard, but when no flux is present, the noise disappears. Thy system is thought to be extraordinary (for its class) in detecting small magnetic fields, and is particularly notable for finding the east-west null in the earth's magnetic field by simply scanning the device in a horizontal arc. Discrimination between east and west is readily achieved by sensing the rise of the null towards compass north or the sinking to the south.
As a possible explanation of the sensitivity that has been observed, it is thought that the wide distribution of frequencies so reduce the energy at any one frequency that magnetostrictive effects are abated. Also conversion of the frequency of the external mechanical force to alien noise energy reduces input and output coupling, to make discrimination by the ear easy. Noise is peculiarly advantageous for nulling by ear, and it can be pulsed 3 times a second, say, to fight wind noise.
Referring to FIGS. 4 and 5, the reed 12 in this case is driven by an elongated bar 40 mounted at nodes 42 to vibrate in the manner of a xylophone bar. Hammer 32 at one end of the bar strikes the loosely mounted reed 12 in the manner previously described, while the opposite end of the bar is driven by an electromagnetic drive system 44. For this purpose magnet 46 is carried by the bar, arranged to interact with electromagnet 48 which is driven by a control chip 50 powered e.g. by 3 v. battery. The bar, for instance, may be 1/8 inch diameter brass tubing, 7 inches in length, adapted to resonate at 100 Hz. The electromagnet drive system may be taken from a STAR MMB Buzzer sold by Meshna of Lynn, Massachusetts, the pickup coil may be a telephone pickup and the reeds may each be 11/2 inch by 1/4 inch by 0.010 inch M5 silicon steel.
In this design the pickup, being quite remote from the drive, does not respond substantially to stray oscillating energy of the drive.
Other embodiments for delivering noisy agitation to a flux path, and in particular to a gap of a flux path, are within the spirit and scope of the claims. | Concentrated lines of flux through two loosely mounted magnetically contacting reeds are intermittently mechanically interrupted by breaking the contact infinitesimally, thus deriving a near-maximum generated EMF in a coil surrounding the contact. A piezo transducer driven in feedback arrangement by an oscillator provides an energy-efficient drive for a hammer that irregularly strikes one of the reeds. A compass based on this noncoherent modulation of a flux path is shown and other devices based upon this principle are mentioned. | 6 |
BACKGROUND OF THE INVENTION
For the decaffeination of coffee, a fairly large number of processes have been proposed in the past. Many if not most of these processes have in common a pretreatment of the raw coffee with water, followed by a treatment with solvents designed to act as selectively as possible on the caffeine to dissolve and permit the removal of the same. Prime examples of solvents proposed in the prior art are esters, aromatic hydrocarbons and particularly, halogenated hydrocarbons used either by themselves or as mixtures. Also known is the treatment of aqueous extracts of raw or roasted coffee, in counter-current apparatus, e.g. with chlorinated hydrocarbons whereby to remove the caffeine, the aqueous extract free from caffeine being returned to the extracted beans.
The solvent used must be completely removed, at elevated temperature, from the beans and the extracts, a requirement usually met by steaming with water vapor, a procedure which entails technical and analytical complications and expenditure. For this reason, numerous attempts have been made to remove the caffeine from coffee in some other way. Thus, U.S. Pat. No. 1,640,648, for example, proposed a method utilizing the property of caffeine to sublimate at elevated temperatures. In an initial stage of this process, the raw coffee, in order to be liberated from caffeine, is treated with alkaline substances. Subsequently, the raw coffee is heated to 178° C. and while at this temperature, exposed to a current of inert gas passed through it. The caffeine which sublimates at this temperature, is carried away by the gas current. Inert gases proposed include hydrogen, nitrogen and carbon dioxide. This process did not succeed in attaining terminal values below 0.35 percent of caffeine in the raw coffee, with the result that coffee so processed may not be considered to be free from caffeine, or to have a low caffeine content, by the standard set e.g. by German nutritional regulations. Further important drawbacks of this method include exposure of the coffee to alkali, and to high temperatures.
Another process disclosed in (printed German application) DT-AS No. 2,005,293 removes caffeine from moistened raw coffee by means of supercritical, i.e. gaseous carbon dioxide. The preferred range of operation is between 40° C. and 80° C.; the lower limit is the critical temperature of the carbon dioxide. The treatment of the raw coffee at temperatures within this range yields a coffee which when roasted, fails to have a fully satisfying taste.
Further research demonstrated that caffeine may be removed from raw coffee also at temperatures below the critical temperature, by means of liquid carbon dioxide. The decaffeination works with a mixture of liquid and gaseous carbon dioxide as well as with liquid carbon dioxide alone (i.e. at pressures somewhat above the vapor pressure of the liquid carbon dioxide). Under these conditions, however, the dissolving power of the liquid carbon dioxide is not very selective so that in addition to caffeine, other substances are removed from the raw coffee which play an important part in the formation of aroma in the course of roasting. Coffee treated with liquid CO 2 , therefore, suffers from an inferior aroma.
The properties of liquid carbon dioxide when used as a solvent for caffeine, have been investigated and described a number of times. Thus M. Sivetz, in "Coffee Processing Technology", vol. 2, pp. 21-23, discusses the recovery of coffee aroma oil. In this connection, British Pat. No. 11 06468 and Austrian Pat. No. 2 85 307 may also be mentioned. Similarly, the production of other aroma concentrates by means of liquid carbon dioxide has been described e.g. in "Food Technology" No. 23,11,50 (1969); such aroma concentrates are mixtures of a very large number of components. Thus, in the extraction of raw coffee with liquid carbon dioxide, removal of caffeine is accompanied by the simultaneous removal of other substances. As a result, the caffeine recovered is badly contaminated while the coffee lacks components which have an important influence on the formation of aroma.
A more recent proposal made in DT-AS No. 22 12 281 utilizes the fact that an increase of pressure in the extractor, greatly increases the selectivity of liquid carbon dioxide for caffeine. With pressures above the critical pressure, in particular, the caffeine removed from the coffee is substantially pure, while the content, in the coffee, of substances important for aroma formation, is not noticeably reduced. This process involves treatment of raw coffee with water until a moisture content of from 10 to 60 percent by weight has been obtained, and selective extraction of caffeine with liquid carbon dioxide saturated with water, at a pressure exceeding the critical pressure.
The caffeine so extracted is recovered as a white powder of a purity above 98 percent. Preferably, the extraction is carried out in the temperature range between 0° C. and the critical temperature of the carbon dioxide, and at pressures above 80 bar. The moisture content of the raw coffee is obtained, in known manner, by a steaming preceeding the extraction. The caffeine dissolved in the liquid CO 2 is removed in an activated carbon adsorber. The activated carbon, which previously had been saturated with water, adsorbs the dissolved caffeine quantitatively. The solvent is purified and recycled by a pump.
Instead of purifying the circulating medium by means of an activated carbon adsorber, the caffeine may be separated from the solvent also by first conducting the caffeine containing solvent into a separator, for evaporation therein. The vapor is condensed in a cooler and returned by a liquid pump to the extractor. On evaporation the solvent, the caffeine is retained quantitatively in the separator for ready discharge therefrom. Inasmuch as in the course of evaporation in the separator, the carbonic acid suffers from a loss of water, a corresponding volume of water must be added to the carbonic acid before it is returned to the extractor.
BRIEF SUMMARY OF THE INVENTION
The present invention involves a process for the decaffeination of coffee and the recovery of the caffeine wherein from raw coffee pretreated with steam until its moisture content is about 15 to 55 percent by weight, the caffeine is removed by means of a compressed gas and an entrainer, and in an auxiliary column, the caffeine is separated from the circulating gas by partial condensation of the entrainer, in the absence of any decompression, the raw caffeine being recovered from the condensate by evaporation of the entrainer.
DETAILED DESCRIPTION OF THE INVENTION
Thus, the invention utilizes for extraction of the caffeine, a mixture of compressed gaseous and volatile components. It has been found that nitrogen, for example, when placed under pressures above 150 bar, has highly selective solvent characteristics with respect to caffeine. The selectivity of nitrogen, however, is not as great as that of compressed carbon dioxide. Yet, the addition of a suitable volatile solvent or entrainer, very materially increases the solubility of the caffeine in a compressed gas such as nitrogen.
The entrainer dissolves in the compressed gas in an amount corresponding to a multiple of its vapor pressure. It is expedient to add to the compressed gas such a quantity of entrainer that under the prevailing process conditions, it is entirely or almost saturated with the entrainer. A particularly advantageous mode of operation involves a selection of pressure and temperature such that the system of compresses gas and entrainer is supercritical, for in this case it is possible to provide a substantially unlimited concentration of entrainer in the gas phase. In this manner, at the same time a high solubility of the caffeine is obtained.
In order to separate the caffeine dissolved in the mixture of compressed gas and entrainer, the compressed gas, at constant pressure, is either heated or cooled, dependent on whether the saturation concentration of the entrainer in the compressed gas rises or falls with the temperature. Both cases are possible. In accordance with the invention, this process step is designed to condense part of the entrainer. At the same time, the condensed part of the entrainer serves the purpose of washing the caffeine out of the circulating compressed gas. If by an appropriate choice of temperature, the condensed portion of the entrainer is kept small, relatively concentrated solutions of caffeine are obtained from which pure caffeine is readily recovered.
If for the extraction, conditions are so selected that the mixture of compresses gas and entrainer is supercritical, for the separation of the caffeine a temperature is chosen which will render the mixture of compressed gas and entrainer subcritical. Usually, this is accomplished by an increase of temperature.
In the drawing accompanying this specification, an embodiment of apparatus suitable for carrying out the process of the invention, is illustrated diagrammatically by way of example.
In the drawing (wherein FIG. 1 is the sole FIGURE). a pressure vessel 1 is shown which serves as the extractor; here the coffee is brought into intimate contact with a mixture of compressed gas and entrainer. As a result, the mixture of compressed gas and entrainer is charged with caffeine. Once it has passed the extractor, the circulating medium enters the column 2. At the head of this column, a heat excharger 4 is located which is designed to condense part of the entrainer. The condensed entrainer descends in the column 2 in counter-current relative to the circulating medium, and in the course of its descent, washes out the caffeine dissolved in the circulating medium. The sump of column 2 accomodates the heat exchanger 3 which may serve the purpose of concentrating the caffeine solution by partial evaporation of the solvent. The entrainer charged with caffeine, which contains dissolved the equilibrium quantity of compressed gas, is discharged at the sump of column 2. Column 2 may be a plate column or a packed column.
The circulating medium freed from caffeine in column 2, is returned, by the circulation gas pump 5, to the extractor 1 wherein it is recharged with caffeine. The losses in compressed gas and entrainer, caused by the withdrawal of the caffeine solution, are replaced by the addition of gas and entrainer to the extractor.
Once the caffeine content of the raw coffee in the extractor has dropped to the desired value, pressure in the extractor is removed and the extractor emptied. The charging and discharging of the extractor, however, may also be effected by means of pressure gates in the absence of decompression of the extractor contents, in known manner. The charging and discharging of a pressure container filled with solid material by means of gates is a known procedure used, for example, in the gasification of solid fuels in stationary beds.
Entrainers contemplated by the invention are, for example, chlorinated hydrocarbons, in particular, chlorinated alkanes, preferably those having from 1 to 2 carbon atoms and from 1 to 4 chlorine atoms in the molecule, as e.g. methylenechloride, dichlorethylene and trichlorethylene.
In another embodiment of the invention, solvents contemplated include esters, preferably those of aliphatic acids, such as fatty acids having from 2 to 4 carbon atoms, with aliphatic alcohols, preferably those with from 1 to 3 carbon atoms. Good results, however, were also obtained when using corresponding esters of aliphatic dicarboxylic acids having from 3 to 4 carbon atoms, or else esters of aceto-acetic acid. Examples are: methylacetate, ethylacetate, propylacetate, ethylpropionate, malonic acid dimethylester and aceto-acetic acid methylester.
Still another embodiment of the invention contemplates, as solvents, ketones having from 3 to 6 carbon atoms, such as acetone, methylethylketone, and acetylacetone.
Solvents particularly preferred for purposes of the invention are aliphatic alcohols, preferably those having up to 3 carbon atoms such as methylalcohol, ethylalcohol, isopropylalcohol, as well as formaldehyde dimethylacetal. If formaldehyde dimethylacetal is used, it is preferably saturated with water. The solubility of water in formaldehyde dimethylacetal, at 20° C., amounts to about 11.5 percent by weight, and at 40° C., to about 14.9 percent by weight.
It is expedient to pretreat the raw coffee to be extracted by the process of this invention, prior to the extraction, by steaming so as to obtain a moisture content between 5 and 55 percent by weight, as is usual for processes of caffeine extraction.
For use as entrainers, solvents are preferred to which water has been added in a quantity such that the binary supercritical mixture of gas and entrainer is saturated with water vapor. Inasmuch as in the column wherein the caffeine is separated, relatively more water condenses than solvent, it is necessary to supply quantities of water and solvent corresponding to the respective losses of either, to the circulating medium after it has passed through the column.
The temperature at which the raw coffee is treated in accordance with the invention, may very between about 0° C. and 100° C. Preferred, however, are temperatures between about 20° C. and 45° C. At temperatures roughly corresponding to room temperature, the raw coffee remains substantially unchanged even over very long periods of treatment, e.g. for 3 days.
In addition to nitrogen, the invention contemplates the use of other compressed gases, such as carbon dioxide, nitrous oxide, ethane, ethylene, methane, propane, propylene, and monochlorotrifluoromethane.
The working pressures used in the extraction may very within wide limits. Nevertheless, with gases having a low critical temperatures, such as nitrogen and methane, higher pressures in the range from about 150 to about 1000 bar, and preferably from about 150 to about 500 bar, should be selected. If as the compressed gases according to the invention, gases are used the critical temperature of which is near or within the temperature range from about 0° C. to 100° C., the working pressures will exceed the respective critical pressures. In the latter case, generally speaking, a somewhat lower pressure of up to about 200 bar will suffice. Thus, the pressure range of CO 2 is situated between about 75 and about 200 bar, that of nitrous oxide between about 72 and about 200 bar, that of ethane between about 50 and about 200 bar, that of ethylene between about 51 and about 200 bar, that of propane between about 40 and about 200 bar, that of propylene between about 45 and about 200 bar, and that of monochlorotrifluoromethane between about 40 and about 200 bar.
The invention may be further illustrated by the following examples which are intended to more fully explain the invention rather than to limit it beyond the scope of the claims.
EXAMPLE 1
In apparatus corresponding to FIG. 1 of the drawing, 0.5 kg of raw coffee pretreated to have a moisture content of 46 percent by weight, are treated, at a temperature of 40° C. and at a pressure of 200 bar, for 14 hours, with nitrogen and formaldehyde dimethylacetal; the nitrogen contained about 3 percent by weight of formaldehyde dimethylacetal. The circulating gas composed of nitrogen and formaldehyde dimethylacetal was saturated with water vapor. In the auxiliary column, the circulation gas was cooled to 20° C. The mixture of water and fromaldehyde dimethylacetal which condensed due to the cooling of the circulating medium, contained, in solution, the extracted caffeine. At the end of the extraction procedure it was found that the caffeine content of the raw coffee had been reduced to 0.07 percent by weight.
EXAMPLE 2
In apparatus according to FIG. 1, 0.5 kg of raw coffee with a moisture content of 50 percent by weight, were treated, at 45° C. and at a pressure of 90 bar, for 14 hours, with carbon dioxide and formaldehyde dimethylacetal, the formaldehyde dimethylacetal being contained in the carbon dioxide in an amount of 17 percent by weight of the carbon dioxide. The circulating gas composed of carbon dioxide and formaldehyde dimethylacetal was saturated with water vapor. In the auxiliary column, the circulating gas was heated to 80° C. The mixture of formaldehyde dimethylacetal and water which condensed, contained dissolved in it, the caffeine extracted. The extraction process resulted in a lowering of the caffeine content of the raw coffee, to 0.06 percent by weight.
We wish it to be understood that we do not desire to be limited to the details of process and apparatus described in the specification and shown in the drawing, as modifications within the scope of the claims and not departing from the spirit of the invention, may readily occur to those skilled in the art. | The invention involves a process for the decaffeination of coffee, wherein--usually moistened--coffee is exposed to a circulating medium essentially composed of a compressed gas and an entrainer; this medium is subjected to partial condensation of the caffeine containing entrainer, in the absence of decompression; the caffeine is recovered from the condensate by evaporation of the entrainer portion thereof, and the medium is recycled to the coffee for continued extraction of caffeine therefrom. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a frame which can be moved between a folded-in position and a folded-out position and which is provided with suspension means intended for suspending the frame from a vertical element, an arm assembly comprising at least three arms which, at one end, are hingedly connected to an arm joint and a rod assembly, the rods of which, at one end, are hingedly connected to a rod joint which cooperates with the arm assembly, which assemblies are designed such that the arms extend substantially in the same direction in the folded-in position at a relatively small distance next to one another and occupy a relatively small area in a direction transverse thereto, and in the folded-out position occupy a relatively large area in a direction transverse thereto.
2. Description of Related Art
A frame of this type is known for example from rotary clotheslines. These rotary clotheslines have a central column or pole, relative to which usually four arms can be folded out or in. The pole has to be placed in a sleeve which is arranged in the ground, or in a base which serves to ensure the stability of the drying device.
Although the known rotary clotheslines have been in use for a long time and are also relatively user-friendly, they nevertheless also have drawbacks. The fact is that a rotary clothesline is often not installed permanently in a specific position. This is due to the space a rotary clothesline occupies; even in the folded-in position, the rotary clothesline is an inconvenient obstacle. Furthermore it is often not a viable option to install the rotary clothesline permanently because of its less attractive appearance.
For these reasons, the rotary clothesline is re-installed with every use and then removed again. This is inconvenient and leads to the user being less satisfied. In addition, this makes it less attractive to use the rotary clothesline for small amounts of washing.
SUMMARY OF THE INVENTION
It is therefore an object of the invention to provide a frame of the abovementioned type, for example for a drying device, which does not have these drawbacks. This object is achieved by the suspension means cooperating with a section of the arm assembly and/or with a section of the rod assembly which is/are at the periphery of the planes defined by the frame.
Positioning the suspension means on the periphery of the frame results in a number of advantages which were hitherto impossible to achieve with the known rotary clotheslines. First and foremost, it is no longer necessary to use a pole. As there no longer is a pole under the frame, the frame can be used to better advantage. Another important fact is that the frame can be folded up, for example against a wall. Such a position is usually at such a distance from the open space that it is not inconvenient to permanently attach the frame which has been folded in such a manner to a wall or the like. This increases user-friendliness. It is then no longer necessary to hang the frame or put it away each time it is being used. The frame only has to be folded out and is then ready for use.
The suspension means can in particular be connected to at least one of the arms; alternatively or additionally, the suspension means are connected to at least one of the rods. As is conventional, the arms are hingedly connected at one end to an arm joint and the rods of the rod assembly are hingedly connected at one end to a rod joint; each of these rods is connected to an associated arm at a distance from the rod joint by means of a hinge pin, which hinge pin is located between the ends of this arm.
According to a preferred embodiment of the invention, one of these rods extends beyond the hinge pin of the associated arm; this rod and arm support the suspension means at their end which is remote from the end remote from the rod joint and arm joint, respectively. The aim joint and the arms are provided with stops which interact with one another in the folded-out position; the rod joint and the rods are likewise provided with stops which interact with one another in the folded-out position.
The arm which is provided with the suspension means is preferably designed in two sections, comprising two parallel arm sections enclosing a gap. The associated rod which is also provided with suspension means is accommodated between those arm sections and hingedly connected thereto.
The suspension means connected to the arm preferably comprise a suspension piece which can be connected to the vertical element, which suspension piece is connected to the arm by means of a fixed hinge; the suspension means connected to the rod preferably comprise a detachable coupling.
The detachable coupling can be designed in various ways. By way of example, an embodiment is mentioned in which the detachable coupling comprises a base piece which can be connected to the vertical element and counterpiece connected to the rod, which base piece has at least one stop face and which counterpiece has at least one stop element such that the stop face is directed transversely to the rod in the stop position of the rod, in which the stop element bears against the stop face. By tilting the frame about the fixed coupling of the arm, the rod can be coupled and uncoupled, respectively. Such a coupling movement is easy to carry out when putting the frame away or putting it out to use.
Furthermore, locking means may be provided for locking the rod relative to the base piece. These locking means may comprise a snap element which is under resilient prestress and can be displaced counter to the spring prestress by the counterpiece and which, once the stop position of the counterpiece has been reached, can rebound relative to the base piece in order to lock the counterpiece relative to the base piece.
In a very stable embodiment, two stop faces and associated stop elements may be provided, the snap element being located between the two stop faces.
A guide may be provided opposite each stop face, which stop face and which guide enclose a guide slot in such a manner that the associated stop element can be guided to the stop position through the guide slot.
The suspension means may comprise a suspension plate which is connected to one of the arms and one of the rods; the suspension means can preferably pivot about a hinge pin which is parallel to the direction in which the folded-in arms extend.
The invention also relates to a drying device, comprising a frame as described above, and to lines extending in each case between two neighboring arms. Finally, the invention relates to a screen device comprising a frame of this type and screens extending in each case between two neighboring arms.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described in more detail below with reference to an exemplary embodiment of a frame which forms a section of a wall drier illustrated in the figures, in which:
FIG. 1 shows a vertical section through the wall drier according to the invention in the folded-out position;
FIG. 2 shows the semi-folded position;
FIG. 3 shows the folded-in position;
FIG. 4 shows a perspective view of the folded-out frame of the wall drier according to FIGS. 1-3 ;
FIG. 5 shows a plan view of the folded-out wall drier;
FIG. 6 a shows a detail on an enlarged scale according to VI of FIG. 1 ;
FIG. 6 b shows the operational principle of the detail of FIG. 6 ;
FIG. 6 c shows the locking action of the detail of FIG. 6 a;
FIG. 7 shows the detail of FIG. 6 in the position where it is almost locked;
FIG. 8 shows the detail of FIG. 6 in the unlocked position;
FIG. 9 shows a cross section along IX-IX according to FIG. 6 ;
FIG. 10 shows the view X-X from FIG. 6 c.
DETAILED DESCRIPTION OF THE INVENTION
The wall drier illustrated in FIGS. 1-3 and 5 comprises an arm assembly denoted overall by reference numeral 1 and a rod assembly denoted in its entirety by reference numeral 2 . In the exemplary embodiment shown, the arm assembly comprises four arms 3 , 4 , which are hingedly connected to one another at the arm joint 5 . The rod assembly comprises four rods 6 , 7 which are hingedly connection to one another by a rod joint 8 .
Approximately halfway along its length, each of the arms 3 is connected to a rod 6 by means of a respective hinge 9 . As illustrated in FIGS. 1-3 , a handle 41 is provided on a section of the arm assembly 1 which is remote from the section of the arm assembly 1 on which a suspension piece 13 is provided. The arm 4 is designed in two sections and comprises two adjacent arm sections 4 ′, 4 ″, which enclose a gap 10 between them. The rod 7 is accommodated in this gap. This rod 7 is hingedly connected to both arm sections 4 ′, 4 ″ of the arm 4 by means of a hinge 11 (see FIGS. 3 and 4 ). The rod 7 has centering tracks 40 which extend transverse to its longitudinal direction for centering the rod 7 between the coupling parts 27 when the rod 7 is swung to the coupled state.
As illustrated in FIGS. 1 to 3 , the end of the arm sections 4 ′, 4 ″ remote from the arm joint 5 is connected to the suspension piece 13 by means of the hinge 12 . The suspension piece 13 can pivot about a hinge pin 12 which is perpendicular to the direction in which the arms 3 , 4 extend in the folded-in position. The rod 7 is connected in turn to the suspension piece 13 by means of a detachable coupling 14 . The detachable coupling 14 includes a base piece 23 which can be connected to the vertical element, and a counterpiece 25 , e.g., a pin 25 , connected to the rod 7 , which base piece 23 has at least one stop face 24 and which counterpiece 25 has at least one stop element such that the stop face 24 is directed transversely to the rod 7 in the stop position of the rod 7 , in which the stop element bears against the stop face. The suspension piece 13 has a top cover 15 and a bottom cover 16 , within the contour of which the rod 7 and arms 3 , 4 of the frame can fall in the folded-in position. The suspension piece 13 may, for example, be attached to a wall, i.e., the vertical element. Incidentally, the other portion of the suspension piece 13 , which is below the coupling 14 , can also be omitted.
Each of the arms 3 , 4 has holes 17 for passing washing lines through, which are taut when the frame is in its folded-out position. In the plan view of FIG. 5 , the washing lines 22 are illustrated which are pulled taut between the arms 3 , 4 .
Both the arm joint 5 and the rod joint 8 have stops 18 and 19 , respectively, against which the flat sides 20 and 21 of the arms 3 , 4 and 6 , 7 , respectively, come to bear in the completely folded-out position. Thus a stable folded-out position of the frame is ensured.
The enlarged detail of FIGS. 6 a to 8 illustrates the detachable coupling 14 . This coupling comprises a base piece 23 which has a stop face 24 . In the coupled state, the longitudinal direction of the rod 7 runs approximately perpendicular to the stop face 24 . As a result, the pin 25 connected to this rod 7 rests against the stop face 24 in a stable manner.
When the arm 7 is coupled to the base piece 23 , the pin 25 slides along the stop face 24 and beyond the snap element 37 (see also FIG. 10 ). This can be resiliently pushed back counter to the prestress, for example by spring 39 . Once the pin 25 has parried the snap element 37 , the snap element 37 snaps back and the arm 7 is locked behind the nose 38 of the snap element 37 .
The arm 7 is furthermore connected to the base piece 23 by the coupling element 26 . To this end, the coupling element 26 , which has two parallel arms 27 (see also FIG. 9 ), is connected on one side to the rod 7 via hinge 28 and on the other side to the base piece 23 via hinge 29 . The hinge 28 is accommodated in a sliding piece 30 , which is held against the stop face 32 by means of the prestressing spring 31 , i.e. away from the base piece 23 . In the position of FIG. 6 , the spring 31 thus continuously pushes the pin 25 against the stop face 24 . The coupling element 26 also facilitates displacement of the pin 25 in the slot 35 and over the stop face 24 .
When the coupling 14 is uncoupled, the frame is withdrawn in the direction away from the base piece 23 , in such a manner that the pin 25 falls into the slot 34 via the curved slot 33 and can be pushed down. In this case, the coupling element rotates about the hinges 28 , 29 , as illustrated in FIGS. 7 and 8 , to the folded-in position.
FIG. 10 shows that the stop face consists of two parts 24 , between which the snap element 37 is accommodated. The pin 25 of the arm 7 rests on one respective part 24 with both ends and hooks behind the two sets of noses 38 of the snap element 37 .
Although a particular suspension method has been described above, the invention is not limited thereto. It is also possible to connect the rod 7 to the suspension piece 13 so as to be displaceable. If required, the rod 7 can also be coupled to the suspension piece by means of a coupling element 26 which is hingedly connected to the suspension piece 13 on one side and to the rod 7 on the other side. It is also possible for the rod 7 to be of articulated design and to connect it to the suspension piece by means of a fixed hinge. | A frame which can be moved between a folded-in position and a folded-out position includes suspension means for suspending the frame from a vertical element, an arm assembly having at least three arms and a rod assembly which cooperates with the arm assembly. The arm and rod assemblies are designed such that the arms may extend between a folded-in position and a folded-out position. The suspension means cooperate with a section of the arm assembly and/or with a section of the rod assembly which is/are at the periphery of the planes defined by the assemblies. | 3 |
[0001] This document is arranged in three sections:
[0002] (A) A written description of the invention;
[0003] (B) The manner and process of making and using the invention (the enablement requirement)
[0004] (C) The best mode contemplated by the inventor of carrying out the invention.
[0005] (A) Video Text Strip Search Description
[0006] The invention is a software solution that utilizes the text and timestamp information found in the closed caption, subtitle or transcript files, used as companions to most educational video collections. This solution serves essentially the same purpose as an index at the back of a text book. Alphabetized phrases are used to locate, and launch specific video lessons to within 2 seconds of the desired content. The program's unique architecture (the distributed decigram) makes knowing a single word in a phrase the foundation of a meaningful search. No words are typed into the system. The alphabetized phrases are placed within 36 buckets, which are quickly and easily searched by dragging the mouse (or finger on a smart phone or tablet) over a strip. Clicking on the strip once the desired phrase has been located, creates a hyperlink, when followed launches the video to the precise location of where the phrase was spoken.
[0007] (note: this process is designed to be used in conjunction with conventional search systems, where topics, descriptions and meta data guide the student to a subset of video lessons. The Video Text Strip Search is designed to take the student the rest of the way by helping them locate specific frames within a particular lesson).
DETAILED DESCRIPTION OF THE INVENTION
[0008] All spoken words held within a video collection are arranged in ten word phrases (which I call distributed decigrams). These phrases are constructed from sub-title, closed caption or transcript files that accompany each video, rather than indexing the video file itself. Each phrase consists of a single word (located at a specific timestamp), followed by the nine following words, and separated by spaces. These phrases are then arranged in alphabetical order and placed within 36 buckets (0-9 and a-z correspond to the keys on a keyboard). The first letter of each phrase corresponds to the name of the bucket. Clicking one of the thirty six keys allows the user to load the top accelerator search strip with the selected bucket, providing the first layer of filtering. Moving the mouse (or finger on a tablet) over the top strip presents each ten word phrase in alphabetical order. Scanning through the ten word phrases allows the user to read how the words are used in their proper context. Clicking the mouse (or finger) on the accelerator strip creates a link to the specific video content. When the link is followed the video is launched to within 2 seconds of the spoken content. A secondary accelerator strip is also provided to allow more refinement. It provides access to the ten decigram phrases preceding the current location (determined by the top accelerator) and nine decigrams following the current location. The user can also click the “Previous” and “Next” button to decrement/increment through each phrase of the decigram collection to further refine the search.
[0009] (note: sub title, close caption or transcript files must be present to create the index. The video files do not).
[0010] (B) Making a Video Text Strip Search
Overview (Detailed Description Follows)
1. Read closed captioned, subtitle or video transcript file into an array and convert to lower case, remove all punctuation and special characters except the periods at the end of the sentence. 2. Read through this array creating a secondary array of individual words transposing rows to a single column and assigning timestamps to each word. Timestamps are interpolated by divided the number of words between timestamps by the number of seconds between timestamps. These timestamps are rounded down to insure that the user is placed before the spoken segment as it is displayed in the video, rather than after. 3. Create URL linking timestamps to specific locations within each indexed video lesson. 4. Create a file topic. This topic corresponds to the name of each video being indexed. This topic will provide secondary confirmation for content relevancy. 5. Create decigram phrase array. Populate the decigram field by appending the following nine words in the array to the current word (separated by a space). This will become the ten word phrase that the user interacts with on the accelerator strip. 6. Attach each decigram to the timestamped URL. 7. Sort on the decigram field and create the file names (using the first letter of the decigram) for each of the 36 output JavaScript files, along with their corresponding html templates. Each JavaScript file will contain 3 arrays of data pertaining to specific keys (0-9) and (a-z). These files are dynamically loaded into an iframe as the user interacts with the primary interface document. 8. Create and populate the JavaScript files with three arrays: 1) the txtArray consisting of each decigram, 2) the urlArray consisting of each timestamped url, 3) the topicArray consisting of the URL associated with the single topic. 9. Create the html templates to hold and interact with the javascript arrays. 10. Create the primary user Interface html document. This html document consists of 36 buttons (0-9) and (a-z) keys, and an i-frame to present each template. The html template has 2 accelerator strips: a coarse accelerator (top) and a refine accelerator (bottom). A “Previous” and “Next” button enable the user to decrement/increment through each decigram in the array.
[0022] Making the Video Text Strip Search (Details)
[0023] I've created an excel workbook to show the data structure as it moves from raw input to the finished Video Text Strip Search documents. Screenshots are included to illustrate the objective (and outcome) at each step of the process. The input data source used is a transcript text file (similar to the transcripts found on Youtube) name vtsshelp.txt
[0024] 1) Read closed captioned, subtitle or video transcript file into an array and convert to lower case and remove all punctuation and special characters (the period at the end of the sentence is the exception).
[0025] The screenshot (below) shows the original transcript file (vtsshelp.txt) in notepad as it was brought into Excel (this constitute the first data array).
[0026] 2) Read through this array creating a secondary array of individual words transposing rows into a single column and assigning timestamps to each word. Timestamps are interpolated by divided the number of words between timestamps by the number of seconds between timestamps. These timestamps are rounded down to insure that the user is placed before the segment as it is displayed in the video, rather than after.
[0027] The screen below shows the original timestamps in column 1, the interpolated timestamps in column 2 and the transposed text in column 3.
[0028] 3) Create URL linking timestamp to location within video. In this case, we're looking at a local file name vtsshelp.mp4. The suffix “#t=” represents start video at this timestamp (in seconds) and column E shows the URL address with the timestamp appended.
[0029] 4) Create a file topic. This topic corresponds to each video being indexed (remember a collection of videos are being indexed so identification by topic is very important). This topic will provide secondary confirmation of content relevancy and become a hyperlink, when clicked, takes the user to the beginning of that particular video.
[0030] 5) Create decigram phrase array. Populate the decigram field by appending the following nine words in the array to the current word (separated by a space). This will become the ten word phrase that the user interacts with on the accelerator strip.
[0031] 6) Attach each decigram to the timestamp URL. These URLs will serve as the final link and will place the user to within 2 seconds of the desired video content.
[0032] 7) Sort on the decigram field and create the file names (using the first letter of the decigram) for each of the 36 output JavaScript files, along with their corresponding html templates. Each JavaScript file will contain 3 arrays of data pertaining to specific keys (0-9) and (a-z). These files are dynamically loaded into an iframe as the user interacts with the primary interface document.
[0033] (note: some of the 36 keys may not be represented. In the example below there is no decigram that begins with the number “1”. In this case, the primary user interface will display a placeholder without the key value so that the user doesn't click on key having no data behind it).
[0034] 8) Create and populate the Javascript files with three arrays: 1) the txtArray consisting of each decigram, 2) the urlArray consisting of each timestamped url, 3) the topicArray consisting of the URL associated with the single topic.
[0035] Shown below; is the contents of “v” javascript file. The arrays are populated in the decigram's chronological order.
[0036] 9) Create the html templates to hold and interact with the javascript arrays. Shown below is the html document that will be presented in the iframe if the user clicked on the “v” key. Both strips are 600 pixels in length. A decigram phrase is mapped to each of the 600 pixels in the top strip. If there are more 600 decigrams, say 1200, then every other decigram is mapped and the secondary strip is utilized
[0037] 10) Create the primary user Interface html document. This html document consists of 36 buttons (0-9) and (a-z) keys, and an i-frame to present each template. The html template has 2 accelerator strips: a coarse accelerator (top) and a refine accelerator (bottom). A “Previous” and “Next” button enable the user to decrement/increment through each decigram in the array.
[0038] Show below is the final product where the letter “v” was clicked and the mouse was moved over the top accelerator strip. The code (lower right) shows the “src” section of the iframe that changes when a user clicks on a different key.
[0039] (Note: a working example of the program can be seen at this URL: http://www.sharexl.comNTS/EastSide/EastSide.html)
[0040] Relationship Between The Components:
[0041] The program interacts directly with the 36 html and JavaScript data files corresponding to each key. The data file is selected when the user clicks on a key within the User Interface which constitutes the first round of filtering. This places the html template and JavaScript file corresponding to the selected key into the i-frame. The data found in the selected JavaScript file serves as a searchable dataset. Moving the mouse over the top “accelerator strip” presents a series of ten word phrases arranged in alphabetical order. The user clicks the top “accelerator strip” at the location of the desired text. A link appears, when clicked, launches the video to within 2 seconds of the spoken text. The selected record location and number of records are also displayed, along with the topic. After clicking on the top accelerator for close proximity in a large index, the user can refine the search by scrolling the lower accelerator strip to the desired location, or clicking the “Previous” or “Next” buttons. The record location within the array is used as reference to determine the bottom accelerator center point. Ten records preceding and nine following the center point are accessible through the bottom accelerator. The record location can also be decremented/incremented using the “Previous” and “Next” buttons respectively.
[0042] (C) The Best Mode Contemplated by the Inventor of Carrying Out His Invention
[0043] The Effective Use Of A Video Text Strip Search In An Educational Environment
[0044] I can see the Video Text Strip Search (VTSS) as a tool that greatly enhances the speed and effectiveness of video education. This product is designed to be a companion to any online video education solution where the student views between 20-30 online video lessons (approximately 8-10 minutes in length) and takes a series of periodic quizzes and exams that quantify knowledge transfer.
[0045] By establishing a “best practice” for lesson design, I see instructors specifically announcing objectives, sample #, figure # and summaries within their video lessons. Once the student understands the structure, answers to incorrect test questions will be located within seconds, rather than minutes.
[0046] But this is just the beginning. I can imagine this process significantly improving the quality of teaching. In all online courses there is an assumption that the material is well presented and only the students are scored. By matching missed test scores, and examining the student's click stream, the instructor can see where their message needs improving. Having this new level of granularity will enable the instructor to really focus on improving the message, utilizing the phrases each student used while to locate the correct answer. | Video search mechanism using text based accelerator strip is disclosed. It utilizes the text and timestamp information found in the closed caption and subtitle files to locate specific video content. Knowing a single word in a phrase will create the foundation of a meaningful search. No words are typed directly into the system. The text is arranged in alphabetical order and placed into buckets, which are quickly and easily searched, leaving the user to within 2 seconds of the desired content. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This patent arises from a continuation of U.S. patent application Ser. No. 12/251,931, which was filed on Oct. 15, 2008, and which claims the benefit of U.S. Provisional Application Ser. No. 60/980,373, which was filed on Oct. 16, 2007, both of which are hereby incorporated by reference in their entireties.
FIELD OF THE DISCLOSURE
[0002] This disclosure relates generally to systems for online polling of users.
BACKGROUND
[0003] It is often desirable to gather the opinions or characteristics of a population. One way this can be done by polling a group of people. The people can be asked about their opinion on certain matters or can be asked for demographic information about themselves (e.g., age, gender, marital status). These polls are useful for a variety of purposes. For example, a business can use polls to perform market research, including getting opinions about possible product ideas and getting information about their potential customers. Research through polls may also be conducted by other parties, such as academic researchers or the government.
[0004] In many cases, the research requires that the polling be targeted to a specific group of people with certain characteristics. For example, a business may want to target its polling to people who have characteristics that would make them likely customers. To do this, the business may need to recruit people with specific backgrounds or perform panel-based research. This can be expensive and require a significant amount of time. Panels are also often subject to incentive biases and self-selection biases. Therefore, there is a need in the art for a way to poll a desired group of people, where a potentially large group of people can be reached quickly and inexpensively.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 is a high-level diagram illustrating an example environment for polling users.
[0006] FIG. 2 is a block diagram illustrating an example computer that can serve as a polling server, researcher client, publisher server, or poll user client.
[0007] FIG. 3 is a block diagram illustrating an example polling server.
[0008] FIG. 4 is a flowchart illustrating an example method for polling users.
[0009] FIG. 5 is a flowchart illustrating an example method for characterizing and polling users.
[0010] The figures depict example implementations constructed in accordance with the teachings of this disclosure for purposes of illustration only. One skilled in the art will readily recognize from the following description that alternative examples of the structures and methods illustrated herein may be employed without departing from the principles of the teachings disclosed herein.
DETAILED DESCRIPTION
[0011] The above need is met by a system, method, and computer program product for polling users. In an example of the method, targeting parameters for a plurality of poll campaigns are received. The targeting parameters indicate the desired characteristics of a user audience for a poll campaign. Information about the type of content on a publisher webpage or the characteristics of typical visitors to the webpage is also received. A user is characterized based on the user's responses to characterization polls, such as polls that ask for demographic information about the user. A request for displaying a poll in a poll zone of the publisher webpage is received, and a poll is selected for display based at least in part on the targeting parameters, information about the publisher webpage, and the characterization of the user. In another example of the method, the audience of the publisher webpage is characterized based on responses to characterization polls by visitors to the publisher webpage.
[0012] FIG. 1 is a high-level diagram illustrating an example environment 100 for polling users. The environment 100 includes a polling server 102 , a researcher client 104 , a publisher server 108 , and a poll user client 110 . The polling server 102 receives requests to display various polls and causes the polls to be displayed. A researcher can submit a request to display a poll using a researcher client 104 . The polling server 102 can then present the poll on an appropriate publisher webpage 116 of the publisher server 108 , and the poll can be viewed and responded to by users from user web browsers 118 on poll user clients 110 . Though only one researcher client 104 , publisher server 108 , and poll user client 110 are shown in FIG. 1 , there may be thousands of these entities in the environment 100 . There may also be multiple polling servers 102 for load balancing or backup purposes. The polling server 102 , researcher clients 104 , publisher servers 108 , and poll user clients 110 can communicate through a network 106 , such as the Internet.
[0013] A research client 104 can be used by a researcher to interact with the polling server 102 . A researcher can create a poll campaign comprising poll information and targeting parameters. The poll information includes one or more poll questions that are interactively displayed to and answered by a group of users. The targeting parameters specify desired characteristics of the group of users to which the poll is displayed and the desired characteristics of the publisher webpages 116 on which the poll is displayed. A researcher can be, for example, a corporation or an academic researcher. After the poll has been answered by some users, the researcher receives the results and can use the results for market research or other purposes. The researcher may pay a fee to the polling server operator for running a poll campaign. The researcher can use the researcher client 104 to submit poll campaigns, receive results, and submit payment to the polling server 102 .
[0014] In some examples, the publisher server 108 displays polls to users. The publisher server 108 can be operated by a publisher that provides content or services to users. A publisher can be, for example, an operator of a news website, a web log (blog), a search engine, or any other website that users are likely to visit. The publisher server 108 may include a web server that displays various publisher webpages 116 to users. Some of these web pages may include poll zones 114 for displaying polls provided by the polling server 102 . In some examples, a poll zone 114 is a widget included on a publisher webpage 116 for displaying polls in a specified format and location on the webpage. Users can view polls on the publisher webpage 116 and submit answers to the polls. The poll results can then be sent back to the polling server 102 for retrieval and analysis by researchers and the publisher.
[0015] A publisher webpage 116 may attract viewers with specific characteristics. For example, a webpage 116 offering discounts for seniors may attract older users, while a blog about patent law may attract users who are patent lawyers. The audience characteristics of a publisher webpage 116 may be used to determine the polls that the polling server 102 provides to the publisher 108 . This determination can be made based targeting parameters provided by the researcher. The publisher can be paid by the polling server for displaying polls to users. The publisher server 108 may also display unpaid polls for its own purposes, such as learning about its viewer demographics or providing entertainment to its viewers.
[0016] A user interacts with a publisher server 108 through a poll user client 110 . The poll user client 110 can execute a user web browser 118 for displaying publisher webpages 116 containing polls. The user generally visits the publisher webpage 116 for the purpose of accessing content or services, but may notice a poll displayed in a poll zone 114 and decide to participate in the poll. A user identifier 112 may be stored on the poll user client 110 to identify a particular user across multiple browsing sessions and multiple publisher servers 108 . In some cases it is not possible to differentiate between individual users on a poll user client 110 , so in this case, a “user” represents all users from a particular poll user client. This user identifier 112 may be used by the polling server to track the polls previously viewed by and answered by the user so that appropriate polls can be displayed to the user in the future. The user identifier 112 may also be used to correlate the user's answers to one poll with the user's answers to another poll for analysis purposes. The user identifier 112 can be implemented as a web cookie managed by the user web browser 118 .
[0017] FIG. 2 is a block diagram illustrating an example computer 200 that can serve a polling server 102 , researcher client 104 , publisher server 108 , or poll user client 110 . Illustrated are at least one processor 202 coupled to a bus 204 . Also coupled to the bus are a memory 206 , a storage device 208 , a keyboard 210 , a graphics adapter 212 , a pointing device 214 , and a network adapter 216 . A display 218 is coupled to the graphics adapter 212 . The storage device 208 is a device such as a hard drive, CD or DVD drive, or flash memory device, and holds files containing executable code and/or data utilized during the operation of the computer 200 . The memory 206 , in some examples, is a random access memory (RAM) and holds instructions and data loaded from the storage device 208 , generated during processing, and/or from other sources.
[0018] Computers acting in different roles may have different and/or additional elements than the ones shown in FIG. 2 . For example, a computer 200 acting as a polling server 102 may have greater processing power and a larger storage device than a computer acting as a poll user client 110 . Likewise, a computer 200 acting as a polling server 102 may lack devices such as a display 218 and/or keyboard 210 that are not necessarily required to operate it.
[0019] The computer 200 executes one or more operating systems such as a variant of MICROSOFT WINDOWS or LINUX. In general, the operating system executes one or more application programs. The operating system and application programs executed by the computer are formed of one or more processes. This description utilizes the term “module” to refer to computer program logic for providing a specified functionality. A module can be implemented in hardware, firmware, and/or software. A module is typically stored on the storage device 208 , loaded into the memory 206 , and executed by the processor 202 . A module can include one or more processes, and/or be provided by only part of a process.
[0020] FIG. 3 is a block diagram illustrating an example polling server 102 . As mentioned above, the polling server 102 interacts with researcher clients 104 and publisher servers 108 . The researcher module 302 can be used to interact with a researcher client 104 . The researcher module 302 may include a web server that serves web pages to a browser running on the researcher client 104 , providing a researcher with a graphical user interface to the polling server 102 . The researcher module 302 receives poll campaign information from a researcher, the poll campaign information including poll question information and targeting parameters.
[0021] The researcher module 302 can assist the researcher in creating poll question information by presenting various options for designing a poll to the researcher. Poll question information may include a text prompt, such as “What is your marital status?” or “Choose your favorite actor from the choices below” followed by possible response choices. The poll question information may indicate that only one response choice can be selected by a user, or may allow for selection of multiple response choices. The poll question information may specify that the answer choices should be displayed in the same order each time, or may specify that the answer choices be displayed in a random order (e.g., to reduce bias). The poll question information can include graphic images to be displayed along with the text prompt or any of the response choices. The poll question does not need to be in a multiple-choice format. The poll question information can specify that users respond to the text prompt by typing in a text response.
[0022] The researcher module 302 can also assist the researcher in creating targeting parameters. These parameters can specify that a poll question be displayed a certain number of times, for a certain length of time, or until a certain number of responses are received. The targeting parameters can also include information that specifies a desired audience for the polls. This can include demographic criteria for poll users, such as age, gender, income, marital status, and geographic location. The parameters can specify that the poll should only be shown to users that are known to meet the desired demographic criteria.
[0023] The parameters can also indicate criteria for determining the publisher servers 108 , webpages 116 , and poll zones 114 on which to display the poll question. The parameters can specify that the poll question should be displayed on publisher servers 108 that are known to have an audience from a particular country or with a generally known demographic. The parameters can also indicate that the publisher server 108 have a specific type of audience such as tech-savvy users, physicians, or politically conservative college students. The parameters can specify that the poll question should be displayed on webpages 116 with certain types of content such as tech news, entertainment news, or stock quotes. The parameters can also list specific publisher servers 108 or webpages 116 for displaying the poll question.
[0024] The researcher module 302 can store the poll campaign information received from the researcher in the poll storage 304 . The poll storage 304 stores poll campaign information for research polls and for other types of polls, described below. The poll storage 304 can be accessed by other modules to present the polls to users. Once a research poll campaign has been defined, the polling server 102 can quickly begin displaying the poll question to users. This allows for results to be obtained faster than traditional methods where a panel of users must first be assembled before polling begins. The researcher module 302 can also be used to provide poll responses to the researcher. Poll responses can be accessed from the poll results storage 306 , described below. Poll responses can be provided while the poll is still running and can be updated in real time. An analysis of the responses can also be provided, such as a breakdown of responses by various demographic categories of users, or by the publisher webpages 116 or poll zones 114 used to display the poll.
[0025] The publisher module 312 can be used to interact with a publisher. The publisher can interact with the publisher module 312 through the publisher server 108 or through another computer 200 (not illustrated). The publisher module 312 may include a web server that serves web pages to a browser used by a publisher, providing the publisher with a graphical user interface for communicating with the polling server 102 .
[0026] A publisher can configure poll zones 114 on its web pages 116 for displaying polls provided by the polling server 102 . The types of polls that can be displayed include research polls, demographic polls, publisher polls, and content polls. Research polls are polls designed by a researcher, as described above. The publisher may be compensated for displaying research polls. Since a given research poll campaign can be spread across multiple publisher servers 108 , the poll can be used effectively even on small publisher servers 108 with relatively few visitors.
[0027] Demographic polls request demographic information about users. For example, a demographic poll question may ask “How old are you?” and provide various age ranges as possible answers. Demographic polls allow the polling server 102 to learn demographic information about poll users. This information can be used to determine whether a user satisfies the targeting parameters of a research poll so that the research poll can be displayed to the user. Research poll results can also be analyzed by correlating the results with demographic information of users. Demographic information can also be provided to a publisher to help the publisher learn about the visitors to its webpages 116 (i.e., characterize the audience of its webpages). Since a publisher receives valuable information from demographic polls, the publisher may not be compensated for displaying these polls. The results of demographic polls may also be provided or sold to external parties that are interested in knowing about visitors to the publisher's webpages 116 . A predetermined set of standard demographic questions can be used by the polling server 102 for demographic polls.
[0028] A publisher poll is a poll that is designed by a publisher for display on the publisher's webpages 116 . A publisher poll can be used by a publisher to get the opinions of visitors to its website. A publisher poll is similar to a research poll, but is limited to display on the publisher's own webpages 116 . The publisher module 312 can include features similar to the features in the researcher module for assisting the publisher in creating poll question information and, if desired, targeting parameters for targeting the poll to specific users. The results of the publisher poll can be provided to the publisher along with a demographic breakdown of the results.
[0029] Content polls are predetermined poll questions designed to serve as additional content for a publisher's webpages 116 . Content poll questions may include entertaining questions about political candidates or television shows, for example. A publisher may choose to display a content poll on its webpages 116 . Since predetermined questions are available, a publisher does not expend effort designing poll questions. The results of content polls can be provided to the publisher through the publisher module 312 . The publisher may use content polls to obtain additional psychographic data about its visitors to further characterize them.
[0030] The publisher module 312 enables a publisher to create poll zones 114 for displaying polls in the publisher's webpages 116 . A poll zone 114 identifies a region of a webpage 116 where polls are displayed and includes configuration parameters for displaying the polls in the region. In one example, a poll zone 114 includes a widget on a publisher webpage 116 , where the widget can display polls received from the polling server 102 . This widget can be partially implemented as a code fragment included in the source code of the publisher webpage 116 . The code fragment can be, for example, HyperText Markup Language (HTML) or JavaScript.
[0031] The publisher module 312 allows a publisher to choose various configuration parameters when creating a poll zone 114 . The publisher can specify the height and width (e.g., in pixels) of the poll zone 114 . The publisher can also specify the colors or color scheme to use for displaying the poll and can specify various other parameters controlling the display of the poll. The publisher can specify the types of polls (e.g., research polls, demographic polls, publisher polls, and content polls) that are allowed to be displayed in the poll zone 114 . The publisher may also indicate the relative frequencies for showing the various types of polls. The publisher can specify further details about which polls should be displayed, such as identifying particular publisher polls or demographic polls, or indicating specific types of research polls to allow or disallow.
[0032] After receiving configuration parameters for a new poll zone, the publisher module 312 generates an identifier for the poll zone and stores the configuration parameters with the poll zone identifier in the publisher data storage 316 . The publisher data storage 316 contains poll zone data and other data about publishers, described below. The publisher module 312 can also generate a widget to be included on the publisher webpages 116 to activate the poll zone and cause polls to be retrieved from the polling server 102 and displayed at the location of the widget. The widget may include the poll zone identifier so that the polling server is able to identify the poll zone.
[0033] The configuration parameters of a poll zone 114 can be changed after the poll zone has been created and deployed on publisher webpages 116 . The publisher module 312 can allow a publisher to access the configuration of a poll zone 114 by inputting a poll zone identifier. The publisher module 312 can then allow the configuration parameters to be changed and saved to the publisher data storage 316 . If a publisher notices a current poll campaign running in the publisher's poll zone 114 and desires to change it, the publisher can modify the configuration parameters of the poll zone to explicitly disallow the unwanted poll campaign.
[0034] When a publisher registers with the polling server 102 to create poll zones 114 , the publisher module 312 can also obtain publisher information. The publisher information can be stored and later used to determine whether a publisher webpage 116 satisfies the targeting parameters of a research poll being considered for display on the webpage. To obtain this information, the publisher module 312 can ask the publisher about the type of content on its website and about the typical visitors to the website. The publisher module 312 can also request a uniform resource locator (URL) of the publisher website, retrieve the publisher webpages 116 from the website, and perform an automated analysis of the webpages (e.g., based on text and graphics) to determine the type of content. The publisher information can be stored in the publisher data storage 316 along with information about the publisher's poll zones 114 .
[0035] The poll presentation module 310 , user tracking module 318 , and poll selection module 320 provide functionality for displaying polls in poll zones 114 . When a user at a poll user client 110 views the publisher webpage 116 in a user web browser 118 , the poll zone 114 of the publisher webpage directs the user web browser to the polling server 102 to retrieve poll content to display in the poll zone 114 . The poll zone 114 may do this through code that causes the user web browser 118 to send a request to the polling server 102 for poll zone content, where the request includes the poll zone identifier (e.g., a number or character string).
[0036] In some examples, when a request for poll zone content is received by the polling server 102 , the user tracking module 318 is notified. The user tracking module 318 keeps track of which poll zones 114 each user has viewed, across all poll zones of all publisher servers 108 . Normally, if the user viewing the current poll zone 114 has previously viewed any poll zone, then the user web browser 118 will recognize the polling server 102 when sending the poll zone content request and will automatically also send the user identifier 112 associated with the user. The user tracking module 318 reads the user identifier 112 to determine the user and retrieves any stored information associated with the user from the user data storage 314 . The user tracking module 318 provides the retrieved user information to the poll selection module 320 .
[0037] The user data storage 314 contains information about users that have viewed polls. The user information can include previous polls that have been displayed to the user and previous poll answers received from the user. The user information can also include timestamps, publisher webpages 116 , and poll zones 114 associated with the displayed and answered polls. The user information can be used for selecting a poll to display to the user, as described below. It can also be used to provide information about users to researchers or publishers.
[0038] In some cases, a user identifier 112 is not provided to the polling server 102 when a poll zone content request is received. This can occur because the user has never viewed a poll zone 114 before or because the user identifier was deleted since the last time the user viewed a poll zone. If no user identifier 112 is received, the user tracking module 318 can construct a new user identifier and provide the user identifier to the user web browser 118 to be stored on the poll user client 110 . The user tracking module 318 can also create a new entry in the user data storage 314 associating the user identifier 112 with the new user.
[0039] The poll selection module 320 determines which poll to display in response to the current poll zone content request. The poll selection module 320 uses the poll zone identifier included in the request to retrieve the poll zone configuration parameters and publisher information from the publisher data storage 316 . The poll selection module 320 also receives information about the requesting user from the user tracking module 318 . Based on this information, the poll selection module 320 determines a poll to display. As mentioned above, information about active poll campaigns is stored in the poll storage 304 . The poll campaigns include research polls, demographic polls, publisher polls, and content polls. Various algorithms that the poll selection module 320 might use are described below. If there are several possible polls that can be displayed, the poll selection module 320 can randomly select one of the possible polls to be displayed.
[0040] The poll selection module 320 can use the poll zone configuration parameter indicating the allowed poll types to select a poll for display or to narrow the possible polls that can be displayed. If the poll type parameter indicates that a research poll can be displayed, then the research poll campaigns can be searched to determine those that are appropriate for the poll zone 114 . Research poll campaigns can be chosen based on a comparison of the poll's targeting parameters and publisher information retrieved from the publisher data storage 316 . For example, if the publisher webpage 116 is a medical news website mostly viewed by physicians, research poll campaigns with targeting parameters specifying news content pages or a physician audience can be considered for display.
[0041] If the poll type parameter indicates that a publisher poll can be displayed, then poll campaigns created by the publisher can be considered for display. If the poll type parameter indicates that a demographic poll or content poll can be displayed, then the poll selection module 320 can choose a predefined demographic poll or content poll to be displayed. If the poll type parameter allows for multiple types of polls, various priorities can be assigned to poll types, such as giving paid research polls highest priority for display. Other poll zone configuration parameters can be examined to determine a poll to display. These parameters describe allowable poll subject matter, for example.
[0042] User information can also be used by the poll selection module 320 . The poll selection module 320 can examine polls that the user previously answered or viewed to determine appropriate polls to show the user. This can avoid repeatedly presenting the same poll to the user. For example, if a user has already answered a certain demographic poll, a different demographic poll can be displayed so that more information about the user can be obtained. Also, if a poll has been shown to a user a certain maximum number of times, but the user has never answered it, a new poll can be shown to the user for a certain period of time (e.g., two weeks), before displaying the unanswered poll again. The maximum number can be higher for poll questions that are less likely to be answered (e.g., questions that take longer to read). If the user information indicates that the user has not yet answered an available research poll for which the user is qualified, that poll can be shown to the user rather than an available publisher poll or content poll.
[0043] Some polls may require that certain information about the user, such as demographic information, be known before the poll can be displayed. For example, a research poll campaign may have targeting parameters specifying that the research poll should only be displayed to users of a certain age range from a particular country. If the required information is not yet known for a particular user, then this research poll is not considered for display to the user. As a result, the poll selection module 320 may choose to display polls to the user that further characterize the user by obtaining further information about the user. These polls are referred to as characterization polls. Characterization polls are often demographic polls but can also include other types of polls such as publisher polls, content polls, or research polls. For example, content polls can provide psychographic data for characterizing users. The poll selection module 320 may choose to display several characterization polls in sequence to new users so that new users become rapidly qualified for a wide range of research polls that require knowledge of the user's characteristics.
[0044] The poll presentation module 310 manages the displaying of polls in poll zones 114 and the receipt of poll responses submitted by users. When the polling server 102 receives a request for poll zone content from a poll user client 110 , the poll selection module 320 determines which poll should be sent (as described above) and the poll presentation module 310 composes a response that includes the selected poll. The poll presentation module 310 can retrieve poll question information about the selected poll, such as the text prompt and response choices, from the poll storage 304 . If the poll question information indicates that the answer choices should be displayed in a random order, the poll presentation module 310 can choose a particular order for this instance of the poll. The poll presentation module 310 can also retrieve poll zone configuration parameters from the publisher data storage 316 to determine how to format the poll. These parameters may include the colors, fonts, and sizes to use for formatting the poll.
[0045] Based on the poll question information and poll zone configuration parameters, the poll presentation module 310 sends a response to a poll zone content request over the network 106 . The response includes information that enables the selected poll to be displayed on the user web browser 118 . The information in the response includes, for example, HTML code, JavaScript code, Adobe Flash code (e.g., ActionScript), graphics, text, animation, and sound. The information can also describe radio buttons for a user to select a poll response and a submit button for the user to submit the response. In one example, some general instructions for displaying polls may already be included in the poll zone 114 . These general instructions can process the received information to display the selected poll.
[0046] The user web browser 118 receives the response and displays the selected poll to the user. When the user answers the poll (e.g., by selecting a response and pressing a “Submit” button), the user web browser 118 sends the answer chosen by the user to the polling server 102 . The poll presentation module 310 receives this answer and stores the answer in the poll results storage 306 . The poll results storage 306 stores the answer along with the identity of the user, the poll zone, a timestamp, and other desired information. The poll presentation module 310 also updates the user information in the user data storage 314 to reflect the user's answer to the poll, further characterizing the user. The poll presentation module 310 can send information to the user web browser 118 to be displayed in the poll zone 114 after the poll has been answered. This information can summarize the current poll results and possibly include a bar chart or pie chart.
[0047] In some examples, the payment module 308 processes payments between the researchers, publishers, and polling server operator. As mentioned above, a researcher can be required to pay a fee to have research polls displayed on publisher webpages 116 . Also, a publisher can be paid for displaying research polls on its webpages 116 . The payment module 308 can determine the amount due from a researcher and can determine the amount to be paid to the publisher, and can process the payments. The payment module 308 can use the researcher module 302 and publisher module 312 to send and receive payments. For example, an input form on a web page provided by the researcher module 302 can collect credit card information from a researcher
[0048] The amount to charge to a researcher can be based on the targeting parameters associated with the research poll campaign. A research poll that requires a greater number of responses or that runs for a longer time can incur a greater charge. Targeting parameters that specify a more narrow or unusual user demographic or that specify more restrictive publisher requirements can incur a greater charge. Publishers can be paid based on the number of times they display a research poll or the number of research polls that are answered by viewers of their websites. Publishers with viewer audiences that are more highly sought-after or that have more specific profiles can be paid a higher amount. The payment amounts can be set so that the amount paid by the researcher is somewhat greater than the amount paid to the publisher, allowing the polling server operator to receive payment for its services.
[0049] FIG. 4 is a flowchart illustrating an example method for polling users. The researcher module 302 receives 402 poll question information and targeting parameters for a poll campaign. The targeting parameters can describe desired characteristics of the audience of the poll. The poll question information and targeting parameters are stored in the poll storage 304 . The publisher module 312 receives 404 poll zone configuration parameters for displaying polls in a poll zone 114 on a publisher webpage 116 . A user then visits the publisher webpage 116 and the polling server 102 receives 406 a poll zone content request from a user web browser 118 on a poll user client 110 . The polling server 102 may also receive a user identifier 112 from the poll user client 110 . The user tracking module 318 determines 408 user information based on the user identifier 112 and the user data storage 314 . The user information may include demographic information about the user.
[0050] The poll selection module 320 selects 410 a poll for display. If adequate demographic information about the user is known, a poll can be selected from the poll storage 304 by comparing the user demographic information with the targeting parameters of poll campaigns in the poll storage. A poll can also be selected by comparing information about the publisher of the poll zone with the targeting parameters. If some demographic information about the user is not yet known, a demographic poll can be selected for display to obtain further demographic information about the user. The poll presentation module 310 sends 412 information about the selected poll to the poll user client 110 . The poll is displayed to the user, the user submits a response to the poll, and the response is received 414 and stored by the poll presentation module 310 in the poll storage results 306 and user data storage 314 . The current results received for a particular poll campaign can be provided to a researcher associated with the poll campaign. The results associated with a publisher (across multiple campaigns) can also be provided 416 to the publisher.
[0051] FIG. 5 is a flowchart illustrating an example method for characterizing and polling users. The user tracking module creates 502 a user identifier 112 and sends it to the poll user client 110 . This can occur when a poll zone content request is received from an unknown user. The user is then characterized 504 based on the user's responses to characterization polls presented to the user. The user's responses can be tracked with the user identifier 112 . The characterization polls presented to the user can include demographic polls, and the user's responses can provide demographic information about the user. When the user has been sufficiently characterized, appropriate research polls can be displayed 506 to the user. As described above, the poll selection module 320 can determine if a user has been sufficiently characterized for presenting a particular research poll to the user based on the targeting parameters of the research poll.
[0052] The above description is included to illustrate the operation of certain examples that are not meant to limit the scope of this patent. On the contrary, the scope of this patent extends to all methods and systems fairly falling within the following claims either literally or under the doctrine of equivalents. From the above discussion, many variations will be apparent to one skilled in the relevant art that would yet be encompassed by the spirit and scope of the teachings disclosed herein. | Systems, methods, and articles of manufacture for polling users are disclosed. An example method is disclosed that involves counting a number of times a first poll is provided for display to a user with two or more different webpages in two or more different Internet domains and, if the number of times the first poll has been provided for display to the user exceeds a first threshold number of times, selecting a second poll for display to the user with the two or more different webpages or a third webpage different from the two or more different webpages. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a cutting device for breaking fragile materials such as semiconductor wafers or the like and, more particularly, to such a cutting device, which uses lifting, rotary, and feed mechanisms to adjust the position and angle of the diamond cutter, enabling the diamond cutter to scribe and break the workpiece precisely.
2. Description of Related Art
In semiconductor foundries, wafer scribing and breaking apparatus are used to scribe and break 8″ or 12″ semiconductor wafers into individual dies. The cutting tips of cutters for use in wafer scribing and breaking apparatus are commonly made from diamond for the advantage of high hardness. Conventional wafer scribing and breaking apparatus commonly use a rotary mechanism and a feed mechanism to control the cutting position of the diamond cutter relative to the workpiece. This design can simply achieve a coarse manipulation, i.e., the distance between the cutter and the workpiece cannot be precisely controlled, affecting the precision of the scribing of the cutter on the workpiece.
Further, during cutting working of the diamond cutter according to conventional methods, one specific crystal phase position of the diamond cutter is used as the cutting point. This cutting point wears quickly with use. When the cutting point worn out, the diamond cutter becomes useless and must be replaced. When a new diamond cutter installed, the alignment of the newly installed diamond cutter must be calibrated again. It takes time to calibrate the alignment of the loaded diamond cutter. Additionally, it is very hard to manually adjust the angle of the specific crystal phase point of the newly installed diamond cutter to a precise position corresponding to the workpiece.
Therefore, it is desirable to provide a cutting device for breaking fragile materials that eliminates the aforesaid drawbacks.
SUMMARY OF THE INVENTION
It is one object of the present invention to provide a cutting device for breaking fragile materials, which uses lifting, rotary, and feed mechanisms to adjust the position and angle of the diamond cutter, enabling the diamond cutter to scribe the workpiece precisely.
It is another object of the present invention to provide a cutting device for breaking fragile materials, which uses a feed mechanism to control the federate of the diamond cutter relative to the fragile workpiece.
It is still another object of the present invention to provide a cutting device for breaking fragile materials, which uses a rotary mechanism to adjust the angle of the diamond cutter, enabling the diamond cutter to scribe the fragile workpiece with one of multiple cutting points thereof.
To achieve these and other objects of the present invention, the cutting device for breaking fragile materials is comprised of a base frame, a lifting mechanism, a rotary table, a cutter holder, and a cutter module. The base frame is installed in a worktable of a wafer scribing and breaking apparatus, having a front mounting face. The lifting mechanism comprises a base block fixedly mounted on the mounting face of the base frame, and a lifting block coupled to the base block for vertical movement on the base block. The rotary table comprises a fixed member fixedly mounted on the lifting block of the lifting mechanism, and a rotary member supported on the fixed member for rotation relative to the fixed member. The rotary member has a front face. The cutter holder is installed in the front face of the rotary member, having a through hole. The through hole has a center axis in parallel to the front face of the rotary member. The cutter module is installed in the through hole of the cutter holder and holding a diamond cutter, comprising a rotary mechanism adapted to rotate the diamond cutter around the center axis of the through hole and a feed mechanism adapted to move the diamond cutter axially along the center axis of the through hole.
By means of the linear or rotary motion of the lifting mechanism, the rotary table and the feed mechanism of the cutter module, the position of the diamond cutter can be precisely adjusted, i.e., the diamond cutter can be shifted vertically through a coarse manipulation of the lifting mechanism, and then rotated to the desired cutting angle on the workpiece, for example, a semiconductor wafer, and then linearly adjusted through a fine micromanipulation of the feed mechanism of the cutter module. Therefore, the relative angle and distance between the diamond cutter and the semiconductor wafer can be adjusted, causing the diamond cutter to scribe the semiconductor wafer precisely.
Furthermore, when the diamond cutter started to wear after long uses, the rotary mechanism is controlled to rotate the diamond cutter through an angle (for example, 90°), enabling the diamond cutter to cut the workpiece with another crystal phase cutting point. Therefore, the diamond cutter can be rotated to different angular positions to cut the workpiece with different crystal phase cutting points, preventing the occurrence of a precision problem due to a replacement of the diamond cutter.
Other objects, advantages, and novel features of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a cutting device installed in a wafer scribing and breaking apparatus according to the present invention.
FIG. 2 is an exploded view of the cutting device according to the present invention.
FIG. 3 is an exploded view of the lifting mechanism for the cutting device according to the present invention.
FIG. 4 is an assembly view of the cutter module for the cutting device according to the present invention.
FIG. 5 is a sectional view of the cutter module for the cutting device according to the present invention.
FIG. 6 is a schematic drawing showing the cutter module rotated relative to the semiconductor wafer according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to FIG. 1, a cutting device 1 is installed in the worktable 91 of a wafer scribing and breaking apparatus 9 , and controlled to scribe a semiconductor wafer 92 .
With reference to FIG. 2, the aforesaid fragile material cutting mechanism is comprised of a base frame 2 , a lifting mechanism 3 , a rotary table 4 , a cutter holder 5 , and a cutter module 6 . The base frame 2 is installed in the worktable 91 of the wafer scribing and breaking apparatus 9 (see FIG. 1 ), having a front mounting face 21 at the front side. The lifting mechanism 3 is comprised of a base block 32 located on the mounting face 21 of the base frame 2 , and a lifting block 31 coupled to the base block 32 for vertical movement on the base block 32 .
Referring to FIG. 3, the lifting mechanism 3 further comprises a screw rod 35 fastened pivotally with the base block 32 , a nut 36 threaded onto the screw rod 35 , a connecting block 360 connected between the lifting block 31 and the nut 36 , and a power drive 37 adapted to drive the screw rod 35 in the base block 32 . When driving the screw rod 35 , the lifting block 31 is driven to move with the nut 36 upwards or downwards along the screw rod 35 . The screw rod 35 preferably has a relatively greater screw pitch to provide a relatively greater vertical moving distance during lifting/lowering of the lifting mechanism 3 .
According to this embodiment, the power drive 37 of the lifting mechanism 3 is a motor 371 . Alternatively, a hydraulic cylinder or air cylinder may be used for the power drive 37 . Further, a pair of first sliding rails 34 are vertically arranged in parallel on the base block 32 , and a pair of second sliding rails 33 are vertically arranged in parallel on the lifting block 31 and respectively coupled to the first sliding rails 34 to guide vertical movement of the lifting block 31 along the first sliding rails 34 .
Referring to FIG. 2 again, a coupling plate 8 is fastened to the lifting block 31 to hold the rotary table 4 on the lifting block 31 . The rotary table 4 is comprised of a fixed member 42 and a rotary member 41 . The rotary member 41 can be rotated on the fixed member 42 by a motor. The coupling plate 8 is connected between the lifting block 31 and the fixed member 42 , for enabling the rotary table 4 to be moved vertically up and down with the lifting block 31 . The coupling plate 8 has optics sensors 81 , 82 , 83 for detection of angle of rotation of the rotary member 41 . The coupling plate 8 is not requisite, i.e., the fixed member 42 can directly be fastened to the lifting block 31 .
The rotary member 41 has a front face 410 , and a raised alignment portion 411 for supporting the bottom edge 53 of the cutter holder 5 during installation of the cutter holder 5 .
Referring to FIGS. 4 and 5, the cutter holders has a through hole 51 . The central axis 510 of the through hole 51 is disposed in parallel to the front face 410 of the rotary member 41 . The cutter module 6 is mounted in the through hole 51 of the cutter holder 5 to hold a diamond cutter 7 , comprising a rotary mechanism 61 and a feed mechanism 62 . The feed mechanism 62 comprises a hollow column 63 , a coil 621 , and a permanent magnet 622 . The hollow column 63 is axially movably mounted in the through hole 51 of the cutter holder 5 . The cutter holder 5 has an axially endless groove 511 concentrically extended around the through hole 51 . The permanent magnet 622 is mounted within the endless groove 511 . The hollow column 63 has an axially concentric flange 630 holding the coil 621 and insertable with the coil 621 into the endless groove 511 and relative to the permanent magnet 622 . Further, the cutter holder 5 has an extension 52 extended in axial direction at one side of the through hole 51 , and a sliding track 521 located on the extension 52 in parallel to the center axis 510 of the through hole 51 . The cutter module 6 comprises a sliding block 631 fixedly fastened to the hollow column 63 and coupled to the sliding track 521 , and a return spring 623 connected between the sliding block 631 and the extension 52 of the cutter holder 5 . When the coil 621 is electrically connected, controlling the amount of current controls the movement of the feed mechanism 62 along the sliding track 521 , and therefore the diamond cutter 7 can be moved axially along the center axis 510 of the through hole 51 . When the coil 621 is electrically disconnected, the return spring 623 imparts an upward recover force to the cutter module 6 , preventing damage to the diamond cutter 7 .
By means of the linear or rotary motion of the lifting mechanism 3 , the rotary table 4 and the feed mechanism 62 of the cutter module 6 , the position of the diamond cutter 7 can be precisely adjusted, i.e., the diamond cutter 7 can be shifted vertically through a coarse manipulation of the lifting mechanism 3 , and then rotated to the desired cutting angle θ 2 on the workpiece, for example, a semiconductor wafer 92 (see FIG. 6) by using the rotary table 4 and then linearly adjusted through a fine micromanipulation of the feed mechanism 62 of the cutter module 6 . Therefore, the relative angle and distance between the diamond cutter 7 and the semiconductor wafer 92 can be adjusted, causing the diamond cutter 7 to scribe the semiconductor wafer 92 precisely. According to the present preferred embodiment, regulating the amount of electric current to the coil 621 controls the feedrate of the feed mechanism 62 . Therefore, the feed mechanism 62 can be used to control the amount of force applied to the semiconductor wafer 92 when operating the diamond cutter 7 to scribe the semiconductor wafer 92 .
Furthermore, the rotary mechanism 61 of the aforesaid cutter module 6 is mounted in the inside space of the hollow column 63 . The rotary mechanism 61 comprises a rotary chuck 612 holding the diamond cutter 7 , a motor 611 , a coupling 613 coupled between the rotary chuck 612 and the motor 611 for enabling the motor 611 to rotate the rotary chuck 612 and the diamond cutter 7 around the center axis 510 of the through hole 51 , and an encoder 614 adapted to detect the angle of rotation of the motor 611 . The motor 611 is carried on a mount 64 , which is installed in the hollow column 63 . Therefore, the diamond cutter 7 can be rotated with the rotary chuck 612 , and moved axially up and down with the motor 611 and the hollow column 63 .
When the diamond cutter 7 begins to wear after long uses use for example, when the cutting point B is worn out (see FIG. 6 ), the DC servo motor 611 of the rotary mechanism 61 is numerically controlled with the monitoring of a CCD device 901 electrically connected to a monitor 902 (see FIG. 1) to rotate the diamond cutter 7 through an angle θ 1 (for example, 90°) or other predetermined angle precisely, enabling the diamond cutter 7 rotated to a precise angle to cut the workpiece with different crystal phase cutting points (for example, cutting point C, D, or A). Therefore, the diamond cutter 7 can be used repeatedly, preventing the occurrence of a precision problem due to a replacement of the diamond cutter. Further, the diamond cutter 7 can have its angle easily adjusted to a precise position with numeric control, preventing the precision problem caused by conventional manual adjustment.
When the diamond cutter 7 begins to wear after long uses use for example, when the cutting point B is worn out (see FIG. 6 ), the DC servo motor 611 of the rotary mechanism 61 is numerically controlled with the monitoring of a CCD device 901 electrically connected to a monitor 902 (see FIG. 1) to rotate the diamond cutter 7 through an angle θ 1 (for example, 90°) or other predetermined angle precisely, enabling the diamond cutter 7 rotated to a precise angle to cut the workpiece with different crystal phase cutting points (for example, cutting point C, D, or A). Therefore, the diamond cutter 7 can be used repeatedly, preventing the occurrence of a precision problem due to a replacement of the diamond cutter. Further, the diamond cutter 7 can have its angle easily adjusted to a precise position with numeric control, preventing the precision problem caused by conventional manual adjustment.
Although the present invention has been explained in relation to its preferred embodiment, it is to be understood that many other possible modifications and variations can be made without departing from the spirit and scope of the invention as hereinafter claimed. | A cutting device for breaking fragile materials is constructed to include a lifting mechanism adapted to move the cutter vertically, a rotary table adapted to control the cutting angle of the cutter on the workpiece, a feed mechanism adapted to control the federate of the cutter, and a rotary mechanism adapted to rotate the cutter for enabling the cutter to cut the workpiece with one of multiple cutting points thereof selectively. | 1 |
This application is a division of U.S. application Ser. No. 08/889,180, filed Jul. 7, 1997, now U.S. Pat. No. 6,385,675, which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a printing system, and more particularly, to a system in which accounting (cost assessment) is based on the specific functions used in the course of outputting a given body of text data or image data.
2. Related Background Art
In order to account for the usage of a copying machine a copy shop operator counts the number of pages to be copied and the number of copies of each page; and he makes his accounting based on these numbers. However, this accounting does not take into consideration any special functions that are carried out in connection with the copying. Recently, several special functions have been provided in automatic copying machines, such as automatic sorting, automatic stapling, double sided printing, etc. These special functions add value to the copied product; and therefore there is a need to account for their operation when calculating the usage of the copying machine.
SUMMARY OF THE INVENTION
It is an object of this invention to provide a printing system in which use of the above-mentioned specific functions can be accounted for appropriately.
According to one aspect of the present invention, there is provided a printing system which comprises means for performing a printing operation according to a requested mode; and means for performing an accounting operation according to the printing operation.
According to more specific aspects of the invention, the accounting operation is carried out based on one or more of the time or date of printing, the number of pages to be printed or copied, the size of the copy or document to be printed, the kind of paper to be printed on, and the name of the user.
According to a further aspect of the invention, there is provided a printing system which comprises means for printing documents, means for carrying out an accounting operation in regard to the operation of the printing means, means for printing based on a predetermined program, and means for storing the program in a manner such that it can be executed only upon receipt of a predetermined password.
According to yet another aspect of the invention, there is provided a novel printing system having a host computer and a printer which are connected with each other, and wherein the printer prints according to a plurality of operational modes. In this aspect the printing system comprises means for carrying out accounting operations based on the operational modes, means for executing a printing operation based on a command from the host computer, and means for displaying an amount of charge for the printing operation to the host.
According to additional specific features of the invention, there are provided means for prohibiting printing if the charge exceeds a predetermined amount or prohibiting printing until after the amount of charge has been transmitted to the host computer.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram showing one embodiment of a printing system according to the present invention;
FIG. 2 is a block diagram of an image processor in the system of FIG. 1 ;
FIG. 3 is a flow chart for explaining the operation of the system of FIG. 1 ;
FIG. 4 is a flow chart for explaining the operation of a first modification of the system of FIG. 1 ;
FIG. 5 is a flow chart for explaining the operation of a second modification of the system of FIG. 1 ; and
FIG. 6 is a flow chart for explaining the operation of a third modification of the system of FIG. 1 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The first embodiment of this invention will be described with reference to FIG. 1 .
The system of FIG. 1 comprises a digital copying machine 100 , an image processor 101 and a plurality of host computers 102 . The digital copying machine 100 is connected to the image processor 101 via an exclusive interface (I/F). The host computers, 102 ′ are connected with the image processor apparatus 101 via a wide area interface or network such as Ethernet.
Image and text data (PDL) as well as commands from the host computers, 102 ′ are transmitted to the digital copying machine 100 via the image processor 101 .
In this embodiment, the digital copying machine 100 has several different copying functions such as a full color copying function, a mono-color copying function, a tri-color copying function, a twin-color copying function, etc., as well as several kinds of extension functions such as a printing function, a sorting function, a stapling function, a preview function, a color copy mode specifying function, and so on.
The full-color copying function is carried out by using the colors Y (Yellow), M (Magenta), C (Cyan) and K (Black). The mono-color copying function is carried out by using only K (Black). The tri-color copying function is carried out by using Y (Yellow), M (Magenta) and C (Cyan). The twin-color copying function is carried out by using the colors R (Red) and K (Black). The preview function is used for adjusting colors and for publishing by displaying the expected image on the screen of the host computer 102 . The color copy mode specifying function is used to specify the printing mode, that is, if it is to be the full-color copy mode, the tri-color copy mode, the twin-color copy mode or the mono-color copy mode.
As shown in FIG. 2 , the image processor 101 includes an interface 101 A for transferring data to and from the host computers 102 via the wide area network. The image processor 101 also includes an exclusive interface 101 B for transferring the data to and from the digital copying machine 100 . There are also provided in the image processor 101 , a PDL processor 101 C for processing the PDL (image and text) data, an image processor 101 D for carrying out several kinds of image processing such as gamma processing for the image data, a timer 101 E, a circuit 101 F for managing and logging each job, including a spooler, a discriminator 101 G for checking the authenticity of each job order, an account processor 101 H for processing the cost of the job based on an accounting program, and a controller 101 I for controlling the accounting operations, the image processing operations, the communications and the changing of the accounting programs. The controller 101 I controls the digital copying machine 100 so that it carries out a function specified by one of the host computers 102 . The controller then logs the job and prepares an account based on the log. It then gives an account notice to each host computer according to a predetermined timing.
The account notice may be sent to the appropriate each host computer 102 along with each copying job, or periodically, such as monthly, or when the total charge exceeds a predetermined amount, or as requested by the user.
The accounting operation is carried out based on the following parameters: an acceptance time (this may be, for example, a week, a day or a holiday, daytime or nighttime, etc.), the number of pages to be copied, the kind of paper to be used in the copying operation, such as ordinary paper or OHP (Overhead Transparency Paper), etc., paper size, size of the file, name of the user (discountable or not), copy mode (full-color copy or mono-color copy, etc. in a case where the copying machine 100 is a color copying machine), necessity for logging after copying, user functions (these may be expansion functions or ordinary functions) and time. In this embodiment, these parameters may be set by the host computer 102 .
In this embodiment, the image processor 101 normally executes the accounting operation when the copying operation is completed. The accounting operation for each parameter is executed according to a software program in the image processor 101 . The specific program or the specific parameters may be changed upon inputting a password or by carrying out a special operation for that purpose.
The host computer prints the text data and image data which is picked-up by a digital camera (not shown) or by a scanner 102 A. The data, which may include several kinds, may be delivered via a network, or reproduced by means of a player such as a CD-ROM player, etc., by using the digital copying machine 100 and the image processor 101 .
The basic operation of the system will now be described with reference to FIG. 3 .
The host computer 102 transfers the user's password and operation code to the image processor 101 . The image processor 101 confirms the password and an operation code, and decides if the user is authorized to operate the copying machine 100 . The image processor 101 gives notice of the decision to the host computer 102 ; and the image processor 101 then confirms this information to the user. For example, the image processor 101 confirms whether the user is permitted to access the program, to change the program, etc.
After confirmation, the user specifies the image or document to be copied, sets the parameters and the copy mode, and then issues instructions to begin copying. The host computer 102 changes the image data or the text data to PDL data which includes the copy mode code, expansion function code, etc. The host computer 102 sends the PDL data and the user's ID (identification) code or machine's identification code to the image processor 101 .
The image processor 101 stores the PDL data in a memory and records the PDL data in each user's assigned memory region according to each user's turn.
The discriminator 101 G of the image processor 101 ascertains whether there is any prohibition regarding copying or printing of the PDL data. If the PDL data relates to a bill (i.e., money) or securities or involves copyrighted material, the copying of such data is prohibited. Accordingly, the discriminator 101 G confirms that the PDL data is not such prohibited data. Then the image processor 101 carries out predetermined image processing.
In this embodiment, the discriminator 101 G determines whether the data is copyable or not. This determination is made according to a control code which is sent with the PDL data from the host computer 102 , and which represents several kinds of regulations regarding restrictions on copying, image processing etc. The discriminator 101 G first reads the control code and then makes its decision based on the code. The various regulations corresponding to the control code are stored in a controlled access memory.
The discriminator 101 G may include a function for checking specified images or like, copyright marking and the design of billing forms.
The image processor 101 instructs the digital copying machine 100 to carry out copying and expansion functions, and to begin operation of a clock in order to ascertain copying time.
At each job's turn, the digital copying machine 100 carries out the job (i.e., copying in a specified copy mode and carrying out expansion functions). Then the digital copying machine 100 reports to the image processor 101 that the copying job will be completed in the normal manner.
The image processor 101 clocks the copy time, and confirms whether the copying operation has been completed in the normal manner. Then, if this has been done, the image processor 101 carries out an accounting operation. The image processor 101 carries out this accounting operation based on the copy mode, the number of copies, the copy time, etc. The image processor 101 records the results of the accounting operation in a log and communicates the results to the appropriate host computer 102 .
Next, another operation will be described with reference to FIG. 4 . In the above-described embodiment, the accounting operation is performed only by the image processor 101 . However, in this next embodiment, the user can confirm the amount of the charge and can change the functions specified by the use, if needed.
As in the above described first embodiment, the user in this embodiment specifies the image or document to be copied, sets the parameters and the copy mode, and then instructs the system to begin the copying operation. The image processor 101 stores the PDL data into the user's assigned memory according to the user's turn.
The discriminator 101 G of the image processor 101 ascertains whether there is any restriction as to the copying or printing of the PDL data. The image processor 101 also carries out to an accounting operation and calculates an estimated charge. Then the image processor 101 transmits the estimated charge to respective host computer 102 .
The host computer 102 displays the estimated amount of charge to the user so that the user may change the specified functions.
The host computer 102 then gives notice of completion of the confirmation and the charge to the image processor 101 . The image processor 101 carries out the image processing and sends the PDL data and a start copy instruction to the digital copying machine 100 . The following operations of this embodiment are the same as for the previous embodiment. Thus, the image processor 101 carries out the accounting operation based on the job report, the represented number of pages, the copying mode, etc. According to this embodiment, a user can make copies while remaining within budget; and any possible problems regarding charges will be avoided beforehand.
Also, an upper limit of the amount to be charged may be preset, and the image processor 101 may give the notice of any excess when the charge amount exceeds this upper limit. This also helps to avoid problems in advance.
Another operation will be described with reference to FIG. 5 . In the above described embodiment, the accounting operation is carried out the image processor 101 . In this embodiment however, the accounting operation is carried out by the host computer 102 .
The host computer 102 specifies the functions and the document or documents to be copied, and requests the image processor 101 to send program software for an accounting operation.
The image processor 101 sends the program software to the host computer 102 after checking the user's code sent from the host computer 102 . The host computer 102 then uses the program software to estimate the amount to be charged for the copying which is to be carried out according to the specified functions, and displays the amount so that it can be confirmed by the operator; and so that the operator can change the specified functions if desired.
After completion the final confirmation, the host computer 102 sends the PDL data to the image processor 101 and instructs it to start the copying operation as in the previous embodiment.
The operation of this embodiment in the same as that of the previously described embodiment. The image processor 101 transfers a job completion report, which has been sent from the digital copying machine 100 , to the host computer 102 . The image processor 101 then requests the host computer to delete the program software for the accounting operation. The host computer 102 carries out the accounting operation based on the job completion report, and deletes the program software.
Next, another operation, in which a preview operation is carried out, will be described with reference to FIG. 6 .
The operation of this embodiment is basically the same as in the previously described embodiments. However, in this embodiment, before a copying operation is executed, the image data which is processed by the digital copying machine 100 is transferred to the host computer 102 via the image processor 101 . The host computer 102 displays an image based on the image data which was sent from the digital copying machine 100 so that the user can confirm the image, adjust the color of the image, etc.
The user specifies the document, the image to be copied and the expansion functions by using the host computer 102 . Then the user issues an instruction to start copying by operation of the host computer 102 .
The details of this operation will now be described.
The host computer 102 transforms the image data to be copied into the PDL data. This data includes the copy mode code, an expansion function code and a command for preview. The host computer 102 transfers this PDL data to the image processor 101 via a network. In addition, the host computer 102 transfers the user's password and operation code to the image processor 101 .
The image processor 101 stores the PDL data in a memory, and records the PDL data in each user's assigned region of the memory according to the user's turn.
The discriminator 101 G of the image processor 101 discriminates whether copying or printing according to the PDL data is prohibited. Then the image processor 101 carries out the prescribed image processing.
The image processor 101 instructs the digital copying machine 100 to carry out copying and the expansion functions, and to begin clocking of the copying time.
The digital copying machine 100 does image processing which is different from the image processing carried out in the image processor 101 ; and it returns the processed image data to the image processor. The image processor 101 transforms the processed image data into the PDL data, and transfers the PDL data to the host computer 102 .
The host computer 102 displays the processed image data so as to confirm the data and to permit the user to adjust the color and details of picture based on the processed image data. Then the host computer 102 transforms the image data into PDL data, and transfers the PDL data to the image processor 101 .
The digital copying machine 100 carries out the requested jobs (i.e., copying in specified copy mode and carrying the requested expansion functions). Upon completion of the copying operation, the digital copying machine 100 transmits a report to the image processor 101 that the copying operation is completed is finished and that the copying mode is normal.
The image processor 101 stops clocking of the copy time, and confirms if the copying operation is completed and was performed normally. Then, if the copying operation was normal, the image processor 101 carries out the accounting operation. This accounting operation is based on the copy mode, the number of copies, the copy time, etc. The image processor 101 records the amount in a log and informs the host computer 102 of the amount.
According to the above embodiments, an accounting corresponding to particular parameters is obtained automatically. As a result, an operator can carry out an accounting operation in a simple manner and with little difficulty.
It is easy to change or modify the charge for copying and printing by changing the program software and associated parameters.
As mentioned above, it is possible with this embodiment to automatically request a charge according to several kinds of service which may be specified by a user. Further, this embodiment can automatically request a charge according to copy mode and functions requested by a user. | There is disclosed a printer or copying machine which operates according to several different functional and operational modes, a host computer which sends a print or copy order to the printer or copying machine, which order may include the number of copies to be made, the time of printing or copying, and an operational mode, such as size of copy, two-sided copying, collating, stapling, etc., and an accounting means which calculates charges based on the order before it is carried out by the printer or copying machine and which transmits those charge to the host computer. | 6 |
BACKGROUND OF THE INVENTION
The present invention is directed to the use of recombinant DNA techniques to confer upon microorganism host cells the capacity for selected bioconversions. More specifically, the invention is directed to the cloning of toluene monooxygenase genes from a newly isolated and characterized Pseudomonas strain, Pseudomonas mendocina KR-1. The present invention thus provides genetically engineered microorganisms that over produce toluene monooxygenase enzymes and proteins, and therefore provides more efficient means of conducting bioconversions dependent on this enzyme system.
Recently, a bacterium identified as Pseudomonas mendocina KR-1 (PmKR1) was isolated by Richardson and Gibson from an algal-mat taken from a fresh water lake. Whited, Ph. D. Dissertation, The University of Texas at Austin, Library Reference No. W586 (1986). PmKR1 utilizes toluene as a sole carbon and energy source. Other strains of Pseudomonas have been previously isolated and described which metabolize or degrade toluene, including Pseudomonas putida mt-2 (Pp mt-2). Williams and Murry, J. Bacteriol. 120: 416-423 (1974) and Pseudomonas putida PpF1 (PpF1) (Gibson, et al. Biochemistry 9:1626-1630 (1970). However, the genes, the enzymes and the pathways for toluene metabolism in these various Pseudomonas strains are distinct and non-overlapping.
The catabolic pathway for the degradation of toluene by Pp mt-2 has been designated TOL. The genes for the TOL pathway are encoded on isofunctional catabolic plasmids found in certain strains of Pseudomonas. The reference plasmid for the TOL degradative pathway is pWWO originally isolated from Pp mt-2. The genetics and biochemistry of the TOL pathway are well described. Kunz and Chapman, J. Bacteriol. 146:179-191 (1981); Williams and Murry, J. Bacteriol. 120:416-423 (1974); Williams and Worsey, J. Bacteriol. 125:818-828 (1976); Worsey and Williams, J. Bacteriol. 124:7-13 (1975); Murry, et al., Eur. J. Biochem. 28:301-310 (1972). A brief summary of the TOL pathway is as follows: initial attack of toluene is at the methyl group which undergoes successive oxidations to form benzoic acid, which is further oxidized by formation of a cis-carboxylic acid diol, which is oxidized to form catechol, which is then degraded by enzymes of a meta cleavage pathway to acetaldehyde and pyruvate.
A second catabolic pathway for the degradation of toluene by PpF1 has been established and designated TOD. In contrast to the TOL pathway, the genes for the TOD pathway are located on the bacterial chromosome and are not plasmid-encoded. Finette, et al., J. Bacteriol. 160:1003-1009 (1984); Finette, Ph. D. Dissertation, The University of Texas at Austin, Library Reference No. F494 (1984). The genetics and biochemistry of the TOD pathway has been studied by Finette, et al. (supra); Finette (supra); Gibson, et al. Biochemistry 9:1626-1630 (1970); Kobal, et al., J. Am. Chem. Soc. 95:4420-4421 (1973); Ziffer, et al., J. Am. Chem. Soc. 95:4048-4049 (1973); Dagley, et al., Nature 202:775-778 (1964); Gibson, et al., Biochemistry 7:2653-2662 (1968). A brief summary of the TOD pathway is as follows: the initial attack of toluene is by a dioxygenase enzyme system to form (+)-cis-1(S),2(R)-dihydroxy-3-methylcyclohexa-3,5-diene(cis-toluene dihydrodiol) which is oxidized to 3-methylcatechol which is further degraded by enzymes of a meta cleavage pathway.
A third catabolic pathway for the degradation of toluene has been recently identified in PmKR1. It has been found that PmKR1 catabolizes toluene by a novel pathway which is completely different than either of the two pathways described above. Richardson and Gibson, Abst. Ann. Meet. Am. Soc. Microbiol. K54:156 (1984). The catabolic pathway for the degradation of toluene by PmKR1 has been designated TMO, because the first step in the pathway is catalyzed by a unique enzyme complex, toluene monooxygenase. The biochemistry of the enzymes and proteins of this pathway has been recently studied in detail by Whited, Ph. D. Dissertation, The University of Texas at Austin, Library Reference No. W586 (1986).
A brief summary of the TMO pathway in PMKR1 is as follows: in the initial step toluene is oxidized to p-cresol, followed by methyl group oxidation to form p-hydroxybenzoate, followed by hydroxylation to protocatechuate and subsequent ortho ring cleavage. The steps of the TMO pathway as outlined by Whited (supra) are diagrammed in FIG. 1. In the first step of the TMO pathway, toluene is converted by toluene monooxygenase to p-cresol. PmKR1 elaborates a unique multicomponent enzyme system which catalyzes this first step monooxygenase reaction. According to Whited, (supra), at least three protein components are involved: oxygenase (at least 2 subunits of 50,000 d. and 32,000 d.), ferredoxin (23,000 d.) and NADH oxidoreductase (molecular weight unknown).
At present, despite the substantial advances in the understanding of the biochemistry of the enzymes and proteins of the TMO pathway and beginning genetic studies (Yen et al. Abstract, University of Geneva EMBO Workshop, Aug. 31-Sept. 4, 1986), the art has not been provided with information regarding the genes encoding the enzymes and proteins of the toluene monooxygenase system in PmKR1 or the usefulness of such genes and gene products in certain microbial bioconversions. The art has also not been provided with microorganism host cells containing novel recombinant plasmids containing PmKR1 toluene monooxygenase genes, in which certain of these microorganism host cells express toluene monooxygenase enzyme activity at levels that exceed the activity of wildtype PmKR1 cells.
SUMMARY OF THE INVENTION
The present invention provides novel gene segments, biologically functional plasmids and recombinant plasmids, and microorganism host cells, all of which contain the PmKR1 toluene monooxygenase genes. The present invention further provides a microorganism host cell containing a novel recombinant plasmid containing PmKR1 toluene monooxygenase genes, in which the host cell expresses toluene monooxygenase enzyme activity at levels that exceed the activity of wildtype PmKR1 cells. In addition, the present invention provides a method for using transformed microorganism host cells containing the PmKR1 toluene monooxygenase genes utilized in microbial bioconversions. Thus, the present invention provides microorganisms genetically engineered to overproduce toluene monooxygenase enzymes and proteins and therefore provides a more efficient means of conducting bioconversions dependent on this enzyme system.
The present invention encompasses a biologically functional plasmid derived from PmKR1 containing toluene monooxygenase genes. This plasmid (designated pAUT 1) can be transferred by conjugation to a microorganism host cell lacking the toluene monooxygenase gene system and thus unable to convert toluene to p-cresol. In a particularly preferred embodiment of the present invention, the microorganism host cell for the pAUT1 plasmid is Pseudomonas putida Y2101.
The present invention also encompasses the toluene monooxygenase genes which have been isolated and cloned as various DNA gene segments from PmKR1 into a suitable, autonomously-replicating plasmid vector, resulting in a series of recombinant plasmids each of which contains a toluene monooxygenase gene segment. Each such recombinant plasmid is biologically functional and can be used to transform a microorganism host cell, conferring on the microorganism host cell the ability to convert toluene to p-cresol.
The present invention further encompasses a series of such transformed microorganism host cells. In a particularly preferred embodiment of the present invention, the microorganism host cell is E. coli HB101, the recombinant plasmid is pMY402 and the inducer is isopropylthiogalactoside (IPTG). The pMY402 recombinant plasmid is the pMMB66EH plasmid into which has been inserted a 4.6 kb Xho I fragment encoding the PmKR1 toluene monooxygenase genes. In another particularly preferred embodiment of the present invention, the microorganism host cell is E. coli FM5, the recombinant plasmid is pKY287 and the inducer is heat (42° C.). The pKY287 recombinant plasmid is the pCFM1146 plasmid into which has been inserted a 4.6 kb Xho I fragment encoding the PmKR1 toluene monooxygenase genes. These resulting recombinant host cells express toluene monooxygenase enzyme activity at levels exceeding the activity of wildtype PmKR1 cells from which the toluene monooxygenase genes were isolated.
The present invention is directed to a method for certain microbial bioconversions using PmKR1 or the transformed microorganism host cells containing the PmKR1 toluene monooxygenase genes, in particular, the conversion of a selected phenyl compound to a selected phenolic compound. In a particularly preferred embodiment of the present invention, a method is provided for making p-hydroxyphenylacetic acid using the transformed microorganism host cells containing the PmKR1 toluene monooxygenase genes.
The present invention is also directed to a method for the microbial production of indigo from indole using PmKR1 cells or the transformed microorganism host cells containing the PmKR1 toluene monooxygenase genes. Further aspects and advantages of the present invention will become apparent to those skilled in the art upon consideration of the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates the steps of the PmKR1 toluene monooxygenase (TMO) pathway.
FIG. 2 shows a map of the pKY235 plasmid vector.
FIG. 3 illustrates a summary of recombinant plasmids, plasmid vectors and restriction maps of the PmKR1 DNA segments containing toluene monooxygenase genes.
DETAILED DESCRIPTION
The methods and materials that provide an illustration of the practice of the invention and that comprise the presently preferred embodiments relate specifically to plasmid-borne DNA gene segments of PmKR1 origin encoding the genes for the PmKR1 toluene monooxygenase enzyme system. By conjugation or transformation, these plasmid-borne DNA gene segments can be introduced and expressed in certain microorganism host cells. Microorganism host cells containing PmKR1 toluene monooxygenase genes are useful in a method for certain bioconversions.
The invention is now illustrated by the following Examples, with reference to the accompanying drawings. The examples do not include detailed descriptions for conventional methods employed in the isolation of DNA, the cleavage of DNA with restriction enzymes, the construction of vectors, the insertion of DNA gene segments encoding polypeptides of interest into such vectors (e.g. plasmids) or the introduction of the resulting recombinant plasmids into microorganism host cells. Such methods are well-known to those skilled in the art of genetic engineering and are described in numerous publications including the following: Maniatis et al., Molecular Cloning-A Laboratory Manual, Cold Spring Harbor Laboratory (1982); Davis et al., Basic Methods in Molecular Biology, Elsevier Science Publishing Co. (1986); Current Protocols in Molecular Biology, edited by Ausubel et al., Greene Publishing Associates and Wiley Interscience (1987).
EXAMPLE 1
Growth of PmKR1 Cells
Pseudomonas mendocina KR-1 was grown overnight at 30° in PAS medium or on a PAS agar plate (Chakrabarty, et al., Proc. Natl. Acad. Sci. U.S.A., 70:1137-1140 1973) with toluene (supplied as vapor) for growth and for induction of the toluene monooxygenase genes.
EXAMPLE 2
Construction of PmKR1 Bgl II Library in E. coli HB101
A. Preparation of PmKR1 DNA
Total DNA was isolated from PmKR1 by conventional methods. Briefly, PmKR1 was inoculated into PAS medium containing toluene according to Example 1 and incubated with shaking at 30° C. overnight (13-17 hours). After incubation, PmKR1 cells in the stationary growth phase were collected by centrifugation. The cells were lysed and total PmKR1 DNA was then extracted and purified as described by Dhaese et al., Nucleic Acid Res. 7: 1837-1849 (1979).
B. Preparation of Plasmid DNA
E. coli HB101 containing the pRK290 plasmid (Ditta, et al., Proc. Natl. Acad. Sci. U.S.A. 77: 7347-7351 (1980)) was inoculated into L broth and incubated with shaking at 37° C. overnight. The bacterial cells were collected by centrifugation, lysed and the bulk of chromosomal DNA and cellular debris was removed by centrifugation. The pKR290 plasmid DNA was then purified by conventional techniques using cesium chloride/ethidium bromide density gradients.
C. Preparation of Recombinant Plasmid
Total PmKR1 DNA obtained in Part A above and pRK290 plasmid DNA obtained in Part B above were separately treated with the restriction endonuclease Bgl II, under conditions of complete digestion. The Bgl II digested PmKR1 DNA was mixed with Bgl II digested pRK290 plasmid DNA and the mixture then incubated with DNA ligase.
D. Transformation with Recombinant Plasmid
The ligated DNA obtained in Part C above was used to transform E. coli HB101 and the transformed cells were plated on selection plates of L-agar containing 10 μg/ml tetracycline. Only those cells which are successfully transformed and which contain the pRK290 plasmid or a recombinant pRK290 plasmid with PmKR1 DNA can grow on the selection plates. Colonies which grew on the selection plates were tested for the presence of recombinant plasmids containing PmKR1 toluene monooxygenase genes by the conjugation and complementation screening assay of Example 3.
EXAMPLE 3
Conjugation and Complementation Screening Assay
A complementation assay involving plasmid transfer via bacterial conjugation was used to screen the PmKR1 Bgl II library made according to Example 2 and the PmKR1 Sac I library made according to Example 8 in order to detect recombinant plasmids containing PmKR1 toluene monooxygenase genes. Accordingly, plasmids were transferred between bacterial strains by the conjugation ("mating") procedure described by Yen and Gunsalus, Proc. Natl. Acad. Sci. U.S.A., 79:874-878 (1982) which procedure is summarized briefly as follows.
Colonies were removed from the selection plates of Example 2 or Example 8 by gentle scraping with L-broth. The resulting bacterial cell suspension was washed to remove any tetracycline and suspended in L-broth for the mating. Suspensions of donor cells, helper cells (if necessary) and recipient cells in logarithmic phase were mixed in equal volumes. Small aliquots of the mixture were placed on L-agar plates thus allowing all cell types to grow. After overnight incubation at 30° C., the cells were replated on a PAS agar selection plate containing 50 μg/ml tetracycline. Toluene was provided as sole carbon source for growth. Toluene vapor was supplied to the selection plate by taping a cotton-stoppered toluene containing tube to the lid of the plate. This selection plate permits only the desired trans-conjugates to grow. In all experiments performed, the donor cells were from an E. coli HB101 library (either the Bgl II library of Example 3 or the Sac I library of Example 8) carrying a recombinant plasmid (pRK290 or pKY235 containing PmKR1 gene segments) to be transferred in the mating. The helper cells used were E. coli HB101 cells carrying the helper plasmid pRK2013 which plasmid provided the transferring functions for those transferring plasmids which do not carry the tra genes. Alternatively, the helper plasmid pRK2013 was introduced directly into the donor cells to provide its transferring function. The recipient strain was one of several mutant strains of Pseudomonas mendocina KR-1 (Pm Y4001, Pm Y4002, Pm Y4007) prepared as described in Example 4. Each of the mutant strains has a defective toluene monooxygenase gene and is unable to convert toluene to p-cresol. When a recombinant plasmid containing the specific PmKR1 toluene monooxygenase gene which is defective in the recipient strain has been successfully transferred during conjugation, the resulting transconjugate will be able to grow as a colony on the selection plates containing toluene as the sole carbon source for growth.
The colonies which grew on the selection plates were purified by restreaking each colony once or twice on a selection plate. These transconjugates are further manipulated according to Example 5.
EXAMPLE 4
Preparation of Pseudomonas mendocina KR-1 Mutant Strains
PmKR1 cells were mutagenized and the toluene monooxygenase defective mutants were isolated according to the following protocol. Cells were grown in 5 ml of L broth to O.D. 660 of approximately 0.7 and resuspended into 2 ml of 50 mM citrate buffer pH 6.0 containing N-methyl-N'-nitro-N-nitrosoguanidine (nitrosoguanidine) at a concentration of 0.2 mg per ml. After incubation at room temperature for 20 minutes, the cells were washed twice with 2 ml of 1M phosphate buffer pH 7.0 and resuspended into 50 ml of L broth. After growth overnight, the cells were streaked on L agar plates for single colonies. The individual colonies were picked and streaked onto PAS plates containing toluene or p-cresol as sole carbon source. The toluene monooxygenase defective mutants, PmY4001, PmY4002 and PmY4007 were isolated as strains which grew on p-cresol but not on toluene. The toluene monooxygenase assay as described in Example 11 further confirmed that these mutants have a defective toluene monooxygenase enzyme system.
Similar mutagenesis techniques may be used to obtain mutants defective in the enzyme p-hydroxybenzaldehyde dehydrogenase of the TMO pathway. After nitrosoguanidine treatment of PmKR1 cells as described above, p-hydroxybenzaldehyde dehydrogenase defective mutants are isolated as strains which grow on p-hydroxybenzoate but do not grow on toluene, p-cresol, p-hydroxybenzylalcohol or p-hydroxybenzaldehyde.
EXAMPLE 5
Isolation of 9.4 kb Bgl II Fragment
A number (12) of the transconjugate colonies of PmY4001 containing PmKR1 toluene monooxygenase genes isolated according to Example 3 were further characterized as follows. Each colony was grown and plasmid DNA was isolated by conventional methods. The plasmid DNA from each isolate was used to transform E. coli HB101 cells. The plasmid in each transformant was transferred to PmY4001 by conjugation according to Example 3 except that the selection plates contained tetracycline and glucose (2 mg/ml). Each transconjugate was tested for growth on toluene by plating the cells on PAS agar supplemented with 50 μg/ml tetracycline and toluene vapor. After the toluene monooxygenase complementing activity of the plasmid was confirmed in the transconjugates each such HB101 transformant was grown and plasmid DNA was isolated by conventional methods.
The DNA was digested with Bgl II and a 9.4 kb fragment was isolated from each transconjugate colony which complemented each PmKR1 mutant strain of Example 4 for toluene utilization. This result indicated that the 9.4 kb Bgl II fragment from PmKR1 contained one or more toluene monooxygenase genes. Two Sac I sites were mapped close to one end of the 9.4 kb Bgl II fragment.
EXAMPLE 6
Construction of pKY235 Plasmid Vector
The starting material for the construction of the pKY235 plasmid was the pKY217 plasmid described by Yen and Gunsalus, J. Bacteriol. 162: 1008- 13 (1985). The pKY235 plasmid was constructed according to the following series of steps. In the first step, a 5.1 kb Hind III fragment from pKY217 containing the nahR and nahG genes was cloned into the Hind III site of the pKT240 plasmid described by Bagdasarian et al., Gene 26: 273-82 (1983). The resulting plasmid from this first step was designated pKY219. In the second step, an approximately 7 kb Bam HI - Sac I fragment from pKY219 containing the nahR and nahG genes was cloned into the Bam HI and Sac I sites of the pKT231 plasmid described by Bagdasarian et al. Gene 16: 237-47 (1981). The resulting plasmid was designated pKY223. In the next step, a 6 kb Pst I fragment from pKY223 containing the nahR gene, 200 base pairs of the nahG gene and the gene conferring kanamycin resistance was cloned into the Pst I site of the pUC19 plasmid described by Yanisch-Perron et al., Gene 33: 103-119 (1985). The resulting plasmid was designated pKY256. The orientation of the 6 kb Pst I fragment in pKY256 placed the multicloning site of pUC19 from the Sal I to the Eco RI site immediately downstream to the Pst I site in the nahG gene. In the final step, a 5.4 kb BstE II - Eco RI fragment from pKY256 containing the gene conferring kanamycin resistance, the nahR gene, 200 base pairs of the nahG gene and a multiple cloning site was end-filled with the large fragment of E. coli DNA polymerase I and inserted into the pRK290 plasmid described by Ditta et al., Proc. Nat'l Acad. Sci. U.S.A. 77; 7347-7351 (1980) to replace the approximately 1 kb Sma I fragment of pRK290. The resulting plasmid was designated pKY235 and a map of pKY235 is shown in FIG. 2.
EXAMPLE 7
Construction of pCFM1146 Plasmid Vector
The starting material for the construction of the pCFM1146 plasmid was the pCFM836 plasmid. A detailed description of the construction of expression vectors, including pCFM836, is described in U.S. Pat. No. 4,710,473, which is hereby incorporated by reference in its entirety. The pCFM836 plasmid contains a heat inducible promoter, a restriction site bank (cloning cluster), plasmid origin of replication, a transcription terminator, genes regulating plasmid copy number, and a gene conferring kanamycin resistance but no synthetic ribosome binding site immediately preceding the cloning cluster. The pCFM1146 plasmid ATCC number 67671 was derived from pCFM836 by substituting the small DNA sequence between the unique Cla I and Xba I restriction sites with the following oligonucleotide
______________________________________ 5' CGATTTGATT 3' 3' TAAACTAAGATC 5'______________________________________
and by destroying the two endogenous Nde I restriction sites by cleavage with Nde I and then filling with T 4 polymerase enzyme, followed by blunt end ligation.
EXAMPLE 8
Construction of PmKR1 Sac I Library in E. coli HB101
The pKY235 plasmid vector prepared according to Example 6 was used to construct a Sac I library in E. coli HB101 according to conventional techniques for constructing genomic libraries. Total DNA from PmKR1 was isolated as described in Example 2, Part A. The isolated PmKR1 DNA was treated with the restriction endonuclease Sac I under conditions of partial digestion. In order to produce a population of DNA fragments enriched in those fragments containing some or all of the PmKR1 toluene monooxygenase genes for use in constructing this Sac I library, the partially digested PmKR1 DNA was fractionated by size using a 10%-40% sucrose density gradient according to conventional procedures. After centrifugation for 24 hours at 26,000 rpm in an SW-28 centrifuge tube and rotor, the DNA fractions were collected and tested by hybridization. The 9.4 kb Bgl II fragment isolated from the Bgl II library constructed according to Example 3, known to complement each PmKR1 mutant strain for toluene utilization according to Example 5 and thus likely to contain at least one of the PmKR1 toluene monooxygenase genes, was radiolabeled and used as a probe to select hybridizing fractions from the sucrose gradient. The hybridizing fractions were pooled to provide a population of DNA fragments enriched in PmKR1 toluene monooxygenase containing fragments. This enriched population of DNA fragments was used to construct the Sac I library.
The enriched Sac I digested PmKR1 DNA was mixed with Sac I digested pKY235 plasmid DNA and incubated with DNA ligase. The ligated DNA was used to transform E. coli HB101 and the transformed cells were plated onto selection plates of L-agar containing 10 μg/ml tetracycline. Only those cells which were successfully transformed and containing the pKY235 plasmid or a recombinant pKY235 plasmid with PmKR1 DNA can grow on the selection plates. Transformed colonies were tested for PmKR1 toluene monooxygenase genes by the conjugation and complementation assay of Example 3.
EXAMPLE 9
Isolation of 20.5 kb Sac I Fragment
A number (10) of the transconjugates which utilized toluene as a sole carbon source were further characterized by isolating the plasmid DNA, transforming E. coli HB101, and conjugating into PmKY4001 to test for growth on toluene according to Example 5. An E. coli HB101 transformant containing a recombinant pKY235 plasmid (designated pKY266) ATCC number 67672 carrying toluene monooxygenase genes was grown and plasmid DNA was isolated by conventional methods. Restriction enzyme analysis of the insert in pKY266 plasmid indicated that it carried two Sac I fragments of 10.2 kb and 10.3 kb, respectively. The 10.2 kb Sac I fragment contains 8 kb of the 9.4 kb Bgl II fragment described in Example 5.
EXAMPLE 10
Construction of Recombinant Plasmids to Map the Toluene Monooxygenase Genes
The 10.2 kb Sac I fragment of pKY266 was further subcloned into the high-copy-number E. coli expression vector pUC19 described by Yanisch-Perron et al., Gene 33: 103-119 (1985) and the resulting recombinant plasmid was designated pKY277. The pKY277 plasmid was used to transform E. coli JM109 cells. This new E. coli strain designated JM109/pKY277, synthesized a blue pigment with properties expected of indigo in L broth. Toluene monooxygenase activity was also detected in this strain. Further mapping of the toluene monooxygenase genes correlated the indigo-producing property with the presence of toluene monooxygenase activity. (See Table I).
The 10.2 kb Sac I fragment of pKY277 was digested with a series of restriction enzymes and a partial restriction map was generated as shown in FIG. 3. Based on this restriction map, a series of DNA fragments were deleted from one end of the 10.2 kb Sac I fragment in pKY277 to generate plasmids pKY280, pKY281, pKY282 and pKY283 shown in FIG. 3. A 4.6 kb Xho I fragment of pKY282 was subcloned into the Sal I site of pUC19 to generate the plasmid pMY401. A 4.6 kb Bam HI - Sph I fragment of pMY401 containing the 4.6 kb Xho I fragment was inserted into the E. coli expression vector pUC18 described by Yanisch-Perron et al., Gene 33: 103-119 (1985) to generate the plasmid pMY404. The pUC18 plasmid is identical to pUC19 except the polycloning site is in an opposite orientation with respect to the lac promoter. As a result, the 4.6 Xho I fragment was inserted into the pUC18 plasmid in an opposite orientation to that in the pUC19 plasmid with respect to the lac promoter. The 4.6 kb Xho I fragment of pKY277 was also cloned into the broad host range plasmid vector pMMB66EH described by Furste et al., Gene 48: 119-131 (1986) to construct the plasmid pMY402. In addition, as shown in FIG. 3, a 2.2 kb Sac I - Bgl II fragment was deleted from the left end of the 5.9 kb Sac I - Xma I fragment of pKY282 by digesting pKY282 DNA with Sac I and Bgl II, filling the ends with the large fragment of E. coli DNA polymerase I and ligating the ends. The resulting plasmid was designated pMY400.
As shown in Table I (according to the assay of Example 11), pMY402 containing cells responded to IPTG for induction of the toluene monooxygenase genes. This result located the toluene monooxygenase genes in the 4.6 kb Xho I fragment and revealed the direction of transcription of the toluene monooxygenase genes as from left to right shown in FIG. 3. The difference in the orientation of the 4.6 kb Xho I fragment in pMY401 and pMY404 as well as the difference in toluene monooxygenase activity in pMY401 and pMY404 containing cells (Table I) are also consistent with this transcriptional direction of the toluene monooxygenase genes. In order to express the toluene monooxygenase genes at a high level, the 4.6 kb Xho I fragment of pKY282 was also cloned into the Xho I site of the E. coli expression vector pCFM1146 (as described in Example 7) to construct pKY287.
EXAMPLE 11
Toluene Monooxygenase Assay
Cells were grown in PAS medium containing 0.4% glutamate or in L broth to saturation. They were resuspended into an appropriate volume of the same medium to an O.D. 660 of 3.0. An aliquot of the cells was used for the determination of protein concentration by the method of Bradford, Anal. Biochem. 72: 248 (1976) using the Bio-Rad Protein Assay. An aliquot of 0.5 ml of cells was mixed with 4 μmoles of p-cresol in 10 μl and 15 nmole of radioactive toluene (toluene-ring- 14 C, Sigma Chemical Co., 56.3 mCi/mmole) in 5 μl and the mixture was incubated at room temperature with occasional vortexing for 20 minutes. After incubation, 20 μl of the mixture were spotted on a small piece of a thin-layer chromatography plate and the plate was air-dried for twenty was determined in a liquid scintillation counter and was used to calculate the amount of toluene degradation product on the plate and the specific activity of toluene monooxygenase. The results are presented in Table I.
TABLE I______________________________________Expression of the Toluene Monooxygenase (TMO)genes in E. coli and P. mendocina Specific Activity of TMO (nmole Indigo min.sup.-1 For-Plasmid Inducer Host Cell mg.sup.-1) mation______________________________________pAUT1 Toluene P. mendocina KR1 0.130 +pAUT1 None P. mendocina KR1 0.010 +pKY266 None P. putida KT2440 0.020 +pKY277 None E. coli JM109 0.010 +pMY405 None E. coli HB101 0.005 -pMY405 IPTG E. coli HB101 0.015 +pKY280 None E. coli JM109 0.010 +pKY281 None E. coli JM109 0.010 +pKY282 None E. coli JM109 0.010 +pKY283 None E. coli JM109 0.005 -pMY400 None E. coli JM83 0.005 -pMY401 None E. coli JM83 0.035 +pMY404 None E. coli JM83 0.010 +pMY402 None E. coli HB101 0.005 -pMY402 IPTG E. coli HB101 0.200 +pMY287 Heat E. coli FM5 0.500 +pUC19 None E. coli JM109 0.005 -pMMB66EH IPTG E. coli HB101 0.005 -pFCM1146 Heat E. coli FM5 0.005 -______________________________________
EXAMPLE 12
Conversion of Certain Phenyl Compounds to Certain Phenolic Compounds
A. Conversion by PmKR1 Cells
Many phenyl compounds, including toluene, methylphenylacetic acid, ethylphenylacetic acid, 2-phenylethanol, acetanilide, fluorobenzene and ethylbenzene, may serve as substrates and thus be converted to phenolic compounds via para-hydroxylation by the toluene monooxygenase system of PmKR1. The following schemes illustrate several possible conversions:
SCHEME A ##STR1## wherein:
I is toluene
II is p-cresol
SCHEME B ##STR2## wherein:
III is methylphenylacetic acid
IV is p-hydroxymethylphenylacetic acid
SCHEME C ##STR3## wherein:
V is 2-phenylethanol
VI is p-hydroxy-2-phenylethanol
For each conversion, a phenyl compound substrate (for example, Formulas I, III or V) was mixed with PmKR1 cells, incubated for a period sufficient to effect the bioconversion and then assayed for the presence of phenolic compounds as follows.
Pseudomonas mendocina KR1 cells were grown at 25° C.-30° C. in 50 ml PAS medium supplemented with 0.4% glutamate to stationary phase (12-16 hours) n the presence (induced) or absence (uninduced) of toluene vapor supplied from 2.5 ml toluene. An aliquot of 5-50 ml cells were resuspended into the same volume of the same medium or concentrated 2.5 fold in the same medium. A given amount of the substrate equivalent to form a 15-30 mM solution was mixed with the cells and the mixture was incubated at 25° C.-30° C. with vigorous shaking for 1-24 hours. Typically the mixture was incubated for 5-6 hours Formation of phenolic compounds was determined according to the assay method of Gupta et al., Clin. Biochem. 16 (4): 220-221 (1983). The assay results for conversion of several phenyl substrates to phenolic compounds at various times and temperatures of incubation are shown in Table II.
TABLE II______________________________________Synthesis of Phenolic Compounds by TolueneMonooxygenase of Pseudomonas mendocina KR1Substrate (Time and Temperature O.D..sub.660 readingof Incubation) in Assay______________________________________acetanilide (6 hrs., 25° C.) 1.07fluorobenzene (24 hrs., 25° C.) 0.73methylphenylacetate (6 hrs., 30° C.) 0.23ethylphenylacetate (6 hrs., 30° C.) 0.13ethylbenzene (6 hrs., 30° C.) 0.372-phenylethanol (5 hrs., 30° C.) 0.16substrate in uninduced culture 0.03______________________________________
B. Conversion by Microorganism Host Cells Containing Recombinant Plasmids encoding PmKR1 Toluene Monooxygenase Genes
The same conversions according to Part A may be accomplished by using microorganism host cells containing the recombinant plasmids of Example 10. Any of the recombinant plasmids (except pKY283 or pMY400) which encode functional PmKR1 toluene monooxygenase genes may be used to transform an appropriate microorganism host cell as described in Example 10. A preferred method is to use pMY402 as the recombinant plasmid, E. coli HB101 as the microorganism host cell and IPTG as the inducer, as described in Example 11. The resulting strain was designated HB101/pMY402. Another preferred method is to use pKY287 as the recombinant plasmid, E. coli FM5 ATCC number 53911 as the microorganism host cell and heat (42° C. for 1-3 hrs). as the inducer. The resulting strain was designated FM5/pKY287.
For each conversion, a phenyl compound (for example, Formulas I, III or V) is mixed with HB101/pMY402 or FM5/pKY287 cells. The mixture is incubated for a period sufficient to effect the bioconversion and then assayed as described in Part A for the presence of phenolic compounds. For each bioconversion with HB101/pMY402 cells, the cells must be grown and assayed in the presence of IPTG to induce PmKR1 toluene monooxygenase activity as follows. Cells are grown in PAS medium containing 0.4% glutamate and 1 mM IPTG or grown in L broth with 1 mM IPTG to saturation. The cells are resuspended in an appropriate volume of the same medium to an O.D. 660 of 3.0 and incubated with substrate and assayed as described in Part A. For each bioconversion with FM5/pKY287 cells, the cells must be grown under the following temperature conditions to induce PmKR1 toluene monooxygenase activity. FM5/pKY287 cells are grown in L broth to an OD 660 of 0.4. The cultures are incubated with shaking at 42° C. for 3 hours and then shifted to 30° C. to incubate for another 2 hours. Cells are resuspended in fresh L broth to an O.D. 660 of 3.0 and incubated with substrate and assayed as described in Part A.
EXAMPLE 13
Conversion of Toluene to p-Hydroxyphenylacetic Acid
A. Conversion by PmKR1 Cells
For the conversion of toluene substrate to p-hydroxyphenylacetic acid, toluene is mixed with a PmKR1 mutant containing defective p-hydroxybenzaldehyde dehydrogenase as described in Example 4 and incubated for a period sufficient to effect the conversion of toluene to p-hydroxybenzyl alcohol. In the second step, the cell mixture containing the p-hydroxybenzyl alcohol intermediate is reacted with nickel (Ni) and carbon monoxide (CO) in such concentrations and at such temperatures sufficient to convert the p-hydroxybenzyl alcohol to p-hydroxyphenylacetic acid, according to the methods of U.S. Pat. Nos. 4,482,497; 4,659,518; 4,631,348, which are hereby incorporated by reference. The conversion scheme is illustrated as follows: ##STR4##
B. Conversion by Microorganism Host Cells Containing Recombinant Plasmids encoding PmKR1 Toluene Monooxygenase Genes
The same conversion according to Part A may be accomplished by using microorganism host cells containing the p-cresol hydroxylase gene and the recombinant plasmids of Example 10. The p-cresol hydroxylase gene may be cloned by conventional genetic engineering techniques from a variety of microorganisms containing this gene, including for example, from PmKR1 or from plasmid pND50 (Hewetson et al., Genet. Res. Camb. 32: 249-255, 1978). Any of the recombinant plasmids (except pKY283 or pMY400) which encode functional PmKR1 toluene monooxygenase genes may be used to transform an appropriate microorganism host cell described in Example 10. A preferred method is to use HB101/pMY402 cells. Another preferred method is to use FM5/pKY287 cells.
For the conversion as illustrated in Part A, toluene is mixed with HB101/pMY402 cells grown and induced with IPTG or FM5/pKY287 cells grown and induced with heat as described in Example 12. The mixture is incubated for a period sufficient to effect the conversion of toluene to p-hydroxybenzyl alcohol, and then is reacted with Ni and CO according to Part A to effect the conversion to p-hydroxyphenylacetic acid.
EXAMPLE 14
Conversion of Methylphenylacetic Acid to p-Hydroxyphenylacetic Acid
A. Conversion by PmKR1 Cells
For the conversion of methylphenylacetic acid substrate to p-hydroxyphenylacetic acid, methylphenylacetic acid is mixed with PmKR1 grown as described in Example 12 and incubated for a period sufficient to effect the conversion of methylphenylacetic acid to p-hydroxymethylphenylacetic acid. In the second step, the cell mixture containing the p-hydroxyphenylacetic acid intermediate is subjected to acid hydrolysis at acid concentrations and temperatures sufficient to convert the p-hydroxymethylphenylacetic acid to p-hydroxyphenylacetic acid. The conversion scheme is illustrated as follows: ##STR5##
B. Conversion by Microorganism Host Cells Containing Recombinant Plasmids encoding PmKR1 Toluene Monooxygenase Genes
The same conversion according to Part A may be accomplished by using microorganism host cells containing the recombinant plasmids of Example 10. Any of the recombinant plasmids (except pKY283 or pMY400) which encode functional PmKR1 toluene monooxygenase genes may be used to transform an appropriate microorganism host cell described in Example 10. A preferred method is to use HB101/pMY402 cells. Another preferred method is to use FM5/pKY287 cells.
For the conversion as illustrated in Part A, methylphenylacetic acid is mixed with HB101/pMY402 cells grown and induced with IPTG or FM5/pKY287 cells grown and induced with heat as described in Example 12. The mixture is incubated for a period sufficient to effect the bioconversion of p-hydroxymethylacetic acid and then the mixture is subjected to acid hydrolysis at acid concentrations and temperatures sufficient to yield p-hydroxyphenylacetic acid.
EXAMPLE 15
Conversion of Indole to Indigo
A. Conversion by PmKR1 Cells
For the conversion of indole substrate to indigo, 50 μg/ml indole was mixed with PmKR1 cells grown as described in Example 12 and incubated for a period sufficient to effect the conversion of indole to indigo, generally 48 hours. The indigo may be isolated from the cell mixture by the procedure described by Ensley in Example 5 of U.S. Pat. No. 4,520,103.
B. Conversion by Microorganism Host Cells Containing Recombinant Plasmids encoding PmKR1 Toluene Monooxygenase Genes
The same conversion according to Part A may be accomplished by using microorganism host cells containing the recombinant plasmids of Example 10. Any of the recombinant plasmids (except pKY283 or pMY400) which encode functional PmKR1 toluene monooxygenase genes may be used to transform an appropriate microorganism host cell described in Example 10. A preferred method is to use HB101/pMY402 cells. Another preferred method is to use FM5/pKY287 cells.
For the conversion as illustrated in Part A, indole is mixed with HB101/pMY402 cells grown and induced with IPTG or FM5/pKY287 cells grown and induced with heat as described in Example 12. The mixture is incubated for a period sufficient to effect the bioconversion of indole to indigo. The indigo may be isolated from the cell mixture according to the procedure of Part A. | Disclosed and claimed are DNA gene segments, biologically functional plasmids and recombinant plasmids, and microorganism host cells containing such plasmids, all of which contain toluene monooxygenase genes from Pseudomonas mendocina KR-1 and which are useful in a method for the microbial bioconversion of selected phenyl compounds to selected phenolic compounds. In particular, the method is useful for making p-hydroxyphenylacetic acid which is a valuable chemical intermediate in the preparation of certain antibiotics and certain β-adrenergic blocking agents. | 8 |
BACKGROUND OF THE INVENTION
[0001] This invention pertains to a method for the production and use of hydrogen donor solvents to increase the efficiency of processes to convert hydrocarbon residua feedstocks to lower boiling hydrocarbon liquid products.
[0002] It is well known that more hydrogen rich and lower boiling point hydrocarbon distillates can be produced from hydrogen deficient petroleum residua (resid) by thermally cracking in presence of a hydrogen donor diluent. U.S. Pat. No. 2,848,530 disclosed a process to produce lower boiling liquid hydrocarbons from a higher boiling hydrogen deficient petroleum oil by heat treatment in the presence of lower boiling point and partially hydrogenated aromatic-naphthenic diluent. Thermal tars, coal derived liquids, and catalytic cycle oils are preferred hydrogen donor diluent precursors.
[0003] U.S. Pat. No. 3,238,118 teaches the use of a gas oil hydrocracker to produce hydrogen donor diluent precursor. U.S. Pat. No. 4,090,947 teaches the use of a premium coker gas oil as the hydrogen donor precursor. U.S. Pat. No. 4,292,168 provides guidance on the desired hydrogen donor diluent properties using model compounds, but does not provide any guidance on commercially viable methods to produce a hydrogen donor diluent with the required properties. U.S. Pat. No. 4,363,716 teaches production of the hydrogen donor diluent precursor by contacting a gas oil stream with a molybdenum on alumina catalyst and hydrogen at 500 psia and 500° C. with a 0.5 hour residence time. One problem with all these processes is that the more aromatic hydrogen donor precursor is diluted with the less aromatic gas oil product from the hydrogen donor cracking product.
[0004] Other patents focused on increasing hydrogen donor process efficiency and maximum operable resid-to-distillates yield. U.S. Pat. No. 2,873,245 teaches the use of a second thermal cracking stage with catalytic cracking cycle (or decant) oil as make-up hydrogen donor diluent precursor. In a similar manner, U.S. Pat. No. 2,953,513 teaches the use of a second thermal cracking stage with a thermal tar hydrogen donor diluent precursor. U.S. Pat. No. 4,698,147 teaches the use of high temperature, short residence time operating conditions to increase the maximum resid conversion. U.S. Pat. No. 4,002,556 teaches the use of multiple point hydrogen donor diluent addition points to decrease the hydrogen requirement. U.S. Pat. Nos. 6,183,627 and 6,274,003 teach the use of a deasphalter to recover and recycle deasphalted oil to increase the maximum operable resid conversion to distillates by selectively removing coke precursors in the asphaltene product stream. U.S. Pat. No. 6,702,936 further increased the process efficiency by using partial oxidation of the asphaltene product to produce hydrogen for the hydrogen donor diluent cracking process.
[0005] U.S. Pat. No. 4,640,765 demonstrated that the addition of a hydrogen donor diluent to a batch ebullated bed hydrocracker increased the rate of residua conversion to distillates. Unfortunately, the addition of the hydrogen donor diluent also decreased the concentration of the residual oil in the ebullated bed hydrocracker. In a continuous ebullated hydrocracker, the adverse dilution effect is much greater than the beneficial effect of the more rapid resid conversion kinetics. As a result, efforts to increase the ebullated bed hydrocracker process maximum resid conversion and process efficiency have primarily focused on methods to selectively remove coke precursors from the reactor (U.S. Pat. Nos. 4,427,535; 4,457,830; and 4,411,768) and preventing coke precursors from precipitating in the process equipment (U.S. Pat. Nos. 4,521,295 and 4,495,060).
[0006] U.S. Pat. Nos. 5,980,730 and 6,017,441 introduced the concept of using a solvent deasphalter to remove coke precursors and recycle hydrotreated deasphalted oil to the ebullated bed resid hydrocracker. However, this process does not provide a method to control the hydrogen donor precursor properties required to produce an effective hydrogen donor solvent and recycles undesirable more paraffinic residual oil species to the ebullated bed resid hydrocracker. U.S. Pat. No. 5,228,978 teaches using a solvent deasphalting unit to separate the cracked resid product from an ebullated bed resid hydrocracker into an asphaltene coker feed stream, resin stream that is recycled to the ebullated bed resid hydrocracker, and more paraffinic residual oil stream that is fed to a conventional catalytic cracking unit. U.S. Pat. No. 4,686,028 teaches the use of a deasphalter to separate a resid oil feed into asphaltene, resin, and oil fractions and upgrading the resin fraction by visbreaking or hydrogenation.
[0007] Therefore, there remains a need for a practical means to effectively produce and use a hydrogen donor solvent in resid hydrocracking processes that has not been met by the prior processes.
SUMMARY OF INVENTION
[0008] The present invention provides for a method to use a process derived hydrogen donor solvent to increase the maximum resid conversion and resid conversion rate in an ebullated bed resid hydrocracker. The hydrogen donor solvent is produced by hydroreforming and cracking reactions within an ebullated bed resid hydrocracker, recovered as the resin fraction using a solvent deasphalting unit, regenerated in a separate hydrotreater reactor, and fed to the ebullated bed resid hydrocracker.
[0009] In one embodiment of the present invention, there is disclosed a method for increasing the maximum resid conversion and resid conversion rate in a resid hydrocracker upgrader comprising the steps:
[0010] a) producing a hydrogen donor solvent precursor in the resid hydrocracker, wherein the hydrogen donor solvent precursor is produced by hydroreforming reactions of the hydrogen donor solvent feed;
[0011] b) directing the hydrogen donor solvent precursor to a solvent deasphalting unit, wherein a resin stream containing the hydrogen donor solvent precursor is formed;
[0012] c) directing the resin stream to a resid hydrotreater unit, wherein a hydrogen donor solvent is regenerated; and
[0013] d) directing the hydrogen donor solvent to the resid hydrocracker upgrader.
[0014] In a further embodiment of the present invention, there is disclosed a method for increasing the maximum resid conversion and resid conversion rate in a resid hydrocracker upgrader comprising the steps:
[0015] a) producing a hydrogen donor solvent precursor in the resid hydrocracker, wherein the precursor is produced by hydrocracking of the resid feed;
[0016] b) directing the hydrogen donor solvent precursor to a solvent deasphalting unit, wherein a resin stream containing the hydrogen donor solvent precursor is formed;
[0017] c) directing the resin stream to a resid hydrotreater unit, wherein a hydrogen donor solvent is regenerated; and
[0018] d) directing the hydrogen donor solvent to the resid hydrocracker upgrader.
[0019] A simplified reaction system may be useful to illustrate the hydrogen donor process concept and differentiate this invention from the prior art. For simplicity, this reaction system uses a phenanthrene hydrogen donor diluent precursor to illustrate the hydrogen donor process. However, this invention advantageously uses the much higher molecular weight, more complex, and higher boiling point
resin hydrogen donor solvent. The hydrogen donor process typically starts by hydrogenating a hydrogen donor precursor solvent or diluent at moderate temperature and high pressure in the presence of a catalyst such as nickel-molybdate, to partially saturate the conjugated aromatic ring structure, which is represented by dihydrophenanthrene. The hydrogen donor solvent or diluent is mixed with the residual oil and fed to a resid hydrocracker upgrader. Hydrogen radicals (H) are produced by the hydrogen donor solvent or diluent to decrease the polymerization rate of the cracked products. Then, the spent hydrogen donor solvent is recovered by distillation and deasphalting and recycled to the hydrotreating step. The prior art exclusively uses distillation or the combination of reaction and distillation to produce a distillate process derived hydrogen donor diluent precursor. This invention uses solvent deasphalting to produce a non-distillable resin hydrogen donor solvent precursor.
BRIEF DESCRIPTION OF DRAWINGS
[0020] The FIGURE is a schematic of a process according to one embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0021] A description of the preferred embodiment of this invention utilizes the stream and unit operation equipment identification numbers on the FIGURE. The preferred process operating conditions are highly dependent on the properties of the resid feed 1 . The residual oil feed may be derived from a wide variety of hydrocarbon sources, e.g., petroleum oil, bitumen, coal derived liquids, or biomass. Distillates are preferably removed from the hydrocarbon resid source by conventional vacuum distillation. Preferably 95% of the components in the resid feed by weight have normal boiling points greater than 450° C., more preferably greater than 480° C., and more preferably about 520° C. Typically, an appropriate resid feed has a Conradson Carbon content greater than 10 weight %, greater than or about 1 weight % sulfur, vanadium and nickel content greater than 100 ppm, heptane insoluble fraction greater than about 5 weight %, and hydrogen to carbon atomic ratios less than about 1.2, and density great than about 1.0 gm/cm 3 .
[0022] The resid hydrocracker upgrader 2 converts the resid feed 1 , recycle donor solvent feed 3 , and optional oil product feed 5 from a deasphalter 6 to petroleum distillates through line 7 and cracked resid through line 8 products. The resid hydrocracker upgrader 2 would typically consist of a conventional ebullated bed hydrocracker (see U.S. Pat. No. 4,686,028 for process details), atmospheric distillation column, and vacuum distillation column.
[0023] The ebullated bed hydrocracker (resid hydrocracker upgrader 2 ) typically operates in a hydrogen partial pressure range between 50 and 210 bar and typically about 140 bar, temperature range of 410 to 530° C. and typically about 470° C., and a hydrogen donor solvent to resid feed weight ratio range of 0.1 to 1. The liquid reactant residence time is adjusted to provide a resid-to-distillate conversions between 30% and 90% and typically about 70%. The ebullated bed hydrocracker typically uses a conventional cobalt-molybdenum, nickel-molybdenum or nickel-cobalt-molybdenum on alumina catalyst in a spherical or extrudate form with a means to periodically replace a portion of the catalyst inventory with fresh catalyst during normal operations. In addition, a conventional colloidal molybdenum sulfide catalyst may be advantageously used. The preferred ebullated bed hydrocracker operating conditions are highly dependent on the resid feed 1 source and are best determined based on pilot plant tests. An ebullated bed hydrocracker typically operates with a temperature between 415 and 450° C., a hydrogen partial pressure 140 and 210 bar, a ratio of the hourly resid volumetric feed rate to reactor volume between 0.25 and 5, and cobalt-molybdate or nickel-molybdate catalyst bed at between 5 and 30% volume expansion. The cracked resid product in line 8 is typically produced by first removing gas and distillate components in a distillation column operating at a pressure slightly greater than atmospheric pressure and then removing a majority of the remaining distillate components in a vacuum distillation to produce the upgraded distillate oil 7 product stream and the cracked resid feed through line 8 to deasphalter 6 .
[0024] The methods for the production of asphaltene in line 10 , resin in line 11 , and deasphalted oil in line 5 products in a deasphalter 6 are well established (U.S. Pat. Nos. 4,686,028; 4,715,946; 4,810,367; 5,228,978; 5,914,010; 5,919,355; and 6,106,701). The deasphalting process separates species in residual oil based on their solubility in paraffinic solvents. The effectiveness of the solvent in line 9 can be decreased by any combination of increasing the number of carbon atoms in the paraffinic solvent (usually between 3 and 5 carbons) or approaching the solvent's critical temperature by decreasing the solvent's temperature. Any number of deasphalter products can theoretically be produced by progressively decreasing the solvent's effectiveness and removing the separated phase. Both the deasphalter unit operation and laboratory heavy oil analytical methods use the sequential elution fractionation to separate heavy oil into fractions for analysis and products. See, for example, Klaus H. Altgelt and Mieczyslaw M. Boduszynski, “Composition and analysis of heavy petroleum fractions,” Marcel Dekker, 1994, ISBN 0-8247-84946-6, page 63. A typical deasphalter unit is generally designed to produce two or three products. A two product deasphalter produces an asphaltene stream and deasphalted oil stream with the asphaltene stream having the lower solubility in the solvent. A three product deasphalter additionally produces a resin product with intermediate solubility between the oil and asphaltene products.
[0025] The deasphalter operating conditions are adjusted to provide the desired asphaltene, resin, and oil properties. In the present invention, the asphaltene product yield should be minimized with the constraint that the asphaltene product passing through line 10 can be handled by the downstream processing unit, e.g., an asphaltene gasifier 12 in the FIGURE. Oxygen is fed to the asphaltene gasifier 12 through line 15 . Once the minimum practical asphaltene yield has been determined, a reasonable resin yield can be estimated based on the resin hydrogen to carbon ratio as a function of the resin yield. Analysis of laboratory scale sequential elution fractionations can be used to determine the effect of oil, resin, and asphaltene weight fraction yield on the oil, resin, and asphaltene product stream properties. The hydrogen donor solvent precursor should have a hydrogen to carbon atomic ratio that is preferably less than 1.5:1, more preferably less than 1.3:1, and most preferably less than 1.2:1. The deasphalter oil product in line 5 is essentially the components in deasphalter feed 8 that did not report to either the asphaltene or resin products, which are fed to the asphaltene gasifier 12 and resid hydrotreater 11 , respectively. The deasphalter oil product in line 5 may be recycled to the ebullated bed resid hydrocracker 2 .
[0026] However, this deasphalter oil product is a poor ebullated bed resid hydrocracker feedstock because it has a lower cracking rate than either resin or asphaltenes and is also is a relatively poor solvent for coke precursors. This material is a more appropriate feedstock for a fluid catalytic cracker or coker.
[0027] The solvent deasphalter 6 resin product 11 and hydrogen 13 are fed to a resid hydrotreater 14 . The resid hydrotreater 14 may be a conventional trickle-bed, down-flow, ebullated bed, or entrained flow resid hydrotreating reactor. The trickle-bed and ebullated bed reactors would typically use a nickel-molybdenum on alumina catalyst with sufficient pore diameter to allow ready access of the resin feedstock. The entrained flow reactor would typically use a colloidal molybdenum sulfide catalyst. The ebullated bed reactor could also use a colloidal molybdenum sulfide catalyst in addition to the supported catalyst. The hydrogen feed is generally between 250 and 500 Nm 3 H 2 /m 3 resin, and is fed to resid hydrotreater 14 via line 13 . The resid hydrotreater 14 operating pressure is preferably greater than the ebullated bed resid hydrocracker upgrader 2 operating pressure to allow the hydrogen donor solvent and unreacted hydrogen to flow to the ebullated bed resid hydrocracker via line 3 . The resid hydrotreater generally operates in the range of about 370° to 430° C., significantly lower than the 410° to 530° C. typical operating temperature range for the ebullated bed resid hydrocracker. The resid hydrotreater 14 catalyst bed volume is adjusted such that the hydrogen consumption is between 100 and 200 Nm 3 H 2 /m 3 resin.
[0028] This invention offers a number of advantages relative to earlier processes. First, the resid hydrotreater is much more efficient than the ebullated bed resid hydrocracker because the catalyst deactivation rate due to metals and carbon deposition is much lower. The resid hydrotreater can operate at the optimum temperature for hydrogenation.
[0029] Second, the hydrogen donor solvent significantly improves the performance of the ebullated bed resid hydrocracker. The maximum operable resid conversion in an ebullated bed resid hydrocracker tends to decrease with increasing reactor operating temperature, e.g., see U.S. Pat. No. 4,427,535. Therefore, there is a decrease in reactor operability associated with an increase in the resid cracking rate. With hydrogen donor solvents and diluents, the hydrogen use efficiency and maximum operable resid conversion increases with increasing temperature e.g. see U.S. Pat. Nos. 4,698,147 and 4,002,556. The major advantage of a process derived resin hydrogen donor solvent relative to distillate hydrogen donor diluent is that a process derived resin hydrogen donor solvent provides the opportunity to significantly increase resid hydrocracker operability at high temperature without diluting the resid reactant with a distillate hydrogen donor diluent.
[0030] Since asphaltenes in line 10 are not stable, a method must be identified to promptly and usefully dispose of this troublesome material. Conventional pitch gasification for hydrogen production (see U.S. Pat. Nos. 4,115,246 and 5,958,365 and Gasification by Christopher Higman and Maarten van der Bugrt-SBN 0-7506-7707-4) is the preferred asphaltene disposal method. The raw gas leaves the asphaltene gasifier through line 16 and enters the hydrogen production and purification unit 17 . Hydrogen from the hydrogen production and purification unit leaves through line 18 where it may optionally connected with a supplemental hydrogen source 20 and is available for use in the resid hydrotreater 14 through line 13 and the resid hydrocracker 2 through line 4 . Waste gas from the hydrogen production and purification unit 17 leaves through line 19 where it can be disposed of or employed in an appropriate manner.
[0031] While this invention has been described with respect to particular embodiments thereof, it is apparent that numerous other forms and modifications of the invention will be obvious to those skilled in the art. The appending claims in this invention generally should be construed to cover all such obvious forms and modifications which are within the true spirit and scope of the present invention. | A process derived hydrogen donor solvent is used to increase the maximum resid conversion and conversion rate in an ebullated bed resid hydrocracker. The hydrogen donor solvent precursor is produced by hydroreforming reactions within the resid hydrocracker, recovered as the resin fraction from a solvent deasphalting unit, regenerated in a separate hydrotreater reactor, and recycled to the ebullated bed resid hydrocracker. The major advantage of this invention relative to earlier processes is that hydrogen is more efficiently transferred to the resin residual oil in the separate hydrotreater and the hydrogen donor solvent effectively retards the formation of coke precursors at higher ebullated bed resid hydrocracker operating temperatures and resid cracking rates. | 2 |
BACKGROUND OF THE INVENTION
The present invention relates to a movable cover or roof for covering crops such as orchard trees and protecting them from frost damage.
Frost can kill or injure crops and is an especially grave danger in orchards where the fruit itself is exposed during periods of cold weather. Methods of protecting crops against frost include smudge pots, university return stack heaters, liquid fuel heaters and wind machines all of which consume expensive fuel as well as portable covers which act to retain warm air or to block cold drafts. Portable covers may be used to cover individual plants or all the plants on a plot of land to retain warm air and to block cold air radiation.
Protective coverings for agricultural plots found in the prior art include movable protective covering for orchards disclosed in U.S. Pat. No. 1,106,624 to Cadwallader et al. In Cadwallader a framework of static rigging is formed by vertical uprights, carrying guy wires. A flexible fabric covering is extended over the framework by turning large drums located at opposite ends of the framework that operate as take-up reels for the fabric and for the cable which draws the fabric across the crossbars and rollers and along the support wires.
Movable fabric panels are found in U.S. Pat. No. 2,051,643 to Morrison which discloses a cloth house for protecting plants. In Morrison an insect-proof fabric house composed of numerous strips joined edge to edge is supported over a framework of posts, guy wires and supporting cables. Some fabric joints incorporate weight supporting wires and the lowermost edges of the fabric are held fast to a framework by wires within the fabric edge which connect to gourmets located on baseboards of the framework. Morrison's cloth house was improved by adding the transverse cords disclosed in U.S. Pat. No. 2,143,659 to Morrison to the top surface of the house.
Another form of portable plant protection is disclosed in U.S. Pat. No. 3,100,950 to Heuer in which a cover is suspended between or across rows of posts. The cover can be folded back by manually drawing it back in a direction along the row.
While the devices disclosed in the identified patents and other devices in the prior art were satisfactory for their intended use, they were not intended to be adapted for use with lightweight synthetic materials.
Thus there existed a need for a plant protecting cover which could selectably be placed over the crops to protect them or be withdrawn to allow light and water to enter the orchard. Ideally the cover should be easily operated by one man, should be able to be quickly opened or retracted, should be relatively inexpensive to fabricate and should be able to be exposed to the elements for a long period of time without damage. The present invention fulfills these requirements.
SUMMARY OF THE INVENTION
The present invention is embodied in a cover for protecting crops from frost damage. The cover is attached to a permanently installed framework and can be selectively extended to the covering position or withdrawn therefrom by means of a sheet rake which can move outwardly carrying an outer edge of the cover to an outer edge of the framework or inwardly scooping up and holding the cover as it moves inwardly. The sheet rake is propelled by running rigging comprising a plurality of winches that control sets of cables. Each set of cables contain at least one cable pulling the sheet rake and extending the cover over the framework and at least one other cable withdrawing the sheet rake and cover.
The framework comprises rows of posts joined by wires extending at right angles to the rows. The sheet rake moves atop the wires which support it. The winches and running rigging are attached to and support by the posts.
The cover of the invention is lightweight polyethylene film which is easily moved to and withdrawn from the covered position.
The present invention using a cover in two independently moved sections can cover an agricultural plot of about one acre. An operator winches one section into position, then the other section and can position both in about ten minutes. The invention protects from still air radiation frost without burning expensive fuels.
Other features and advantages of the present invention will become apparent from the following detailed description, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of a cover of the invention covering a plot of land having the cover shown only in broken line in order to reveal a framework below the cover;
FIG. 2 is a front elevational view taken substantially in the direction of the arrows 2--2 in FIG. 1;
FIG. 3 is a fragmentary enlarged view of an area substantially enclosed by circular line 3 in FIG. 1 having the cover broken away to show a post and winches;
FIG. 4 is a rear elevational view taken substantially in the direction of the arrows 4--4 in FIG. 3 and showing the post, the winch and cables;
FIG. 5 is a fragmentary enlarged view of an area substantially enclosed by circular line 5 in FIG. 1 showing the winch and a portion of a sheet rake;
FIG. 6 is a left elevational view taken substantially in the direction of the arrows 6--6 in FIG. 5 and showing the post, winch and a sheet rake;
FIG. 7 is a fragmentary sectional view taken substantially in the direction of the line 7--7 in FIG. 1 and showing a transverse cable, the post and the cover;
FIG. 8 is fragmentary sectional view taken substantially along the line 8--8 in FIG. 7;
FIG. 9 is a fragmentary enlarged view of an area substatially enclosed by circular line 9 in FIG. 1 and showing a backstay, static rigging and one post;
FIG. 10 is a full left elevational view taken substantially in the direction of the line 10--10 in FIG. 9 and showing one post and backstay;
FIG. 11 is a sectional view substantially taken along the line 11--11 in FIG. 3.
FIG. 12 is a fragmentary elevational view looking in the direction of the arrow 12 in FIG. 6 and showing the sheet rake.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention resides in a framework 20 permanently installed in an agricultural plot and having a movable cover 22 which can be drawn over the framework to protect crops from damage resulting from still air radiation frost. The cover 22 is supported above the crops, which for the purpose of illustration will be described as fruit trees, by standing rigging 24 comprised of wires supported by upright posts 28. The posts 28 extend above the top of the fruit trees and thereby support both the standing rigging 24, attached to the post tops, and the cover 22 well over the protected fruit trees.
In accordance with the present invention, the flexible cover is supported over the fruit trees by standing rigging 24 while a movable sheet rake assembly 30 extending across and supported by the standing rigging 24 carries the free outer edges of the cover 22 outwardly from the center to the edges of the framework 20. As the sheet rake assembly 30 is drawn back towards the center of the framework 20, it gathers the cover 22 in a series of gathering tines 32 and carries the gathered cover back to the center of the framework. Running rigging 34 drawn by winches 36 and 37 enables one man to quickly and manually extend the cover 22 above the fruit trees or to withdraw the cover.
More particularly, as can best be seen in FIGS. 1 and 2, the standing rigging 24 supporting the cover 22 comprises, in a typical installation, three rows of upright posts 28, a center row 38 and two edge rows 40. The posts 28 are permanently anchored in the earth, for example, in concrete filled holes, and the tops of the posts 28 extend sufficiently above the fruit trees so that no portion of the standing rigging is less than 18 inches above the fruit trees. As is shown in FIGS. 4 and 6 at least one step 82 is provided on each post 28 to enable a laborer to work atop the post.
Each post 28, herein 11/2 inch galvanized steel, is connected to the corresponding post in the adjacent row by a laterally running support wire 42. Typical support wires 42 are 1/8 inch galvanized wire that are attached to the posts as can be seen in FIG. 10 by 1/4 inch eye bolts 43. A transverse cable 44, made of 3/32 inch galvanized steel or other light cable, extends along the center row 38 passing through the top of each post 28 in the row.
The posts 28 are guyed into position by back stays 46. As can best be seen in FIG. 10, each back stay 46 includes the back stay itself made of wire, as well as an eye bolt clamp 48 connecting the stay to the post, a 1/4 inch turnbuckle 50 and a 3 foot long 1/2 inch metal stake 52 that anchors the back stay into the ground. As can best be seen from FIG. 1, the back stays 46 extend perpendicularly outward of the framework 20 except for four back stays attached to posts 28a supporting the running rigging 34. These four posts extend outwardly in a direction opposite to the direction of force which the running rigging 34 applies to the post.
The cover 22 which can overlay the entire framework includes unitary sections of synthethic film stretching along the length of the sheet rake assembly 30 and extending between immediately adjacent rows of posts 28. The cover is made from films of polyethylene, polypropylene, nylon or other materials which form a tough plastic film having excellent fatigue and tear strength. The thickness of the cover is in the range between 4 and 6 mils. In the embodiments shown in FIG. 1, the cover sections are attached to one another at a location near the center of the framework 20 and along row 38. As is shown in FIG. 7, one method of connecting these sections to each other is accomplished by passing the transverse cable 44 through grommets 54 lying near the edges of the sections to be joined. In the illustrated embodiment, the cover 22 lies atop each post 28 in the center row 38 and the transverse cable 44 passes through the cover in the vicinity of each of those posts running from outside the cover to the inside thereof. Thereafter the transverse cable 44 passes through the top portion of the post 28 and thence outwardly of the cover 22 through another grommet 54. The transverse cable 44 is connected to the outermost posts 28b in the center row 38 by an eye bolt 56 and therefore the transverse cable passes only once through the cover in the vicinity of the outermost posts.
The movable portions of the invention comprise, as is shown in FIG. 1, the sheet rake assembly 30, the running rigging 34 and the outward pulling 36 and inward pulling winches 37 that move the running rigging. The sheet rake assembly 30 includes two elongated wooden members that extend across the entire framework 22, transversely to the support wires 42. The sheet rake assembly 30 holds the outer edge of the cover 22 sections between the wooden members. In the illustrated embodiment, and as is best shown in FIG. 6, the sheet rake assembly 30 has a rectangular cross section measuring 2 inches across and 1 inch high and that includes a frame 64 made of a 2"×3/4" piece of wood to which a cap 66, made of a 2"×1/4" piece of wood is joined by counter sunk screws 68. A bottom cover 70, a sheet of 1/8 inch aluminum protects the bottom and reduces friction between the sheet rake assembly 30 and the support wires 42. To increase the ability of the sheet rake assembly 30 to hold the cover, the outermost end of the cover is wrapped around, and is sewn to, a cord 72, typically 3/16 inch polypropylene. The cord 72 is placed on the outer side of the sheet rake assembly 30 defined in this specification and the appended claims as the side opposite the inside of the sheet rake which is the side facing the center of the framework 20, or facing the location at which the cover 22 is permanently attached to the framework.
As can best be seen in FIGS. 1 and 12, a pair of metal tines is attached to the sheet rake assembly 30 in the vicinity of each support wire 42. A scoop tine 73 extends generally inwardly and downwardly from the sheet rake assembly 30 in order to scoop the cover 22 up from the support wires 42 and on to the sheet rake assembly itself, thus preventing the cover from becoming trapped under the sheet rake assembly. The gathering tine 32, describing an arc commencing upwardly and rearwardly of the sheet rake assembly 30, holds the cover atop the assembly as the assembly moves toward the center of the framework 20 collecting the cover as it moves. Both tines are aluminum, have a rounded surface and are about 18 inches in length.
The running rigging 34, referred to above, moves the sheet rake assembly 30 outwardly and inwardly along the support wires 42. As shown in FIG. 1, the running rigging 34 includes four winches 36 and 37 each of which moves three cables 74 and 76. The outward pulling winches 36 take in those cables 74 that move the cover into the covering position by pulling the sheet rake assembly towards the edge rows 40, while the inwardly pulling winches 37 take in cables 76 that pull the cover back to the center. Each winch 36 and 37 the locations of which are described below carries three cables, one connected to the center of the sheet rake assembly and one on each side. The cables attached to the sides of the sheet rake assembly are placed at a suitable distance from the center of the framework 20, so that the pulling force of the cables is distributed uniformly along the length of the sheet rake assembly. The inward pulling center cable 76, as is shown in FIG. 3 and 4, is lead by a block 80, attached on the inward face of the center post 28, to its running position while the inwardly pulling cables connected to the sides of the sheet rake assembly 30 are led by blocks 80a and 80b on the side faces of the center post 28 and by blocks 82a and 82b on the outer running rigging posts 28a to their operating location. The corresponding outward pulling cable blocks have identical but primed numbers in the drawings, thus, one winch 36 or 37 draws three cables and thereby moves the sheet rake assembly 30.
In the embodiment depicted in FIG. 1, each outward pulling two winches 36 is attached to one of the posts 28 in the middle of edge rows 40, while both the inwardly pulling winches 37 are attached to one post 28 in the middle of the center row 38. Suitable winches for use in the invention are single spur gear, half ton winches such as those manufactured by Thern, Inc. of Winona, Wisconsin. The running cable herein is 1/8 inch galvanized steel, 7×19, winch cable having a breaking strength of 2000 pounds.
From the foregoing, it will be appreciated that the protective cover 22 of the invention provides a device that protects agricultural crops from frost damage without the burning of costly fuels. The cover can be quickly moved into position by a single operator who can move the cover 22 over a one acre plot in about ten minutes. The cover 22 can be withdrawn to permit sunlight or rain to enter on the agricultural plot.
While a particular form of the invention has been illustrated and described, it will be apparent that various modifications can be made without departing from the spirit and scope of the invention. | A retractable cover for protecting agricultural crops against radiation frost. The polyethelene film cover lies atop a static rigging comprised of rows of posts permanently anchored in the earth and wires joining the posts. An elongated sheet rake extending the length of one row is attached to one side of the cover and is adapted to move the cover between a covering position and a retracted position adjacent a location where the cover is connected to the posts. Winch driven cables are used to move the sheet rake. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The field of invention relates to hair brush cleaning apparatus, and more particularly pertains to a new and improved hair brush cleaning apparatus wherein the same is arranged for the removal of hair and debris from within a hair brush matrix of bristles.
2. Description of the Prior Art
Various hair brushing cleaning apparatus has been utilized in the prior art and exemplified in the U.S. Pat. No. 4,403,364 to Schroeder; U.S. Pat. No. 3,470,575 to Larson, et al.; and U.S. Pat. No. 3,590,413 to Couleon, Jr.
The prior art has set forth various elaborate constructions utilizing machinery to effect cleaning of hair brush bristles, where the instant invention sets forth a new and improved hair brush cleaning apparatus wherein the same is arranged to effect the mechanical cleaning of hair brush bristles and in this respect, the present invention substantially fulfills this need providing for a simplified inter-digited plurality of plates cooperating to remove hair from within a matrix of hair brush bristles.
SUMMARY OF THE INVENTION
In view of the foregoing disadvantages inherent in the known types of hair brush cleaning apparatus now present in the prior art, the present invention provides a hair brush cleaning apparatus wherein the same is arranged to provide a housing to receive a hair brush therewithin to effect removal of hair from the hair brush bristles upon removal of the hair brush subsequent to its projection within the housing of the organization. As such, the general purpose of the present invention, which will be described subsequently in greater detail, is to provide a new and improved hair brush cleaning apparatus which has all the advantages of the prior art hair brush cleaning apparatus and none of the disadvantages.
To attain this, the present invention provides a housing arranged with a plurality of adjacent plates pivotally mounted below a top wall of the housing, wherein the plates include inter-digited finger members that are aligned in a first coplanar relationship relative to one another to receive a hair brush, whereupon projection of the hair brush between the plates effects engagement of the plates with the associated hair brush bristles to effect cleaning of the bristles upon projection of the fingers within the hair brush.
My invention resides not in any one of these features per se, but rather in the particular combination of all of them herein disclosed and claimed and it is distinguished from the prior art in this particular combination of all of its structures for the functions specified.
There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto. Those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
Further, the purpose of the foregoing abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientists, engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The abstract is neither intended to define the invention of the application, which is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way.
It is therefore an object of the present invention to provide a new and improved hair brush cleaning apparatus which has all the advantages of the prior art hair brush cleaning apparatus and none of the disadvantages.
It is another object of the present invention to provide a new and improved hair brush cleaning apparatus which may be easily and efficiently manufactured and marketed.
It is a further object of the present invention to provide a new and improved hair brush cleaning apparatus which is of a durable and reliable construction.
An even further object of the present invention is to provide a new and improved hair brush cleaning apparatus which is susceptible of a low cost of manufacture with regard to both materials and labor, and which accordingly is then susceptible of low prices of sale to the consuming public, thereby making such hair brush cleaning apparatus economically available to the buying public.
Still yet another object of the present invention is to provide a new and improved hair brush cleaning apparatus which provides in the apparatuses and methods of the prior art some of the advantages thereof, while simultaneously overcoming some of the disadvantages normally associated therewith.
These together with other objects of the invention, along with the various features of novelty which characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:
FIG. 1 is an isometric illustration of the instant invention.
FIG. 2 is an isometric illustration of the instant invention illustrating a hair brush member directed therewithin.
FIG. 3 is an orthographic cross-sectional illustration of the invention with the hair brush in a first position above the housing of the invention.
FIG. 4 is an orthographic cross-sectional illustration of the hair brush in a second position directed between the plates.
FIG. 5 is an orthographic cross-sectional illustration of the invention illustrating the hair brush removed from between a place to effect removal of undesirable hair from between the bristle matrix of the hair brush.
FIG. 6 is an orthographic cross-sectional illustration of section 6 as set forth in FIG. 3.
FIG. 7 is an isometric illustration of a modified apparatus utilized by the invention.
FIG. 8 is an isometric illustration of section 8 as set forth in FIG. 7.
FIG. 9 is an isometric illustration of the invention arranged for mounting to an associated lid of a refuse disposal member.
FIG. 10 is an isometric illustration of a modified cleaning structure utilized by the invention.
FIG. 11 is an orthographic view, taken along the lines 11--11 of FIG. 10 in the direction indicated by the arrows.
FIG. 12 is an orthographic cross-sectional illustration of the FIG. 10 in a second position.
FIG. 13 is an isometric illustration of one of the support flanges in associated structure utilized by the invention, as set forth in the FIGS. 10-12.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference now to the drawings, and in particular to FIGS. 1 to 13 thereof, a new and improved hair brush cleaning apparatus embodying the principles and concepts of the present invention and generally designated by the reference numerals 10 and 10a will be described.
More specifically, the hair brush cleaning apparatus 10 of the instant invention essentially comprises a housing 11 that includes a housing rear end wall 12 spaced from a housing front end wall 13. Housing first and second side walls 14 and 15 respectively have slidingly directed therethrough a tray member 16, with the tray member 16 including a first and second respective tray wall 17 and 18 that are each respectively coplanar with the respective first and second side walls 14 and 15 when positioned within the housing. A first and second handle 17a and 18a mounted to the respective first and second tray walls 17 and 18 permit sliding projection of the tray from the housing to permit cleaning of the tray subsequent to use of the organization. A housing top wall 19 includes spaced coplanar top wall first and second side flanges 31 and 32 defining a top wall opening 30 therebetween. The top wall opening 30 merges with a rear end wall recess 20 to receive the handle portion of an associated brush member, such as illustrated in FIG. 2, with the head, and more specifically the matrix of brush bristles 25, directed into the top wall opening 30. The organization further includes first and second plates 21 and 22 respectively mounted within the housing at an intersection of the respective first and second side walls 14 and 15 and the respective top wall first and second side flanges 31 and 32. A first and second pivot hinge 26 and 27 are thusly mounted adjacent an upper terminal end of the first and second side walls 14 and 15 at interior surfaces thereof, each mounted to a respective first and second plate support flange 28 and 29 mounted to the respective first and second pivot hinge 26 and 27 below the top wall first and second side flanges 31 and 32.
The first and second plates 21 and 22 include respective first and second plate teeth 23 and 24 that are interdigited in the first coplanar relationship between the first and second plate 21 and 22 and are displaced for projection between the brush bristles 25. Upon removal of the brush, as illustrated in FIG. 5, from between the plates, hair is thusly prevented from escape from between the plates 21 and 22 and deposited into the underlying tray 16 below.
The apparatus 10a, as illustrated in FIGS. 7 and 8 for example, further utilize a reservoir 33 mounted to the front end wall 13, including a reservoir fill cap 36 to permit filling of the reservoir with a disinfectant fluid 35 that is projected from the reservoir by a pump plunger 34. First and second flexible conduits 37 and 38 upon pressurizing of the reservoir by the plunger 34 effects projection of fluid within the first and second conduits 37 and 38, wherein the first and second conduits 37 and 38 terminate in respective first and second nozzles 39 and 40 directed upwardly relative to the first and second plate teeth 23 and 24 for projection onto the associated brush head for its disinfecting.
The apparatus further, as illustrated in FIG. 9, is arranged for mounting to an associated container 41 that includes a container lid 42 secured to an upper terminal end of the container 41. The container lid 42 includes a lid top wall 47 formed with a lid opening 46 therethrough. On opposed ends of the lid opening 46 are support plates 45 directed orthogonally and upwardly relative to the top wall of the lid, wherein the flange projections 44 projecting exteriorly of each of the support plates 45 for reception within respective rear and front end wall slots 43 mounted within the rear and front end walls 12a and 13a, as illustrated in FIG. 9, for securement of the housing 11 and the associated reservoir to the container lid 42, and more specifically to permit securement of the housing between the support plates for the direct deposit of hair within an underlying container for use in a commercial environment.
With reference to FIGS. 11-13, the first and second teeth 23 and 24 are fixedly positioned to first and second plates 21 and 22. The housing top wall first and second flanges 31 and 32 are slidably mounted orthogonally relative to the housing side walls 14 and 15, with the use of top wall flange first and second skirts 56 and 57 orthogonally mounted to respective top wall first and second flanges 31 and 32. The first plate 21 and the second plate 22 include respective first and second support flanges 50 and 52 orthogonally mounted to a rear edge of the respective first and second flanges 50 and 52 respectively. The first and second support flanges extend orthogonally downwardly relative to the first and second plates, with the first support flange 50 including a plurality of spaced parallel first flange plates 54 orthogonally mounted to the first support flange to opposed sides thereof extending rearwardly of the first support flange 50. Second flange plates 55 mounted orthogonally and rearwardly of the second support flange 52 are arranged in a parallel coextensive relationship. The first and second flange plates 54 and 55 include guidance cam slots therewithin, wherein the first flange plates 54 include first flange plate first and second slots 58 and 59, with each pair of first flange plates first slots 58 arranged in a coextensive relationship, as well as the first flange plate second slots 59 arranged in a coextensive relationship relative to one another through the respective first flange plates 54. Similarly, the second flange plates 55 illustrated in more detail in FIG. 13 illustrates the use of the second flange plate first and second slots 60 and 61. First and second L-shaped guide rods 62 and 63 mounted to the housing floor 49 are received within the respective first flange plate first and second slots 58 and 59. Third and fourth L-shaped guide rods 64 and 65 are received within the respective second flange plate first and second slots 60 and 61. The cam slot configuration of the slots 58-61 and the respective guide rods 62-65 that are directed through the associated slots effect forward projection towards one another of the first and second teeth 23 and 24 from the first position, as illustrated in FIG. 11, to the second position, as illustrated in FIG. 12, when a brush member is positioned and forcibly directs the first and second plates 21 and 22 downwardly, wherein accordingly, the first and second teeth 23 and 24 project into the brush upon lifting of the brush subsequent to the projection of the teeth therewithin and effects a roll of hair and debris from within the brush structure. A top wall first spring 66 is positioned between the first side wall 14 and the top wall first flange 31, with a top wall second spring 67 mounted between an upper distal end of the housing second side wall and the top wall second flange 32 to bias the top wall first and second flanges 31 and 32 upwardly. First and second slide links 68 and 69 are mounted to the top wall first and second flanges 31 and 32, with the lower distal ends of the first and second slide links 68 and 69 mounted to the respective first and second support flanges 50 and 52 to effect guidance of the support flanges in a downward and forward projection towards one another within the housing. First support flange first springs 70 are mounted between the first flange plates 54 and an interior surface of the first side wall 14. Second support flange first springs 71 are mounted between the second flange plates 55 and the interior surface of the second side wall 15. First support flange second springs 72 are mounted between bottom surfaces of the first flange plates 54 and the housing floor 49, with second support flange second springs 73 mounted between lower edges of the second flange plates 55 and the housing floor 49 to normally bias the first and second plates 21 and 22 upwardly subsequent to their cleaning procedure. It should be noted that the organization of the FIGS. 7 and 8 are arranged for inclusion with the apparatus as illustrated in the FIGS. 11 and 12, but for purposes of clarity have been deleted from such illustration, where it is to be understood that the various conduit structure and nozzle members are contemplated for optional use within the structure set forth in the FIGS. 11 and 12.
FIG. 13 is an isometric illustration of the first and second plate members in cooperation with the associated supporting structure, for purposes of illustration.
Accordingly, it is believed the above set forth a complete disclosure as to the structure and functioning of the instant organization and no further discussion relative to the instant invention shall be provided.
With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.
Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention. | A housing is arranged with a plurality of adjacent plates pivotally mounted below a top wall of the housing, wherein the plates include inter-digitated finger members that are aligned in a first coplanar relationship relative to one another to receive a hair brush, whereupon projection of the hair brush between the plates effects engagement of the plates with the associated hair brush bristles to effect cleaning of the bristles upon projection of the fingers within the hair brush. | 0 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 62/180,953 filed on Jun. 17, 2015, which is incorporated by reference herein in its entirety.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] This invention was made with government support under IOS1256664 awarded by the National Science Foundation. The government has certain rights in the invention.
BACKGROUND
[0003] This application relates to chitooligosaccharides that lack a lipid moiety, and to methods of using such chitooligosaccharides to promote growth and/or development of non-leguminous plants.
[0004] Plants associate with a wide range of microorganisms that facilitate the acquisition of nutrients and protect them against biotic and abiotic stresses. For example, interactions with arbuscular mycorrhizal (AM) fungi are widespread in land plants, and this association aids in the uptake of nutrients from the soil (Harrison, M. J. (2005), Annu. Rev. Microbiol. 59: 19-42). Because AM fungi are obligate symbionts, little is known about the molecular and genetic basis of this symbiosis.
[0005] Much of what is known about AM fungi/plant symbiosis has come from studies of the symbiotic association between plants and nitrogen-fixing rhizobium bacteria, which most notably results in the formation of nitrogen-fixing nodules. Unlike the association between AM fungi and plants, the rhizobium bacteria symbiosis is restricted to specific groups of plants, primarily legumes (Soltis, D. E., et al. (1995), Proc. Natl. Acad. Sci. USA 92: 2647-2651). However, both interactions are similar in that they require chemical communication facilitated by the production of diffusible signals by the symbiont (Oldroyd, G. E. (2013), Nat. Rev. Microbiol. 11: 252-263).
[0006] Rhizobial bacteria signal to legumes with Nod factors, which are lipochitooligosaccharides (LCOs) containing a chitin backbone substituted with a lipid moiety, an N-acyl group, and a number of additional groups that vary between Nod factors produced by different species of rhizobia (Dénarié, J. et al. (1996), Annu. Rev. Biochem. 65: 503-535). Nod factor perception utilizes a signalling pathway that is also involved in the establishment of mycorrhizal associations (Oldroyd, G. E. (2013)).
[0007] AM fungi also produce diffusible signals that are recognized by the host plant via the common symbiosis signalling pathway. Research suggests that at least two different mycorrhizal signals are active on Medicago truncatula (Chabaud, M., et al. (2011), New Phytol. 189: 347-355). Similarly, work in rice ( Oryza sativa ) demonstrates mycorrhizal signalling that is both dependent and independent of the common symbiosis signalling pathway (Gutjahr, C., et al. (2008), Plant Cell 20: 2989-3005).
[0008] The AM fungus Rhizophagus irregularis produces LCOs (Maillet, F., et al. (2011), Nature 469: 58-63), some of which are sulfated, resulting in a structure very similar to the Nod factor produced by Sinorhizobium meliloti , the symbiont of M. truncatula . These Myc-LCOs activate responses in M. truncatula similar to those activated by Nod factor, including the promotion of lateral root outgrowth. Consistent with these findings, U.S. Patent Publication No. 2011/0301032 discloses a method of stimulating a plant by contacting the plant with Myc-LCOs and variants thereof, wherein the variants all retain a lipid moiety.
[0009] The lipid moieties incorporated into the LCOs disclosed by, e.g., U.S. Patent Publication No. 2011/0301032, make it difficult and/or expensive to synthesize large quantities of such compounds from commonly available chitooligosaccharide source materials. Furthermore, the lipid moieties decrease the solubility of such compounds in water, increasing the challenges associated with dissolving the compounds in aqueous solutions for scaled up application to seeds, seedlings, or plants. Accordingly, there is a need in the art for alternate compositions and methods for stimulating plant growth and/or development that do not have these disadvantages in large-scale applications.
BRIEF SUMMARY
[0010] In addition to LCOs, AM fungi produce short-chain chitooligosaccharides lacking a lipid moiety (COs), such as CO4 and CO5, that may be involved in AM/plant interactions (Genre, A., et al. (2013), New Phytol. 198: 190-202). Furthermore, longer chain COs, such as CO8, are known to function as pathogenic signals that stimulate plant defenses. The inventors disclose herein that both shorter and longer chain COs can be used to promote the growth and/or development of non-leguminous plants, including, without limitation, of cereal grains, such as rice, wheat or corn (maize).
[0011] The term “non-leguminous plant” refers to plant species that are not classified as legumes. It is well-known in the art as to which plant species are legumes. The term “cereal grain” refers to a grass that is cultivated as a crop for the edible components of its grain (a type of fruit known in the art as a caryopsis).
[0012] Accordingly, in a first aspect, this disclosure encompasses a method for stimulating the growth of a non-leguminous plant. The method includes the step of contacting a non-leguminous plant, a part thereof, or a seedling or seed thereof with a composition that includes a chitooligosaccharide (CO) having the formula:
[0000]
[0000] where n is 0, 1, 2, 3, 4, 5, or 6; R1 is —H, —CH 3 , —COCH 3 , —SO 3 H, —SO 3 Na, arabinose, methylated arabinose, fucose, or methylated fucose; R2 is —H, —CH 3 , —COCH 3 , —SO 3 H, —SO 3 Na, arabinose, methylated arabinose, fucose, or methylated fucose; and each R3 is independently —H or —COCH 3 . As a result of practicing the method, the growth of the plant is stimulated.
[0013] “Stimulated” plant growth means that the quantity, weight and/or size of one or more parts of the plant is increased, relative to a plant where the seed, seedling, plant, or plant part has not been contacted with the composition that includes the CO. Such increased quantity, size or mass may include, but is not limited to, increased length of the root system, increased number of crown roots, increased number of lateral roots, increased dry weight, increased shoot length, or some combination of these. Such plant growth stimulation can have some beneficial effects on the plant, including, without limitation, enhancing soil nutrient acquisition, facilitating the establishment of young plants in the field, and increasing crop plant yield.
[0014] In some embodiments, the composition is contacted with one or more leaf and/or root surfaces of the non-leguminous plant. In some such embodiments, the composition further comprises a surfactant. A “surfactant,” also known as a “wetting agent,” is a substance that is capable of reducing the surface tension of a liquid composition.
[0015] In some embodiments, the composition is contacted with a seedling, seedling part or seed of the non-leguminous plant. In some such embodiments, the seedling, seedling part or seed of the non-leguminous plant is submerged in and subsequently removed from the composition. In some embodiments, the seedling part may include plant foliage or plant roots.
[0016] In some embodiments, the composition is contacted with the plant, plant part, seedling or seed for about 1 hour to about 96 hours. In some such embodiments, the composition is contacted with the plant, plant part, seedling or seed for about 6 hours to about 48 hours.
[0017] In some embodiments, the concentration of the CO in the composition is within the range of about 10 −3 M to about 10 −10 M. In some such embodiments, the concentration of the CO in the composition is within the range of about 10 −3 M to about 10 −9 M. In some such embodiments, the concentration of the CO in the composition is within the range of about 10 −3 M to about 10 −8 M.
[0018] In some embodiments, the composition further includes water and alcohol. The alcohol acts to increase the solubility of the CO in the aqueous composition. In some such embodiments, the alcohol is ethanol.
[0019] In some embodiments, the non-leguminous plant is a monocotyledon. In some such embodiments, the monocotyledon is a cereal grain. Non-limiting examples of cereal grains that can be used with the method include rice, wheat and corn (maize).
[0020] In some embodiments, R1 is —H, R2 is —H, and each R3 is —COCH 3 . In some such embodiments, n is 2 (the compound is tetra-N-acetylchitotetraose, CO4) or 6 (the compound is octa-N-acetyl-chitooctaose, CO8).
[0021] Other features of the disclosed methods will become apparent from a review of the specification, claims, and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 shows calcium spiking in rice in response to Myc-LCOs, Nod factors, and CO4. Representative calcium traces from rice atrichoblasts on lateral roots treated with 10 −8 M Myc-LCOs and LCO isolations from Rhizobium sp. NGR234 and R. tropici , as well as 10 −5 M and 10 −8 M treatments of CO4. The number of cells showing calcium spiking, relative to the total number of cells analyzed is indicated.
[0023] FIG. 2 shows calcium spiking in rice in response to CO4 and CO8. Representative calcium traces from rice atrichoblasts on lateral roots treated with 10 −8 M and 10 −5 M CO4 and CO8. Plants appear to respond equally well to CO4 as to CO8.
[0024] FIGS. 3A, 3B, and 3C show promotion of root system development in rice by NS-LCO, S-LCO, CO4, and CO8. The mean number of lateral roots ( FIG. 3A ), the length of the root system ( FIG. 3B ) and the number of crown roots ( FIG. 3C ) produced per rice plant is shown in response to treatments of 10 −8 M COs or LCOs. Plants were treated for 24 hours and then grown for two weeks before assessment. Results displayed are based on at least two replicated experiments (n≧28). The p-value was calculated using a t-test, assuming a normal distribution of the data, or a Wilcoxon signed-rank test when a normal distribution was not observed. Significance was determined within a 95% confidence interval. Error bars indicate standard error.
[0025] FIGS. 4A, 4B, and 4C show that lateral root induction is dependent upon the symbiotic signalling pathway. The mean percentage of lateral roots ( FIG. 4A ), the length of the root system ( FIG. 4B ) and the number of crown roots ( FIG. 4C ) produced per rice plant is shown in response to treatments of 10 −8 M COs or LCOs in wild-type rice plants as well as Ospollux and Osdmi3 mutants. Plants were treated for 24 hours and then grown for two weeks before assessment. Results displayed are based on at least two replicated experiments and calculated as percentage over average of the control treatment (n≧28). The p-value was calculated using a t-test, assuming a normal distribution of the data, or a Wilcoxon signed-rank test when a normal distribution was not observed. Significance was determined within a 95% confidence interval. Error bars indicate standard error.
[0026] FIG. 5 shows induction of calcium spiking in rice trichoblasts and atrichoblasts. The graph shows the percentage of calcium responsive cells among trichoblasts and atrichoblasts of rice. Treatments of 10 −5 M and 10 −8 M CO4 and the response of trichoblasts near R. irregularis hyphae were analyzed.
[0027] FIG. 6 shows calcium responses to LCOs and COs in rice trichoblasts with representative calcium traces of root hair cells (trichoblasts) treated with mixes of 10 −8 M CO4, S-LCO, and NS-LCO. Note that mixes of Myc-LCOs with CO4 induced calcium oscillations, but the Myc-LCOs alone did not. The number of cells showing calcium responses, relative to the total number of cells analyzed is indicated.
[0028] FIG. 7 shows promotion of lateral root emergence in M. truncatula by NS-LCO, but not by CO4. M. truncatula roots were treated with 10 −7 M CO4 or 10 −7 M NS-LCO and the effect on lateral root emergence was measured. The numbers in parentheses indicate the number of plants analyzed. The significance of the difference to the treated control plants, as measured using a t-test, is indicated. The treatments are measured as fold induction relative to the control. Error bars represent the standard error.
[0029] FIG. 8 shows the in vitro effect of seed application on HRSW root system length. Compared with control treatment, CO4 treatment significantly promoted root growth. One star (*) indicates significant difference at the P<0.05 (n=15).
[0030] FIG. 9 shows the “in pot” effect of seed application on HRSW seedling growth. Compared with control treatment, CO4 and CO8 treatment significantly promoted plant growth. One star (*) indicates significant difference at the P<0.05 (n=20).
[0031] FIG. 10 shows the effect of seed application on rice shoot and root length. Rice seeds were treated with three different solutions of 0.5% ethanol (control), 10 −6 M CO4, or 10 −6 M CO8, and grown on modified Fahraeus medium for 33 days. The length of roots (left bar) and shoots (right bar) were measured. Compared with ethanol treatment, CO4 treatment significantly promoted shoot and root growth. One star (*) and two stars (**) indicate significant difference at the P<0.1, P<0.01 level each. (n=10).
[0032] FIG. 11 shows the effect of seed application on corn lateral root development. Compared with control treatment, CO4 treatment significantly promoted lateral root production. One star (*) indicates significant difference at the p<0.1 (n=20).
[0033] FIGS. 12 A and 12 B show the effect of foliar application on the shoot and root length. Three-weeks-old rice leaves were treated with three different solutions of 0.5% ethanol, 10 −6 M CO4, or 10 −6 M CO8 by painting brushes, and the length of shoots ( 12 A) and roots ( 12 B) were measured at treatment day ( 12 A left bar), 14 days after treatment ( 12 A center bar), and 18 days after treatment ( 12 A right bar and 12 B). Both shoot and root lengths of CO4 treated rice were significantly longer than ethanol treated ones at 14 days and 18 days. One star (*) and two stars (**) indicate significant difference at the P<0.1, P<0.01 level each (n=11).
DETAILED DESCRIPTION
A. In General
[0034] This invention is not limited to the particular methodology, protocols, or reagents described, as these may vary. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the scope of the present invention, which will be limited only by the appended claims.
[0035] As used herein and in the appended claims, the singular forms “a”, “an” and “the” include plural reference, unless the context clearly dictates otherwise. As well, the terms “a” (or “an”), “one or more” and “at least one” can be used interchangeably herein. Also, the terms “comprising”, “including” and “having” can be used interchangeably.
[0036] Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of ordinary skill in the art to which this invention belongs. Although any methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention, certain exemplary methods and materials are now described.
B. The Invention
[0037] The present invention provides methods and compositions for promoting plant growth and/or development in non-leguminous plants.
[0038] The method includes the step of contacting a non-leguminous plant, a part thereof, or a seedling or seed thereof with a composition that includes a chitooligosaccharide (CO), as described above.
[0039] The method used for contacting the composition with the plant, part thereof, or seedling or seed thereof (the “target”) can include any method known in the art, including, without limitation, spraying the target with the composition, dipping the target into the composition, soaking or submersing the target in the composition, coating the target with the composition, or adding the composition to the soil in proximity to the target, whereby the composition comes in contact with the composition. Optionally, to facilitate the contacting step, the composition is in the form of a liquid, such as an aqueous solution or an oil-based mixture. In such embodiments, the composition may further include a solubilizing agent that increases the solubility of the CO within the liquid composition, and/or a surfactant or wetting agent that facilitates maximum contact between the liquid composition and the plant or seed surface to which it is applied.
[0040] The period for which the target is contacted with the composition can vary. In some embodiments, the composition is contacted with the plant, plant part, seedling or seed for about 5 minutes to about a week. Optionally, the contacting step occurs for a period that falls within a range having a lower value of about 10 minutes, about 20 minutes, about 30 minutes, about 40 minutes, about 50 minutes, about one hour, about two hours, about three hours, about four hours, about five hours, about six hours, about seven hours, about eight hours, about nine hours, about ten hours, about eleven hours, or about twelve hours. Optionally, the contacting step occurs for a period that falls within a range having an upper value of about 20 minutes, about 30 minutes, about 40 minutes, about 50 minutes, about one hour, about two hours, about three hours, about four hours, about five hours, about six hours, about seven hours, about eight hours, about nine hours, about ten hours, about eleven hours, about twelve hours, about one day, about two days, about three days, or about four days.
[0041] The concentration of the CO in the composition can vary. Optionally, the concentration of the CO within the composition falls within a range having a lower value of about 10 −4 M, about 10 −5 M, about 10 −6 M, about 10 −7 M, about 10 −8 M, about 10 −9 M, about 10 −10 M, about 10 −11 M, or about 10 −12 M. Optionally, the concentration of the CO within the composition falls within a range having an upper value of about 10 −3 M, about 10 −4 M, about 10 −5 M, about 10 −6 M, about 10 −7 M, about 10 −8 M, about 10 −9 M, about 10 −10 M, about 10 −11 M, or about 10 −12 M.
[0042] The compositions may include a single type of CO, but may also include mixtures of two or more distinctly different COs, as described above.
C. Examples
[0043] The following Examples are offered by way of illustration only, and not by way of limitation.
Example 1
CO4 and CO8 Activate Symbiotic Signalling and Promote Root System Development in Rice
[0044] Plants establish root symbioses with arbuscular mycorrhizal fungi to facilitate nutrient acquisition. Establishment of this interaction requires plant recognition of diffusible signals from the fungus, including lipochitooligosaccharides (LCDs) and chitooligosaccharides (COs). Nitrogen-fixing rhizobia bacteria that form symbioses with leguminous plants also signal to their hosts via LCOs (Nod factors). In legumes, it is thought that both the mycorrhizal and rhizobial symbioses use a common signaling pathway.
[0045] In this example, we have assessed the induction of symbiotic signalling processes by the mycorrhizal (Myc)-produced LCOs and COs in rice, a model non-leguminous mycorrhizal plant. We show that the chitin oligomers CO4 and CO8, but not Myc-LCOs, activate symbiotic calcium oscillations in rice atrichoblasts, although CO4 and Myc-LCOs combined were required to induce calcium spiking in root hair cells. In contrast, lateral root emergence was promoted in rice by non-sulphated-LCO (NS-LC), sulphated-LCO (S-LCO), CO4 or CO8, in a DMI3 and POLLUX dependent manner. Our work demonstrates that COs such as CO4 and CO8 can be used to promote increased root system development in non-leguminous mycorrhizal plants, such as rice.
[0046] Introduction
[0047] To better understand the mechanisms by which AM fungi signal to non-leguminous host plants, we assessed the induction of symbiotic signalling in rice by the AM produced LCOs and COs. We show in this example that rice appears to respond primarily to COs for activation of calcium oscillations, rather than the LCOs that legumes respond to (although rice does respond to LCOs with the promotion of lateral root emergence). Furthermore, we show for the first time that COs, such as CO4 and CO8, can be used alone or in combination with LCOs to promote root system development in non-leguminous plant species, such as rice. We conclude that COs activate different symbiotic signalling processes in non-leguminous plant species, such as rice, from those activated in legumes.
[0048] Materials and Methods
[0049] Seed Preparation, Plant Growth Conditions, and Treatment with LCOs and COs.
[0050] Oryza sativa cv Nipponbare wild-type and Tos17 insertion lines in POLLUX (line NC6453) and DMI3 (line 8513) were used for root architecture experiments (12, 13). Seeds were prepared by sterilizing with 2% bleach for 20 minutes, followed by 3, 5-minute rinses with sterile water. The sterile seeds were then imbibed overnight. Seeds were then plated on damp germination paper in Petri plates under sterile conditions and germinated in the dark at 25 degrees for 7 days. Germinated rice plants were then plated on Fahraeus medium on germination paper and grown at 22 degrees under constant light. After 5 days the plants were treated with 10 −8 M LCOs and COs for 24 hours by submersion and re-plated onto Fåhræus Medium 1.5% agar plates (0.132 g/L CaCl2, 0.12 g/L MgSO 4 .7H 2 O, 0.1 g/L KH 2 PO 4 , 0.075 g/L Na 2 HPO 4 .2H 2 O, 5 mg/L Fe-citrate, and 0.07 mg/L each of MnCl 2 .4H 2 O, CuSO 4 .5H 2 O, ZnCl 2 , H 3 BO 3 , and Na 2 MoO 4 .2H 2 O, adjusted to pH 6.5 before autoclaving). As all signals were suspended in 50% ethanol, the appropriate concentration of ethanol in sterile DI water served as a control. Root system architecture was assessed after 2 weeks.
[0051] Calcium Imaging.
[0052] Mycorrhizal induced calcium responses were measured as described previously (14). Transgenic Oryza sativa Nipponbare lines carrying Yellow Cameleon 3.6 (YC3.6) FRET-based calcium sensor was used to detect calcium spiking. YC3.6 was imaged on a Nikon Eclipse Ti inverted microscope (Nikon, Japan) equipped with an OptoLED Illuminator (model OptoLED, Cairn Research Ltd, UK). YC3.6 was excited at a wavelength of 455 nm using a royal blue LED and was captured with a charge-coupled device (CCD) camera (model RETIGA-SRV, Qimaging, Canada). Emitted fluorescence was separated by an image splitter with a dichroic mirror (model Optosplit II, Cairn Research Ltd, UK) and then passed through a fluorescence filter set. Images were collected every 5 seconds with 1-second exposure and analyzed using MetaFluor (Molecular Devices, Sunnyvale, Calif., USA).
[0053] Mathematical Analysis of Calcium Oscillations.
[0054] For Bayesian Spectrum Analysis we computed the most probable periods in the time series following published procedures (15). Ten traces per treatment were analyzed. The joint distributions over the period were used to characterize each group. The plots show binned data to summarize the key periods. These ten traces per treatment were also analyzed for interspike intervals. The point of maximum height for each spike was computed after detrending of the time series using a moving average algorithm. The distances between these maxima gave rise to an interspike distribution. We used the non-parametric Mann-Whitney U-test, also known as the Mann-Whitney-Wilcoxon test (16, 17) to test for significant differences between the distributions.
[0055] Three traces per treatment, with approximately 80 spikes altogether, were analyzed for calcium spike characteristics. The time series had an interval of 5 seconds between data points. The traces were detrended using a moving average algorithm (18). We then characterized the spikes by the time required for each upward and downward phase. This was computed by the number of data points it took from the maximum spike height to the baseline fluctuation of the trace. The plots show the mean value of the upward and downward phases for each treatment, and the associated standard deviations are indicated by the error bars.
[0056] Measurements of Root Architecture Modifications.
[0057] Total lateral roots of rice were enumerated manually two weeks after application of 10 −8 M COs and LCOs. As COs and LCOs were suspended in 50% ethanol, the control is sterile deionized water containing the appropriate amount of ethanol. Lateral roots were defined as large and fine lateral roots emerging from crown roots, as well as fine lateral roots emerging from large lateral roots. Root system length was measured starting from the root-shoot junction to the tip of the longest root. The number of crown roots was assessed manually as those roots emerging from the root-shoot junction. Root type characterizations were based upon the descriptions in Gutjahr et al. (19). Data were assessed for normality using the Shapiro-Wilk test (α=0.01), and statistical significance was determined using a paired t-test assuming unequal variances, or a Mann-Whitney-Wilcoxon Test if normality was not observed (α=0.05). All statistical analysis was conducted using the R software package (20).
[0058] Results
[0059] Activation of Calcium Oscillations by Myc-LCOs and COs in Rice.
[0060] Mycorrhizal fungi associate with a wide range of plant species, and at least in rice this association is dependent on the common symbiosis signalling pathway (12, 21-23). Hence, non-legumes should be able to recognize the mycorrhizal produced LCOs and/or COs. Two major species of LCOs have been characterized from exudates of R. irregularis : LCO-IV (C16:0, S or C18:1, S), which we will refer to as sulfated (S)-LCO and LCO-IV (C16:0 or C18:1), which we will refer to as non-sulfated (NS)-LCO (24). For this study, we used S-LCOs and NS-LCOs that were either purified from R. irregularis exudates or were synthesized in genetically-modified bacteria as previously described (24). To define the activation of the symbiosis signalling pathway by the AM-produced LCOs and COs, we assessed their ability to activate calcium oscillations, the pathway's earliest measurable event (3).
[0061] Calcium responses were assessed using a stably transformed line of Oryza sativa cv Nipponbare carrying YC3.6. AM fungi have been shown to predominantly colonize the large lateral roots (19), and therefore, we focused on this root type. No calcium responses were observed following treatment with any of the LCOs assessed, but strong calcium oscillations were observed following treatment with 10 −5 M CO4 ( FIG. 1 ). To test an array of different LCO structures, we analyzed calcium spiking in response to Nod factor isolations from the broad host range rhizobial species, Rhizobium sp. NGR234, as well as Rhizobium tropici , in addition to the Myc-LCOs. Considering that these LCO treatments were performed with 10 −5 M, we are confident that rice does not respond to the Nod factors or Myc factors tested. Treatments with 10 −8 M CO4 still showed calcium oscillations in rice epidermal cells, but the robustness of the response was reduced and the number of responsive cells was also reduced ( FIG. 1 ). Unlike results reported in M. truncatula , rice appears to respond equally well to both CO4 and CO8 with calcium oscillations ( FIG. 2 ).
[0062] Mycorrhizal LCOs and COs Induce Rice Root Architecture Modification.
[0063] Rice has been shown to respond to AM fungi and exudates from the spores of AM fungi, with changes to root structure, in particular, the promotion of lateral root outgrowth (19, 25). These responses were independent of the common symbiosis signalling pathway. In contrast, we have observed CO4 and CO8 induction of the common symbiosis signalling pathway in rice as measured by the activation of calcium oscillations. In an attempt to understand these seemingly contradictory results, we tested the promotion of lateral root outgrowth in rice by S-LCO, NS-LCO, CO4 and CO8. This study showed that NS-LCO, S-LCO, CO4 and CO8 all promoted lateral root and crown root growth in rice ( FIG. 3 ). Interestingly, root system length was only enhanced upon application of NS-LCOs ( FIG. 3 ). These results imply that COs and LCOs activate two modalities of signalling in rice: calcium oscillations that are activated by COs and a separate signalling pathway activated by both LCOs and COs that is associated with changes to root architecture.
[0064] Root Architecture Modification by COs and LCOs are DMI3 and POLLUX Dependent.
[0065] To assess the role of the common symbiotic pathway in regulating root architecture modifications in response to purified LCOs and COs, we quantified root responses to mycorrhizal signals in rice knock-out mutants of pollux (upstream of calcium spiking) and dmi3 (downstream of calcium spiking). We found that lateral root growth promotion by LCOs and CO4 was dependent on both POLLUX and DMI3, while the response to CO8 was dependent on POLLUX ( FIG. 4 ). The increase in crown root growth by both LCOs and COs was dependent upon DMI3 and POLLUX, and there were significantly fewer crown roots in response to all treatments in the pollux mutant ( FIG. 4 ). Finally, the overall root length increase observed in response to NS-LCO was dependent upon both POLLUX and DMI3 ( FIG. 4 ). These results demonstrate that root architecture changes in response to purified mycorrhizal signals require proteins of the common symbiotic pathway.
[0066] Both LCOs and COs are Required to Induce Calcium Spiking in Trichoblasts.
[0067] Rhizobia colonize legumes by root hair cells (trichoblasts), whereas AM fungi colonize roots via non-root hair epidermal cells (atrichoblasts). Thus, these different root epidermal cell types may respond differently to COs and LCOs. To test this, we directly compared trichoblast and atrichoblast responses using high concentrations of CO4 in rice. Calcium oscillations observed in rice following treatments of CO4 were restricted to atrichoblasts, with no responses in trichoblasts even with CO4 treatments of 10 −5 M ( FIG. 5 ). This preferential nature of rice atrichoblasts to respond to the AM signals is consistent with a preference for AM fungi to colonize the root via atrichoblasts (26). It is possible that either AM fungi produce signalling molecules other than S-LCO, NS-LCO and CO4 that induce calcium oscillations in rice trichoblasts, or that the mix of signalling molecules is important. To test this, we assessed induction of calcium oscillations by an equimolar mix of 10 −5 M S-LCO, NS-LCO, and CO4. Strikingly, we observed calcium spiking in rice root hair cells when treated with this mix of signal molecules, yet these signal molecules, when applied individually at 10-5 M, did not induce calcium spiking ( FIG. 6 ).
[0068] Discussion
[0069] COs and LCOs Act Synergistically as Symbiotic Signals in Rice.
[0070] AM fungi signal to the host plant via diffusible signals (14, 25-27), and at least some of these signals are LCOs (24) and COs (9). In this example, we show that the AM-produced COs can activate calcium oscillations in rice. S-LCO and NS-LCO were purified from exudates of AM fungi based on their capability to activate symbiotic responses in M. truncatula that were dependent on the common symbiosis signalling pathway (24). The fact that these LCOs do not trigger calcium spiking in rice may reflect this selectivity in their initial identification. However, rice can sense LCOs since the mix of Myc-LCOs and CO4 activated calcium oscillations in rice root hair cells and LCOs can also promote lateral and crown root growth. Therefore, the absence of calcium responses in rice to the LCO treatments alone does not indicate a lack of response of LCOs by rice.
[0071] Our work has revealed a close correlation between the cell-type and its responsiveness to LCOs and CO4. We observed that calcium responses to COs were restricted to atrichoblasts in rice. This preferential response in atrichoblasts correlates well with a preferential colonization of atrichoblasts by AM fungi (26). However, we observed calcium oscillations in rice trichoblasts in treatments where LCOs and CO4 were combined. It would appear that responses in rice trichoblasts are at least partially explained by the mix of LCOs and CO4 produced by the AM fungus. Interestingly, it was shown some years ago that a mix of Nod factors and COs was better at inducing nodulation associated gene expression in soybean than Nod factor treatments alone (28). Perhaps these earlier observations reflect responses to AM fungi, rather than what was previously thought to be a rhizobial response. Alternatively, a mix of LCOs and COs may be relevant in rhizobial interactions as well as AM associations.
[0072] Multiple Pathways Mediate LCO and CO Responses in Rice.
[0073] We established that rice can distinguish between LCOs, CO4, and CO8, and responds accordingly with either calcium oscillations and/or root architecture modifications. The fact that rice responds to AM fungi with at least two separate signalling pathways has already been shown (23), and the promotion of lateral roots by AM fungi in a manner independent of the common symbiosis signalling pathway was also already shown (25). Thus, there is ample evidence in rice for two pathways of symbiosis signalling. Our work shows that root architecture modification in response to LCOs and CO4 requires the common symbiotic pathway; however, CO8 does not require DMI3. The ability of AM fungi to stimulate lateral root emergence independent of the symbiotic pathway may indicate that the plant responds differently to a mixture of signals and stimuli than it does to purified signals and that during symbiosis the pathway governing root architecture modification does not require calcium spiking to be initiated.
[0074] In Arabidopsis , lateral root development is under the control of auxin signalling modules. Under high auxin conditions, lateral root founder cells polarize and divide (29). Further rounds of cell division result in lateral root emergence at specific sites in the root. The process leading to lateral root emergence is similar in rice and using the DR5:GUS auxin reporter system, auxin was shown to accumulate in emerging lateral roots (30). Under high auxin concentrations, AUX/IAA proteins are degraded. AUX/IAA proteins repress ARF transcriptional activators, and thus their degradation leads to the transcription of auxin-responsive genes (29). Auxin positively regulates lateral root formation, as a rice plant containing a constitutively active version of IAA13 has fewer lateral roots than wild type (31). Interestingly, auxin signalling is also implicated in the production of crown roots in rice (32, 33). It seems likely, therefore, that the application of LCOs and COs activates the auxin-dependent lateral root and crown root emergence programs. Given that this phenotype was dependent on DMI3 and POLLUX in the case of Myc-LCOs and CO4, it may be that there is cross talk between the common symbiosis pathway and auxin signaling, which results in increased lateral root emergence and crown root growth. Assessing expression of auxin-responsive genes in Ospollux and Osdmi3 mutants in response to COs and LCOs may reveal the mechanisms of this signalling pathway.
CONCLUSION
[0075] AM fungi have the distinctive capability of colonizing a broad group of plants. In this example, we demonstrate that CO4 and CO8 form at least part of the spectrum of AM symbiotic signals that can be recognized by a variety of plant species to activate a range of symbiotic signalling processes. More specifically, both CO4 and CO8 can be used to promote increased root system development in non-leguminous plants, such as rice.
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Example 2
CO4 does not Promote Root System Development in Legumes
[0109] This example shows that the results obtained in Example 1 using rice, a non-leguminous mycorrhizal plant model, cannot be replicated in legumes. Specifically, we demonstrate that in M. truncatula , stimulation of lateral root emergence occurred following treatment with Myc-LCOs, but not following treatment with CO4. In contrast, Example 1 showed that both Myc-LCOs and CO4 (along with CO8) promoted increased root system development in rice. This work indicates that legumes and non-legumes differ in their perception of Myc-LCO and CO signals, suggesting that legume and non-legume species respond to different components in the mix of signals produced by arbuscular mycorrhizal fungi.
[0110] Results
[0111] LCOs, CO4, and CO8 Promote Root Development in Rice, while LCOs, but not COs, Promote Root Development in the Legume M. truncatula.
[0112] We tested the promotion of lateral root outgrowth in rice by S-LCO, NS-LCO, CO4, and CO8, and found that all four molecules could promote lateral root outgrowth and enhance overall root system growth (see Example 1). In contrast to what we observed in rice, using the protocol of Example 1, CO4 could not induce lateral root emergence in M. truncatula ( FIG. 7 ), but the Myc-LCOs can activate this response (Maillet, F., et al. (2011), Nature 469: 58-63). This demonstrates that legumes and non-legumes differ fundamentally in their response to the spectrum of Myc-LCOs and COs for modifications to root architecture. Accordingly, the disclosed method is limited in scope to treating non-leguminous plants, or seeds, seedlings or plant parts thereof.
Example 3
The Effect of CO4 and CO8 Seed Treatment on Growth and Development of Hard Red Spring Wheat, Rice and Corn
[0113] This example demonstrates that CO4 and/or CO8 when applied to the seeds of three different grain crop plants, promotes the growth of the plants, as measured by one or more parameters of plant growth or development.
Experiment 1
Effects of CO4 and CO8 Treatment on Hard Red Spring Wheat (HRSW) In Vitro
[0114] Methods
[0115] Hard red spring wheat seeds were surface sterilized using ethanol and bleach. The sterilized seeds were then divided among 4 treatment groups of 5 grams each into 50 ml falcon tubes. To the control tube, 0.5% ethanol in water was added. To the CO4 tube, 125 μl of 10 −6 M CO4 solution was added. To the CO8 tube, 125 μl of 10 −6 M CO8 solution was added. To the “Consensus” tube, 125 μl of 10 −6 M solution of chitosan (CONSENSUS® chitosan; Loveland Products, Inc., Loveland, Colo.) was added. Each tube was then shaken to coat the seeds. The coated seeds were then placed on sterile Petri dishes in a hood and were left to dry overnight in the hood.
[0116] The seeds were then germinated on damp germination paper in sterile Petri dishes for 4 days. The resulting seedlings were transferred to Fahräeus medium plates containing damp germination paper, and the plates were wrapped in Parafilm®. Fahräeus medium contains 0.5 m M MgSO 4 , 0.7 mM KH 2 PO 4 , 0.4 mM Na 2 HPO 4 , 0.02 mM Fe-EDTA, 0.01 mM MnSO 4 , 0.007 mM CuSO 4 , 0.006 mM ZnSO 4 , 0.016 mM H 3 BO 3 , 0.001 mM Na 2 MoO 4 , and 15 g/L Agar for plant tissue, adjusted to pH 6.5 before autoclaving. The plants were grown at room temperature under continuous light for 4-5 days. The number of primary roots (PR), lateral roots (LR), root system length (RSL) and dry weight (DW) was then measured for all plants.
[0117] Results
[0118] The results are tabulated in Table 1 below:
[0000]
TABLE 1
Measured Parameters for Control, CO8, CO4 and
Consensus Treatment Groups (Wheat)
Number of
Number of
Primary
Lateral
Root System
Dry Weight
Treatment
Roots
Roots
Length (cm)
(g)
Control
5.64
3.21
11.82
0.0194
CO8
5.20
3.00
11.51
0.0191
CO4
5.20
3.73
13.21*
0.0206
Consensus
5.27
3.53
11.52
0.0213
*Significant difference at P < 0.05
[0119] CO4 treatment significantly increased root system length over the control (see also FIG. 8 ), indicating that the treatment facilitates at least one growth parameter in wheat.
Experiment 2
Effects of CO4 and CO8 Treatment on Hard Red Spring Wheat in Pots
[0120] Methods
[0121] Five grams of hard red spring wheat seeds were added to three separate 50 ml tubes. A water solution containing 0.5% ethanol was added to the control tube, 125 μl of 10 −6 M CO4 solution was added to the CO4 tube, and 125 μl of 10 −6 M CO8 solution was added to the CO8 tube. Each tube was then shaken to coat the seeds. Seeds were potted immediately following treatment into moistened SUNGRO® potting mix in 4×6×6 cm pots. Plants were watered by pouring water into the tray containing the pots up to about ¾ inch high.
[0122] After sowing the seeds, the pots were randomly distributed (16 pots per treatment) throughout the tray and placed underneath continuous light at room temperature for 1 week. Liquid Fahräeus medium (plant fertilizer solution; see above) was applied every 2 days or when necessary. After a week, the pots were placed underneath 10 h light and 14 h dark cycle at room temperature for 1 week. After 1 week underneath 10 h light and 14 h dark cycle (2 weeks after planting), the plants were carefully removed from the pots, and as much soil as possible was shaken off. The remaining soil was removed by submerging the root system into a beaker of water.
[0123] The number of primary roots (PR), lateral roots (LR), root system length (RSL) and dry weight (DW) was then measured for all plants.
[0124] Results
[0125] The results are tabulated in Table 2 below:
[0000]
TABLE 2
Measured Parameters for Control, CO8 and
CO4 Treatment Groups (Wheat)
Number of
Number of
Primary
Lateral
Root System
Dry Weight
Treatment
Roots
Roots
Length (cm)
(mg)
Control
3.30
14.45
10.70
24.03
CO8
3.35
14.30
12.22
32.38*
CO4
3.15
16.25
11.75
30.20*
*Significant difference at P < 0.05
[0126] Both CO4 and CO8 seed treatments significantly increased dry weight (a measurement of total plant growth) in the wheat plants (see also FIG. 9 ), confirming that such treatments facilitate plant growth in wheat. A similar dry weight increase was not shown with plants grown in plates in Experiment 1 above, likely because of the limitations on growth that plates impose. Average root system length was also higher for both CO4 and CO8 treatments, although the increased length was not great enough to be significant at P<0.05.
[0127] Together, the results of Experiment 1 and 2 demonstrate that CO4 and/or CO8 treatment of wheat seeds facilitates growth and development of the wheat plants that germinate from the treated seeds.
Experiment 3
Effects of CO4 and CO8 Treatment on Rice In Vitro
[0128] Methods
[0129] Rice seeds were sterilized using 2% bleach. The sterilized seeds were then divided among 3 treatment groups of 10 seeds each into 15 ml falcon tubes. To the control tube, 0.5% ethanol in water was added. To the CO4 tube, 100 μl of 10 −6 M CO4 solution was added. To the CO8 tube, 100 μl of 10 −6 M CO8 solution was added. Each tube was then shaken to coat the seeds. The coated seeds were then placed on sterile Petri dishes in a hood and were left to dry overnight in the hood.
[0130] The seeds were then germinated on damp germination paper in sterile Petri dishes for 5 days. The resulting seedlings were transferred to Fahräeus medium plates containing damp germination paper, and the plates were wrapped in Parafilm®. The roots part of the plate was covered with aluminum foil. The plants were grown at room temperature under continuous light for 33 days. The length of the shoot and root systems was measured for all plants.
[0131] Results
[0132] CO4 treatment significantly increased both shoot and root system length compared with the ethanol control (see FIG. 10 ). This data supplements the data disclosed in Example 1 above indicating that both CO4 and CO8 treatment can be used to facilitate growth and development in rice.
Experiment 4
Effects of CO4 and CO8 Treatment on Corn in Pots
[0133] Methods
[0134] Five grams of corn (maize) seeds were added to three separate 50 ml tubes. A water solution containing 0.5% ethanol was added to the control tube, 125 μl of 10 −6 M CO4 solution was added to the CO4 tube, and 125 μl of 10 −6 M CO8 solution was added to the CO8 tube. Each tube was then shaken to coat the seeds. Seeds were potted immediately following treatment into moistened SUNGRO® potting mix in 4×6×6 cm pots. Plants were watered by pouring water into the tray containing the pots up to about ¾ inch high.
[0135] After sowing the seeds, the pots were randomly distributed (16 pots per treatment) throughout the tray and placed underneath continuous light at room temperature for 1 week. Liquid Fahräeus medium (plant fertilizer solution; see above) was applied every 2 days or when necessary. After a week, the pots were placed underneath 10 h light and 14 h dark cycle at room temperature for 1 week. After 1 week underneath 10 h light and 14 h dark cycle (2 weeks after planting), the plants were carefully removed from the pots, and as much soil as possible was shaken off. The remaining soil was removed by submerging the root system into a beaker of water.
[0136] The number of primary roots (PR), lateral roots (LR), root system length (RSL) and dry weight (DW) was then measured for all plants.
[0137] Results
[0138] The results are tabulated in Table 3 below. As shown in Table 3 and FIG. 11 , corn plants resulting from seeds receiving both CO4 and CO8 treatments exhibited increased number of lateral roots, as compared to corn plants resulting from seeds receiving the control treatment. However, the increased lateral root development with CO8 treatment was not great enough to be significant at P<0.1, likely due to high variability. CO4 did significantly increase lateral root growth at P<0.1. This experiment demonstrates that the disclosed seed treatment method can be used to facilitate growth in corn.
[0000]
TABLE 3
Measured Parameters for Control, CO8 and
CO4 and Treatment Groups (Corn)
Average
Root
Dry
Treatment
Seminal Roots
Lateral Roots
System Length
Weight
Control
4.40
38.95
21.53
0.1176
CO4
4.45
45.00*
23.76
0.1225
CO8
4.75
44.95
21.42
0.1229
*Significant difference at P < 0.1
Example 4
The Effect of CO4 and CO8 Foliar Treatment on Root/Shoot Growth of Rice
[0139] This example extends the results of the previous examples to foliar treatment in rice. Specifically, foliar treatment with CO4 in rice is shown to facilitate both shoot growth and root growth.
[0140] Methods
[0141] Rice seeds were surface sterilized using 2% bleach. Seeds were then germinated on damp germination paper in sterile Petri dishes for 5 days. The seedlings were then transferred to Fahraeus medium plates containing damp germination paper. The plates were wrapped in Parafilm®, and the roots part of the plate covered with aluminum foil.
[0142] The plants were grown at room temperature under continuous light for 21 days. The plants were then transferred to moistened SUNGRO® soil pots (8×8×10 cm) and grown for 3 days under greenhouse condition. The plants were hydrated by pouring water into the tray underneath the pots.
[0143] The soil surface was then covered with plastic wrap to prevent any liquid droplets from contacting the soil. Using painting brushes, the front, and back of the plant leaves were treated with 3 ml of chitin derived compounds (CO4 and CO8) at 10 −6 M or a control (0.5% ethanol), each including 0.05% of Silwet L-77 (surfactant). Eleven plants were treated with each solution. The plants were subsequently grown for 14 days, and the shoot length was measured. Once a week, half-strength Hoagland solution was added into the trays underneath the pots. The plants were grown for another 4 days, and the lengths of the shoot and root systems were measured.
[0144] Results
[0145] CO4 foliar treatment on rice significantly increased shoot length at day 14 after treatment, and the significance was even higher at day 18 ( FIG. 12A ). CO4 treatment also significantly promoted root system length at day 18 ( FIG. 12B ). In sum, this example shows that foliar application of CO4 in rice promotes plant growth in the rice.
Example 5
CO4 and CO8 Seed Treatment Reduce Root Growth in an Exemplary Legume
[0146] Consistent with the results reported in Example 2, this example confirms that the results reported in various non-leguminous plants (see Examples 1, 3 and 4) cannot be replicated in legumes. Thus, the disclosed method is limited to non-leguminous plants.
[0147] Methods
[0148] Five grams of pea seeds (the legume Pisum sativum ) were added to three separate 50 ml tubes. A water solution containing 0.5% ethanol was added to the control tube, 125 μl of 10 −6 M CO4 solution was added to the CO4 tube, and 125 μl of 10 −6 M CO8 solution was added to the CO8 tube. Each tube was then shaken to coat the seeds. Seeds were potted immediately following treatment into moistened SUNGRO® potting mix in 4×6×6 cm pots. Plants were watered by pouring water into the tray containing the pots up to about ¾ inch high.
[0149] After sowing the seeds, the pots were randomly distributed (16 pots per treatment) throughout the tray and placed underneath continuous light at room temperature for 1 week. Liquid Fahräeus medium (plant fertilizer solution; see above) was applied every 2 days or when necessary. After a week, the pots were placed underneath 10 h light and 14 h dark cycle at room temperature for 1 week. After 1 week underneath 10 h light and 14 h dark cycle (2 weeks after planting), the plants were carefully removed from the pots, and as much soil as possible was shaken off. The remaining soil was removed by submerging the root system into a beaker of water.
[0150] The number of primary roots (PR), lateral roots (LR), root system length (RSL) and dry weight (DW) were then measured for all plants.
[0151] Results
[0152] The results are tabulated in Table 4 below:
[0000]
TABLE 4
Measured Parameters for Control, CO8 and CO4 Treatment Groups (Peas)
Average
Lateral
Tap Root
Treatment
Primary Roots
Roots
Length
Dry Weight
Control
18.45
22.45
10.31
.15
CO4
14.20*
13.35*
10.25
.13
CO4
15.50*
15.00*
10.28
.14
*Significant difference at P < 0.05
[0153] In contrast to the results demonstrated with non-leguminous plants, CO4, and CO8 seed treatments significantly decreased the number of primary and lateral roots of pea seedlings compared to the control. None of the other variables were affected by the CO treatment.
[0154] Together, the results of Example 2 and this example demonstrate that the disclosed chitin oligomers cannot be used to promote the growth and/or development of leguminous plants. Accordingly, the disclosed method is limited to promoting the growth and/or development of non-leguminous plants.
[0155] The examples and embodiments described herein are for illustrative purposes only. Various modifications or changes in light thereof will be suggested to persons skilled in the art and are to be included within the spirit and purview of this application and scope of the appended claims. All publications, patents, and patent applications cited herein are hereby incorporated by reference in their entirety for all purposes. | Methods for stimulating the growth of non-leguminous plants are disclosed. In the methods, a non-leguminous plant, a part thereof, or a seedling or seed thereof is contacted with a composition comprising a chitooligosaccharide (CO) having the formula:
R1 is —H, —CH 3 , —COCH 3 , —SO 3 H, —SO 3 Na, arabinose, methylated arabinose, fucose, or methylated fucose; R2 is —H, —CH 3 , —COCH 3 , —SO 3 H, —SO 3 Na, arabinose, methylated arabinose, fucose, or methylated fucose; each R3 is independently —H or —COCH 3 ; and n is 0, 1, 2, 3, 4, 5 or 6. As non-limiting examples, the method can be used to stimulate production and yield in a cereal grain crop plant, such as rice, wheat or corn (maize). | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a mounting system and in particular but not exclusively to a counting system for motor vehicle engines/gearboxes.
2. Description of the Prior Art
Currently, vehicle engines/gearboxes are mounted to motor vehicles by means of compliant mounts which isolate engine/gearbox vibrations from the vehicle body. In a simplified form, the engine/gearbox mount may comprise a single coil spring. Such mounts suffer however from lack of inherent damping and poor lateral control. Rubber mounts provide an inexpensive form of mount which can be designed to provide appropriate damping and to give good lateral support. However, the effectiveness of the rubber mount is limited by the need to compromise between low frequency stiffness which improves vibration isolation while the engine is idling, and higher frequency stiffness which improves vibration isolation at high engine and vehicle speeds, and which improves the constraint of the engine/gearbox.
Low frequency vibration isolation of the mount may be improved by means of harmonic damping effects produced by the use of two spring elements with a mass located therebetween. With such a system, the low frequency vibration of the engine/gearbox is damped by the vibrations of the mass acting between the spring elements. In order for this to work properly, the natural frequency of the mass must be outside the natural body frequency of the vehicle body and the engine order frequencies. If this is not achieved, the system will amplify those inputs which coincide with the natural frequency of the mount. In order to ensure that this is avoided, the natural frequency of the mount needs to be 30 Hz or lower. This frequency can only be achieved by using springs with a low spring rate and by using a large mass. This is not desirable since low spring rates reduce low frequency vibration control and also the large mass is undesirable since minimising the mass of the motor vehicle improves fuel economy and reduces costs. Furthermore, harmonic damping mounts of this form are of inherently complex design and expensive to produce.
Low frequency isolation of the engine/gearbox can be improved by the use of a hydraulic mount known as a hydramount in which, fluid is pushed through a long tube between a pair of chambers. With this system, if the vibration is of high frequency, the fluid has sufficient inertia to resist movement, resulting in the vibration being isolated solely by the flexibility of a rubber diaphragm by which the engine/gearbox is connected to the hydraulic circuit. During low frequency vibration fluid passes more freely between the chambers resulting in the rubber diaphragm being effectively more flexible. Hydromounts of this form are of complex design and are expensive components. Furthermore, due to the hydraulic nature of its operation, a degree of damping is unavoidable as fluid is forced from the chambers into the smaller diameter connecting tube. Moreover, hydraulic mounts do not generally resist large fore-aft movements as they have little inherent strength in these directions.
SUMMARY OF THE INVENTION
The present invention provides a mount with good low frequency isolation characteristics, which has fully tunable fore-aft and lateral spring rates and fully tunable damping characteristics allowing less damping than is possible with a hydramount. The mount is also of relatively simple construction, compact, and of low cost.
According to one aspect of the present invention, a mounting system for securing a first component compliantly with respect to a second component comprises: a flywheel adapted to be mounted with respect to one of said components for rotation in a plane normal to the direction of movement of said first component towards the second component, and means for driving the flywheel upon movement of the first component towards and away from the second component, with the other of said components being compliantly connected to the flywheel and/or drive means.
According to a preferred embodiment of the invention, the other of said components is connected to the flywheel by one or more spring elements, with each spring element being attached at one end to said other component and at the other end to the flywheel, and with the spring elements being inclined relative to the plane of rotation of the flywheel, so that movement of the first component normal to the plane of rotation of the flywheel will cause the flywheel to rotate.
With the mounting system disclosed above, when the first component vibrates at low frequency relative to said second component, the flywheel undergoes rotational oscillation at or slightly below its natural frequency of rotation. This causes the system to attempt to reduce the force supporting the engine/gearbox as the engine/gearbox attempts to move towards the body, thereby reducing the transmission of the increased force to the body. Similarly, as the engine/gearbox moves away from the body, rotation of the flywheel attempts to increase the force supporting the engine/gearbox, with similar effect.
The natural frequency of oscillation of the flywheel may be altered by altering the mass of the flywheel, the leverage exerted on the flywheel by the spring element, the diameter about which the spring element will act on the flywheel, the diameter about which the effective mass of the flywheel is situated and/or the spring rate of the spring elements. It is consequently possible to obtain a system of the desired natural frequency, without the use of undesirably large masses or spring elements of undesirably low spring rate.
The preferred embodiment has only a bearing and additional metal (in the flywheel) in addition to the components of a standard engine/gearbox mount and consequently results in only a small increase in cost over the standard engine/gearbox mount. Furthermore, the design can easily be tuned to provide varying individual fore-aft and lateral rates.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is now described, by way of example only, with reference to the accompanying drawings, in which:
FIG. 1 illustrates in cross-section a mounting system in accordance with the present invention;
FIG. 2 illustrates in plan view the mounting system illustrated in FIG. 1;
FIG. 3A and 4A show modifications to the spring elements us d in the mounting system illustrated in FIG. 1;
FIGS. 3B and 4B show plots of load against deflection for the spring elements illustrated in FIGS. 3A and 4A respectively;
FIGS. 5 and 6 illustrate composite spring elements that may replace the spring elements of the mounting system illustrated in FIG. 1;
FIG. 7, illustrates an alternative form of spring element that may be used in the mounting system illustrated in FIG. 1; and
FIG. 8 illustrates an alternative form of flywheel that may be used in the mounting system illustrated in FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As illustrated in FIGS. 1 and 2, a mounting system 10 for a gearbox of a motor vehicle comprises a mounting plate 12 of frustoconical configuration. Means (not shown), for example, one or more studs, are provided on the mounting plate 12 by which it may be secured to the gearbox of the vehicle, with conical surface 14 extending downwardly.
Flywheel 20 is rotatably mounted coaxially of the mounting plate 12 to the vehicle body or a sub-frame attached to the vehicle body. The flywheel 20 has a roller bearing formation, 22 which is mounted on a stub axle secured to the vehicle body or sub-frame.
Elastomeric blocks 24, 26, 28, 30 are mounted between conical surface 14 of mounting plate 12 and a parallel opposed surface 32 of flywheel 20. Blocks 24, 26, 28, 30 are inclined outwardly from mounting plate 12 to flywheel 20. Blocks 24, 26, 28, 30 are also inclined with respect to flywheel 20, so that the positions at which blocks 24, 26, 28, 30 are secured to flywheel 20 are advanced angularly in a clockwise direction from the positions at which blocks 24, 26, 28, 30 are secured to mounting plate 12.
As a consequence of the tangential inclination of blocks 24, 26, 28, 30 with respect to flywheel 20, vertical downward movement of plate 12 compressing blocks 24, 26, 28, 30 will be translated into a load which will cause flywheel 20 to rotate in a clockwise direction. Vertical upward movement of mounting plate 12, putting blocks 24, 26, 28, 30 into tension, will be translated into a load causing flywheel 20 to rotate in an anti-clockwise direction.
When the gearbox vibrates at low frequency relative to the body of the vehicle, the vertical movement of the gearbox will thereby cause the flywheel 20 to undergo rotational oscillation at or slightly below its natural frequency of rotation. This causes the system to attempt to reduce the force supporting the gearbox as the gearbox attempts to move towards the body, thereby reducing the transmission of the increased force to the body. Similarly, as the gearbox moves away from the body the rotation of the flywheel 20 attempts to increase the force supporting the gearbox, with similar effect. For low frequency vibrations, the rotation of the flywheel 20 will thereby effectively reduce the stiffness of elastomeric blocks 24, 26, 28, 30.
For higher frequency vibrations, the inertia of flywheel 20 will inhibit rotation so that the stiffness of mounting system 10 will correspond to the stiffness of blocks 24, 26, 28, 30.
Inclination of blocks 24, 26, 28, 30 outwardly from mounting block 12 to flywheel 20 will also provide fore/aft and lateral restraint of the gearbox relative to the vehicle body.
In the mounting system illustrated in FIGS. 1 and 2, the natural frequency of oscillation of the flywheel may be increased or decreased by increasing or decreasing the radius at which blocks 24, 26, 28, 30 are secured to flywheel 20.
With the elastomeric blocks 24, 26, 28, 30 illustrated in FIGS. 1 and 2, the spring rates of the blocks 24, 26, 28, 30 will remain constant over the full range of operation of the mount. As illustrated in FIGS. 3A-B and 4A-B, the blocks 24, 26, 28, 30 may be designed to provide a varying spring rate over the range of operation of the mount.
As illustrated by FIGS. 5 and 6, the individual elastomeric blocks 24, 26, 28, 30 of the mounting system 10 illustrated in FIGS. 1 and 2 may be replaced by single elastomeric molded elements 40, 45. In the embodiment illustrated in FIG. 5, helical formations 41 are provided externally of a hollow, cylindrical elastomeric block 40 to translate axial loads into tangential loads. In the embodiment illustrated in FIG. 6, inclined portions 46 of a hollow, cylindrical elastomeric block 47 are removed to leave helically inclined spokes 48 which will translate axial loads into tangential loads, in similar manner to blocks 24, 26, 28, 30 of the mounting system illustrated in FIGS. 1 and 2.
While it is convenient to use elastomeric spring elements which may be bonded between opposed surfaces of the mounting plate 12 and flywheel 20, other forms of spring elements may be used. For example, as illustrated in FIG. 7, a steel diaphragm spring 50 may be used, with the diaphragm spring 50 having circumferentially resiliently extending fingers 51 which are pressed out of the plane of the diaphragm 50, to provide the spring elements which extend between the mounting plate 12 and flywheel 20. Diaphragm 50 may be secured to either mounting plate 12 or to flywheel 20, with the free ends 52 of the fingers 51 secured to the other of flywheel 20 or mounting plate 12 in suitable manner.
As illustrated in FIG. 8, flywheel 60 need not be circular, provided that it is of symmetrical configuration. Flywheel 60 may consequently be designed to conform with limited angular articulation and packaging constraints. The bearing for the flywheel may be provided on the flywheel itself and a stub axle secured to the vehicle body or sub-frame, or the bearing may be provided on the vehicle body or sub-frame and an axle formation provided on the flywheel. The bearing may be a simple roller bearing with means to prevent axial movement. Alternatively, provision may be made for restrained axial movement of the flywheel, such movement being resisted at a sufficiently high rate, so that the natural frequency of axial vibration of the flywheel will be above any vehicle body or engine/gearbox resonances. Rotational resistance or damping may also be introduced into the bearing in order to further fine tune the mount.
Further resilient elements, for example, elastomeric blocks, may be provided between the mounting plate 12 and flywheel 20 or between the mounting plate 12 and/or flywheel 20 and the vehicle body or sub-frame, to act as dampers, buffers or snubbers, in order to modify the damping effect, lateral, fore/aft and/or vertical compliance of the mounting.
Various modifications may be made without departing from the present invention. For example, while in the above embodiments the flywheel is driven by spring elements other drive means which will redirect the movement of the gearbox into the flywheel may be used. Such drive means include:
i) a hydraulic or pneumatic coupling between the vertical movement of the gearbox and the rotational movement of the flywheel;
ii) a screw drive in which the gearbox is attached to a shaft with a helical screw which is then located in splines in the centre of the flywheel thus causing the flywheel to rotate as the screw is moved up and down; or
iii) a lever mechanism where a bent lever which is mounted on a pivot is actuated vertically by the movement of the gearbox and which then reacts the force horizontally against the flywheel.
Furthermore, while in the above embodiment the flywheel is rotatably mounted to the vehicle body or a sub-frame and connected to the gearbox by the spring elements, the flywheel may alternatively be rotatably connected to the gearbox and compliantly connected to the vehicle body or sub-frame. | A mounting system for securing a first component compliantly with respect to a second component has a flywheel mounted rigidly with respect to one of the components and compliantly with respect to the other component for rotation in a plane normal to the direction of movement of the first component towards the second component. One or more spring elements acting between the other component and the flywheel drive the flywheel upon movement of the first component towards the second component. | 8 |
BACKGROUND OF THE INVENTION
This invention relates to a semiconductor device with a substrate in which is contained a first vertical MISFET (Metal Insulator Semiconductor Field Effect Transistor) of a first channel type with a source zone on the substrate surface, a gate zone and a gate electrode whose drain zone is formed by the substrate.
Vertical MISFETS of this type are suited for power applications and have been described in German patent document DE-OS No. 27 03 877, for example. When driven directly, such as by ICs (integrated circuits) they are activated relatively slowly because of their high input capacitance. The switching speed could be increased by external driver circuits, however, such measures involve greater costs.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a semiconductor device of the above mentioned kind so that the switching speed can be increased without additional cost even in response to relatively low input power.
This object and others are realized by providing a semiconductor with the following features:
(a) The substrate contains another vertical MISFET of a first channel type with a source zone on the substrate surface, a gate zone and a gate electrode whose drain zone is formed by the substrate;
(b) the substrate contains a lateral MISFET of a second channel type with a source zone on the substrate surface and a drain zone on the substrate surface;
(c) the source zones of the other vertical MISFET and of the lateral MISFET are electrically connected to each other and to the gate electrode of the first vertical MISFET;
(d) the gate electrodes of the lateral MISFET and of the additional vertical MISFET are electrically connected to each other; and
(e) the drain zone of the lateral MISFET is electrically connected to the source zone of the first vertical MISFET.
Other features and advantages of the invention will be apparent from the following description of the preferred embodiments, and from the claims.
For a full understanding of the present invention, reference should now be made to the following detailed description of the preferred embodiments of the invention and to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an equivalent circuit diagram of a semiconductor arrangement according to a preferred embodiment of the invention.
FIG. 2 shows an integrated circuit layout for a preferred embodiment.
FIG. 3 shows another preferred embodiment of the invention.
FIGS. 4 and 5 are top views of two embodiments in which the components of the semiconductor arrangement are coordinated differently.
DETAILED DESCRIPTION
In the equivalent circuit diagram according to FIG. 1, the power MISFET is marked with reference numeral 1. On the drain side of the MISFET 1 a resistor R representing the bulk resistance of the substrate is shown. Also, on the drain side, a voltage +U is applied to the FET 1 via the resistor R and a load L. At the source side a ground potential is applied, for instance, via the terminal S. In parallel with the MISFET 1 and its bulk resistance R is a series connection consisting of a second MISFET 2 of the same channel type and a third MISFET of an opposite channel type. The MISFETs 1 and 2 are shown as n-channel MISFETs while MISFET 3 is of the p-channel type. The source electrodes of MISFETs 2 and 3 are electrically connected to each other on the one hand and to the gate electrode of MISFET 1 on the other. The gate electrodes of MISFETs 2 and 3 form a pre-amplifier for MISFET 1. The gate/source capacitance C GS of the first MISFET 1 is shown in order to explain the operation of the device. If a signal voltage U.sub. E as shown in FIG. 1 is applied to the gate terminal G, the second FET 2 is biased on and a positive voltage appears at the gate electrode of FET 1. It charges the capactance C GS , and the FET 1 is activated. When the input voltage U E becomes zero again, the gate/source voltage stays positive at first at the FET 1 due to the charge stored in C GS . This causes the potential at the source electrode of FET 3 to become positive relative to its gate potential, and FET 3 begins to conduct. This causes the capactance C GS to discharge quickly, and the FET 1 is blocked.
For purposes of illustration the symbols of FET 1, 2 and 3 are shown in the sectional view of FIG. 2. The semiconductor device is disposed on a substrate comprising, for example, of an n + -doped layer 5 and an n - -doped layer 6. The latter may be an epitaxial layer, for example. Embedded in the surface of layer 6 are two p-conducting zones 7 and 9. The zones 7 and 9 form the drain zone and source zone, respectively, of FET 3. The latter is a lateral p-channel FET. Embedded in the zones 7, 9 are n + -doped zones 8 and 10, respectively. They are the source zones for the first vertical FET 1 and second vertical FET 2, respectively. The zones 7, 9 also form the gate zones for FET 1 and FET 2. This arrangement provides a particularly effective utilization of the semiconductor material. However, the channel zones of the FETs 1 and 2 may also be separated spacially from the source and drain zones of FET 3. The zones 7, 8 and 9, 10 are respectively connected to each other electrically by a contact 16 and 15. Except for the areas where the contacts 15 abnd 16 are located, the surface of the substrate 4 is covered by an insulating layer 11 which may comprise silicon dioxide. Disposed on the layer 11 is a gate electrode 12 which covers part of gate zone 7 located between the source zone 8 and zone 6. The gate electrode 12 is coordinated with the FET 1. Two more gate electrodes 13, 14 are coordinated with the FETs 3 and 2, respectively.
The FET 3 is a p-channel lateral FET while FET 2 and FET 1 are n-channel vertical FETs. The FETs 2 and 3 can be produced simultaneously with FET 1 without additional manufacturing steps by producing the additional zones 9 and 10. To achieve a low channel resistance of FET 3, zones 7 and 9 are arranged close to each other, e.g. 10 to 20, μm. The width of its channel should be as great as possible for the same reason.
The FETs 2 and 3, forming the pre-amplifier of the semiconductor arrangement, are preferably disposed at the edge of the substrate. Such a configuration is shown in FIG. 3. In FIG. 3, parts or elements identical with parts in FIG. 2 have the same reference symbols.
The substrate 4 has a multiplicity of first MISFETs, of which only a few are shown here. They have gate zones 18, 19, into which source zones 20, 21 are embedded. These first MISFETs are paralleled to each other by a metal layer 17. Associated with each first MISFET is a gate electrode 22 of which only one is shown. The gate electrode 22 is electrically connected to additional gate electrodes which may be provided and to the gate electrode 12. All gate electrodes are electrically connected to the zones 9, 10 via the contact 15.
The control electrode 14, located between the vertical MISFET 2 and the edge of the substrate 4, may be located further away from the substrate surface towards the edge rather than over the gate zone 9. This measure, together with a channel stopper 24 situated on the edge and an auxiliary electrode 23 overlapping the gate electrode 14 and electrically insulated from it by the insulating layer 11, serves the purpose of improving the distribution by spreading the edge field strength on the substrate surface.
As shown in FIG. 3, the MISFETs 2, 3 of the input amplifier may be disposed at the edge of the substrate. They may be disposed within an area of the substrate 4 left vacant by the main FET 1, as shown in FIG. 4. But it is also possible to design the pre-amplifier FETs 2, 3 in a ring shape and arrange them between the edge of the substrate 4 and the FET 1. The illustration in FIGS. 4 and 5 is rather simplified and does not take into account the actual fine structure of the FETs 1, 2 and 3.
The invention is useful, for instance, for high-voltage MISFETs of a cut-off voltage starting at e.g. 500 V.
There has thus been shown and described a novel semiconductor device which fulfills all the objects and advantages sought therefor. Many changes, modifications, variations and other uses and applications of the subject invention will, however, become apparent to those skilled in the art after considering the specification and the accompanying drawings which disclose preferred embodiments thereof. All such changes, modifications, variations and other uses and applications which do not depart from the spirit and scope of the invention are deemed to be covered by the invention which is limited only by the claims which follow. | A power FET is preceded by an input amplifier consisting of a second FET of the same channel type and a third FET of an opposite channel type. The FETs of the pre-amplifier can be integrated into the chip of the power FET without additional production steps if the power FET and the second FET are designed as vertical FETs and the third FET as a lateral FET. Through this semiconductor device, the relatively high input capacitance of power MISFETs, which results in slow switching speeds when driven by standard ICs, is overcome. | 7 |
BACKGROUND OF THE INVENTION
The present invention relates to the field of manufacturing semiconductor integrated circuit (IC) devices, and more particularly, to a method of fabricating metal gate complementary metal oxide semiconductor (CMOS) transistors with self-aligned source and drain regions.
In the present state of art, methods for manufacturing CMOS transistors in an integrated circuit which has a polysilicon gate electrode layer usually include a self-alignment technique to form the source and drain electrodes. As such, difficulties due to misalignment are reduced. Unfortunately, prior art self-alignment techniques cannot be utilized to produce a metal gate CMOS transistor. As a result, the channel length of the metal gate CMOS transistor cannot be as precisely defined as is desired. The resulting misalignment results in a larger leakage of current, and the metal gate cannot precisely cover the source region and the drain regions, and therefore the performance of the CMOS is reduced.
SUMMARY OF THE INVENTION
The primary object of the present invention is to provide a method for fabricating a metal gate CMOS transistor, which has the advantage of self-alignment.
Another object of the present invention is to provide a method for fabricating a metal gate CMOS transistor, which has a precise channel length.
Another object of the present invention is to provide a method for fabricating a CMOS transistor with a lower leakage current.
Another object of the present invention is to provide a method for fabricating a CMOS transistor with a higher threshold voltage.
The objects of the present invention are fulfilled by providing a method for fabricating a metal gate MOS transistor of a first conductivity type on an substrate of the first conductivity type. The method comprises the following steps: (a) implanting an impurity of a second conductivity type into a predetermined position of said substrate and driving in, to form a well of the second conductivity type in said substrate; (b) forming a masking layer on the well of the second conductivity type at predetermined positions; (c) forming first field oxides; (d) removing the first field oxides; (e) implanting impurities of the first and second conductivity types into predetermined positions in the well of the second conductivity type by self-alignment using said masking layer as a mask, to form first conductivity type source and drain electrodes of said NMOS transistor and second conductivity type contact regions of the well of the second conductivity type; (f) forming second field oxides; (g) forming a gate oxide and on a predetermined position and vias on predetermined positions of said second field oxides; and (h) forming a metal gate of said MOS transistor of the first conductivity type over said gate oxide and metal contacts of said source and drain electrodes and said second contact region.
BRIEF DESCRIPTION OF THE FIGURES
The present invention will become more fully understood from the detailed description given hereinafter and the accompanying drawings which are given by way of illustration only, and thus are not limitative of the present invention and wherein:
FIGS. 1a to 1g are cross sectional views showing a method of manufacturing a metal gate NMOS transistor on an N type substrate according to the present invention;
FIGS. 2a to 2g are cross sectional views showing a method of manufacturing a metal gate PMOS transistor on an N type substrate according to the present invention;
FIGS. 3a to 3g are cross sectional views showing a method of manufacturing a metal gate PMOS transistor on an P type substrate according to the present invention; and
FIGS. 4a to 4g are cross sectional views showing a method of manufacturing a metal gate NMOS transistor on an P type substrate according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The method is suitable for making a MOS transistor of a first and second conductivity type (such as a NMOS transistor 20 shown in FIG. 1g, or a PMOS transistor 22 shown in FIG. 2g) on a substrate of a first conductivity type (such as the N-type substrate, or a P-type substrate, although an N-type substrate 1 is utilized in the description of the present invention.) The disclosed fabrication method is particularly characterized by the formation of self-aligned source/drain regions and is described below:
FIGS. 1a to 1g show the first preferred embodiment of the present invention, which is applied to an N type substrate 1 to produce a metal gate NMOS transistor. The method is described below:
STEP 1
As shown in FIG. 1a, a P well 10 is formed in an N type substrate 1. This step may be done by various conventional methods well understood by those skilled in this art. For example, a photoresist (not shown in the figures) may be applied over the substrate 1. The predetermined position for the P well in the photoresist is removed by lithography technology. After that, P type impurity is implanted and driven into the substrate, to form the P well 10.
STEP 2
As shown in FIG. 1b, a masking layer 30 is formed on the P well 10 using conventional techniques. This step may be done by various conventional methods well understood by those skilled in the art. For example, a pad oxide 310 may be formed by thermal oxidation or chemical vapor deposition (CVD) with a thickness of about 200 Å to 1 kÅ. Then a nitride layer is deposited with a thickness of about 1 kÅ to 2.5 kÅ. The nitride layer is then patterned by conventional lithography techniques and reactive ion etching (RIE) techniques to form the masking layer 30.
STEP 3
First field oxides 40 are formed between the nitride layer 320 by thermal oxidation to a thickness of 3 kÅ to 10 kÅ, as shown in FIG. 1c.
STEP 4
The first field oxides 40 are removed by conventional etching method using the nitride layer as a mask, as shown in FIG. 1d. Next, P type impurity is implanted into the P well 10 to form P + contact regions 210. N type impurity is implanted into the P well 10 to form N + source and drain electrode regions 200. Both two implantations are done by using the masking layer 30 as a portion of mask. Therefore, the N + source and drain electrode regions 200 and the P + contact regions 210 are formed self-aligned since the thickness of layer 30 is sufficiently thick to stop both of the implantations. In order to implant both P and N type impurities, that two separate masking, patterning and mask removal sequences are used. The masks would be patterned so that their edges land on the tops of masking layer 30. For example, a photoresist layer is coated and patterned. P type and N type impurities are then implanted. At last the photoresist layer is removed.
STEP 5
As shown in FIG. 1e, second field oxides 42 are grown by thermal oxidation to a thickness of 3 kÅ to 10 kÅ. Then the masking layer 30 is removed to expose the underlying P-well 10.
STEP 6
The threshold voltage of the NMOS transistor can be increased, if desired, by implanting P-type impurities, such as boron ions, into the regions A of the P-well 10 which are located between the N + source and drain electrode regions 200 and the P + contact regions 210, as shown in FIG. 1f. Then, gate oxides 50 are formed between the second field oxides 42 and over regions A. This can be done by, for example, thermally growing the gate oxides 50 in a suitable oxidizing atmosphere. Referring again to FIG. 1f, vias 52 are formed in the second field oxides 42 by conventional lithography and etching techniques.
STEP 7
As shown in FIG. 1g, a metal layer, like Al--Si--Cu, is deposited and patterned using conventional techniques to form a metal gate 220 of the NMOS transistor 20, and metal contacts 230 for the N + source and drain electrode regions 200, and metal contacts 240 for the P + contact regions 210. This is done by conventional deposition, lithography, and etching steps that are well understood by those skilled in the art.
Another embodiment of the present invention, which is applied to an N type substrate 1 to produce a metal gate PMOS transistor, is described herein below. For convenience, similar elements are labeled with same numerals as that of the first embodiment.
STEP 1
An N type substrate 1 is prepared as shown in FIG. 2a.
STEP 2
As shown in FIG. 2b, a masking layer 30 is formed on the N type substrate 1 using conventional technique. This step may also be done by various conventional methods understood by those skilled in the field. For example, a pad oxide 310 is firstly formed by thermal oxidation or chemical vapor deposition (CVD) with a thickness of about 200 Å to 1 kÅ. Then a nitride layer is deposited with a thickness of about 1 kÅ to 2.5 kÅ. The nitride layer is then patterned by conventional lithography technique and reactive ion etching (RIE) technique to form the masking layer 30.
STEP 3
First field oxides 40 are formed between the nitride layer by thermal oxidation to a thickness of 3 kÅ to 10 kÅ, as shown in FIG. 2c.
STEP 4
The first field oxides 40 are removed by conventional etching method using the nitride layer as a mask, as shown in FIG. 2d. Next, N type impurity is implanted into the N type substrate 1 to form N + contact regions 210. P type impurity is implanted into the N type substrate 1 to form P + source and drain electrode regions 200. Both two implantations are done by using the masking layer 30 as a portion of mask. Therefore, the P + source and drain electrode regions 200 and the N + contact regions 210 are formed self-aligned since the thickness of layer 30 is sufficiently thick to stop both of the implantations. In order to implant both N and P type impurities, that two separate masking, patterning and mask removal sequences are used. The masks would be patterned so that their edges land on the tops of masking layer 30. For example, a photoresist layer is coated and patterned. N type and P type impurities are then implanted. At last the photoresist layer is removed.
STEP 5
As shown in FIG. 2e, second field oxides 42 are grown by thermal oxidation to a thickness of 3 kÅ to 10 kÅ. Then the masking layer 30 is removed to expose the underlying N type substrate 1.
STEP 6
The threshold voltage of the PMOS transistor can be increased, if desired, by implanting N-type impurities, such as phosphorous ions, into the regions B of the N type substrate 1 which are located between the P + source and drain electrode regions 200 and the N + contact regions 210, as shown in FIG. 2f. Then, gate oxides 50 are formed between the second field oxides 42 and over regions B. This can be done by, for example, thermally growing the gate oxides 50 in a suitable oxidizing atmosphere. Referring again to FIG. 2f, vias 52 are formed in the second field oxides 42 by conventional lithography and etching techniques.
STEP 7
As shown in FIG. 2g, a metal layer, like Al--Si--Cu, is deposited and patterned using conventional techniques to form a metal gate 220 of the PMOS transistor 20, and metal contacts 230 of the P + source and drain electrode regions 200, and metal contacts 240 of the N + contact regions 210. This is done by conventional deposition, lithography, and etching steps that are well understood by those in the art.
The above stated processes for producing NMOS transistors and PMOS transistors may be applied at the same time to produce a complete CMOS transistor. Since the combination is apparent to those skilled in the art, the details are not further discussed.
Although not described in detail, it is apparent that the methods can be applied to a P type substrate to produce a metal gate PMOS transistor as shown in FIGS. 3a to 3g. Another embodiment to produce a metal gate NMOS on a P type substrate is shown in FIGS. 4a to 4g.
As stated above, the NMOS and PMOS transistors made according to the present invention are produced with their source and drain electrode regions being self-aligned. Therefore the channel length can be precisely defined. Moreover, the source and drain regions can be precisely isolated from the contact regions, so that the current leakage of the transistor can be reduced. In addition, since the concentration of impurities in the substrate can be increased by implantation, the breakdown voltage can be increased.
While the invention has been described by way of examples and in terms of several preferred embodiments, it is to be understood that the invention need not be limited to the disclosed embodiment. On the contrary, it is intended to cover various modifications and similar arrangements included within the spirit and scope of the appended claims, the scope of which should be accorded the broadest interpretation so as to encompass all such modifications and similar structures. | A method for manufacturing a CMOS transistor of integrated circuits having metal gates and self-aligned source and drain electrodes. The channel length can be precisely defined, and the leakage current can be reduced. Furthermore, the threshold voltage of the transistor can be increased by implanting impurities into the well or the substrate. | 7 |
BACKGROUND
The invention relates to a control valve for influencing the pressurization of a camshaft adjuster of an internal combustion engine with pressurized medium according to the preamble of Claim 1 and Claim 3 . The invention further relates to a control valve according to the preamble of Claim 6 .
From the non-published patent applications DE 10 2004 038 160.7 and also DE 10 2005 037 480.8 by the applicant, a control valve for influencing the pressurization of a camshaft adjuster of an internal combustion engine with pressurized medium is known, in which a control piston can move axially in a pocket borehole of a valve housing. The control valve has a pressurized medium connection, two tank connections, and two work connections, which are allocated to working chambers acting against each other in a hydraulic camshaft adjuster. In one axial position of the control piston in the control valve, a first working connection is connected to a tank connection and a second working connection is connected to the pressurized medium connection, so that an adjustment movement of the camshaft adjuster can be brought about, in which the working chamber allocated to the second working connection increases its volume. In another axial position of the control piston, the second working connection is connected to a tank connection and the first working connection is connected to the pressurized medium connection, so that an opposite adjustment movement can be brought about, in which the working chamber allocated to the first working connection increases its volume. For changing the axial position of the control piston, this has a pressure part, on which an actuator acts for bringing about a displacement of the control piston. From production reasons, the pressure part is formed separate from the control piston and embedded in the valve housing with an outer casing surface in the region of an inner casing surface of an end-face recess of the valve housing.
SUMMARY
The invention is based on the object of providing a control valve with an improved integrated pressure part.
According to the invention, the objective of the invention is met by the features of the independent Claim 1 . An alternative solution to meeting the objective forming the basis of the invention is given by the features of Claim 3 . The solution forming the basis of the invention is further provided by the features of Claim 6 . Additional constructions of the invention emerge from the dependent Claims 2 , 4 , 5 , and 7 to 9 .
The present invention is based on the knowledge that, for a positive-fit and/or friction-fit connection of a pressure part to a control piston, radially oriented contact forces are generated between the pressure part and the control piston, wherein these contact forces involve a radially elastic and/or plastic deformation of the pressure part and/or the control piston and are generated while being embedded, for example, with an over-dimensioning of the outer casing surface of the pressure part relative to the inner casing surface of the control piston, especially with simultaneous heating. The control piston moves in a guide borehole formed by a pocket borehole of the valve housing. For guaranteeing
the effect of control edges of the control piston, good fixing of the control piston in the valve housing, and easy movement of the control piston without the control piston seizing in the valve housing,
it is necessary that the diameters of the outer casing surface of the control piston and the guide borehole of the valve housing be constructed with a fit. With respect to the setting of the diameter
of the outer casing surface of the pressure part, of the inner casing surface of the control piston, and of the outer casing surface of the control piston,
the geometries of the previously mentioned components as well as the embedding processes are to be optimized, which leads, under some circumstances, to a conflict in objectives:
on one hand, a fixed connection of the pressure part shall be achieved with the control piston, which requires rather large contact forces between the pressure part and control piston. on the other hand, a small expansion of the outer casing surface should be given due to the embedding, which requires rather small contact forces between the pressure part and control piston.
The above optimization can be made more difficult under some circumstances in such a way that a requirement on a given, tight fit range between the control piston and valve housing requires, for given material properties of the pressure part and control piston, especially for given stiffness, a tight tolerance for the production of the diameter of the outer casing surface of the pressure part and also the inner casing surface of the control piston.
As an aid, the invention proposes that at least one casing surface of the pressure part and/or the control piston forming a contact face has a partial region, which has a reduced stiffness relative to deformation in the radial direction than another partial region of the casing surface, in the contact area between the pressure part and the control piston. This possibly leads to the following advantages:
The partial regions with reduced stiffness can reduce the stiffness in partial regions of the periphery, by which tolerance-dependent deviations in the production of the involved contact geometries lead to a smaller change of the generated contact forces. In this way, the connection produced by the embedding process between the pressure part and the control piston becomes less dependent on the production tolerances. On the other hand, this construction of the invention is based on the knowledge that for a contact between two cylindrical casing surfaces, the contact force is not distributed constantly over the entire periphery. According to the invention, targeted smaller contact surfaces can be given in the partial regions of reduced stiffness, while in the other partial regions, targeted contact regions of greater contact forces can be provided. Furthermore, by setting the dimensions of the partial regions of the reduced stiffness as well as the selection of the stiffness, for example, by the material selection in the partial regions, the necessary joining force is structurally provided for embedding the pressure part into the control piston. Through the use of partial regions of reduced stiffness, the radial forces in the contact region between the pressure part and control piston can be reduced, indeed, also for the selection of a relatively stiff base material for the pressure part and/or control piston. This leads, under some circumstances, to a reduced expansion of the control piston in the embedding region.
The partial regions with reduced stiffness can be constructed with a softer, more pliable material than the partial regions of the other partial regions. According to a preferred construction of the invention, the partial regions with reduced stiffness are formed with radial recesses. Such radial recesses can involve, for example, radial boreholes or grooves running in the axial direction or spiral grooves. The recesses thus form partial regions with zero stiffness, so that contact forces between the outer casing surface of the control piston and the inner guide surface of the valve housing are formed only in the partial regions lying apart from the recesses.
The recesses can be formed radially outwardly in the control piston or else radially inwardly in the outer casing surface of the pressure part, wherein the recesses can be formed immediately during production or at a later time, for example, by a cutting production method, such as milling or boring. For the case that recesses are formed both in the control piston and also in the pressure part, these can transition into each other in the radial direction or else can be offset relative to each other in the radial and/or axial direction.
Through a structural setting of the extent B of the recesses in the peripheral direction, in a simple way the magnitude of the joining forces can be set. It is also conceivable that the extent of the recesses in the peripheral direction varies in the axial direction, by which a variation of the contact forces and the elastic expansion of the control piston in the axial direction or, for example, an increase of the joining force with increasing insertion of the pressure part into the control piston can be set.
Preferably, the radial recesses have a multifunctional construction: in addition to the setting of the joining and pressing forces, the radial recesses can be used, in particular, for the case that these are formed continuous over the entire length of the pressure part or start from the end side of the pressure part, as channels, which connect an inner space or pressure space of the control piston with the outside of the control piston, in particular, with the end face allocated to the pressure part. For example, the inner space of the piston can be vented via the recesses. Alternatively or cumulatively, it is possible that the pressurized medium arranged in the interior is discharged through the channels formed with the radial recesses in the region of the end side of the control piston. For example, in the region of the end side, an electromagnetic actuator can be provided with a magnetic pin and suitable mounting, as well as an armature interior. In this case, the pressurized medium communicates via the radial recesses with the actuator, in particular, the armature interior, for exchanging the pressurized medium for lubrication purposes and for heat dissipation. Furthermore, such a pressurized medium flow is used for lubricating a magnetic mounting and/or for reducing the friction between the pressure part and the magnetic pin acting on the pressure part.
The interior of the control piston can be vented in this case in such a way that the pressurized medium passing through the recesses is fed from the interior of the control piston into an unpressurized intermediate space between the actuator and the pressure part and can flow from there into a motor sump. Through rotation of the control valve during operation, air in the pressurized medium can be separated and can also be discharged via the radial recesses.
Another alternative or cumulative solution according to the invention provides play in the embedding region of the pressure part between an outer casing surface of the control piston and a guide borehole of the valve housing. This construction of the invention takes into account the fact that the embedding the pressure part causes a more or less large radial increase in the allocated embedding region of the control piston, so that in each case the fit between the control piston and the valve housing is changed. This is especially disadvantageous when the outer casing surface of the control piston in the embedding region of the pressure part forms a guide surface, which contacts the guide borehole of the valve housing during the axial movement of the control piston and, under some circumstances, should also fulfill a sealing function. According to the invention, this guide surface is displaced away from the embedding region of the pressure part. Instead, in the embedding region of the pressure part between the control piston and the valve housing, there is play, so that the control piston does not come into contact with the guide borehole of the valve housing in the embedding region even for radial expansion of the control piston due to the embedding of the pressure part. In this way, seizing of the control piston in the guide borehole can be reliably prevented, under some circumstances, also independent of any tolerances in the production of the pressure part and/or control piston and/or guide borehole.
For the case that the guide borehole is constructed as a continuous pocket borehole with constant diameter, especially in the axial region covered by the embedding region in the course of the axial movement, the play named above can be easily generated in such a way that the outer casing surface of the control piston has a region of reduced diameter, which transitions, for example, over a cross-sectional extension into a guide surface, in the embedding region of the pressure part.
An alternative or cumulative solution of the problem forming the basis of the invention is given by the features of Claim 6 . Accordingly, the pressure part has a hardened surface at least in the region of an end face facing the actuator. For such a construction, it is not necessary, in particular, that the entire control piston is subjected to a hardening process, which takes into account the bonding or the contact between the actuator and the pressure part. For the case that such hardening is performed for the entire control valve, this could lead to warping of the control piston, which could also have disadvantageous effects on the formation of the contact surfaces between the pressure part and the control piston on one hand and also the control piston and the valve housing on the other hand. Instead, according to the invention the pressure part could be hardened separately from the control piston. Hardening could also be performed taking advantage of the residual carbon content of the pressure part, in that the pressure parts are inserted into a hardening bath. For example, pressure parts for several control valves could also be inserted together in one hardening bath.
According to another construction of the invention, the surface is hardened in the contact region between the pressure part and the actuator by a deep-drawing process. The use of a deep-drawing process is preferred especially for an approximately pot-shaped construction of the pressure part with a U-shaped longitudinal section of the pressure part.
An increase in the production accuracy can be achieved advantageously in such a way that a calibration stage is then used at a deep-drawing processing step, for which the pressure part is then pressed into a mold in the deep-drawing processing step, in which the final dimensions of the pressure part are at least approximated.
Alternatively or additionally, the hardened surface can be hardened under the use of a heat treatment.
Advantageous refinements 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 and these do not absolutely have to be achieved 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 relative to each other and also their relative arrangement and active connection. The combination of features of different embodiments of the invention or of features of different claims is also possible deviating from the selected references of the claims and is herewith suggested. This also relates to those features, which are shown in separate drawings or which 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 is a longitudinal section view of a control valve for controlling a hydraulic camshaft adjuster with a pressure part embedded in the control piston and a valve housing,
FIG. 2 is a longitudinal section view of a first construction according to the invention of a connection of a pressure part with a control piston,
FIG. 3 is a view of the connection of the pressure part with the control piston according to FIG. 2 for taken in a direction from an actuator of the control valve,
FIG. 4 is a longitudinal section view of a second construction according to the invention of a connection of a pressure part with a control piston,
FIG. 5 is a view of the connection between the pressure part and control piston according to FIG. 4 taken from an actuator of the control valve,
FIG. 6 is a longitudinal section view of another construction according to the invention of a control piston with pressure part embedded in this piston,
FIG. 7 is a view of the control piston with pressure part embedded in this piston from a direction of an actuator of the control valve.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A camshaft adjuster, as described in the not previously published state of the art named above, for example, typically has a stator and a rotor, wherein a drive wheel is locked in rotation with the stator. The stator is mounted rotatable relative to the rotor, wherein the stator has several recesses spaced apart from each other in the peripheral direction. The recesses are separated by vanes extending radially from the rotor into two pressure chambers, wherein a change in the pressure relationships in opposing pressure chambers is associated with an adjustment movement of the camshaft adjuster.
The pressure chambers are each connected via suitable supply lines to a working connection 1 , 2 of a control valve 3 . The control valve 3 has a control piston 5 that can move axially in a valve housing 4 . For generating an adjustment movement of the camshaft adjuster, the working connections 1 , 2 can be connected to a pressurized medium connection 6 or a tank connection 7 according to the axial position of the control piston 5 in the valve housing 4 . The control valve 3 is preferably integrated in a central, axial recess of the rotor of the camshaft adjuster.
With respect to other constructions of the control valve as well as their integration into a camshaft adjuster, refer to the not previously published patent applications by the applicant noted above.
According to FIG. 1 , the control piston 5 has an approximately U-shaped construction in the longitudinal section with a base leg 8 and two side legs 9 , 10 . Inside of the control piston 5 an interior 11 is formed, which is limited by the legs 8 , 9 , 10 and also a pressure part 12 embedded between the side legs 9 , 10 opposite the base leg. The pressure part 12 is embedded in an embedding region 13 through the formation of a radial contact force in the control piston 5 . In the embedding region 13 , the pressure part 12 has an outer, cylindrical casing surface 14 and the control piston 5 has an inner, cylindrical casing surface 15 , wherein the casing surfaces 14 , 15 form an interference fit.
The pressure part 12 has a U-shaped longitudinal section with a base leg 16 and two side legs 17 , 18 . The U-shaped longitudinal sections of the control piston 5 and the pressure part 12 are inserted one inside the other with an opposite orientation sense. The length of the side legs 17 , 18 corresponds to the extent of the embedding region 13 in the axial direction.
According to FIG. 2 , the control piston 5 has coaxial guide surfaces 19 , 20 , 21 , 22 , which are spaced apart from each other axially, wherein the guide surface 22 allocated closest to the end side 27 of the control piston 5 allocated to the pressure part 12 extends in the embedding region 13 and projects past this region according to FIG. 2 .
According to FIG. 3 , the control piston 5 provides recesses 23 , 24 , 25 , 26 oriented radially outwards and distributed uniformly in the peripheral direction. The recesses 23 to 26 extend like grooves starting from the end side 27 over the entire embedding region 13 with a projection 28 past the pressure part 12 in the axial direction. The recesses 23 to 26 have an approximately U-shaped construction in the cross section shown in FIG. 3 with a groove base 29 as well as two parallel borders 30 , 31 oriented approximately radially. In the region of the projection 28 , the recesses 23 to 26 form openings 32 , which create a pressurized medium connection between the interior 11 and the recesses 23 - 26 . The pressure part 12 can have a cylindrical, outer casing surface 14 without a recess. For the embodiment shown in FIG. 3 , it can be seen that the pressure part 12 also has recesses 33 , 34 , 35 , 36 oriented radially inwardly, which extend in the area of the recesses 23 to 26 , by which channels are formed with approximately rectangular cross section. With the embedding of the pressure part 12 in the control piston 5 ,
partial regions 37 are given, which contact the casing surface 14 of the pressure part 12 under formation of a contact force at the casing surface 15 of the control piston 5 , and also partial regions 38 are given, which are arranged in the peripheral direction between the partial regions 37 and in the region of which the pressure part 12 and the control piston 5 do not contact each other in the radial direction, but instead in which the pressure part 12 and control piston 5 have channels.
For the embodiment shown in FIGS. 4 and 5 , the control piston 5 has no recesses 23 to 26 . The recesses 33 to 36 of the pressure part 12 are constructed with a depth that is increased relative to the embodiment according to FIGS. 2 and 3 in such a way that these extend completely through the side legs 17 , 18 , so that the pressure part 12 is not circular in the region of the side legs 17 , 18 , but instead provided merely with “fingers” 39 extending between the recesses 36 to 33 into the partial regions 37 . Due to the increased depth of the recesses 33 to 36 , the recesses 33 to 36 form, in the region of the end side 27 , openings 40 , 41 , 42 , 43 , in the region of which a direct pressurized medium connection is given between the interior 11 and the surrounding 44 of the end side 27 of the control piston 5 .
The surrounding 44 involves, in particular, a contact surface between the pressure part and an actuator not shown in the figures, under some circumstances with a pressurized medium connection with a motor sump and/or additional components, lubricating positions, or cooling positions of the actuator.
For the embodiment shown in FIGS. 6 and 7 , the outer casing surface of the control piston 5 in the region of the end side 27 allocated to the pressure part 12 has a partial region 47 with cylindrical casing surface, which is advanced relative to the guide surface 22 with a shoulder 45 with a cross-sectional reduction 46 in the direction of the end side 27 . For the control piston 5 inserted into the valve housing, a radially surrounding gap 49 , whose size corresponds to the cross-sectional reduction 46 , is formed between an inner casing surface 48 of the valve housing 4 and the partial region 47 . In the partial region 47 , to prevent a contact between the control piston 5 and valve housing 4 , the cross-sectional reduction 46 is suitable structurally, in order to take into account the expected expansion of the control piston 5 due to the embedding of the pressure part 12 . This means, e.g., that for an increase of the setting of the covering of the press connection, the cross-sectional reduction 46 must have an increased construction.
The length x of the partial region 47 is to be adapted to the region, in which a cross-sectional expansion of the control piston 5 is expected due to the embedding of the pressure part 12 . For the embodiment shown in FIGS. 6 and 7 , x is smaller than the embedding region 13 , so that the embedding region 13 extends approximately up to the middle of the guide region 22 .
The end side 27 of the pressure part 12 has a contact surface 50 , in the region of which an actuator, especially a magnetic pin or a tappet of the actuator, acts on the pressure part 12 , in order to move the control piston 5 axially in the valve housing 4 . For preventing wear of the pressure part 12 in the region of the contact surface 50 , the contact surface 50 , the end side 27 of the pressure part 12 , or the surface of the entire pressure part 12 can be hardened.
Such hardening can be performed, on one hand, by deep-drawing production with a subsequent calibration stage and, on the other hand, by a corresponding heat treatment of the pressure part 12 . Such hardening is thus realized only for the pressure part 12 , by which a separate treatment of the entire control piston 5 is prevented for guaranteeing a fatigue endurable contact surface.
Through the use of the recesses 23 to 26 and also 33 to 36 , the interior 11 can be vented and/or sufficient leakage volume flow for supplying a mounting of an actuator, for example, a mounting of a magnet, with pressurized medium can be guaranteed.
The recesses 23 to 26 and 33 to 36 represent a partial reduction of the joint diameter, by which the contact and pressing forces can be influenced. As a whole, through the measures according to the invention, the production of the control piston 5 with the pressure part 12 can be simplified. The width B of the recesses 23 to 26 and 33 to 36 , that is, in particular, the width of the groove base 29 , can be suitable structurally and varied, in order to influence the magnitude of the necessary joining forces and the retaining forces in the connection. The goal in the setting of the width B is to avoid an expansion of the control piston 5 in the embedding region 13 , in order to avoid seizing of the control piston 5 in the valve housing 4 .
In the embedding region 13 , the control piston 15 has an outer casing surface 51 .
LIST OF REFERENCE SYMBOLS
1 Working connection
2 Working connection
3 Control valve
4 Valve housing
5 Control piston
6 Pressurized medium connection
7 Tank connection
8 Base leg
9 , 10 Side leg
11 Interior
12 Pressure part
13 Embedding region
14 , 15 Casing surface
16 Base leg
17 , 18 Side leg
19 - 22 Guide surface
23 - 26 Recess
27 End side
28 Projection
29 Base groove
30 , 31 Boundary
32 Opening
33 - 36 Recess
37 , 38 Partial region
39 Finger
40 - 43 Opening
44 Surrounding
45 Shoulder
46 Cross-sectional reduction
47 Partial region
48 Casing surface
49 Gap
50 Contact surface
51 Casing surface | A control valve for a hydraulic adjuster for the camshaft of an internal combustion engine is provided, wherein an actuator acts on a pressure part ( 12 ) embedded in a control piston ( 5 ). In order to prevent the piston ( 5 ) from being blocked in the valve housing by the expansion thereof caused by the pressure part embedment, the pressure part ( 12 ) and/or the control piston ( 5 ) is/are provided with radial recesses ( 34 ) in the embedment area ( 13 ) which make it possible to limit joining forces and the resulting radial expansion of the piston ( 5 ). Alternatively or in addition, the external surface of the control valve ( 5 ) has a reduced cross-section in the embedment area ( 13 ). | 5 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of Invention
[0002] The present invention relates to a mesh, and more particularly to a multilayer mesh structure for upholstery or shoes.
[0003] 2. Description of the Related Art
[0004] Conventional materials for a mattress or a seat pad, such as plastic foam, dry grasses, coconut shell fibers or the like, are either non-breathable or water permeable, they are also prone to mold.
[0005] A shoe has a sole and the sole is used to enhance a breathability and elasticity of a shoe. Unfortunately, conventional materials for the sole of a shoe are heavy or water permeable.
[0006] The present invention provides a multilayer mesh structure to obviate or mitigate the shortcomings of the conventional materials for upholstery and shoes.
SUMMARY OF THE INVENTION
[0007] The primary objective of the present invention is to provide a multilayer mesh structure that is elastic, breathable and covered by a mildew growth-preventing film, suitable for shoes or upholstery.
[0008] The multilayer mesh structure has multiple mesh layers being stacked on each other, and may have a woven sheet and a covering layer. Each mesh has multiple primary and secondary fibers. The secondary fibers are mounted crossing over and connecting to the primary fibers at multiple bonded intersections to form the mesh. The woven sheet is formed on a surface of the mesh and may be a natural or man-made fiber (such as rayon, nylon cotton or linen fibers) woven sheet. The covering layer is a film material to enclose and hold the multiple mesh layers.
[0009] Other objectives, advantages and novel features of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a perspective view of a multilayer mesh structure in accordance with the present invention;
[0011] FIG. 2 is an exploded perspective view of a first embodiment of the multilayer mesh structure in FIG. 1 ;
[0012] FIG. 3 is an enlarged perspective view of a mesh layer in FIG. 1 ;
[0013] FIG. 4 is a perspective view of a second embodiment of the multilayer mesh structure in accordance with the present invention;
[0014] FIG. 5 is an exploded perspective view of the multilayer mesh structure in FIG. 4 ;
[0015] FIG. 6 is an enlarged perspective view of a mesh in FIG. 4 ;
[0016] FIG. 7 is a perspective view of a third embodiment of the multilayer mesh structure in accordance with the present invention;
[0017] FIG. 8 is an enlarged perspective view of a mesh layer in FIG. 7 ;
[0018] FIG. 9 is a perspective view of a fourth embodiment of the multilayer mesh structure in accordance with the present invention;
[0019] FIG. 10 is an exploded perspective view of the multilayer mesh structure in FIG. 9 ;
[0020] FIG. 11 is a perspective view of the multilayer mesh structure with a covering in accordance with the present invention;
[0021] FIG. 12 is a perspective view of the multilayer mesh structure with an assistant layer in accordance with the present invention;
[0022] FIG. 13 is a cross-sectional view of two enhanced multilayer mesh structures applied on a shoe;
[0023] FIG. 14A is an exploded perspective view of one of the enhanced multilayer mesh structures in FIG. 13 ;
[0024] FIG. 14B is an enlarged perspective view of a woven sheet in FIG. 14A ;
[0025] FIG. 15 is a perspective view of the enhanced multilayer mesh structures in FIG. 14A ;
[0026] FIG. 16 is an exploded perspective view of the other one of the enhanced multilayer mesh structures in FIG. 13 ; and
[0027] FIG. 17 is a perspective view of the enhanced multilayer mesh structure in FIG. 16 .
DETAILED DESCRIPTION OF THE INVENTION
[0028] With reference to FIGS. 1 , 4 , 7 , 9 , 12 , 14 A, 15 and 16 , a multilayer mesh structure ( 1 , 1 A, 1 B, 1 C, 1 D, 1 E) in accordance with the present invention comprises multiple mesh layers ( 10 , 10 A, 10 B), an optional covering layer ( 20 ), an optional assistant layer ( 30 ), and an optional woven sheet ( 13 ).
[0029] The mesh layers ( 10 , 10 A, 10 B) are non-woven, are stacked on top of each other, may be elastic, breathable and have a mildew growth-preventing film, may be thermoplastic elastomer or plastic materials made such as polyethylene (PE), ethylene-vinyl acetate copolymer (EVA), thermoplastic elastomer (TPE) thermal plastic rubber (TPR) or the like. Each mesh layer ( 10 , 10 A, 10 B) may be bonded to adjacent mesh layers by sewing or adhesion such as thermal adhesion, super sonic adhesion or the like. Each mesh layer ( 10 , 10 A, 10 B) has two surfaces, multiple primary fibers ( 11 , 11 A), multiple secondary fibers ( 12 , 12 A) and multiple breathing holes formed between the primary and secondary fibers ( 11 , 11 A, 12 , 12 A). The breathing holes may be uniform in each of the multiple mesh layers ( 10 , 10 A, 10 B)
[0030] The primary fibers ( 11 , 11 A) are mounted substantially parallel to each other, are extruded to have at least one regular cross section that may be circular, quadrangular, hexagonal, rectangular or the like and have at least one thickness.
[0031] The secondary fibers ( 12 ) are mounted substantially parallel with each other, cross the primary fibers ( 11 ) at bonded intersections to form the mesh layer ( 10 , 10 A, 10 B) and are extruded to form at least one regular cross section that may be circular, quadrangular, hexagonal, rectangular or the like and have at least one thickness.
[0032] The multiple mesh layers ( 10 , 10 A, 10 B) are stacked on top of each other to form a multilayer mesh structure ( 1 , 1 A, 1 B, 1 C, 1 D, 1 E) having two surfaces and two surface mesh layers respectively closest to each surface and at least one middle mesh layer.
[0033] With further reference to FIG. 11 , the covering layer ( 20 ) is a film to enclose the multiple stacked mesh layers ( 10 , 10 A, 10 B), to allow the multilayer mesh structure ( 1 , 1 A, 1 B, 1 C) to be implemented as upholstery such as a cushion, mattress or the like.
[0034] The assistant layer ( 30 ) may be a plastic foam, silicon foam or the like, is soft and resilient and is bonded adjacent to at least one multilayer mesh structure ( 1 , 1 A, 1 B, 1 C), and may be bonded between two multilayer mesh structures ( 1 , 1 A, 1 B, 1 C) inside the covering layer ( 20 ) to further increase comfort of the upholstery.
[0035] With further reference to FIG. 14B , the woven sheet ( 13 ) may be natural or man-made fibers (such as rayon, nylon cotton or linen fibers) woven together to form a sheet, and is mounted on one of the surfaces of the multilayer mesh structure ( 1 D, 1 E).
[0036] With further reference to FIGS. 2 , and 3 , in a first embodiment of the present invention, the multilayer mesh structure ( 1 ) has six stacked mesh layers ( 10 ) wherein, the thickness of the primary and secondary fibers ( 11 , 12 ) of each mesh layer is progressively reduced from one surface mesh layer ( 10 ) to the other surface mesh structure ( 10 ), so the multiple breathing holes are also progressively reduced from large to small and the primary and secondary fibers ( 12 ) are circular in cross-section.
[0037] With further reference to FIGS. 5 , and 6 , in a second embodiment of the present invention, the multilayer mesh structure ( 1 A) has four stacked mesh layers ( 10 A) wherein, the cross-section of the primary fibers ( 11 ) and secondary fibers ( 12 ) are rectangles.
[0038] With reference to FIG. 8 , in a third embodiment of the present invention, the multilayer mesh structure ( 1 B) has four mesh layers ( 10 B) wherein, each mesh layer ( 1 B) has alternatively arranged primary fibers ( 11 , 11 A) respectively having circular and rectangular cross sections and alternatively arranged secondary fibers ( 12 , 12 A) respectively having circular and rectangular cross sections.
[0039] With further reference to FIGS. 9 and 10 , in a fourth embodiment of the present invention, the multilayer mesh structure ( 1 C) has six mesh layers ( 10 , 10 A, 10 B), wherein, the cross-section of the primary and secondary fibers ( 11 , 12 ) of one surface mesh layer ( 10 ) and the mesh layer ( 10 ) adjacent to the surface mesh layer ( 10 ) are circles, the cross-sections of the primary and secondary fibers ( 11 , 12 ) of two middle mesh layers ( 10 A) are rectangles, and the other surface mesh layer ( 10 B) and the mesh layer ( 10 B) adjacent to the other surface mesh layer have alternatively arranged primary and secondary fibers ( 12 , 12 A) respectively having circular and quadrangular cross sections.
[0040] With further reference to FIGS. 13 and 17 the multilayer mesh structure ( 1 D, 1 E) may be implemented in a shoe ( 40 ). The shoe ( 40 ) has an outer upper ( 41 ), an inner upper ( 42 ), an outsole ( 43 ), a sole cushion ( 44 ) and innersole ( 45 ).
[0041] The outer upper ( 41 ) corresponds to a foot and has an inner surface and a connecting edge.
[0042] The inner upper ( 42 ) corresponds to the outer upper ( 41 ), is formed on the inner surface of the outer sheet ( 41 ), has a connecting edge and comprises the multilayer mesh structure ( 1 D). The multilayer mesh structure ( 1 D) has three stacked mesh layers ( 10 ) and one woven sheet ( 13 ), wherein breathing holes formed between the primary and secondary fibers ( 11 , 12 ) of the three mesh layers ( 10 ) are progressively decreased in size. The woven sheet ( 13 ) is attached to the mesh layer ( 10 ) having smaller breathing holes.
[0043] The outsole ( 43 ) is shaped corresponding to a sole of a foot and attached to the connecting edge of the uppers ( 41 , 42 ).
[0044] The sole cushion ( 44 ) corresponds to and is formed on the outsole ( 43 ).
[0045] The innersole ( 45 ) corresponds to and is formed on the sole cushion ( 44 ) and comprises the multilayer mesh structure ( 1 E). The multiple mesh structure ( 1 E) has three stacked mesh layers ( 10 ) and one woven sheet ( 13 ), wherein, the breathing holes formed between the primary and secondary fibers ( 11 , 12 ) of the three mesh layers ( 10 ) are gradually reduced from outside to in. The woven sheet ( 13 ) is attached to the mesh ( 10 ) having smaller holes between weft and warp than the breathing holes and is larger than the multilayer mesh structure ( 1 E) to cover and hold the multilayer mesh structure ( 1 E) in place.
[0046] Even though numerous characteristics and advantages of the present invention have been set forth in the foregoing description, together with details of the structure and function of the invention, the disclosure is illustrative only. Changes may be made in detail, especially in matters of shape, size and arrangement of parts within the principles of the invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed. | A multilayer mesh structure has multiple mesh layers being stacked on each other, and may have a woven sheet and a covering layer. Each mesh has multiple primary and secondary fibers. The secondary fibers are mounted crossing over and connecting to the primary fibers at multiple bonded intersections to form the mesh. The woven sheet is formed on a surface of the mesh and may be a natural or man-made fiber (such as rayon, nylon cotton or linen fibers) woven sheet. The covering layer is a film material to enclose and hold the multiple mesh layers. When the multilayer mesh structure is used as a shoe-pad or the like, the multilayer mesh structure provides a shoe with the shoe-pad better air permeability and elasticity. | 3 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an automatic tool changing device for a machine tool.
[0003] 2. Description of the Related Art
[0004] In case that a tool is changed, machining accuracy on a workpiece is maintained by properly fitting a tool holder onto the spindle of a machine tool. Occasionally, however, the tool holder may not be fitted to the spindle properly because of foreign matter, such as swarf, adhered to contact surfaces of the spindle and the tool holder, which affects the machining accuracy. For this reason, there has been employed a method of cleaning a surface of a taper hole of the spindle and/or a tapered portion of the tool holder as the contact surface is cleaned by removing the swarf and the like using fluid, such as air in an operation of a tool change.
[0005] There is a known method in which an air nozzle is opened in the taper hole of the spindle to which the tapered portion of the tool holder is fitted. When the tool holder is detached from the taper hole of the spindle or when a new tool is fitted to the spindle, the pressurized air is supplied from an air supply onto the contact surfaces of the tool holder and the spindle taper hole through an air hole and the air nozzle that are provided to the spindle. Thus, swarf and the like adhered to the tapered portions of the contact surfaces of the tool holder and the spindle is removed and cleaned up by the air (see JP 52-49579B, JP 47-46705B and JP 2503170B).
[0006] The cleaning methods as described in the above publications, however, require an air passage to be provided to the spindle to blow air out from the spindle taper hole provided thereto through the air passage. The necessity for forming the air passage in the spindle complicates fabrication of the spindle.
[0007] There is another known method in which the operation similar to the tool change is performed, and a cleaning tool, such as a brush, held by a tool changing arm is pressed towards the spindle taper hole to clean the spindle taper hole (see JP 9-29577A). In this method using the extra cleaning tool, such extra leaning tool needs to be prepared. At the same time, it is also required to carry out the cleaning operation by pressing the cleaning tool towards the spindle taper hole at the time of tool change, and thereafter to exchange a new tool with the cleaning tool on the tool changing arm. This entails an additional cleaning operation for each the tool change operation, so that it accordingly takes a long time to complete the tool change, thereby lowering operation efficiency.
[0008] There is known a tool changing device in which an air passage is formed in a tool holder with an air discharge opening on a contact surface of the tool holder to be in contact with a spindle taper hole, and a tool changing arm is provided with tool gripping sections in a twin form from JP 3203598B. At the time of tool change, a tool holder attached to the spindle and a tool holder attached to a magazine pot are gripped by the two tool-gripping sections of the exchange arm. When the tool holder is held by the tool gripping section, an air passage formed at the tool changing arm and the air passage of the tool holder communicates with each other to flow air. After starting of pulling out the tool holder, the air blows out from a gap between the spindle taper hole and the tapered portion of the tool holder and sweeps away dust to clean. The magazine pot is cleaned up in the same manner. When a new tool holder is to be attached to the spindle, the cleaning is carried out in a similar way. The cleaning method described in this document requires an air passage formed in the tool holder, which makes the tool holder costly. Furthermore, since the existing tool holders have no air passage, the aforementioned method cannot be applied to the tool change using existing tool holders.
[0009] In addition, there is known an automatic tool changing device in which tool allocating means allocates a tool holder to be attached to the spindle among a plurality of tool holders held by a turret by rotating the turret by transmitting rotation of the spindle to the turret through a speed reducer, and the tool holder is fitted to a tapered hole of the spindle using up-and-down motion of a spindle head, as disclosed in JP 2535479B.
SUMMARY OF THE INVENTION
[0010] The present invention provides an improvement in an automatic tool changing device as disclosed in JP 2535479B, which has tool allocating means for allocating a tool utilizing rotation of a spindle, to clean a contact face of the spindle to be in contact with a tool holder with a simple structure.
[0011] An automatic tool changing device of the present invention comprises: tool allocating means for allocating a tool holder to be attached to the spindle among a plurality of tool holders by utilizing a rotation of the spindle; and fluid spouting means for spouting fluid toward a contact surface of the spindle to be in contact with the tool holder from outside of the spindle while the tool allocating means is allocating the tool holder so as to clean the contact surface of the spindle entirely.
[0012] The spindle is rotated during the allocation of the tool by the tool allocating means, so that the fluid spouted from the fluid spouting means flushes and cleans the whole of the contact surface of the spindle.
[0013] The tool allocating means may allocate no tool holder and the fluid spouting means may spout fluid to the contact surface of the spindle with no tool holder attached while the spindle is rotated.
[0014] The fluid spouting means may include means for spouting fluid toward a contact surface of the tool holder to be in contact with the spindle, which is allocated to be attached to the spindle by the tool allocating means, to thereby clean the contact surface of the tool holder as well as the contact surface of the spindle.
[0015] The automatic tool changing device fluid spouting means may further comprise a distance sensor for measuring distance to a periphery of the tool holder attached to the spindle, and the fluid spouting means may include means for spouting fluid toward the periphery of the tool holder to be cleaned. With this arrangement, the distance between the distance sensor and the periphery of the tool holder is accurately measured to enable accurate detection of whether or not the tool holder is properly attached to the spindle.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is an explanatory view of a substantial part of one embodiment of an automatic tool changing device according to the present invention;
[0017] FIG. 2 is a side view of a tip end of a spindle, a manifold, and a nozzle portion according to the embodiment;
[0018] FIG. 3 is a bottom plan view facing into a bottom of FIG. 2 ; and
[0019] FIG. 4 is an explanatory view for explaining a state in which a tapered portion of a tool holder is washed according to the embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] FIG. 1 is an explanatory view of a substantial part of one embodiment of an automatic tool changing device according to the present invention. The device of the embodiment is identical to one described in JP 2535479B, except that according to the embodiment, a manifold 4 and a nozzle portion 5 serving as fluid spouting means, and a pipe 7 for supplying fluid, such as a coolant, to the manifold 4 as the fluid spouting means are added to the automatic tool changing device disclosed in the above publication. First, a summary of a known part of the automatic tool changing device will be described.
[0021] The automatic tool changing device according to the embodiment comprises an arm member 11 , a turret 2 having a plurality of grippers 2 b on an outer circumference thereof and holding a tool holder 1 a by means of the grippers 2 b, a crank 12 secured onto a back face of the turret 2 , first and second cams Cs, CL fastened to a spindle head, a swing roller 12 a provided to the crank 12 , which swings the turret 2 in consort with the first cam Cs, a lift slider 14 coupled to the crank 12 by a rotary shaft 13 , a lift link 15 coupled to the lift slider 14 , a lift lever 18 having two arm members 18 a, 18 b fastened to the lift link 15 with a pin 16 , which rotate around a rotary shaft 17 , a lift roller 18 c provided to the arm member 18 b of the lift lever 18 and engaged with the second cam CL, a turret gear 2 a disposed in the turret 2 and engaged with a spindle gear 3 b provided to a spindle 3 , a speed reducer 9 provided to the turret 2 , which reduces and transmits rotation of the turret gear 2 a to the turret 2 to rotate the turret 2 , and so on. The turret 2 , the turret gear 2 a and the speed reducer 9 compose tool allocating means.
[0022] Based on a tool change command, a spindle head 10 moves upward and stops at a Z-axial original point position, and orientation of the spindle is performed at the position. After the orientation is completed, the spindle head 10 moves up again. Due to this ascending motion of the spindle head 10 , the swing roller 12 a and the first cam Cs cause the turret 2 to swing counterclockwise, and the grippers 2 b arranged on the outer circumference of the turret 2 are engaged with grooves of the tool holder 1 a of a tool 1 attached to the spindle 3 . Further ascension of the spindle head 10 pulls the tool holder 1 a out of the spindle 3 as illustrated in FIG. 1 . When the ascending motion of the spindle head 10 is finished, the spindle gear 3 b and the turret gear 2 a are engaged with each other. In this state, the spindle 3 is rotated to implement the allocation of a desired tool 1 . In other words, the spindle gear 3 b rotates with the rotation of the spindle and rotates the turret gear 2 a engaged with the spindle gear 3 b. The speed reducer 9 reduces a speed of the rotation to rotate the turret 2 , thereby determining a turret position for obtaining the desired tool (tool holder) 1 . FIG. 1 shows a state in which the desired tool holder 1 a is allocated. After the desired tool holder 1 a is selected in the aforementioned manner, the spindle head 10 moves downward, which releases the engagement between the spindle gear 3 b and the turret gear 2 a, fits the tool holder 1 a to a spindle taper hole 3 a, and causes the grippers 2 b to retreat from the tool holder 1 a. Due to the descending motion of the spindle head 10 , operations are implemented in inverse order to the ascending motion of the spindle head 10 .
[0023] The aforementioned are about a known structure of the automatic tool changing device and a known tool change operation, as described in detail in JP 2535479B, the disclosure of which is hereby incorporated by reference. The present invention is so designed that fluid spouting means is provided to wash the spindle taper hole 3 a functioning as an interfitting part of the tool holder 1 a and the spindle 3 at the time of tool change. According to the embodiment shown in FIG. 1 , there is provided the manifold 4 having the nozzle portion 5 that constitutes the fluid spouting means attached to the spindle head 10 . A coolant supplied from the nozzle portion 5 through the pipe 7 is spouted onto a contact surface of the spindle taper hole 3 a, which is to be in contact with a tapered portion 1 b of the tool holder 1 a, to thereby clean the contact surface, and wash the tapered portion 1 b of the tool holder 1 a with the coolant spouted from the nozzle portion 5 .
[0024] FIG. 2 is a side view of a tip end of the spindle 3 , the manifold 4 and the nozzle portion 5 , and FIG. 3 is a bottom view facing into a bottom of FIG. 2 . According to this embodiment, the nozzle portion 5 of the manifold 4 comprises a pair of spindle taper hole-washing nozzles 5 c for washing the contact surface of the spindle taper hole 3 a, which is to be in contact with the tapered portion 1 b of the tool holder 1 a, a pair of spindle end face-washing nozzles 5 b for washing an end face of the spindle for the use of double fit tooling, a distance sensor 6 for detecting an orientation of the tool holder 1 a attached to the spindle 3 , a pair of tool holder detection face-washing nozzles. 5 a for washing a detection face, i.e. an outer periphery of the tool holder 1 a, which is subjected to measurement using the distance sensor 6 , and a pair of tool holder-washing nozzles 5 d for washing the tapered portion 1 b of the tool holder 1 a.
[0025] Connected to each of the nozzles 5 a, 5 b, 5 c and 5 d is a flow channel opening 8 for the coolant supplied through the pipe 7 , to thereby supply the coolant to each nozzle. As shown in FIGS. 2 and 3 , directions of the nozzles 5 c are set such that the coolant spouted from the spindle taper hole-washing nozzles 5 c strikes the surface of the spindle taper hole 3 a, which is to be in contact with the tapered portion 1 b of the tool holder 1 a. Directions of the spindle end face-washing nozzles 5 b are so determined that the spouted coolant strikes the end face of the spindle 3 , with which an end face of the tool holder 1 a is to be in contact.
[0026] Directions of the tool holder-washing nozzles 5 d, 5 d are, as shown in FIG. 4 , adjusted such that the spouted coolant strikes the tapered portion 1 b of the tool holder 1 a in a state where the tool holder 1 a is pulled out of the spindle 3 and in a state right before the tool holder 1 a is interfitted in the taper hole 3 a of the spindle 3 .
[0027] At a tool change command, the spindle head 10 moves upward, and as stated, the positioning of the spindle 3 and the shifting thereof to the Z-axial original point are carried out. The spindle head 10 further ascends to cause the grippers 2 b arranged on the outer circumference of the turret 2 to hold the tool holder 1 a attached to the spindle 3 . The tool holder 1 a is pulled out by being unclamped, and the spindle gear 3 b and the turret gear 2 a are engaged with each other. Subsequently, in order to select the tool holder 1 a to be attached to the spindle 3 , the tool selecting operation is begun by rotating the spindle 3 , and the discharge of the coolant is started.
[0028] The rotation of the spindle 3 causes the turret 2 to start rotating through the spindle gear 3 b, the turret gear 2 a and the speed reducer 9 . Since the turret 2 is rotated at a reduced speed with respect to the rotation of the spindle 3 , even if a tool is selected by rotation of a tool selection minimum unit of the turret 2 , the spindle 3 makes one or more rotations. Simultaneously with the rotation of the spindle 3 , the coolant is spouted from each nozzle, and the coolant spouted from the spindle taper hole-washing nozzles 5 c and the spindle end face-washing nozzles 5 b then strikes a tapered face of the spindle taper hole 3 a and the end face of the spindle over the whole circumference, thereby washing and cleaning the faces.
[0029] When the spindle 3 is rotated for tool selection, the coolant is supplied to each nozzle at the same time. Thus, with respect to the tool holder 1 a pulled out of the spindle 3 and the tool holder 1 a that is selected but not yet inserted in the spindle taper hole 3 a, the coolant is spouted toward the tapered portions 1 b of the tool holders 1 a as illustrated in FIG. 4 , to thereby wash and clean the tapered portions 1 b. In other words, the tapered portions 1 b of the tool holders 1 a are washed with the coolant to remove swarf and the like before being accommodated in the turret 2 and before being attached to the spindle 3 .
[0030] Once the tool 1 is allocated, the rotation of the spindle 3 is halted, and the spindle head 10 is made to move downward to release the engagement between the spindle gear 3 b and the turret gear 2 a. Furthermore, the tool holder 1 a is interfitted in the spindle taper hole 3 a to be clamped. The supply of the coolant is stopped at this point. Thereafter, the grippers 2 b retreat from the tool holder 1 a, and the tool change operation is completed.
[0031] By taking advantage of rotation of the spindle 3 for tool selection before the step of selecting and attaching a new tool 1 to the spindle 3 as described above, the coolant is spouted and strikes the contact surface of the spindle taper hole 3 a, which is to be in contact with the tapered portion 1 b of the tool holder 1 a and the end face of the spindle, which is put together with the end face of the tool holder 1 a, over the whole circumference, to thereby wash these faces. In addition, the tapered portion 1 b of the tool holder 1 a is washed by spouting the coolant onto the tapered face of the tool holder 1 a in the process of the tool change operation, more specifically in the step of pulling the tool holder 1 a out of the spindle 3 and of attaching the tool holder 1 a to the spindle 3 .
[0032] As a result, the spindle 3 and the tool holder 1 a are fitted to each other after the spindle taper hole 3 a serving as the contact surface of the spindle 3 and the tool holder 1 a and the surface of the tapered portion 1 b of the tool holder 1 a are washed and cleaned by removing a foreign object, such as swarf, with the coolant, thereby resulting in proper attachment of the tool holder 1 a to the spindle 3 .
[0033] When the tool holder 1 a is attached to (and detached from) the spindle 3 , the coolant spouted from the tool holder detection face-washing nozzles 5 a also washes an outer periphery of the tool holder 1 a, which is subjected to the measurement using the distance sensor 6 . On this account, at the time the spindle 3 is caused to make one rotation, and the distance between the distance sensor 6 and the detection face of the tool holder 1 a is accurately measured by the distance sensor 6 after the tool holder 1 a is attached to the spindle 3 , the measurement detection face has been washed, so that there is no swarf and the like attached thereto, which enables accurate measurement. This makes it possible to detect whether the tool holder 1 a is properly interfitted in the spindle taper hole 3 a. If the fitting of the tool holder 1 a to the spindle taper hole 3 a is not properly carried out, the distance to the tool holder 1 a which is measured by the distance sensor 6 varies according to the rotation of the spindle 3 . Therefore, based on a variation value, it is possible to determine if the tool holder 1 a is properly attached to the spindle 3 .
[0034] According to the above embodiment, the taper hole 3 a of the spindle 3 , which serves as the contact surface of the spindle 3 and the tool holder 1 a, and the tapered portion 1 b of the tool holder 1 a are washed and cleaned with the coolant at the time of tool change. However, the spindle taper hole and the spindle end face may be washed and cleaned by causing the turret 2 to carry out the tool change operation after selecting a place having no tool to create a state in which the tool holder 1 a is not fitted in the taper hole 3 a of the spindle 3 , rotating the spindle 3 at a high speed, and simultaneously spouting the coolant from the spindle taper hole-washing nozzles 5 c and the spindle end face-washing nozzles 5 b. In this case, the high-speed rotation of the spindle produces a velocity differential between the coolant and the spindle, and high washing property can be achieved by the velocity differential.
[0035] Although in each of the aforementioned embodiments, the coolant is used as means for washing and cleaning the spindle taper hole 3 a and the tool holder 1 a, another fluid or pressurized air may be used in place of the coolant.
[0036] According to the present invention, in the automatic tool changing device having the tool allocating means that performs tool selection by utilizing the rotation of the spindle, the fluid spouting means is disposed in the vicinity of the spindle, and the fluid is spouted onto the contact surface of the spindle that rotates during the tool selection, which is to be in contact with the tool holder. Thus, the spouted fluid strikes the entire contact surface, to thereby remove a foreign object, such as swarf, adhered to the surface, and wash and clean the surface. Only by providing the fluid spouting means, it is possible to efficiently wash and clean the contact surfaces of the spindle and the tool holder with a simple and inexpensive structure.
[0037] Furthermore, since the spindle is rotated at a high speed with no tool holder attached to the spindle, and simultaneously the fluid is spouted from the fluid spouting means onto the surface of the spindle, with which the tool holder is to be in contact, the velocity differential between the spouted fluid and the spindle makes it possible to efficiently wash the surface of the spindle, with which the tool holder is to be in contact, and then to achieve high washing property.
[0038] Furthermore, it is also possible to wash the contact surface of the tool holder, which is to be in contact with the spindle, by spouting the fluid from the fluid spouting means. As a consequence, the contact surfaces of the spindle and the tool holder can be more reliably washed and cleaned. | An automatic tool changing device capable of cleaning a contact surface of a spindle, which is to be in contact with a tool holder, with a simple structure. The device includes a turret having a plurality of grippers on its outer circumference and holding the tool holder by means of the grippers. At the time of tool change, the grippers grip and pull out the tool holder fixed to the spindle. Rotation of the spindle causes the turret to rotate through a spindle gear, a turret gear, and a decelerating device, to thereby select a tool. At this moment, a coolant is spouted from a nozzle portion of a manifold toward a spindle taper hole in which the tool holder is interfitted and washes the taper hole. Due to the rotation of the spindle, the coolant is spouted onto the whole circumference of the taper hole, and the surface to be in contact with the tool holder is surely washed. Therefore, it is possible to perform the cleaning with a simple structure in which the nozzle portion is arranged near the spindle without machining the spindle and the tool holder. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a national phase application of PCT/EP99/06912 filed Sept. 17, 1999, which claims priority to EP 98 11 7745.4 filed Sept. 19, 1998 and EP 98 11 7799.1 filed Sept. 18, 1998, and which are incorporated in their entirety by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a novel method for the amplification of DNA, this method being particularly useful for the amplification of the DNA or the whole genome of a single cell, chromosomes or fragments thereof. The present invention further relates to the application of the method in DNA analysis for medical, forensic, diagnostic or scientific purposes, like comparative genomic hybridization (CGH), fluorescence in situ hybridization (FISH), polymerase chain reaction (PCR), single strand conformation polymorphism analysis (SSCP), DNA sequence analysis, “loss of heterozygosity” analysis (LOH), fingerprint analysis, and/or restriction fragment length polymorphism analysis (RFLP).
2. Description of the Related Art
Several documents are cited throughout the text of this specification. Each of the documents cited herein (including any manufacturer's specifications, instructions, etc.) are hereby incorporated by reference; however, there is no admission that any document cited is indeed prior art of the present invention.
PCR (polymerase chain reaction) is an extremely powerful in vitro method for the amplification of DNA, which was initially introduced in 1985 (Saiki (1985), Science 230, 1350-1354). By repeated thermal denaturation, primer annealing and polymerase extension, PCR can amplify a single target DNA molecule to easily detectable quantities.
Although PCR was initially applied to amplify a single locus in target DNA, it is increasingly being used to amplify multiple loci simultaneously. Frequently used primers for this general amplification of. DNA are those based on repetitive sequences within the genome, which allow amplification of segments between suitable positioned repeats. Interspersed repetitive sequence PCR (IRS-PCR) has been used to create human chromosome- and region-specific libraries (Nelson (1989), Proc. Nati. Acad. Sci. USA 86, 6686-6690). In humans, the most abundant family of repeats is the Alu family, estimated to comprise 900,000 elements in the haploid genome, thus giving an average spacing of 3-4 kb (Hwu (1986), Proc. Natl. Acad. Sci. USA 83, 3875-3879). However, a major disadvantage of IRS-PCR is that repetitive sequences like Alu or L1 are not uniformly distributed throughout the genome. Alu elements, for example, are preferentially found in the light bands of human chromosomes. Therefore, such a PCR method results in a bias toward these regions while other regions are less represented and thus not amplified or an amplification can only be obtained below detectable levels. Furthermore, this technique is only applicable to those species where abundant repeat families have been identified, whereas other species such as Drosophila and less well characterized animals and plants cannot be subjected to this method.
A more general amplification than with ISR-PCR can be achieved with “degenerate oligonucleotide-primed PCR” (DOP-PCR), with the additional advantage of species independence (Telenius (1992), Genomics 13, 718-725). DOP-PCR is based on the principle of priming from short sequences specified by the 3′-end of partially degenerate oligonucleotides used, during initial low annealing temperature cycles of the PCR protocol. Since these short sequences occur frequently, amplification of target DNA proceeds at multiple loci simultaneously.
DOP-PCR can be applied for generating libraries containing a high level of single-copy sequences, provided pure and a substantial amount of DNA of interest can be obtained, e.g. flow-sorted chromosomes, microdissected chromosome bands or isolated yeast artificial chromosomes (YACs). However, DOP-PCR seems to be not capable of providing a sufficient, uniform amplification of the DNA content of a single cell (Kuukasjärvi (1997), Genes, Chromosomes & Cancer 18, 94-101).
The sensitivity of PCR allows for the analysis of a specific target DNA in a single cell (Li (1988), Nature 335, 414-417). This led to the development of preimplantation genetic disease diagnosis using single cells from early embryos (Handyside (1989), Lancet 1, 347-349) and genetic recombination analysis using a single sperm (Cui (1989), Proc. Nati. Acad. Sci. USA 86, 9389-9393) or oocyte (Cui (1992), Genomics 13, 713-717). However, in all these cases the single cell can be analyzed only once for a given target sequence and independent confirmation of the genotype of any one cell is impossible.
A method called “primer-extension preamplification” (PEP) is directed to circumvent this problem by making multiple copies of the DNA sequences present in a single cell. PEP uses a random mixture of 15-base fully degenerated oligonucleotides as primers, thereby leading to amplification of DNA sequences from randomly distributed sites. It is estimated that about 78% of the genomic sequences in a single human haploid cell can be copied no less than 30 times (Zhang (1992), Proc. Natl. Acad. Sci. USA 89, 5847-5851). However, up to now, a complete and uniform amplification of a whole genome of a single cell has not been documented with methods such as PEP.
A method called representational difference analysis (RDA) is a subtractive DNA hybridization technique that discovers the differences between paired normal and tumor genomes (Lisitsyn (1993), Science 259, 946-951). The minimal amount of DNA needed for RDA shown is 3 ng, corresponding to ≈1×10 3 cells. However, only 70% of the genomic sequences can be reproducibly amplified by RDA (Lucito (1998), Proc. Natl. Acad. Sci. USA 95, 4487-4492). Therefore, a uniform and complete amplification of the entire genome of a single cell by representational difference analysis is not possible.
BRIEF SUMMARY OF INVENTION
Therefore, considering the prior art described above, there is a demand for a method capable of substantially uniform and preferably complete amplification of genomic DNA, particularly from a single cell.
Thus, the technical problem consists in providing means and methods which comply with the needs as described above and which eliminate the above-mentioned disadvantages.
The solution to this technical problem is achieved by providing the embodiments characterized in the claims.
Accordingly, the present invention relates to a method for the amplification of DNA, comprising the steps of
(a) providing a sample comprising DNA;
(b) digesting the DNA to be amplified with a restriction endonuclease under conditions suitable to obtain DNA fragments of similar length, wherein said restriction endonuclease-is capable of providing 5′ overhangs wherein the terminal nucleotide of the overhang is phosphorylated or 3′ overhangs wherein the terminal nucleotide of the overhang is hydroxylated on said DNA fragments,
(c) annealing at least one primer to said DNA fragments wherein
(ca) (caa) simultaneously or subsequently, oligonucleotides representing a first primer are hybridized to said 5′ overhangs on said DNA fragments of step (b) and wherein oligonucleotides representing a second primer hybridize to 3′ overhangs generated by said first primer and wherein said first and second primer are of different length;
(cab) said second primer is ligated to said 5′ overhangs; and
(cac) said first primer is removed from said DNA fragments; or
(cb) (cba) simultaneously or subsequently, oligonucleotides representing a first primer wherein the nucleotide at the 5′ terminus is phosphorylated are hybridized to said 5′ overhangs on said DNA fragments of step (b) and wherein oligonucleotides representing a second primer hybridize with said first primer; and
(cbb) said first and second primer are ligated to said DNA fragments; or
(cc) (cca) oligonucleotides representing said primer are hybridized to said 3′ overhangs so that 5′ overhangs are generated; and
(ccb) said primer is ligated to recessed 5′ ends of said DNA fragments;
(d) filling in generated 5′ overhangs; and
(e) amplifying said DNA fragments with primers which are capable of hybridizing with the complementary strand of said primer(s) of step (c).
As used in accordance with the present invention, the term “DNA fragments of similar length” denotes fragments which, at a statistical level, have a size which is of comparable length. DNA fragments of comparable length are, for example, fragments of 50+/−5 bp or of 4 kbp +/−0.4 kbp. The length range of DNA fragments that is preferably generated is advantageously between about 50 bp and about 4 kbp. DNA fragments of greater or shorter length may be used as well, although they may be amplified or represented to a lesser extent than the above defined fragments. Preferably, the DNA fragments have a size of ≦3 kbp, more preferably said DNA fragments have an average length of about 1000 bp and particularly preferred are fragments of about 200-400 bp.
The term “5′ overhangs” as used herein means the 5′ phosphate group, provided e.g. by a staggered cleavage of DNA by restriction endonucleases, and denotes a single stranded overhanging 5′ end on DNA.
The term “primer” as used herein refers to an oligonucleotide whether occurring naturally as in a purified restriction digest or produced synthetically. The primer is preferably single stranded for a maximum of efficiency in the method of the present invention, and is preferably an oligodeoxyribonucleotide. Purification of said primers is generally envisaged, prior to their use in the method of the present invention. Such purification steps can comprise HPLC (high performance liquid chromatography) or PAGE (polyacrylamide gel-electrophoresis), and are known to the person skilled in the art.
As used herein, the term “restriction endonuclease” refers to bacterial enzymes capable of cutting double stranded DNA at or near a specific nucleotide sequence. The term “filling in” as used herein means a DNA synthesis reaction, initiated at 3′ hydroxyl ends, leading to a fill in of the complementary strand. This DNA synthesis reaction is Preferably carried out in presence of dNTPs (dATP, dGTP, dCTP and dTTP). Thermostable DNA polymerases such as Taq polymerases are generally used and are well known to the person skilled in the art.
The term “hybridized to” in accordance with the present invention denotes the pairing of two polynucleotide strands by hydrogen bonding between complementary nucleotides. This hybridization includes hybridization wherein a primer is hybridized directly adjacent to said 5′ overhangs as well as hybridization wherein gaps between primers and protruding or receding ends of said DNA fragments are generated. For example, the method of the present invention can be conveniently carried out in the case that a gap is formed between said second primer and the 5′ end of the DNA fragment, to name an example, since this gap will be filled in by DNA polymerases, such as Taq polymerases, in embodiments where said Taq polymerase is added before or during annealing and hybridization steps.
Oligonucleotides, representing primers as used in the method of the present invention can be identified, obtained and tested according to the state of the art especially represented by computer based sequence analysis and laboratory manuals, e.g. Sambrook (Molecular Cloning; A Laboratory Manual, 2 nd Edition, Cold Spring Harbour Laboratory Press, Cold Spring Harbour, N.Y. (1989)).
Furthermore, the setting of conditions for the above described steps of the method of the present invention is well within the skill of the artisan and to be determined according to protocols described, for example in Sambrook et al, loc. cit., or in the appended examples. Further examples of broader range hybridization conditions that can be employed in accordance with the invention are described, inter alia, in Ausubel, “Current Protocols in Molecular Biology”, Green Publishing Associates and Wiley Interscience, N.Y. (1989), or Higgins and Hames (Eds) “Nucleic acid hybridization, a practical approach” IRL Press Oxford, Washington DC, (1985).
From the above recited options of the following method for the amplification of DNA is preferred, said method comprising the steps of
(a) providing a sample comprising DNA;
(b) digesting the DNA to be amplified with a restriction endonuclease under conditions suitable to obtain DNA fragments of similar length, wherein said restriction endonuclease is capable of providing 5′ overhangs wherein the terminal nucleotide of the overhangs is phosphorylated or 3′ overhangs wherein the terminal nucleotide of the overhangs is hydroxylated on said DNA fragments;
(c) annealing at least one primer to said DNA fragments wherein
(ca) (caa) simultaneously or subsequently, oligonucleotides representing a first primer are hybridized to said 5′ overhangs on said DNA fragments of step (b) and wherein oligonucleotides representing a second primer hybridize to 3′ overhangs generated by said first primer and wherein said first and second primer are of different length;
(cab) said second primer is ligated to said 5′ overhangs; and
(cac) said first primer is removed from said DNA fragments;
(d) filling in generated 5′ overhangs; and
(e) amplifying said DNA fragments with primers which are capable of hybridizing with the complementary strand of said primer(s) of step (c).
In the case that the two primers are hybridized subsequently, the first primer after hybridization forms a 5′ overhang to which the second primer subsequently hybridizes.
The present invention is based on the surprising finding that the combination of the above mentioned steps leads to a substantially uniform and complete amplification of DNA, as demonstrated in Examples 2 and 3. In particular, the method of the invention has been exemplified as follows:
A DNA sample to be amplified can be obtained by isolating a single cell, i.e., for example, a bone marrow stroma cell, a single (tumorous) cell from peripheral blood, a single cell from umbilical vein blood or from a lymph node which is subjected to a digestion with a proteinase. After inactivation of the proteinase-activity, said sample DNA can be digested with a restriction endonuclease with four-nucleotide recognition site, like Msel, leading to DNA fragments of a similar length of about 200 to 400 bp.
The annealing and hybridization of a first and a second primer can be achieved by adding a primer comprising the nucleotide sequence as depicted in SEQ ID NO: 2, and a longer second primer comprising the nucleotide sequence as depicted in SEQ ID NO: 1. Said first primer can be additionally modified in that the last 3′ nucleotide of said primer is a dideoxy (dd)-nucleotide. The final concentration of primers in the following ligation reaction was 5 μM. The ratio between primers used in the present invention to DNA to be amplified was in a range 3 Mio:1, more preferably said ratio was in the range of 300,000:1, most preferably said ration was in the range of 30,000:1. Furthermore, said primers can be pre-hybridized to each other before their addition to said DNA sample.
An annealing reaction was started at a temperature which served also to inactivate said restriction enzyme, i.e. 68° C. Said second primer was ligated to said DNA fragments, in contrast to said first primer which is not ligated since no 5′ phosphate necessary for ligation was available. Therefore, the reaction temperature was gradually lowered to a temperature where such a ligation reaction can be carried out, i.e. 15° C. Ligation was obtained by the addition of ATP and a T4-DNA-ligase, to said primers and DNA fragments. After ligation, said first primer was removed from said DNA fragments by a denaturation step, involving a change of temperature to a higher temperature (e.g. of about 68° C.) wherein said primer dissociates from said DNA fragments. Said second primer remained ligated to said DNA fragments.
Resulting 5′ phosphate extensions on said DNA fragments were filled in by the addition of DNA polymerases, in the present case Taq and Pwo polymerase, in the presence of dNTPs (dATP, dCTP, dGTP and dTTP), under suitable conditions, as indicated in the examples.
The resulting mixture was then subjected to PCR amplification with said second primer, in a concentration of 1 μM, as specified in examples 2 and 3.
The amplification product was then further analyzed as described in Example 3.
The method of the present invention is substantially independent from particular precautious measures that have to be observed in methods of the prior art. For example, with the method of the present invention, it is not necessary to extract or purify the DNA of interest (which could lead to losses of DNA) prior to amplification.
Thus, in contrast to the above-mentioned methods for DNA amplification, the method of the present invention can be carried out under amplification conditions which are convenient and optimal for the further use of different adaptor-ligated sequences of choice.
The method of the present invention for the first time allows the amplification of the entire genome of a single cell even from unextracted DNA samples. This enables e.g. the genomic analysis of individual isolated disseminated tumor cells, applying comparative genomic hybridization (CGH) to single cells. Therefore, this method provides, e.g., the means to identify the individual genetic changes in a single cell that might promote dissemination and ectopic growth of disseminated tumor cells with metastatic potential. The genomic profile of such single disseminated cells could provide useful information on whether certain clonal genotypes are associated with disseminative events.
Furthermore, the method of the present invention for the first time allows for the reproducible application of CGH to individual cells, whereas other protocols for “whole genome amplification” such as PEP, DOP-PCR and Alu-PCR do not provide homogenous staining patterns by CGH wherein the origin of test-DNA is a single cell, single chromosomes or parts thereof. This reproducible application of CGH on individual single cells can be explained, inter alia, by the fact that a non-degenerate primer is used that drastically reduces the complexity of primer binding sites of oligonucleotides hitherto used in the DOP and PEP techniques. These previously numerous different sites require equally numerous different specific PCR conditions impossible to achieve during the same reaction. Additionally, since the amplification method of the present invention does not depend on repetitive sequences within the genome (like IRS-PCR), it is possible to reliably amplify the genomic DNA of single cells from species where such repetitive sequences are less frequent or even non-existent.
In a preferred embodiment of the method of the present invention DNA which is amplified is the genome of a single cell or chromosomes or (a) fragment(s) thereof. It has surprisingly been found that the method of the present invention is particularly useful for the analysis of single cells such as disseminating tumor cells, cells obtained from a lymph node, peripheral blood cells, cells from bone marrow aspirates, cells from tumor biopsis, cells obtained from microdissected tissue, or the like. As shown in the appended examples, the method of the present invention is also useful for the analysis of the genome of any single cell (or chromosomes or fragments thereof) wherein said single cell is a rare event containing potentially interesting genetic information. Said single cell which is a rare event might be, inter alia, the cells described hereinabove or embryonic/fetal cells in the venous blood of the mother and the like. The inventive method is particularly useful for the assessment of clonal evolution events of genetic variants in complex (cell) populations, like, inter alia, the clonal evolution of single micro-metastatic cells isolated from peripheral blood, bone marrow, or the like.
The DNA content of a single diploid cell amounts only to 6-7 pg. In prior art DNA amplification methods, like DOP-PCR, at least 25 pg of DNA, corresponding to four diploid cells, are necessary for effective amplification of the entire DNA. However, as demonstrated in Examples 3, 4, 5 and 6 the method of the present invention provides the means to reliably amplify and analyze the entire genome of a single cell.
In another preferred embodiment of the method of the present invention said DNA is present in the form of one copy of a double stranded DNA sequence.
In a further preferred embodiment of the method of the present invention the numerical abundance of said DNA fragments is essentially maintained. As has been found in accordance with the present invention, the method of this invention is capable of reproducibly amplifying genomic sequences. Usually, 80%, preferably more than 90%, more preferably more than 95% and most preferably 99% or more of the genomic sequences can be amplified by the method of the present invention, and the amount of the amplification product for each of those genomic sequences substantially corresponds to their copy number in the genome, as demonstrated in example 4. Therefore, with the method of the present invention it is possible to amplify DNA of a given sample so that the ratio between genomic sequences remain the same before and after said DNA amplification. As discussed above, methods such as RDA (Lucito (1998), PNAS USA 95, 4487-4492) provide for amplifications wherein only 70% of genomic sequences are amplified. It is questionable whether the DNA fragments which are amplified by the prior art methods retain their relative numerical abundance.
In an additional preferred embodiment of the method of the present invention said method comprises, prior to step (a), the step (a′) wherein said sample comprising DNA is digested with a proteinase and wherein, after the protein digest in step (b′), the proteinase is inactivated. Preferably, said proteinase is thermo-labil. Accordingly, said proteinase can be thermally inactivated in step (b′). In a preferred embodiment of the method of the present invention the said proteinase is Proteinase K.
In a further preferred embodiment of the method of the present invention said restriction endonuclease does not comprise any cytosine/guanine in its restriction site. It is well known in the art that genomic cytosine and guanine rests can be methylated, which might lead to a reduced enzymatic cut by restriction enzymes.
In a particularly preferred embodiment of the method of the present invention said restriction endonuclease recognizes a motif with four defined bases. Such endonucleases comprise enzymes which have four distinct nucleotides, e.g. Msel, in their recognition side as well as enzymes where an additional wobble base lies within the restriction side, like e.g. Apol. Preferably, said restriction endonuclease recognizes the consensus sequence TTAA.
In a most preferred embodiment of the method of the present invention said restriction endonuclease is Msel or an isoschizomer thereof. The convenience of using said restriction enzyme is demonstrated in example 2.
The first primer may be longer than the second primer, yet in another preferred embodiment, the present invention relates to the above described method wherein in step (caa) said second primer is longer than said first primer. As demonstrated in the examples, a convenient length difference is 8 to 12 bp.
In another preferred embodiment of the method of the invention the annealing temperature of said second primer in step (caa) is higher than the hybridizing temperature of said first primer to said second primer and said 5′ overhangs, as demonstrated in example 2.
In a particularly preferred embodiment of the method of the present invention in step (caa) said first primer comprises 11 or 12 nucleotides and said second primer comprises 21 nucleotides.
It is understood that in accordance with the method of the present invention said first primer in step (caa) or step (cba) is at least partially complementary to said second primer. In a particularly preferred embodiment said first and said second primer comprise a palindromic sequence.
In yet another preferred embodiment of the method of the present invention, the sequence of said first and said second primer is non-degenerate. As described above, other methods known to the person skilled in the art, such as DOP-PCR (Telenias (1992), Genomics 13, 718-725) are based on the use of degenerate oligonucleotides or partially degenerate primers. Such degenerate primers bear a high risk of self-annealing, thereby inhibiting themselves (each other) from binding to target sequences and resulting in the reduction of amplification efficiency.
In a yet more preferred embodiment, said first primer used in step (caa) has the sequence shown in SEQ ID NO: 2 and/or said second primer used in step (caa) has the sequence as shown in SEQ ID NO: 1.
In a further preferred embodiment of the method of the present invention, the last 3′ nucleotide of the first primer in step. (caa) of the above described method is modified, such that said primer cannot be elongated by polymerase activity (e.g. Taq polymerase activity). The person skilled in the art is well aware of such modifications and methods for producing such modified oligonucleotides. One of these modifications can be the addition of a dd-nucleotide at the 3′ end of the first primer in the above described step (caa).
In an additional preferred embodiment, said first and said second primer of the method of the present invention are hybridized to each other separately from said DNA fragments and are added to said DNA fragments after they hybridized to each other. The addition of the hybridized primers to said DNA fragments is effected prior to step (ca) or step (cb). Such a pre-hybridization of primers leads, inter alia, to a higher hybridization efficiency to said DNA fragments and interfering to chromosomal DNA can be avoided.
In another preferred embodiment of the method of the present invention essentially the whole nuclear genome of a single cell is amplified.
Usually, 80%, preferably more than 90%, more preferably more than 95% and most preferably 99% or more of the whole nuclear genome can be amplified by the method of the present invention.
In a particularly preferred embodiment of the method of the present invention said single cell is a chemically fixed cell. One option for chemically fixing a cell or tissue is formalin. Others are well known to the person skilled in the art.
The inventive method described herein can be applied to DNA of different sources, such as solid tumor DNA isolated from frozen sections and/or cryosections and/or paraffin embedded, formalin fixed specimens. For decades these tissue sections have been stored mainly for histopathological diagnosis. Single cells or small samples, comprising a limited amount of cells, from histopathological tissue can be screened for specific genetic changes and compared with other areas from the same tissue that may exhibit distinctly different histopathological features or, for control purposes, with areas of apparently normal tissue. Global screening of copy number sequence changes within a tumor genome from archival tissue material could increase the knowledge about cytogenetic alterations in solid tumors significantly. A direct comparison of these cytogenetic data with histological and histochemical results and clinical follow up data would become possible.
Furthermore, the method of the present invention may be used for the amplification of single-cell DNA which stems from microdissected and/or laser-microdissected (for example, laser microbeam microdissection preferably combined with laser pressure catapulting) material from, inter alia, cryosections, as shown in the appended examples.
In yet a more preferred embodiment of the method of the present invention steps (a) to (e) are carried out in one reaction vessel. This has the advantage that a potential template loss is avoided and, moreover, an additional opening and closing of the reaction vessel, which may involve contamination and is troublesome, is avoided.
As is evident to the person skilled in the art, the method of the present invention and/or the amplified DNA fragments obtained by the method of the present invention are particularly useful in diagnostic assays and as research tools. Said amplified DNA fragments are, inter alia, useful in areas and fields were only limited amounts of target-DNA is available, such as in forensic investigations (inter alia DNA-fingerprinting), in paleontology and/or in paleoarcheology. Furthermore, the method of the present invention and/or the amplified DNA fragments obtained therewith are particularly useful in preimplantation diagnosis on human and animal embryos. Said method and/or said amplified DNA fragments can furthermore be used, inter alia, in combination with chip-technologies, for identification assays for DNA of contaminating organisms in samples, such as food products or in blood- or liquor samples. Furthermore, the inventive method and/or the amplified DNA fragments obtained by said method may be useful in the detection of contaminating DNA in pharmaceutical compositions or diagnostic solutions.
The present invention therefore further relates to the use of the amplified DNA fragments obtained by the above described method in methods and techniques for DNA analysis. Such methods and techniques are routinely used in prenatal diagnosis, forensic medicine, pathogenic analysis or biological/biochemical research and are known to the person skilled in the art.
In a particularly preferred embodiment of the use of the present invention, the methods for DNA analysis are comparative genomic hybridization (CGH), representational difference analysis (RDA), analytical PCR, restriction enzyme length polymorphism analysis (RFLP), single strand conformation polymorphism analysis (SSCP), DNA sequence analysis, “loss of heterozygosity” analysis (LOH), fingerprint analysis and/or fluorescence in situ hybridization (FISH).
A variety of techniques are now available for genome-wide screening of alterations in copy-number, structure and expression of genes and DNA sequences. These include molecular cytogenetic techniques (such as comparative genomic hybridization (CGH) and multicolor fluorescence in situ hybridization (M-FISH)), as well as molecular genetic techniques (such as representational difference analysis (RDA), differential display, serial analysis of gene expression (SAGE) and microarray techniques). CGH was the first molecular cytogenetic tool that allowed comprehensive analysis of the entire genome (Kallioniemi (1992), Science 258, 818-821). CGH allows for the screening for DNA sequence copy-number changes and provides a map of those chromosomal regions that are gained or lost in a DNA specimen. Because DNA copy-number alterations are of pathogenetic importance in cancer, most of the applications of CGH are in cancer research.
In CGH, which is based on a modified in situ hybridization, differentially labeled test (green) and reference (red) DNAs are co-hybridized to normal metaphase spreads. Copy-number differences between test and reference genomes are seen as green:red fluorescence intensity differences on the metaphase chromosomes. DNA gains and amplifications in the test DNA are seen as chromosomal regions with an increased fluorescence ratio, while losses and deletions result in a reduced ratio. An important contribution of CGH to cancer research has been in pinpointing putative locations of cancer genes, especially at chromosomal sites undergoing DNA amplification. A large number of subregional chromosomal gains and DNA amplifications have been discovered by CGH in some cancers. Because oncogenes and drug-resistance genes are known to be upregulated by DNA amplifications, it has been speculated that DNA amplification sites in cancer could pinpoint locations of novel genes with important roles in cancer progression. Tumor progression implies the gradual transition of a localized, slow growing tumor to an invasive, metastatic and treatment refractory cancer. This progression is thought to be caused by a stepwise accumulation of genetic changes affecting critical genes. By providing genome-scale information of clonal genetic alternations, CGH is extremely useful in the analysis of the biological basis of the tumor progression process. Two cancer specimen taken from the same patient at different stages of progression can be analyzed. For example, genetic changes that are not found in primary tumors, but do occur in their metastases could be informative in pinpointing genetic changes and genes with important roles in the metastatic progression. Metastatic relapse is caused by early dissemination of individual tumor cells, which leave their primary site and enter into the circulation prior to diagnosis and surgical removal of the primary tumor. The vast majority of these cells will be eliminated by the immune system or undergo apoptosis, while others will survive the perils of the circulation, invade tissues at a secondary site, and remain in a dormant stage for years before they finally grow to metastases. This early stage of metastasis formation (minimal residual disease), when tumor cells are few and dispersed, represents the “Achilles' Heel” of cancer, being a promising target for the development of new therapeutic approaches to prevent clinical metastasis. Therefore, in order to screen individual tumor cells by methods like CGH, it is desirable to uniformly and accurately amplify the whole genome of such a cell. Accordingly, the above described method is particularly useful for screening individual tumor cells by CGH and therefore allowing early diagnosis of e.g. neoplastic disorders or patients susceptible to such disorders. The term “neoplastic disorders” is intended to mean the whole spectrum from initiation of malignant transformation in a single cell to advanced cancer disease, including distant solid metastasis.
Based on CGH and DOP-PCR the minimal amount of target DNA so far needed for a reproducible amplification is 50 pg, corresponding to 8 diploid cells (Speicher (1993), Hum. Mol. Genet. 11, 1907-1914). Smaller amounts of genomic DNA could not be reproducibly amplified. Using the method of the present invention a further reduction of the amount of DNA necessary for a single test is possible.
The method of the present invention not only provides for example uniformly amplified DNA for the subsequent use in CGH, but also allows the reliable uniform amplification of even smallest quantities of DNA for further techniques and methods, wherein samples contain only small amounts of DNA. For example, in forensic science, DNA typing procedures have become increasingly important in the last few years (Lee (1994), Am. J. Forensic Med. Pathol. 15, 269-282): PCR and RFLP analysis, also called fingerprint analysis, are carried out with only minute available quantities of DNA found in sperm, blood traces or individual cells and the like.
Another important application of the presented method is prenatal diagnosis using embryonic or fetal cells in maternal blood. The ability to use embryonic or fetal cells enriched from maternal blood of pregnant women for prenatal diagnosis of chromosomal abnormalities has been a long-sought goal for those pursuing a non-invasive alternative to current methods, such as amniocentesis or chorionic villus sampling. The localization and identification of novel disease genes allows for mutation analysis or linkage studies on fetuses at risk for single gene disorders or chromosomal abnormality etc. The method of the present invention improves the accuracy as well as applicability of methods for the diagnosis of preimplantation genetic disorders or for the diagnosis on fetal cells isolated from maternal blood, whereby analyses can be performed on a single cell level, thus abolishing the need for preceding enrichment of cells. As demonstrated in the appended examples, the method of the present invention provides for the reliable amplification of DNA from a single fetal or embryonic cell isolated from maternal blood, inter alia, from the umbilical vein blood.
The present invention further relates to a kit comprising at least one primer and/or a first and/or a second primer as defined above. Advantageously, the kit of the present invention further comprises, besides said primer and/or the primers, optionally, proteinases, restriction enzymes, DNA-ligases (such as T4-DNA-Ligase), DNA-polymerases (such as Taq polymerase), Pwo polymerase, and/or ThermoSequenase, as well as (a) reaction buffer(s) and/or storage solution(s). Furthermore, parts of the kit of the invention can be packaged individually in vials or in combination in containers or multicontainer units. As it has been usefully demonstrated in the examples, a Proteinase K-digestion, a four-cutting restriction-endonuclease and primer(s) as defined above are suitable for the method of the invention. Thus, the kit of the invention preferably comprises Proteinase K, a four-cutting restriction endonuclease (such as Msel), Taq and/or Pwo polymerase, primer(s) as defined above, and/or T4-Ligase. The kit of the present invention may be advantageously used for carrying out the method of the invention and could be, inter alia, employed in a variety of applications referred to above, e.g. in diagnostic kits or as research tools. Additionally, the kit of the invention may contain means for detection suitable for scientific and/or diagnostic purposes. The manufacture of the kits follows preferably standard procedures which are known to the person skilled in the art.
Furthermore, the present invention relates to the use of a first and/or second primer as defined above for the preparation of a kit for carrying out the method of the present invention.
Throughout this specification and the claims which follow, unless the context requires otherwise, the word “comprise”, and variations such as “comprising” and “comprising”, will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integer or step.
BRIEF DESCRIPTION OF THE DRAWINGS
The figures show:
FIG. 1 . CGH-profile of a peripheral blood leukocyte of a patient with Down's syndrome. In order to be considered significant, deviations from the black midline have to cross the right (chromosomal gain) or left (chromosomal loss) punctate line. The black horizontal bars indicate regions excluded from analysis due to the prevalence of heterochromatic DNA. The chromosome 21 (except for the blocked heterochromatic region) was found to be amplified entirely, whereas all other chromosomes showed normal profiles. Deviations from the midline have to cross the right (chromosomal gain) or left (chromosomal loss).
FIG. 2 . Comparison of the CGH profiles of a conventional CGH experiment using 1 μg nick-translated DNA prepared from the MCF-7 cell line and from a single cell of the same cell line after PCR-amplification. For both experiments chromosomes 2, 3, 8, 19 and 20 are shown for comparison of differences between the single cell and the cell line. The single cell profiles are depicted in the upper panel, the cell line profiles in the lower. Bars on the right side of the chromosome symbol indicate chromosomal gains, bars on the left side chromosomal losses of the test-DNA. Chromosome 10 represents one example, where no change could be seen in either sample. Deviations from the midline have to cross the right (chromosomal gain) or left (chromosomal loss).
FIG. 3 . Two-color interphase-FISH on MCF-7 cells with YAC clones for 2p25 (red) and 2q31 (green). In the upper right cell three signals can be identified for the 2p region but only two for 2q. The other cells show two signals for both the 2p and 2q probe.
FIG. 4 . Isolation of a single disseminated tumor cell from bone marrow of a breast cancer patient. After immunostaining, the cell suspension was pipetted onto a slide and checked for immunofluorescent cells (A). (B) demonstrates the bright cytoplasmic staining and that the surrounding cells do not show any background fluorescence. The cell was then aspirated by a glass capillary (C) and transferred to a new slide. No other than the fluorescent cell was transferred as the whole visual field did not contain any other cell. From there the cell was taken to the amplification tube. (D) depicts the chromosomal changes of the cell.
FIG. 5 . CGH-profile of four single tumor cells (T#1-T#4) and one normal cell of a patient with CUP-syndrome. Chromosomes 2, 5, 7 and 15 are chosen for comparison of identical and divergent findings. The losses on chromosomes 2, 5 and 15 are common for all tumor cells whereas the loss of chromosome 7 was only seen for T#2. As in the other profiles, chromosomal losses are marked by vertical bars at the left side of the chromosome symbol.
FIG. 6 . (A) LOH-analysis using the dinucleotide repeat polymorphism at D5S346 locus linked to the APC gene (upper part) and PCR-RFLP of a Alw21I site within exon 15 of the APC gene (lower part). In the first experiment all four tumor cells demonstrate loss of one allele, whereas the single control cells contained two alleles except for #2. In the APC PCR-RFLP experiment all but one control cell (#3) had two alleles, whereas the tumor cells only contained the uncut fragment. The fragment of tumor cell #4 was not amplified (−, negative control; M10, 10 bp ladder; M50, 50 bp ladder; M, marker for agarose gel electrophoresis).
(B) Sequence of the mutation found in codon 215. The single control cells contained the wild type sequence with an A at nt 643 (upper two sequences), whereas the tumor cells were mutated at this position showing a A→G mutation (lower two sequences). The sequences of four of the eight cells are shown.
FIG. 7 . SSCP analysis of exon 6 of the tumor suppressor gene p53. Three normal cells and three tumor cells as well as a biopsy from a metastasis were subjected to SSCP analysis. The PCR products of the single normal cells migrate at different position than those of the tumor cells. The point mutation is easily in all tumor cells. Interestingly, both bands can be seen in the biopsy sample that obviously contained normal stromal or infiltrating cells in addition to tumor cells.
FIG. 8 . CGH profile of a single leukocyte isolated from the umbilical cord of a newborn boy. The cell was stained using an antibody directed against fetal hemoglobin, a marker frequently used to detect cells from the child in the peripheral blood of the mother during pregnancy. Female DNA served as control DNA in the CGH experiment. The quality of the hybridization can then be assessed by the demonstration of a “loss” of the X chromosome and a “gain” of the Y chromosome as a consequence of this experimental design. As it is depicted, the sex could be successfully determined as well as all autosomes showed normal profiles.
FIG. 9 . Identification of polymorphisms in single cells for fingerprint analysis. In microsatellite PCR the size of a band corresponds to a polymorphism. The identification of a polymorphism requires therefore that the size is not changed by the procedure. Here, PCR products of a dinucleotide microsatellite marker (D5S1975) derived from 12 single cells are shown next to the bands generated from the DNA of thousands of cells (+). The two alleles of the marker amplified from the individual cells and the positive control migrate at the same size. No loss of heterozygosity is observed.
FIG. 10 . (A): Isolation of a BCIP/NBT stained cell using alkaline phosphatase by micromanipulation. (B): PCR analysis of the genomic sequence of cytokeratin 19 (CK19) of 24 consecutively isolated cells that were immuncytochemically stained with the mab A45 B/B3, as mentioned in example 15. No loss in sensitivity as compared to immunofluorescent labeling is observed, the whole genome amplification, exemplified by the CK19 PCR, was successful in all cells. C: CGH profile of cell number 4 from FIG. 10B. A variety of aberrations are present in the genome.
DETAILED DESCRIPTION OF THE INVENTION
The invention will now be described by reference to the following biological examples which are merely illustrative and are not to be construed as a limitation of scope of the present invention.
EXAMPLE 1
Digestion of DNA
In a comparative study several restriction enzymes recognizing a four base motif were tested whether they are able to generate DNA fragments from 0.2-2 kb length that are suitable for the method of the invention. Fragments with an average length of 256 bp (4 4 ) were predicted under the premise that the four bases are evenly distributed and that the digest is complete. Five enzymes were tested: TaqI (TCGA), Csp6I (GTAC), MspI (CCGG), Acil (CCGC, GCGG) and MseI (TTAA). Only MseI, an enzyme without a C/G in its recognition site, produced a smear visible in the range from 100-1500 bp length and was therefore used in the protocol.
EXAMPLE 2
Amplification of DNA of a Single Cell
In order to avoid template loss, all preparatory steps were performed in one tube. For DNA isolation, restriction enzyme digest, primer ligation and PCR-amplification all buffers and conditions were adjusted for optimal performance to guarantee highest reliability and reproducibility. Generally, high concentrations of proteinase K, Msel, T4 DNA ligase and Taq polymerase gave the best results.
A single cell (e.g. peripheral blood lymphocyte or bone marrow stoma cell) in 1 μl pick buffer (50 mM Tris/HCl, pH 8.3, 75 mM KCl 3mM MgCl 2 , 137 mM NaCl) was added to 2 μl Proteinase K digestion buffer (10 mM Tris-Acetate (pH 7.5), 10 mM Mg-Acetate, 50 mM K-Acetate (0.2 μl of Pharmacia One-Phor-AII-Buffer-Plus), 0.67% TWEEN (Sigma), 0.67% Igepal (Sigma), 0.67 mg/ml Proteinase K) and incubated for 10h at 42° C. in a PCR machine with heated lid. Proteinase K was inactivated at 80° C. for 10 minutes. After inactivation of Proteinase K, Mse I restriction endonuclease digest was performed in 5 μl by adding 0.2 μl One-Phor-AII-Buffer-Plus, 0.5 μl Mse I (10 U; New England Biolabs) and 1.3 μl H 2 O, for 3 hours at 37° C. Annealing of primers was achieved by adding MseLig 21 primer, as shown in SEQ ID: 1, (5′-AGT GGG ATT CCG CAT GCT AGT-3′) and MseLig 12 primer, as shown in SEQ ID: 2, (5′-TAA CTA GCA TGC-3′, 0.5 μl each of 100 μM stock solution, Metabion), 0.5 μl One-Phor-AII-Buffer and 1.5 μl H 2 O, giving a final concentration of the primers in the PCR reaction of 1 μM. Annealing was started at temperature of 65° C. (also serving to inactivate the restriction enzyme before ligation) and was shifted down to 15° C. with a ramp of 1° C./minute. At 15° C. 1 μl ATP (10 mM) and 1 μl T4-DNA-Ligase (5 U; Boehringer Mannheim) was added and primers and DNA fragments were ligated over night.
For primary PCR amplification 40 μl consisting of 3 μl PCR buffer (Boehringer Mannheim, Expand Long Template, buffer 1), 2 μl dNTPs (10 mM) and 35 μl H 2 O were added to the 10 μl reaction volume. The PCR-program started with a denaturation step at 68° C. for 4 minutes to remove the MseLig-12 oligonucleotide, addition of 1 μl (3.5 U) of DNA polymerase mixture of Taq and Pwo polymerase (Boehringer Mannheim, Expand Long Template) and 3 minutes incubation for the fill-in-reaction. The Stratagene Robocycler was programmed to 94° C. (40 sec.), 57° C. (30 sec.), 68° C. (1 min. 15 sec.) for 14 cycles; 94° C. (40 sec.), 57° C. (30 sec.), 68° C. (1 min. 45 sec.) for 34 cycles; and 94° C. (40 sec.), 57° C. (30 sec.), 68° C. (5 min) for the final cycle.
As to the choice of primers, HPLC purification and a high concentration in the annealing/ligation reaction (5 μM) were prerequisites for successful performance. Under these conditions amplification of the digested single cell DNA resulted in a smear of a size similar to a complete digest of 1 pg high molecular weight DNA.
EXAMPLE 3
CGH With Amplified DNA From Peripheral Blood Lymphocytes
DNA isolated from a single unfixed and paraformaldehyde (PFA)-fixed peripheral blood lymphocyte was amplified as described in Example 2 and competitively hybridized with 1 μg nick-translated, unamplified placenta DNA. Labeling was most efficient using ThermoSequenase in combination with a ratio of dTTP/bio-dUTP of 7/1. Reamplification was performed in 30 μl using 0.5 μl LigMse-21 primer (100 μM), 1 μl dNTP (dATP, dCTP, dGTP, 10 mM each, 8.6 mM dTTP) and 1.3 μl biotin-16-dUTP (1 mM, Bboehringer Mannheim), 13 U ThermoSequenase (USB) in 1×ThermoSequenase buffer and 0.5 μl of the primary PCR. In total 25 cycles were programmed with the temperatures set to 94° C. (1 min.), 65° C. (30 sec.), 72° C. (2 min.) for 1 cycle; 94° C. (40 sec.), 65° C. (30 sec.), 72° C. (1 min. 30 sec.) for 94° C. (40 sec.), 65° C. (30 sec.), 72° C. (2 min.) for 9 cycles and an additional final extension step at 72° C. for 5 min. Before using 2 μg reamplified, labeled DNA, primers were removed by Msel digest. Nick translation of control DNA, as well as MCF-7 cell line DNA, metaphase spread preparation and hybridization was done as published in Speicher (1993), Hum. Mol. Genet 2, 1907-14. Images were captured with the Leica DMXA-RF8 microscope, equipped with a Sensys CCD camera (Photometrix, Tucson, Ariz.). Quantitative evaluation of the ratio of test and control DNA was done according to du Manoir (1995), Cytometry 19, 27-41, using the Leica software package Q-CGH. Seven to twelve metaphase spreads fitting the requirements of the program were evaluated in each experiment. In the course of experiments the profiles became smoother with no change in results when PCR-amplified and labeled control DNA was used instead of nick-translated chromosomes (compare FIG. 1 : PCR-labeled control DNA, and FIG. 2 : 0.5 μg nick-translated control DNA). 0.5 μg control DNA was modified and amplified as described for single cells and labeled in the reamplification reaction with digoxigenin-UTP (Boehringer Mannheim). The smoother CGH profiles probably reflect that fragment size and blocking efficacy for repetitive sequences are identical under these conditions for the two DNA samples.
In seven independent single cell experiments the obtained CGH profiles, CGH was carried out as described in Speicher (1993), Hum. Mol. Gen. 2, 1907-1914) showed no PCR-related chromosomal gains or losses detectable as a significant deviation from the central line. In fact, in all cases analyzed the sex of donor could be confirmed. PFA fixation had no effect on the outcome of the experiment.
EXAMPLE 4
Detection of Chromosomal Changes in a Patient With Down's Syndrome
In order to determine whether known chromosomal changes could be detected by the single cell analysis, DNA of a single leukocyte from a blood sample of a patient with Down's syndrome and its DNA was isolated and amplified as described in Example 2. The CGH-profile showed a gain of chromosome 21 as single detectable abnormality (FIG. 1 ).
EXAMPLE 5
Detection of Chromosomal Alterations in Single MCF-7 Cells
Detection of more complex numerical alterations was verified by comparing the ratio profiles of a single cell from the MCF-7 breast cancer cell line (ATCC HTB-22) and of 1 μg unamplified DNA isolated directly from MCF-7 cells (FIG. 2 and Table 1). The extra gain on chromosome 2p as detected in single cell CGH was not due to a PCR artefact but was also seen by two-color interphase FISH (FISH analysis was performed as described in Lengauer [(1992), Cancer Res . 52, 2590-6] performed with the CEPH-YACs 695h7 and 963d11 probes, mapped to 2p25 and 2q31, respectively). As summarized in Table 2, 16% of all cells evaluated showed 3 signals for 2p but only two for 2q (FIG. 3 ). A numerical abnormality present in only 16% of a cells population does not change a CGH-profile made of pooled DNA (du Manoir (1995), loc. cit.), however, it may become clearly visible if CGH is performed with a single cell from this minor subclone.
TABLE 1
Comparison of changes found in MCF-7 and a single cell of the same
cell line. Most of the changes found in MCF-7 can be detected in a single
cell. Differing changes of either the cell line or the single cell are shown
in bold letters.
chromosomal
Hybridization with
chromosomal gains
losses
Cell line DNA
8 q, 11 p, 11 q, 15 q, 19 q, 20 q
3 p, 8 p
Single cell amplified
2 p, 8 q, 11 p, 15 q, 19 q, 20 q
3 p, 8 p
DNA
TABLE 2
Results of interphase cytogenetics on cells from the breast cancer cell line
MCF-7 and normal lymphocytes. 100 nuclei were evaluated in each case.
1 × 2 p
1 × 2 p
2 × 2 p
2 × 2 p
2 × 2 p
3 × 2 p
3 × 2 p
4 × 2 p
4 × 2 p
1 × 2 q
2 × 2 q
1 × 2 q
2 × 2 q
3 × 2 q
2 × 2 q
3 × 2 q
2 × 2 q
3 × 2 q
MCF-7
6
0
2
70
0
16
3
2
1
normal
1
3
4
89
1
1
1
0
0
cell
EXAMPLE 6
CGH Analysis of a Single Tumor Cell From a Patient With a Primary Breast Cancer
The extremely rare individual tumor cells in bone marrow were identified in marrow aspirates by indirect immunofluorescence with the monoclonal cytokeratin antibody A45 B/B3 (Micromet). Cytokeratin-epitopes recognized by A45B/B3 have been mapped to cytokeratins 8, 18 and heterodimers of 8/18 and 8/19 (Stigbrand (1998), Tumor Biol . 19, 132-52).
Aspiration of the bone marrow samples and isolation of mononucleated cells was performed as described (Pantel (1996), Lancet 347, 649-653). Cells were washed in PBS and fixed for 5 minutes in 0.2% PFA. Blocking of unspecific binding with 5% AB-serum as well as incubation with 10 μg/ml A45-B/3 (Micromet) in 2% Pepton/PBS, 10 minutes each, was performed in the presence of 0.05% saponin (Sigma) to permeabilize the cells. After washing the cells in 2% Pepton/PBS, the antigen-antibody complexes were incubated with PE conjugated goat antibody to mouse IgG (Jackson) for detection (10 minutes).
All single cells were isolated from cell suspensions by micromanipulation. Bone marrow cells were plated at a density of 250,000 cells/0.8 cm 2 in a volume of 200 μl on a microscope slide. Single fluorescent cells were aspirated into a glass pipette of approximately 30 μm diameter and transferred to a new slide. After confirming that only a single cell had been transferred, this cell was finally picked in 1 μl pick buffer into the PCR-reaction tube.
In the marrow aspirate from the pelvic bone of a patient, diagnosed with a primary breast cancer without evidence for distant metastasis, staged according to the international classification as pT3, pN1, pM0, pG3, a single immunofluorescence-labeled cell detected among unstained bone marrow cells, was picked by micromanipulation and transferred to a new slide for visual control that no additional cell was inadvertently aspirated (FIG. 4 A-C). From this slide the cell was taken to the final reaction tube. FIG. 4D depicts the chromosomal gains and losses found by CGH analysis in this cell that were consistent with chromosomal imbalances reported earlier for breast cancer. For example, the observed amplifications on 8q and 17q represent two of the three most common gains while losses of 8p and 13q are also known to occur frequently in breast cancer (Forozan (1997), Trends Genet 13, 405-9).
EXAMPLE 7
CGH Analysis of a Tumor Cell From a Patient With CUP-syndrome
The same procedure as in Example 6 was applied to four individual cytokeratin-positive tumor cells and four unstained control cells isolated from the bone marrow of a patient with a cancer of unknown primary lesion (CUP-syndrome), who was initially presented with liver metastasis. The findings of the CGH analysis of the four tumor cells, summarized in FIG. 5 and in Table 3, showed a remarkable congruent pattern of genomic changes (Table 3). Particularly the distinct loss of the so-called consensus deletion regions- 3p, 5q, 10q, 13q, and 17p-, suggested that the cytokeratin-positive cells originated from a small cell lung cancer (Ried (1994), Cancer Res 54, 1801-6). Clinical imaging of a characteristic pulmonary lesion and histopathological examination of a metastasis led to the diagnosis of a “small to intermediate cell—most likely epithelial—tumor”—thus corroborating CGH based suspicion.
TABLE 3
Summary of the CGH results of four individual cytokeratin-positive
cells isolated from the bone marrow of a patient with CUP-syndrome.
Some deviations from the central line did not reach significance, but were
very similar in their profile to the other tumor cells with significant
changes as opposed to the control cell at the respective locus. These are
given in parentheses. Changes unique to one cell are in bold letters.
tumor
chromosomal
cell #
gains
chromosomal losses
1
8 q
2 p, 3 p, 5 q, (8 p), 10, 13, 15, 16 q, 17 p, 22, Y
2
(8 q)
2 p, 3 p, 5 q, 7, 8 p, 10, 13, 15, 16 q, 17 p, 22, Y
3
8 q
2 p, 3 p, 5 q, (8 p), 10, 13, 15, 16 q, 17 p, 22, Y
4
8 q
2 p, 3 p, 5 q, 8 p, 10, 13, 15, 16 q, 17 p, 22, Y
EXAMPLE 8
Loss of Heterozygosity-analysis
In order to detect loss of heterozygosity and mutations in epithelial tumors, the amplified DNA of all four tumor cells from the patient with CUP syndrome (see Example 7) and the four unstained bone marrow cells were examined for the presence of loss of heterozygosity (LOH) and mutations. The detection of LOH in a single cell requires that the two allelic DNA strands are cut, ligated to the adaptor and amplified in a nearly identical fashion. For LOH analysis of the APC tumor suppressor gene on 5q21, the dinucleotide repeat polymorphism D5S346 located 40 kb downstream of the gene and a polymorphic AIw21I site located within exon 15 were used (Groden (1991), Cell 66, 589-600). The D16S3019 marker tightly linked the E-cadherin gene (Guilford (1998), Nature 392, 402-5) on 16q22 was applied to assess LOH of E-cadherin. Since the CGH results of the respective chromosomes already suggested a loss of chromosomal material from 5q and 16q, amplification of two alleles from each control cell and one from each tumor cell was calculated to result in 12 fragments (4×2 for the normal cells and 4×1 for the tumor cells) for each of the three markers, adding up to 36 independently amplified fragments. As it is depicted for APC in FIG. 6A, both alleles could be amplified from three of the four control cells for each of the two markers analyzed. The primary PCR-products were diluted 1:5 in H 2 O. 1 μl of this dilution was used in the specific PCR. This specific PCR was carried out under standard primer conditions and the sequence of the D16S3019 locus, the D5S346 locus, the APC PCR-RFLP and the exons 2-9 of the p53 gene (Futeral (1991), Nucleic Acids Res. 19, 6977). Gel conditions for microsatellite analysis was performed as described in Litt (1993), Biotechniques 15, 280-4, and developed by incubation with SYBR-Green followed by fluorimaging. Analysis of the APC PCR-RFLP was performed by digesting 5 μl of the PCR products in a volume of 30 μl with 15 U AIw21I (MBI Fermentas) for 3h. The result was visualized in an ethidium bromide stained agarose gel.
While the losses found in control cell #2 and #3 were not seen with the second marker, all tumor cells showed LOH in both experiments. Similar results were obtained for E-cadherin: all control cells were informative and showed two alleles whereas all four tumor cells had lost one allele. Taken together, 33 of the 36 expected fragments were amplified and detected. These data not only demonstrate a respectable reliability of the method but also indicate that a presumed loss needs to be controlled by additional markers (FIG. 6 A).
In order to avoid Taq polymerase errors during the early cycles the PCR, a mixture of Taq polymerase with a proofreading enzyme, Pwo polymerase was used. Because the CGH-profiles of all four tumor cells showed a loss of 17p, it was examined whether the remaining allele of the p53 tumor suppressor gene had been inactivated by a mutation. Mutations in p53, the most commonly mutated tumor suppressor gene in human cancer, occur in about 50% of lung carcinomas (Greenblatt (1994), Cancer Res . 54, 4855-78). Since the vast majority of mutations are localized within the core domain, exon 4-9 was amplified for sequencing. Successful amplification of all exons proved that the primary PCR conditions are sufficiently robust to yield products at least as large as 1374 bp, despite the presence of much smaller fragments. There are no Msel sites contained within these exons, a prerequiste for successful amplification. The map of Msel cleavage sites in the p53 gene region predicted four exon containing fragments: one of 1374 bp with exons 2, 3 and 4, another of 1032 bp with exons 5 and 6, a third of a 722 bp fragment with exon 7, and a fourth of a 558 bp with exons 8 and 9. Sequencing of all four tumor cells showed an A→G mutation in codon 215 of p53, leading to a serine to glycine exchange, which had already been described in several human cancers before (Hainaut (1998), Nucleic Acids Res . 26, 205-13). Four normal bone marrow cells contained the wild-type sequence at codon 215 (FIG. 6B) of p53, virtually excluding that a Taq polymerase error accounted for the A→G mutation. No other deviation from the wild type sequence was found in the exons of tumor and control cell DNA, indicating that Taq polymerase induced mutations are rather rare under the applied conditions.
EXAMPLE 9
DNA Sequence Analysis by Direct Sequencing and SSCP
After detection of said A→G mutation in codon 215 of p53, it was tested whether it would be possible to detect said point mutations by single strand conformation polymorphism (SSCP). Single strand conformation polymorphism relies on the principle that single stranded DNA strands of different sequences exhibit different mobilities during electrophoresis in non-denaturing polyacrylamid gels. The strategy of the method is to amplify the segment of interest of a gene by PCR and then to compare the mobility of the denatured DNA with that of a reference segment of known sequence. Single point mutations within a sequence already lead to changed running behaviour in the gel, this method is very well suited for detecting the presence of mutations in a segment of DNA. Under non-denaturing conditions single stranded DNA exhibits a folded structure, which is determined essentially by intramolecular interactions and thus by the sequence. The occurrence of mutational changes in the DNA sequence causes a changed folded structure. Thus, in the SSCP analysis the detection of a mutated sequence is determined by the changed mobility in the polyacrylamid gel electrophoresis. The method has to be adjusted for sensitivity for each fragment to be analyzed. Important variables are the length of the fragment, ideally between 120-350 bp, and the temperature of the gel run. Once established SSCP has the advantage of screening a high number of probes at the same time without expensive and laborious sequencing. However, a fragment with a changed running behaviour should subsequently sequenced in order to name the mutation.
In this experiment, the running behavior of three single cytokeratin-negative cells from the patient with CUP syndrome and the cancer cells that had already been sequenced was compared. The mutation could be picked up in all cytokeratin-positive cells, whereas the normal cells did not show a changed mobility, as demonstrated in FIG. 7 .
EXAMPLE 10
CGH of Laser-microdissected Single Cells
Analysis of many clinical samples requires the isolation of the cells of interest from the surrounding tissue. It was tested whether the procedure also works in the setting of laser assisted microdissection. In one of the more advanced techniques laser microbeam microdissection (LMM) is combined with laser pressure catapulting (LPC): the cells are cut out and subsequently catapulted into the tube. To avoid the introduction of confounding variables such dissected nuclei cytospins of normal leukocytes were prepared and then isolated the single cells by LMM and LPC. The DNA preparation and CGH was performed as in examples 1-3 and results were as expected: The profiles were normal for normal cells demonstrating that the method is applicable to microdissected single cells the same way as to cells isolated from suspensions.
EXAMPLE 11
Isolation of Single Disseminated Tumor Cells From Lymph Nodes
Lymphogenic metastasis is a very important way for tumor cells to disseminate and often determines the prognosis of the patient. Immunohistochemically/immunocytochemically detectable disseminated tumor cells have been shown to predict the patients outcome in a variety of studies. The genetic changes of these cells have not yet been characterized so far. Cell suspensions from lymph nodes were prepared and tested the application of the present invention. Cell suspensions were prepared using the Medi-Machine from Biorad according to the manufacturer's instructions. Tumor cells were detected by staining with the mab Ber-EP4 from Dako that recognizes the EpCAM epitope and has been shown to be even more specific in lymph nodes than cytokeratin antibodies. Stained cells were isolated and the single cell DNA prepared as mentioned. Then, CGH was performed. Normal, unstained cells demonstrated normal profiles and in tumor cells a variety of aberrations could be detected.
EXAMPLE 12
Isolation of Single Circulating Tumor Cells From Peripheral Blood
In analogy to the analysis of disseminated tumor cells isolated from bone marrow and lymph nodes it was also looked for cells in the peripheral blood of patients with malignant disease. Peripheral blood cells of carcinoma patients were screened with the cytokeratin antibody A45 B/B3, of a melanoma patient with the mab 9.2.27 (from R. Reisfeld, San Diego, USA) directed against the human melanoma associated chondroitin sulfate proteoglycan (MCSP). The blood of a B-CLL patient was screened with an antibody directed against CD24 (antibody from Cymbus Biotechnology, CBL478). The method worked equally well as with cells isolated from bone marrow and lymph node.
EXAMPLE 13
Isolation and Characterization of Single Hb-F Positive Cells
Circulating cells from the child can be detected in the venous blood of the mother during pregnancy and also up to 27 years postpartum, as demonstrated in one study (Bianchi (1996), P.N.A.S. USA 93, 705-709). During pregnancy these cells could be useful for prenatal diagnosis without any danger for the mother and the child. The persistent microchimerism in the mother has been connected to higher prevalence of autoimmune diseases in women. One way to detect these fetal cells is the use of antibodies to fetal hemoglobin (Hb-F) for the detection of erythroblasts. This antibody (mouse mab to Hb-F: Coltag, Cat. No. MHFHOO) was used to detect erythroblasts in umbilical cord blood of a newborn. Single cells were isolated and the methods applied as described. The CGH profiles were normal for all chromosomes. The boy was healthy, as demonstrated in FIG. 8 .
EXAMPLE 14
Fingerprints of Single Cells
The reliability of amplification for a sequence that is only once present in a genome was shown in a large number of experiments to be 90%. This is an important value for the analysis of loss of heterozygosity. However, for fingerprint analysis it is not only important that the sequences are reliably amplified but also that a polymorphism can be identified. In order to test this, the band sizes obtained from a PCR reaction with 3000 cells with those from a single cell were compared. It was detected that—within the known limits of the microsatellite analysis—the bands showed no altered migration behaviour as compared to the positive control. This is demonstrated in FIG. 9 . Therefore, the polymorphic bands can be identified and fingerprints be obtained from single cells.
EXAMPLE 15
Isolation of Single Enzymatically Stained Cells For Routine and Diagnostic Procedures
For many diagnostic and routine uses it is advantageous to avoid immunofluorescence. Ways to prepare cells for experiments that imply routine light microscopy were tested. The first experiments tested which enzymatic staining reaction with alkaline phosphatase can be applied without damaging the DNA. Several commercially available substrates of alkaline phosphatase were tested, such as different preparations of Neufuchsin and BCIP/NBT (Biorad). Only single cells stained with BCIP/NBT were successfully amplified. In a next step, intact cells were isolated from routine slides. For doing so, cells in PBS were pipetted on special positively charged slides (Menzel), where they adhered within 30 minutes, the PBS was discarded and the slide were air-dried. After this treatment routine staining procedures such as the APAAP technique (alkaline phosphatase-anti-alkaline phosphatase technique) with BCIP/NBT development can be applied. Addition of a non-ionic detergent to PBS later helps to overcome the adhesive forces during the micromanipulation for isolation of the stained cells. Results of these experiments are demonstrated in FIG. 10 .
All CGH-, LOH- and SSCP-experiments, i.e. with normal cells from peripheral blood, tumor cells from bone marrow, blood and lymph node, stained with cytokeratine ab, Ber-EP4 and anti-Hb-F have also been performed using this procedure giving equally excellent results.
EXAMPLE 16
Application of the Method of the Invention to Single Cells of Various Sources
In summary, it can be stated that the method of the invention works independently of the source of tissue from which the cell is derived, of the antibody used to detect the rare cell within a cell population or environment and/or of the choice of labeling, i.e. fluorescent dyes or enzymatically activated substrates such as BCIP/NBT (see Table 4).
TABLE 4
Application of single cell PCR to individual cells from different tissues
and diagnostic settings
PCR analysis (Analytical PCR,
LOH, SSCP, fingerprint or
CGH
Sample
sequencing)
analysis
Normal PBL
60
10
PBL with trisomy 21
4
2
Hb-F positive PBL
10
10
Laser-microdissected PBL
2
2
Tumor cells from BM of
carcinomas patients:
Breast cancer
140
69
Prostate cancer
17
9
Gastric cancer
6
Colon cancer
Pancreatic cancer
17
Oesophageal cancer
2
Lung cancer
8
CUP
16
8
Cervix
6
3
Tumor cells from LN of
carcinoma patients:
Gastric
21
Colon
11
Lung
4
Tumor cells from peripheral
blood of carcinoma patients
Breast
3
2
Cervix
3
1
Lung
7
Tumor cells from
peripheral blood of non-
epithelial malignancies
Melanoma
5
1
B-CLL
5
2
M. Hodgkin
1
BM = bone marrow;
LN = lymph node
2
1
21
DNA
Artificial Sequence
Description of Artificial Sequence Synthetic
oligonucleotide
1
agtgggattc cgcatgctag t 21
2
12
DNA
Artificial Sequence
Description of Artificial Sequence Synthetic
oligonucleotide
2
taactagcat gc 12 | The present invention relates to a novel method for the amplification of DNA, this method being particularly useful for the amplification of the DNA or the whole genome of a single cell, chromosomes or fragments thereof. Described is also the use of the method in DNA analysis for medical, forensic, diagnostic or scientific purposes, like comparative genomic hybridization (CGH)-, fluorescence in situ hybridization (FISH)-, polymerase chain reaction (PCR)-, single strand conformation polymorphism (SSCP)-, DNA sequence-, “loss of heterozygosity” (LOH)-, fingerprint- and/or restriction fragment length polymorphism (RFLP)-analysis. | 2 |
BACKGROUND OF THE INVENTION
This invention relates to a fuel injection timing device for adjusting the injection timing for fuel supplied from a fuel injection pump according to the operating conditions of an internal combustion engine.
In an engine of a fuel injection type, fuel is delivered from a fuel injection pump which is driven by the power of the engine, and the injection timing needs to be advanced or delayed according to the operation conditions of the engine, such as change of engine speed. Accordingly, a timer unit is interposed between the engine and the fuel injection pump so that the timing of the engine rotation is advanced or delayed by the timer unit, and is transmitted to a pump driving shaft, for example, a cam shaft of the pump.
FIG. 1 shows an arrangement of a conventional fuel injection timing device in which the fuel injection pump is located outside a cylinder block on the engine side and the timer unit is located between the pump and the cylinder block. In FIG. 1, a gear case 2 is coupled to a cylinder block 1 on the engine side by means of bolts 3. A fuel injection pump 4 is fixed to the gear case 2 by bolts 5. A timer unit 6 is housed in the gear case 2. The timer unit 6, which may be of any conventional type, e.g., of a hydraulically-operated or centrifugal-weight type, advances the timing of the rotation of the engine according to the operating conditions, and transmits the adjusted rotation to a cam shaft 7 used as a pump shaft. The timer unit 6 has a casing 8 and a driven gear 10 coupled to one end of the casing 8 by means of bolts 9. The driven gear 10 is in mesh with a driving gear 11 which is driven by the crank shaft of the engine. The cam shaft 7 is supported on a bearing cover 13 by a bearing 12, and the bearing cover 13 is attached to the pump 4 by means of bolts 14. The bearing cover 13 is fitted in one end of the gear case 2, the other end of which is fitted in an opening 1a of the cylinder block 1.
In the prior art construction as shown in FIG. 1, however, engagement between the driven gear 10 and the driving gear 11 is attained by centering between the cam shaft 7 and the opening 1a of the cylinder block 1 by successively mating the bearing cover 13, the gear case 2, and the opening 1a of the cylinder block 1 with one another. In this case, some fit tolerances need to be set to facilitate the assembly of the mating parts. These fit tolerances or erros, when added up, prevent accurate centering. As a result, the timer characteristic (engine speed-injection timing characteristic) of the timer unit is subject to hysteresis, so that the engine characteristics in case when the engine speed increases and decreases will vary differ from each other.
The gear case 2 is provided outside the casing 8 of the timer unit 6 to form a dual covering structure. Thus, both axial and diametrical dimensions of the timer unit 6 are substantially large, so that the timer unit 6 cannot be used if the space between the pump 4 and the cylinder block 1 is small.
Moreover, the dual structure requires a great distance L between the driven gear 10 and the pump housing 1. Therefore, a great bending moment will probably be applied to the cam shaft 7 to damage the same during the drive.
SUMMARY OF THE INVENTION
The object of this invention is to provide a fuel injection timing device for an internal combustion engine which is capable of high-accuracy centering between a fuel injection pump and the engine, and operates under a stable timer characteristic, and whose number of parts is reduced for miniaturization.
According to this invention, there is provided a fuel injection timing device for an internal combustion engine, which comprises a cam shaft connected to a fuel injection pump, a driven section coupled to the cam shaft and having a driven flange, a driving flange adjacent to the driven flange and coaxial with the cam shaft, a driven gear fixed to the driving flange so as to be coaxial with the cam shaft and in mesh with a driving gear driven by the internal combustion engine in a cylinder block facing the fuel injection pump, cam shaft phase angle changing means for advancing and delaying the cam shaft in phase angle in cooperation with the driving flange and the driven flange, and a casing containing the driven section, the driving flange, and the cam shaft phase angle changing means and having two ends, one of which is supported by the fuel injection pump and the other of which supports the driving flange and is supported by the cylinder block.
BRIEF DESCRIPTION OF THE DRAWINGS
This invention can be fully understood from the following description with reference to the accompanying drawings, in which:
FIG. 1 is a vertical sectional view of a prior art fuel injection timing device;
FIG. 2 is a vertical sectional view of a fuel injection timing device according to one embodiment of this invention;
FIG. 3 is a sectional view taken along line III--III of FIG. 2;
FIG. 4 is a front view of a fitting hole shown in FIG. 2; and
FIG. 5 is a vertical sectional view of a fuel injection timing device according to another embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIGS. 2 and 3, a cylinder block 1, a fuel injection pump housing 4, and a cam shaft 7 are similar to their counterparts shown in FIG. 1.
A casing 20 has its one end fitted in an opening 1a of the cylinder block 1 and coupled to the cylinder block 1 by means of a bolt 21. The other end of the casing 20 is fixed to the pump housing 4 by means of bolts 5. In fixing the casing 20 to the cylinder block 1 by means of the bolt 21, the bolt 21 is passed through a fitting hole 22. As shown in FIG. 4, the fitting hole 22 is an arcuate slot extending along the circumferential direction of the cylinder block 1. Thus, the casing 20 is coupled to the cylinder block 1 so as to be rockable within a range corresponding to the length of the fitting hole 22.
The casing 20 contains a timer unit 23 which constitutes cam shaft phase angle change means. A driving flange 24 is connected to a driven gear 10 by means of bolts 25 at the cylinder block side end of the timer unit 23. A ball bearing 26 is fitted on the outer peripheral surfaces of the abutting regions of the driving flange 24 and the driven gear 10. The outer peripheral surface of the ball bearing 26 is pressed on the inner peripheral surface of one end portion of the casing 20. The ball bearing 26 is set in position on the driving flange 24 and the driven gear 10 by a spacer 27, and is prevented by a snap ring 28 from slipping out of the timer unit 23.
A driven section 29 at the central portion of the timer unit 23 is formed of a hub 30 and a driven flange 31 integrally formed at the cylinder block side end portion of the hub 30. The hub 30 is fixed to the cam shaft 7 by a key 70 and a round nut 32 which is screwed on a threaded portion of the cam shaft 7 on the cylinder block side. The driven flange 31 is in sliding contact with the driving flanges 24 on their opposed end faces, and is fitted in the casing 20 so that its outer peripheral surface may slide on the inner peripheral surface of the casing 20. The driven flange 31 is provided with a pair of dual eccentric cam mechanism 100. Referring now to FIG. 3, the dual eccentric cam mechanism 100 will be described in detail. The driven flange 31 has a pair of circular holes 33 in diametrically opposite positions. A larger eccentric cam 34 is diposed in each of the circular holes 33. An eccentric hole 35 is formed in the larger eccentric cam 34, and a smaller eccentrical cam 37 is rotatably fitted in the eccentric hole 35. A pin 38 protrudes from a portion of the smaller eccentric cam 37 off its center, and is rotatably fitted in the driving flange 24 (FIG. 2). An eccentric pin 39 protrudes from a portion of the larger eccentric cam 34 off its center, and is rotatably passed through the respective one of a pair of sliders 40 which are oppositely arranged in a cylindrical space surrounded by the driven flange 31 and the casing 20 so as to be coaxial with the casing 20 (FIGS. 2 and 3). The sliders 40 are radially moved by a pair of parallel guide shafts 41 passing the opposed ends of the sliders 40, and are urged toward each other by return springs 42. Each return spring 42 has its one end supported by a spring mounting portion 43 at one end portion of the slider 40 with a seat 44 interposed therebetween. The other end of the return spring 42 is supported by another seat 46 which is fitted on the end portion of the guide shaft 41 by means of a circle clip 45. A slide contact plate 47 is interposed between the opposed faces of the sliders 40 and the casing 20 so that the sliders 40 do not directly contact with the casing 20 while rotating (FIG. 2).
Referring to FIG. 2, a sleeve portion 50 surrounding the outer periphery of the hub 30 is integrally formed on the casing 20 at its driven side end portion. An annular pressure chamber 51 is formed around the sleeve portion 50 in the casing 20. An axially slidable cylindrical piston 52 surrounds the hub 30 in the pressure chamber 51. A truncated conical surface 52a is formed at the cylinder block side end portion of the piston 52. The face 52a is in slide contact, with reversely truncated conical surfaces 40a of the sliders 40 complementary thereto. Thus, when the piston 52 is moved to the right of FIG. 2, the sliders 40 are moved outward. Each slider 40 is provided with at least one radially penetrating oil escape hole 53 for the smooth movement of the slider 40.
An oil inlet port 54 on the casing side is connected to the fuel injection pump housing side end of the pressure chamber 51. The port 54 communicates with a pressure control valve 56 through an oil passage 55. The pressure control valve 56 is connected to an oil tank 58 through an engine pump 57 and also through a by-pass line 59. The pressure control valve 56 is opened and closed by an electronic control device 60 such as a microcomputer (CPU). The electronic control device 60 operates the pressure control valve 56 to control the oil pressure in the pressure chamber 51. Signals from various sensors are sent to the electronic control device 60. These signals include signals for the engine exhaust gas temperature T1, engine speed N, advance or delay angle α of the pump driving shaft, ambient temperature T2, ambient pressure P1, fuel injection quantity Q, etc. The electronic control device 60 can also be supplied with signals for various other factors related to the operation of the engine that are detected by conventional sensors.
Oil leaked from the sliding parts in the casing 20 and oil in the space surrounded by the driven flange 31 and the slide contact plate 47 are allowed to escape into the oil tank 58 through a return passage 61 in the casing 20, an escape port 62, and an escape passage 63 connected to the escape port 62.
In operation, the rotation of the engine is transmitted to the driving gear 11 through the crankshaft and then to the driven gear 10. The gear 10 drives the flanges 24, and then flange 31 by means of the pins 38 and the larger and smaller eccentric cams 37 and 34 of the dual eccentric cam mechanism. Thus, the hub 30 rotates the cam shaft 7. As the cam shaft 7 rotates, a plunger (not shown) of the fuel injection pump is operated to inject fuel.
If the driven flange 31 needs to be advanced in phase angle in this state, the electronic control device 60 operates in accordance with the input signals from the sensors and sends the signals to the valve 56. Then, the valve 56 is operated to increase the oil pressure in the pressure chamber 51, so that the piston 52 is moved toward the right of FIG. 2. As the piston 52 moves in this way, the pair of sliders 40 are moved radially outward. The radially outward movement of the sliders 40 causes the large eccentric cams 34 to rock in the direction of arrow A of FIG. 3 by the eccentric pins 39. The rocking of the larger eccentric cams 34 causes the smaller eccentric cams 37 to rock in the direction of arrow B, so that the pins 38 are moved in the direction of arrow C or the circumferential direction of the casing 20, and the driven flange 31 is advanced relatively to the driving flange 31.
As a result, the cam shaft 7 is rotated with respect to the engine shaft in the advancing direction through a required angle. Thus, the injection timing for the fuel injected from the fuel injection pump is advanced.
If the driven flange 31 needs to be delayed in phase angle, an operation reverse to the phase-angle advancing operation is performend.
Thus, when the pressure control valve 56 is controlled by means of the electronic control device 60 to adjust the oil pressure in the pressure chamber 51, the rotation phase difference of the fuel injection timing can be regulated freely.
In the embodiment described above, the pump housing 4 is attached to the cylinder block 1 on the engine side by means of the casing 20 of the timer unit 23 itself. It is therefore unnecessary to use the gear case 2 as shown in FIG. 1, so that the number of parts used in the device, as well as the outer diameter and axial dimension L of the device, can be reduced. Accordingly, the pump housing 4 can be mounted even if the space between the pump housing 4 and the cylinder block 1 is narrow.
For proper engagement between the driven gear 10 and the driving gear 11, the pump housing 4 is first removed from its mounting section (not shown), and the bolt 21 is loosened. Since the ball bearing 26 between the casing 20 and the driving flange 24 supporting the driven gear 10 is located close to the driven gear 10 in the structure of FIG. 2, the engagement between the driven gear 10 and the driving gear 11 will hardly be influenced by lateral movement of the cam shaft 7. Accordingly, the bolts 21 are first tightened, and then the pump housing 4 is fixed to the mounting section. In the prior art device shown in FIG. 1, on the other hand, the ball bearing 12 supporting the cam shaft 7 on the gear case 2 is considerably separated from the driven gear 10, so that the degree of engagement between the driven gear 10 and the driving gear 11 will vary if the pump housing 4 is fixed to its mounting section after previously tightening the bolts 3. Therefore, the engagement between the gears 10 and 11 must be adjusted after fixing the pump housing 4 to its mounting section. Thus, the device of the invention has an advantage over the prior art device, and is less liable to hysteresis in timer characteristic.
The casing 20 can be adjusted along the arcuate fitting hole 22, so that errors in machining and assembly can readily be absorbed, and the injection timing can be set also by rockably adjusting the casing 20.
This invention is not limited to the aforementioned embodiment shown in FIGS. 2 to 4. FIG. 5 shows another embodiment, in which the casing 20 is formed of a main body section 69 surrounding the timer unit 23 and the driven section 29, and a coupling member 700 retaining the ball bearing 26. This embodiment is adapted to the case where the area (D) of the opening portion 1a of the cylinder block 1 is small. In general, the manufacturing cost may be reduced by using a small ball bearing. In this case, however, the ball bearing fitting hole of the casing 20 is so small that the timer unit 23 cannot be put into the casing 20 through the fitting hole. Thereupon, the use of the coupling member 700 facilitates the setting of the timer unit 23 in the casing 20. Namely, after the driven gear 10 is removed, the coupling member 70 is fixed to the cylinder block 1 by means of blots 71, and the casing 20 containing the timer unit 23 is fixed to the coupling member 70 by means of the arcuate fitting hole 22 and the bolt 21. The driven gear 10 is coupled to the driving flange 24 by means of the bolts 25 with a cover 72 removed from the cylinder block 1. Thereafter, the cover 72 is attached to the cylinder block 1.
The timer unit 23 of this invention is not limited to the one which uses the hydraulically operated piston 52 and the dual eccentric cam mechanism, and may also be of, e.g., the conventional centrifugal weight type. | A fuel injection timing device for an internal combustion engine comprises a cam shaft connected to a fuel injection pump, a driven section coupled to the cam shaft and having a driven flange, a driving flange adjacent to the driven flange and coaxial with the cam shaft, a driven gear fixed to the driving flange so as to be coaxial with the cam shaft and in mesh with a driving gear driven by the internal combustion engine in a cylinder block facing the fuel injection pump, and a cam shaft phase angle changing mechanism for advancing and delaying the cam shaft in phase angle in cooperation with the driving flange and the driven flange. The timing device has a casing which contains the driven section, the driving flange, and the cam shaft phase angle changing mechanism. One end of the casing is supported by the fuel injection pump, and the other end supports the driving flange. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to a method of making organo-silicon polymers and more specifically to a method of making such polymers having both mono- and tetra-functional siloxane units.
2. Description of the Prior Art
Organo-silicon polymers having both mono- and tetra-functional siloxane units are well known in the art. In the past, such polymers have generally been prepared by cohydrolysis of a hydrolyzable silane or disiloxane (which are used as the feed material for mono-functional siloxane units) and a silicate salt or an alkyl silicate (which are used as the feed material of the tetra-functional siloxane units.)
When a disiloxane is used as the feed material for the mono-functional siloxane units, the average molecular weight can be controlled, so that the organo-silicon polymer which forms can have a relatively narrow distribution of the average molecular weight.
In Japanese Kokai Patent Application No. Sho 61[1986]-195129 there is proposed such a method wherein tetraethoxysilane or another alkyl silicate is added drop-wise to a mixture of hexamethyldisiloxane or other alkyldisiloxane, concentrated hydrochloric acid, water and ethanol. The drawback of the method, however, is that when a disiloxane having C 2 or higher monovalent hydrocarbon radicals is used as the feed material, the products formed therein have a tendency to gel during reaction. The gel so-formed is resistant to dissolution, even with the addition of more solvent.
In accordance with the method of the present invention, the tendency of the reaction products to gel during formation has been overcome, even when a mixture of disiloxane having C 2 or higher monovalent hydrocarbon radical and alkyl silicate is used as the feed material in making the aforementioned organo-silicon polymer.
SUMMARY OF THE INVENTION
In accordance with the present invention there is provided a method for making an organo-silicon polymer of the general formula:
(Me.sub.2 RSiO.sub.1/2).sub.m (SiO.sub.4/2).sub.n
wherein:
Me is a methyl radical;
R is a substituted or unsubstituted monovalent hydrocarbon radical having two or more carbon atoms; and
the ratio of m/n is between 0.2 and 4;
the method comprising the steps of:
mixing components
(A) a disiloxane of the general formula (Me 2 RSiO) 2 (wherein Me and R are as defined above) and
(B) an alkyl silicate;
said components (A) and (B) being present in a molar ratio of substantially 1/2 m/n;
adding between 0.005 parts and 50 parts by weight of a strong protic acid to 100 parts by weight of the above mixture of components (A) and (B) and allowing the same to react; and
adding an aqueous solution of hydrochloric acid to the above reaction mixture in a drop-wise manner.
As used herein in connection with the description of component (B), the term "alkyl silicate" is meant to include partial hydrolysis products of alkyl silicates.
Also as used herein to describe the addition of certain reactants or catalysts, the term "drop-wise" means that the reactant or catalyst is being added at a relatively slow rate. In the case of an experiment being carried out on a laboratory scale, such additions are made at a rate that is literally drop-wise. Those skilled in the art, however, will recognize that for the same reaction being carried out on a manufacturing or pilot plant scale, the use of the term "drop-wise" will not mean that the addition is literally being made drop-wise, but that the rate of addition is relatively slow.
DETAILED DESCRIPTION OF THE INVENTION
In accordance with the method of the invention, a mixture of a disiloxane and an alkyl silicate is first made. A strong protic acid is then added to the mixture and reaction is allowed to proceed. Thereafter, an aqueous solution of hydrochloric acid is added to the reaction mixture in a drop-wise manner, which results in the production of the organo-silicon polymer.
The disiloxanes used in the method of the invention are represented by the general formula (Me 2 RSiO) 2 , wherein R represents a substituted or unsubstituted monovalent hydrocarbon radical, such as: an ethyl radical, propyl radical, butyl radical, or other alkyl radical; a cyclohexyl radical, or other cycloalkyl radical; a vinyl radical, allyl radical, hexenyl radical, or other alkenyl radical; a phenyl radical, xylyl radical, or other aryl radical; a phenylethyl radical, or other aralkyl radical; or 3-chloropropyl radical, 3,3,3-trifluoropropyl radical, etc. The various types of disiloxanes may be used either alone or in combination.
Examples of alkyl silicates (which by definition include partial hydrolysis products thereof) used in the method of the invention include orthomethyl silicate, polymethyl silicate, orthoethyl silicate, polyethyl silicate, orthopropyl silicate and polypropyl silicate.
Strong protic acid catalysts suitable for practicing the method of the invention include sulfuric acid, trifluoromethanesulfonic acid, chlorosulfonic acid, trichloroacetic acid, trifluoracetic acid, p-toluenesulfonic acid, phosphoric acid, nitric acid, etc.
In the first stage of the method of the invention, a strong protic acid is added to a mixture of the disiloxane, component (A), and the alkyl silicate, component (B), for reaction therewith. The mixing ratio of component (A) to the component (B) should be selected such that the ratio of the mono-functional siloxane units to the tetra-functional siloxane units of the organo-silicon polymer (i.e. m/n) represented by the general formula (Me 2 RSiO 1/2 ) m (SiO 4/2 ) n is between 0.2-4.
The amount of the strong protic acid catalyst added to 100 parts by weight of the sum of components (A) and (B) should be 0.005-50 parts by weight, or preferably 0.015-10 parts by weight.
The first stage of the method of the invention is preferably carried out at a temperature between about 0° C. and 180° C., and more preferably between room temperature and 100° C. The reaction time may depend on the reaction temperature, and is usually 30 minutes to 3 days.
More specifically, the reaction time for the first stage is determined by tracing the decrease in the amount of disiloxane, component (A), using chromatography or other analysis means. In the first stage, a portion of component (A) is decomposed to silane represented by the formula SiOR'(CH 3 ) 2 R (wherein R has the same meaning as above and R' represents the alkyl radical in component (B)), and the other portion is taken up into alkyl silicate in units of (CH 3 ) 2 RSiO.
In carrying out the first stage of the method of the invention, an organic solvent not directly related to the reaction may be added as a diluent to the mixture of components (A) and (B). Examples of such organic solvents include benzene, toluene, xylene and other aromatic hydrocarbons; hexane, heptane, and other alkanes; diethyl ether, tetrahydrofuran, and other ethers; acetone, methyl isobutyl ketone, and other ketones; 1,1,2-trichlorotrifluoroethane, 1,1,1,-trichloroethane, dichloromethane, α,α,α-trifluorotoluene, hexafluoroxylene, and other halogenated hydrocarbons; methanol, ethanol, isopropanol and other alcohols; etc.
In accordance with the method of the invention, a second reaction results when hydrochloric acid solution is added drop-wise to the aforementioned reaction mixture. It is preferred that an aqueous hydrochloric acid solution containing over 5 wt % of hydrogen chloride, or more preferably over 10 wt % hydrogen chloride, be used. The amount of the aqueous hydrochloric acid solution should be enough to ensure that the amount of water contained in the hydrochloric acid solution is enough to perform hydrolysis for all of the alkoxy radicals present after the strong protic acid has been added to the mixture of components (A) and (B). However, it is also acceptable to use more aqueous hydrochloric acid solution. The temperature during the drop-wise addition should be 0°-100° C. It is nevertheless convenient to use the temperature set for the first stage of operation continuously.
After the end of the first stage of the method of the invention and before drop-wise addition of aqueous hydrochloric acid solution in the second stage of the invention, it is acceptable to add hydrolyzable alkyl silane represented by the formula R" 3 SiX (where R" represents a monovalent hydrocarbon radical, X represents halogen atom or alkoxy radical, etc.) as the feed material of mono-functional siloxane units.
As described above, it is possible to manufacture organo-silicon polymers represented by the general formula
(Me.sub.2 RSiO.sub.1/2).sub.m (SiO.sub.4/2).sub.n
where Me, R, m and n have the same meanings as above.
After the method of the invention is used to make the aforementioned organo-silicon polymer, the organic layer is isolated from the water layer; the organic layer is neutralized and washed with water; dehydration is carried out in an azeotropic process with the organic solvent. If needed, the organic solvent is removed, and the desired organo-silicon polymer is isolated.
The following examples illustrate the method of the invention in greater detail. In the examples, Me represents a methyl radical, and Et represents an ethyl radical.
APPLICATION EXAMPLE 1
11.9 g (0.04 mol) of component (A) represented by the formula (CH 2 ═CHC 4 H 8 Me 2 Si) 2 O, 41.6 g (0.2 mol) of tetraethoxysilane, 20 g of toluene, and 0.03 g of trifluoromethanesulfonic acid were added to a flask, and reaction was performed at 65° C. for 5 hours while the mixture was stirred.
As the reaction mixture was analyzed using gas chromatography, it was found that almost all of component (A) disappeared. Then at 60° C., a mixture of 10.1 g of water and 6.8 g of 36% aqueous hydrochloric acid solution was added drop-wise over 30 minutes. After the end of the drop-wise addition, stirring was continued at 72° C. for 6 hours. Then the reaction mixture was cooled and 50 g of toluene were added. The organic layer was isolated from the water layer, and was washed with water to neutrality. It was then moved to a flask with a water isolating tube attached, where dehydration was performed at reflux temperature. After cooling, the solvent was removed, and 14.3 g of light-yellowish transparent oil-like substance were obtained.
The analytical results of the oil-like substance are as follows.
SiNMR δ(ppm): 13(0.33Si, br, CH 2 ═CHC 4 H 8 Me 2 SiO 1/2 ); Si-100(0.19Si, br, ROSiO 3/2 ); -110(0.48Si, br, SiO 4/2 ); (R is CH 3 CH 3 CH 2 or H.).
13 CNMR δ(ppm): 139(1.00C, s, ═CH--); 115(0.94C, s, CH 2 ═); 59(1.54C, s, --OCH 2 CH 3 ); 34(1.00C, s, Si(CH 2 ) 3 CH 2 --); 33(1.06C, s, Si(CH 2 ) 2 CH 2 --); 23(0.90C, s, SiCH 2 CH 2 --); 18(2.56C, s, SiCH 2 -- or --OCH 2 CH 3 ); 0(1.12C, s, SiCH 3 ).
GPC (gel permeation chromatography): Mw: weight-average molecular weight=1.5×10 4 ; Mn: number-average molecular weight=4.1×10 3 .
It was determined that the obtained hexenyl radical-containing silicone resin is an organo-silicon polymer with residual hydroxy radicals and ethoxy radicals on its terminals and having a chemical configuration represented by the average unit formula:
(CH.sub.2 ═CHC.sub.4 H.sub.8 Me.sub.2 SiO.sub.1/2).sub.0.49 (SiO.sub.4/2).sub.1.0
APPLICATION EXAMPLE 2
14.3 g of toluene were added to 14.3 g of the resin product of Application Example 1, followed by addition of 3.2 g (0.02 mol) of (Me 3 Si) 2 NH, and then heating with reflux for 6 hours. After cooling, the reaction mixture was washed once by 50 g of water, neutralized by an aqeuous hydrochloric acid solution, and then washed with water repeatedly. Then a water isolating tube was used to heat the sample with reflux for dehydration, and solvent was further distilled off, forming 15.1 g of light-yellowish oil-like substance.
The analytical results of the oil-like substance are as follows.
29 SiNMR δ (ppm): 13(0.41Si, br, R'Me 2 SiO 1/2 ); -100(0.11Si, br, ROSiO 3/2 ); -110(0.48Si, br, SiO 4/2 ); (R represents CH 3 CH 2 or H, R' represents CH 2 ═CH(CH 2 )CH 4 or Me).
13 CNMR δ (ppm): 139(1.00C, s, ═CH--); 115(1.00C, s, CH 2 ═); 59(0.25C, s, --OCH 2 CH 3 ); 34(1.06C, s, Si(CH 2 ) 3 CH 2 --); 33(1.06C, s, Si(CH 2 ) 2 CH 2 --); 23(0.94C, s, SiCH 2 CH 2 --); 18(1.28C, s, SiCH 2 -- or --OCH 2 CH 3 ); 0(3.56C, s, SiCH 3 ).
GPC (gel permeation chromatography): Mw: weight-average molecular weight=8.2×10 4 ; Mn: number-average molecular weight=4.0×10 3 .
It was determined that the obtained hexenyl radical-containing silicone resin is an organo-silicon polymer with residual hydroxy radicals and ethoxy radicals on its terminals and having a chemical configuration represented by the average unit formula:
(Me.sub.3 SiO.sub.1/2).sub.0.22 (SiO.sub.4/2).sub.1.0 (CH.sub.2 ═CHC.sub.4 H.sub.8 Me.sub.2 SiO.sub.1/2).sub.0.48
COMPARATIVE EXAMPLE 1
The method described in Japanese Kokai Patent Application No. Sho 61[1986]-195129 was adopted in a test to synthesize an organo-silicon polymer represented by the formula (CH 2 ═CHC 4 H 8 Me 2 SiO 0 .5) 0 .45 (SiO 2 ) 1 in the following process: 6.71 g (0.0225 mol) of disiloxane represented by the formula (CH 2 ═CHC 4 H 8 Me 2 Si) 2 0, 4 g of toluene, 2 g of ethanol, 2 g of acetone, and 8 g of 12N hydrochloric acid were mixed by stirring and heating at 76° C., while 20.8 g (0.1 mol) of ethyl silicate were added drop-wise. However, midway through the drop-wise addition of ethyl silicate, a gel-like substance was generated. The gel-like substance could not be dissolved even after adding an organic solvent.
APPLICATION EXAMPLE 3
6.52 g (0.02 mol) of disiloxane represented by the formula (CF 3 CH 2 CH 2 Me 2 Si) 2 0 20.8 g (0.1 mol) of tetraethoxysilane, 12.0 g of α,α,α-trifluorotoluene as the organic solvent and 0.02 g of trifluoromethanesulfonic acid were added to a flask, and reaction was performed at 65° C. for 5 hours while the mixture was stirred.
Then at 65° C., a mixture of 10.1 g of water and 6.8 g of 36% aqueous hydrochloric acid solution were added drop-wise over 30 minutes. After the end of the drop-wise addition, stirring was continued at 77° C. for 30 minutes. Then the reaction mixture was cooled and the organic layer was isolated from the water layer, and was washed with water to neutrality. It was then moved to a flask with a water isolating tube attached, where dehydration was performed at reflux temperature. After cooling, the solvent was removed, and 13.9 g of white solid substance at room temperature were obtained.
The white solid substance obtained was soluble in tetrahydrofuran, acetone, methyl isobutyl ketone, α,α, α-trifluorotoluene, and other organic solvents. The analytical results of the white solid substance are as follows.
29 SiNMR δ(ppm): 13(0.30Si, br, CF 3 CH 2 CH 2 Me 2 Si 1/2 ); -100(0.25Si, br, ROSiO 3/2 ); -110(0.45Si, br, SiO 4/2 ); (R is CH 3 CH 2 or H.).
13 CNMR δ(ppm): 128(3.81C, q, --CF 3 ); 59(0.91C, s, --OCH 2 CH 3 ); 28(4.20C, s, --SiCH 2 CH 2 CF 3 ); 18(1.00C, s, --OCH 2 CH 3 ); 10(4.06C, s, SiCH 2 --); 0(8.16C, s, S, SiCH 3 ).
GPC (gel permeation chromatography): Mw: weight-average molecular weight=8.0×10 3 ; Mn: number-average molecular weight=6.2×10 3 .
It was determined that the obtained trifluoropropyl radical-containing silicone resin is an organo-silicon polymer with residual hydroxy radicals and ethoxy radicals on its terminals and having a chemical configuration represented by the average unit formula: (CF 3 C 2 H 4 Me 2 SiO 1/2 ) 0 .43 (SiO 4/2 ) 1 .0
COMPARATIVE EXAMPLE 2
The method disclosed in Japanese Kokai Patent Application No. Sho 61[1986]-195129 was used. 18.6 g (0.1 mol) of disiloxane represented by the formula (CH 2 ═CHMe 2 Si) 2 O, 30 g of toluene, 6 g of acetone, 6 g of ethanol, 12 g of concentrated hydrochloric acid and 17 g of water were mixed. While the mixture was stirred at 70° C., 83.3 g (0.4 mol) of ethyl silicate were added drop-wise. After cooling, 100 ml of toluene were added. After isolation from the water layer, the organic layer was washed with water to neutrality, and dehydration was carried out by azeotropic process with toluene. Then 11.3 g of hexamethyldisilazane were added, followed by heating with reflux for 6 hours in toluene solvent. The organic layer was then washed with water to neutrality, and dehydration was performed with azeotropic process with toluene to further remove the low-boiling-point components, forming the organo-silicon polymer. This organo-silicon polymer was in solid form at room temperature. The organo-silicon polymer was dissolved in toluene with a concentration of 10 wt %. It was found that when the solution was filtered under a reduced pressure using No. 5A filter paper, clogging occurred, and the filtering property was poor.
APPLICATION EXAMPLE 4
18.6 g (0.1 mol) of disiloxane represented by the formula (CH 2 ═CHMe 2 Si) 2 O, 83.3 g (0.4 mol) of tetraethoxysilane, 40 g of toluene and 4 g of 98% sulfuric acid were blended and heated at 80° C. for 6 hours. Then a mixture of 12 g of 12N hydrochloric acid and 20 g of water was added drop-wise. After the end of the drop-wise addition, stirring was continued at 76° C. for 4 hours.
Then the reaction mixture was cooled and 50 g of toluene were added. After the organic layer was isolated from the water layer, it was washed with water to neutrality. It was then moved to a flask with a water isolating tube attached, where dehydration was performed at reflux temperature. Then toluene was removed until the solids content became 50 wt %. After cooling, 11.3 g of hexamethyldisilazane were added, followed by 6 hours of heating with reflux. After cooling, the organic layer was washed with water to neutrality, and dehydration was performed with an azeotropic process with toluene to further remove the organic solvent, forming organo-silicon polymer. NMR analysis of the organo-silicon polymer indicated that it has a chemical configuration represented by the formula (CH 2 ═CHMe 2 SiO) 0 .5 (Me 3 SiO 0 .5) 0 .1 (SiO 2 ) 1 .0, and is in solid form at room temperature.
The organo-silicon polymer was dissolved in toluene to form a solution with a concentration of 10 wt %. When it was filtered using a No. 5A filter paper under a reduced pressure, excellent filtration property was displayed, and there was no problem.
APPLICATION EXAMPLE 5
45.0 g (0.15 mol) of disiloxane represented by formula (CH 2 ═CHC 4 H 8 SiMe 2 ) 2 O, 624.9 g (3.00 mol) of tetraethoxysilane, 360.0 g of toluene, and 240 μL of trifluoromethanesulfonic acid were added to a flask, and reaction was performed at 65° C. for 5 hours while the mixture was stirred. As the reaction mixture was analyzed using gas chromatography, it was found that almost all of the disiloxane represented by the formula (CH 2 ═CHC 4 H 8 Me 2 Si) 2 O disappeared. After cooling, 141.6 g (1.20 mol) of trimethylethoxysilane were added, followed by heating and stirring. Then at 60° C., a mixture of 151.2 g of water and 102.0 g of 36% aqueous hydrochloric acid solution was added drop-wise in 30 min. After the end of the drop-wise addition, stirring was continued at 73° C. for 4 hours. Then the reaction mixture was cooled, the lower organic layer was taken and 550 g of toluene were added to it. It was then moved to a flask with a water isolating tube attached, where dehydration was performed at reflux temperature, and toluene was removed until the solid concentration became 50 wt %. After cooling, 145.3 g (0.9 mol) of hexamethyldisilazane were added, followed by 6 hours of heating with reflux. After cooling, the organic layer was washed with water to neutrality, and dehydration was performed using azeotropic process with toluene; the solvent was removed, and 324.8 g of light-yellowish transparent solid substance were obtained.
The analytical results of the solid substance are as follows.
29 SiNMR δ (ppm): 13(0.41Si, br, R'Me 2 SiO 1/2 ); -100(0.07Si, br, ROSiO 3/2 ); -110(0.52Si, br, SiO 4/2 ); (R is CH 3 CH 2 or H, R' represents CH 2 ═CH(CH 2 ) 4 or Me.).
13 CNMR δ (ppm): 139(0.82C, s, ═CH--); 115(0.82C, s, ═CH 2 ); 59(1.36C, s, --OCH 2 CH 3 ); 34(1.00C, s, Si(CH 2 ) 3 CH 2 --); 33(1.09C, s, Si(CH 2 ) 2 CH 2 --); 23(1.00C, s, SiCH 2 CH 2 --); 18(2.45C, s, SiCH 2 -- or --OCH 2 CH 3 ); 0(12.30C, s, SiCH 3 ).
GPC (gel permeation chromatography): Mw: weight-average molecular weight=6.5×10 3 ; Mn: number-average molecular weight=3.1×10 3 .
It was determined that the obtained hexenyl radical-containing silicone resin is an organo-silicon polymer with residual hydroxy radicals and ethoxy radicals on its terminals and having a chemical configuration represented by the average unit formula:
(CH.sub.2 ═CHC.sub.4 H.sub.8 Me.sub.2 SiO.sub.1/2).sub.0.14 (Me.sub.3 SiO.sub.1/2).sub.0.54 (SiO.sub.4/2).sub.1.0 | There is disclosed a method for making organo-silicon polymers from alkyldisiloxanes and alkylsilicates wherein the alkyl groups of the disiloxanes have two or more carbons. Gelling of the organo-silicon polymers is avoided by; first mixing the disiloxane with the alkylsilicate and adding thereto a strong protic acid; and, after reaction has occurred in the aforementioned mixture, adding thereto, in a drop-wise manner, a solution of hydrochloric acid. | 2 |
RELATED APPLICATIONS
This patent application is a divisional of prior application U.S. Ser. No. 11/894,359, filed on Aug. 24, 2007, now pending; which is a continuation-in-part of U.S. Ser. No. 11/005,561, filed on Dec. 6, 2004, now pending; which is a divisional of Ser. No. 10/329,630, filed on Dec. 6, 2002, which issued as U.S. Pat. No. 6,858,140 on Feb. 22, 2005; all of which are incorporated herein.
FIELD OF THE INVENTION
The present invention relates generally to water and wastewater treatment processes. More particularly, the present invention relates to stationary cloth media filtration systems and devices, as well as processes and devices for uniform flow distribution and backwashing.
BACKGROUND OF THE INVENTION
There are a variety of established water and wastewater treatment systems. One type that has been in use for decades, in one form or another, is granular media gravity filtration. Granular media gravity filters, such as conventional deep bed sand filters, are used to strain out particles from a wastewater stream. Typically, wastewater is introduced into a sand filtration region from an influent chamber through inlet ports. The influent flows by gravity through the granular media filter, such as sand contained by a porous plate, to an effluent chamber. The granular media filter bed, which is typically divided into a series of adjacent cells, is then periodically cleaned using a variety of backwash procedures. See, for example, U.S. Pat. No. 4,152,265.
Another well known type of water and wastewater filtration is rotating cloth media filtration, often referred to as disk or drum filtration. In general, disk or drum filtration systems include a tank having an inlet and outlet and a rotatable filter frame positioned between the inlet and outlet. Cloth filter media is stretched over large drums or disk-type frame sections of the rotatable filter frame. During filtering, influent flows into the tank and passes through the cloth filter media, depositing the suspended solids on the filter media. The filtered effluent is then discharged from the tank outlet. See, for example, U.S. Pat. Nos. 4,090,965 and 4,639,315. The cloth filter media is periodically cleaned by a variety of procedures, including backwashing and/or high pressure sprays. See, for example, U.S. Pat. Nos. 5,374,360, 5,876,612 and 6,090,298. And, an improved self-aligning backwash system, among other things, for cleaning stationary cloth media is also described in U.S. Publication No. US2005/0161393A1, which is also incorporated herein.
In the early 1970's, a stationary cloth media filtration system was attempted in Europe. As shown schematically in FIG. 29 , it is believed that this system included a filtration basin with a series of rectangular effluent chambers, each effluent chamber sandwiched between a pair of rectangular influent chambers. The vertical walls between influent chambers and the effluent chamber had a series of openings or windows across which cloth media screens were attached ( FIG. 30 ). In operation, the wastewater to be treated was introduced into the influent chambers through subsurface gates. The influent was filtered by passing the flow through the screened windows of the filtration walls into the effluent chamber. From there, the filtered effluent flowed through subsurface gates to be discharged. The screens of this system were periodically cleaned by backwashing, which was accomplished by pulling a backwash header vertically up against the cloth filter media, using a submerged chain and sprocket arrangement.
This attempt at stationary cloth media filtration suffered from a number of problems. For example, if one of the filter screens failed, that whole section of the filtration system would have to be shut down, i.e., 2 influent chambers and associated effluent chamber. In addition, because of their design, the seals around the filtration screens were prone to leaks or failure, resulting in poor quality effluent. Similarly, since most of the moving parts, such as the chain and sprocket system needed for backwashing, were submerged, the chambers had to be dewatered before maintenance could be conducted. In short, this attempt at a cloth filtration system was very complicated and inefficient. It is believed that the system was a failure and was abandoned. As a result, the industry moved in the direction of rotating cloth media filtration methods, as generally described above.
Cloth media filtration systems require that the cloth filter media be subject to periodic cleaning, such as by backwashing and/or high pressure spray. Typical backwashing, in a system such as that shown in FIGS. 29 and 30 , includes a suction header and backwash shoe assembly which is pressed directly against and pulled along the cloth filter media surface. In operation, a vacuum is applied to the suction header, pulling fluid through the cloth filter media and the backwash shoe in a direction opposite the flow direction during filtering (see FIG. 31 ). This reverse flow removes much of the accumulated solids caught in and blocking the cloth filter media. Typically, the suction header and shoe press directly against the cloth filter media (including the area where the cloth media is pulled against the frame assembly) in the conventional backwash arrangement (even when backwashing is not being conducted), which may put the cloth filter media under a preload. This may result in increased wear and premature break-through of the cloth filter media.
As indicated, regardless of whether cloth media filtration is stationary or rotating, it is necessary to periodically backwash the cloth filter media. In stationary cloth systems, backwashing is typically conducted in conjunction with traversing or traveling bridge type systems. In larger systems, a large number of backwash arms, sequencing valves and control wires may be necessary to properly effectuate the backwashing operation. In addition, in known traversing backwash systems for stationary cloth media filtration, a number of sequencing valves are required to coordinate the backwashing operation to the desired arm and/or shoe. More complicated control wiring is also required.
Conventional rotating cloth media filtration also has some inherent limitations. For example, the filtration area is limited by the size of the disks/drums and/or tanks. Larger disks/drums require deeper and larger tanks, increasing their construction costs. The retrofit or construction of smaller tanks requires smaller disks, which reduces the filtration surface area.
Again, regardless of the type of filtration media used, uneven flow distribution over the volume of the filtration basin or region is a potential problem. For example, uneven or non-uniform flow distribution within the filtration basin or region often results in sludge settling, particularly in areas of low turbulence. This often results in the need for additional sludge removal equipment or increased system down time. In addition, non-uniform flow velocity across the filter may also result in increased sludge settling.
Thus, while the conventional deep bed sand and rotating disk filtration systems generally described above have been widely and successfully used in a variety of applications, each of these systems suffer from drawbacks inherent in or related to their size, design and/or application.
SUMMARY OF THE INVENTION
The present inventions preserve the advantages of known water and wastewater treatment filtration systems and devices and provide new features, advantages and benefits over these systems. In addition, the present inventions preserve the advantages of known systems and devices that may be used and/or are associated with these systems and provide new features, advantages and benefits.
For example, the present inventions provide higher quality effluent (even at high solids and hydraulic loading rates), lower backwash rates and higher capacity for a given basin footprint, when compared to conventional sand filters. They also eliminate sand or other granular media, making backwashing faster and more efficient. When compared to rotating disk-type or drum-type cloth media filtration systems, the present inventions provide, among other things, higher capacity while maintaining a comparably high quality effluent, continuous filtration during the backwash cycle and the elimination of the necessity for rotary disks and drums and their associated hardware. The present invention also provides more uniform flow distribution in the basin and over the filtration media, regardless of the type of filtration media used. The present inventions also improve the backwashing operation and reduce wear and break-through of cloth filter media for a variety of types of cloth media filtration.
In addition, the present inventions provide for effective stationary cloth media filtration, using unique filter plates that overcome the disadvantages of the previously attempted stationary cloth media filtration. Uniform flow distribution and decreased sludge settling, as well as improved backwashing procedures, are also provided.
The present inventions also provide for an improved backwash assembly having rotating backwash arms which are capable of cleaning more than one row of cloth media filtration surfaces. This results in a reduction of the number of backwash arms and sequencing valves required to conduct the backwash operation.
In a preferred embodiment of the present invention, a stationary cloth media filtration system for treating an influent flow of water or wastewater in a filtration basin is provided having an influent channel that receives influent flow; at least one influent plenum having metering slots to distribute the influent flow across the bottom of the filtration basin; at least one effluent plenum sealed from the unfiltered influent; and, at least two adjacent filter plates supporting a cloth filter media to filter the influent in a filtration region of the filtration basin, said at least two adjacent filter plates in fluid communication with said at least one effluent plenum through which the filtered effluent is discharged from the system. In addition, a preferred embodiment also provides a backwash assembly to periodically clean said cloth filter media on said at least two adjacent filter plates, said backwash assembly including at least one rotating backwash arm. The rotating backwash arm may also include a fixed attachment assembly, a sealed rotation assembly and a shoe attachment assembly. A motor may also be provided on a traveling bridge structure to cause the selective rotation of the rotating backwash arms.
In a preferred embodiment of the present invention, a stationary cloth media filtration system for treating a flow of water or wastewater in a filtration basin is provided which includes at least one influent plenum having metering slots to distribute the influent flow across the bottom of the filter basin; at least one effluent plenum sealed from the influent plenum to discharge filtered flow from the system; a filtration region having a series of filter plates which are in fluid communication with the effluent plenums; and, a backwash assembly to periodically clean the filter plates. Preferred embodiments may also include generally trapezoidally shaped, influent and effluent plenums that are complementary to one another and located along the bottom of the filter basin. Moreover, filter plates may be fastened directly to the plenums. Preferred embodiments may further include a backwash system having rotatable backwash arm assemblies.
Also in a preferred embodiment of the present invention, a method of treating water or wastewater in a filtration basin using filter plates is provided. The method includes providing an influent flow of water or wastewater to be treated to an influent channel and uniformly distributing the influent flow along the length of the bottom of the filter basin; distributing the influent flow uniformly across the width of the bottom of the filter basin; filtering the influent flow with the filter plates; discharging the filtered effluent with a relatively constant flow velocity and reduced head loss; and, periodically cleaning the filter plates with suction. Preferred embodiments may also include a backwash system having rotatable backwash arm assemblies.
The present inventions also provide a system for providing uniform flow distribution for filtering a water or wastewater influent flow in a filtration region with at least one trapezoidally shaped influent plenum with orifices to distribute the influent flow into the filtration region, and at least one trapezoidally shaped effluent plenum having orifices to receive the filtered effluent flow.
Another preferred embodiment of the present invention provides an improved backwash system for backwashing cloth filter media attached to a frame. This system includes a backwash header, a backwash shoe and a means to create a gap between the backwash shoe and the cloth filter media.
Still another preferred embodiment of the present invention provides an improved traversing backwash system that includes rotating backwash arm assemblies capable of conducting the cleaning operation on multiple cloth filter media surfaces. Such embodiments may include a fixed attachment assembly, a sealed rotation assembly and a shoe attachment assembly. A means for simultaneous rotation of a number of rotatable arms may also be provided. And, a flow shut off valve or valve assembly may be provided for the outside rotating backwash arms to prohibit the application of suction to those arms when backwash is not desired.
Yet another embodiment of the present invention provides an improved backwash system for backwashing cloth filter media attached to a frame, including a suction header, a rotating backwash arm in fluid communication with said suction header, a backwash shoe in fluid communication with said rotating backwash arm and a rotating means to cause the selective rotation of said rotating backwash arm. A preferred rotating backwash arm assembly may include a fixed attachment assembly, a sealed rotation assembly engaged with said fixed attachment assembly and a shoe attachment assembly mounted to said sealed rotation assembly. Flow restriction means for selectively stopping backwash to a particular rotating backwash arm may also be provided.
The present invention also provides at least one rotating backwash arm assembly for backwashing cloth filter media, said rotating backwash arm attached to a traveling bridge assembly, including a sealed rotation assembly and a shoe attachment assembly including a backwash shoe. In addition, the present invention may also provide a system for backwashing at least one filter plate and having at least two rotating backwash arm assemblies for periodically cleaning the cloth filter media on the at least one filter plate.
The present inventions still further provide a stationary cloth media filtration system for treating an influent flow of water or wastewater in a filtration basin. An influent channel which receives the influent flow and distributes the influent flow into the filtration basin is also provided with at least one outlet sealed from the unfiltered influent; at least two adjacent filter plates supporting a cloth filter media to filter the influent in a filtration region of the filtration basin, the at least two adjacent filter plates in fluid communication with the at least one outlet through which the filtered effluent is discharged from the system; and, a backwash assembly to periodically clean said cloth filter media on the at least two adjacent filter plates, the backwash assembly including at least one rotating backwash arm. A traveling bridge that transverses the length of the filtration basin and/or which serves as a suction manifold for the backwash assembly may also be provided.
The present inventions further provide for a method for backwashing cloth filter media attached to a frame including the steps of introducing untreated influent into a treatment basin; filtering the influent through cloth filter media; periodically cleaning at least one surface of the cloth filter media by backwashing through a rotating backwash arm assembly in fluid communication with a suction header; and, selectively rotating the backwash arm assembly to enable the backwashing of an adjacent cloth filter media surface.
Accordingly, it is an object of the present invention to provide processes and devices for stationary cloth media filtration and/or the backwashing thereof;
Another object of the present invention is to provide processes and devices for stationary cloth media filtration that may be retrofit into existing filtration basins or designed for new installations;
An additional object of the present invention is to provide processes and devices for stationary cloth media filtration that provide the capability of continuous filtration during backwashing;
A further object of the present invention is to provide processes and devices for stationary cloth media filtration with high quality effluent and the maintenance of high quality effluent at high solids and high hydraulic loading rates;
Still another object of the present invention is to provide processes and devices for stationary cloth media water and wastewater filtration that eliminate the need for traditional granular media;
Still an additional object of the present invention is to provide processes and devices for stationary cloth media filtration that may provide cost advantages over traditional granular media filtration, including but not limited to, reduced site footprint requirements, resulting in less land use, decreased concrete costs, as well as reduced enclosure costs in colder climates, and/or reduced operational, maintenance and manufacturing costs, such as the ability to change components above the water, easy replacement of cloth media filter membranes and the like;
Still a further object of the present invention is to provide processes and devices for the uniform fluid flow distribution into and/or over the volume of a filtration region or filtration basin;
Still an additional object of the present invention is to provide processes and devices for the maintenance of consistent flow velocity in a filtration region or filtration basin;
Yet an additional object of the present invention is the uniform distribution of flow in a filtration basin or filtration region;
Yet another object of the present invention is to provide processes and devices for distributing and/or collecting flow in a filtration region or basin having increased turbulence at the lower portion of the filtration region or filtration basin and/or reduced amounts of sludge settlement or other solids and/or a reduced need for dedicated sludge removal equipment;
Yet a further object of the present invention is to provide processes and devices that effectuate uniform flow distribution over the filtration region or basin using a combination of influent and effluent channeling to control flow and distribution;
Still yet another object of the present invention is to provide processes and devices for improved backwashing of cloth filter media and/or the integration of rotating backwash arms to the suction header to reduce the number of or eliminate sequential valves;
Still yet an additional object of the present invention is to provide processes and devices for cloth filtration media backwashing without a preload on the cloth filter media;
Still yet a further object of the present invention is to provide processes and devices for cloth filter media backwashing, including a stop to position the suction header and shoe away from the cloth filter media;
Still yet a further object of the present invention is to provide an improved backwash assembly including a rotating backwash arm that is capable of cleaning more than one row of cloth filter media and/or which reduces the number of backwash arms or shoes required, eliminates or reduces sequencing valves and/or reduces control wiring;
An additional object of the present inventions is to provide a traveling bridge assembly that serves as a common suction header/manifold for a plurality of backwash arms;
Still yet a further object of the present invention is to provide processes and devices for backwashing cloth filter media that extend cloth filter media life by decreased wear rate; and,
Still yet a further object of the present invention is to provide water and wastewater filtration systems and devices that include one or more of the above stated objects, features or advantages, alone or in combination.
Definition of the Terms
The following terms which may be used in the various claims of this patent are intended to have their broadest meaning consistent with the requirements of law:
Cloth filter media: Any permeable cloth-like material, including but not limited to natural or synthetic fiber or membrane compositions.
Filtration basin: The overall area devoted to the filtration process, which may typically be divided into various filtration regions, and which may have associated chambers, channels and the like.
Filtration region: The area or areas in a filtration basin where water and wastewater filtering is conducted, for example, by using stationary cloth filter media in accordance with the present inventions.
Filter plate(s): The cloth media filter frame assembly, including at least the side, top and bottom frame members, and associated cloth filter media. It may optionally include other components as well and the term may often be used interchangeably with filter frame assembly herein.
Traveling bridge assembly: The structural and mechanical assembly typically located above the filtration basin that carries the components necessary to conduct the backwash and other operations, including the common suction header and/or manifold, and which is able to traverse the effective length or portion of the filtration region or filtration basin.
Where alternative meanings are possible, in either the specification or claims, the broadest meaning is intended. All words used in the claims are intended to be used in the normal, customary usage of grammar and the English language.
BRIEF DESCRIPTION OF THE DRAWINGS
The above described objects, features and advantages, as well as other features and advantages of the present inventions will become apparent by reference to the specification and drawings; wherein like reference numbers are used for like elements among the several views, and in which:
FIG. 1 is a side perspective view of a typical configuration of a filtration basin of the present invention having an exemplary two filtration regions;
FIG. 1A is a top plan view of the typical arrangement of the filtration basin of FIG. 1 of the present invention;
FIG. 1B is a bottom perspective view looking from below the typical configuration of the present invention of FIG. 1 ;
FIG. 2 is a side cross-sectional schematic view of a typical arrangement of a filtration region of a filtration basin of the present invention having an effluent baffle as a way to control water elevation in the system;
FIG. 2A is a side cross-sectional schematic view of a typical arrangement of a filtration region in a filtration basin of the present invention having an effluent slide gate as an alternative way to control water elevation in the system;
FIG. 3 is a perspective view of portions of the filtration region of the present invention showing the major overall components thereof;
FIG. 4 is a top plan view of a preferred embodiment of an effluent plenum and associated filter frame support mounts of the present invention;
FIG. 5 is a side elevational view of the preferred effluent plenum and filter frame support mounts of FIG. 4 ;
FIG. 6 is an end section view of the effluent plenum and associated filter frame support mounts of FIGS. 4 and 5 , showing the closed end of a preferred effluent plenum;
FIG. 6A is an end plan view of the effluent plenum of FIGS. 4 and 5 , showing the influent or open end of a preferred effluent plenum;
FIG. 7 is a perspective view of a preferred effluent plenum and an alternative arrangement of the associated filter frame support mounts of the present invention, also showing the effluent end of a preferred effluent plenum;
FIG. 7A is a perspective view of a preferred and an associated filter frame support mount, including a schematic view of a filter plate engaged with the filter frame support mount;
FIG. 8 is a perspective view of a preferred effluent plenum and an alternative arrangement of the associated filter frame support mounts of the present invention showing the effluent end of a preferred effluent plenum, the alternative arrangement of filter frame mounts on the effluent plenum and including schematic view of several of the filter frames engaged with their associated filter frame supports;
FIG. 9 is a bottom perspective view of a pair of adjacent effluent plenums looking up from below the representative plenums and showing an influent plenum of the present invention formed from the complimentary exterior of the adjacent effluent plenums;
FIG. 10 is a bottom perspective view of additional adjacent effluent plenums of the present invention showing influent plenums formed from the complimentary exterior of the adjacent effluent plenums;
FIG. 11 is a front plan view of a typical filter frame assembly and associated hardware of the present invention;
FIG. 12 is a side plan view of a typical filter frame assembly and associated hardware of FIG. 11 ;
FIG. 13 is a top plan view of the filter frame assembly and associated hardware of FIG. 11 ;
FIG. 14 is a top view of a filter frame support mount and a filter frame pin retaining plate of the present invention;
FIG. 15 is a side view of the filter frame support mount of FIG. 14 ;
FIG. 15A is an end view of the filter frame support mount and filter frame retaining plate of FIG. 15 ;
FIG. 16 is a top view of a preferred pin retaining plate of FIG. 14 ;
FIG. 16A is a side view of a preferred pin retaining plate of FIG. 16 ;
FIG. 16B is an end side view of a preferred pin retaining plate of FIG. 16 ;
FIG. 17 is a bottom perspective view of two mating filter frame support mounts on adjacent effluent plenums, showing the open end of the filter frame support mount for receiving a portion of the pin retaining plate, and also showing components of a preferred pin retaining bracket of the present invention
FIG. 17A is a top plan view of a preferred pin retaining bracket of a filter frame assembly of the present invention;
FIG. 18 is a bottom view of the filter frame assembly showing a preferred interface between the filter frame and effluent plenum;
FIG. 18A is a side view of the filter frame assembly and a preferred interface between the filter frame and effluent plenum of FIG. 18 ;
FIG. 19 is a perspective view of the orientation of the pin retaining plate of the filter frame support arm and a pin retaining bracket on the filter frame assembly;
FIG. 20 is a perspective view of two adjacent filter frame assemblies showing their alignment with two adjacent and corresponding filter frame support mounts;
FIG. 21 is a side plan view of a spring loaded fastener of the present invention used to secure the filter frame assembly to the filter frame support mount;
FIG. 22 is a schematic view of the general configuration of the motion imparting components of a typical traveling bridge assembly of the present invention;
FIG. 23 is a perspective view of the general configuration of a typical traveling bridge assembly of the present invention shown in a first position;
FIG. 24 is a perspective view of the general configuration of a typical traveling bridge assembly of the present invention shown in a second position;
FIG. 25 is a side perspective view of selected components of a typical traveling bridge assembly showing the overall backwash system components of the present invention;
FIG. 26 is a side plan view of a backwash system of the present invention applied to a filter frame assembly, including cloth filter media, of the present invention;
FIG. 27 is a side perspective view of the backwash system component of the present invention of FIG. 26 ;
FIG. 28 is a side schematic view of the backwash operation of the present invention;
FIG. 29 is a schematic plan view of the general arrangement of a prior art cloth media filtration system;
FIG. 30 is a schematic sectional view of a filtration wall and windows of the prior art filtration system taken along line A-A of FIG. 29 ;
FIG. 31 is a schematic side view of a typical prior art suction header and shoe for backwashing cloth filter media showing direct contact between the suction header and cloth filter media;
FIG. 32 is a plan perspective view of a backwash system having a preferred rotating backwash arm shown in a typical stationary cloth media filtration system;
FIG. 33 is a bottom perspective view of a preferred backwash system of FIG. 32 the present invention with the tank or filtration basin components removed to show preferred rotating arm assemblies and their orientation relative to typical longitudinal spaced rows of filter plates;
FIG. 34 is a bottom perspective view of a preferred embodiment of the rotating backwash arms of FIG. 32 connected to a typical traveling bridge assembly;
FIG. 35 is a schematic view showing the general arrangement of a preferred embodiment of the present invention of the rotating arms in relation to the cloth filter media;
FIG. 36 is a perspective view of a preferred rotating arm assembly of the present invention;
FIG. 37 is a perspective view of a preferred rotating arm assembly of FIG. 36 , cut in half on its longitudinal axis to show the structure and orientation of the preferred components;
FIG. 38 is a perspective view of a preferred fixed attachment assembly of the present invention, shown with an optional valve plate for use with a backwash arm that is on the outside row of filter plates;
FIG. 39 is a side cross-sectional view of the preferred fixed attachment assembly of FIG. 38 ;
FIG. 40 is a perspective view of a preferred sealed pipe assembly of a preferred rotating backwash arm of the present invention;
FIG. 41 is a side cross-sectional view of the preferred sealed pipe assembly of FIG. 40 ;
FIG. 42 is a plan view of a preferred embodiment of a shoe attachment assembly of the present invention;
FIG. 43 is a perspective view of a preferred backwash shoe of the present invention;
FIG. 44 is a cross sectional view of a preferred rotating backwash arm assembly, shown assembled, and including an optional valve plate and rotating valve plate;
FIG. 45 is a perspective view of a typical traveling bridge assembly showing a preferred drive means for causing the selective rotation of the rotating backwash arm assemblies and which may function as a common suction manifold/header;
FIG. 46 is a perspective view of a preferred valve plate of the present invention;
FIG. 47 is a perspective view of a preferred rotating valve plate of the present invention; and,
FIG. 48 is a perspective view of a preferred end cap of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Set forth below is a description of what is currently believed to be the preferred embodiments or best representative examples of the inventions claimed. Future and present alternatives and modifications to the preferred embodiments are contemplated. Any alternatives or modifications which make insubstantial changes in function, purpose, structure, use or result are intended to be covered by the claims of this patent.
The general layout of a typical configuration of one embodiment of the present invention may be seen by reference to FIGS. 1 and 1A . The present invention may be designed to fit into the footprint of an existing filtration basin to replace, for example, a granular media gravity filtration system. It may also be designed for a completely new facility, or installed in a tank arrangement similar to conventional disk filtration. Moreover, many aspects of the present invention may be applicable to other water and wastewater treatment methods.
The present invention includes a filtration basin 10 , divided into a variety of channels, chambers, regions and the like, the walls creating each of which are typically constructed of concrete or other suitable material, such as steel or stainless steel, particularly in a tank setting (see e.g., FIG. 32 ). In the example shown in FIGS. 1 and 1A , filtration basin 10 is divided into two cloth media filtration regions A and B. Cloth media filtration regions A and B are, in all aspects pertinent to the present inventions, identical in structure and operation. It will be understood by those of ordinary skill in the art that one (basin), two or any number of filtration regions may be provided depending upon the requirements of the particular application. For example, as shown in FIG. 32 , basin 10 defines one filtration region. Moreover, to create additional cloth media filter regions, a diversion of the influent into each of the desired regions and collection of the treated effluent out of each of the filter regions will be required.
In a preferred embodiment, and particularly the retrofit of an existing basin, the filtration basin 10 includes a bulk influent chamber 12 that receives the initial flow of water or wastewater to be treated. An influent channel 14 which feeds filtration region A, and an influent channel 15 which feeds filtration region B, are also provided. Influent channels 14 and 15 are responsible for conveying the influent from the upstream process via the bulk influent chamber 12 and distributing the influent along the entire length of a cloth media filtration region. An influent weir 16 (see e.g., FIGS. 2 and 3 ) may be provided along the length of each of the influent channels 14 and 15 to enable the control, adjustment and distribution of flow along the length of each of the filter regions. In addition, an influent baffle 17 (see e.g., FIGS. 2 , 2 A and 3 ) is provided along the length of a filter region to direct the influent flow to the bottom of the filter region for uniform flow distribution and filtration using stationary cloth media as hereinafter described. It will be understood by those of skill in the art that influent channels 14 / 15 may have a manual or an automatic slide gate(s) (not shown) to permit, among other things, water level control and filter isolation.
The filtration basin 10 also includes an effluent channel 18 that receives treated water or wastewater from filter region A, effluent channel 19 that receives treated wastewater from filter region B, and a bulk effluent chamber 11 that receives the treated effluent from effluent channels 18 and 19 . Prior to the treated effluent reaching effluent channels 18 and 19 , the effluent may be subject to an effluent baffle 20 and an effluent weir 13 , both of which help control and distribute the flow as dictated by the requirement of a particular application. The effluent is then transferred to bulk effluent chamber 11 for discharge. In lieu of effluent baffle 20 , an automatically controlled slide gate 27 and its associated components (not shown) may be positioned at the end of effluent channel 18 / 19 which is used to control the water level in and flow through the system (see FIG. 2A ). When the system is used in this configuration, the effluent plenums 24 flow directly to the effluent channels 18 / 19 . It will be understood by those of skill in the art that a wide variety of methods and devices may be used to control the system flow consistent with the present inventions.
The remainder of the discussion of the present inventions and preferred embodiments thereof that relate to stationary cloth filter media filtration will be by reference to a single cloth media filtration region, such as filter region A. The primary components that are part of or associated with a particular filtration region of the present invention may be seen by reference to FIGS. 1B and 3 , and may include: an influent channel 14 , influent plenums 22 , effluent plenums 24 , filter frame assemblies 26 , also referred to as filter plates 26 , an effluent channel 18 and a backwash system assembly 21 , which is part of a traveling bridge assembly 23 . Other embodiments may not include or require all such components, such as effluent plenums and/or influent plenums, as will be understood by those of skill in the art.
The structure and operation of influent plenums 22 and effluent plenums 24 may be understood by reference to FIGS. 4 through 10 . The preferred embodiments of the effluent 24 and influent 22 plenums are shown and described, although other forms may be utilized consistent with the present invention. It is the combination of plenums 22 / 24 and their equivalents that provide uniform distribution of the influent flow across the filtration region, regardless of whether filtration is conducted according to the stationary cloth media filtration aspects of the present invention or other types of filtration systems. In its preferred form, uniform flow distribution is achieved by the influent and effluent channeling, which may include the control and distribution of flow from a single source and which is collected through a single source.
More specifically, in the preferred embodiments, each effluent plenum 24 is a generally trapezoidal shaped chamber that is sealed from the unfiltered influent flow and preferably constructed from a non-corrosive material, including but not limited to stainless steel. Each effluent plenum 24 includes a solid bottom plate 30 , two solid side plates 31 (only one is shown in FIGS. 5 , 6 and 7 ), and a top plate 32 . Top plate 32 is provided with a series of oblong holes 33 that receive the filtered flow as hereinafter described. Aligned with each of the holes 33 is a filter frame support mount 35 . Filter frame support mount 35 is affixed to the top of plate 32 of the effluent plenum 24 and functions to mount the filter frame assembly 26 to the effluent plenums 24 , as well as helping to strengthen the structural integrity of the effluent plenums 24 . As shown, for example, in FIG. 4 , filter frame support mount 35 as well as the longitudinal axis of the oblong holes 33 are aligned perpendicular to the longitudinal axis of the effluent plenum 24 . The filter plates 26 are then vertically mounted thereto as shown generally in FIGS. 7 and 8 .
The preferred effluent plenums 24 have a closed end 34 and an open end 36 , the open end 36 forming the effluent end of effluent plenum 24 . Closed end 34 , as well as bottom 30 and open end 36 , are also provided with a flange 38 or other means to facilitate attachment and alignment of effluent plenum 24 to the bottom and/or side structure of the filtration region. Effluent plenum 24 is provided with an effluent flange 37 , also to facilitate attachment of the effluent plenums 24 to the bottom and/or side structure of the filtration region. The effluent plenums 24 are arranged side-by-side in columns along the width of the bottom of the filtration region (see FIGS. 1 A and 8 - 10 ). Specifically, in a preferred embodiment of the present invention, the longitudinal axis of effluent plenums 24 are aligned with the width of the cloth media filtration region and their length coincides with the width of the region (see e.g., FIGS. 1A and 3 ). The open or effluent ends 36 are adjacent to and are in fluid communication with the effluent channel 18 and the closed ends 34 are typically adjacent to the influent channel 14 , where the influent baffle 17 or other means directs the influent to the bottom or lower portion of the system. As a result, the filter plates 26 are aligned in rows spanning the length of the filtration region which, as discussed herein, enables efficient backwashing and the like using a traveling bridge assembly 23 . In other embodiments of the present invention, effluent plenums 24 as described are not required. In such situations, the filter plates 26 are in fluid communication through channels, pipes or other means 41 to the exterior of the system (see e.g., FIG. 33 ).
The influent plenums 22 are also trapezoidally shaped chambers that are complementary to and formed by the side-by-side effluent plenums 24 . As shown in the drawings (see e.g., FIGS. 9 and 10 ), in a preferred form, influent plenums 22 are tapered channels formed from the pathway created between the sides 31 of effluent plenums 24 , the bottom of the influent plenums 22 being preferably formed from the bottom of the cloth media filtration region or filtration basin (not shown). Influent plenum tops 73 may also be provided (see FIGS. 1 A and 8 - 10 ) and which tops 73 form metering slots 60 as hereinafter described. The influent plenum tops 73 may be formed by a plate extending co-planar to the top surface 32 of the effluent plenum 24 . It will be understood that the influent plenums 22 may be formed from separate components like the effluent plenums 24 . However, this is not required, since only the effluent plenums 24 must be impervious to unfiltered flow. Similar to the formation of the influent plenums 22 from the side-by-side arrangement of the effluent plenums 24 along the bottom of the cloth media filtration region, a series of metering slots 60 are formed in the influent plenum top 73 along the upper portion of the influent plenums 22 as a result of the alignment and spacing of the plates 73 which form the top of influent plenums 22 and metering slots 60 . It will also be understood by those of skill in the art that influent plenums 22 as described are not necessary for some embodiments (see e.g., FIGS. 32 and 33 ). In such embodiments, influent may simply be introduced into the filtration region or basin 10 by well known means, such as wiers, channels and the like.
With reference to FIGS. 6-8 and 14 - 15 A, in a preferred embodiment of the present invention, filter frame support mount 35 is a tubular, generally rectangular member. A pin retaining plate 50 extends laterally outward from one end and may be attached to filter frame support mount 35 by welding or other well known means. Pin retaining plate 50 includes a key slot 51 which is bored or cut through plate 50 . The underside of pin retaining plate 50 is provided with a longitudinal pin lock groove 52 . Pin lock groove 52 is perpendicular to a key way 53 of key slot 51 . The end 59 of filter frame support mount 35 opposite to the pin retaining plate end 50 remains open in a preferred embodiment. These elements function to mount the filter plate 26 to the effluent plenums 24 .
The top 54 and bottom 55 surfaces in the central portion of filter frame support mount 35 are removed or cut away (or filter frame support mount 35 is simply assembled leaving an upwardly open sleeve 57 ), leaving only side surfaces 56 . As indicated, this forms an upwardly facing open sleeve 57 . Open sleeve 57 is slightly larger than the oblong hole 33 on the top plate 32 of effluent plenums 24 , and is centered on filter frame support mount 35 so that it aligns with elongated hole 33 of effluent plenum 24 when the support mount 35 is welded or otherwise attached to the top plate 32 of effluent plenums 24 . When attached to the effluent plenums 24 as described, the open sleeve 57 of filter frame support mount 35 forms a filter plate/effluent plenum interface shown generally as 58 (see FIG. 4 ). This interface 58 may be fitted with gaskets or seals to keep the influent from entering the effluent plenum 24 prior to filtration.
As indicated, the end of filter frame support mount 35 opposite the end with the pin retaining plate 50 remains open 59 . In this manner, when the effluent plenums 24 are arranged longitudinally along the width of the bottom of the filtration region, a portion of pin retaining plate 50 of one effluent plenum 24 is received within the opening of the corresponding filter frame support mount 35 of the adjacent effluent plenum 24 (see FIGS. 17 and 19 ).
Moreover, as shown in FIG. 4 , pin retaining plate 50 may be located on alternate sides of the filter frame support mount 35 . Specifically, in a preferred embodiment, half of the adjacent filter frame support mounts 35 may have the pin retaining plate 50 on one side and the remaining half of the filter frame support mounts 35 may have the pin retaining plate 50 on the other side. Similarly, the filter frame support mounts 35 on the adjacent effluent plenum 24 will have their pin retaining plate 50 on the opposite sides, so that the open ends 59 of filter frame support mount 35 mates with pin retaining plate 50 as described above (see e.g., FIGS. 4 and 9 ).
As referred to above, the openings or metering slots 60 of the influent plenums 22 are formed from the influent plenum tops 73 , as best shown in FIGS. 8 , 9 and 10 . In this manner, and in conjunction with the taper shape of the influent plenums 22 , influent exiting through the metering slots 60 is uniformly distributed within and across the width of the filtration region via the influent baffle 17 and influent plenum 22 . Moreover, because of the taper of the trapezoidal influent plenums 22 , even flow velocity is maintained and there is no tendency for solids to settle on the influent plenum 22 bottom.
The design and structure of filter plate 26 may best be seen by reference to FIGS. 11-13 and 18 - 18 A. As shown, each filter plate or, more generally, filter frame assembly 26 is a generally rectangular frame with a hollow center and consists of side members 41 , top member 42 and bottom member 43 . A handle or handles 44 attached to top member 42 may also be provided to aid installation, maintenance and/or repair. The side 41 , top 42 and bottom 43 members of filter plate 26 form a rectangular box-like structure, the front and back faces 45 of which are fitted with a support screen 46 . Cloth filter media 47 (see e.g., FIG. 3 ) may be stretched across and attached to the front and rear filter faces 45 . However, in a preferred embodiment, cloth media 47 is stretched around the whole filter frame assembly 26 which eliminates the risk of unfiltered influent into the effluent plenums 24 . Also included are generally v-shaped (in cross-section) top and bottom tensioners 48 . Similarly, the side members 41 are provided with side tensioners 49 . The support screens 46 function to help the cloth filter media 47 from deforming to the hollow center of filter plate 26 , and the tensioners 48 and 49 provide tension to the cloth filter media 47 to form a taught diaphragm for filtering. In addition, top and bottom tensioners 48 act as a rail along the faces 45 of filter plate 26 to create a gap to protect the cloth filter media 47 during backwash operations and to prevent pre-loading as discussed herein. This adjustable or settable gap 40 is shown schematically in FIGS. 26-28 . In preferred embodiments of the rotating backwash arm assembly 200 , maintaining gap 40 as described herein to avoid preload is not required, as a non-contact mode for shoe attachment assembly 203 may be necessary for clearance during movement of rotating backwash arm 200 .
The bottom frame member 43 includes an oblong hole 62 (see FIG. 18 ) that is positioned and sized to communicate with oblong hole 33 on the top 32 of effluent plenum 24 . A collar 63 extends downwardly from and is coincidental with oblong hole 62 . Collar 63 is designed to fit within and create a water-tight seal with the open sleeve 57 of filter frame support mount 35 and completes the filter plate/effluent plenum interface 58 . In this manner, untreated influent passes through the cloth filter media 47 , is filtered and the filtered effluent passes through oblong hole 62 of bottom frame member 43 , into oblong hole 33 into effluent plenum 24 , as hereinafter described in more detail. In this manner, there is only one area of possible penetration of influent flow into the effluent plenum 24 .
In a preferred embodiment of the present invention, each filter plate 26 is attached to the filter frame support mount 35 , and hence, in fluid communication with effluent plenum 24 , through the use of a single fastener. Specifically, collar 63 is provided with a plate latch 64 . Plate latch 64 is essentially a tab or other similar member extending from one end of collar 63 that is designed to fit under and mate with edge 65 of filter frame support mount 35 (e.g., FIGS. 14 and 15 ). As a result, plate latch 64 acts as a hinge to restrain one end of collar 63 of filter plate 26 . As described herein, in embodiments of rotating backwash arm assembly 200 , particular effluent plenums 24 are not required and the filter effluent may be discharged through conduit 341 as shown in FIG. 33 .
At the end of the bottom member 43 of filter plate 26 opposite latch plate 64 , a pin retaining bracket 66 is provided (see FIGS. 14 and 15 ). Pin retaining bracket 66 includes a key slot 67 and a key way 68 that aligns and mates with key slot 51 and key way 53 of pin retaining plate 50 of filter frame support member 35 (see FIGS. 17-17A and 19 ). Pin retaining bracket 66 is secured to pin retaining plate 50 through the use of a spring loaded fastener 69 . Specifically, in a preferred embodiment, spring loaded fastener includes a pin 70 with a key 71 at one end, and a compressive spring 72 at the other. Thus, in order to secure the pin retaining bracket 66 to pin retaining plate 50 , pin 70 is inserted into key slot 67 and key slot 51 so that key 71 passes through key ways 53 and 68 . The pin 70 is then rotated so that key 71 engages pin lock groove 52 , securing the bracket 66 and plate 50 together. In order to ensure a watertight seal at the plenum/plate interface 58 , a closed cell foam gasket seal (not shown) or other suitable gasket may be used. Similarly, each filter plate 26 may include an alignment tab 61 on the end opposite the pin retaining bracket 66 . Alignment tab 61 serves to keep adjacent filter plates 26 in alignment on adjacent filter frame support mount 35 of adjacent effluent plenums 24 (see FIG. 17 ). Other forms of adjustment and retention will be apparent to those of skill in the art.
Having described the majority of the principal components of the present inventions, the typical operation of a preferred embodiment may now be discussed. Specifically, in operation of a preferred embodiment, influent is introduced into bulk influent chamber 12 and is divided between influent channels 14 and 15 (e.g., FIG. 1A ). However, only one filtration region (A) will be discussed. The influent flows over influent weir 16 and is diverted via influent baffle 17 to the bottom of the filtration region (see also FIGS. 2-3 ). The influent flows up through metering slots 60 created by (or alternatively, in) the influent tops 73 . As a result of the shape of influent plenum 22 , the influent is uniformly distributed over the entire width of the filtration region. The influent then flows through the cloth media 47 of filter plate 26 and is filtered. The filtered flow flows into the sealed effluent plenums 24 via the filter plate/plenum interface 58 and is collected in effluent channel 18 , either through the use of an effluent baffle 20 arrangement or an automatic slide gate 27 arrangement.
Since the cloth media 47 becomes clogged over time, it is necessary to periodically backwash the cloth filter media 47 . A traveling bridge assembly 23 is used to house and carry the necessary components for backwashing and other operations. In general, traveling bridge assembly 23 travels along the length of a filtration region (or filtration basin 10 ) from a first position ( FIG. 23 ) to a second position ( FIG. 24 ), and back again. Traveling bridge assembly 23 may include wheels 28 that roll along rails 25 on top of filtration basin 10 . Alignment wheels 29 (see FIG. 22 ) may also be included to help guide and align traveling bridge assembly 23 during travel.
Preferred embodiments of the backwash system 21 of the present invention may better be seen by reference to FIGS. 25-45 . In general, the backwash system assembly includes suction headers 75 connected to a suction pump 308 . A backwash shoe 76 is positioned to ride along the cloth filter media 47 on the front and back faces 45 of each of the adjacent rows of filter plates 26 . In a preferred embodiment of the present invention, backwash shoe 76 rides along top and bottom tensioners 48 of filter frame assembly 26 , thereby producing a gap 40 between the cloth filter media 47 . This reduces wear on the cloth filter media 47 and eliminates preload and its associated problems. In another preferred embodiment, the backwash system includes a rotating backwash arm 200 ( FIGS. 32-48 ).
Thus, during a typical backwash operation, the backwash shoes 76 are pulled along the longitudinal rows of filter plates 26 by traveling bridge assembly 23 and its associated backwash headers 75 of backwash assembly 21 . In a preferred embodiment of the present invention, only half of a row of filter plates is backwashed in each direction of travel of the traveling bridge 23 . That is why, in a preferred embodiment, half of the pin retaining plates 50 are on one side and half on the other side of the filter frame support mount 35 . Backwashing will also start and stop at the same place as the traveling bridge assembly moves from its first to second position and returns.
The embodiment shown schematically in FIG. 25 is representative of one preferred embodiment. In such a system, there are, for example, ten parallel spaced, longitudinal rows of filter plates 26 having cloth filter media on both sides. To conduct the backwash operation, twenty backwash arms are required, one for each side of plate filter 26 . And, to conduct the typical backwash operation in each direction of travel as discussed above, a series of sequencing valves (not shown) are required to apply suction to the appropriate arm conducting the backwash operation in any given direction. Complicated wiring is also required to control the sequencing valves.
In another preferred embodiment, an improved backwash assembly 21 having a rotating backwash arm 200 is provided ( FIGS. 32-48 ). In general, rotating backwash arm 200 enables the cleaning of multiple cloth filter media surfaces 47 on opposing rows of filter plates 26 . As a result, fewer arms are required, sequencing valves may be eliminated and control wiring simplified. The improved backwash assembly 21 is typically included as part of a traveling bridge assembly 23 which may also act as a common suction header/manifold 75 as hereinafter described. As discussed herein, rotating backwash arm assembly 200 may be used to clean the cloth filter media 47 of filter plates 26 or other stationary cloth media filtration systems. For example, it will be understood by those of skill in the art that the improved backwash assembly 21 is applicable to a wide variety of stationary cloth media filtration devices having spaced, parallel rows of cloth filtration media 47 , not just the plates 26 as described herein. In addition, the preferred influent 22 and/or effluent 24 plenums are optional, not required.
A representative of another preferred embodiment will be discussed herein for a filtration region of another typical stationary cloth media filtration system having six longitudinal rows of filter frame assemblies 26 covered with cloth filter media 47 on each side, as shown generally in FIGS. 32-35 . As shown in FIG. 32 , the present invention is discussed in relation to a tank system. It will be understood by those of skill in the art, however, that the invention may be applied to concrete basins and a wide variety of other cloth filter media systems and set-ups. In a system with six rows of filter plates 26 , seven rotating arm assemblies 200 are required: one between each adjacent row of filter plates 26 and one on the outside of each of the last rows of filter plates 26 . In contrast, known backwash systems in similar arrangements with six rows of filter plates 26 would require twelve backwash arms and shoes, as well as sequencing valves and the like, to conduct the same backwash operation of the present inventions.
The general operation of a preferred embodiment of rotating backwash arm assembly 200 is shown schematically in FIG. 35 . During the backwash operation, bridge 23 moves from a first position (see e.g., FIG. 23 ) to a second position (see e.g., FIG. 24 ) or from left to right in FIG. 35 . In a preferred embodiment, as the traveling bridge assembly 23 moves to the right in the schematic of FIG. 35 , rotating backwash arm assembly 200 is positioned so that arms ( 1 ) and ( 2 ) clean the cloth filter media 47 on the sides of filter plate 26 (A); rotating backwash arms 200 ( 3 ) and ( 4 ) clean the cloth filter media 47 on the sides of filter plate 26 (C); and, rotating backwash arms 200 ( 5 ) and ( 6 ) clean the cloth filter media 47 on sides with filter plate 26 (E). In this direction, arm ( 7 ) is closed to suction until the return direction. At the end of travel, the rotating backwash arms 200 are rotated 180° using a drive motor or means 350 to rotate the drive gears 351 as hereinafter described. On the return travel to the left of the FIG. 35 schematic, rotating backwash arms 200 ( 2 ) and ( 3 ) clean the cloth filter media 47 of filter plate 26 (B); arms ( 3 ) and ( 4 ) clean cloth filter media 47 on the sides of filter plate 47 (D); and, arms ( 6 ) and ( 7 ) clean the sides of filter plate 47 (F). In this direction, the outside rotating backwash arm 200 ( 1 ) is optionally blocked-off from the backwash operation since it is no longer in a position to backwash cloth filter media 47 , also as hereinafter described.
The structure, orientation and operation of preferred components of the improved backwash assembly 21 will be described. Rotating backwash arm 200 has two principal structural components in its preferred form; namely, sealed rotation assembly 202 and shoe attachment assembly 203 . Rotating backwash arm assembly 200 is rotatably mounted to and in fluid communication with fixed attachment assembly 201 , which is in fluid communication with suction manifold 75 . These assemblies are shown generally in FIGS. 36 , 37 and 44 . It will be understood by those of skill in the art that rotating arm assembly 200 may be one piece or more than two pieces. Similarly, other ways of mounting rotating arm 200 to the traveling bridge assembly 23 and suction header 75 are also contemplated. However, for reasons of strength, installation and efficiency, the examples described herein are preferred.
A preferred embodiment of fixed attachment assembly 201 is more particularly shown in FIGS. 38 and 39 . Fixed attachment assembly 201 includes a pipe 300 having a proximal end 302 which is closest to the traveling bridge assembly 23 and a distal end 301 suspended downward from the traveling bridge assembly 23 . Proximal end 302 is adapted to be connected to traveling bridge assembly 23 and to be in fluid communication with common suction header 75 (see e.g., FIGS. 33 , 34 and 45 ). In a preferred embodiment, proximal end 302 is provided with a header flange 303 having bolt holes 304 . Flange 303 may be welded or otherwise secured to proximal end 301 of pipe 300 . Fixed attachment assembly 201 is then secured to the underside of traveling bridge assembly 23 using bolts through bolt holes 304 in flange 303 .
In the preferred embodiment, fixed attachment assembly 201 is in fluid communication with suction header 75 and drops down from traveling bridge 23 and terminates in an open distal end 301 . Fixed attachment assembly 201 functions to rotatably mount rotating backwash arm assembly 200 and to accommodate the flow of backwash fluid to the suction header 75 , as hereinafter described. Distal end 301 may be machined or otherwise adapted in order to accommodate the rotational and other components of backwash arm assembly 200 . An optional valve plate 305 having a flow orifice 306 may also be provided at the open portion of distal end 301 and secured thereto ( FIG. 46 ). Valve plate 305 is intended to be included on the fixed assembly 201 that rotatably secures the rotating backwash arm assembly 200 on the outside edges of the system as hereinafter described. Valve plate 305 is not necessary on the interior arms 200 .
A preferred embodiment of rotating backwash arm assembly 200 is shown in the drawings (see FIGS. 36 , 37 and 44 ). As indicated, in the preferred embodiment, rotating backwash arm assembly 200 is composed of two major structural components, the sealed rotation assembly 202 and the shoe attachment assembly 203 . It will be understood by those of skill in the art that, although not preferred, rotating arm assembly 200 may be one piece or several pieces consistent with the teachings of the present inventions. Similarly, fixed attachment assembly 201 may take a variety of configurations, or be omitted entirely, as long as rotating backwash arm 200 is in fluid communication with the suction header 75 of backwash assembly 21 and is permitted to rotate to effectuate cleaning of two adjacent rows of filter plates 26 as discussed herein.
Details of the sealed rotation assembly 202 component of preferred arm assembly 200 are shown in FIGS. 40 and 41 . A pipe 310 is provided which is sized to fit concentrically over fixed attachment assembly 201 . Pipe 310 has a proximal end 311 and a distal end 312 . Proximal end 311 is provided with a gear flange 313 having bolt holes 314 to secure a rotation gear 315 (see e.g., FIG. 36 ) using bolts 316 or cable, lines, screws or other well known means (not shown). In a preferred embodiment, an upper bearing 317 , having an orifice 318 sized to engage the exterior of pipe 300 of fixed attachment assembly 201 , is provided within the opening of proximal end 312 .
The distal end 312 of pipe 310 is provided with a lower attachment flange 319 having holes 320 to accept bolts 321 to secure shoe attachment assembly 203 . The interior of distal end 312 of pipe 310 is provided with a distal bearing 322 that is secured within the opening of distal end 311 using screws 323 or other well known fastening means. Distal bearing 322 includes an opening 324 that is sized to sealingly engage the exterior circumference of proximal end 301 of pipe 300 of fixed attachment assembly 201 , yet at the same time, permit rotation of sealed pipe assembly 202 above fixed assembly 201 . Distal bearing 322 may be further secured within the distal end 312 of pipe 310 with a spacer ring 326 that fits with a groove (not shown) on the interior circumference of distal end 312 of pipe 310 .
As shown in FIGS. 36 , 37 and 44 , sealed rotation assembly 202 is placed over fixed attachment assembly 201 . Upper bearing 317 is selected and sized so that it rotatably and sealingly secures, at least in part, sealed rotation assembly 202 to the proximal end 311 of pipe 310 . Similarly, distal bearing 322 is selected and sized to sealingly and rotatably secure, at least in part, sealed pipe assembly 202 to distal end 312 of pipe 310 . Together, upper bearing 317 and lower bearing 322 are sufficient to rotatably mount sealed rotation assembly 202 (as well as shoe attachment assembly 303 to fixed attachment assembly 201 ). Upper bearing 317 and lower bearing 322 act as spaced apart bushings that also hold rotating backwash arm assembly 200 in tight concentric alignment with fixed attachment assembly 201 . It will be understood by those of skill in the art that the seal created by bearings 317 and 322 do not have to be completely water tight seals, but sufficient to provide adequate suction during the backwashing operation. However, it is preferred that the seal created by bearings 317 and 322 be airtight to prevent the entry of air and/or the cavitation of the pump (not shown). And, although the above means of securing rotating arm assembly 200 to fixed attachment assembly 201 is preferred, other means of rotating attachment are contemplated and will be understood by those of skill in the art.
Shoe attachment assembly 203 may best be seen by reference to FIGS. 42 and 43 . In a preferred embodiment, attachment assembly 203 also includes a pipe 330 having a proximal end 331 and a distal end 332 . Proximal end 331 is provided with a coupling flange 333 having holes 334 (not shown in FIG. 42 ) designed to mate with and be secured to distal flange 319 of sealed rotation assembly 202 . In the case of an outside arm 200 , a rotating value plate 307 having a flow orifice 309 ( FIG. 47 ) is sandwiched between coupling flange 333 of shoe attachment assembly 203 and distal bearing 322 of sealed rotation assembly 202 . Rotating valve plate 307 cooperates with valve plate 305 to prevent flow to an outside arm, as hereinafter described. The open distal end 332 of pipe 330 is sealed with an end cap 336 ( FIG. 48 ), which may be secured with fasteners 337 . A longitudinal slit 338 is provided through pipe 330 , through which backwash water may flow. A backwash shoe 76 , having a longitudinal slit 339 that coincides with slit 338 of pipe 330 is also provided. Backwash shoe 76 may then be attached to pipe 330 using screws 340 or other well known means and is designed to contact or otherwise clean cloth filter media 47 .
Rotation of arm assemblies 200 in the preferred embodiment may be seen by reference to FIGS. 32-35 and 45 . As indicated, the proximal end 311 of each arm is provided with a rotation gear 315 . When installed, the gears 315 of each of the arms are intermeshed so that they are able to rotate together ( FIGS. 32 and 33 ). Rotation gears 315 of arms 200 are rotated using drive gear 351 ( FIG. 45 ). Drive gear 351 mates with one or more rotation gears 315 and is driven by a motor 350 on traveling bridge assembly 23 . Although preferred, arms 200 do not have to rotate together. For example, the may be individually controlled and/or individually rotated with their own motors 350 or other drive means that will be understood by those of ordinary skill in the art. In operation, once backwashing is accomplished in one direction of travel, the arms 200 are rotated 180° so that other cloth filter media surfaces are backwashed in the other direction of travel (see e.g., FIG. 35 ). Other rotational patterns or sequences may be used, consistent with the inventions and as will be understood by those of skill in the art.
In order to have efficient backwashing with relatively even suction, the exterior arms 200 should preferably be shut off during the direction of travel that they are not conducting the backwash operation. In a preferred embodiment, this is accomplished with the valve plate 305 and the rotating valve plate 307 . Specifically, to conduct the backwash operation, flow orifice 306 of valve plate 305 is aligned with flow orifice 309 of rotating valve plate 307 . When the arms are rotated to backwash in the other direction, orifice 306 is no longer aligned with flow orifice 309 and flow through that arm is shut off. It will be understood that the flow does not have to be completely blocked, so long as suction to the arm 200 is substantially reduced. Other means of stopping the flow to the exterior arms when they are not conducting the backwash operation are contemplated and will be understood by those of skill in the art.
The above description is not intended to limit the meaning of the words used in the following claims that define the invention. Rather, it is contemplated that future modifications in structure, function or result will exist that are not substantial changes and that all such insubstantial changes in what is claimed are intended to be covered by the claims. Thus, while preferred embodiments of the present inventions have been illustrated and described, it will be understood that changes and modifications can be made without departing from the claimed invention. In addition, although the term “claimed invention” is sometimes used herein in the singular, it will be understood that there are a plurality of inventions as described and claimed.
Various features of the present inventions are set forth in the following claims. | The present invention relates to a method for cleaning cloth filter media supported on a plurality of opposingly-spaced filter plate frames. A backwash assembly ( 23 ) moves linearly and includes at least one cylindrical backwash arm ( 200 ) that rotates to consecutively clean the media of the spaced filter plate frames. | 1 |
RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 60/850,149, filed Oct. 5, 2006.
FIELD OF THE INVENTION
[0002] The present invention relates to hydraulic fluid exchanging devices, and more particularly to an apparatus for achieving and maintaining proper fluid flow alignment between a fluid exchange device and an accessed hydraulic fluid system, particularly those fluid systems having low flow, such as certain types of vehicular automatic transmissions.
BACKGROUND OF THE INVENTION
[0003] The market for fluid exchanging equipment for vehicular hydraulic fluid systems, such as power steering and automatic transmissions, has undergone relatively rapid expansion. Many such devices have been recently developed. One unresolved problem has been the inherent need for an inexpensive fluid exchange system which is simple to operate and which supports desirable features of some known, more complex and expensive exchange units, such as an automatic bypass mechanism and such as the automatic fluid flow alignment mechanism as disclosed in U.S. Pat. No. 5,472,064 and U.S. Pat. No. 6,330,934 and U.S. Pat. No. 6,779,633 to Viken, each patent being incorporated by reference herein.
[0004] An unresolved need remains for a fluid exchanger capable of servicing automatic transmissions having low fluid flow such as certain Ford Explorers, Ford pick-up type trucks, and other Ford vehicles, and some Geo Metros and other small foreign designed vehicles, and certain Toyotas and the like.
[0005] A need remains for simple and inexpensive fluid exchanger which can be interconnected to a low flow hydraulic circuit, such as that of a vehicular automatic transmission, and which has features of automatic fluid flow alignment, automatic bypass established at the completion of the fluid exchange, and which has the ability to apply low pressure to the fluid being discharged from the accessed hydraulic circuit while pumping the fresh fluid into that hydraulic circuit. Such a device would need to accomplish these objects without disrupting the normal fluid flow patterns of the accessed hydraulic circuit while preferably maintaining equalized flow rates between the used fluid being discharged from the hydraulic circuit and the fresh fluid being pumped into that circuit.
SUMMARY OF THE INVENTION
[0006] A fluid exchange device in accordance to the present invention includes a multi-port valve assembly and a lock component. The valve assembly is in fluid communication with an accessed hydraulic system via a pair of flexible conduits. The valve assembly controls directions of fluid flow within the device during an exchange procedure. A boost pump may be utilized to increase a flow of fluid through the exchange device. In one embodiment, the lock component restrains a portion of the valve assembly during the exchange procedure in order to maintain proper fluid flow while the boost pump is activated.
[0007] Addressing the deficiencies of the conventional art, a fluid exchange device of the present invention resolves unmet needs in an efficient, cost effective manner. The fluid exchange device is relatively easy to operate and adaptable to a variety of automatic transmissions or hydraulic circulating systems and the like of vehicles, machinery, aircraft and equipment. In one embodiment, a fluid exchange device in accordance with the present invention includes a locking mechanism connected to an automatic flow-aligning valve assembly which allows a boost pump to be operated. A bypass device for removing a portion of the exchange device from the accessed hydraulic circuit at the completion of the fluid exchange is also provided. The fluid exchange system of the present invention can be utilized while the accessed hydraulic circuit is operational and without any change in the fluid volume contained in the accessed hydraulic system. The locking mechanism allows the fluid exchange system to include a boost pump to either the used fluid conduit on the fresh fluid conduit or both without disrupting the operation of the automatic fluid alignment assembly which is controlled at the onset by the fluid pressure provided by the accessed hydraulic system alone. As such, the fluid pressure of the accessed hydraulic system determines the fluid alignment of the fluid exchange device at the start of the exchange procedure after which the locking mechanism is activated to maintain fluid flow alignment after the boost pump is activated.
[0008] The foregoing has outlined rather broadly the features and technical advantages of the present invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the invention will be described hereinafter which form the subject of the claims of the invention. It should be appreciated by those skilled in the art that the conception and specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims. The novel features which are believed to be characteristic of the invention, both as to its organization and method of operation, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures. It is to be expressly understood, however, that each of the figures is provided for the purpose of illustration and description only and is not intended as a definition of the limits of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a schematic view of a fluid exchange system according to the present invention
[0010] FIG. 2 is a schematic view of the automatic fluid-aligning valve assembly and the locking mechanism of FIG. 1 .
[0011] FIG. 3 is an exploded view of the integral parts of the automatic flow alignment structure and locking mechanism of FIGS. 1, 2 , 4 and 5 .
[0012] FIG. 4 is a schematic view of the automatic fluid alignment structure and its attached locking mechanism of FIG. 2 and shows the automatic fluid alignment structure in its initial unlocked condition as proper fluid flow alignment in the process of being attained.
[0013] FIG. 5 is a schematic view of the automatic fluid alignment structure with locking mechanism operating in a properly aligned and locked condition, thus maintaining proper flow alignment while the fluid pump arranged to its used fluid conduit is operated to assist the exchange of fluids of a low flow hydraulic circuit or to speed up the fluid exchange.
[0014] FIG. 6 is a schematic view of an alternative embodiment of an automatic fluid-alignment valve assembly with more than one locking mechanism operating in a properly aligned and locked condition.
DETAILED DESCRIPTION OF THE INVENTION
[0015] Referring now to the drawings, where like numerals represent like parts throughout, FIG. 1 is a schematic view of fluid exchange system 10 having an automatic flow-aligning valve assembly 2 and locking mechanism 1 . A fluid exchanger, in this embodiment, diaphragm tank 3 , is utilized during an exchange procedure to receive used fluid from an accessed hydraulic system and provide fresh fluid to the hydraulic system. Diaphragm tank 3 provides for a substantially equivalent exchange rate, i.e., the flow rate of used fluid extracted from the hydraulic system is about the same as the flow rate of new fluid introduced into the hydraulic system. Additional features of diaphragm tank 3 as well as alternative fluid exchangers are found in applicant's U.S. Pat. Nos. 5,318,080, 6,082,416, 6,164,346, 6,223,790, 5,267,160, 6,378,657, 6,446,682, 6,779,633, 6,962,175, each being incorporated by reference herein. As a result, a variety of different fluid exchanger may be utilized with flow-aligning valve assembly 2 and locking mechanism 1 in accordance with the present invention. For example, a moveable piston with seals inside a fixed volume cylinder, with the piston separating variable volume but reciprocally interdependent fresh and used fluid chambers is another type of used fluid and fresh fluid flow balancing structure that can be substituted for diaphragm tank assembly 3 .
[0016] Fluid exchange system 10 includes a pair of fluid exchange conduits 15 , 17 which are respectively connected at one end to quick connect 21 and quick connect 19 , and at the other end to port 50 and port 52 of the automatic flow-aligning valve assembly 2 .
[0017] Prior to the exchange procedure, quick connect 19 and quick connect 21 are selectively connected to an opened fluid circulation circuit of the hydraulic system. A fluid exchange system may be accessed by way of adapters connected to the opened fluid circulation circuit. For example, the cooling circuits of a variety of different automatic transmissions may be accessed with quick connects 19 , 21 and an adapter kit (not shown, but well understood in the art).
[0018] Automatic flow-aligning valve assembly 2 is operatively connected to locking mechanism 1 . Locking mechanism 1 has solenoid coil 6 that is energized by 120 volts AC electrical current supplied by relay 9 . An AC plug 13 has ground wire 38 that is connected to relay 9 and to ground wire 36 that is in turn connected to boost pump 5 at one of a set of leads 83 . Automatic flow-aligning valve assembly 2 has hex plug 63 and hex plug 69 which seals and blocks, at either end, valve bore 178 (shown in FIGS. 2, 3 , 4 and 5 ). Locking mechanism 1 may include other mechanical and/or electro-mechanical devices operatively connected to flow-aligning valve assembly 2 in order to lock a component or assembly within flow-aligning valve assembly 2 in a selected position during a fluid exchange procedure.
[0019] Locking mechanism 1 is fresh fluid controlled and allows the automatic flow-aligning valve assembly to be interconnected into the two fluid exchange hoses at any point, even close to the ends of the hoses where they are connected to the opened hydraulic circuit being serviced. This allows automatic flow-aligning valve assembly 2 and locking mechanism 1 to be sold as an aftermarket item to be easily retrofitted to any fluid exchanger which does not have an integral automatic flow alignment valve and which has a pair of fluid exchange hoses with one being a used fluid discharge hose and the other being a fresh fluid delivery hose.
[0020] Locking mechanism 1 has an operator rod containment assembly 4 , which contains an internal operator rod assembly 166 (shown in FIGS. 2, 3 , 4 and 5 ). Operator rod containment assembly 4 has balance port 28 to which check valve 86 is connected, which in turn is connected to used fluid conduit 23 . Used fluid conduit 23 is connected at another one of its ends to used fluid outlet port 58 of automatic flow alignment valve 2 , connected at another one of its ends to check valve 37 , and connected at another of its ends to pump head 18 .
[0021] Locking mechanism 1 is electrically operated. Referring to FIG. 1 , hot wire 48 is connected at one end to relay 9 and at the other end to an on-off toggle switch 11 . Neutral wire 51 is connected at one end to relay 9 and at the other end to toggle switch 11 . Hot wire 42 is connected at one end to AC plug 13 and at its other end to on-off toggle switch 11 . Hot wire 46 is connected at one end to one of the set of leads 83 of boost pump 5 , at another end to relay 9 , and also to hot wire 22 . Neutral wire 40 is connected at one end to AC plug 13 and at its other end to on-off toggle switch 11 . Hot wire 22 is connected to one of a pair of leads 69 of solenoid coil 6 at one end and at its other end to hot wire 46 that is connected at one end to relay 9 and at another end to one of a set of leads 83 of boost pump 5 . Hot wire 24 is connected at one end to one of the pair of leads 69 of solenoid coil 6 and at its other end to neutral wire 39 which is connected at one end to one of the set of leads 83 of boost pump 5 and at its other end to relay 9 . Signal wire 44 is connected at one end to one of a pair of leads 81 of flow switch 7 and at its other end to relay 9 . Signal wire 47 is connected at one end to one of the pair of leads 81 of flow switch 7 and at its other end to relay 9 .
[0022] Boost pump 5 in this embodiment is vane pump having pump head 18 , which is powered by pump motor 16 at 120 volts AC. Pump motor 16 is connected to pump head 18 by pump coupler assembly 20 . Pump head 18 contains a set of rotating vanes (not shown but understood in the art). Of course many other types of pumps can be substituted and would work equivalently. In this preferred embodiment boost pump 5 is a rotary vane pump, such as manufactured by Tuthill Corporation, Pump Model No. P11347 and disclosed in U.S. Patent Pub. No. 2005/0214153 to Citro et al., incorporated by reference herein.
[0023] Used fluid conduit 23 connects used fluid outlet port 58 of automatic flow-aligning valve assembly 2 with check valve 37 , with pump head 18 , and with check valve 86 which is connected to balance port 28 of operator rod containment assembly 4 within locking mechanism 1 . Operator rod containment assembly 4 contains an operator rod assembly 166 (as shown in FIGS. 2 , 3 , 4 , 5 ). Fresh fluid conduit 25 connects fresh fluid inlet port 54 and fresh fluid inlet port 56 to flow switch 7 .
[0024] Fresh fluid conduit 29 connects fresh fluid fill port quick connect 30 to bypass valve 35 at port 94 and to flow switch 7 . Bypass valve 35 has male threads at its base (not shown) and is sealably connected with a nitrile type O-ring type seal to an opening at a top female threaded orifice (not shown) of top tank half 59 of diaphragm tank assembly 3 which also has bottom tank half 62 .
[0025] Used fluid conduit 26 connects pump head 18 to check valve 37 , to used fluid port 31 of bottom tank half 62 , to bypass check valve 34 , and to used fluid discharge port quick connect 32 . Bypass conduit 27 is connected at one end to bypass check valve 34 and at its other end to bypass valve 35 .
[0026] Diaphragm tank assembly 3 is comprised of displaceable diaphragm 8 enclosed inside top tank half 59 and bottom tank half 62 , and secured to be fluid tight by a set of 24 identical fastener assemblies of which a connecting bolt/washer/nut assembly 12 and a connecting bolt/washer/nut assemblies 14 comprise two of the 24 identical fastener assemblies.
[0027] Bypass valve 35 contains bypass valve slide 65 , which has an internal passage 82 with side port 84 that allows bypass conduit 27 connection to internal passage 82 when diaphragm 8 displaces bypass valve slide 65 , moving it upward to attain a bypass mode of operation for the fluid exchanger which is characterized by establishing fluid communication between flexible fluid exchange conduits 15 and 17 via bypass conduit 27 through check valve 34 , which removes the diaphragm tank assembly 3 from the fluid flow into and out of the hydraulic system being serviced.
[0028] Diaphragm 8 divides the interior of the diaphragm tank assembly 3 into fresh fluid chamber 43 and used fluid chamber 45 . Bypass valve 35 has an automatic air vent 85 connected to it. Automatic air vent 85 bleeds off air unintendedly entering chamber 43 without leaking fluid from fresh fluid chamber 43 . A bypass valve of the same design was disclosed in U.S. Pat. Nos. 6,082,416 and 6,267,160, each to Viken and each being incorporated by reference herein.
[0029] Tank top half 59 has position sensor 49 with a pair of leads 60 which are connected in series to a red indicator light, a warning tone, and a source of electric current (not shown but disclosed in U.S. Pat. No. 6,082,416 to Viken) such that when diaphragm 8 reaches its uppermost position conforming to tank top half 59 it activates the position sensor 49 and turns on the red indicator light and warning tone indicating to the operator that diaphragm tank assembly 3 is essentially filled with used fluid.
[0030] Tank bottom half 62 has position sensor 53 with pair of leads 61 which are connected in series to a green indicator light and a source of electric current (not shown but disclosed in U.S. Pat. No. 6,082,416 to Viken) such that when diaphragm 8 reaches its lowermost position conforming to tank bottom half 62 , it activates the position sensor 53 and turns on the green indicator light and indicates to the operator that the diaphragm tank assembly 3 is essentially filled with fresh fluid.
[0031] A number of different rubber compounds can be used to construct diaphragm 8 . Such compounds should be resistant to the effects of the particular hydraulic fluids that the fluid exchanger will be handling during the fluid exchanges. There are a number of different methods of constructing diaphragms, including molding with or without an integral reinforcing fabric. In the present invention diaphragm 8 is molded without any integral reinforcing fabric and is comprised of a nitrile-type compound.
[0032] FIG. 2 is a schematic view of the automatic flow alignment valve 2 operating in an initial random, but non-aligned, not-locked mode of operation, characterized by valve 165 being position in a non-aligned position relative to the flow of used fluid being discharged from the hydraulic circuit accessed for fluid exchange. FIG. 3 is an exploded view of the integral parts of the automatic flow-aligning valve assembly 2 and locking mechanism 1 . Automatic flow-aligning valve assembly 2 includes multi-port valve body 184 containing movable valve 165 .
[0033] A valve slide 165 is contained within valve bore 178 of automatic flow-aligning valve assembly 2 . Valve bore 178 is threaded at each end to receive hydraulic hex plug 63 at its leftmost end and hex plug 64 at its rightmost end, both in this case being fitted with an integral O-ring for suitable sealing (not shown). FIG. 3 shows valve slide 165 having left internal fluid passage 289 which has one end near the left side of valve slide 165 at left transverse cutout 296 and terminates at an end near right transverse fluid port 290 which is located between left land 294 and center land 293 . FIG. 3 shows valve slide 165 to be constructed to have right internal fluid passage 292 which starts at the right side of valve slide 165 at right transverse cutout 297 and terminates at left transverse fluid port 291 which is located between right land 295 and center land 293 . Left internal fluid passage 289 is not connected to the right internal fluid passage 292 , and therefore no fluid can pass through either passage to the other (as shown in FIG. 2 ). Valve bore 178 has left chamber 157 which is between hex plug 63 and valve slide assembly 165 , and has right chamber 155 which is between hex plug 64 and valve slide assembly 165 .
[0034] As shown in FIG. 2 , locking mechanism 1 has an operating rod containment tube 168 which is in this case constructed of an essentially magnetic neutral metal, brass in this instance. Various types of plastics and other essentially non-magnetic materials could be alternatively used. Operating rod containment tube is inserted through an internal bore 188 of solenoid coil 6 which has a suitably sized male threads at both ends, with the one at its lower end screwed into threaded port 171 of operator rod containment assembly 4 at one end and suitably sealed, with an anaerobic hydraulic sealer used in this case. At its other end operating rod containment tube 168 is screwed into threaded port 170 of valve body 184 of automatic flow alignment valve 2 and suitably sealed, with an anaerobic hydraulic sealer.
[0035] Operator rod containment assembly 4 has female threaded port 173 to which check valve 86 , which has a male thread at one end, is screwed into busing 174 , and busing 174 is then turned into threaded port 173 of operator rod containment assembly 4 . Solenoid coil 6 has an internal passage 188 through which operator rod containment tube 168 can be inserted ( FIG. 3 ). Rod operator assembly 166 is comprised of two integral parts which are counter threaded at their meeting ends for easy assembly, with an operator rod top half 176 and an operator rod bottom half 177 (as shown in FIG. 2 ). Rod operator assembly 166 (shown in exploded view in FIG. 3 ), has top crown 175 which has vent 285 and vent 286 cutout of it on either side, allowing any fluid pressure differential on either side of top crown 175 to be quickly vented and equalized. Operator rod top half 176 is constructed of a magnetic material, such as iron. Operator rod bottom half 177 is constructed of a non-magnetic material, such as brass.
[0036] In addition, locking mechanism 1 as shown in FIG. 2 can incorporate an interiorly placed diaphragm seal constructed of a nitrile type compound. This seal can be placed above operator rod crown 175 inside operator rod containment assembly 4 . This diaphragm seal when arranged above rod operator assembly 166 inside rod operator containment assembly 4 and fresh fluid conduit 25 , will allow fresh fluid delivered from fresh fluid chamber 43 to actuate the locking mechanism and keep it locked during the fluid exchange, as long as all the fresh fluid being conducted to the automatic flow-aligning valve assembly 2 passes into the top of operator rod containment assembly 4 on the way to the automatic flow-aligning valve assembly 2 and can only pass through it if the rod operator assembly of FIG. 2 moves into and remains in its locked position. This allows automatic flow-aligning valve assembly 2 with such a modified fresh fluid operated locking mechanism to be easily interconnected into the two fluid exchange hoses of any fluid exchanger which has a pair of fluid exchange hoses, one of which is a fresh fluid delivery hose and the other of which is a used fluid discharge hose, transforming the points at which each hose is connected to opened hydraulic circuit being serviced to become bi-directional fluid exchange hoses. This transformation of each of the fluid exchange hoses to bi-directional capability allows each to serve as a fresh fluid supply hose or a used fluid discharge hose for the hydraulic circuit, as will be determined by the direction of fluid flow in the hydraulic service being connected to for service, which is typically unknown at the time at which that circuit is opened and the hoses are connected (one each) to a side of the opened hydraulic circuit to be serviced.
[0037] FIG. 3 shows operator rod containment tube 168 having internal bore 187 to which rod operator assembly 166 is inserted and fits relatively loosely, able to easily slide up and down within the bore, allowing fluid pressure to quickly dissipate between the internal bore 187 and rod operator assembly 166 .
[0038] Referring to FIG. 2 , valve body 184 has an internal rod port 183 which allows the operator rod bottom half 177 to slide within and through to fit between either pair of lands of valve slide assembly 165 , center land 293 and right 295 , or between center land 293 and left land 294 , depending on whether valve slide 165 is in its leftmost or rightmost position respectively. Operator rod bottom half 177 can be moved into its locked position located between either of these sets of lands under power of the solenoid coil 6 when it is provided electrical current and draws the operator rod top half 176 downward, under power of the magnetic force provided by solenoid coil 6 . During assembly, operator rod assembly 166 is inserted through return spring 167 , into and through an internal cavity 172 of rod operator containment assembly 4 , and into and through operator rod containment tube 168 . Rod operator assembly 166 can move back into its unlocked position when electrical current is removed from solenoid coil 6 , which results when flow switch 7 stops providing signal to relay 9 to provide current to solenoid coil 6 . When current is removed from solenoid coil 6 , return spring 167 moves operator rod assembly 166 back into its unlocked position. Alternatively, for some low pressure hydraulic circuits, if locking mechanism 1 is positioned on the bottom side of automatic flow-aligning valve assembly 2 , return spring 167 can be eliminated, with gravity providing the power to move rod operator assembly 166 back into position.
[0039] FIG. 3 shows valve body 184 to have five ports machined to its bottom side which penetrate from the outside into valve bore 178 , and these include port 50 and port 52 to which flexible fluid exchange hoses 15 and 17 of FIG. 1 are connected respectively. Fresh fluid port 54 and fresh fluid port 56 are both connected to fresh fluid conduit 25 of FIG. 1 . Used fluid outlet port 58 is connected to used fluid conduit 23 of FIGS. 1 and 2 . These port connections are made using conventional sealing methods such as inserting threaded hose barbs into female threads cut into each port (not shown but known in the art), with the conduits and hoses then connected to the hose barbs by conventional means such as hose clamps or self-locking methods known in the art.
OPERATION OF THE PREFERRED EMBODIMENT
[0040] The preferred embodiment of FIG. 1 is interconnected to the hydraulic fluid circuit that is to be serviced, which in this instance is a fluid cooling line of an automatic transmission (not shown, but understood in the art). The fluid cooling line is opened, establishing two ports or orifices, each of which will serve as a suitable connection point for one of the flexible fluid exchange conduits 15 and 17 which in this case are constructed of flexible rubber which is resistant to automatic transmission fluids. In this case as shown in FIG. 1 , the particular connections made to these orifices are flexible fluid exchange conduit 17 connected to the higher pressure side (discharge side) of the cooling circuit of the automatic transmission, and flexible fluid exchange conduit 15 connected to the lower pressure side (return side) of the cooling circuit. In FIG. 1 , fluid flow is represented by use of arrows. The fluid exchange system operator does not need to identify or know which of the two orifices provides access to either the lower pressure, return side of the cooling circuit, or the higher pressure, outlet side of the cooling circuit in order to operate the system and institute a fluid exchange procedure.
[0041] The fluid exchange system 10 aligns itself with the direction of fluid flow in the hydraulic circuit being serviced. As the engine of the vehicle is started and operated in park, neutral or drive (with the parking brake applied) the automatic transmission is rendered operative to flow fluid through its cooling circuit. This causes used fluid to be discharged into and through flexible fluid exchange conduit 17 , then into right valve chamber 155 of the automatic flow-aligning valve assembly 2 . Valve slide 165 begins to be moved toward and into the left chamber 157 of valve bore 178 as shown in FIG. 4 , which depicts the operation of automatic flow-aligning valve assembly 2 in a transitional mode of operation before valve slide 165 has moved into proper flow alignment position. At the same time any pressure differential between used fluid outlet port 58 and the topside of operator rod crown 175 is equalized through check valve 86 and balance port 28 ( FIG. 2 ).
[0042] The fluid pressure provided by the accessed cooling circuit of the automatic transmission through flexible fluid exchange conduit 17 continues to move valve slide assembly 165 toward and into left chamber 157 until it can go no further, at which time valve slide 165 is properly aligned with the operator rod bottom half 177 as shown in FIG. 5 . When valve slide 165 has become moved into its proper alignment position, used fluid flows from used fluid outlet port 58 into and through used fluid conduit 23 , through check valve 37 , then into port 31 of diaphragm tank assembly 3 to be deposited in used fluid chamber 45 (as shown in FIG. 1 ).
[0043] This causes used fluid chamber 45 to increase in volume, which causes diaphragm 8 to be displaced by the same volume, which then results in an essentially equivalent volume of fresh fluid being pumped out of fresh fluid chamber 43 into and through bypass valve slide 65 through its side port 94 and into and through fresh fluid conduit 29 . Fresh fluid then flows through flow switch 7 , through port 54 ( FIG. 2 ), through left transverse fluid port 290 , through left internal fluid passage 289 , into left chamber 157 , through port 50 , and then into flexible fluid exchange conduit 15 to be delivered into the lower pressure side (return side) of the cooling circuit of the automatic transmission having its fluid exchanged.
[0044] When fluid begins to flow through flow switch 7 , an electrical switch (not shown) closes and provides an electrical signal to relay 9 that activates to provide power to boost pump 5 and solenoid coil 6 . As boost pump 5 is activated to pump fluid, solenoid coil 6 is energized to move rod operator assembly 166 ( FIG. 2 ) downward into and through internal rod port 183 to rest between right land 295 and center land 293 ( FIG. 5 ). The space between right land 295 and center land 293 is in proper position to receive rod operator assembly 166 because valve slide 165 has already moved into proper position before fluid flows through flow switch 7 to cause solenoid coil 6 to become energized and activate boost pump 5 . As long as fluid continues flowing through flow switch 7 , rod operator assembly 166 is held in position and blocks any movement of valve slide 165 which could occur due to the operation of boost pump 5 , which could raise the fresh fluid pressure in left chamber 157 of automatic flow-aligning valve assembly 2 to be greater than the used fluid pressure at its right chamber 155 .
[0045] Referring to FIG. 2 , if the fluid pressure in left fluid chamber 157 is greater than the fluid pressure in right chamber 155 , then valve slide 165 will move into its furthermost right position unless locking mechanism 1 has been operated to attain its properly locked position. Alternatively, if the fluid pressure in right fluid chamber 155 is greater than the fluid pressure in left fluid chamber 157 , then the valve slide 165 will move into its furthermost left position. Once rod operator assembly 166 is pulled into and through internal rod port 183 and held there by force of energized solenoid coil 6 , automatic flow-aligning valve assembly 2 is in locked position characterized by rod operator assembly 166 blocking any potential shift of valve slide 165 out of its proper alignment position. This proper alignment position is initially determined by the direction of fluid flow in the hydraulic circuit being serviced in relation to the particular random choice made by the operator for connecting the flexible fluid exchange conduits to the two orifices made available by opening the hydraulic circuit. In vehicular fluid exchanges, valve slide 166 moves into proper alignment position before used fluid flows out of automatic flow-aligning valve assembly 2 into used fluid conduit 23 . In even those which involve higher flow transmissions which operate at much higher pressures, a delay in the activation of flow switch 7 would result from the wall flexibility of in the conduits of the present invention in its preferred embodiment because the flexible used and fresh fluid conduits 15 and 17 respectively are constructed of a nitrile based rubber hose which is resistant to automatic transmission fluid.
[0046] Conduit 15 , 17 flexibility typically allows a small amount of wall expansion which can provide enough delay in the pressure increase in fresh fluid conduit 29 transmitted to port 54 of automatic flow-aligning valve assembly 2 for the solenoid coil 6 to move the operator rod assembly 166 downward to place the lowermost end of operator rod bottom half 177 into proper locked position before the boost pump is activated. This assures that the valve slide assembly 165 will stay in proper fluid flow alignment position when the boost pump is activated to increase the pressure of the fresh fluid to be greater than the pressure of the used fluid, which could increase the fresh fluid pressure in chamber 157 to be greater than the used fluid pressure of chamber 155 ( FIG. 5 ) which would otherwise cause valve slide 165 to move towards its rightmost position.
[0047] If the internal fluid exchange conduits are constructed of a hard, non-expanding material such as steel or aluminum tubing, or the pressures of the hydraulic fluid circuit being serviced with a fluid exchange are relatively high, an electronic time delay relay can be used to delay the activation of locking mechanism 1 and boost pump 5 to assure that the valve slide 165 has reached its proper flow alignment position. For example, such electronic time delay relay can be interconnected to either signal wire 44 , or to signal wire 47 of flow switch 7 , or within relay 9 , or to hot wire 46 of boost pump 5 .
[0048] As shown in FIG. 5 , valve slide 165 has moved into its left most position establishing fluid flow alignment. This direction to which valve slide 165 moves is based on the direction of fluid flow in the hydraulic fluid circuit being accessed in coordination with the particular selection of which flexible fluid exchange conduit 15 or 17 is connected to the higher pressure side of that circuit. In this case the operator has connected flexible fluid exchange conduit 17 to the higher pressure (discharge) side of that hydraulic circuit and flexible fluid exchange conduit 15 to the lower pressure (return) side of that circuit.
[0049] As shown in FIG. 5 , once valve slide 165 has moved into its left most position, it has established fluid flow alignment, the used fluid will flow into the used fluid chamber 45 ( FIG. 1 ), thus displacing an essentially equivalent amount of fresh fluid from fresh fluid chamber 43 . Once this occurs, fresh fluid will flow into and through fresh fluid conduit 29 to flow through flow switch 7 , thus activating flow switch 7 which results in providing an electrical signal to relay 9 which in turn provides current to energize solenoid coil 6 and to operate boost pump 5 as shown in FIG. 1 . Referring to FIG. 5 , as used fluid flows through port 58 and into used fluid conduit 23 , it also exerts the same fluid pressure to internal rod port 183 of valve body 184 , which could create a pressure differential on both sides of the rod operator assembly 166 , with the higher pressure on its lower side, thus potentially keeping it in its upper most position. Any tendency for there to be a pressure differential impacting rod operator assembly 166 to keep it in its uppermost position is neutralized because this pressure differential has been dissipated and equalized through a venting system and check valve 86 .
[0050] Referring to FIGS. 2 and 3 , this venting system is comprised of the gap between the operator rod assembly 168 and the internal bore 187 of operator rod containment tube 168 and internal port 183 , through the vents 285 and 286 of top crown 185 of rod operator assembly 166 , through balance port 28 , and through used fluid conduit 23 . This venting system for rod operator assembly 166 makes it essentially pressure neutral, allowing it to move freely to lock valve slide 165 in automatic flow-aligning valve assembly 2 in its proper flow alignment position when solenoid coil 6 is energized, and to also able to return under the power of return spring 167 when electrical current is removed from solenoid coil 6 after the fluid stops flowing through the fluid exchange system which occurs when the when the operator turns off the engine of the vehicle (in a vehicular fluid exchange) or turns off the hydraulic supply pump (in other industrial hydraulic systems).
[0051] As shown in FIG. 1 , when boost pump 5 is operated it can increase increases the fresh fluid pressure in fresh fluid conduit 29 to be greater than the fluid pressure of used fluid conduit 23 by applying lower pressure to the top side of check valve 86 than to used fluid out port 58 . Because check valve 86 does not allow flow upward through it, any additional low pressure at the topside of check valve 86 prevents that additional low pressure to be communicated through it to urge rod operator assembly 166 upward.
[0052] It should be noted that in some lower pressure applications, use of the balance port 28 or any connection of operator rod containment assembly 4 to used fluid conduit 23 would not be required, since the remaining part of the venting system would be adequate to prevent enough used fluid pressure differential from diminishing the movement of rod operator assembly 166 when force is being applied to rod operator assembly 166 by solenoid coil 6 .
[0053] Referring to FIG. 5 , once valve slide 165 has moved into its left most position establishing fluid flow alignment and is locked into its proper flow alignment position by the energizing of solenoid coil 6 as shown in FIG. 5 , used fluid flow into used fluid chamber 45 ( FIG. 1 ) is boosted by boost pump 5 and system 10 is placed it its operational, fluid pumping mode. If the hydraulic system being serviced with a fluid exchange is a higher flow type system which pumps used fluid into used fluid conduit 23 at a higher flow rate than provided by boost pump 5 , then used fluid flows through check valve 37 ( FIG. 1 ), which prevents the fluid exchange from being slowed needlessly down. On the other hand, if the hydraulic system being serviced with a fluid exchange is a lower flow type system which pumps used fluid into used fluid conduit 23 at a flow rate less than provided by boost pump 5 , then check valve 37 closes and prevents the used fluid provided by pump 5 from being bypassed back into used fluid conduit 23 and into pump head 18 of boost pump 5 , which could slow or even potentially stop the fluid exchange.
[0054] Boost pump 5 in this depiction of FIG. 1 is arranged intermediate between used fluid conduit 23 and used fluid conduit 26 , therefore before the used fluid enters used fluid port 31 of diaphragm tank assembly 3 to enter used fluid chamber 45 , it either passes through check valve 37 or is pumped through boost pump 5 . Alternatively boost pump 5 could be arranged intermediate to fresh fluid conduit 29 . This would also function effectively.
[0055] Referring to FIG. 1 the fluid exchange system 10 will continue until the engine of the vehicle is turned off to render the automatic transmission inoperative, or until fresh fluid chamber 43 reaches its uppermost position in diaphragm tank assembly 3 , at which time it moves bypass valve slide 65 into its upper position, which in turn positions internal passage 82 of bypass valve slide 65 to allow fluid to flow from used fluid conduit 26 , through check valve 34 and into bypass conduit 27 , through bypass valve 35 and into fresh fluid conduit 29 . Thus, when bypass valve slide 65 is moved by diaphragm 8 into its upper most position, the fluid exchange system 10 is shifted into bypass mode, allowing the fluid being discharged from the hydraulic circuit to be immediately returned (without exchange) back into the inlet (return) side of the hydraulic system. This feature allows the operator of the fluid exchange system freedom of movement away from the vehicle during the exchange procedure without fear of vehicle damage. In addition, when diaphragm 8 reaches its uppermost position, it activates position switch 49 which then energizes a red LED and warning tone which notify the operator that the fresh fluid supply of fresh fluid chamber 43 is depleted and the fluid exchange system is in bypass mode.
[0056] Before another fluid exchange is instituted for another hydraulic system, the operator should determine which type of new fluid should be used to fill fresh fluid chamber 43 . In this example, another vehicle with an automatic transmission with a circulating hydraulic fluid system, an external cooling circuit. In order to fill fresh fluid chamber 43 , diaphragm tank assembly 3 must be recharged, which involves the pumping of fresh fluid into fresh fluid fill port quick connect 30 accompanied by the simultaneous venting into a waste receiver of the used fluid of used fluid chamber 45 through used fluid discharge port quick connect 32 .
[0057] During the recharging of diaphragm tank assembly 3 , the volume of the used fluid being discharged is essentially equivalent to the volume of fresh fluid being pumped in because it is being displaced by the fresh fluid being pumped into chamber 43 . As fresh fluid is pumped into fresh fluid fill port quick connect 30 , it flows into the top of bypass valve 35 and through bypass valve slide 65 to enter fresh fluid chamber 43 . Check valve 34 provided to bypass conduit 27 prevents fresh fluid from flowing out of used fluid discharge port quick connect 32 during the recharge.
[0058] This recharging of diaphragm tank assembly 3 can be instituted by the operator connecting a separate used fluid drain hose (not shown) to used fluid discharge port quick connect 32 which has its own compatible quick connect at that connection end and then placing its other end to discharge into a suitable waste receiver for proper disposal later. The operator also connects a pressurizable source of fresh fluid to with a quick connector compatible with fresh fluid fill port quick connect 30 . Then the operator pumps fresh fluid from this fresh fluid source into fresh fluid fill port quick connect 30 while used fluid is simultaneously discharged. This recharging is continued until fresh fluid chamber 43 is full and used fluid chamber 45 is essentially emptied. A complete recharge is characterized as the movement of diaphragm 8 to its lowermost position possible in diaphragm tank assembly 3 . When this lowermost position of diaphragm 8 is attained, then it activates position sensor 53 that in turn energizes a green LED, signaling the operator that the recharge procedure is complete and the unit is now ready to institute another fluid exchange procedure as soon as connections to fresh fluid fill port quick connect 30 and used fluid discharge port 32 are removed.
[0059] Alternatively, the used fluid position sensor 53 can be used to provide a signal to relay 9 to control current to operate boost pump 5 as soon as diaphragm 8 is moved slightly upward from its most downward position, with the fresh fluid position sensor 49 used to provide signal to relay 9 to remove the current to boost pump 5 .
[0060] FIG. 6 shows an alternative form of an automatic flow alignment valve 413 with dual locking mechanisms connected to valve block 414 . This form can be substituted for the preferred form shown in FIGS. 1-5 and used in almost any other fluid exchange system which utilized electrical current and has two flexible fluid exchange conduits, one for dispensing fresh fluid to the hydraulic circuit having a fluid exchange and the other one for receiving used fluid from that hydraulic circuit. Two separate locking mechanisms, right locking mechanism 401 and left locking mechanism 402 are connected to automatic flow alignment valve 413 . Both locking mechanism 401 and locking mechanism 402 are internally configured the same as the locking mechanism 1 as shown in FIGS. 1-5 , operate according to the same principles, and are arranged on valve block 414 as shown in FIG. 6 .
[0061] Locking mechanisms 401 and 402 each contain a rod operator assembly, rod operator assembly 405 and rod operator assembly 406 respectively. Used fluid discharged from the hydraulic circuit being serviced is flowing through flexible fluid exchange conduit 17 (shown in FIG. 1 ) and into port 452 of valve block 414 and has already moved valve slide 465 into proper flow alignment position after which used fluid flows out of port 458 . Fresh fluid is flowing from fresh fluid conduit 425 through flow switch 410 , through fresh fluid conduit 427 , into fresh fluid inlet port 454 of valve block 414 , and out of port 450 and into flexible fluid exchange conduit 15 (shown in FIG. 1 ). Valve block 414 has an internal bore 478 which has hex plugs 463 and 464 screwed into each of its ends which are provided with suitably matched female threads. Bore 478 has two internal access ports, ports 411 and port 412 provided which allow rod operator assemblies 405 and 406 respectively to intersect and lock valve slide 465 when either one is moved downward by activation of their corresponding solenoid coils 407 or 408 respectively.
[0062] Flow switch 410 has been activated by the fresh fluid flowing through it and has triggered relay 9 ( FIG. 1 ) which in turn has provided current to boost pump 5 ( FIG. 1 ) and to both solenoid coils 407 and 408 . Only rod operator assembly 405 can move downward into position since valve slide 465 blocks complete extension downward of rod operator assembly 406 . The downward movement of rod operator assembly 405 into proper locked position will prevent valve slide 465 from moving to its right if the boost pump 5 increases the fresh fluid pressure in fresh fluid conduit 425 to be greater than the pressure in used fluid conduit 423 at automatic alignment valve 413 .
[0063] A balance conduit 428 is connected at one end to check valve 418 , and at another end to balance port 429 of an operator rod containment assembly 404 of locking mechanism 402 , and also connected at another end to balance port 430 of an operator rod containment assembly 403 of locking mechanism 401 .
[0064] In FIG. 6 , there are two separate flow switches, flow switch 409 and flow switch 410 . Flow switch 409 is connected at one end to fresh fluid conduit 426 that is in turn connected to fresh fluid inlet port 456 , and at its other end to fresh fluid conduit 425 . Flow switch 410 is connected at one end to fresh fluid conduit 427 that is in turn connected to fresh fluid inlet port 454 , and at its other end to fresh fluid conduit 425 . When this automatic flow alignment valve 413 with dual locking mechanisms 401 and 402 and dual flow switches 409 and 410 is substituted for automatic flow alignment valve 2 with locking mechanism 1 and flow switch 7 of FIG. 1 , fresh fluid conduit 425 of FIG. 6 is connected to fresh fluid conduit 29 of FIG. 1 , and balance conduit 428 is connected to check valve 418 at one end, to balance port 429 at an other end, and balance port 430 at another end.
[0065] Additional forms using other multiple fluid flow valves configured to provide automatic alignment can be fitted with associated multiple locking devices can be utilized and do not depart from this novel art. The locking mechanisms can be configured to operate from the power provided by fresh fluid or by power of an electric solenoid coil in combination with an electric flow switch and relay. For example, an automatic fluid flow alignment structure comprised of 4 separate check valves such as disclosed in U.S. Pat. No. 5,806,629 to Dixon et al, or an automatic fluid flow alignment structure comprised of a shuttle valve and two check valves such as disclosed in U.S. Pat. No. 6,267,160 to Viken, can have each valve provided with a locking device.
[0066] Pairs of check valves can utilize combination locking mechanisms based on the locking mechanism herein disclosed can be arranged and sealed between two check valves each, able to lock one when activated, and locking the other in default. These pairs of check valves then can share a single locking mechanism with a two sided operator rod assembly, which is operated in a first direction by default under spring power, and can operate in the opposite direction under power provided by the solenoid coil after a signal is generated to direct the proper operation of such combination locking device. This allows the use of a boost pump to pump the fresh fluid at a higher pressure than the incoming used fluid from the accessed hydraulic circuit, which would otherwise disrupt the function of the automatic flow alignment valve structure.
[0067] Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the invention as defined by the appended claims. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the disclosure of the present invention, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized according to the present invention. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps. | A system and method for exchanging used hydraulic fluid with fresh hydraulic fluid in an accessed hydraulic fluid system. The system includes a fluid exchange assembly, a flow-aligning valve assembly and a locking mechanism. The locking mechanism allows the pressure of the fresh fluid being conducted to the hydraulic fluid system to be increased by a boost pump beyond the nominal pressure of the used fluid being conducted from the fluid system to the valve assembly during an exchange procedure. Together the boost pump and locking mechanism provide for an efficient exchange of fluids within a hydraulic system, particularly those hydraulic systems exhibiting relatively low flow. | 5 |
SUMMARY OF THE INVENTION
This invention deals generally with process control and more specifically with control of a dyeing apparatus in which a moving strip or sheet of material is sprayed with dye from a transversely moving station which has several spray nozzles upon it.
The typical equipment used to apply color patterns to moving strip or sheet material, such as carpet, involves moving the material by means such as rollers along a surface over which are located dye spray heads. These spray heads are typically constructed so that several of them are located on a structure oriented transverse to the moving strip, and the apparatus is designed so that the spray head structure moves back and forth transversely across the moving material. The combination of the motion of the material and the motion of the spray structure, along with the timing of the spray heads, yields a pattern of dye on the material.
A simple example of this action is when the transverse structure moves back and forth at a uniform speed with the spray heads operating continuously as the material moves under it. Such an arrangement would yield a pattern of adjacent wiggly lines, more specifically, wave patterns. Adjustment of the size of the spray pattern from each head and the spreading effect of the dye on the material would determine the width of the individual lines of the pattern.
Another example of the effect of the apparatus can be understood when the spray heads are operated intermittently for short time periods when the operating time of the spray heads is short relative to the speed of the moving strip. In such a case, and with a continuous uniform speed of the transverse structure and operation of the spray nozzles at regular repeating intervals, the resulting pattern from each spray head would be a series of spots, also following a wave path.
It can readily be appreciated that, as the timing of the material movement, the transverse structure, and the spray heads is varied, many patterns can result. Moreover, if the transverse structure is also moved much more than the spacing between heads, as the timing of the spray from each nozzle is varied relative to the other nozzles, and as additional transverse structures are added along the path of the material, the resulting patterns become more complex and can take on the appearance of random patterns.
In the commercial area of salable products, it is the appearance of a random pattern that is frequently desirable. However, true random patterns are extremely difficult to achieve in a machine where the transverse structure is moved by cyclic mechanical means, and it is just that type of machine which is in general use in industry. The actual problem arising is not only that the resulting pattern is not random, but that, in fact, the pattern is noticeably repetitious. Moreover, the repeating features are sometimes highly visible and undesirable, such as those caused by the overlap of two different color spots.
Such problems are the result of the timed relationship between the operation of the dye nozzles and the oscillating structure upon which they sit and the interplay between several of these configurations. Moreover, since each oscillating structure is operated by a separate electric motor, even, if by analysis and study, a satisfactory pattern is attained and all motor speeds are set identically, the independent motors are actually always at slightly different speeds and the pattern nevertheless changes slowly.
At present, the furnished pattern is continuously inspected by a skilled and experienced operator and continuous speed adjustments are made during production. It is clear that such a procedure is not adapted to high production and, in fact, an unsatisfactory product is a frequent result even at low production speeds.
The present invention removes the entire control process from the realm of the operator and makes it completely automatic. By the use of electronic control and feedback technology, it times both the operation of all the dye valves and the movement of the several oscillating structures relative to the speed of the product. Moreover, once phase relationship between dye valves and oscillating structure movement is set, the control system continuously checks and adjusts the system parameters to maintain the exact prescribed settings.
Such an arrangement can produce, if not a true random pattern, one which, while actually having a cyclic repeat, appears random, meaning in fact that the repeat is infrequent enough to satisfy the visual test by the product designer. More important the pattern repeats faithfully, with no anomalies caused by slight drifts in motor speeds.
This result is accomplished by using a control system which takes its primary timing signals from the roller which moves the material through the apparatus. In the preferred embodiment, two encoders are connected to the motor driven material roller. The first feeds a timed pulse signal to a pattern controller which controls the operation of the dye valves located on the oscillating structure. The second encoder feeds an electrical speed signal to the master controller. Since the encoders are actually on the same rotating shaft, the shaft of the material drive roller, they are themselves synchronized. The use of two separate encoders, however, provides electronically isolated but numerically related signals.
The pattern controller selects the particular timing of the operation of the several dye valves to produce the desired color pattern on the product strip. In the preferred embodiment the pattern controller is actually a computer. This is particularly advantageous for varying the pattern and storing previous pattern control sequences, but other devices could also be used for pattern control, including such a basic apparatus as motor driven timers. Along with generating the specific timing control signals for each of the several dye valves, the pattern controller generates a pattern synchronization pulse which is transmitted to the master controller for comparison to the other critical signals in the system and for use in control of the entire system.
Two other signals are also generated and sent to the master controller. One signal is generated by an encoder attached to the motor which drives the transverse oscillating structure upon which the dye valves are mounted. This furnishes a speed signal for the oscillating structure. The other signal is generated by a proximity switch which monitors the transverse motion of the oscillating structure. This proximity switch generates a signal only when the oscillating structure is in a particular location during its motion.
The several electrical signals are therefore generated and sent to the master controller in response to (1) the speed of the product drive roller, (2) the synchronization of the dye valves, (3) the speed of the oscillating structure and (4) a unique position of the oscillating structure.
The master controller independently controls the speed of both the product drive roller and the transverse oscillating structure relative to a manually controlled product speed setting which is set by the machine operator, but, more important, it continuously checks and readjusts the synchronization of the dye valve operation and the speed of the oscillating structure to synchronize them with the motion of the product through the machine.
Moreover, since most production machines have more than one transverse oscillating structure, the master controller maintains the proper phase relationship relative to the product motion, not only of the several dye valves relative to their own oscillating motion, but also of each of the several oscillating structures relative to each other.
By this means the present invention generates exact repeating patterns on any material without any cummulative error or drift in the pattern and thereby assures high quality product regardless of machine speed drift or operator error.
BRIEF DESCRIPTION OF THE DRAWINGS
The FIGURE is a simplified block diagram of the control system of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The preferred embodiment of the invention is depicted in the FIGURE which is a simplified block diagram of carpet decorating machine 10 in which carpet roller 12 moves carpet 14 in direction A under transverse oscillating structures 16 and 17. Roller 12 is rotated by motor 18, while oscillating structure 16 is moved in direction B, transverse to direction A, by motor 20 which powers cam system 22 which converts the rotary motion of motor 20 into the transverse oscillation required by structure 16. Transverse oscillating structure 17 is similar to structure 16 and is powered and controlled in a similar fashion, but for clarity its attached devices and control connections are not shown.
Several dye valves 23, 24, and 25 with nozzles (not seen) on the underside of structure 16 are attached to oscillating structure 16 and are independently controlled by pattern controller 26. Therefore, as carpet 14 moves under structure 16 and the valves are opened to spray dye from their respective nozzles, dye pattern 28 is produced on carpet 14. Dye pattern 28 is shown as a wave which might be the result of dye valve 23 being continuously open with a specific speed of oscillation for structure 16. Similarly, spot pattern 30 is the result of intermittent operation of valve 24.
The typical pattern which is produced by such machines as carpet decorating machine 10 is a repeating pattern of some sort with a pattern repeat cycle of, for instance, 36 inches. Also typically, the dye valves are spaced at about one inch intervals across the carpet on oscillating structure 16. Since the transverse motion of structure 16 is considerably greater than the one inch spacing between valves, the actual patterns produced by the several valves overlap. Moreover, the patterns are further complicated by additional oscillating structures such as structure 17.
Pattern controller 26, typically an electronic computer, is used to control the multitude of valves to produce the desired pattern by proper sequencing of the valves.
However, control of the pattern resulting on finished product also depends upon the speed of motors 18 and 20 which respectively control the motion of carpet 14 and oscillating structure 16. Moreover, oscillating structure 17 has its own motor (not shown), as does any other additional transverse oscillating structure on the production line. To produce high quality repeating patterns, it is also necessary to accurately control these other motors.
This task and that of synchronizing the actions on all the components of the apparatus is accomplished by master controller 32.
Master controller 32 is fed electrical signals from the various components to indicate the particular status of each. Speed monitor 34, typically an optical encoder, is associated with motor 18 and produces a signal related to the speed of carpet roller 12. This signal is fed to master controller 32 and compared to the setting of manual speed control 36. A feedback circuit internal to master controller 32 then instructs motor speed control 38 to adjust the speed of motor 18 if required. The signal from speed monitor 34 is also used to control the speed of motor 20 which drives oscillating structure 16 at a speed related to the speed of motor 18. The speed relationship between the motors is determined by master controller 32 based on the pattern desired.
The speed of motor 20 is regulated in a similar manner to that of motor 18, except that it is manually controlled by oscillation repeat control 40. Speed monitor 42, typically an optical encoder, produces a signal related to the speed of motor 20. This signal is sent to master controller 32 which compares it to the speed of motor 18 and adjusts the speed of motor 20, by means of its motor control 44, so that the speed of motor 20 is correct, relative to the speed of motor 18, for the selected pattern. For instance, if it is desired to have four cycles of oscillating structure 16 for every 36 inch length of carpet, oscillation repeat control 40 establishes the appropriate ratio of the speed of motor 20 to that of motor 18 to accomplish that, regardless of the speed of the carpet strip. Master controller 32 then maintains the proper ratio by continuous comparison of the two motor speeds and correction of the speed of motor 20. This is accomplished by conventional feedback circuitry.
Speed alone is, however, not the sole criterion of a correct design. The other critical factor is synchronization of the mechanical motion of oscillating structure 16 with the operation of valves 23, 25 and 24. Master controller 32 also verifies and adjusts this synchronization.
To accomplish this, pattern controller 26 generates and sends to master controller 32 a pattern synchronization pulse once during each of its pattern cycles. This pulse is accurately timed relative to the pattern being generated, for instance it might be simultaneous with the exact opening of the first valve to generate the designed pattern cycle. Master controller 32 is thereby furnished with an electrical signal precisely related to the repeating action of the dye valves.
Pattern controller 26 is itself timed relative to a synchronization pulse furnished from encoder 45 which is on the shaft of carpet roller 12 and produces a signal related to the speed of carpet roller 12. In the preferred embodiment, an encoder is used which generates 14 pulses for each inch of carpet motion. Therefore, for a 36 inch repeating pattern, pattern controller 26 is programmed to repeat its pattern once every 504 pulses. Various intermediate pulse counts can then be used to activate the various valves. This automatically adjusts the operation of the dye valves to the carpet speed.
Master controller 32 is also supplied with an electrical signal precisely related to the location of the oscillating structure. Proximity switch 46 furnishes this signal each time activating element 48 passes it as oscillating structure 16 moves back and forth. Conventional proximity switch systems make it possible to distinguish the direction of motion, for instance, by switch 46 actually including two adjacent switches and a discriminating circuit to transmit only if one sequence of operation of the two switches occurs. Switch 46, therefore, sends a signal to master controller 32 which is timed precisely to when oscillating structure 16 passes a certain point in its cyclic travel path.
Master controller 32 then compares the synchronization pulse received from pattern controller 26 and the timed signal received from proximity switch 46 and checks them against the relationship required by the pattern synchronization control 50, which is manually set by the operator. If correction is required master controller 32 momentarily varies the speed of motor 20 to reestablish correct synchronization.
The synchronization of the pattern is therefore maintained by operating the dye valve cycle from encoder 45 and relating the speed of oscillating structure 16 to speed monitor 34, both encoder 45 and speed monitor 34 being related to the speed of roller 12. Operating through master controller 32 which maintains the relationships once they are manually set by the operator, oscillation repeat control 40 determines the number of mechanical oscillations for a specific length of carpet; pattern controller 26 determines the pattern of operation of the dye valves; pattern synchronization control 50 controls the relationship of the motion of oscillating structure 16 to the operation of the dye valves; and manual speed control 36 controls the speed of the carpet strip which, in turn, automatically controls the speed of the other actions.
It should be apparent that the addition of another oscillating structure 17 requires only another pattern synchronization control, another oscillation repeat control and another pattern controller. The second pattern controller function is easily within the capability of the typical process control computer which is likely to be used as first pattern controller 26. Such additional pattern producing systems would, however, be synchronized from the signals generated by speed monitor 34 and encoder 45.
A particular advantage of the present invention is that it can easily be added to existing strip product machines. Typically, for such an addition the attachment required would be only shaft encoders 34, 42 and 45 and proximity switch activating element 48. Signal cables from these devices furnish all the information required to accomplish complete control of the system by the usually available motor speed controls and dye valve actuating controls.
It is to be understood that the form of this invention as shown is merely a preferred embodiment. Various changes may be made in the function and arrangement of parts, equivalent means may be substituted for those illustrated and described, and certain features may be used independently from others without departing from the spirit and scope of the invention as defined in the following claims.
For example, encoders 34 and 45 could be combined into a single unit feeding signal to both the pattern controller and the master controller. | An apparatus for maintaining the relationship of a transverse oscillating mechanical production member containing dye valves with a product moving linearly at a relatively high speed and with the program of operation of the valves. Encoders related to both the linear motion and the transverse motion are continuously monitored and the speed of the oscillating element adjusted to match the linear motion while a proximity switch operated at one point in the oscillating member cycle monitors the synchronization of the oscillating member which is adjustable once every cycle to maintain synchronization. | 3 |
CLAIM OF PRIORITY
This application claims the benefit of the earlier filing date, under 35 U.S.C. §119(a), to that Korean Patent Application entitled “APPARATUS AND METHOD FOR SIMPLIFYING THREE-DIMENSIONAL MESH DATA” filed in the Korean Intellectual Property Office on Jan. 3, 2008 and assigned Serial No. 10-2008-0000558, the contents of which are herein incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to 3-Dimensional (3D) mesh data imaging and, more particularly, to an apparatus and method for extending a Quadric Error Metrics (QEM) algorithm by discrete curvature for simplifying 3D mesh data.
2. Description of the Related Art
With the recent progress of advanced automation and development into information society, applications of computer graphic have increased rapidly, e.g., animation, simulation, etc. Amid this, the recent introduction of 3-Dimensional (3D) graphic techniques into electronic equipments leads to paying attention to the development of a high speed graphic processing technology for processing large numbers of polygons and efficiently processing special effects, such as lighting effects, in order to configure a little more realistic graphic.
Mesh simplification is a technique to retain the original desired shape and feature of a 3D model while reducing the number of polygons necessary to render the shape and features. That is, mesh simplification refers a process of removing polygons having topological and geometrical information more than needed from an initial model, thus simplifying the initial model. A technology for simplifying such a 3D model has been utilized in many fields such as a Level of Detail (LOD) control technology of a computer animation and 3D game, a 3D graphic solution of the Internet, a real-time 3D graphic simulation, etc.
A goal of mesh simplification is to provide good approximation to retain geometrical information on the original model and a phase with less vertex and face. An advantage of mesh simplification is to reduce the amount of storage space required for rendering a large size model, reduce a data-structure building time, and visualize a model at high speed.
A conventional simplification algorithm can give rise to a change of a volume of the original mesh model during the simplification process. Performance of the mesh simplification algorithm depends on an execution time for simplifying the original mesh model and a quality of approximation of the simplified model. Thus, a volume of a simplified mesh model has been considered using a distance based QEM algorithm of several simplification algorithms that uses the sum of squares of distances from one point on a plane providing relatively good performance.
The QEM algorithm is an algorithm for simplifying a mesh model using iterative edge contraction in which a method of selecting an edge to contract is of importance. The QEM algorithm determines a vertex whose distance error is minimal at each edge as a position of a new vertex after edge contraction, using a cost function of prioritizing an edge to contract (i.e., so-called QEM), first selects an edge at which the vertex has the least distance error among edges, and contracts the selected edge.
However, the QEM algorithm performs quick and high quality simplification, but there is a problem that it cannot keep a feature of the original 3D model when completing a simplification step of simplifying the original 3D model.
SUMMARY OF THE INVENTION
According to one aspect of the present invention, a method for simplifying 3-Dimensional (3D) mesh data in an electronic equipment is provided. The method includes measuring discrete curvature at each point in said 3D mesh data, calculating an error based on distance-curvature error metrics comprising the discrete curvature measured at each point, selecting a minimum error among the calculated errors, contracting a corresponding edge of said 3D when the minimum error is more than the threshold to obtain a simplified version of said edge, recalculating an error of a surface neighboring to a surface on which the contracted edge belongs, and re-sorting said calculated error values.
According to another aspect of the present invention, an apparatus for simplifying 3-Dimensional (3D) mesh data is provided. The apparatus includes a controller and a graphic engine. The controller controls a function of measuring discrete curvature at each point, calculating an error based on distance-curvature error metrics including the measured discrete curvature, first sorting a low curvature one of the calculated error values of respective points in ascending order, determining if a minimum error among the calculated errors is less than a threshold, contracting an edge if the minimum error is more than the threshold, recalculating an error of a surface neighboring to a surface on which the edge contracts, and re-sorting the calculated errors. The graphic engine performs simplification by contracting an edge of the 3D mesh data under control of the controller.
BRIEF DESCRIPTION OF THE DRAWINGS
The above features and advantages of the present invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings in which:
FIG. 1 is a block diagram illustrating a construction of an apparatus for simplifying 3-Dimensional (3D) mesh data according to an exemplary embodiment of the present invention;
FIG. 2 is a flow diagram illustrating a process of simplifying 3D mesh data in according to an exemplary embodiment of the present invention;
FIG. 3 is a diagram illustrating simplified data according to an exemplary embodiment of the present invention; and
FIG. 4 is a diagram illustrating simplified data according to an exemplary embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Exemplary embodiments of the present invention will be described herein below with reference to the accompanying drawings. In the following description, well-known functions or constructions are not described in detail as they would obscure the invention in unnecessary detail.
FIG. 1 is a block diagram illustrating a construction of an apparatus for simplifying 3-Dimensional (3D) mesh data according to an exemplary embodiment of the present invention.
In this case, the apparatus refers to a plurality of equipments for processing graphic such as a portable terminal, a personal computer, a mobile communication terminal, etc. or may represent one component or equipment among the plurality of the graphic processing equipments.
Referring to FIG. 1 , the apparatus includes a controller 100 , a graphic engine 102 , a memory 104 , a display unit 106 , and an input unit 108 .
The controller 100 controls a general operation of the apparatus and in addition to a general function, controls and processes a function of receiving 3D mesh data, measuring discrete curvature, measuring an error based on distance and curvature, first sorting and simplifying a middle point having less error, and providing an output to the display unit 106 according to an exemplary embodiment of the present invention.
Under control of the controller 100 , the graphic engine 102 measures discrete curvature of the received 3D mesh data, measures an error based on distance and curvature, first sorts and simplifies a point having less error, and provides an output to the controller 100 . The graphic engine 102 also directly outputs simplified 3D mesh data to the display unit 106 .
The memory 104 stores a program for controlling a general operation of the electronic equipment, temporary data generated during an operation of the electronic equipment, a system parameter, and other depository data. In particular, the memory 104 stores a program for simplifying 3D mesh data. Memory 104 may be composed of well-known memory types such a PROM, RAM, and/or Flash.
The display unit 106 displays state information generated during an operation of the apparatus, and limited number of numerals and characters. The display unit 128 outputs a simplification model whose feature is preserved according to an exemplary embodiment of the present invention.
The input unit 108 includes keys for receiving numeral or character information and function keys for setting various kinds of functions, and outputs functions corresponding to the keys pressed by a user to the controller 100 .
FIG. 2 is a flow diagram illustrating a process of simplifying 3D mesh data according to an exemplary embodiment of the present invention.
Referring to FIG. 2 , upon receiving 3D data in step 201 , measurement of discrete curvature is performed at each point at step 203 . The discrete curvature, a surface curvature of mesh constituted of a discrete surface, is calculated using geometrical information on the mesh. As the discrete curvature, there are an average curvature, a Gaussian curvature, and a principal curvature, and each curvature has a different characteristic.
Then, in step 205 , an error is calculated based on distance-curvature error metrics and then, in step 207 , a sort of the calculated errors.
Then, in step 208 , a minimum error is selected from among the errors and then, in step 209 , a determination is made whether the minimum error is less than a threshold value. If the minimum error is less than the threshold, in step 213 , an edge of a vertex is contracted and in step 215 , an error of a surface neighboring to a surface on which the edge contracts, is recalculated the calculated errors are resorted. Then, processing returns to step 209 and again performs the processing steps illustrated.
If the minimum error is less than the threshold value, then in step 211 , the simplified data is outputted and processing is terminated according to the illustrated exemplary embodiment of the present invention.
With regard to the error calculation, a distance from one point on a plane of a triangular mesh is measured and the measured distance is used as an error, and is given in Equation 1 as:
d ( v ,p i )= n i · v +c i (1)
wherein d( v ,p i ) represents a distance from a new vertex v =( v x , v y , v z ) on a plane (p i ), and n=(n ix , n iy , n iz ) represents a vector of the plane (p i ).
Discrete curvature for the vertex v =( v x , v y , v z ) represents a curved degree at the vertex.
An error obtained using the discrete curvature is substituted for c i in Equation 1. By the thus measured numerical value, a distance error (i.e., QEM) is extended into distance-curvature error metrics including discrete curvature(s). The distance-curvature error metrics change a sequence (order) of a heap to simplify a high curvature part last and simplify a low curvature part (i.e., a flat part) first by changing a sequence of the computed errors. For example, an error is measured by measuring discrete curvatures at vertexes (v 1 ) and (v 2 ) in Equation 2 and substituting the thus measured values in Equation 3.
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The error obtained from Equations 2 and 3 is put in a heap for simplification and, among error values, an error value of a high curvature part moves to a rear part of the heap. By doing so, simplification is, although much, done with a feature of the original 3D mesh data that is preserved.
FIG. 3 is a diagram illustrating simplified data according to an exemplary embodiment of the present invention.
Referring to FIG. 3 , upon simplification, a conventional QEM method expresses a part 301 of the original 3D mesh data model like a part 303 (see FIG. 3(B) ). However, in the exemplary embodiment of the present invention received herein, if a high curvature part is simplified last, simplification is performed with a feature preserved like a part 305 (see FIG. 3(C) ). In FIG. 3 , “T” denotes number of triangles marked on a model. FIG. 4 is a diagram illustrating simplified data according to an exemplary embodiment of the present invention.
Referring to FIG. 4 , upon simplification, a conventional QEM method expresses parts 401 and 403 (see FIG. 4 (A)), of the original 3D mesh data model a represented by parts 405 and 407 (see FIG. 4(B) ). In an exemplary embodiment of the present invention, if a high curvature part is simplified last, simplification is performed with a feature preserved like parts 409 and 411 . (see FIG. 4( c )). In FIG. 4 , “T” denotes number of triangles marked on a model.
The above-described methods according to the present invention can be realized in hardware or as software or computer code that can be stored in a recording medium such as a CD ROM, an RAM, a floppy disk, a hard disk, or a magneto-optical disk or downloaded over a network, so that the methods described herein can be rendered in such software using a general purpose computer, or a special processor or in programmable or dedicated hardware, such as an ASIC or FPGA. As would be understood in the art, the computer, the processor or the programmable hardware include memory components, e.g., RAM, ROM, Flash, etc. that may store or receive software or computer code that when accessed and executed by the computer, processor or hardware implement the processing methods described herein.
As described above, an exemplary embodiment of the present invention has an effect of, upon simplification of 3D mesh data, being able to first simplify a specific part of the 3D mesh data model and thus increase the accuracy of a contour and a shape of the simplified model, by extending a QEM algorithm by discrete curvature and simplify a high discrete curvature part last.
While the invention has been shown and described with reference to certain preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims. | An apparatus and method for simplifying 3-Dimensional (3D) mesh data are disclosed. The method includes measuring discrete curvature at each point of received 3D mesh data, calculating an error based on distance-curvature error metrics including the discrete curvature, first sorting a low curvature one of the calculated error values in a heap in ascending order, selecting a minimum error among the calculated errors, determining if the minimum error is less than a threshold, contracting an edge if the selected minimum error is greater than the threshold, and recalculating an error of a surface neighboring to a surface on which the contracted edge belongs and re-sorting the calculated error values. | 6 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application Ser. No. 60/696,242 entitled “A Local Adaptive Algorithm for Microaneurysms Detection in Digital Fundus Images,” filed on Jul. 1, 2005, the contents of which are hereby incorporated by reference herein in their entirety.
FIELD OF THE INVENTION
[0002] The present invention relates generally to the field of medical imaging analysis, and more particularly, to techniques and systems for automatically identifying microaneurysms (MAs) in digital ocular fundus images.
BACKGROUND OF THE INVENTION
[0003] Diabetic retinopathy is a widespread eye disease that Nay cause blindness in diabetic patients. Often patients are not aware of the disease until its late stages, thus annual screening of patients for possible diabetic retinopathy is recommended.
[0004] In the screening, microaneurysms (MAs) are one of the earliest visible lesions in diabetic retinopathy, and are therefore an important pathology to be detected and followed closely. The number, density and locations of MAS are important factors to quantify the progression of diabetic retinopathy.
[0005] MAs are saccular outpouchings of the retinal capillaries. Their size ranges from 10 μm to 100 μm, and may be assumed always to be less 125 μm. As capillaries are too thin to be visible in a digital fundus image, MAs appear to be isolated patterns that are disconnected from the blood vessels.
[0006] Hemorrhages are blood leaking from MAs and deposited in the retina. Small dotted hemorrhages arc often hard to visually differentiate from MAs. Consistent with most published work in this area, no distinction is made herein between small dotted hemorrhages and MAs,
[0007] FIG. 1 is an illustration of various structures contained in a digital fundus image 100 . The white rectangular region in the right image is zoomed as the left image for better visibility. The ocular fundus image 100 contains several MAs 110 and a hemorage 120 . In addition, several ocular structures appear in the image, including an optic disk 130 , hard exudate 140 and the macula 150 .
[0008] Manual identification of MAs in a fundus image is time-consuming and subjected to inter- and intra-operator variability. Screening a large number of diabetic patients annually poses a huge workload for ophthalmologists. A system is needed wherein MAs and other lesions are automatically and accurately detected, and only suspicious cases are referred to ophthalmologists for further evaluation and treatment.
[0009] Most existing MA detection techniques were developed for use with a fluorescein angiogram, which is an image of the ocular fundus obtained after a fluorescent dye is injected into a patient's body and passed through the blood vessels of the retina. MAs are thereby highlighted in fluorescein angiograms, making MAs detection easier.
[0010] In recent years, digital ocular fundus images, which do not require dye injection, are more commonly used in screenings. In a digital fundus image, MAs are small dark red dots several pixels in size, depending on image resolution. Although many of the techniques developed for fluorescein angiograms can be directly applied to digital fundus images, care must be taken to account for the weaker contrast of MAs to the surrounding pixels. The present invention addresses MAs detection using a digital ocular fundus image.
[0011] A number of algorithms have been proposed for MAs detection in mass screening Most of them process digital fundus images globally without a mechanism to take into account local properties and changes in the image. Performance of those algorithms is often susceptible to non-uniform illumination and to the locations of MAs in different retinal regions. To keep sensitivity at a relatively high level, a low threshold value must be applied to the entire image globally, resulting in a much lower specificity in MAs detection. Post-processing steps, such as feature extraction and classification, must he implemented to improve the specificity at the cost of sensitivity.
[0012] A widely used scheme 200 for MAs detection is shown in FIG. 2 . The sequence of operations includes image preprocessing (step 210 ), global thresholding of the enhanced image (step 220 ), region growing (step 230 ), feature extraction (step 240 ) and classification (step 250 ) to discriminate true MAs from false detections. That technique has achieved some degree of success in MA detection; however, several factors constrain further improvement of the detection accuracy,
[0013] For example, local properties of the retina and inhomogeneous illumination of different regions are not considered in that framework. Thus, a global processing method often generates a considerable number of false detections. Some preprocessing techniques, such as shade correction, can ease the severity of inhomogeneous imaging conditions; however, the problems associated with global thresholding still exist.
[0014] The region grow, feature extraction and classification steps can remove some false detections, but those steps may also introduce additional errors. For example, region growing for small objects such as MAs is not very reliable. The shape feature in MAs detection is essential to classification; however, due to the irregular shape of MAs, the classifier is usually trained to accept shapes varying in a large range, which leads to misclassification.
[0015] Those issues exist for MAs detection using fluorescein angiograms, and are likely to be more severe with digital fundus images, where MAs appear to have much weaker contrast with neighboring pixels. In addition, all parameters in the sequential procedure 200 are coupled and affect each other; i.e., the parameters in a later processing step must be adjusted according to the output of the previous one. As a result, performance is more sensitive to parameter adjustment, and is less robust.
[0016] Another method based on normalized cuts has been proposed for MA detection. Several factors, however, may hinder its success in real applications. Its performance is sensitive to the number of segments selected, and the computational complexity can be as high as O(n 3 ), where n is the number of pixels. The method therefore becomes impractical with digital fundus images, which are normally 1024×1280 pixels.
[0017] There is presently a need to provide a method and system for reliably detecting MAs in a digital ocular fundus image. To the inventors' knowledge, there is currently no such technique available.
SUMMARY OF THE INVENTION
[0018] In order to address the above-described problem, a local adaptive algorithm is proposed for automatic detection of MAs, where multiple subregions of each image are automatically analyzed to adapt to local intensity variations and properties. A priori structural features and pathology, such as region and location information of vessels, optic disk and hard exudates, are further incorporated to improve the detection accuracy. The method effectively improves the specificity of MA detection in digital fundus images, without sacrificing sensitivity. The technique has the potential for use in automatic level-one grading of diabetic retinopathy screening.
[0019] One embodiment of the present invention is a method for detection of microaneurysms in a digital ocular fundus image. The method comprises the steps of subdividing the image into a plurality of subregions; adaptively enhancing each subregion to correct for background variations within the subregion; and segmenting microaneurysms from a background image and from other structures in each subregion using shape features of microaneurysms and directional morphological operations.
[0020] The step of subdividing the image into a plurality of subregions may further comprise separating the regions into overlapping regions. For example, where the digital ocular fundus image is 1024×1280 pixels, the subregions may be 120 pixels per side and the regions may overlap by 10 pixels per side.
[0021] The step of image enhancing each subregion to correct for background variations within the subregion may further comprise correcting for shading effect in each subregion. The step of correcting for shading in each subregion may include the steps of estimating a background image in the subregion, and subtracting the estimated background image from an original image. The step of estimating a background image in the subregion may further include applying a low-pass two-dimensional Gaussian filter.
[0022] In addition to correcting for shading effect, the step of image enhancing each subregion may also include enhancing local contrast in the subregion, and smoothing to reduce step effects.
[0023] The step of segmenting microaneurysms from a background image and from other structures in each subregion using shape features of microaneurysms and directional morphological operations may further comprise the step of using a “Top Hat” filter to identify microaneurysms. The segmenting step may compromise the step of dilating structures in the image using a linear structuring element.
[0024] The method may further comprise the steps of identifying a structure other than a microaneurysm in the digital ocular fundus image, and discounting a false microaneurysm identification based on its location relative to the identified anatomical structures. The identified structure may be one or more of an optic disk, a hard exudate and a blood vessel.
[0025] Another embodiment of the invention is a computer program product comprising a computer readable recording medium having recorded thereon a computer program comprising code means for, when executed on a computer, instructing said computer to control steps in the method described above.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] FIG. 1 is a depiction of a digital fundus image showing several structures.
[0027] FIG. 2 is a flow chart showing a prior art method.
[0028] FIG. 3 is a flow chart showing a method according to one embodiment of the present invention.
[0029] FIG. 4 is a depiction of a non-overlapping subregion of a digital fundus image.
[0030] FIG. 5 is a plot showing a mapping function used for contrast enhancement in one embodiment of the present invention.
[0031] FIGS. 6 a - 6 d are depictions of operations on a digital fundus image for shade correction and contrast enhancement according to one embodiment of the invention.
[0032] FIG. 7 a is a depiction of a processed digital fundus image showing MA detection using a global method.
[0033] FIG. 7 b is a depiction of a processed digital fundus image showing MA detection using a local adaptive method according to one embodiment of the invention.
DESCRIPTION OF THE INVENTION
[0034] The inventors have developed a new scheme for robust MAs detection using digital ocular fundus images. The new scheme: (1) takes into account the local properties and variations to improve sensitivity of detection; (2) incorporates a priori knowledge during detection to further reduce false detections (such as, no MAs would appear on blood vessels); and (3) is more robust to parameter selections, and thus to different imaging conditions.
[0035] A flow chart illustrating the inventive scheme 300 is shown in FIG. 3 . A fundus image 310 is first automatically subdivided (step 320 ), and each subregion is then analyzed adaptively (steps 330 , 340 ). Detections of optic disk (step 350 ), vessel regions (step 370 ) and hard exudates (step 360 ) are introduced in parallel to incorporate prior knowledge about locations where MAs would not appear. The a priori information is combined by multiplication (step 380 ) with the analysis results to yield accurate MAs detection.
[0036] Image Division and Enhancement
[0037] The first step in the MA detection method of the invention is to divide an entire fundus image into multiple subregions such that, in each subregion, potential MA candidates can be robustly identified. Two options are available for image division: overlapping and non-overlapping. In an overlapping scheme, neighboring subregions share common regions or pixels. In a non-overlapping scheme, no regions or pixels are shared by adjacent subregions.
[0038] In a preferred embodiment of the present invention, overlapping division is used to avoid generating false MA candidates. For example, a false candidate that could be generated by a non-overlapping division is shown in FIG. 4 . In that example, part of another structure 410 is cropped into a subregion 420 . The partial structure 410 may be mistakenly identified as an MA candidate.
[0039] In the technique of the present invention, the original fundus image is divided into subregions with a size of M 1 ×M 2 , where only the central m 1 ×m 2 (m 1 <M 1 , m 2 <M 2 ) region is of interest. Given an image I with a size of
N 1 × N 2 , N 1 m 1 × N 2 m 2
subregions are obtained, and each subregion I n 1 ,n 2 is cropped from I as:
I n 1 , n 2 ( i , j ) = I [ m 1 n 1 - 0.5 ( M 1 - m 1 ) + i , m 2 n 2 - 0.5 ( M 2 - m 2 ) + j ]
where
0 ≤ i ≤ M 1 - 1 , 0 ≤ j ≤ M 2 - 1 , 0 ≤ n 1 ≤ N 1 m 1 - 1 ,
and
0 ≤ n 2 ≤ N 2 m 2 - 1.
[0040] When m 1 =N 1 and m 2 =N 2 , the local adaptive method becomes a global one. Large amounts of artifact may be generated when subregions are too small. For the typical digital fundus image size of 1024×1280, the inventors have found that M 1 =M 2 =120 and m 1 =m 2 =100 is a good compromise.
[0041] Shading effect presents slowly varying image intensity in the background, which may be due to the different physiological properties in the retina, and the nonuniform illumination across the field of view. Usually, the optic disk region is brightest in a retinal image, and macular region appears the darkest. The shading effect in MAs detection is very undesirable, and must therefore be compensated before detection. Correction for shading effect is done by first estimating a background image, and then subtracting the estimated background image from the original to correct for background variations.
[0042] In the present invention, a low-pass, 2-dimensional, 25×25 Gaussian filter may be used to estimate a background image. To enhance the visibility of small structures like MAs, contrast enhancement is applied to the difference image, with the following mapping function.
I = { a 1 t r + b 1 , if t ≤ μ a 2 t r + b 2 , if t > μ
where
a 1 = 1 / 2 u max - u min μ r - t min r , b 1 = u min - a 1 t min r , a 2 = 1 / 2 u max - u min t max r - μ r
and
b 2 = u max - a 2 t max r .
μ is the mean gray value of all pixels to be enhanced. An example of the function is shown in FIG. 5
[0043] Step effects are obvious in the difference image obtained from shading correction and contrast enhancement. To correct for step effects, a low pass filter with a small window (a 5×5 2D Gaussian filter in one example) is used to smooth the difference image.
[0044] An illustration of the effect of shading correction and contrast enhancement is given in FIGS. 6 a - 6 d. In FIG. 6 a , a green channel image is shown before correction and enhancement. FIG. 6 b shows an estimated background. A difference image between a green channel image and the estimated background is shown in FIG. 6 c. FIG. 6 d shows a difference image after contrast enhancement.
[0045] Local Adaptive MAs Detection
[0046] MAs appear to be small dark round areas in the image obtained from shading correction and contrast enhancement. Other structures, such as blood vessels and hard exudates, also appear to be dark in the same image. All valid MAs have a diameter less than 10 pixels in a 1024×1280 digital fundus image. A filter called “Top-Hat,” which is based on directional morphological operations, has been developed for segmenting MAs from the background. One example of its application may be found in Cree, M., Olson, J., McHardy, K., Forrester, J., Sharp, P., Automated Microaneurysm Detection. Proceedings of the International Conference on Image Processing 699-702 (1996).
[0047] The operation of the “Top-Hat” filter may be described as follows. Dilation of an image I in the gray value domain is a mapping function from R to R in R 2 space. Given an image I and a structuring element B, the dilation operation D can be defined as:
D B [ I ( i , j ) ] = Max ( i ′ , j ′ ) ∈ B ( i , j ) ( I ( i ′ , j ′ ) )
[0048] where B defines the neighboring region for (i,j). For MAs detection, a flat linear structuring element is used. Given length L and orientation angle θ, the neighboring region is defined as:
B L θ ( i , j ) = { ( i ′ , j ′ ) } , i - L 2 sin θ ≤ i ′ ≤ i + L 2 sin θ , j ′ = j + ( i ′ - i ) ctg θ .
[0049] The “Top-Hat” filter is then defined as the minimum value obtained by rotating the structuring element at different orientation angles:
TH ( I ( i , j ) ) = min 0 < θ < 180 { D B L θ [ I ( i , j ) ] } .
[0050] In the present implementation, the angle θ is incremented, and the resolution is set to an interval of 10 degrees:
θ={10× n θ }, 0≦ n 74 ≦17
[0051] The length L of structuring element B 1 θ should be chosen to be larger than the diameter of a typical MA; i.e., 10. In the embodiment tested by the inventors, L is set to 15. Because MAs are isolated dark dots surrounded by relatively brighter neighboring pixels, the “Top-Hat” filter will remove MAs from the subregion, filling dark MA regions with bright pixels. For large structures like a vessel, at least in one direction, the dilation operation obtains a small value (dark pixel) from the same vessel, thus the dark pixels on the vessel are still dark after this operation.
[0052] Finally, the difference image δI=TH(I)−I contains large values (bright pixels) for MA regions. A large value of δI has two meanings: (1) the corresponding pixel in the original image I is from an isolated black region; and (2) the size of the black region is small (with diameter less than 15). A larger value of δI indicates that the small black region is better contrasted.
[0053] Prior art techniques used morphological opening in the “Top-Hat” filter instead of dilation. The inventors have found that dilation gives better results for MAs detection in digital ocular fundus images.
[0054] To determine a proper threshold value for MAs detection in δI, two factors are taken into account: the area of a single MA and the absolute value of the threshold value. The pixel values of δI are first sorted in the descending order to obtain a one-dimensional array δI′; i.e., δI′(i)≧δI′(j), given that i≧j. Denoting the area of a typical MA as a, then the threshold value t is set as:
t= min{δ I ′( a ), t low }
[0055] Note that the pixel values of δI need not actually be sorted, because fast algorithms are well known for extracting the a th largest value from an unsorted array. One such algorithm is described in Cormen, T., Leiserson, C., Rivest, R., Stein, C., eds., Introduction to Algorithms, MIT Press (2d ed. 2001).
[0056] t low is placed in the formula to avoid the threshold being too high, which may occur when there are multiple MAs in a subregion. t low is a relatively high value, predefined to be the same for all subregions. For most subregions, t low >δI′(a). Therefore, the threshold values are automatically adapted to the properties of different image regions. For embodiments described herein, the value of a is set to 25. Each connected region in the thresholded image is taken as a candidate region MA n . The mean value of MA n is calculated to reflect the confidence of the region being an MA as follows.
C ( MA n )=mean(δ I ( i,j )), where( i,j )ε MA n .
[0057] A higher value of C(MA n ) indicates that the region is more likely a true MA, With that method, at least one MA candidate will be detected in each subregion. The MAs with low confidence values, however, will be discarded.
[0058] The enhancement procedure may introduce some artifacts: a slightly gray dot in a bright region will be enhanced to a region that has a high confidence value from δI. To address that problem, the MAs detection procedure described above is repeated on the original green channel subregion. Only regions with high confidence values from both the green channel subregion and the enhanced subregion are kept. For the original green channel subregion, t low is empirically set to 12, and for the enhanced subregion, t low is set to 100. The much higher value of t low for the enhanced image reflects the better contrast resulting from the enhancement step.
[0059] The technique of the present invention therefore replaces the global application of a single threshold to the entire image, with a local adaptive detection method. That technique effectively avoids generating large numbers of false detections. To illustrate, assume that an MA with confidence value t 1 less than t low exists in an image. To detect that MA, a threshold value less than t 1 must be applied to all regions of the image in the global thresholding method. However, in the local adaptive method, the effect of the MA with a low confidence value is confined to a single subregion.
[0060] Incorporate Prior Knowledge for MAs Detection
[0061] It is known that, physiologically, MAs do not appear in the optic disk (OD), hard exudates (HE) and blood vessel (VS). Therefore, incorporating that prior knowledge helps reduce the number of false detections. OD is the brightest region in the normal fundus image. HE appears to be yellow waxy regions with varying sizes and shapes. VS appears to be a connected tree structure distributed over the whole image. Those properties make the whole image better for detecting those structures than local subregions. Some OD/HE/VS detection algorithms are given in literature; e.g., Li, H., Chutatape, O., A Model - Based Approach for Automated Feature Extraction in Fundus Images, Proceedings of the International Conference on Computer Vision (2003) (Li et al.).
[0062] For OD detection, the algorithm introduced by Li et al. is simplified and applied, as follows, The gray image is first thresholded to segment the brightest pixels whose number is roughly equal to the number of pixels in a typical OD region. The segmented pixels are then clustered, and the cluster with the maximum number of pixels is selected as the original optic disk. The selected cluster is then grown to neighboring bright regions to form the final OD region.
[0063] The shape of the detected OD is not very accurate as compared to the actual OD shape. The detected GD, however, covers most of the OD region, and is good enough to remove false MAs that are likely to appear at the central OD regions when the local adaptive detection method of the invention is used.
[0064] HE has been separated in a single image using its features in a color space. Large variance in a color space, however, exists among different digital fundus images. An improved HE detection algorithm is applied by the inventors by combining both color features and texture features. The waxy structure of HE causes strong response in the “Top-Hat” filter, while other smooth yellow regions do not. That property, which exploits the texture of the HE, is utilized in the HE detection for more robust detection.
[0065] The problem of blood vessel detection has been addressed in the prior art. For the purpose of removing false MAs, the inventors utilize a computationally efficient algorithm for vessel detection based on multi-level image enhancement and binarization.
[0066] The combined result of OD/HE/VS detection is a boolean template, where “1” denotes a non-OD/HE/VS region and “0” denotes a OD/HE/VS region. As shown in FIG. 3 , the multiplication (step 380 ) of that boolean template with the result of local adaptive MA detection generates final decisions on MAs detection.
[0067] Experiments
[0068] Experiments were conducted on twelve digital fundus images with a size of 1024×1280. Four images (labeled below from ‘A1’ to ‘A4’) are taken from healthy eyes; four images (labeled below from ‘R1’ to ‘R4’) are taken from eyes that need further treatment by ophthalmologists; the remaining four images (labeled below from ‘U1’ to ‘U4’) are taken from eyes that need immediate medical treatment. Images of type ‘A’ do not contain any MA, while ‘R’ and ‘U’ types of images contain different numbers of MAs.
[0069] The positions of the MAs are much more important than the number of MAs in classifying those images into the three types mentioned above. The appearance of MAs in the neighboring area of macular is enough to classify a fundus image into ‘U’ type, though the number of MAs may be much smaller than that of ‘R’ type.
[0070] Sensitivity and specificity are often used to evaluate the performance of an MA detection system. Sensitivity is defined as the probability that an MA is detected given that there is an MA in the image. Specificity is defined as the probability that no MA is detected given that the there is no MA in the image. Given an algorithm, the change in sensitivity is inversely proportional to the change in specificity.
[0071] To compare the local adaptive detection algorithm with the global detection algorithm, the inventors fixed the sensitivity to 100% (i.e., all true MAs are detected) and compared the number of false detections generated by both algorithms. In order to test the effect of incorporating prior knowledge, the number of false detections removed from the detected OD/HE/VS regions is also reported.
[0072] Results of both methods are reported in Table 1 and Table 2, separately:
TABLE I Global Thresholding Image A1 A2 A3 A4 R1 R2 R3 R4 U1 U2 U3 U4 without 25 23 10 16 68 56 60 43 20 15 62 72 OD/HE/VS with 14 12 4 9 45 42 41 32 13 8 27 23 OD/HE/VS true MA 0 0 0 0 26 28 28 22 8 4 20 16 FP 14 12 4 9 19 14 13 10 5 4 7 7
[0073]
TABLE II
Local Adaptive Thresholding
Image
A1
A2
A3
A4
R1
R2
R3
R4
U1
U2
U3
U4
without
5
6
2
3
39
38
40
30
10
7
48
49
OD/HE/VS
with
0
1
0
0
29
30
31
25
8
4
21
18
OD/HE/VS
true MA
0
0
0
0
26
28
28
22
8
4
20
16
FP
0
1
0
0
3
2
3
3
0
0
1
2
[0074] In each of Table 1 and Table 2, the first row contains an index of the image, and the following four rows are: (1) the number of detected MAs without OD/HE/VS detection; (2) the number of detected MAs with OD/HE/VS detection; (3) the number of true MAs; and (4) the number of false detections with OD/HE/VS detection.
[0075] With both thresholding methods, either global or local, false MAs are more likely to be generated in the HE regions. For images ‘R1’ and ‘R2’. HE is small, and for image ‘U3’ and ‘U4’, HE is large. For those images, the effect of removing false MAs from OD/HE/VS detection is most obvious.
[0076] For all images from ‘A1’ to ‘U4’, different numbers of false MAs are removed (see the difference between the row without OD/HE/VS and the row with OD/HE/VS) by incorporating prior knowledge in both thresholding techniques. That shows that the detection of OD/HE/VS and incorporating their location information into the MAs detection is effective in removing false MAs. From those tables, it is clear that the local adaptive detection method generates fewer false detections than a global detection method. Region growing/feature extraction/statistical classifier can be applied to both global detection results and local adaptive detection results.
[0077] FIG. 7 presents results from a global method ( FIG. 7 a ) and the local adaptive method ( FIG. 7 b ) for the same image. The detected MAs are labeled black. The results make clear that for that image, the global method generates more false detections than the local adaptive method, for the same sensitivity.
[0078] The invention is a modular framework and method and is deployed as software as an application program tangibly embodied on a program storage device. The application is accessed through a graphical user interface (GUI). The application code for execution can reside on a plurality of different types of computer readable media known to those skilled in the art. Users access the framework by accessing the GUI via a computer.
[0079] CONCLUSION
[0080] The inventors have improved two aspects of the existing MAs detection method: reducing the number of false detections through local adaptive detection and incorporating prior knowledge for MAs detection. The lower number of false MAs generated by the local adaptive detection method permits the removal of some post-processing steps, thus reducing the problem of parameter coupling and error propagation that are inherent in the sequential operations of the global detection method. Experimental results show that, compared to the existing method, the method of the invention effectively reduces the number of false detections, while keeping the detection sensitivity at a comparable level.
[0081] The foregoing Detailed Description is to be understood as being in every respect illustrative and exemplary, but not restrictive, and the scope of the invention disclosed herein is not to be determined from the Description of the Invention, but rather from the Claims as interpreted according to the full breadth permitted by the patent laws. For example, while the method is disclosed herein is applied specifically to the detection of microaneurysms in a digital ocular fundus image, the method may be applied to images made using other imaging techniques, as those techniques become available, while remaining within the scope of the invention. It is to be understood that the embodiments shown and described herein are only illustrative of the principles of the present invention and that various modifications may be implemented by those skilled in the art without departing from the scope and spirit of the invention. | A local adaptive method is proposed for automatic detection of microaneurysms in a digital ocular fundus image. Multiple subregions of the image are automatically analyzed and adapted to local intensity variation and properties. A priori region and location information about structural features such as vessels, optic disk and hard exudates are incorporated to further improve the detection accuracy. The method effectively improves the specificity of microaneurysms detection, without sacrificing sensitivity. The method may be used in automatic level-one grading of diabetic retinopathy screening. | 6 |
BACKGROUND OF THE INVENTION
This invention relates to the field of acoustic speakers and more particularly to speaker enclosures or cabinets formed using a plastic rotomolding process.
Traditionally, speaker enclosures have been made from several individual pieces to form enclosures of varying dimensions and shapes. In such speaker enclosures, the pieces may be made from wood, particle board, chip board, some metals and plastics. In the case of plastic enclosures, one of two methods of fabrication is usually employed. In the first method, individual pieces of plastic in thick sheet form are fastened together by known means and in the second method, the main walls of the speaker enclosure are molded using rotational or injection molding techniques. In each method, the enclosure is generally a five-sided cuboid with the sixth side left open for the mounting of speakers and grills therein. Said speakers generally do not have means thereon for stabilizing said speakers in the event two or more enclosures are stacked one on top of the other or side by side. Consequently, said speaker enclosures, when so stacked or combined, may fall or tip over during use.
SUMMARY OF THE INVENTION
The above-discussed and other drawbacks and disadvantages of prior art molded speaker enclosures may be overcome or alleviated by the rotomolded speaker enclosures of the present invention wherein said speaker enclosures are provided with stabilizing means.
The speaker enclosures of the present invention are generally produced using basic rotomolding processes such as described in U.S. Pat. No. 4,284,202 which is incorporated herein by reference. Said speaker enclosures include a five-side speaker box, speaker and grill members in said box and a shallow lid or cover which is releasably affixed to said speaker box for covering said speakers and grill during transport and storage.
As a feature of the present invention, said speaker enclosures are provided with stabilizing means for permitting said enclosures to be stacked on top of each other or combined in side-by-side relationship.
As a further feature of the present invention, said speaker enclosures are provided with means for attaching the lid or cover to the rear of the enclosure during use which gives added stability to the enclosure.
The forgoing and other objects, features and advantages of the present invention will become more apparent in light of the following detailed description of exemplary embodiments thereof as illustrated in the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the speaker enclosure of the present invention;
FIG. 2 is a perspective view of the speaker enclosures of the present invention with the cover or lid attached to the rear of the enclosure;
FIG. 3 is a section view taken along the line 3--3 of FIG. 2; and
FIG. 4 is a perspective view of two speaker enclosures stacked one on top of the other.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
As shown in FIGS. 1 and 2, the speaker enclosure of the present invention is indicated at 10. Said enclosure 10 is comprised of a base unit 12 and a removable cover or lid 14. As shown, the base unit 12 is basically a box comprising 2 side walls 16 and 18, a top wall 20, a bottom wall 22 and a rear wall 24. The cover or lid 14 is similar to the base unit 12 in that it has sides 26 and 28, a top wall 30, a bottom wall 32 and a rear wall 34. As shown, the side walls 16 and 18 are provided with a first set of latches 36 which are engagable with a set of strikes 38 disposed on the sides of the cover or lid 14 for releasably holding said cover 14 in closed relationship with the base unit 12. As also shown, said base unit 12 is also provided with a second set of latches 40 adjacent the rear of said enclosure 10. Said latches 40 are engagable with a second set of strikes disposed on the side walls 26 and 28 of the cover or lid 14 adjacent the front surface 34. The purpose of said second set of strikes and latches will be explained below.
As best seen in FIG. 2, the enclosure 10 is provided with a speaker and grill system which may include one or more audio speakers 44 attached to a grill 46 which is mounted in a front wall of said speaker enclosure 10 by known means.
As will be appreciated by those skilled in the art, the speaker enclosure 10 with speakers 44 disposed therein are protected during transport and storage by latching the cover or lid 14 to the base unit 12 with latches 36 and strikes 38. When said enclosures are placed in an "operation mode", the cover 14 is removed from the front of the base unit 12 and latched to the rear of said unit 12 as shown in FIGS. 2 and 3. In this mode, latches 40 on the base unit 12 are attached to strikes 42 on the lid 14 so that the rear wall 34 of the lid 14 and the rear wall 24 of the base are adjacent one another. As also shown, the rear wall 34 of the lid 14 is provided with a plurality of convex ribs 48, while the rear wall 24 of the base unit 12 is provided with corresponding concave ribs 50. Said ribs 48 and 50, which are integrally molded with the parts, provide strength to each part and act as positioning means between the lid 14 and the base unit 12. When the lid 14 and the base unit 12 are disposed in this relationship, the natural drafts on the lid 14 and the base unit 12 caused by the molding process provide very stable edge-only contact with the surface on which they are placed.
As shown in FIGS. 2 and 3, stacking stabilizing means in the form of a fin or plate 52 is employed when one wishes to stack one or more enclosures on top of each other during operation of said speakers. Said fin or plate 52 is preferably a flat thin strip of metal such as aluminum which is inserted between the rear wall 34 of the lid 14 and the rear wall 24 of the base 12 as they are being latched together as depicted. In that said fin 52 extends above the upper walls 20 and 30 of the base 12 and lid 14, it may also be inserted between the base 12 and lid 14 of a second speaker enclosure placed on top of the first speaker enclosure. This stacking of enclosure units is shown in FIG. 4. As will be recognized by those skilled in the art, the fin 52 may also be employed to stabilize speaker enclosures in side by side relationship as well as in stacked relationship.
While the present invention has been disclosed in connection with a preferred embodiment thereof, it should be appreciated that there may be other embodiments which fall within the spirit and scope of the present invention as defined by the appended claims. | Molded enclosures for audio speakers and the like comprising a molded base and a releasably-attachable molded cover wherein said cover may also be attached to the rear of said base for stabilizing said enclosure and supporting an outwardly-extending stabilizing fin for attachment to another enclosure stacked thereon. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a method for improving the ground to intensify subterranean loose ground or prevent water permeability in a water-permeable stratum, and also to an apparatus for carrying out the method.
2. Description of the Prior Art
In order to prevent spring water occurrence or water leakage in the ground comprising clayey soil, sandy soil or sands and pebbles or to prevent rupture of soil or intensify soils, it has been so far usually practised to inject a grouting agent in the ground through a hollow injection rod such as a boring rod, a strainer pipe, a double pipe, etc. to be solidified. It is not always satisfactory for stably and uniformly improving the ground depending on the soil stratum conditions such as the intensity, water-permeability, etc. of the ground. In other words, it is not always satisfactory for forming a columnar or spherical coagulation with a uniform diameter, for the following reasons.
When the grouting agent is injected according to the conventional methods, the ground is often ruptured in weak region. Once the ground is ruptured, the grouting agent flows along the ruptured surfaces, and consequently the formed coagulation presents irregular cross-sectional shapes. The rupture of ground has been so far presumed to take place, because the infiltration pressure due to the injection of the grouting agent becomes too high relative to the shearing strength of the concerned region. In other words, according to the conventionally accepted theory, the cause for failure to form a uniform coagulation is an occurrence of a hydraulic fracturing phenomenon in the ground due to that a high infiltration pressure is brought about by the injection, which results in forming shear planes in the ground and occurring infiltration of the grouting agent along these planes, so that the vein-like, irregular coagulation is formed. Thus, it is the conventional expedient to inject the grouting agent under a constant pressure so that the infiltration pressure may not exceed the shearing strength of ground. In order to obtain a thorough infiltration up to the desired region, it takes a long time with an economical dissatisfaction.
As a result of extensive studies, the present inventors have found that the conventionally accepted theory is not correct and the hydraulic fracturing phenomenon of the ground appears to be caused mainly by a tensile stress developed in the ground by the injection of the grouting agent, which is excess of the tensile strength of the ground. When the grouting agent is injected under some pressure through the hollow injection rod, the tensile stress rapidly decreases with increasing distance from the center of the hollow injection rod in the radial direction and rapidly increases towards the center to the contrary. That is, in a diagram having a tensile stress on the ordinate and a distance from the center of the hollow injection rod on the abscissa, the tensile stress can be plotted in a concave curve running from the left upside to the right downside (see FIG. 1). According to this finding, it can be assured that the grouting agent must be injected at an injection rate as low as possible in the initial period of injection, and after the infiltration has been made to the region near the center where the excessive tensile stress is liable to form, the injection rate may be increased continuously (see FIG. 2, curve a) or stepwise (see FIG. 2, curve b) in contrast to said curve of tensile stress. This assumption has been proved to be correct through many tests.
When the grouting agent for stabilizing the ground is injected through the hollow injection rod inserted in the ground according to the well known method, the grouting agent is generally gushed or leaked upwards along the periphery of the injection rod, and consequently it is very difficult to form coagulation in the desired region. That is, prevention of water permeability, or intensification or improvement of the ground cannot be thoroughly attained.
In order to solve the problem that the grouting agent gushes or leaks out, a chemical packer has been proposed, which is a gelation product formed by forcedly injecting a flash setting chemical solution between the periphery of the hollow injection rod and the bore wall. However, the strength of the gelation product is too low to withstand the injection pressure of the grouting agent, and the gelation product is liable to be ruptured and loopholes are liable to develop so that the packer effect will be lost and that the grouting agent will gush or leak out through the loopholes of the packer.
Also proposed are a sleeve injection method comprising steps of providing an outer pipe in a bore hole after a casing boring has been made with a rotary boring machine or a rotary percussion boring machine, filling sealing agent into the clearance between the outer pipe and the bore wall, setting a double packer in the outer pipe at a position corresponding to depths of the ground destined to the injection, then supplying a grouting agent under pressure into a space formed by the packer elements through an inner pipe arranged in the outer pipe, making the grouting agent gushing out the space through small holes formed in the outer pipe, rupturing the sealing agent by the gushing grouting agent and injecting the grouting agent through the resulting cracks, a method utilizing a mechanical packer such as a rubber ring arranged to be pressed on the both sides by a screw means so that a portion thereof is circumferentially protruded beyond the outer surface of the rod or such as an air packer inflatable by compressed air so as to seal the clearance between the periphery of the hollow injection rod and the boring wall. However, these methods need the casing boring in order to set the packer and thus complicate the injection operation, and the maintenance of boring wall is difficult, so that the function of mechanical packer or air packer is deteriorated. That is, no satisfactory packer effect can be obtained.
In a rod injection method using a hollow injection rod, the grouting agent is liable to leak through voids around the hollow injection rod or along the boundary surfaces of coarse grain layers in an unconsolidated ground such as alluvium. In order to prevent grouting agent from leaking out of the injection region, a method for injecting a flash setting grouting agent through a double pipe rod has been proposed, but owing to the short gelation time, the injection of the grouting agent into the ground leads to a vein-like split infiltration, so that the infiltration into the soil grains becomes incomplete.
An injection method using a strainer pipe is not preferable, because the strainer pipe is left in the ground after the injection has been made, and also it is troublesome to insert the strainer pipe in the ground. Also proposed in a composite injection method comprising steps of forming at first the flash setting chemical packer around the double pipe rod above the portion destined for the injection and then infiltrating a long gel-time grouting agent into soil grains. However the strength of the resulting packer is low because of the chemical packer, as described above.
SUMMARY OF THE INVENTION
The present invention has been made in order to solve these problems and is to provide a method capable of stably and uniformly injecting the grouting agent into the ground having complicated structure and properties and thus capable of uniformly improving the intensity or water cutoff ability of the ground, and also an apparatus for carrying out the method.
According to the first step of the method in accordance with present invention, the grouting agent is injected under a controlled injection pressure by keeping a discharge rate of the grouting agent at a low value, thereby keeping a tensile stress to be developed in the ground by the injection of the grouting agent lower than the tensile strength of the ground until some initial infiltration region is formed around the hollow injection rod.
According to the second step of the method, the grouting agent is injected under a controlled injection pressure by changing the discharge rate of the grouting agent continuously or stepwise, after the formation of said initial infiltration region, by keeping a tensile stress to be developed by further injection outside the said initial infiltration region lower than the tensile strength of the ground in the region of further injection.
The tensile strength of the ground can be indirectly detected by, for example, a lateral load test in a bore hole. According to the lateral load test in the bore hole, boring is made with a hollow injection rod, then compressed air or liquid is supplied to an inflatable packer element attached to the tip end of the hollow injection rod so that the inflated packer element is tightly contacted to the boring wall, then an air or liquid pressure applied on the packer element is stepwise increased by means of a pressure gauge, and the strength of soil is determined from a change in the amount of the compressed fluid with time and the applied pressure value.
How to control the injection pressure according to the obtained values of tensile strength (and circumferentially, of water permeability coefficient of the ground) at conducting the injection can be determined in advance experimentally with using a test ground. Otherwise the injection pressure can be obtained by an appropriate formula.
According to a preferable embodiment of the present invention, the grouting agent is injected with keeping the viscosity of the injecting agent low and substantially constant until some initial infiltration is made in a center region having a radius smaller than the desired infiltration radius. This is because, when the grouting agent having a high viscosity is injected, hardening proceeds during the injection, and thus the infiltration pressure must be considerably increased.
The present invention is further characterized by an end member having a packer and at least two discharge outlets for the grouting agent, the end member being provided at the lower end of an inner tube of the rod so as to be pulled into an outer tube when the rod is thrusted into the ground and exposed from the outer tube when the forward end of the rod reaches a position desired to the injection, the packer being actuated when the end member is exposed, and then the grouting agent is introduced into the inner tube and gushed out through said discharge outlets.
The present invention is further characterized in that, after the protrusion of said end member by the pressurized fluid, the inflation pressure in the packer is adjusted in accordance with the injection pressure and the bore wall state by a pressure converter, that the supply of the grouting agent is adjusted by a supply-rate adjusting means which converts a difference between a preset supply rate and an indicated supply rate to a signal, so as to develop a tensile stress by the initial injection lower than the tensile strength of the ground, that, after the initial injection has been completed, the supply of the grouting agent is adjusted by said supply-rate adjusting means so as to inject the grouting agent at a continuously or stepwise increased discharge rate, and that a hardening time of the grouting agent is adjusted by transmitting the signal of said supply-rate adjusting means to automatic discharge control valves.
By successively and rapidly changing the discharge rate of the grouting agent depending on the condition of the ground destined to the injection, the grouting agent can be stably and uniformly injected into the ground having complicated structure and properties.
Mechanism of the injection method according to the present invention for changing the discharge rate of the grouting agent with a remarkable injection effect is given below:
When changes in the injection pressure of the grouting agent in the ground, as discharged from the hollow grouting agent injection rod are investigated in a pressure reduction ration around the hollow injection rod, generally the pressure reduction ratio is not large in a central circular region having a radius of about 20 cm from the center of the hollow injection rod, though it depends on the soil quality, relative density (for example, N value), void ratio, water content, presence of underground water, etc. in the ground, and the pressure reduction ratio is extremely increased with radially going apart from the said central circular region.
That is, the pressure reduction ratio is not large at a position relatively near the hollow injection rod when the grouting agent is injected, and the injection pressure gives a load directly to the ground. In order to uniformly infiltrate the grouting agent without rupturing the ground, the grouting agent must be injected at such a low discharge rate as to produce a lower injection pressure than the resistance pressure of the ground. On the other hand, the pressure reduction ratio is large in the ground outside the said central circular region near the hollow injection rod, and the ground is hardly susceptible to the influence of the outlet pressure of the grouting agent at the discharge outlet. Thus, even if the grouting agent is injected at a higher discharge rate (pressure), the injection pressure becomes lower than the resistance pressure in the ground destined to the further injection, and the grouting agent can be thoroughly and uniformly infiltrated into the ground without rupturing it.
The present method can attain the injection effect only by changing the discharge rate of the grouting agent, and more uniform infiltration of the grouting agent into the ground can be attained with using a packer according to the present invention.
The grouting agents for use in the present invention include a combination of cement slurry and water glass, a combination of water glass and acid substance with an additive such as inorganic acid salts of alkaline earth metals and trivalent metal salts, and a combination of water glass and bicarbonate of alkali with an additive such as inorganic acid salts of alkaline earth metals, trivalent metal salts, or organic substances decomposible in an alkali region to produce an acid substance.
THE BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects as well as various advantages of the invention will be more clearly appreciated by studying the following detailed explanation to be made in reference to the accompanying drawings, in which:
FIG. 1 is a graph showing a tensile stress to be developed in a ground by a grouting agent discharged from a hollow injection rod with respect to a radial distance from the hollow injection rod;
FIG. 2 is a graph showing injection at varied discharge rates according to the present invention;
FIG. 3 is a schematic view showing a state of boring down to a desired depth by the boring-injection rod;
FIG. 4 is a schematic view showing a state of injecting the grouting agent while a protrusible end member is exposed;
FIG. 5 is a diagram showing an apparatus according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 3 and 4 show processes of boring and successive injection of the grouting agent with the present apparatus, where numeral 1 is a duplex boring-injection hollow rod, 2 a boring machine, 3 a device of rotating or vertically moving the boring-injection rod, and 4 is a swivel for introducing a boring water, a pressurized fluid, the grouting agent, etc. into the device, the swivel being fixed at the upper end of the boring-injection rod.
In boring work shown in FIG. 3, the rod 1 is rotated and given a pushdown force by the boring machine 2, and the boring water is supplied into the rod 1 through the swivel 4 and gushed from the lower end of the rod. At the lower end of the rod, bits for scraping the soil is provided (not shown in the drawings). The scraped soil is mixed with the boring water to make slime, and some of the slime is infiltrated into the ground, while the other is sent back to the ground surface along the outer periphery of the rod 1. After boring has been effected to a predermined depth, only an outer tube 6 of the rod 1 is pulled up over a predetermined range to expose a protrusible end member 5 connected at the lower end of an inner tube of the rod 1 (not shown in the drawings), or the entire rod is slightly pulled up, and then the protrusible end member 5 is pushed out of the outer tube 6, as shown in FIG. 4. Then, a packer sleeve 7 mounted on the protrusible end member 5 is inflated by a pressurizing fluid supplied into the spaced formed between the inner and outer tubes of the rod 1, and then the grouting agent is supplied through the swivel 4 into the inner tube and gushed from fluid discharge openings formed in the periphery of the protrusible end member 5, as shown by arrows, to be injected into the ground.
FIG. 5 shows an apparatus for supplying the grouting agent into the hollow rod 1 under a controlled pressure and for supplying the pressurizing fluid for pushing the end member 5 out of the rod 1 and inflating the packer 7, where pipes 8, 9 and 10 are connected to the swivel 4 shown in FIGS. 3 and 4.
In FIG. 5, 11 is a tank for a main grouting agent liquid, 12 is that for a hardening agent liquid, and 13 is that for an additive liquid such as a hardening-promoting agent liquid or water; 14 and 15 are liquid supply pumps; 16 and 17 injection pumps; 18 a line mixer; 19 a flow rate detecting means for converting a supply liquid flow rate to a signal; 20 an indicator for controlling automatic discharge control valves 21, 22, 23 and 24 belonging to the liquid supply pumps 14 and 15 and injection pumps 16 and 17 respectively, depending on the signal applied from the flow rate detecting means 19 (the flow rate detecting means 19 and the indicator 20 together are called "an injection flow rate-controlling means"); 25 a pressure gauge; 26 flow rate meters. As the line mixer 18, for example, a shot mixer, a brush mixer, an ejector, a static mixer, etc. can be used, and a recorder 28 is connected to the indicator 20. The recorder 28 has a mechanism for summing up the quantity of injected materials. 30 is an indicator for delivering an instruction signal upon receipt of a signal from an injection pressure-detecting means 29. 31 is an indicator for delivering an instruction signal upon receipt of a signal as to a predetermined injection amount per step as summed up in the recorder 28, 32 an indicator for delivering an instruction signal to an automatic discharge control valve 34 belonging to a pressurizing fluid tank 33 upon receipt of a signal from the injection pressure-detecting means 29 to adjust the inflation pressure of an inflatable packer 7 fixed to the end member 5. The protrusion pressure for the end member 5 is usually above 1 kg/cm 2 , and the inflation pressure of the packer is set in accordance with the injection pressure of the grouting agent and the boring wall state. In FIG. 5, dotted lines indicate signal lines.
The hardening agent liquid is supplied by the liquid supply pump 14, the additive liquid such as a hardening-promoter liquid or water is supplied by the liquid supply pump 15 and they are mixed in the line mixer 18. The resulting mixture is supplied under pressure by the injection pump 17 to the hollow injection rod 1, mixed with the main grouting agent liquid supplied under pressure by the injection pump 16 and injected into the ground through discharging outlets formed at the end member 5.
In the indicator means 20, a preset discharge rate (injection rate) of the grouting agent depending on the tensile strength, water permeability coefficient, etc. of the ground at the site is memorized, and the discharge valves 23 and 24 are controlled in accordance with the preset value to adjust the discharge rate (i.e. discharge pressure) of the grouting agent through the hollow injection rod 1. Furthermore, in the indicator means 20, a desired injection amount for a first step and also desired injection amounts for the individual successive steps are memorized. When the flow rate detecting means 19 confirm that the desired injection amount has been injected for each step and transmits a signal to the indicator means 20, the indicator means 20 controls the valves 21, 22 and 24 to change a mixing ratio of the grouting agent and set the viscosity and hardening time of the grouting agent for the successive step.
The injection pressure detecting means 29 monitors the pressure of the grouting agent supplied to the hollow injection rod 1, and delivers a signal to the indicator 32 in accordance with the gauged pressure. The indicator 32 controls the valve 34 to adjust the inflation pressure of a packer.
The injection amount in the individual steps are transmitted from the indicator means 20 to the recorder 28 and recorded and summed up therein. When the summed-up value reaches the desired injection amount at a given injection depth, a zero pressure signal is transmitted from the injection pressure detecting means 29 through the indicator 30 to the indicator 31 which transmits an instruction signal for stepping up the hollow injection rod 1 to the boring machine 2. Then, the similar injection steps as described above are repeated.
In the present invention, the curing time of the grouting agent for the initial injection and for the secondary and successive injections is usually set to 30 seconds or more to avoid vein-like and split injection. That is, if the hardening time is set to, for example, less than 30 seconds, the hardening of the grouting agent takes place in the vicinity of the hollow injection rod, and the successive injection proceeds through the gel of hardened grouting agent. That is, the successive injection can be carried out only under an injection pressure in excess of the injection resistance by the gel, and thus the injection pressure becomes larger than the resistance of the ground, and uniform infiltration and injection to the ground becomes difficult.
EXAMPLE
In a concrete artificial pit, 350 cm wide, 600 cm long and 300 cm high, a stamped test ground of sand soil having a water permeability coefficient of 1.12× 10 -2 cm/sec, a porosity of 42% and a water content of 13% was formed. With a double pipe rod consisting of the outer tube, 45 mm in outer diameter having boring bits at the lower end thereof and the inner tube, 20 mm in outer diameter, having the end member 5 at the lower end thereof, the test ground was bored. The end member 5 is provided with a 100 mm-long rubber packer and discharge outlets for the grouting agent with an opening diameter of 5 mm, a set of four discharge outlets being formed on a same level at an angle of 45° along the periphery and four sets of discharge outlets are arranged one below another with leaving a distance of 20 mm to one another. Each set of discharge outlets is covered with an elastic ring fitted on the periphery of the end member 5. In order to form a columnar coagulation having an injection improvement diameter of 0.8 m in an injection improvement depth range of GL (Ground Level) -2.75 to -0.5 m, boring was made with the double pipe rod at first until the end of the rod reached GL -2.75 m, where the end member 5 was protruded from the outer tube 6 under a protrusion pressure of 4 kg/cm 2 , and then the packer 7 of the end member 5 was inflated with the pressurized air supplied by a compressor 33 under a pressure of 4.5 kg/cm 2 .
Then, a water glass-based grouting agent (MG Rock No. 1, a product made by Mitsui Toatsu Chemicals, Inc., Japan) was initially injected through the discharge outlets at a discharge rate of 2 l/min. for 5 minutes while setting the hardening time of the grouting agent to 6 minutes, and successively at a discharge rate of 8 l/min. for 4 minutes, and further at a discharge rate of 16 l/min. for 4 minutes with the same curing time, with a total of 106 l at the same level. After the injection of 106 l for one step, the application of pressure to the packer was discontinued to shrink the packer, and then the double pipe rod was pulled up step for step each by 50 cm by means of the automatic pulling machine 3, and the similar injecting operations was carried out at the individual level. The positions for inflating the packer were at 4 levels of GL -2.0 m, -1.5 m, -1.0 m and -0.4 m to effect 4 step injections.
After the injection was completed, the test ground was disintegrated to investigate the injection state of the grouting agent. It was found that the grouting agent was uniformly injected in a columnar state having a diameter of about 80 cm around the injection rod in the depth range of GL -2.75 to -0.5 m. Particularly, even when the grouting agent was injected at a shallow position from the ground surface, such as GL -0.5 m, no gushing of the grouting agent was observed. The actual injection pressure was 1.0 to 2.5 kg/cm 2 over the entire injection time.
Then injection was carried out in the same test ground as above with the double pipe rod with no end member under the same injection conditions as above as to the injection step levels, hardening time of grouting agent, changes in the discharge rate, and injection amount for each step. After the injection was completed, the test ground was disintegrated to invenstigate the injection state of the grouting agent. It was found that the grouting agent was gushed along the injection rod and substantially no solidified soil was observed in a depth range of GL -2.75 to -1.0 m, and that an irregular coagulation with no columnar uniform infiltration was formed in a depth range GL -1.0 to -0.3 m. | A method for improving the ground or foundation by injecting a grouting agent from the tip end of a hollow injection rod inserted into a boring hole formed in the ground at site so as to infiltrate it into the ground to be solidified. The injection is carried out by varying an injection pressure or injection rate depending on the intensity, particularly, the tensile strength, of the ground so that no vein-like coagulation can be formed around the injection rod, and a columnar or spherical coagulation can be formed. | 4 |
FIELD OF THE INVENTION
This invention relates to a locking device for bung plugs in a container, such as a drum containing chemicals and the like.
BACKGROUND OF THE INVENTION
Drums containing petroleum products, various chemicals, and other liquids and materials, some of which may be corrosive, or toxic and thus a health hazard, are usually provided with a bung hole and a vent hole in their top covers. These holes are usually plugged with a bung and a vent closure, both threadably received in the respective holes to prevent leakage of the contents from the drums. To prevent contamination of the contents of the drums, and/or, the removal of the contents therefrom, locking means have been used to lock the bung and vent closures against removal.
DESCRIPTION OF PRIOR ART
U.S. Pat. No. 4,655,060, to Jakubas, relates to a locking device for drums which includes a pair of caps, one for the bung hole and one for the vent hole, each cap having an opening therethrough and a swivel arrangement for alignment of the openings therein. After threading the caps into their respective holes, the openings are aligned and a locking bar with a flanged end is passed through the cap's opening, the flanged end forming a stop for that end of the bar. The shackle of a padlock is passed through an opening in the bar which is at the opposite end thereof from the flange and which extends beyond the cap, and the padlock is locked.
The caps are constructed of several pieces to permit the swiveling thereof, including a spring means; a costly construction. The springs are subject to corrosion and failure due to fatigue.
BRIEF DESCRIPTION OF THE INVENTION
According to the present invention, the bung plug and vent plug of a drum, constructed of either metal, such as steel, or plastic, are replaced with threaded lugged closure members, i.e., flanged top threaded members with upstanding lugs, each of which is substantially identical to the other. The lugs are formed with an opening therethrough in the shape of a slotted circle, as will be explained in detail later and which is clearly illustrated in the drawings. In many drums, the bung is larger in diameter than the vent plug, so that a threaded adapter is used to receive the lugged closure members. In other drums, both the bung and vent plugs are the same diameter. In any event, the lugged closure members, as used in this invention, are substantially identical, and when adapters are used, they are provided with a threaded cavity of the same size and threads as the lugged closure members. Generally, a gasket surrounds the threaded portion of the lugged closure members and is positioned closely adjacent the flange. The adapters are usually constructed of a plastic, but they can be constructed of metal.
Once the bung hole closure member with, when necessary, an adapter, and the vent hole closure member (with an adapter if necessary) are screwed into their respective holes and tightened so as to seal the drum's contents, a locking bar means is provided to engage the closure member lugs. The shackle of a padlock is passed through the opening in one of the lugs and the padlock is locked to lock the bung hole and vent hole closure members against removal from the drum.
The locking bar means is unique, being a pair of generally flat and substantially identical bars, each having a width greater than the diameter of the circular portion of the openings in the lugs and a cross-section slightly smaller than that of the slotted portion of the openings through the lugs. Each bar has a slotted, flanged end and a spade-like end, the latter having one or more reduced width portions closely adjacent the spade-like end of the bar and an elongated opening therethrough which can be generally uniform in width or in the shape of a bow tie, or a figure eight or an opening defined by a reduced waist. The bars are assembled so that each passes through the slot of the other, thus providing a telescoping locking bar means whereby its length can be adjusted to accommodate different bung and vent hole spacings. Because of this feature, the locking device of this invention is usable for drums of various sizes and capacities, for example the 55 gallon drum as well as the 15 gallon drum.
By turning the assembled bar means from a flat position to an angle approching 90 degrees from the flat, the spaded end of one of the bars is passed through the opening of one of the upstanding lugs, so that the reduced width portion is aligned with the lug's opening. When the bar means is turned back to the flat, the bar means is locked with respect to that lug. The bar means is adjusted for closure spacing and the opening at the other end of the bar means is then passed over the other lug. The bow tie or figure eight opening permits the assembly of the locking bar over the lug even though the lug is acutely angled with respect to the length of the bar means. The shackle of a padlock is passed through that lug's opening and locked so that the bar means cannot be removed from the lugs. Thus the closure members are locked in their respective holes and the drum's contents are safe from removal and contamination, as the case may be.
The bars forming the locking bar means are also formed with end portions at their flanged ends which are so dimensioned and shaped to be usable as wrenches to remove the usual bung and vent plugs. Each plug is generally formed with a slotted head or with stops defining a slot which are adapted to be engaged by a wrench and the like, so that the bung and vent plugs can be tightened when the drum is originally filled with its contents. Another feature of this invention is the ability to use a locking bar as a wrench or lever when inserting, tightenting, or removing the replacement closure means by inserting the spade-like end portion of a bar through a lug hole or placing the bar's opening over a lug, and turning the bar as necessary.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an illustration showing the locking device of this invention in use;
FIG. 2 is an enlarged partial illustration of a locking bar means inserted into an opening of a lugged closure member;
FIG. 3 is an illustration of a lugged closure member;
FIG. 4 is an illustration of an adapter closure member and a portion of a lugged closure member to be received therein;
FIG. 5 is an illustration of a locking bar and indicating its use as a wrench for tightening or removing a bung plug or bung plug adapter;
FIG. 5A is a partial illustration of another form of a spade end of a locking bar; and
FIG. 6 is an illustration of using the locking bar as a wrench to remove or tighten a vent plug drum.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Looking now at the drawings, there is illustrated in FIG. 1, a drum 10 having a cover 11 with the locking device 12 of this invention. The locking device 12 comprises a pair of substantially identical lugged closure members 14 (see also FIGS. 2 to 4), each having a flanged threaded part 16 and an upstanding lug 18, the lug 18 having an opening 20 formed by a circular part 22 and a slot part 24. A resilient gasket 25 surrounds the flanged threaded part 16. As illustrated, one of the closure members 14 is threadably received in a threaded vent opening 26 and the other closure member is threadably received in a threaded bung adapter 28, the latter being threadably received in a bung hole 30. In the event the vent opening is the same diameter as the bung hole, an adapter is used. A locking bar means 32 extends between the pair of closure members 14 and comprises a pair of substantially identical generally flat bars 34 (see also FIGS. 5 and 6), each having a flanged end 36 with a slot 38, and a reduced width portion 40 adjacent the other end 42. As an alternative, the end 36 of a bar can be formed as illustrated in FIG. 5A, wherein a rounded or balled portion 40A separates a pair of reduced width portions 40B and 40C. Inwardly of the reduced width portion 40, each bar 34 is provided with an opening 44 having a generally uniform width, a figure eight shape or a reduced waisted shape, so as to be loosely received over a lug.
The bars 34 are just slightly smaller in section than the slotted portion 24 of the openings 20 in the lugs 18 , so as to fit therethrough, but wider than the diameter of the circular portion 22 of the openings 20 in the lugs 18, so as to be non-removable when turned as shown in FIG. 2.
As can be seen from FIG. 1, the bars 34 telescope, each bar 34 fits through the slot 38 of the other bar, so that the length of the bar means 32 is adjustable. By turning the bar means 32, the spade-like end 42 fits through the slot part 24 of the opening 20 of a lug 18 and when a reduced portion is within the lug's opening 20, the bar means is rotated in the opposite direction back to its initial relationship with the drum and the lugs, locking it with respect to that lug. The opening 44 in the opposite end 32, because of its size and shape can be slipped over the other lug without having the lugs precisely aligned in parallel relationship. The shackle 46 of a padlock 48 is passed through the lug opening 44 and above the bar means and the padlock is locked, thus locking the lugs 18 against removal from the drum.
The usual, non-locking bung and vent plugs are illustrated in FIGS. 5 and 6, and are identified as 50 and 52, respectively. Each is so formed to receive a wrench means and to be tightened after insertion and to be loosened for removal from the drum. The locking bars 34 of this invention are formed at their flanged ends 36 with generally flat portions of a size and shape to be usuable as wrenches when removing or tightening the bung and vent plugs 50 and 52, as illustrated in FIGS. 5 and 6.
The locking bars 34 are generally formed by conventional metal working operations from flat metal. The closure members are formed by joining the lug portion to threaded closure members. Without departing from the spirit of the invention, the lugged closure members can be made of one piece of metal. In the event that the drum's contents are corrosive, the threads of the lugged closure members as well as those of any adapter members can be coated with or made of a corrosion resistant material. The closure adapters can be manufactured to provide a cup-like threaded receptacle for the lugged closure members as illustrated in FIG. 4, or can be made with a threaded opening therethrough. The closure adapters can be manufactured of metal or of a suitable plastic.
The appended claims are intended to cover all reasonable equivalents and are to be interpreted as broadly as the prior art will permit. | A drum locking device which comprises a telescoping locking bar means, one end of which fits into locking relationship with one of a pair of lugged closure members and the other end of which fits over the other of said pair of lugged closure members, and a lock securing the device to prevent removal of the contents of the drum. | 8 |
BACKGROUND OF THE INVENTION
The present invention relates to a method of resistance welding in which the welding electrode movement takes place at least by means of one working piston-cylinder unit.
Furthermore, the invention relates to a resistance welding plant with a working piston-cylinder unit for carrying out an electrode movement during the welding process.
Resistance welding is a generally known method in which, for example, two pieces of sheet metal are connected together, in that they are pressed together by two electrodes, of which at least one is movable, and fusing and subsequent solidification of the material takes place at the joint location by means of adequate electrical resistance heating through the welding current.
The quality of the welded connection is decisively influenced by how good the contact is between the electrode and the workpiece, because the contact resistances and thus the distribution of the heat produced are influenced by this contact.
The manner in which the electrode is placed onto the workpiece is thus, first of all, of significance, because if the placement movement is too rapid, the electrode rebounds so that the contact pressure force initially oscillates and the decay of this oscillation must be waited for prior to switching on the welding current, which, however, reduces the working speed in a disadvantageous manner. During spot welding rapid placement can lead to an uncontrolled high striking energy, which leads to cold deformation and rapid wear of the electrodes.
During projection welding the too rapid placement brings about an uncontrolled cold deformation of the projection prior to switching on of the welding current, and thus to an uncertain welding result.
One has hitherto attempted to regulate the speed of placement through the association of damping and restrictor valves. One has achieved a certain improvement of the placement behavior through the use of double stroke and feed stroke units.
The force responsible for the contact pressure between the electrode and the workpiece must, however, not only be made available at the start of welding but rather also during welding.
Of significance in this connection is the fact that the material to be welded becomes soft during the welding, i.e. pasty, and fuses at the joint position. When the electrode cannot be adequately quickly replenished, the force between the workpiece and the electrodes can, in unfavorable cases, reduce to such an extent that no adequate electrical contact is any longer present between the electrodes and the workpiece. This leads, having regard to the extremely high current density, to disadvantageous spray formation and premature electrode wear. If, during projection welding, the electrode is not adequately rapidly replenished, the contact pressure between the impressed projection of the one piece of sheet metal and the counter-sheet reduces, whereby the softened projection can spray away or pore formation can arise in the welding spot.
In the previously known methods, the electrode force is primarily made available during welding by single stroke cylinders, or by the working stroke of twin or feed stroke cylinders, which are, as a rule, pneumatically actuated.
SUMMARY OF THE INVENTION
It is an object of the present invention is to improve the welding of workpieces, and in particular the quality of the welding and/or the welding speed is to be increased. In this respect a rapid, precise follow-up movement of the welding electrode should be ensured during the welding procedure.
This object is satisfied in a method of the initially named kind in that the welding electrode is located prior to the start of the welding process in a position ready for use in which it gently contacts the workpiece or in which a distance in the range of tenths of millimeters exists between the welding electrode and the workpiece, and in that, during the subsequent welding procedure, a pneumatic loading of the working piston-cylinder unit takes place, with the maximum possible stroke of the working piston-cylinder unit starting from the position ready for use, corresponding to
1 to 40 times the follow-up movement path of the collapsing workpiece projections during projection welding, or
1 to 120 times the penetration path of the welding electrode into an originally hard workpiece, which becomes pasty during the welding process when spot welding, or
1 to 60 times the penetration path of the welding electrode into an originally soft workpiece which becomes pasty during the welding process when spot welding.
Furthermore, this object is satisfied in an apparatus of the initially named kind in that the maximum possible stroke of the working piston-cylinder unit corresponds to
1 to 40 times the follow-up movement path of the collapsing projections during projection welding, or
1 to 120 times the penetration path of the welding electrode into an originally hard workpiece, which becomes pasty during the welding process when spot welding, or
1 to 60 times the penetration path of the welding electrode into an originally soft workpiece which becomes pasty during the welding process when spot welding.
Both in the method of the invention and also in the plant of the invention it is of advantage
when the maximum possible stroke of the working piston-cylinder unit corresponds, starting from the position ready for use, to 1 to 20 times, in particular 1 to 10 times, and preferably to 1 to 5 times the follow-up movement of collapsing projections during projection welding, or
when the maximum possible stroke of the working piston-cylinder unit corresponds, starting from the position ready for use, to 1 to 60 times, in particular to 1 to 30 times, and preferably to 1 to 20 times the penetration path of the welding electrode into an originally hard material, which becomes pasty during the welding process when spot welding, or
when the maximum possible stroke of the working piston-cylinder unit corresponds, when starting from the position ready for use, to 1 to 30 times, and in particular to 1 to 15 times, and preferably to 1 to 10 times the penetration path of the welding electrode into an originally soft material, which becomes pasty during the welding process when spot welding.
In the context of the invention it has been recognized that in the previously known arrangements the maximum possible stroke lengths of the single, twin or feed stroke cylinders are of large dimensions, so that, during the welding process, a relatively large air volume flows into the cylinder space above the working piston and is compressed, and mainly so that a larger compressed air volume must escape from the cylinder space beneath the working piston. The long airflow times which arise through this influence the follow-up movement behavior of the electrode during the welding very unfavorably.
Since, in accordance with the invention, the maximum possible stroke of the pneumatically actuated piston-cylinder unit out of the position ready for use essentially only corresponds to the required working stroke of the welding electrode for the penetration path of the spot welding electrodes into the pasty material during spot welding and/or for the follow-up movement path of the collapsing projections during projection welding, only a very small working cylinder volume has to be loaded with compressed air in order to move the working piston and thus the working electrode in the direction of the workpiece. At the same time only a very small volume beneath the working piston need be displaced out of the working cylinder.
This requires less time than the previously known methods so that the pressure relationships required for the necessary welding electrode pressure force set in very rapidly in the working piston-cylinder unit. Moreover, through the low extent of the pressure loaded volume, only a smaller compression effect has to be brought about than with larger volumina, which leads to improved force action of the electrode.
Starting from the fact that the welding electrode gently contacts the workpiece in the position ready for use, or has a spacing from the workpiece in the range of tenths or hundredths of a millimeter, an electrode movement is hardly perceptible after pneumatic loading of the working piston-cylinder unit. If now, e.g., two pieces of sheet metal with a sheet metal thickness of 2 mm each are projection welded, then for this the volume above the piston must be filled with compressed air, whereby the workpieces are pressed together by the electrode at the start of the welding process. As a result of corresponding dimensioning, the distance between the working piston and the cylinder cover associated with it amounts to only ca. 1 mm for the said welding tasks and similar welding tasks (including multiprojection welding).
Since the relatively small volume brought about by this small spacing can be filled with compressed air within a very short time, the welding current can be switched on after the expiration of only milliseconds from the actuation of the working piston-cylinder unit. This is additionally assisted by the relatively large air entry cross sections and the thereby caused good flow speeds for the compressed air.
Following the switching on of the welding current, the fusing of the projection takes place, which, with the said sheet metal thickness, has a height of ca. 1 mm, and from now on a visible electrode movement starts, which terminates after the return deformation of the projection (ca. 1 mm).
The electrode pressure is maintained for a short time for the solidification of the weld spot. Thus, for the piston path of ca. 1 mm for the entire welding process, a volume above the piston with a height of a total of ca. 2 mm must be filled, which takes place within a very short period of time and thus enables rapid follow-up movement of the electrode.
In order to be able to fully exploit the rapid pressure build up above the piston with the theoretical electrode force which results from it, the compressed air volume located beneath the piston must also be able to escape rapidly when the working piston-cylinder unit is loaded.
This is achieved in accordance with the invention in that the maximum possible stroke is kept as small as possible, and is in particular very small. Taking account of a possible machine bending, the stroke in the described embodiment amounts to ca. 2 mm. The compressed air escapes very rapidly from the relatively small volume through the air outlet cross sections, which are also made large here, and the electrode force quickly becomes fully effective.
Through the fact that the welding current is switched on within milliseconds after the loading of the working piston-cylinder unit, an uncontrolled cold deformation of the projection prior to welding is precluded. This advantage also proves to be particularly favorable in conjunction with the subsequent rapid follow-up movement of the electrode during the projection welding of aluminum and similar materials of soft form.
Provision is preferably made for the welding electrode to be returned after termination of the resistance welding into the position ready for use by pneumatic actuation of the working piston-cylinder unit.
In an alternative manner the return stroke movement of the welding electrode can, however, also take place by spring force.
The control of the compressed air for the mutual movement of the working piston-cylinder unit is preferably executed for both types of resetting using corresponding changeover valves.
A prestroke arrangement is preferably connected after the working piston-cylinder unit, by means of which the welding electrode can be moved from a starting position removed from the workpiece up to the workpiece into the position ready for use.
The prestroke arrangement can selectively be actuated pneumatically, hydraulically, by an electric motor, by muscle power, by hand, or by some other type of kinematics.
With respect to the position and direction of movement of the welding electrode the coupling of the prestroke arrangement and the working piston-cylinder unit to one another can take place in a different association.
Furthermore, the possibility exists of separating the prestroke arrangement from the working piston-cylinder unit and arranging it, in relation to the workpiece, on the opposite side of the working piston-cylinder unit. In this way the prestroke movement from the starting position into the position ready for use is executed by the counter-electrode. Subsequently, the resistance welding takes place by the loading of the working piston-cylinder unit of the invention.
The interplay between the prestroke arrangement and the working piston-cylinder unit is variably designed through corresponding program preselection of the machine sequence control. For the welding tasks which are primarily to be carried out, the workpiece is removed from the machine after the termination of the welding. As a result of this, the prestroke arrangement is also moved back, with the retraction of the working piston-cylinder unit, into the starting position for each working cycle.
When using a prestroke arrangement, the working piston-cylinder unit can be arranged between the prestroke arrangement and the welding electrode. In just the same way it is possible to arrange the prestroke arrangement between the working piston-cylinder unit and the welding electrode.
Furthermore, in certain applications, for example with hand-guided welding tongues, it can be of advantage when the electrode is moved by the working piston-cylinder unit and the counter-electrode is loaded by the prestroke arrangement.
It should, however, once again be mentioned that the prestroke arrangement can also be omitted completely, with the workpiece being pushed from the side beneath the upper welding electrode after the distance between the welding electrode has previously been set. The resistance welding then takes place through the loading of the working piston-cylinder unit of the invention.
A further advantage in comparison to the previously used methods lies in the operating mode “series spot welding”. In this generally known type of resistance welding, two pieces of sheet metal are, for example, connected together by weld points, which are to be arranged closely one after the other. After each weld has been completed, the electrode is lifted from the workpiece in the tenth of a millimeter range, the workpiece is moved on further by the desired spot spacing, and the next weld is carried out. These procedures take place continuously until the execution of the last weld point.
Through the use of the method of the invention, after the insertion of the workpiece during series spot welding, the welding electrode is moved by means of the prestroke arrangement out of the starting position into the position ready for use. In the welding processes which now take place, only the working piston-cylinder unit is cycled until the last welding spot, and the prestroke arrangement moves the welding electrode back into the starting position only after termination of the welding process.
Through the volumina of the working piston-cylinder unit which are made small, the continuous pressurization and venting in each case takes place in a very short time, whereby a high welding speed and spot welds which take place rapidly one after the other are achieved.
In accordance with the invention the spacing of the welding electrode from the workpiece in the position ready for use is variable and is set accordingly prior to the start of welding. A gentle contact of the workpiece by the electrode, or a spacing between the electrode and the workpiece in the range of tenths or hundredths of a millimeter, such as is, for example, necessary for series spot welding, is preferred here. With this setting, the electrode is essentially placed onto the workpiece free of blows and jolts on being moved out of the starting position into the position ready for use.
During multiprojection welding, the advantage results that with the electrode movement from the starting position into the position ready for use the projection is pressed by an intentional amount in the range of tenths of millimeters by the placement of the large area electrode onto the workpiece. Through this the height tolerances, which are unavoidable in the pressing of the projection, are leveled out and the electrical resistances between the individual projections and the counter-sheet are equalized for the subsequent welding process. The welding result is hereby improved.
Through the rapid follow-up movement of the electrode during the welding process the method of the invention is advantageous for almost all the types of resistance welding work that are encountered.
The improved follow-up movement characteristics in accordance with the invention are also advantageous during the spot and projection welding of sheet steel with metallic coatings and with non-ferrous metals, because a lack of force-transmitting capability would in this case lead to overheating of the workpiece surface.
It should be particularly emphasized that in accordance with the invention even aluminum, aluminum alloys and similar materials of soft form can be projection welded, although one is concerned with materials in which the transition from the solid state into the pasty or liquid state takes place within a very short space of time. This physical characteristic presupposes a particularly rapid follow-up movement of the welding electrode during the welding. In this respect it is no longer necessary (as previously) to press the projections with increased strength and special shapes into the sheet aluminum, but rather the round projection customary during steel welding is sufficient.
Through the small air volumes of the working piston-cylinder unit on both sides of the piston, the advantage furthermore results that with a pressure change the desired electrode force change sets in very rapidly, i.e. in the millisecond range.
The change of pressure can be carried out with the generally customary techniques of pressure program resistance welding. This method advantageously brings additional advantages during many resistance welding tasks, especially during the projection welding and spot welding of aluminum. The pore formation within the weld spot is reduced through a pressure program or also a current pressure program, in which the electrode force is preferably increased towards the end of the welding procedure.
The resistance welding plant of the invention can, for example, be a C-shaped stand machine, a portal machine, a multi-cylinder welding plant, hand-guided welding tongues in scissors or C-shape, robot-guided welding tongues in scissor or C-shape, or can also be any other resistance welding plant. The resistance welding plant can be equipped with one of the different current types in accordance with the prior art.
In a preferred embodiment the working piston-cylinder unit is formed as a closed, classical cylinder with an associated cylinder cover and cylinder base. In this way the same working stroke is, in particular, available in each position ready for use, which is determined by the position of the prestroke arrangement.
The sealing of the piston of the working piston-cylinder unit relative to the air volumes present at both sides (cylinder cover side and cylinder base side) and also the sealing of the piston rod within the cylinder base can, for example, take place via sliding seals or through membranes of rubber or similar materials.
Through the very small maximum possible stroke of the invention for the working piston-cylinder unit, the cylinder function is considerably more reliable if the piston and piston rods are sealed by membranes and the wear of the membranes is lower than with the previously, sometimes used roll membrane cylinders.
The prestroke arrangement includes, in a preferred embodiment of the invention, a spindle which can be energized by an electric motor and which runs in the prestroke direction, and a threaded element which is moved by the spindle and connected to the working piston-cylinder unit. With this prestroke arrangement the position of the welding electrode ready for use can be set in a simple manner in that the electric motor is actuated until the welding electrode has reached the desired position ready for use.
This permits a particularly convenient setting of the electrode spacing from the workpiece in the position ready for use, for example through a numerical control.
A plant in accordance with the invention can further include at least one working piston-cylinder unit formed as a twin piston or multiple piston arrangement. In this manner the electrode force is increased. When, in this arrangement, the working piston-cylinder unit is executed as a twin piston or multiple piston arrangement, then the maximum possible stroke of each working piston-cylinder unit is executed in accordance with the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a double stroke cylinder which can be operated in accordance with the resistance welding method of the invention, and
FIG. 2 shows an electrode force unit in accordance with the invention for a resistance welding plant in accordance with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1 an electrode force unit 10 , for the execution of the method of the invention, is schematically shown, close to its starting position in which a welding electrode (not shown) which is to be secured to the connection plate 44 is essentially fully retracted from a workpiece to be welded (not shown).
The electrode force unit 10 comprises a housing 14 in which a prestroke cylinder bore 16 and a working cylinder bore 18 are provided on a common axis A—A.
In the prestroke cylinder bore 16 there is sealingly and slidingly arranged a prestroke piston 22 with a prestroke piston flange 22 ′ at the side remote from the workpiece and a hollow prestroke piston rod 22 ″ closed at the workpiece side. An abutment 26 , which is broadened at the workpiece side, on a setting, spindle or adjustment 24 passes through the prestroke piston flange 22 ′ into the piston rod 22 ″ to restrict the prestroke piston movement in the direction towards the workpiece. The abutment 26 is connected for its positioning to the adjustment spindle 24 via a pressure, tight lead-through 28 .
A through-way 30 for a fluid under pressure, such as compressed air, is provided in the housing 14 above the prestroke piston flange 22 ′, in order to connect the interior of the housing 14 via a pressure fluid valve 32 , to a pressure fluid source (not shown), for example to a compressed air source. The pressure of the pressure fluid is so selected that the desired force arises with the preset diameters of the piston. For this purpose a pressure of 1 to 6 bar can be required with customary diameters.
At its side facing the workpiece the prestroke piston rod 22 ′ sits in the starting position on a working piston 34 , which is sealingly slidingly arranged in the working cylinder bore 18 , with a working piston rod 34 ′ being secured to the lower side of the working piston.
Above the working piston 34 , but still below the lower edge of the prestroke piston flange 22 ′ even with the fully lowered prestroke piston 22 , there is provided a further through-opening 38 for compressed air, via which a second valve 40 can introduce compressed air into the working cylinder 18 .
To the side of the housing 14 there is provided a guide bore 42 parallel to the axis A—A, in which a guide rod 42 ′ is slidingly received, which is connected via a connection plate 44 to the piston rod 34 ′ which emerges out of the housing 14 in order to prevent a rotation of the working piston 34 . The electrode force unit 10 is operated in accordance with the invention as follows:
First of all, the prestroke piston abutment 26 is adjusted on the adjustment spindle 24 so that the welding electrode is moved closely up to the workpiece to be welded, when the prestroke piston 22 is energized with pressure fluid via the compressed air valve 32 and the compressed air inlet opening 30 above the prestroke piston flange 22 ′, in order to move the working piston 34 and the working piston rod 34 ′ with the welding electrode in the direction of the workpiece.
The position ready for use is in this way precisely selected in accordance with the invention by setting of the adjustment spindle 24 and thus of the abutment 26 , so that the working piston 34 can only move via a stroke in the working cylinder 18 , which corresponds essentially to the required working stroke of the welding electrode, but is at the same time preferably at least sufficiently large that the working piston 34 does not strike the limit within the working cylinder 18 on follow-up movement of the welding electrode.
In accordance with the setting of the abutment in accordance with the invention the prestroke arrangement is moved by a corresponding opening of the valve 32 from the starting position into the position ready for use.
In order to shift the welding electrode from the position ready for use further in the direction towards the workpiece, compressed air is then fed into the working cylinder 18 via the second valve 40 and the passage opening 38 . Since only a very small working cylinder volume is to be filled with compressed air, and since only a small stroke is to be executed, the electrode movement takes place very rapidly.
After the electrode presses against the workpiece to be welded, the current can be switched on for the welding time that is provided, or for a predetermined number of mains cycles. The workpiece material which is softened by the welding current yields under the force of the electrode, whereby the electrode moves slightly. This leads to the working piston 34 being shifted further in its working cylinder 18 in the direction towards the workpiece, which brings about a short term reduction of the contact pressure force, with which the welding electrode is pressed onto the workpiece, because the working piston 34 which follows the yielding workpiece must, on the one hand, displace air, and, on the other hand, the volume above the working piston 34 is increased, i.e. the pressure prevailing in the working cylinder is reduced at least until compressed air has flowed in from the compressed air source. Only when this has taken place does the electrode force correspond again to its starting value.
This is a problem which exists both in the prior art and also with the invention. However, only a small volume corresponding to a very small stroke is present beneath the working piston 34 of the invention, which is why, in accordance with the invention, these processes, which are necessary for the follow-up movement, take place very much more rapidly than when operating customary electrode force units, whereby the problem that has been addressed is practically overcome by the invention.
After the welding current has flowed through the workpiece for the predetermined time, switching off takes place. The electrode is preferably held for a predetermined further holding time on the workpiece in order to press the workpieces together during the solidification or cooling of the weld position.
Thereafter the welding electrode can be moved back into the position ready for use. For this purpose the second valve 40 is first switched. Then the working piston 34 is either pneumatically energized in the direction away from the workpiece via through openings 38 ′, or, for example, is shifted by a compression spring. At the same time the compressed air above the working piston escapes.
Insofar as a plurality of weld positions are to be welded one after the other on a workpiece, such as for example in the operating mode “series spot welding”, then the workpiece can be moved beneath the welding electrode which is located in the position ready for use. The electrode can then be started for a new welding process. Since the working piston only needs to move over a small stroke in the working cylinder, and a more rapid pressure, build up can take place, a significantly increased step sequence is possible with this arrangement.
Although the principle of an electrode force unit in accordance with the invention can be realized in accordance with FIG. 1, changes are possible in order to improve the operation in accordance with the invention. Thus the prestroke piston rod 22 ′ can, for example, extend close to the lateral prestroke cylinder wall. Since the volume between the prestroke piston rod 22 ″ and the prestroke cylinder wall communicates with the working cylinder 18 , the working cylinder volume, which has to be filled, is further reduced and the follow-up movement behavior is improved.
A further arrangement in accordance with the invention is shown in FIG. 2 in which, for similar parts, the same reference numerals are used as in FIG. 1, but with a prefix 1 .
In accordance with FIG. 2 an electrode force unit 110 includes a prestroke arrangement 106 with a first housing 114 a and a working piston-cylinder unit 108 connected after it and having a second housing 114 b separate from the first. The housings 114 a and 114 b each comprise a cylinder cover, a cylinder jacket and a cylinder base.
A prestroke cylinder space 116 is provided in the housing 114 a of the prestroke arrangement, and a prestroke piston 122 , which is sealingly slidable for the movement over large prestroke paths, along the axis of movement B—B is received in the prestroke cylinder space 116 . The prestroke piston 122 is secured to a piston rod 122 ′, which is led out of the housing 114 a at both sides in the direction of the axis of movement B—B.
Pressure fluid through-ways 130 , 130 ′ are provided in the housing 114 a above and below the piston 122 and are selectively connected to a pressure fluid source, such as a compressed air source, via a pressure fluid changeover valve 132 . The diameter of the prestroke arrangement and the pressure of the fluid are so matched to one another that the required electrode force is achieved.
At the side (at the top of FIG. 2) of the prestroke piston rod 122 ′ remote from the welding electrode (not shown) there is provided an adjustable counter-nut arrangement 124 a for the coarse restriction of the prestroke piston movement in the prestroke cylinder 116 .
The prestroke piston rod 122 ′ is provided with a bore which extends along the axis B—B, through which a fine adjustment spindle 124 , which can be locked by the locking element 124 b , is guided beyond the workpiece end (at the bottom in FIG. 2) of the piston rod 122 ′. The housing 114 b of the working piston-cylinder unit is secured to the workpiece end of the fine adjustment spindle 124 .
In the housing 114 b there is provided a cylinder space 118 for the reception of a working piston 134 , which can be slidingly and sealingly moved therein over a short stroke along the axis B—B. The working piston 134 is secured to a working piston rod 134 ′, which, for example, emerges through a rolling or sliding bearing in the direction of the workpiece. In the end position of the working piston 134 remote from the workpiece, i.e. in the position ready for use, there is provided a small air distribution gap 118 ′ between the working piston 134 and the working cylinder 118 . A connection plate 144 which connects the working piston 134 to a guide rod 142 ′ guided in a guide bore 142 is preferably mounted outside of the housing 114 b to the working piston rod 134 ′. The guide rod 142 ′ prevents a rotation of the (not shown) electrode coupled to the connection plate 144 .
Compressed air supply and discharge lines 138 and 138 ′ are provided in the housing 114 b , which can optionally energize the working piston 134 from both directions with compressed air from a compressed air source via a compressed air changeover valve 140 . The diameter of the working piston 134 and a compressed air pressure are matched to one another for the required electrode force. The diameter of the working piston 134 , i.e. of the associated working cylinder space 118 , is preferably smaller than the diameter of the corresponding elements of the prestroke piston arrangement 106 .
It is important in this arrangement that with a given diameter of the cylinder space 118 the volume above and below the working piston 134 is kept as small as possible. This is achieved in that the maximum possible stroke of the working piston 134 is kept small. Thus, by way of example, provision can be made for the working piston 134 and the working cylinder 118 to have a stroke of only about 2 mm in the position ready for use, in the direction towards the workpiece, and to have an air distribution gap 118 ′ of approximately 1 mm available away from the workpiece, whereas, in comparison to this, the maximum possible prestroke can, for example, include the range from a few tens of millimeters to a few hundred millimeters.
The electrode force unit 110 of the invention in accordance with FIG. 2 is operated as follows:
First of all, the desired prestroke is roughly preset at the lock nut 124 a.
Then compressed air is applied via the pressure changeover valve 132 via the compressed air opening 130 remote from the workpiece in order to shift the welding electrode through a prestroke movement out of its starting position into the roughly set position ready for use, with the air which is still present beneath the prestroke piston 122 in the prestroke cylinder 116 being displaced through the openings 130 ′.
If the welding electrode is located in the roughly set position ready for use, then the desired position ready for use in which the welding electrode is located closely above the workpiece or gently contacts the workpiece can be precisely set at the fine adjustment spindle 124 b.
The fine adjustment spindle 124 b can also be reset to the extent that with multiprojection welding, in particular round projection welding, such as of aluminum or its alloys, the projections can be intentionally cold deformed in the submillimeter range and contact the electrodes through the prestroke movement.
Subsequently, through corresponding control of the valve 140 which can be changed over, the working piston 134 can be loaded in the direction of the workpiece to be welded until the welding electrode presses against the workpiece. The filling and venting of the cylinder volume takes place in a very short time.
Subsequently, the welding current which is provided can be switched on. When the material to be welded thereby becomes soft, the electrode together with the working piston 134 execute a follow-up movement.
The large cross-sections of the working cylinder pressure supply and discharge lines and the low working cylinder volume enable a very precise follow-up guidance. The compressibility of the quantity of gas contained in the working cylinder 118 , which is only very small because of the small volume, also contributes to this.
After the welding has been terminated, and the post holding time has elapsed, the pressure valve 140 associated with the working piston-cylinder unit 108 is changed over and the double acting working piston 134 is pneumatically moved away from the workpiece.
Insofar as further welds are to be effected on the same workpiece, such as for example in the operating mode “series spot welding” the next weld position can be moved under the welding electrode in the position ready for use and the welding process is repeated. After the conclusion of the desired number of welds, the welding electrode is first retracted by a retraction stroke of the working piston into the position ready for use, and is then moved back into the starting position by a changeover of the prestroke valve 132 .
With the apparatus of the invention a rebound of the welding electrode during contact can be largely avoided. Moreover, the follow-up movement is improved to the extent that the round projection welding of aluminum and aluminum alloys is now also possible. Moreover, in the operating mode “series spot welding” a stroke sequence can be achieved which is almost an order of magnitude faster than in the arrangements in accordance with the prior art.
Whereas the housing 114 b of the working piston-cylinder unit 108 is connected via the fine adjustment spindle 124 to the prestroke arrangement 106 in the illustrated electrode force unit 110 , other types of connection in series are also possible. Thus, for example, the working piston 134 can be connected to the prestroke arrangement 106 , with the welding electrode then being secured to the now moved housing 114 b.
Furthermore, one further or a plurality of such units can be connected after the illustrated working piston-cylinder unit 108 to increase the electrode force. Of importance in this respect is the fact that the stroke which is possible in a working piston-cylinder unit 108 , and thus also the corresponding volume, is kept as small as possible.
Whereas the electrode force unit 110 explained by way of example has a pneumatically actuated prestroke arrangement, it is also possible in place of this to, for example, hydraulically actuate the described working piston-cylinder unit or to mount a prestroke arrangement on a threaded element, which can be shifted on a spindle turned by an electric motor. | A resistance welding process in which the welding electrodes are moved at least via a wording piston-cylinder unit, wherein before the start of the welding process, the welding electrode is in a ready position in which it gently touches the workpiece or there is a gap in the tenth of a millimeter range between the welding electrode and the workpiece, and during the subsequent welding process pneumatic force is applied to the working piston-cylinder unit, where the maximum possible stroke of the working piston-cylinder from the position of readiness corresponds to 1 to 40 times the travel of collapsing bulges in projection welding or 1 to 120 times the penetration distance of the welding electrode in an originally hard material becoming pasty during the welding process in spot welding, or 1 to 60 times the penetration distance of the welding electrode in an originally soft material becoming pasty during the welding process in spot welding. The invention also relates to a device for implementing the process. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to a device for eliminating miter joints in a frame assembly. More particularly, the invention relates to a corner fastener for adjoining tubular members of a frame assembly used in the construction of windows, window screens, picture frames, and the like.
2. Description of the Prior Art
Heretofore, windows, window screens, picture frames, and the like are manufactured by miter cutting a length of hollow tubular material by means of two rotary saws positioned at a 90° angle with respect to each other. Of necessity due to the position of the two saws, approximately two inches of waste material are created with each cut or about eight inches per four-sided frame. A corner key (a pair of perpendicularly oriented legs with each leg being arranged to fit within the hollow interior of a respective tubular member) effects the interconnection of the tubular members at right angles to each other.
Storm windows, window screens, and the like are usually secured to conventional window frames by means of various types of metal tabs. However such method of securement has the disadvantage of not permitting easy removal of storm windows, window screens, and the like for cleaning and maintenance purposes. Additionally, storm windows, window screens, and the like are not provided with means for permitting the removal of water of condensation that can form and collect, for example, between a window frame and a window screen causing material damage and deterioration problems. And picture frames are not provided with means for minimizing the scratching and marring of surfaces on which such frames rest.
SUMMARY OF THE INVENTION
The present invention provides a corner fastener of a frame assembly for joining angularly oriented members and concomitantly for forming a corner thereof. In a preferred embodiment the corner fastener comprises a pair of legs perpendicular to one another with each leg being arranged to securely fit within the hollow interior of tubular material effectuating the perpendicular interconnection of tubular material to one another. In another form of the preferred embodiment a resilient finger is adjoined to a corner fastener to provide easy securement to and subsequent removal of a frame assembly from a window frame. And in yet another form of the preferred embodiment a hemispherically-shaped nipple is adjoined to a corner fastener to provide a spacer to separate the frame assembly from an underlying surface area.
It is therefore an object of the present invention to provide a device for eliminating miter joints in the construction of a frame assembly thereby minimizing wastage of tubular material used therein.
It is a further object of the invention to provide a device for interconnecting angularly oriented tubular members to each other and concomitantly forming a corner of a frame assembly.
Still another object of the invention is to provide a device for facilitating the installation and removal of a frame assembly from a window frame.
Yet another object of the invention is to provide a device for minimizing the amount of surface contact a frame assembly has with an underlying support.
Achievement of the above and other objects and advantages which will be apparent from a reading of the following disclosure and overcoming of the shortcomings and disadvantages of prior art devices have preceded in the case of the present invention from the discovery by the instant inventor that frame assemblies which are simple to build, inexpensive, and rigid may be constructed using corner forming connectors having projecting resilient fingers and corner forming connectors having hemispherically-shaped nipples.
BRIEF DESCRIPTION OF THE DRAWINGS
For a further understanding of the nature and objects of the invention, reference should be had to the detailed description of the exemplary embodiments taken in connection with the appended drawings in which:
FIG. 1 is a fragmentary perspective view showing the device of this invention used in the construction of a window screen.
FIG. 2 is a fragmentary plan view of the window screen shown in FIG. 1 to particularly illustrate the normally uncompressed position of a resilient finger of the device of this invention. And the compressed position of a resilient finger caused by the placement of the window screen within a window frame is shown by dash lines.
FIG. 3 is a perspective view of one form of the device of this invention.
FIG. 4 is a perspective view of an alternate form of the device of this invention.
FIG. 5 is a plan view of a portion of an elongated tubular body illustrating by dash lines the position of angular cuts required in the miter joining of the resulting two cut pieces and the scrap material produced therefrom.
FIG. 6 is a plan view of the mitered tubular pieces of FIG. 5 to particularly illustrate by dash lines an internal key used to connect the pieces to each other.
FIG. 7 is a plan view of a portion of an elongated tubular body illustrating by dash lines the position of the cross cut required in the corner joining of the resulting two cut pieces by means of the device of this invention.
FIG. 8 is a plan view of the tubular pieces of FIG. 7 corner joined by still another form of the device of this invention.
FIG. 9 is a perspective view showing the device of this invention used in the construction of a picture frame.
FIG. 10 is an exploded perspective view of the device of this invention used in the construction of a corner of the picture frame shown in FIG. 9.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the several figures of the drawings wherein like reference numerals refer to like parts, the device of this invention, corner fastener 10a, 10b, 10c, may be fabricated from a suitable metal such as aluminum, copper, steel or the like or from a suitable plastic such as polyvinyl chloride (geon), polytetrafluoroethylene (teflon), polymethylmethacrylate (lucite) or the like.
Corner fastener 10a, 10b, 10c is made to interconnect a pair of enlongated tubular members 11 to each other to form a segment of a frame assembly 12a, 12b. Elongated tubular member 11 has a hollow internal space formed by two vertically oriented side walls and two horizontally oriented cross members. Corner fastener 10a, 10b, 10c comprises a pair of legs 13 connected to each other at junction member 14. Legs 13 are U-shaped and are adapted for disposition within the interior spatial area of elongated tubular members 11 to effect the securement of corner fastener 10a, 10b, 10c thereto and the concomitant securement of elongated tubular members 11 to each other.
Junction member 14, which appears as a visible corner-piece in frame assembly 12a, 12b, has its external walls contiguous with the external walls of elongated tubular members 11. Additionally, junction member 14 is shouldered to serve as a stop for elongated tubular member 11. Projecting outwardly and curving medially from junction member 14 is resilient finger 15, a pair of which are located at the two uppermost corners of frame assembly 12a. In this embodiment of the device of the invention corner fastener 10a is best seen in the perspective view of FIG. 3.
In order to provide a temperature and humidity equilibrium between the frame assembly and the window frame projecting downwardly from junction member 14 is a hemispherically-shaped nipple 16, a pair of which are located at the two lowermost corners of frame assembly 12a. In this embodiment of the device of the invention corner fastener 10b is best seen in the perspective view of FIG. 4.
Adjoining to, but preferably as a part of one of the cross members of tubular member 11 and extending the entire length of tubular member 11 is L-shaped member 17 forming with such cross member a U-shaped channel 18. A spline 19 fabricated from a suitable material such as polyvinyl chloride, nylon, or the like is adapted for disposition within U-shaped channel 18 to further effect the securement of tubular members 11 to one another and in some embodiments of the invention the concomitant securement of a wire or fabric screen 20 to frame assembly 12b.
Referring to FIGS. 5 and 6, the prior art method of miter joining elongated tubular member 11 is illustrated whereby tubular member 11 is twice-cut to produce two angled pieces that are secured to each other with an internal key 21. Contrastingly, in FIGS. 7 and 8 the instant method of joining elongated tubular member 11 is illustrated whereby tubular member 11 is once-cut to produce two square pieces that are secured with corner fastener 10c with junction member 14 forming a right angle corner and with pair of legs 13 securing tubular members 11 to corner fastener 10c and concomitantly securing tubular member 11 to one another.
Referring to FIGS. 9 and 10, an alternate aspect of an embodiment of the device of this invention is illustrated whereby corner fastener 10c is used to secure tubular member 11 to one another to form frame assembly 12b but has neither resilient finger 15 nor hemispherically-shaped nipple 16 projecting from junction member 14. The surfaces of junction member 14 of corner fastener 10c may be plain without ornamentation or alternately may be embelished with an ornamental design as seen in FIG. 10.
While the within invention has been described as required by law in connection with certain preferred embodiments thereof, it is to be understood that the foregoing particularization and detail have been for the purposes of description and illustration only and do not in any way limit the scope of the invention as it is more precisely defined in the subjointed claims. | A corner fastener is disclosed for joining angularly oriented tubular members concomitantly forming a corner of a frame assembly. Moreover, resilient fingers and hemispherically-shaped nipples of corner fasteners respectively facilitate securement of frame assemblies to window frames and provide breather-space separation of frame assemblies from window frames. | 4 |
BACKGROUND
[0001] 1. Field of the Invention
[0002] The present invention relates generally to the field of hair treatment products, and more particularly to a channel coloring system.
[0003] 2. Description of Related Art
[0004] Personal appearance may well be one of the most important and definitive statements an individual can showcase to the world. It is the first thing that others sense about another person; and it is often used to make a variety of assumptions about that person, whether those assumptions are correct or not. Needless to say, a great number of people are concerned with how they appear to others. In this vein, people alternatively attempt to conform their looks to some standard, or attempt to differentiate their appearance away from what is considered the norm.
[0005] One of the ways individuals may enhance or alter their appearance is through the style and color of their hair. Many individuals, both male and female, style their hair with shapes and color to achieve a desired look. Not surprisingly, the quantity of hair styling products, salons and hair styling professionals is great.
[0006] A number of prior art solutions have been proposed to achieve certain hair styles and colors. Some of the solutions incorporate various brushes, chemicals, cleaners and conditioners as well as specialized techniques, and are discussed in further detail below.
[0007] Breitenbach, U.S. Pat. No. 1,689,855 discloses a striping brush for painting substantially parallel lines. The brush includes a casing that divides the bristles of a standard brush thereby providing the desired bristle arrangement. Also provided is a tray that includes an outer casing in which a number of individual channels may be placed. The number of channels corresponds to the desired brush configuration.
[0008] Poole, et al., U.S. Pat. No. 3,349,781 discloses a method for hair coloring and an associated apparatus. The applicator used in the process includes a spaced series of bristle tufts. The preferred method allows for one stroke of the applicator to provide the desired colorant. The specification also discloses that different tuft arrangements of the brush may be employed, i.e. any different numbers and widths.
[0009] Wong, U.S. Pat. No. 5,337,765 discloses a so-called modular brush for streaking hair that includes a number of bristle modules. In one embodiment the modules are round, but in others (see FIG. 4 ) they may be substantially rectangular. The bristles are arranged such that the tufts are spaced to provide streaks of color in the hair. Also disclosed is a multi-channeled tray that coordinates with the bristle arrangements of the brush. In practice, it is desired that the modular brush is rotated within the tray to apply the desired colors to the bristles.
[0010] Hirsch, U.S. Pat. No. 5,507,063 discloses a hair coloring brush designed to solve the problem of previous hair streaking brushes that color in distinct streaks. The configuration of the bristles allows for less color to be applied by the shorter bristles relative to the longer bristles. The desired result is a blended, more natural high-lighted look.
[0011] Bonazza, U.S. Pat. No. 5,819,960 discloses a hair coloring easel. The easel includes a smaller center compartment located and configured to allow for drawing color from the smaller compartment to the larger with the aid of a channel between the two compartments. Additionally, the design of the tear-shaped compartments (tint bowls) also allows the user to easily “scoop” chemicals and/or colors from one compartment to the next.
[0012] Moore, U.S. Pat. No. 6,092,535 discloses a hair coloring tool that includes bristles arranged in a serrated pattern. This pattern is designed to provide a more natural coloring to the hair, in contrast to other tools that result in clearly demarcated lines of color. The handle of the tool may include a hook useful for insertion within a standard hair coloring cap.
[0013] One disadvantage of the aforementioned devices is that none of them provide a complete system with a minimum number of instruments.
[0014] Therefore, what is required is a hair coloring system that employs a brush that can be used to mix the hair colorings in addition to applying it to the hair.
[0015] Also, it is required to provide a hair coloring system that uses an applicator that can also prepare the hair prior to application of color.
[0016] In addition, it is required to provide a hair coloring system that comprises an applicator that includes a handle that can be used as a hair pick for sectioning the hair.
[0017] Further, it is required to provide a hair coloring system that includes a color tray comprising a desired number of color channels and color bowls.
[0018] It is also required to provide a method for using the applicator and the color tray in combination to provide a complete hair coloring system.
BRIEF SUMMARY OF THE INVENTION
[0019] Accordingly, what is provided is a hair coloring system that employs a brush that can be used to mix the hair colorings in addition to applying it to the hair. Also, provided is a hair coloring system that uses an applicator that can also prepare the hair prior to application of color. In addition, a hair coloring system is provided that comprises an applicator that includes a handle that can be used as a hair pick for sectioning the hair. Further, a hair coloring system is provided that includes a color tray comprising a desired number of color channels and color bowls. Also provided is a method for using the applicator and the color tray in combination to provide a complete hair coloring system.
[0020] The versatility of the channel coloring system is one of its strongest attributes. Any number of color combinations may be used, from a single color to many different colors. Highlighting, streaking, frosting and any application of color is within the scope of the present invention. A different color may be used within each channel, and additional colors may be used within the outer color bowls. This arrangement allows for countless color variations and styles, whether highlighting the hair with one or two colors, applying five or more colors simultaneously, or forming secondary colors due to the bleeding together of adjacent colors. The segregated bristle tufts on the brush allow for a more natural look because the colors are adjacent and applied to each layer of hair. This alleviates the problem of applying one color, and then having to switch brushes and trays for additional colors. The hair styling professional is able to do all of this with a single instrument, and a single color tray.
[0021] Additional features and limitations will be apparent from the accompanying detailed description and drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0022] FIG. 1 is a perspective view of a three-channel embodiment and brushes of the present invention.
[0023] FIG. 2 is a perspective view of a five-channel embodiment and brush of the present invention.
[0024] FIG. 3 is a perspective view of the present invention illustrating a user mixing the colors with a brush.
[0025] FIG. 4 is a side view of a cut-away aspect showing three channels and two of the single color bowls.
[0026] FIG. 5 is a side view of the applicator tool of the present invention displaying the three bristle group configuration.
[0027] FIG. 6 is a side view of the applicator tool of the present invention displaying the five bristle group configuration.
DETAILED DESCRIPTION OF THE INVENTION
[0028] The channel coloring system 14 comprises at least one applicator tool 1 , and a color tray 2 . The applicator tool 1 of the present invention is unique in the way that it combines many common styling elements into a single instrument. The applicator tool 1 includes a handle 9 that may also be used as a hair pick 11 for slicing or separating the hair. The hair pick 11 may be integral to the brush body 10 , simply an extension of the brush body 10 ; with both brush body 10 and hair pick 11 comprising a plastic material, for example. In another embodiment, the handle 9 may comprise a hair pick 11 that comprises a material that differs from the material of the brush body 10 , such as metal.
[0029] The handle 9 is also fashioned to properly fit within the brush storage region 12 of the color tray 2 . This ensures that everything needed is always easily accessible and available to the hair styling professional. The brush angle A that is created between the plane that contains the handle 9 and the plane that contains the bristle attachment region 13 is preferably acute. The exact angle A measurement may vary, but an angle A between 85 degrees and 5 degrees is preferred, and an angle A that measures approximately 45 degrees, is optimal. Angle A is a carefully chosen design feature, the benefit of which is most easily recognized with use of the applicator tool 1 , but may also be understood through careful study of the applicator tool 1 as it is used in mixing the color solutions, loading the applicator tool 1 with color, and/or applying color to the hair. The benefit may be understood by considering a prior art styling brush that does not include the angle A as claimed by the present invention. If the brush handle 9 and bristle attachment region 13 lie in the same plane, the hair-styling professional's hand would hit the color tray 2 , possible spilling the various chemicals used during the coloring process; or at the very least, would impede the efficiency of the coloring process, possibly resulting in an undesired finish color. With the appropriate handle angle A, the hand of the hair professional is raised a suitable distance above the color tray 2 , while the ends of the bristle groups 7 will lay substantially within a plane parallel to that of the color tray 2 . This allows for free movement while mixing colors and loading the bristles, as well as when applying color to the hair.
[0030] The applicator tool 1 also includes a comb 8 that is integral to the brush body 10 . In conjunction with the pick 11 , the comb 8 may be used to ready the hair for coloring by assisting in sectioning, layering or any other standard comb uses as desired. Again, the key is that a single instrument can be utilized for all coloring functions with a simple flip or turn of the applicator tool 1 .
[0031] The bristle groups 7 themselves must comprise materials that are stiff enough to properly mix the color within the channels, but must also include sufficient flexibility to properly load color and apply the color to the hair. The bristle groups 7 are attached to a bristle attachment region 13 in a manner sufficient to create the brush angle A mentioned above in any manner that is known in the art, such as being slightly recessed within the brush body 9 and secured with a glue or similar fastener. The bristle groups 7 are also preferably arranged in a segregated fashion. In this context, segregated means two or more bristle groups 7 are separated by a space. The bristle groups 7 may vary in the number of individual bristle members depending on the diameter of each bristle member, and the size of the group that is desired. The space between bristle groups 7 need only be large enough to allow for a channel wall 15 to pass through the space. In that regard, the bristle groups 7 should comprise a length that preferably at least reaches the channel bottom, or in terms of the channel walls 15 , the bristle groups 7 should be at least as long as the channel wall height, but preferably slightly longer to allow for sufficient mixing of the colors. This is important because the color material will often comprise a greater density than the mixing material, which may be, for example, a peroxide solution. If the bristle groups 7 did not reach the channel bottom 16 a portion of the color would go unmixed, thereby possibly resulting in insufficient mixing of the color and peroxide solution. If it is desired to mix the color solution less than completely, the hair styling professional need only manually raise the bristle groups 7 slightly above the channel bottoms 16 .
[0032] The present invention also comprises a color tray 2 that includes a plurality of channels 4 , but the preferred embodiments include either three or five channels 4 . The plurality of channels 4 are elongate, and are formed by channel walls 15 on either side of a channel bottom 16 . The channel bottoms 16 may be either substantially flat or rounded. Adjacent channels 4 will normally share the channel wall 15 that is between them. Preferably, the channel coloring system 14 will be utilized such that an applicator tool 1 comprising three bristle groups 7 is used with a color tray 2 comprising three channels 4 , but it would clearly be within the scope of the invention to use an applicator tool 1 that included only three bristle groups 7 with a five channel color tray 2 . In the preferred embodiment, the color tray 2 also includes additional color bowls 5 on either side of the plurality of channels 4 . In the simplest embodiment, the color bowls 5 will frame the plurality of channels 4 in a symmetrical fashion; two color bowls 5 on each side. In this way the color tray 2 will have a configuration that is easily manufactured, and easy to use.
[0033] The color tray 2 may also include a base 6 . The base 6 may extend beyond the channel walls 15 and color bowls 5 , creating a portion that may be gripped by the hair styling professional, or secured to an auxiliary retaining device. The perimeter of the base 6 may mirror the perimeter of the channels and color bowls, or may be shaped in any fashion so as to provide better comfort and/or security. For example, the base 6 could include curves or a ridge that enhances the ability of the hair styling professional to hold the color tray 2 , or improve the ability to secure the color tray 2 to the auxiliary retaining device.
[0034] In a preferred embodiment, the color tray 2 would also include a brush storage region 12 . The brush storage region 12 comprises portions that define an opening that is sufficient to insert the handle 9 of the applicator tool 1 , as well as a variety of standard brushes, but the opening of the brush storage region 12 is small enough to provide sufficient friction to retain the brush or applicator tool 1 . The frictional force that exists between the brush handle 9 and the brush storage region 12 should be sufficient to prevent a brush or applicator tool 1 from sliding out or falling over; yet brush storage region 12 must be loose enough to allow for easy removal and insertion of the brush/tool during the coloring process.
[0035] Also claimed is a method for coloring hair utilizing a channel coloring system 14 . The hair may first be prepared via washing or wetting, if desired. The hair may then be combed and sectioned, preferably into four quadrants. A layer of hair is then separated with the pick 11 portion of the applicator tool 1 ; and the hair layer is preferably laid atop a piece of backing, comprising a rectangular piece of foil or other suitable material. The applicator tool 1 is then loaded with color and applied to the hair layer. The pick 11 may then be used to assist with folding the backing upwards, thereby enveloping the layer of hair for a desired amount of time. At this point, treatment may follow the standards for setting the color as is known in the art, such as wrapping the head, applying heat or other setting methods as desired. The pieces of backing may be removed and the hair prepared for final finishing in any manner desired as is known in the art.
[0036] In another embodiment the process comprises the preparation of the desired colors. The color preparation comprises depositing a first color within one of a plurality of channels 4 . Typically this entails laying a bead of color along the channel bottom 16 . Next, a peroxide solution is added that readies the color for application to the hair. This process may be repeated for as many channels as are present in the embodiment of the color tray 2 being used, or fewer as desired. At this point, the applicator tool 1 may then be employed, mixing all of the colors and the peroxide solution simultaneously. Once mixed to the desired point, the applicator tool 1 may then be loaded with a quantity of color. The loaded applicator tool 1 may then be applied directly to the hair, known as normal tint application on scalp, or the backings mentioned previously may be employed.
[0037] Another feature of the method of the present invention is the ability to create a secondary color. During application to the hair, adjacent colors will tend to bleed together due to the configuration of the bristle groups 7 . Therefore, in the case of a three bristle group configuration that includes three different colors, two secondary colors may be formed by the bleeding together of the outer colors with the inner color. A subsequent application stroke will result in the first color bleeding into the third color, thereby creating a third secondary color. Therefore, for three colors, a total of six colors will be realized by the final application if only adjacent applications are used. If any type of overlap is utilized during application, even more color variations may be created. This can be easily understood via the following color chart, where C 1-3 represent primary colors located within the color tray, and C 4-6 represent secondary colors created by the bleeding of the colors. The total number of colors possible also increases with the increase in the number of colors utilized in the color tray 2 .
TABLE C 1 C 2 C 3 C 1 C 4 C 5 C 6
[0038] The specific order of the steps is not entirely crucial, in that the color mixture may be prepared prior to preparation of the hair, or vice versa. Obviously, steps such as applying the color to the hair would be subsequent to the step of preparing the hair for color, but these types of variations are well within the knowledge of persons of ordinary skill in the art.
[0039] Although the present invention has been described with reference to particular embodiments, it will be apparent to those skilled in the art that variations and modifications can be substituted therefore without departing from the principles and spirit of the invention. | The hair coloring system of the present invention comprises a tray that includes three to five color channels, open square bowls for single brushes and an open slot in which brush handles may be placed for storing a number of brushes. Different colors may be squeezed into the channels along with the appropriate mixing solution. A coloring brush is also provided that comprises a handle, hair pick, comb, and brush. The brush portion includes segregated tufts of bristles that correspond to the color channels. The brush may be used to divide the hair into sections, mix the colors, and then to apply the colors to the hair. In this way a single brush and tray combination can do what previously required many different instruments. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a stationary flat to be fitted onto the peripheral surface of a cylinder of a carding engine.
2. Description of the Prior Art
Conventionally, as shown in FIG. 10, a plurality of stationary flats 33 are fixed on a cylinder 29 of a carding engine 28 between a top 30 and a doffer 31 or between a top 30 and a taker-in 32 (Japanese Patent Application Laid Open Gazette No. 61-1604727). However, since each of such stationary flats is fastened to the cylinder of a carding engine by bolts, it has been very difficult to regulate accurately the gauge of each of the plural stationary flats. Also, in the case where the card clothing of each of such plural stationary flats has worn due to carding action, it has been impossible to grind the card wires. Moreover, in the case where the stationary flats are cleaned and the card wires of a drum are ground and cleaned, the stationary flats must be detached one by one and when they are refixed to the carding engine, it is necessary to reregulate the gauge of each stationary flat. Thus, the trouble has been that complicated operations and a large number of steps are required for grinding, cleaning and refixing.
As a means of solving the above problem of the prior art, a stationary flat proper (a covering plate with metallic card clothing mounted on the inner side thereof) swingably mounted at the proper place of the peripheral surface of a cylinder on an arm has been suggested (Japanese Patent Application Laid Open Gazette No. 62-41322). However, since the above-mentioned stationary flat is a covering plate with a card clothing mounted on the inner side thereof, when the card clothing is partially damaged, it must be replaced in its entirety. Thus, labor and expense are required for replacing and it is impossible to grind card wires while they are on the carding engine.
SUMMARY OF THE INVENTION
An object of the present invention is to make the gauge regulation during the fitting of stationary flats simple and uniform and to substantially reduce the time required for fitting stationary flats.
Another object of the present invention is to make it possible to exchange only a damaged top bar and thereby reduce the frequency of maintenance.
In order to attain the above objects, the present invention provides a stationary flat unit which is constituted in the following way. A stationary flat is formed by two base members, each having the required radius of curvature and plural stud bolts at its upper surface, and a plurality of top bars, each having brackets at both ends thereof and card clothing on the under side thereof, in which the stud bolts of the base member have the brackets of the top bars fitted thereon and the top bars are fixed adjustably in the up and down direction by nuts. A stationary flat unit is constituted by fixing arms on both side faces of the above stationary flat.
By fitting the stationary flat unit of the above structure swingably through the medium of the arm so that the surface of its card clothing can approach the peripheral surface of the cylinder, a carding engine equipped with stationary flats of the opening and closing type is provided.
In the stationary flats of the above structure and a carding engine provided with such stationary flats, stationary flats are arranged on the peripheral surface of the carding engine and are fixed by bolts, and the gauge between the card clothing of the cylinder and the top bar is regulated properly by a nut which mounts the top bar to a base member and finally said nut is tightened to fasten the top bar to the base member. In the case where cotton dust and other foreign matter adhere to the surfaces of card clothings of the stationary flats and the drum due to carding action are to be cleaned, a bolt by which a stationary flat is mounted is removed, the stationary flat is freed from the peripheral edge of the cylinder by swinging the arm, the surface of the card clothing is cleaned, the stationary flats are rearranged on the peripheral surface of the cylinder and are again fixed by bolts. Thus, cleaning and fitting operations are completed. In the case where the card clothing of the stationary flats is worn due to carding action, it is possible to remove the top bar and grind the card wires by a grinding machine.
Since the gauge of the stationary flats according to the present invention is adjustable at each top bar, gauge regulating steps during fixing of stationary flats to the carding engine can be carried out easily and uniformly, resulting in a large reduction of time required for fitting. Also, only those top bars which are damaged need be exchanged and therefore exchange of top bars is simple and maintenance frequency can be reduced.
Moreover, as guide parts for the grinding card clothing are provided at both ends of the top bar proper, when a card clothing is worn it is possible to grind the card clothing by a grinder on the basis of the guide part and therefore it is not necessary to replace the card clothing. Thus, the usable life of the card clothing is prolonged to a large degree and an excellent fiber loosening effect can be maintained for a long period of time.
Since the carding engine fitted with stationary flats according to the present invention has openable and closable stationary flats, foreign matter such as cotton dust adhered between the teeth of the stationary flat or between the flat and the drum can be removed easily. Moreover, gauge regulation is not necessary when refitting stationary flats after cleaning. Thus, the time required for cleaning and regulation is greatly reduced and productivity is improved. By providing a blowoff preventive member on the stationary flat, blowoff of air currents is eliminated, parallelism of the fiber is improved and the yield rate is also improved.
BRIEF DESCRIPTION OF THE DRAWINGS
The nature and advantages of the present invention will be understood more clearly from the following description made with reference to the accompanying drawings, in which:
FIG. 1a is a plan view of the stationary flat;
FIG. 1b is a bottom view of the stationary flat shown in FIG. 1a;
FIG. 2a is a cross section of the stationary flat shown in FIG. 1;
FIG. 2b is a sectional end elevation view of the stationary flat of FIG. 2a, taken along line A--A in FIG. 2a;
FIG. 2c is a sectional end elevation view of the stationary flat of FIG. 2a, taken along line B--B in FIG. 2a;
FIG. 3 is an exploded view of a card clothing body partly disassembled;
FIG. 4a is a front view of the top bar of a stationary flat according to a second embodiment of the invention;
FIG. 4b is an end view of the top bar shown in FIG. 4a;
FIG. 5a is a cross section of the stationary flat according to a second embodiment of the invention;
FIG. 5b is a sectional end view of the stationary flat, taken along line C--C in FIG. 5a;
FIG. 6a is a plan view of the stationary flat according to a second embodiment of the invention;
FIG. 6b is a bottom view of the stationary flat shown in FIG. 6a;
FIG. 7 is an end elevation view showing a main part of an embodiment of the carding engine according to a third embodiment of the invention;
FIGS. 8 and 9 are graphs showing the spinning data for a carding engine using and not using stationary flats, respectively, according to the present invention; and
FIG. 10 is a schematic drawing showing a carding engine provided with conventional stationary flats.
DETAILED DESCRIPTION OF THE INVENTION
First Embodiment
As shown in FIGs. 1a and 1b and FIGS. 2a, 2b and 2c, a card clothing 2 is removably mounted on the under surface of a top bar 1 and brackets 3 of inverted-L shape are provided at both ends of the top bar body 17. A bolt hole passes vertically through the upper part of the bracket 3. A base member 4 is a sash-like plate having a radius of curvature which is substantially equal to that of a front concentric bend of the carding engine. A plurality of stud bolts are detachably mounted on the upper surface of the base member 4. Bolt holes 6 are made at both ends of the base member 4. The stationary flat 8 is formed by placing a plurality of top bars 1 in parallel and extending between two base members 4, the holes of the brackets 3 of said top bars being freely movable on upstanding stud bolts 5 on said base members, and adjusting nuts 7 are threaded on the stud bolts 5 above and below the brackets 3, thus making it possible to adjust the vertical position of the top bars 1 by turning the adjusting nuts. Arms 9 are fixed to both sides of a stationary flat 8 by bolts 10 to form a stationary flat unit 11.
In the above embodiment, the base member 4 is formed of two members but may be formed of only one member having an opening for fitting the top bars into the central part thereof. By this arrangement, rigidity of the base member 4 is improved and warp is lessened, with the result that stationary flats of more accuracy of gauge regulation can be obtained.
As shown in FIGS. 2b and 3, the top bar 1 is constituted as follows. A metallic card clothing 2 having a sawtooth part 14 on an outer surface and a dovetail groove 15 in the inner surface thereof is fitted on a liner 13 having a dovetail projection 12 extending in a lengthwise direction of its upper surface. A plurality of such metallic card clothings 2 are arranged in a row to form a card clothing body 16. Such a card clothing body 16 is mounted on the under surface of a top bar body 17 and fixed integrally thereto by side clips 18. Reference numeral 19 designates a stopper at one end of liner 13 for preventing the metallic card clothings 2 from slipping off, and reference numeral 20 designates an end stopping plate attachable to the other end of liner 13 for holding the metallic card clothings 2 on the liner.
In the top bar 1 described above, metallic card clothing is used, but ordinary card clothing may be used as in the case of the conventional top card clothing. As to the method of mounting the metallic card clothing, other means than in the above embodiment can be adopted. The number of top bars 1 is shown as four in this embodiment, but any number of top bars, preferably 2-6, can be adopted.
Second Embodiment
As shown in FIGS. 4a and 4b, a top bar body 34 has a card clothing adhering surface 35 at the under side thereof, guide parts 36 for use in grinding the card clothing at both ends thereof and brackets 37 of inverted-L shape at the upper part of both ends. The top bar 38 is completed by detachably adhering card clothing 2 on the car clothing adhering surface 35 of said top bar body 34 as indicated in FIG. 5.
As shown in FIGS. 5a and 5b, a base member 39 is in the form of a sash-like plate having a radius of curvature which is substantially equal to that of a front concentric bend of the carding engine. A plurality of stud bolts 5 are mounted on the upper surface of the base member 39. Both ends of the base member 39 are connected by a fixing member 40 and a frame body 41 having an opening for accommodating the top bars 38 at the central part thereof.
The top bar 38 and the frame body 41 constituted as above are formed into a stationary flat 42 in the following way. The stud bolts 5 on the base member 39 are put through holes in the brackets 37 and the guide parts 36 and nuts 7 are threaded onto the stud bolts above and below the brackets 37 so that the position of the top bars 38 can be adjusted in the up and down direction and then fixed by tightening the nuts 7. The end surfaces of such stationary flat 42 are fixed to the arms 9 by bolts 10 and thus a stationary flat unit 43 is constituted.
In the stationary flat unit 43, blowoff preventive members 44 are fixed to the under surface of the fixing members 40 so that there is no gap between the top bars 38 and a front top sheet or a front bottom sheet of the carding engine cylinder, namely, the front top sheet or the front bottom sheet will tightly contact with the side surface of the top bars 38. Also, a sheet member 45 of felt, rubber or the like is fixed to the under surface of the stationary members 40 so that there is no gap between the stationary member 40 and the front top bar or the rear top bar.
Since the blowoff preventive member 44 prevents formation of a gap between the stationary member 40 and the top bar 38 as described above, it is possible to prevent an air current produced as a result of rotation of the cylinder from blowing out through such a gap.
As shown in FIG. 4b, the top bar body 34 should preferably be formed in such a fashion that a sliding surface 46 formed at the under side of the guide part 36 is divided into a sliding surface 46a on the toe side and a sliding surface 46b on the heel side, and the height h between the sliding surface 46a on the toe side and the card clothing surface 35 is 1/32", and the height H between the sliding surface 46b on the toe side and the card clothing surface 35 is 1/32"+25/1000. However, it is possible to make the height h 0.7mm ˜0 9mm and the height H 1.3mm˜1.9mm.
In the above construction, if the card clothing 2 on the top bar body 38 is worn, it is easy to take the top bar 38 off the stationary flat 43 and grind it by a top card clothing grinding machine. Therefore, it is not necessary to replace the card clothing 2, and the fiber loosening effect can be maintained for long periods of time.
Third Embodiment
As shown in FIG. 7, a stationary flat unit 11 formed in the same fashion as in the first embodiment is fitted swingably to a doffer bend 21 on both side surfaces of the carding engine by swingably mounting an end portion 9a of the arm 9 on both side surfaces of the stationary flat unit 11 to the doffer bend by a bolt 22 so that the card clothing surface of the stationary flat unit 11 can be carried out easily.
Then the stationary flat 11 is fixed to a front concentric bend 23 by using bolts 24. Reference numeral 25 designates a front top sheet and reference numeral 26 designates a front bottom sheet.
As mentioned above, in the carding engine according to the present invention, a stationary flat or flats are arranged on the peripheral surface of the cylinder between the top and the doffer, but they can be arranged on the peripheral surface of the cylinder between the top and the taker-in.
In adjusting the gauge of the top bar, adjustment nuts 7 provided for each top bar 1 of the stationary flat 11 are loosened, the gauge between the card clothing surface of the top bar 1 and the card clothing surface of the drum is adjusted, and then the nuts 7 are tightened to fix the top bar 7 in position. It is preferable to carry out this gauge adjusting operation beginning with the lowermost top bar.
In the case where the card clothing surfaces of the stationary flat and the drum are to be cleaned, bolts 24 securing the four corners of the stationary flat are removed, the stationary flat is swung in the arrow direction (in FIG. 7) by a handle 27 of the arm 9, around the bolts 22 as an axis, and after cleaning the stationary flat is closed by the handle 27 and is secured by the bolts 24. In this case, since adjustment of the gauge has been carried out beforehand, gauge adjustment is not necessary and therefore cleaning operations can be simply done.
Spinning tests were carried out, with the stationary flats according to the present invention arranged between the top and the doffer.
Spinning Test, Example 1
Spinning conditions:
______________________________________Spinning count Cotton 40'sSpinning grains 380 g/6 yds.R.P.M. of cylinder 300 r.p.m.R.P.M. of doffer 24 r.p.m.______________________________________
As shown in FIG. 3, as compared with the case without stationary flats, the case with stationary flats showed superior spinning, namely, improved fiber openability, reduced number of neps in the sliver and improved sliver U%.
Spinning Test, Example 2
Spinning conditions:
Spinning count Cotton 30's
______________________________________Spinning count Cotton 30'sSpinning grains 400 g/6 yds.R.P.M. of cylinder 310 r.p.m.R.P.M. of doffer 19 r.p.m.______________________________________
As shown in FIG. 9, as compared with the case without stationary flats, the case with stationary flats showed spinning of yarn of fine quality, namely, improved fiber openability, reduced number of neps in the yarn and improved U% of yarn. | In order to make gauge regulation simple and to make it possible to exchange or grind the card clothing in each individual top bar, the present invention provides a stationary flat unit which is composed of a stationary flat having a plurality of top bars adjustably fitted between two sash-like plates for adjustment in up and down directions, and arms fixed to both side surfaces of the statinary flat. This stationary flat has the effect of reducing the time required for fitting, reducing the frequency of maintenance and prolonging the service life of the card clothing. | 3 |
FIELD OF THE INVENTION
This invention relates generally to on-board emission control systems for internal combustion engine powered motor vehicles, evaporative emission control systems for example, and more particularly to a new and unique emission control valve, such as a canister purge solenoid (CPS) valve for an evaporative emission control system.
BACKGROUND OF THE INVENTION
A typical on-board evaporative emission control system comprises a vapor collection canister that collects fuel vapor emitted from a tank containing volatile liquid fuel for the engine and a CPS valve for periodically purging collected vapor to an intake manifold of the engine. In a known evaporative system control system, the CPS valve comprises a solenoid that is under the control of a purge control signal generated by a microprocessor-based engine management system. A typical purge control signal is a duty-cycle modulated pulse waveform having a relatively low operating frequency, for example in the 5 Hz to 20 Hz range. The modulation may range from 0% to 100%. This means that for each cycle of the operating frequency, the solenoid is energized for a certain percentage of the time period of the cycle. As this percentage increases, the time for which the solenoid is energized also increases, and therefore so does the purge flow through the valve. Conversely, the purge flow decreases as the percentage decreases.
The response of certain known solenoid-operated purge valves is sufficiently fast that the armature/valve element may follow, at least to some degree, the duty-cycle modulated waveform that is being applied to the solenoid. This pulsing can cause the purge flow to experience similar pulsations, which may at times be detrimental to tailpipe emission control objectives because such pulsing vapor flow to the intake manifold may create objectionable hydrocarbon spikes in the engine exhaust. Moreover, the pulsating armature/valve element may impact internal stationary valve parts and in doing so may generate audible noise that may be deemed disturbing.
Changes in intake manifold vacuum that occur during normal operation of a vehicle may also act directly on a CPS valve in a way that upsets the intended control strategy unless provisions, such as a vacuum regulator valve for example, are included to take their influence into account. When the CPS valve is closed, manifold vacuum at the valve outlet is applied to the portion of the valve element that is closing the opening bounded by the valve seat. Changing manifold vacuum affects certain operational characteristics of such a valve, potentially causing unpredictable flow characteristics.
The particular construction of a solenoid-actuated valve, and certain external influences thereon, may impair certain operational characteristics, such as the start-to-flow point and the incremental low-flow characteristic.
From commonly assigned U.S. Pat. No. 5,413,082, inter alia, it is known to incorporate a sonic nozzle function in a CPS valve to reduce the extent to which changing manifold vacuum influences flow through the valve during canister purging. From U.S. Pat. No. 5,373,822, it is known to provide pressure- or force-balancing of the armature/valve element.
From other patents, such as commonly assigned U.S. Pat. No. 4,901,974, issued Feb. 20, 1990, it is known to incorporate noise-attenuating bumpers to absorb impact forces created by abutment of the armature with stops as the armature reciprocates.
SUMMARY OF THE INVENTION
The present invention relates to an automotive emission valve having various features that individually and collectively are believed to achieve improved performance, including more predictable purge flow control in spite of influences that tend to impair control accuracy and improved attenuation of internally generated operating noise.
In accomplishment of one or more of the foregoing improvements, one aspect of the present invention relates to an electric-operated valve assembly comprising a body having an internal main flow passage between a first port and a second port, an annular valve seat in circumscribing relation to the passage, an electric actuator comprising an armature, a valve which is operated by the armature to selectively open and close the passage and to which a force due to pressure differential between the ports is applied when the valve is closing the passage, a mechanism that, when the valve is closing the passage, applies a counter-force to the valve opposite the force due to pressure differential between the first and second ports, the mechanism including a chamber space that is internal to the body and bounded in part by a fluid-impermeable movable wall that extends between and is sealed to both the body and the valve, and a communication passage that communicates one of the ports to the chamber space when the valve is closing the passage.
In accomplishment of one or more of the foregoing improvements, another aspect of the present invention relates to valve assembly comprising a body having an internal main flow passage between a first port and a second port, an annular valve seat in circumscribing relation to the passage, a multi-piece valve which selectively opens and closes the passage and to which a force due to pressure differential between the ports is applied when the valve is closing the passage, a mechanism that, when the valve is closing the passage, applies a counter-force to the valve opposite the force due to pressure differential between the first and second ports, the mechanism including a chamber space that is internal to the body and bounded in part by an annular fluid-impermeable movable wall that extends between and the body and the valve, a communication passage that communicates one of the ports to the chamber space when the valve is closing the passage, the movable wall comprising an inner margin and an outer margin, the outer margin being in sealed relation to the body, the valve comprising a head part and a seal part joined together, the seal part sealing the head part to the valve seat when the valve is closing the passage, and a retainer part that holds the inner margin of the movable wall sealed on the head part.
In accomplishment of one or more of the foregoing improvements, another aspect of the present invention relates to a valve assembly comprising a body having an internal main flow passage between a first port and a second port, an annular valve seat in circumscribing relation to the passage, an electric actuator comprising an armature, a valve which is operated by the armature to selectively open and close the passage and to which a force due to pressure differential between the ports is applied when the valve is closing the passage, a mechanism that, when the valve is closing the passage, applies a counter-force to the valve opposite the force due to pressure differential between the first and second ports, the mechanism including a chamber space that is internal to the body and bounded in part by an annular fluid-impermeable movable wall that extends between and is sealed to the body and the valve, a communication passage that communicates one of the ports to the chamber space when the valve is closing the passage, the communication passage extending through the valve and having communication with the chamber space at a region of the valve that is disposed within the chamber space.
Within the foregoing generic aspects, further ancillary aspects of the present invention relate to various embodiments of cushion media that cushions impact of lateral displacements of the armature, to an overmold that encloses internal component parts that have been assembled into the valve body, to certain details of an electromagnetic actuator for operating the valve, and to sonic nozzle structure for the purge flow. The finished valve has improved noise attenuation, durability, and performance.
The foregoing, and other features, along with various advantages and benefits of the invention, will be seen in the ensuing description and claims which are accompanied by drawings. The drawings, which are incorporated herein and constitute part of this specification, illustrate a preferred embodiment of the invention according to the best mode contemplated at this time for carrying out the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of an evaporative emission control system comprising an emission control valve embodying principles of the invention.
FIG. 2 is a longitudinal cross section view through the emission control valve of FIG. 1.
FIG. 3 is an enlarged fragmentary view of a portion of FIG. 2.
FIG. 4 is a fragmentary transverse cross section view in the direction of arrows 4--4 in FIG. 3.
FIG. 5 is a fragmentary transverse cross section view in the direction of arrows 5--5 in FIG. 3.
FIG. 6 is a view similar to FIG. 2, but showing another embodiment.
FIG. 7 is an enlarged fragmentary view of a portion of FIG. 6.
FIG. 8 is a view similar to FIG. 2, but showing another embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows an evaporative emission control system 10 of a motor vehicle comprising a vapor collection canister 12 and an emission control valve 14, embodying principles of the present invention, connected in series between a fuel tank 16 and an intake manifold 18 of an internal combustion engine 20 in customary fashion. An engine management computer 22 that receives various input signals supplies a purge control output signal for operating valve 14.
Detail of valve 14 appears in FIGS. 2-5. Valve 14 comprises a body part 24 having an inlet port 25 and an outlet port 26, the latter including a sonic nozzle structure 28. Body part 24 is fabricated from suitable fuel-tolerant material, such as by injection molding, and embodies the two ports as respective nipples. At the internal end of the nipple forming outlet port 26, an annular seating surface 29 circumscribes an internal main flow passage extending between the two ports.
Valve 14 further comprises a solenoid assembly 30 that is housed within an overmold 32. A joint 34 joins overmold 32 with body part 24 such that the two may be considered to constitute the body of valve 14. Overmold 32 includes a formation 36 that provides for the mounting of the valve at a suitable mounting location on an automotive vehicle.
Solenoid assembly 30 comprises a polymeric bobbin 38 around whose central tubular core 40 an electromagnetic coil 42 is disposed. Reference numeral 44 designates an imaginary longitudinal axis of valve 14 with which core 40 and outlet port 26 are coaxial. Core 40 comprises a circular cylindrical through-hole 46 that is open at opposite axial ends through respective radially directed annular end walls 48, 50 of bobbin 38. Terminations of magnet wire that forms coil 42 are joined to respective electric terminals 52, 54 whose proximal ends are mounted on wall 48. Distal ends of these terminals project radially, passing through overmold 32 where they are laterally bounded by a surround 56, which is an integral formation of the overmold, so that the valve is provided with an electric connector for making connection to a complementary connector (not shown) leading to the management computer.
Solenoid assembly 30 further comprises magnetic circuit structure for concentrating magnetic flux generated by coil 40 when electric current is delivered to the coil via terminals 52, 54. The magnetic circuit structure comprises an armature 58 and a multi-part stator structure that comprises stator parts 60, 62, and 64.
Stator part 60 is a generally cylindrical pole piece that is disposed at one end of the solenoid assembly coaxial with axis 44. Stator part 62 is another pole piece that is disposed at the opposite end of the solenoid assembly coaxial with axis 44. Stator part 64 is a part that completes the magnetic circuit between the two stator pole piece parts 60, 62 exterior of the coil and bobbin. The magnetic circuit includes an air gap 65 between stator part 60 and armature 58; it also includes a gap between armature 58 and stator part 62 occupied by material of bobbin 38.
A portion of stator part 64 comprises a cylindrical wall 66 which is disposed coaxial with axis 44 and with which a head 67 of stator part 60 has a threaded engagement. Overmold 32 stops short of wall 66, comprising a cylindrical surround 32A, to allow external access to stator part 60. Head 67 comprises a tool engagement surface 68 that is accessible through surround 32A for engagement, and ensuing rotation, by a complementary shaped tool (not shown) to adjust the axial position of part 60 along axis 44. A portion of a shank of part 60 passes closely though one axial end of through-hole 46. A distal end portion of this shank comprises a shoulder 70 leading to a reduced diameter section 71 that ends in a tapered tip 72.
Armature 58 comprises a cylindrical shape adapted for axial motion within through-hole 46. One axial end of armature 58 is in juxtaposition to tip 72 of stator part 60 and comprises a nominally flat end surface in whose central region a tapered depression 74 is formed. This depression has a shape complementary to that of tip 72. At the bottom of depression 74 there is an impact absorbing cushion 76, such as an elastomer. Alternatively, cushion could be mounted on tip 72. The opposite axial end of armature 58 comprises a nominally flat end surface whose central region contains a blind circular hole 78 coaxial with axis 44. Radial clearance is provided between armature 58 and the wall of throughhole 46 to allow axial motion of the armature.
When acted upon by magnetic force arising from magnetic flux in the magnetic circuit, armature 58 will not necessarily move with solely an axial component of motion. The motion may be accompanied by a radial, or lateral, component. In order to attenuate undesired consequences, such as noise, resulting from such lateral motion, an impact absorbing cushion 80 is provided external to through-hole 46. The illustrated cushion 80 comprises an elastomeric ring circumscribing the armature, but without imposing any significant influence on desired axial motion of the armature. Cushion 80 is disposed on the inner margin of an annular mounting member 82 whose outer perimeter engages the wall of a counterbore 84 in bobbin end wall 50 to lodge the cushion-retainer assembly in place. Alternatively, cushion 80 and mounting part 82 may be separate parts arranged such that the latter holds the former in place.
A multi-part valve assembly 86 is assembled to armature 58. Assembly 86 comprises a valve head part 88 and a seal part 90. A force-balancing mechanism 92 is associated with valve assembly 86. Mechanism 92 comprises an annular convoluted diaphragm 94 and a retainer 96. The valve assembly and force-balancing mechanism are held in assembly relation with armature 58 by a fastener 98.
Head 88 is generally cylindrical but includes a radially protruding circular ridge 100 midway between its axial ends. Seal 90 comprises a ring-shaped circular body 102 with a groove 104 on its inside diameter providing for body 102 to fit onto the outside diameter of head 88 with ridge 100 lodging in groove 104. A frustoconical sealing lip 106 flares radially outward from the end of body 102 that is toward seat surface 29 to seal thereagainst when valve 14 is in the closed position shown in FIGS. 2 and 3.
Head 88 further comprises an external shoulder 108 at its axial end that is opposite sealing lip 106. Head 88 also comprises a central axially extending through-hole 110. The end of head 88 that is proximate sealing lip 106 comprises a series of circumferentially spaced fingers 111 directed radially inward of the through-hole.
Retainer 96 also has a generally cylindrical shape and comprises a central through-hole 112. The wall of this through-hole is fluted, comprising circumferentially spaced apart, axially extending flutes. Head 88 and retainer 96 are stacked together axially, and the stack is secured to armature 58 by fastener 98 having a press fit to armature 58. Fastener 98 is a hollow tube that has a head 113 and a shank 114. Head 113 bears against radially inner ends of fingers 111, but does not block passage through through-hole 110. Shank 114 passes with clearance through head 88 and retainer 96 and into force-fit with armature hole 78, causing retainer 96 to abut the end of the armature around hole 78. This secures valve assembly 86 to armature 58 so that the two move axially as one.
Retainer 96 further comprises a flange 116 that radially overlaps shoulder 108 of head 88. In assembly, flange 116 and shoulder 108 capture a bead 118 on the inner margin of diaphragm 94 to seal the I.D. of the diaphragm to the O.D. of valve assembly 86. The outer margin of diaphragm 94 comprises a bead 120 that is captured between confronting surfaces of bobbin end wall 50 and an internal shoulder 122 of body part 24. Counterbore 84 and member 94 cooperatively form an internal chamber space 126 as part of force-balancing mechanism 92.
A helical coil bias spring 130 is disposed about the distal end of part 50 with one of its axial ends bearing against a shoulder of part 50 and its opposite end bearing against the flat end surface of armature 58 surrounding depression 74. When no electric current flows in coil 42, spring 130 forces lip 106 against seat surface 29. This closes the main flow passage through the valve between inlet port 25 and outlet port 26. Pressure at outlet port 26 is however communicated to chamber space 126 through a communication passage provided via the through-holes in head 88 and retainer 96. When the main flow passage is closed, it can be seen that tip 72 protrudes slightly into depression 74, creating a slight axial overlap between stator pole piece 60 and armature 58, but tip 72 is spaced from cushion 76.
The delivery of a purge control signal to valve 14 creates electric current flow in coil 42, and this current flow creates magnetic flux that is concentrated in the above-described magnetic circuit. As the current increases, increasing force is applied to armature 58 in the direction of increasingly displacing valve assembly 88 away from seat surface 29. This force is countered by the increasing compression of spring 130. The extent to which valve assembly 88 is displaced away from seat surface 29 is well-correlated with the current flow, and because of force-balancing and the sonic flow, the valve operation is essentially insensitive to varying manifold vacuum. The maximum displacement of armature 58 and valve assembly 86 away from seat surface 29 is defined by abutment of the tapered tip end of the armature with cushion 76.
In the operative emission control system 10, intake manifold vacuum is delivered through outlet port 26 and will act on the area circumscribed by the seating of lip 106 on seat surface 29. Absent force-balancing, varying manifold vacuum will vary the force required to open valve 14 and hence will cause the current flow in coil 42 that is required to open the valve to vary. Force-balancing de-sensitizes valve operation, initial valve opening in particular, to varying manifold vacuum. In the inventive valve 14, force-balancing is accomplished by the aforementioned communication passage through valve assembly 86 to chamber space 126. By making the effective area of the movable wall portion of the chamber space that is formed by diaphragm 94 and valve assembly 86 equal to the area circumscribed by the seating of lip 106 on seat surface 29, the force acting to resist unseating of the closed valve assembly 88 is nullified by an equal force acting in the opposite axial direction. Hence, valve 14 is endowed with a well-defined and predictable opening characteristic which is important in achieving a desired control strategy for canister purging. Although once valve assembly 86 has unseated from seating surface 29, some counter-force continues to exerted on it by the force-balance mechanism. Generally speaking, the counter-force will progressively diminish along a gradient.
Once the valve has opened beyond an initial unseating transition, sonic nozzle structure 28 becomes effective as a true sonic nozzle (assuming sufficient pressure differential between inlet and outlet ports) providing sonic purge flow and being essentially insensitive to varying manifold vacuum. Assuming that the properties of the vapor being purged, such as specific heat, gas constant, and temperature, are constant, mass flow through the valve is a function of essentially only the pressure upstream of the sonic nozzle. The restriction between the valve element and the valve seat upon initial valve element unseating and final valve element reseating does create a pressure drop preventing full sonic nozzle operation, but because these transitions are well-defined, and of relatively short duration, actual valve operation is well-correlated with the actual purge control signal applied to it. The inventive valve is well-suited for operation by a pulse width modulated (PWM) purge control signal waveform from engine management computer 22 composed of rectangular voltage pulses having substantially constant voltage amplitude and occurring at selected frequency.
The constructions of valve assembly 86 and force-balancing mechanism 92 are advantageous. Although the materials of valve head 88, diaphragm 94 and seal 90 are polymeric, they may have certain diverse characteristics. Seal 90 may have a characteristic that allows it to be molded directly onto valve head 88. Such compatibility may not exist between the material of diaphragm 94 and valve head 88. Hence retainer 96, its stacked association with valve head 88, and the use of fastener 98, as herein disclosed, provides a construction that accomplishes the required sealing of both the diaphragm and the seal element to the valve head.
Once all the internal parts of valve 14 have been assembled to body part 24, overmold 32 is created to complete the enclosure. The overmold is created by known injection molding techniques. At joint 34 the overmold material seals to body part 24. Similar sealing occurs around terminals 52, 54. Overmold material encloses the entire side of solenoid 30. At the base of wall 32A overmold material also forms a seal, but leaves access to stator part 60. Stator part 60 provides for proper calibration of the valve by setting the start to open point in relation to a certain current flow in coil 42.
The combination of various features provides a valve that has improved noise attenuation, durability, and performance. The taper angles of tip 72 and depression 74 have been found to influence the force vs. current characteristic of solenoid 30. It has been discovered that taper angles of approximately 30° relative to axis 44 improve low-voltage operation of valve 14 by lowering the "pull in" voltage and improving the low flow, start-to-open characteristic of the valve. For example, initial flow upon valve opening has been reduced from about 2 SLPM to about 1.5 SLPM by incorporation of the taper.
Another embodiment of valve is designated generally by the reference numeral 14' in FIGS. 6-7 and like parts of both valves 14, 14' are designated by like reference numerals. Valve 14' is like valve 14 except that cushioning of lateral components of armature motion is provided by a different construction. Instead of employing cushion 80 and member 82, the combination of a circular cylindrical sleeve 140 and liner 142 is provided. Sleeve 140 is preferably a non-magnetic thin-walled metal within which armature 58 has a close, but low-friction, sliding fit. Liner 142 is preferably an viscoelastic material that is disposed between sleeve 140 and the wall of bobbin through-hole 46. The sleeve and liner are disposed within through-hole 46, preferably at least co-extensive with the length of armature 58 that is within the through-hole. It may be desirable to bond liner 142 to sleeve 140 so that the two form a single part that can be assembled into the valve during fabrication of the valve. Although not specifically illustrated by a separate drawing FIG., both forms of lateral armature cushioning could be incorporated into a valve, if appropriate for a particular usage.
The embodiment of valve 14" in FIG. 8 is like the first embodiment except that the interface between stator part 60 and armature 58 is different. In valve 14" stator part 60 has a flat distal end instead of a tapered one. The juxtaposed end of armature 58 comprises a hole 148 that extends to, but is of slightly smaller diameter than, hole 78. A cushion 150 is mounted on this end of the armature, having a stem 152 fitting to hole 148, and a mushroom-shaped head 154 confronting the flat distal end of stator part 60. This valve shows the incorporation of both types of lateral impact cushioning, namely ring 84 and the sleeve-liner 140, 142.
While a presently preferred embodiment of the invention has been illustrated and described, it should be appreciated that principles are applicable to other embodiments that fall within the scope of the following claims. Moreover, the belief that certain generic aspects of the disclosed valves define novel and non-obvious subject matter is not to be construed to imply that such aspects must necessarily be inherent in other generic aspects. For example, the belief that the disclosed generic aspect of associating the inner margin of the force-balancing diaphragm with the valve is, per se, novel and non-obvious, does not impose a corresponding limitation on other generic aspects believed, per se novel and non-obvious, such as the generic aspect of associating the outer margin of the force-balancing diaphragm with the end wall of the bobbin, and vice versa. | A valve assembly (14) has an internal main flow passage through a valve body (24) between a first port (25) and a second port (26), an electric actuator (30), and a valve (86) operated by an armature (58) of the actuator to selectively open and close the passage. A force-balancing mechanism (92) applies to the valve (86) a force that opposes force created by pressure differential between the first and second ports. This mechanism includes an internal chamber (126) bounded in part by a fluid-impermeable movable wall (94) that extends between and is sealed to both the body (24) and the valve (86), and a communication passage (110, 112) that communicates one of the ports (26) to the chamber space when the valve is closing the passage. The valve (86) has a head part (88) and a seal part (90) joined together. The seal part seals the head part to the valve seat (29) when the valve is closing the passage. A retainer part (116) holds the inner margin of the movable wall sealed on the head part. The communication passage extends through the valve to communicate with the chamber space at a region of the valve disposed within the chamber space. The valve also has cushion media (76, 80, 142) that cushions impact of lateral displacements of the armature, an overmold (32) that encloses internal parts, and sonic nozzle structure (28). | 5 |
CROSS-REFERENCED APPLICATION
[0001] This application claims priority to U.S. Provisional Application Ser. No. 61/898,175, filed on Oct. 31, 2013, which is incorporated herein in its entirety by reference thereto.
BACKGROUND
[0002] 1. Field of the Disclosure
[0003] The present disclosure generally relates to the design of ice making machine evaporator components and the joining process of the evaporator components. In particular, the present disclosure relates to the design and joining of ice making machine evaporator partitions having a crisscross pattern of partitions, and the joining of those partitions to an evaporator pan.
[0004] 2. Discussion of the Background Art
[0005] Conventional ice making machines have an evaporator that is constructed using partitions assembled in a crisscross pattern (generally crisscrossed at about a 90° angle, hereinafter referred to as “horizontal” partitions and/or “vertical” partitions) and joined to an evaporator pan using only butt joints. The crisscross pattern forms individual vessels or cells where ice cubes are formed. On the side of the evaporator pan opposite the crisscross pattern of partitions is generally a serpentine refrigeration coil that chills the evaporator pan, providing an ice-forming surface on the crisscross side of the evaporator pan such that water cascading down the side having the partitions forming the cells will freeze and gradually build up within the cells, forming ice cubes. Once a sufficient amount of ice has formed in the cells, the ice cubes are harvested using a hot gas bypass circuit in the refrigeration system. During the harvest cycle in a conventional ice making machine, the hot gas warms the contact surface between the cubes and the evaporator pan and the cubes are released to fall into, e.g., a storage receptacle. Conventional ice making machine evaporators are constructed using a copper evaporator pan, copper partitions, and a copper serpentine tube or tubes.
[0006] The crisscross pattern of the partitions, as mentioned above, forms cells. These cells have four walls with an interior volume determined by the area (L×W) of the cell surface times the height/depth of the cell walls. The conventional design for the partitions forming the cells is to have a large aspect ratio (length or width to height, or L/W:H) with slots cut halfway across the height of each partition at locations where intersections between a horizontally disposed and a vertically disposed partition will form. As a result, the crossing (vertical and horizontal) partitions each make up slightly less than half the material height as they cross each other. The slots are of sufficient cross-sectional dimension to accommodate the width of the partition of the crossing partition that slides into it. However, the slot cross-sectional dimension is not so large that the crossing partition has “wobble” or “play” when inserted; this could result in problems concerning, e.g., the release of the ice slab/cubes during harvest and, due to the fact that water expands during freezing at certain temperatures, the deformation of the relative size of the cells by water freezing in the spacing provided by the “wobble” or “play”, resulting in damage to the crisscross assembly and/or non-uniform cube size. Thus, the slots generally provide relatively close or no clearance for the width of the mating partition. For partitions that are running horizontally on a vertically disposed evaporator pan in the ice making machine, the slots are cut in the height of the partition an angle 90° to the length of the partition. For the partitions that are running vertically on a vertically disposed evaporator pan in ice making machine, the slots are cut in the height of the partition at an angle, nominally 75°, to the length of the partition. The effect of the 75° angle in the vertically disposed partitions is to put an approximately 15° downward tilt into the horizontally running partitions that fit into the slots in the vertically running partitions. This 15° downward tilt allows gravity to pull the frozen ice slab/cubes from the evaporator pan cells during the harvest cycle of the ice making machine.
[0007] Conventional partitions also include what are known as “weep holes” for the purpose of allowing air to move around behind the slab of ice during the harvest cycle. Without the ability for air to move from cube cell to cube cell behind the slab of ice, the harvest cycle of the ice making machine would be impaired due to a vacuum that would be formed as the slab of ice is pulled away from the evaporator pan by gravity. These “weep holes” are intentionally located in the vertical partitions at the evaporator pan side of the vertical and horizontal partition intersections in conventional ice making machines so that a single “weep hole” is located at the corners of four ice cube-forming cells. Stated otherwise, the “weep hole” is located on the evaporator pan contact point at the end of a centerline running parallel to the angle of the slots in the vertically disposed partition. When the horizontal partitions are joined with the angled slots of the vertical partitions, the open end of the slot on the horizontal partition joins or mates with the “weep hole” located on the evaporator pan contact point at the end of the above-described center line parallel to the angle of the slots on the vertically disposed partition. The result is that there is a “void” (or combined weep hole/slot opening) at the intersection of the vertical and horizontal partitions adjacent the evaporator pan. This “void” creates an area where the crisscrossed vertical and horizontal partitions do not contact the evaporator pan (i.e., the “weep holes”).
[0008] The vertical and horizontal partitions are assembled together in a crisscross pattern and placed on the evaporator pan to form a grid that divides the ice cubes from each other. The evaporator pan is generally contoured so that the crisscross partition grid is disposed on a concave surface of the evaporator pan and the serpentine refrigeration/hot gas coil is disposed on a convex surface of the evaporator pan. This assembly (i.e., crisscross partition grid and concave surface of the evaporator pan) needs to be joined together and is usually joined during the manufacturing process, typically by soldering or brazing. The result of the joinder by soldering/brazing is that each partition (vertical and horizontal) in the grid is joined to the evaporator pan by many solder butt joints. The partitions are not joined to each other (being held together by the close or no clearance between the mated partitions), only to the evaporator pan surface. The serpentine refrigeration/hot gas coil is also typically soldered or brazed to the convex side of the evaporator pan.
[0009] Once the partitions and serpentine tubing are soldered or brazed to the evaporator pan, a coating is typically applied to the assembly to confer food grade safety and corrosion protection to it. This coating is typically a layer of nickel plating, generally either electrostatically or electroless, applied to the assembly. As mentioned above, the partition grid is generally assembled together with tight clearances between the slots and the width of the inserted partition to ensure that the partitions remain parallel to each other. Because of the tight or no clearance and potential lack of clearance between the partition surfaces at their intersections, the plating solutions do not always penetrate into the vertical and horizontal partition intersections and provide plating to all the surfaces forming the partition intersections. The reason for this is that the “void” (i.e., “weep hole”) prevents capillary action from allowing the brazing or soldering alloy to wick into the tight clearance between the slot and the width of its mating partition. Without complete penetration, material forming the base materials of the evaporator pan and/or vertical and horizontal partitions may be left exposed.
SUMMARY
[0010] Thus, it is an object of the present disclosure to provide a design of partitions that allows for more complete coating of plating material thereto.
[0011] It is also an object of the present disclosure to provide a design of a partition-evaporator pan assembly that likewise allows for more complete coating of plating material thereto.
[0012] These and other objects will become apparent to those skilled in the art based on the present disclosure.
[0013] This disclosure provides two different representative solutions that can be used to accomplish the above objects. These two solutions may preferably be used independently of one another. While these two design approaches serve to reduce or prevent the potential for poor plating penetration at the partition intersections, other approaches and specific designs will become apparent to those skilled in the art based on the present disclosure.
[0014] The first solution joins the vertical and horizontal partitions together at their intersections where the intersections meet the evaporator pan surface so that the intersections are susceptible for more complete soldering/brazing. It does this by eliminating the above described “voids” by changing the location and design of the “weep holes” in the vertical and/or horizontal partitions. This change thus provides a more complete capillary path at the joint between the intersections of the vertical and horizontal partitions and the evaporator pan, and therefore allows for improved flow (or wicking) of molten solder or brazing alloy during the joining of the assembled vertical and horizontal grid and the evaporator pan. This design change allows the molten joining material to move from the evaporator pan into the intersections of the partitions through capillary action. This first approach also allows for the intersections of the partitions to be brazed or soldered shut to eliminate the areas of tight clearance or lack of clearance that may not be effectively plated during the plating process.
[0015] To accomplish the first approach of soldering or brazing the partition intersections shut, the present disclosure provides for a capillary path for the solder or brazing material at the contact area of the evaporator pan and the intersection point of the joint between the vertical and horizontal partitions. It has been discovered that the conventional location of the “weep holes” in the vertical partitions, forming “voids” with the ends of the slots in the horizontal partitions, prevents the solder or brazing material from wetting into the vertical and horizontal partition intersection joints. This disclosure relocates the “weep holes” in the evaporator partitions so as to be disposed away from the partition intersections. In doing this, the solder or brazing material is given a capillary path to join together the partitions at their intersections.
[0016] Therefore, one embodiment of the present disclosure comprises a partition for use in forming a crisscross grid capable of substantially completely contacting a substantially planar surface of an evaporator pan of an ice making machine, the partition comprising a length having two opposed edges, a height, a width and a plurality of substantially parallel slots disposed along a first one of the edges, each slot having a centerline, and at least one weep hole disposed proximal a second one of the edges and not disposed along a centerline.
[0017] Another embodiment of the present disclosure comprises a partition for use in forming a crisscross grid capable of substantially completely contacting a substantially planar surface of an evaporator pan of an ice making machine, the partition comprising a length having two opposed edges, a height, a width and a plurality of substantially parallel slots disposed along a first one of the edges and at least one weep hole disposed along the first one of the edges between two of the parallel slots.
[0018] A still further embodiment of the present disclosure comprises a crisscross grid comprised of a first plurality of substantially parallel partitions, each partition comprising a length having two opposed edges, a height, a width and a plurality of substantially parallel slots disposed along a first one of the edges, each slot having a centerline, and at least one weep hole disposed proximal a second one of the edges and not disposed along a centerline, and a second plurality of substantially parallel partitions, each partition comprising a length having two opposed edges, a height, a width and a plurality of substantially parallel slots disposed along a first one of the edges and at least one weep hole disposed along the first one of the edges between two of the parallel slots, wherein the first and second plurality are disposed substantially perpendicular to one another by engagement of the slots.
[0019] Another embodiment of the present disclosure comprises a crisscross grid comprised of a first plurality of substantially parallel partitions, each partition comprising a length having two opposed edges, a height, a width and a plurality of substantially parallel slots disposed along a first one of the edges, each slot having a centerline, and at least one weep hole disposed proximal a second one of the edges and not disposed along a centerline, and a second plurality of substantially parallel partitions, each partition comprising a length having two opposed edges, a height, a width and a plurality of substantially parallel slots disposed along a first one of the edges, wherein the first and second plurality are disposed substantially perpendicular to one another by engagement of the slots.
[0020] Yet another embodiment of the present disclosure comprises a crisscross grid comprised of a first plurality of substantially parallel partitions, each partition comprising a length having two opposed edges, a height, a width and a plurality of substantially parallel slots disposed along a first one of the edges and at least one weep hole disposed along the first one of the edges between two of the parallel slots, and a second plurality of substantially parallel partitions, each partition comprising a length having two opposed edges, a height, a width and a plurality of substantially parallel slots disposed along a first one of the edges, wherein the first and second plurality are disposed substantially perpendicular to one another by engagement of the slots.
[0021] The second solution increases the clearance between the partitions at their intersections to allow the post-joining plating treatment to penetrate and coat all the partition surfaces. This design change involves widening the intersecting slots in the partitions to a width greater than the width of a mating partition, but including “stand-off” features in those slots to center the mating partition in the widened intersecting slot. The result of this second approach is to enlarge the clearance between partitions to eliminate the areas of tight clearance or lack of clearance, yet maintain the intersection between mating partitions without “wobble” or “play”.
[0022] To successfully accomplish the second approach of enlarging clearance between partitions at the intersections, two modifications to the conventional partition need to be made. The first modification is to widen the slot width in each of the vertical and horizontal partitions to allow for more clearance at the partition intersections for the width of the mating partition. The second modification is to add stand-off features inside the slots to keep the mating partition(s) centered within the slots. If the partitions slots were just widened, the mating partition would likely not stay centered within the slot. This would cause that partition to lean to one side of the slot, leading to an area of tight clearance at the intersection and defeating the purpose of widening the slot. It will also be appreciated and understood that the parallelism between partitions would not be maintained if the partitions were free to lean in different directions within the partition grid pattern.
[0023] Therefore, an embodiment of the present disclosure comprises a partition for use in forming a crisscross grid, the partition comprising a length having two opposed edges, a height, a partition width and a plurality of substantially parallel slots disposed along a first one of the edges, each slot having a centerline and at least one weep hole disposed proximal the other edge along the centerline, each slot having a first slot width wider than the partition width of a partition disposed therein for forming the crisscross grid, and each slot having at least two protrusions disposed on opposite sides inside of the slot width, the protrusions providing the slot with a second slot width substantially equal to the partition width of a partition disposed therein for forming the crisscross grid.
[0024] An additional embodiment of the present disclosure comprises a partition for use in forming a crisscross grid, the partition comprising a length having two opposed edges, a height, a partition width and a plurality of substantially parallel slots disposed along a first one of the edges, each slot having a first slot width wider than the partition width of a partition disposed therein for forming the crisscross grid, and each slot having at least two protrusions disposed on opposite sides inside of the slot width, the protrusions providing the slot with a second slot width substantially equal to the partition width of a partition disposed therein for forming the crisscross grid.
[0025] A still further embodiment of the present disclosure comprises a crisscross grid comprised of a first plurality of substantially parallel partitions, each of the first plurality of partitions comprising a length having two opposed edges, a height, a partition width and a plurality of substantially parallel slots disposed along a first one of the edges, each slot having a centerline and at least one weep hole disposed proximal a second one of the edges along the centerline, each slot having a first slot width wider than the partition width of a partition disposed therein for forming the crisscross grid, and each slot having at least two protrusions disposed on opposite sides inside of the slot width, wherein the protrusions provide the slot with a second slot width substantially equal to the partition width of a partition disposed therein for forming the crisscross grid, and a second plurality of substantially parallel partitions, each of the second plurality of partitions comprising a length having two opposed edges, a height, a partition width, and a plurality of substantially parallel slots disposed along a first one of the edges, each slot having a first slot width wider than the partition width of a partition disposed therein for forming the crisscross grid, and each slot having at least two protrusions disposed on opposite sides inside of the slot width, wherein the protrusions provide the slot with a second slot width substantially equal to the partition width of a partition disposed therein for forming the crisscross grid, wherein the first and second plurality are disposed substantially perpendicular to one another by engagement of the slots.
[0026] Any of the embodiments of either of the above two solutions will eliminate the potential for poor plating penetration at the partition intersections, prevent exposed partition material, and eliminate problems that could result from exposed partition material. The first approach accomplishes the desired benefits by eliminating areas where plating may not be complete at the intersection of the vertical and horizontal grid due to tight clearance or lack of clearance. The second approach accomplishes the desired benefits by a somewhat opposite methodology, i.e., widening the intersections where the vertical and horizontal partitions crisscross, to allow for fully effective plating of the areas otherwise difficult to plate completely.
[0027] Potential alternatives for the “weep holes” locations are included in the present disclosure. These alternatives include: (1) not putting “weep holes” in the design at all; (2) including “weep holes” as typical crescent shapes, as small slots, or as fully enclosed holes. Combinations of these alternatives will be further explained in connection with the discussion of the accompanying Figures. These alternatives accomplish the purpose of allowing capillary connection between the partition intersection joint and the evaporator pan contact points still including the “weep holes” in the design to allow air movement behind the ice slab during the harvest cycle. A representative design for widening the slots and enlarging slot clearance, and including stand-offs, is also included in the discussion of the accompanying Figures. Potential alternatives for the embodiment where the slot widths are widened to provide a first slot width greater than the partition width of a mating partition, and stand offs or protrusions are included inside the slot widths to provide a second slot width substantially equal to the partition width of a mating partition, is also included in the discussion of the accompanying Figures.
[0028] Further objects, features and advantages of the present disclosure will be understood by reference to the following drawings, detailed description and appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] FIGS. 1A and 1B provide side views of conventional horizontal and vertical partitions, respectively.
[0030] FIGS. 2A , 2 B, 2 C and 2 D provide side views of alternate horizontal partitions, according to the present disclosure.
[0031] FIGS. 3A , 3 B, 3 C, 3 D, 3 E and 3 F provide side views of alternate vertical partitions, according to the present disclosure.
[0032] FIG. 4A provides a side view of a stand-off horizontal partition; FIG. 4B provides an enlarged view of section “A” of FIG. 4A ; FIG. 4C provides a side view of a stand-off vertical partition; and FIG. 4D provides an enlarged view of section “A” of FIG. 4 C.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0033] FIG. 1A shows a side view of a conventional horizontal partition 100 . Conventional horizontal partition 100 has a length 110 and a height 120 . Conventional horizontal partition 100 has a plurality of substantially equally spaced slots 130 , each slot having a width 140 and a depth 150 . Length 110 is approximately equal to the inside horizontal surface of a vertically disposed evaporator pan (not shown) to which it is affixed. Height 120 is approximately equal to the depth of a vertically disposed evaporator pan (not shown) to which it is affixed. Slots 130 are substantially equally spaced so as to provide substantially equally sized cells (when mated or joined with a vertical partition) for the formation of ice cubes. Slots 130 are also provided with a depth 150 that is, generally, approximately half the height 120 of horizontal partition 100 and vertical partition 170 (see, FIG. 1B ) so that, when inserted into matching slot 130 in vertical partition 170 lower edge 160 of horizontal partition 100 is essentially coplanar with lower edge 160 of vertical partition 170 so that the lower edges 160 substantially completely contact the surface of an evaporator pan (not shown). Slots 130 also have width 140 such that width 140 provides a substantially tight fit with the width (not shown) of vertical partition 170 when horizontal partition 100 is slid into slots 130 of vertical partition 170 .
[0034] FIG. 1B shows a side view of a conventional vertical partition 170 . In FIG. 1B , elements 120 , 130 , 140 , 150 and 160 are as described above with respect to horizontal partition 100 . As can be seen in FIG. 1B , slots 130 disposed in vertical partition 170 are angled so as to provide a downward slope of about 15° to horizontal partition 100 , as described above in paragraph [0003], when horizontal partition 100 is slid into place in vertical partition 170 . Vertical partition 170 also has a series of weep holes 180 , each of which is disposed along lower edge 160 of vertical partition 170 on a centerline 190 of each slot 130 of vertical partition 170 . As can be envisioned, when horizontal partition 100 is mated (or joined) via engagement of slots 130 of horizontal partition 100 with slots 130 of vertical partition 170 , the portion of slots 130 on horizontal partition that are disposed near lower edge 160 effectively mate (or join or match) with weep holes 180 , thereby creating the “voids” and associated problems as described above in paragraph [0004]. In FIG. 1B , length 110 ′ of vertical partition 170 may be the same as or different than length 110 of horizontal partition 100 . Length 110 ′ will be equal to length 110 if the evaporator pan is of a square design or configuration. However, if the evaporator pan is of a rectangular design, length 110 ′ will be different than length 110 .
[0035] FIGS. 2A-2D show side views of various horizontal partitions according to the present disclosure. The horizontal partitions shown in FIGS. 2A-2D vary such that the horizontal partitions of FIGS. 2A and 2B will preferably be used in conjunction with the vertical partitions shown in FIGS. 3A-3D , while the horizontal partitions shown in FIGS. 2C-2D will preferably be used in conjunction with the vertical partitions shown in FIGS. 3E-3F . The various combinations of horizontal partitions and vertical partitions of FIGS. 2A and 2B and FIGS. 3A-3D according to the present disclosure will, therefore, be discussed separately below. As used herein with respect to the present disclosure, the term “weep hole” will be variously referred to, and shown, as weep hole slots, weep holes and weep hole through-holes. The weep holes will also take any of a number of various shapes, including but not limited to oval, circular, elliptical, rectangular, square, triangular, or any other geometry. Also, the size and number of the weep holes can be varied according to design choice and combinations of shapes and sizes may be used according to design choice. The options for weep holes shape, placement, size and number recited above can be used for vertical partitions and/or for horizontal partitions according to the present disclosure.
[0036] FIG. 2A shows a horizontal partition 100 , which is essentially identical to conventional partition 100 shown in FIG. 1A . FIG. 2B shows horizontal partition 210 that is similar in design to horizontal partition 100 , the difference being the addition of weep holes slots 180 disposed between slots 130 along lower edge 160 . FIGS. 3A-3D show vertical partitions 310 , 320 , 330 and 340 that are substantially similar to vertical partition 170 shown in FIG. 1B . Vertical partition 310 differs from vertical partition 170 in that vertical partition 310 does not have any weep holes 180 . Vertical partitions 320 , 330 and 340 differ from the vertical partition 170 in that vertical partitions 320 , 330 and 340 have weep holes placed away from centerline 190 of vertical partitions 320 , 330 and 340 . Weep holes 180 of vertical partitions 320 , 330 and 340 are depicted as being substantially midway between adjacent centerlines 190 ; however, the specific placement of weep holes 180 away from centerlines 190 is a mere matter of choice. Also, although in vertical partitions 320 , 330 and 340 a single weep hole 180 is shown as being disposed between each pair of adjacent centerlines 190 , a plurality of such weep hole slots 180 may be so disposed, so long as each weep hole slot 180 is disposed away from a centerline 190 . Similarly, although weep hole slot 180 in vertical partition 320 is shown as a semicircle and weep hole slot 180 in vertical partition 330 is shown as a longitudinal slot, these configurations are merely exemplary in nature, and the weep hole slots 180 can be of any geometry, or combinations thereof on any individual vertical partition. Likewise, although weep hole slots 180 in vertical partition 340 are depicted as a relatively oval in shape, the through-hole(s) forming weep holes slots 180 can be of any configuration, including circular, elliptical, rectangular, square, triangular, or any other geometry. Also, the size of weep holes 180 can be varied according to design choice. The options for weep holes 180 shape, placement, size and number recited above for vertical partitions 320 , 330 and 340 apply as well to weep holes 180 present in horizontal partitions 210 , 220 and 230 .
[0037] Turning now to the configurations of vertical and horizontal partitions as assembled, horizontal partition 100 can be used with any of vertical partitions 320 , 330 or 340 shown in FIGS. 3B-3D . As will be appreciated, when horizontal partition 100 is mated or joined to any of vertical partitions 320 , 330 or 340 , lower edges 160 of horizontal partition 100 and vertical partitions 320 , 330 and 340 will be essentially coplanar. As a result, individual cells for forming ice cubes will be created, each cell having 2 weep holes 180 along the evaporator pan side of the cells on each vertical edge of the cell. There will be no weep holes 180 along the horizontal edge of these cells. At the same time, lower edges 160 of horizontal partition 100 and vertical partitions 320 , 330 and 340 will substantially completely contact the surface of an evaporator pan, providing for complete wicking of the brazing or soldering material into the intersection of horizontal partition 100 and vertical partitions 320 , 330 and 340 . When horizontal partition 210 of FIG. 2B is similarly assembled with vertical partitions 320 , 330 and 340 similar results are attained with additional weep holes 180 along the horizontal edges of the individual ice cube cells due to the presence of weep holes 180 in horizontal partition 210 . When horizontal partition 210 is used in conjunction with vertical partition 310 , the result is similar to that of the combination of horizontal partition 100 with any of vertical partitions 320 , 334 and 340 , the difference being that the combination of horizontal partition 210 with vertical partition 310 results in weep holes 180 being present along the horizontal edges of the ice cube cells.
[0038] FIGS. 2C and 2D show horizontal partitions 220 and 230 that are generally configured similarly to horizontal partition 210 . The difference between in partitions 220 and 230 as compared to horizontal partition 210 is that horizontal partitions 220 and 230 have weep holes 180 and slots 130 disposed along opposite edges of the horizontal partitions, with the weep holes 180 shown in partition 220 being elongated slots and weep holes 180 in horizontal partition 230 being through-holes. The options referred to above in paragraph [0033] with respect to the shape, placement, size and number of through-holes 180 applies equally as well to the through-holes in horizontal partitions 220 and 230 . FIGS. 3E and 3F show vertical partitions 350 and 360 , respectively, generally similar in design and configuration to vertical partitions 320 , 330 and 340 , with the difference being that vertical partitions 350 and 360 have through-holes 180 disposed along the same edge as slots 130 . And again, similarly, the options available for through-holes 184 vertical partitions 350 and 360 respect to shape, placement, size and number are similar to those options referred to in paragraph [0033].
[0039] Turning now to additional configurations of vertical and horizontal partitions as assembled, horizontal partitions 220 and 230 can be used in combination with any of vertical partitions 310 , 350 and 360 . As will be appreciated, the assembly of either of horizontal partitions 220 or 230 with either of vertical partitions 350 or 360 will result in the configuration having weep holes 180 disposed on all four sides of each ice cube cell of the assembled partition. As will also be appreciated, the assembly of either of horizontal partitions 220 or 230 with vertical partition 310 will result in the configuration having weep holes 180 disposed on the horizontal sides of each ice cube cell of the assembled partition.
[0040] As will be understood from the foregoing discussion relating to the optional vertical partitions and horizontal partition combinations of the present disclosure, the present disclosure is concerned with offsetting the placement of weep holes 180 from association with the intersections of vertical partitions and horizontal partitions. The placement of weep holes 180 at the intersections of vertical partitions and horizontal partitions that is the state-of-the-art results in the problems described in the Background portion of this disclosure. Thus, the exemplary embodiments of the present disclosure discussed above eliminate any weep holes 180 from being located at the intersections of the vertical partitions and horizontal partitions, as discussed above. Also, when the offset placement of weep holes 180 allows complete wicking of soldering and/or brazing material into the intersection of the vertical partitions and horizontal partitions, thus eliminating the possibility of incomplete plating at these intersections during the plating process. This also results in reducing the possibility of undercutting the plating by galvanic action.
[0041] The present disclosure also contemplates an alternative to offsetting weep holes 180 from the intersections of the vertical partitions and horizontal partitions. This alternative is shown in FIGS. 4A and 4B .
[0042] FIG. 4A shows a horizontal partition 400 suitable for use in the alternative embodiment of the present disclosure. Horizontal partition 400 is generally similar to horizontal partition 100 with the exception of two differences. The first difference is that in the embodiment of the alternative shown in FIG. 4A , horizontal partition 400 has weep holes 180 located along centerline 190 of slots 135 and the second difference is that slots 135 have width 141 of a greater dimension than width 140 of slots 130 . This difference will be explained in the following discussion. FIG. 4C shows a vertical partition 410 suitable for use in the alternative embodiment of the present disclosure. Vertical partition 410 is generally similar to vertical partition 170 with the exception of two differences. The first difference is that in the embodiment of the alternative shown in FIG. 4C , vertical partition 410 has no weep holes 180 and, as with horizontal partition 400 , has slots 135 with width 141 of a greater dimension than width 140 of slots 130 . While weep holes 180 are shown on horizontal partition 400 , this is a mere matter of design choice for this alternative of the present disclosure. Weep holes 180 could just as well be located on centerline 190 of vertical partition 410 . Thus, for purposes of the discussion with respect to this alternative of the present disclosure, the location of weep holes 180 is not critical. The alternative shown in FIGS. 4A and 4C of the present disclosure will be more clearly understood in conjunction with the description of FIGS. 4B and 4D . FIGS. 4B and 4D show one configuration of slots 135 having stand offs or protrusions 131 according to the alternative of the disclosure. Slots 135 are nominally of width 141 that is greater than the nominal outside dimensional width of horizontal partition 400 and vertical partition 410 . The nominally greater width 141 of slots 135 avoids the issue of tight or no clearance at the intersections of horizontal partition 400 and vertical partition 410 . However, the greater width 141 of slots 135 in horizontal partition 400 and vertical partition 410 would normally have the effect of allowing for movement or “wobble” between horizontal partition 400 and vertical partition 410 . To overcome this potential problem, the present disclosure contemplates the inclusion of standoffs or protrusions 131 as seen in FIGS. 4B and 4D . Standoffs or protrusions 131 are separated by a distance 132 which is of tight or no clearance to the actual width of the partition ( 400 or 410 ) mated to slot 135 . Stated otherwise, the increased width 141 of slot 135 allows for space (represented by the depth of stand offs or protrusions 131 reducing width 141 of slots 135 ) between the outside surface of horizontal partition 400 /vertical partition 410 and width 141 . In this configuration, when plating of the assembled vertical partition and horizontal partition grid and evaporator pan is performed, plating solution can easily flow into the space provided by standoffs or protrusions 131 and completely coat horizontal protrusion 400 and vertical partition 410 at the intersections thereof. Although standoffs/protrusions 131 are shown in FIGS. 4B , and 4 D, as equally spaced and directly opposite each other on opposing walls of slots 135 , other configurations will be apparent to those of skill in the art. For instance, standoffs/protrusions 131 , could just as easily alternate in a zigzag pattern on opposite sides of the inner wall of slot 135 . The effect sort to be attained by standoffs/protrusions 131 is to stabilize the mated partition in slot 135 , yet allow substantially complete exposure of the surface of the mated partition to the plating solution.
[0043] It should be noted that the terms “first”, “second”, “third”, “upper”, “lower”, and the like may be used herein to modify various elements. These modifiers do not imply a spatial, sequential, or hierarchical order to the modified elements unless specifically stated.
[0044] While the present disclosure has been described with reference to one or more exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the present disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the disclosure without departing from the scope thereof. Therefore, it is intended that the present disclosure not be limited to the particular embodiment(s) disclosed as the best mode contemplated, but that the disclosure will include all embodiments falling within the scope of the appended claims. | Disclosed are methods and apparatuses for overcoming known plating deficiencies in evaporator assemblies in ice making machine. One embodiment joins the vertical and horizontal partitions together at their intersections so that all surfaces are susceptible for increased soldering/brazing by eliminating the “voids” by changing the location and design of the “weep holes” in the vertical and/or horizontal partitions. This provides more complete capillary path at the joint between the vertical and horizontal partitions and the evaporator pan allowing improved flow via capillary action of solder/brazing alloy during the joining of the assembled vertical and horizontal partition grid to the evaporator pan. Another embodiment increases the clearance between the partitions at their intersections to allow the post-joining plating treatment to penetrate and coat all the partition surfaces by widening the intersection slots in the partitions, but including “stand-off” features to center the mating partition in the widened intersection slot. | 8 |
TECHNICAL FIELD
[0001] The present invention relates to a layered double hydroxide, more specifically to a layered double hydroxide which has selective adsorbability to unsaturated fatty acids (in particular, oleic acid) and a cosmetic produced using this layered double hydroxide.
BACKGROUND ART
[0002] Layered double hydroxides (hydrotalcite-like compounds) are compounds represented by the general formula [M 2+ 1-x M 3+ x (OH) 2 ][A n− x/n .mH 2 O] and are known as compounds which have an anion exchange capability. Specifically, such a compound has a structure including base layers formed of bivalent and trivalent metal hydroxides, and an intermediate layer and interlayer water each intercalated between the base layers.
[0003] Such layered double hydroxides can be formed so as to exhibit various characteristics depending on combinations of bivalent and trivalent metal atoms forming base layers and anions forming intermediate layers. Thus, various layered double hydroxides have been developed.
[0004] The applicant of the present application also developed layered double hydroxides in which bivalent and trivalent metal atoms are Mg and Al and various materials are intercalated (refer to Patent Literatures 1 to 3).
[0005] Also, the applicant of the present application found that use of Mg and Al as the bivalent and trivalent metal atoms and use of magnesium acetate or magnesium acrylate as the intercalation compound provide a technical advantage of selective adsorbability to unsaturated fatty acids such as oleic acid. The applicant applied for a patent directed to such a layered double hydroxide and obtained the patent (refer to Patent Literature 4).
[0006] It is known that such unsaturated fatty acids are contained in human sebum components or decomposed substances derived from sebum components, and cause makeup coming off or shine. On the other hand, sebum components also include skin-moisturizing components such as squalene.
[0007] Accordingly, layered double hydroxides which have selective adsorbability to the unsaturated fatty acids, which cause makeup coming off or shine, are highly useful in the cosmetic field. In particular, among unsaturated fatty acids, oleic acid accounts for about 30% to about 40% of sebum components. Thus, layered double hydroxides which have selective adsorbability to oleic acid are very highly useful in the cosmetic field.
CITATION LIST
Patent Literature
[0008] PTL 1: Japanese Patent No. 5022038
[0009] PTL 2: Japanese Patent No. 5155568
[0010] PTL 3: Japanese Patent No. 5178027
[0011] PTL 4: Japanese Patent No. 5065777
SUMMARY OF INVENTION
Technical Problem
[0012] The layered double hydroxide described in PTL 4 has selective adsorbability to unsaturated fatty acids; however, it becomes strongly alkaline (pH: about 10) upon being dispersed in water. Thus, in consideration of, for example, the influence of the layered double hydroxide on the skin, this hydroxide itself is difficult to use as a cosmetic, which has been problematic.
[0013] In addition, the layered double hydroxide described in PTL 4, which employs magnesium acetate as the intercalation compound, has a problem of emission of acetic acid odor. This is also the reason why this hydroxide itself is difficult to use as a cosmetic, which has been problematic.
[0014] This time, the inventors of the present invention performed thorough studies. As a result, the inventors have found that use of a compound represented by a specific chemical formula as the intercalation anion can provide selective adsorbability to unsaturated fatty acids and can also allow a neutral pH value (i.e., a weakly acidic to weakly alkaline pH value) even upon being dispersed in water.
[0015] In view of the above-described known problems, the present invention has been made. An object is to provide a layered double hydroxide which has selective adsorbability to unsaturated fatty acids and can also have a neutral pH value (i.e., a weakly acidic to weakly alkaline pH value) even upon being dispersed in water, and a cosmetic produced using this layered double hydroxide.
Solution to Problem
[0016] In order to achieve the above-described object, a layered double hydroxide according to the present invention is characterized by including base layers each including a metal double hydroxide represented by the formula: M(II) 1-X M(III) X (OH) 2 (wherein M(II) represents one or two bivalent metal atoms; M(III) represents a trivalent metal atom; and x represents 0.2 to 0.33), and an intermediate layer and interlayer water each intercalated between the base layers, wherein the intermediate layer is a compound represented by the following Formula 1 or Formula 2
[0000] R 1 —COOH [Formula 1]
[0017] (wherein R 1 represents at least one substituent selected from an aliphatic hydrocarbon group, a substituted aliphatic hydrocarbon group, an aromatic hydrocarbon group, a substituted aromatic hydrocarbon group, a heterocyclic group and a substituted heterocyclic group)
[0000] R 2 —SO 3 H [Formula 2]
[0018] (wherein R 2 represents at least one substituent selected from an aliphatic hydrocarbon group, a substituted aliphatic hydrocarbon group, an aromatic hydrocarbon group, a substituted aromatic hydrocarbon group, a heterocyclic group and a substituted heterocyclic group).
[0019] A layered double hydroxide according to the present invention is characterized in that M(II) represents Zn and M(III) represents Al.
[0020] A layered double hydroxide according to the present invention is characterized in that M(II) represents Mg and Zn, and M(III) represents Al.
[0021] A layered double hydroxide according to the present invention is characterized in that the compound represented by Formula 1 is at least one compound selected from salicylic acid, hydroxybenzoic acid, aminobenzoic acid, methoxybenzoic acid, pentanoic acid, dodecanoic acid, octadecanoic acid, docosanoic acid, isopentanoic acid, isododecanoic acid, isooctadecanoic acid, 4-aminobutyric acid, 6-aminohexanoic acid, tranexamic acid, picolinic acid, taurine, pyrrolidonecarboxylic acid, and sodium N-lauroylsarcosinate.
[0022] A cosmetic according to the present invention is characterized in that the compound represented by Formula 2 is phenolsulfonic acid or p-toluenesulfonic acid.
[0023] A cosmetic according to the present invention is characterized by including the layered double hydroxide according to any one of claims 1 to 5 .
[0024] (Basic Structure)
[0025] A layered double hydroxide according to the present invention has a structure including base layers each including a metal double hydroxide represented by the formula: M(II) 1-X M(III) X (OH) 2 (wherein M(II) represents one or two bivalent metal atoms; M(III) represents a trivalent metal atom; and x represents 0.2 to 0.33), and a compound represented by a specific chemical formula (intermediate layer) and interlayer water each intercalated between the base layers. In this way, use of a compound represented by a specific chemical formula as an intercalation compound can provide a layered double hydroxide which has a neutral pH value upon being dispersed in water and has selective adsorbability to specific unsaturated fatty acids such as oleic acid.
[0026] In the present invention, the neutral pH value is a weakly acidic to weakly alkaline pH value, more specifically, a pH value in the range of 5 to 9. Incidentally, a layered double hydroxide according to the present invention can be adjusted so as to have a desired pH within the above-described range by adjusting a ratio of an anion to base layers described below. Incidentally, when a layered double hydroxide according to the present invention is added as a cosmetic, from the standpoint of, for example, influence on the skin, the layered double hydroxide preferably has, within the above-described pH range, a weakly acidic pH value of about 6 to a neutral pH value of about 7.
[0027] (Bivalent Metal Atom)
[0028] The bivalent metal atom forming the base layers of a layered double hydroxide according to the present invention is not particularly limited. Various bivalent metal atoms such as Zn, Mg, Mn, Fe, Co, Ni, Cu, and Ca can be used. From the standpoint of, for example, stability, safety, and selective adsorbability of the layered double hydroxide, any one of Zn, Mg, and a mixture of Zn and Mg is preferably used.
(Trivalent Metal Atom)
[0029] The trivalent metal atom forming the base layers of a layered double hydroxide according to the present invention is also not particularly limited. Various trivalent metal atoms such as Al, Cr, Fe, Co, In, and Mn can be used. From the standpoint of, for example, stability and ease of production of the layered double hydroxide, Al is preferably used.
(Intercalation Compound)
[0030] An anion forming the intermediate layer of a layered double hydroxide according to the present invention needs to be selected from compounds represented by the following chemical formulae.
[0000] R 1 —COOH [Formula 1]
[0000] (wherein R 1 represents at least one substituent selected from an aliphatic hydrocarbon group, a substituted aliphatic hydrocarbon group, an aromatic hydrocarbon group, a substituted aromatic hydrocarbon group, a heterocyclic group and a substituted heterocyclic group)
[0000] R 2 —SO 3 H [Formula 2]
[0000] (wherein R 2 represents at least one substituent selected from an aliphatic hydrocarbon group, a substituted aliphatic hydrocarbon group, an aromatic hydrocarbon group, a substituted aromatic hydrocarbon group, a heterocyclic group and a substituted heterocyclic group).
[0031] Examples of the aliphatic hydrocarbon group include an alkyl group, an alkenyl group, an alkynyl group, and a cycloalkyl group.
[0032] Examples of the aromatic hydrocarbon group include a phenyl group, a naphthyl group, an anthryl group, and a phenanthryl group.
[0033] Examples of the heterocyclic group include a pyridyl group, a furanyl group, a pyranyl group, a thienyl group, a pyrrolidinyl group, an imidazolyl group, an imidazolinyl group, an imidazolidinyl group, a pyrazolyl group, a pyrazolinyl group, a pyrazolidinyl group, a pyridazinyl group, a pyrazinyl group, a piperidinyl group, a piperazinyl group, a thiolanyl group, a thianyl group, a quinolyl group, an isoquinolyl group, a benzofuranyl group, a benzothienyl group, an indolyl group, a carbazolyl group, a benzooxazolyl group, a benzothiazolyl group, a quinoxalyl group, a benzoimidazolyl group, a pyrazolyl group, a dibenzofuranyl group, a dibenzothienyl group, and a carbolinyl group.
[0034] Specific examples of Formula 1 wherein R 1 represents a substituted aliphatic hydrocarbon group include butanoic acid (butyric acid), pentanoic acid (valeric acid), hexanoic acid (caproic acid), heptanoic acid (enanthic acid), octanoic acid (caprylic acid), nonanoic acid (pelargonic acid), decanoic acid (capric acid), dodecanoic acid (lauric acid), tetradecanoic acid (myristic acid), pentadecanoic acid (pentadecylic acid), hexadecanoic acid (palmitic acid), heptadecanoic acid (margaric acid), octadecanoic acid (stearic acid), eicosanoic acid (arachidic acid), docosanoic acid (behenic acid), isobutyric acid, isopentanoic acid, pivalic acid, isohexanoic acid, isoheptanoic acid, isooctanoic acid, dimethyloctanoic acid, isononanoic acid, isodecanoic acid, isoundecanoic acid, isododecanoic acid, isotridecanoic acid, isotetradecanoic acid, isopentadecanoic acid, isohexadecanoic acid, isoheptadecanoic acid, isooctadecanoic acid, 4-aminobutyric acid, 6-aminohexanoic acid, tranexamic acid, and sodium N-lauroylsarcosinate.
[0035] Specific examples wherein R 1 represents a substituted aromatic hydrocarbon group include salicylic acid, benzoic acid, hydroxybenzoic acid, aminobenzoic acid, methoxybenzoic acid (anisic acid), and cinnamic acid.
[0036] Specific examples wherein R 1 represents a substituted heterocyclic group include picolinic acid and pyrrolidonecarboxylic acid (PCA).
[0037] Specific examples wherein R 2 represents a substituted aliphatic hydrocarbon group include taurine.
[0038] Specific examples wherein R 2 represents a substituted aromatic hydrocarbon group include phenolsulfonic acid and p-toluenesulfonic acid (PTS).
[0039] Specific examples wherein R 2 represents a substituted heterocyclic group include sodium benzotriazolylbutylphenolsulfonate, hydroxybenzophenonesulfonic acid, and dihydroxydimethoxybenzophenone disulfonic acid.
[0040] Incidentally, the above-described compounds may be various isomers. Such compounds may be used alone or in combination. Such compounds may be various derivatives or metal salts such as sodium salts or zinc salts.
[0041] Of these, from the standpoint of achieving a neutral pH value (i.e., a weakly acidic to weakly alkaline pH value) upon being dispersed in water and selective adsorbability to unsaturated fatty acids, preferably used are salicylic acid, hydroxybenzoic acid, aminobenzoic acid, methoxybenzoic acid (anisic acid), pentanoic acid (valeric acid), dodecanoic acid (lauric acid), octadecanoic acid (stearic acid), docosanoic acid (behenic acid), isopentanoic acid, isododecanoic acid, isooctadecanoic acid, 4-aminobutyric acid, 6-aminohexanoic acid, tranexamic acid, picolinic acid, taurine, pyrrolidonecarboxylic acid (PCA), and sodium N-lauroylsarcosinate.
[0042] In addition, from the standpoint of achieving a weakly acidic pH value of about 6 to a neutral pH value of about 7 upon being dispersed in water, preferably used are benzoic acid, hydroxybenzoic acid, aminobenzoic acid, methoxybenzoic acid (anisic acid), pentanoic acid (valeric acid), dodecanoic acid (lauric acid), isooctadecanoic acid, tranexamic acid, pyrrolidonecarboxylic acid (PCA), sodium N-lauroylsarcosinate, phenolsulfonic acid, and p-toluenesulfonic acid (PTS).
(Molar Ratio of Intercalation Compound to Base Layers)
[0043] In a layered double hydroxide according to the present invention, a ratio of an intercalation compound to base layers is appropriately adjusted in accordance with, for example, the combination of bivalent and trivalent metal atoms and the intercalation compound and a target pH at the time of use as a cosmetic. In particular, from the standpoint of adsorbability to unsaturated fatty acids and pH upon being dispersed in water, the ratio preferably satisfies the intercalation compound/base layers=0.05/1 to 5/1 (molar ratio), more preferably intercalation compound/base layers=0.1/1 to 4/1 (molar ratio), still more preferably intercalation compound/base layers=1/1 to 4/1 (molar ratio).
(Production Method)
[0044] As a method for producing a layered double hydroxide according to the present invention, known methods for producing layered double hydroxides can be used, such as the coprecipitation method, the ion exchange method, and the reconstruction method.
[0045] Specifically, the coprecipitation method for producing a layered double hydroxide is as follows: an aqueous solution mixture of bivalent and trivalent metal ions is added to an anion aqueous solution of the intercalation compound to cause hydrolysis for the metal ions, so that a metal double hydroxide forming base layers is formed and the intercalation compound is incorporated as an intermediate layer.
[0046] The ion exchange method is as follows: a layered double hydroxide in which anions having a low charge density are incorporated as an intermediate layer is produced in advance; and the layered double hydroxide is subsequently added to an anion aqueous solution of a desired intercalation compound to cause ion exchange from the earlier incorporated anions, to thereby produce a desired layered double hydroxide.
[0047] The reconstruction method is a method for producing a layered double hydroxide by the following procedures. First, what is called the carbonate layered double hydroxide (carbonate LDH) in which carbonate ions are incorporated as an intermediate layer is produced in advance. Subsequently, the carbonate LDH is fired (thermally decomposed) to cause decomposition of carbonate ions, emission of carbonic acid gas, release of interlayer water, and dehydration condensation of metal hydroxide forming base layers to produce a thermal decomposition product. Finally, this thermal decomposition product is added to or immersed in an anion aqueous solution of an intercalation compound; subsequently a process such as filtration or decantation is optionally used to remove excess anion component; and precipitate is collected. Thus, a desired layered double hydroxide is produced.
[0048] Of the above-described methods, the reconstruction method is preferably employed because of ease of synthesis, for example.
(Cosmetic)
[0049] As described above, a layered double hydroxide according to the present invention has a neutral pH value (i.e., a weakly acidic to weakly alkaline pH value) upon being dispersed in water. Accordingly, the layered double hydroxide itself without being subjected to neutralization treatment or the like can be added as a raw material for a cosmetic. As a result, the cosmetic which has selective adsorbability to specific unsaturated fatty acids such as oleic acid can be produced.
[0050] The amount of a layered double hydroxide according to the present invention added for producing a cosmetic is not particularly limited and is appropriately determined in accordance with the need.
Advantageous Effects of Invention
[0051] For a layered double hydroxide according to the present invention, benzoic acid or a derivative thereof is intercalated between two- or three-component base layers. This provides a layered double hydroxide which has a neutral pH value (i.e., a weakly acidic to weakly alkaline pH value) upon being dispersed in water and has selective adsorbability to specific unsaturated fatty acids such as oleic acid. Also, the layered double hydroxide obtained does not have an odor such as acetic acid odor.
[0052] A cosmetic according to the present invention, the cosmetic being produced using this layered double hydroxide, has selective adsorbability to unsaturated fatty acids. Accordingly, the cosmetic can effectively address makeup coming off and shine.
[0053] In particular, a layered double hydroxide according to the present invention employs specific metal ions and a specific compound for base layers and an intermediate layer. Accordingly, a layered double hydroxide which has higher selective adsorbability to unsaturated fatty acids can be obtained.
DESCRIPTION OF EMBODIMENTS
[0054] Hereinafter, a layered double hydroxide according to the present invention and a cosmetic produced using this layered double hydroxide will be described in detail with reference to examples. However, the present invention is not limited to the following examples.
EXAMPLES
Example 1
[0055] First, to a 1 mol/l Na 2 CO 3 aqueous solution (2 l), a 1 mol/l ZnCl 2 aqueous solution (2.6 l) and a 1 mol/l AlCl 3 aqueous solution (1.4 l) were dropped while the pH of the reaction solution was maintained to be 7; and the solution was aged at 40° C. for 1 hour. After that, the supernatant fluid of the mixture was removed; a 1 mol/l Na 2 CO 3 aqueous solution (2 l) was subsequently added; and the mixture was heated at reflux for 5 hours. The resultant precipitate was collected, rinsed with water, and then vacuum-dried and pulverized at 60° C. for 24 hours to provide a Zn—Al-based carbonate LDH.
[0056] Subsequently, this Zn—Al-based carbonate LDH was heated at 450° C. for 20 hours to provide a thermal decomposition product.
[0057] Subsequently, 4.2 g of benzoic acid was added to 100 ml of water. Then, 1.37 g of sodium hydroxide was added and the solution was stirred to dissolve benzoic acid. To this aqueous solution, 11.8 g of the thermal decomposition product was added and the solution was stirred at room temperature for 15 hours to provide precipitate. In this case, the molar ratio (B/A) of benzoic acid (B) to base layers (A) was 1.25/1.
[0058] Finally, the precipitate was collected and then dried at 90° C. for 20 hours and pulverized to provide a layered double hydroxide of Example 1 in which benzoic acid was intercalated.
Example 2
[0059] A layered double hydroxide of Example 2 was obtained as in Example 1 except that the sodium hydroxide was changed to 2.34 g of 25% by weight of aqueous ammonia.
Example 3
[0060] A layered double hydroxide of Example 3 was obtained as in Example 1 except that the amount of the thermal decomposition product was changed to 7.5 g. In this case, the molar ratio (B/A) of benzoic acid (B) to base layers (A) was 2/1.
Example 4
[0061] A layered double hydroxide of Example 4 was obtained as in Example 1 except that the amount of the thermal decomposition product was changed to 7.5 g and the benzoic acid was changed to 4.8 g of salicylic acid. In this case, the molar ratio (B/A) of salicylic acid (B) to base layers (A) was 2/1.
Example 5
[0062] A layered double hydroxide of Example 5 was obtained as in Example 1 except that the amount of the thermal decomposition product was changed to 7.5 g and the benzoic acid was changed to 5.2 g of p-anisic acid. In this case, the molar ratio (B/A) of p-anisic acid (B) to base layers (A) was 2/1.
Example 6
[0063] A layered double hydroxide of Example 6 was obtained as in Example 5 except that the sodium hydroxide was changed to 2.34 g of 25% by weight of aqueous ammonia.
Example 7
[0064] First, a Mg—Al-based carbonate LDH (DHT-6 manufactured by Kyowa Chemical Industry Co., Ltd.) was heated at 700° C. for 20 hours to provide a thermal decomposition product.
[0065] Subsequently, 2.1 g of benzoic acid was added to 100 ml of water. Then, 0.69 g of sodium hydroxide was added and the solution was stirred to dissolve benzoic acid. To this aqueous solution, 60 g of the thermal decomposition product was added and the solution was stirred at room temperature for 15 hours to provide precipitate. In this case, the molar ratio (B/A) of benzoic acid (B) to base layers (A) was 0.1/1.
[0066] Finally, the precipitate was collected, subsequently dried at 90° C. for 20 hours and pulverized to provide a layered double hydroxide of Example 7 in which benzoic acid was intercalated.
Example 8
[0067] A layered double hydroxide of Example 8 was obtained as in Example 7 except that the amount of the thermal decomposition product was changed to 30 g, the amount of benzoic acid was changed to 5.2 g, and the amount of sodium hydroxide was changed to 1.73 g. In this case, the molar ratio (B/A) of benzoic acid (B) to base layers (A) was 0.5/1.
Example 9
[0068] A layered double hydroxide of Example 9 was obtained as in Example 7 except that the amount of the thermal decomposition product was changed to 7.4 g, the amount of benzoic acid was changed to 5.2 g, and the amount of sodium hydroxide was changed to 1.73 g. In this case, the molar ratio (B/A) of benzoic acid (B) to base layers (A) was 2/1.
Example 10
[0069] A layered double hydroxide of Example 10 was obtained as in Example 7 except that the amount of the thermal decomposition product was changed to 5.9 g, the benzoic acid was changed to 5.2 g of p-anisic acid, and the amount of sodium hydroxide was changed to 1.37 g. In this case, the molar ratio (B/A) of p-anisic acid (B) to base layers (A) was 2/1.
Example 11
[0070] A layered double hydroxide of Example 11 was obtained as in Example 10 except that the sodium hydroxide was changed to 2.34 g of 25% by weight of aqueous ammonia.
Example 12
[0071] First, a Zn—Mg—Al-based carbonate LDH (ALCAMIZER manufactured by Kyowa Chemical Industry Co., Ltd.) was heated at 600° C. for 20 hours to provide a thermal decomposition product.
[0072] Subsequently, 4.2 g of benzoic acid was added to 100 ml of water. Then, 1.37 g of sodium hydroxide was added and the solution was stirred to dissolve benzoic acid. To this aqueous solution, 41.9 g of the thermal decomposition product was added and the solution was stirred at room temperature for 15 hours to provide precipitate. In this case, the molar ratio (B/A) of benzoic acid (B) to base layers (A) was 0.25/1.
[0073] Finally, the precipitate was collected, subsequently dried at 90° C. for 20 hours and pulverized to provide a layered double hydroxide of Example 12 in which benzoic acid was intercalated.
Example 13
[0074] A layered double hydroxide of Example 13 was obtained as in Example 12 except that the amount of the thermal decomposition product was changed to 8.4 g. In this case, the molar ratio (B/A) of benzoic acid (B) to base layers (A) was 1.25/1.
Example 14
[0075] A layered double hydroxide of Example 14 was obtained as in Example 12 except that the amount of the thermal decomposition product was changed to 5.2 g. In this case, the molar ratio (B/A) of benzoic acid (B) to base layers (A) was 2/1.
Example 15
[0076] A layered double hydroxide of Example 15 was obtained as in Example 14 except that the sodium hydroxide was changed to 2.34 g of 25% by weight of aqueous ammonia.
Example 16
[0077] A layered double hydroxide of Example 16 was obtained as in Example 14 except that the benzoic acid was changed to 4.7 g of salicylic acid. In this case, the molar ratio (B/A) of salicylic acid (B) to base layers (A) was 2/1.
Example 17
[0078] A layered double hydroxide of Example 17 was obtained as in Example 14 except that the benzoic acid was changed to 4.7 g of 3-hydroxybenzoic acid. In this case, the molar ratio (B/A) of 3-hydroxybenzoic acid (B) to base layers (A) was 2/1.
Example 18
[0079] A layered double hydroxide of Example 18 was obtained as in Example 14 except that the benzoic acid was changed to 4.7 g of p-aminobenzoic acid. In this case, the molar ratio (B/A) of 3-hydroxybenzoic acid (B) to base layers (A) was 2/1.
Example 19
[0080] A layered double hydroxide of Example 19 was obtained as in Example 12 except that the amount of the thermal decomposition product was changed to 5.3 g, the benzoic acid was changed to 1.6 g of p-anisic acid, and the amount of sodium hydroxide was changed to 0.42 g. In this case, the molar ratio (B/A) of p-anisic acid (B) to base layers (A) was 0.6/1.
Example 20
[0081] A layered double hydroxide of Example 20 was obtained as in Example 19 except that the amount of p-anisic acid was changed to 2.6 g and the amount of sodium hydroxide was changed to 0.68 g. In this case, the molar ratio (B/A) of p-anisic acid (B) to base layers (A) was 1/1.
Example 21
[0082] A layered double hydroxide of Example 21 was obtained as in Example 19 except that the amount of p-anisic acid was changed to 3.8 g and the amount of sodium hydroxide was changed to 1 g. In this case, the molar ratio (B/A) of p-anisic acid (B) to base layers (A) was 1.45/1.
Example 22
[0083] A layered double hydroxide of Example 22 was obtained as in Example 19 except that the amount of p-anisic acid was changed to 4.7 g and the amount of sodium hydroxide was changed to 1.24 g. In this case, the molar ratio (B/A) of p-anisic acid (B) to base layers (A) was 1.8/1.
Example 23
[0084] A layered double hydroxide of Example 23 was obtained as in Example 22 except that the sodium hydroxide was changed to 2.1 g of 25% by weight of aqueous ammonia. In this case, the molar ratio (B/A) of p-anisic acid (B) to base layers (A) was 1.8/1.
Example 24
[0085] A layered double hydroxide of Example 24 was obtained as in Example 23 except that the amount of p-anisic acid was changed to 5.2 g and the amount of 25% by weight of aqueous ammonia was changed to 2.34 g. In this case, the molar ratio (B/A) of p-anisic acid (B) to base layers (A) was 2/1.
Example 25
[0086] A layered double hydroxide of Example 25 was obtained as in Example 23 except that the amount of p-anisic acid was changed to 5.7 g and the amount of 25% by weight of aqueous ammonia was changed to 2.57 g. In this case, the molar ratio (B/A) of p-anisic acid (B) to base layers (A) was 2.2/1.
Example 26
[0087] First, a Zn—Al-based carbonate LDH was produced as in Example 1.
[0088] Subsequently, this Zn—Al-based carbonate LDH was heated at 450° C. for 20 hours to provide a thermal decomposition product.
[0089] Subsequently, 6 g of 3-hydroxybenzoic acid was added to 100 ml of water. Then, 1.73 g of sodium hydroxide was added and the solution was stirred to dissolve 3-hydroxybenzoic acid. To this aqueous solution, 6 g of the thermal decomposition product was added and the solution was stirred at room temperature for 15 hours to provide precipitate. In this case, the molar ratio (B/A) of 3-hydroxybenzoic acid (B) to base layers (A) was 2/1.
[0090] Finally, the precipitate was collected, subsequently dried at 90° C. for 20 hours and pulverized to provide a layered double hydroxide of Example 26 in which 3-hydroxybenzoic acid was intercalated.
Example 27
[0091] A layered double hydroxide of Example 27 was obtained as in Example 26 except that the 3-hydroxybenzoic acid was changed to 6 g of p-aminobenzoic acid. In this case, the molar ratio (B/A) of p-aminobenzoic acid (B) to base layers (A) was 2/1.
Example 28
[0092] A layered double hydroxide of Example 28 was obtained as in Example 26 except that the 3-hydroxybenzoic acid was changed to 6 g of pentanoic acid. In this case, the molar ratio (B/A) of pentanoic acid (B) to base layers (A) was 4/1.
Example 29
[0093] A layered double hydroxide of Example 29 was obtained as in Example 26 except that the 3-hydroxybenzoic acid was changed to 6 g of dodecanoic acid. In this case, the molar ratio (B/A) of dodecanoic acid (B) to base layers (A) was 2/1.
Example 30
[0094] A layered double hydroxide of Example 30 was obtained as in Example 26 except that the 3-hydroxybenzoic acid was changed to 3 g of dodecanoic acid. In this case, the molar ratio (B/A) of dodecanoic acid (B) to base layers (A) was 1/1.
Example 31
[0095] A layered double hydroxide of Example 31 was obtained as in Example 26 except that the 3-hydroxybenzoic acid was changed to 6 g of tetradecanoic acid. In this case, the molar ratio (B/A) of tetradecanoic acid (B) to base layers (A) was 1/1.
Example 32
[0096] A layered double hydroxide of Example 32 was obtained as in Example 26 except that the 3-hydroxybenzoic acid was changed to 6 g of hexadecanoic acid. In this case, the molar ratio (B/A) of hexadecanoic acid (B) to base layers (A) was 1/1.
Example 33
[0097] A layered double hydroxide of Example 33 was obtained as in Example 26 except that the 3-hydroxybenzoic acid was changed to 6 g of octadecanoic acid. In this case, the molar ratio (B/A) of octadecanoic acid (B) to base layers (A) was 2/1.
Example 34
[0098] A layered double hydroxide of Example 34 was obtained as in Example 26 except that the 3-hydroxybenzoic acid was changed to 3 g of octadecanoic acid. In this case, the molar ratio (B/A) of octadecanoic acid (B) to base layers (A) was 1/1.
Example 35
[0099] A layered double hydroxide of Example 35 was obtained as in Example 26 except that the 3-hydroxybenzoic acid was changed to 6 g of docosanoic acid. In this case, the molar ratio (B/A) of docosanoic acid (B) to base layers (A) was 1/1.
Example 36
[0100] A layered double hydroxide of Example 36 was obtained as in Example 26 except that the 3-hydroxybenzoic acid was changed to 6 g of isooctadecanoic acid. In this case, the molar ratio (B/A) of isooctadecanoic acid (B) to base layers (A) was 2/1.
Example 37
[0101] A layered double hydroxide of Example 37 was obtained as in Example 26 except that the 3-hydroxybenzoic acid was changed to 3 g of isooctadecanoic acid. In this case, the molar ratio (B/A) of isooctadecanoic acid (B) to base layers (A) was 1/1.
Example 38
[0102] A layered double hydroxide of Example 38 was obtained as in Example 26 except that the 3-hydroxybenzoic acid was changed to 6 g of 4-aminobutyric acid. In this case, the molar ratio (B/A) of 4-aminobutyric acid (B) to base layers (A) was 4/1.
Example 39
[0103] A layered double hydroxide of Example 39 was obtained as in Example 26 except that the 3-hydroxybenzoic acid was changed to 6 g of 6-aminohexanoic acid. In this case, the molar ratio (B/A) of 6-aminohexanoic acid (B) to base layers (A) was 3.3/1.
Example 40
[0104] A layered double hydroxide of Example 40 was obtained as in Example 26 except that the 3-hydroxybenzoic acid was changed to 6 g of tranexamic acid. In this case, the molar ratio (B/A) of tranexamic acid (B) to base layers (A) was 2.7/1.
Example 41
[0105] A layered double hydroxide of Example 41 was obtained as in Example 26 except that the 3-hydroxybenzoic acid was changed to 6 g of picolinic acid. In this case, the molar ratio (B/A) of picolinic acid (B) to base layers (A) was 3.5/1.
Example 42
[0106] A layered double hydroxide of Example 42 was obtained as in Example 26 except that the 3-hydroxybenzoic acid was changed to 6 g of taurine. In this case, the molar ratio (B/A) of taurine (B) to base layers (A) was 3.5/1.
Example 43
[0107] A layered double hydroxide of Example 43 was obtained as in Example 26 except that the 3-hydroxybenzoic acid was changed to 6 g of pyrrolidonecarboxylic acid. In this case, the molar ratio (B/A) of pyrrolidonecarboxylic acid (B) to base layers (A) was 3.3/1.
Example 44
[0108] A layered double hydroxide of Example 44 was obtained as in Example 26 except that the 3-hydroxybenzoic acid was changed to 6 g of sodium N-lauroylsarcosinate. In this case, the molar ratio (B/A) of sodium N-lauroylsarcosinate (B) to base layers (A) was 1.5/1.
Example 45
[0109] A layered double hydroxide of Example 45 was obtained as in Example 26 except that the 3-hydroxybenzoic acid was changed to 6 g of phenolsulfonic acid. In this case, the molar ratio (B/A) of phenolsulfonic acid (B) to base layers (A) was 2/1.
Example 46
[0110] A layered double hydroxide of Example 46 was obtained as in Example 26 except that the 3-hydroxybenzoic was changed to 6 g of p-toluenesulfonic acid. In this case, the molar ratio (B/A) of p-toluenesulfonic acid (B) to base layers (A) was 2.5/1.
Comparative Example 1
[0111] A layered double hydroxide of Comparative example 1 was obtained as in Example 7 except that the amount of the thermal decomposition product was changed to 10.1 g and the benzoic acid was changed to 6.3 g of magnesium acetate tetrahydrate, which was dissolved in water without use of sodium hydroxide. In this case, the molar ratio (B/A) of magnesium acetate (B) to base layers (A) was 1/1.
Comparative Example 2
[0112] A layered double hydroxide of Comparative example 2 was obtained as in Example 12 except that the amount of the thermal decomposition product was changed to 5.3 g and the benzoic acid was changed to 5.9 g of toluenesulfonic acid. In this case, the molar ratio (B/A) of toluenesulfonic acid (B) to base layers (A) was 2/1.
Comparative Example 3
[0113] The thermal decomposition product of the Zn—Mg—Al-based carbonate LDH to be subjected to the intercalation treatment (the thermal decomposition product used for the layered double hydroxide of Example 12) was defined as a layered double hydroxide of Comparative example 3.
Comparative Example 4
[0114] The Zn—Mg—Al-based carbonate LDH to be subjected to the thermal decomposition product was defined as a layered double hydroxide of Comparative example 4.
[0115] Subsequently, Examples and Comparative examples were subjected to pH measurement, odor evaluation, water repellency evaluation, and evaluation of adsorbability to unsaturated fatty acids.
(pH Measurement)
[0116] The pH measurement for each of the layered double hydroxides of Examples and Comparative examples was performed by measuring the pH of a dispersion of 1% by weight hydroxide in pure water. The results are described in Table 1 and Table 2.
(Odor Evaluation)
[0117] The odor evaluation was performed by using a sensory evaluation in which five male and five female evaluators (in total ten evaluators) evaluate the odor of each of the layered double hydroxides of Examples and Comparative examples. The results are described in Table 1 and Table 2.
(Water Repellency Evaluation)
[0118] The water repellency evaluation was performed by using the following procedures. The results are described in Table 1 and Table 2.
[0119] 1) Place 50 ml of water into a graduated cylinder.
[0120] 2) Place 1.0 g of a layered double hydroxide into the graduated cylinder prepared in 1).
[0121] 3) Perform agitation for the graduated cylinder prepared in 2) by turning the cylinder upside down ten times with the opening being closed by hand.
[0122] 4) After the agitation, leave the graduated cylinder at rest and determine by observation as to whether the layered double hydroxide floats on the water surface without being dispersed in water (whether the layered double hydroxide has water repellency) or not.
(Evaluation of Adsorbability to Unsaturated Fatty Acids)
[0123] The evaluation for adsorbability to unsaturated fatty acids (selective adsorbability to sebum components) was performed in the following manner.
[0124] First, 0.5 g of each of the layered double hydroxides of Examples and Comparative examples was weighed and placed into 10 ml sample tubes. To these tubes, 1.5 g of fats and oils were added and then stirred with a pencil mixer for 5 minutes to prepare samples.
[0125] Subsequently, the fluidity of each sample after the lapse of 5 minutes was evaluated in accordance with the following evaluation system. The fats and oils were oleic acid, triolein, squalene, glyceryl tri(caprylate/caprate), glyceryl tri(2-ethylhexanoate), and liquid paraffin. The results are described in Table 1 and Table 2.
[Evaluation System]
[0126] A: after the lapse of 2 minutes, no fluidity is observed and solidification is observed
[0127] B: no fluidity is observed and solidification is observed
[0128] C: fluidity and thickening are observed
[0129] D: fluidity and no thickening are observed
[0000]
TABLE 1
Evaluation items
pH of 1 wt %
Base layers
Intercalation compound
Molar ratio
aqueous
Acetic acid
Water
(A)
(B)
(B/A)
dispersion
odor
repellency
Example 1
Zn—Al
benzoic acid
1.25/1
8.5
Absent
Absent
Example 2
1.25/1
6.1
Absent
Absent
Example 3
2.0/1
8.3
Absent
Absent
Example 4
salicylic acid
2.0/1
8.5
Absent
Absent
Example 5
p-anisic acid
2.0/1
8.4
Absent
Absent
Example 6
2.0/1
6.1
Absent
Absent
Example 7
Mg—Al
benzoic acid
0.1/1
8.5
Absent
Absent
Example 8
0.5/1
8.4
Absent
Absent
Example 9
2.0/1
8.4
Absent
Absent
Example 10
p-anisic acid
2.0/1
8.5
Absent
Absent
Example 11
2.0/1
8.3
Absent
Absent
Example 12
Mg—Zn—Al
benzoic acid
0.25/1
8.4
Absent
Absent
Example 13
1.25/1
8.3
Absent
Absent
Example 14
2.0/1
8.3
Absent
Absent
Example 15
2.0/1
6.0
Absent
Absent
Example 16
salicylic acid
2.0/1
8.3
Absent
Absent
Example 17
3-hydroxybenzoic acid
2.0/1
8.4
Absent
Absent
Example 18
p-aminobenzoic acid
2.0/1
8.5
Absent
Absent
Example 19
p-anisic acid
0.6/1
8.6
Absent
Absent
Example 20
1/1
8.4
Absent
Absent
Example 21
1.45/1
8.5
Absent
Absent
Example 22
1.8/1
8.3
Absent
Absent
Example 23
1.8/1
6.2
Absent
Absent
Example 24
2/1
6.2
Absent
Absent
Example 25
2.2/1
6.3
Absent
Absent
Comparative
Mg—Al
Mg acetate•4H 2 O
1/1
10.0
Acetic acid
Absent
example 1
odor
Comparative
Mg—Zn—Al
toluenesulfonic acid
2.0/1
8.4
Absent
Absent
example 2
Comparative
Mg—Zn—Al
None
—
10.0
Absent
Absent
example 3
Comparative
Mg—Zn—Al
carbonate ion
—
10.0
Absent
Absent
example 4
Evaluation items
Evaluation for adsorbability to unsaturated fatty acids
Oleic
Glyceryl
Glyceryl tri(2-
Liquid
acid
Triolein
Squalene
tri(caprylate/caprate)
ethylhexanoate)
paraffin
Example 1
B
D
D
D
D
D
Example 2
B
D
D
D
D
D
Example 3
B
D
D
D
D
D
Example 4
B
D
D
D
D
D
Example 5
B
D
D
D
D
D
Example 6
A
D
D
D
D
D
Example 7
B
D
D
D
D
D
Example 8
B
D
D
D
D
D
Example 9
B
D
D
D
D
D
Example 10
B
D
D
D
D
D
Example 11
B
D
D
D
D
D
Example 12
B
D
D
D
D
D
Example 13
B
D
D
D
D
D
Example 14
B
D
D
D
D
D
Example 15
B
D
D
D
D
D
Example 16
B
D
D
D
D
D
Example 17
B
D
D
D
D
D
Example 18
B
D
D
D
D
D
Example 19
B
D
D
D
D
D
Example 20
B
D
D
D
D
D
Example 21
B
D
D
D
D
D
Example 22
B
D
D
D
D
D
Example 23
B
D
D
D
D
D
Example 24
B
D
D
D
D
D
Example 25
B
D
D
D
D
D
Comparative
B
D
D
D
D
D
example 1
Comparative
C
C
C
C
C
C
example 2
Comparative
D
D
D
D
D
D
example 3
Comparative
D
D
D
D
D
D
example 4
[0000]
TABLE 2
Evaluation items
Base
Molar
pH of 1 wt %
layers
Intercalation
ratio
aqueous
Acetic
Water
(A)
compound (B)
(B/A)
dispersion
acid odor
repellency
Example 26
Zn—Al
3-hydroxybenzoic
2.0/1
7.5
Absent
Absent
acid
Example 27
p-aminobenzoic acid
2.0/1
7.5
Absent
Absent
Example 28
pentanoic acid
4.0/1
7.2
Absent
Present
Example 29
dodecanoic acid
2.0/1
7.2
Absent
Present
Example 30
1.0/1
6.8
Absent
Present
Example 31
tetradecanoic acid
1.0/1
7.5
Absent
Present
Example 32
hexadecanoic acid
1.0/1
8.0
Absent
Present
Example 33
octadecanoic acid
2.0/1
8.0
Absent
Present
Example 34
1.0/1
8.0
Absent
Present
Example 35
docosanoic acid
1.0/1
8.0
Absent
Present
Example 36
isooctadecanoic acid
2.0/1
7.2
Absent
Present
Example 37
1.0/1
7.5
Absent
Present
Example 38
4-aminobutyric acid
4.0/1
8.5
Absent
Absent
Example 39
6-aminohexanoic
3.3/1
8.9
Absent
Absent
acid
Example 40
tranexamic acid
2.7/1
7.2
Absent
Absent
Example 41
picolinic acid
3.5/1
7.8
Absent
Absent
Example 42
taurine
3.5/1
7.8
Absent
Absent
Example 43
pyrrolidonecarboxylic
3.3/1
6.5
Absent
Absent
acid
Example 44
Na N-
1.5/1
7.5
Absent
Present
lauroylsarcosinate
Example 45
phenolsulfonic acid
2.0/1
7.5
Absent
Absent
Example 46
p-toluenesulfonic
2.5/1
7.0
Absent
Absent
acid
Evaluation items
Evaluation for adsorbability to unsaturated fatty acids
Oleic
Glyceryl
Glyceryl tri(2-
Liquid
acid
Triolein
Squalene
tri(caprylate/caprate)
ethylhexanoate)
paraffin
Example 26
B
D
D
D
D
D
Example 27
B
D
D
D
D
D
Example 28
B
D
D
D
D
D
Example 29
A
D
D
D
D
D
Example 30
A
D
D
D
D
D
Example 31
A
D
D
D
D
D
Example 32
A
D
D
D
D
D
Example 33
A
D
D
D
D
D
Example 34
A
D
D
D
D
D
Example 35
B
D
D
D
D
D
Example 36
B
D
D
D
D
D
Example 37
B
D
D
D
D
D
Example 38
B
D
D
D
D
D
Example 39
B
D
D
D
D
D
Example 40
B
D
D
D
D
D
Example 41
B
D
D
D
D
D
Example 42
B
D
D
D
D
D
Example 43
B
D
D
D
D
D
Example 44
B
D
D
D
D
D
Example 45
B
D
D
D
D
D
Example 46
A
D
D
D
D
D
[0130] The results in Table 1 and Table 2 indicate that all the layered double hydroxides of Examples in which specific compounds are intercalated have neutral pH values of 5 to 9 upon being dispersed in water, no odor, and selective adsorbability to unsaturated fatty acids (in particular, oleic acid). In particular, the layered double hydroxides of Examples 2, 6, 15, 23 to 31, 36, 37, 40, and 43 to 46 have no odor, selective adsorbability to unsaturated fatty acids (in particular, oleic acid), and a weakly acidic pH value of about 6 to a neutral pH value of about 7 upon being dispersed in water, so that these layered double hydroxides have been found to be ideal layered double hydroxides. In particular, of these, the layered double hydroxides of Examples 6, 29 to 34, and 46 have been found to have a higher selective adsorbability to unsaturated fatty acids (in particular, oleic acid) than the layered double hydroxides of the other Examples.
[0131] In Examples, in particular, the layered double hydroxides of Examples 28 to 37 and 44 have been found to have higher water repellency than the layered double hydroxides of the other Examples. Accordingly, use of layered double hydroxides of Examples 28 to 37 and 44 for cosmetics can impart, in addition to selective adsorbability to unsaturated fatty acids (in particular, oleic acid), water repellency to the cosmetics. As a result, makeup coming off and shine can be more effectively prevented.
[0132] In contrast, the layered double hydroxide of Comparative example 2 has been found to have a neutral pH value of 5 to 9 upon being dispersed in water and no odor, but found to have nonspecific adsorbability to unsaturated fatty acids and beneficial components such as squalene. The layered double hydroxide of Comparative example 3 has been found to have selective adsorbability to unsaturated fatty acids (in particular, oleic acid), but found to have a strongly alkaline pH value of 10 upon being dispersed in water as described in paragraphs [0007] and [0008], and also found to have acetic acid odor. The layered double hydroxides of Comparative examples 3 and 4 in which the specific compounds were not intercalated exhibited no adsorbability.
(Evaluation for Cosmetic)
[0133] Subsequently, the layered double hydroxides of Examples and Comparative examples 2 to 4 were used to produce powder foundations. The powder foundations were evaluated by a sensory evaluation for the presence or absence of shine on the skin to which the powder foundations were applied, for five male and five female evaluators (in total ten evaluators). Specifically, the skin of each evaluator was evaluated in terms of shine by using a point system (1 point for an evaluator having no shine and 0 point for an evaluator having shine). The powder foundations were produced in the following manner: a powder serving as component A and a liquid serving as component B were separately prepared in accordance with the formulations in Table 3; and the liquid of component B was then gradually added to the powder of component A. The results are described in Table 4 and Table 5. Incidentally, Comparative example 1 was not subjected to this evaluation because of strong acetic acid odor.
[0000]
TABLE 3
Mixing
ratio
Cosmetic labeling
(% by
Trade names
names
weight)
Component A
TAROX LLXLO (manufactured by Titan Kogyo, Ltd.)
yellow iron oxide
1.41
TAROX R516-L (manufactured by Titan Kogyo, Ltd.)
red iron oxide
0.35
TAROX R110-7 (manufactured by Titan Kogyo, Ltd.)
red iron oxide
0.53
TAROX BL-100 (manufactured by Titan Kogyo, Ltd.)
black iron oxide
0.18
Mica R-1000 (manufactured by Kakuhachi Co., Ltd.)
mica
42.53
JA-80R (manufactured by ASADA MILLING CO., LTD.)
talc
20.00
Nylon 12 (manufactured by Toray Industries, Inc.)
nylon 6
5.00
MPY-1133 (manufactured by Tayca Corporation)
titanium oxide
8.00
Layered double hydroxide of Example or Comparative
10.00
example
Component B
Crodalan SWL (manufactured by Croda Japan KK)
purified lanoline
2.40
Squalane (manufactured by Nikko Chemicals Co., Ltd.)
squalane
2.40
COCONARD MT (manufactured by Kao Corporation)
glyceryl
1.80
tri(caprylate/caprate)
TIO (manufactured by The Nisshin OilliO Group, Ltd.)
trioctanoin
1.80
KF56 (manufactured by Shin-Etsu Chemical Co., Ltd.)
diphenylsiloxy phenyl
3.60
trimethicone
100.00
[0000]
TABLE 4
Evaluators
Males
Females
Total
Layered double hydroxide used
1
2
3
4
5
1
2
3
4
5
score
Example 47
Layered double hydroxide of Example 1
1
1
1
1
1
1
1
1
1
1
10
Example 48
Layered double hydroxide of Example 2
1
1
0
1
1
1
1
1
1
1
9
Example 49
Layered double hydroxide of Example 3
1
1
1
1
1
1
1
1
1
1
10
Example 50
Layered double hydroxide of Example 4
1
1
1
0
1
1
1
1
1
1
9
Example 51
Layered double hydroxide of Example 5
1
1
1
1
1
1
1
1
1
1
10
Example 52
Layered double hydroxide of Example 6
1
1
1
1
1
1
1
1
1
1
10
Example 53
Layered double hydroxide of Example 7
1
1
1
1
1
1
1
1
0
1
9
Example 54
Layered double hydroxide of Example 8
1
1
0
1
1
1
1
1
1
1
9
Example 55
Layered double hydroxide of Example 9
1
1
1
1
1
1
1
1
1
1
10
Example 56
Layered double hydroxide of Example 10
1
1
1
1
1
1
1
1
1
1
10
Example 57
Layered double hydroxide of Example 11
1
1
0
1
1
1
1
1
1
1
9
Example 58
Layered double hydroxide of Example 12
1
1
1
1
1
0
1
1
1
1
9
Example 59
Layered double hydroxide of Example 13
1
1
1
1
1
1
0
1
1
1
9
Example 60
Layered double hydroxide of Example 14
1
1
1
1
1
1
1
1
1
1
10
Example 61
Layered double hydroxide of Example 15
1
1
1
1
1
1
1
1
1
1
10
Example 62
Layered double hydroxide of Example 16
1
1
1
1
1
1
1
1
1
1
10
Example 63
Layered double hydroxide of Example 17
1
1
1
1
1
1
1
1
1
1
10
Example 64
Layered double hydroxide of Example 18
1
1
0
1
1
1
1
1
1
1
9
Example 65
Layered double hydroxide of Example 19
1
1
1
1
1
1
1
1
1
0
9
Example 66
Layered double hydroxide of Example 20
0
1
1
1
1
1
1
1
1
1
9
Example 67
Layered double hydroxide of Example 21
1
1
1
1
1
1
1
1
1
1
10
Example 68
Layered double hydroxide of Example 22
1
1
1
1
1
1
1
1
1
1
10
Example 69
Layered double hydroxide of Example 23
1
1
1
1
1
1
1
1
1
1
10
Example 70
Layered double hydroxide of Example 24
1
1
1
1
1
1
1
1
0
1
9
Example 71
Layered double hydroxide of Example 25
1
1
1
1
1
1
1
1
1
1
10
Comparative
Layered double hydroxide of Comparative example 2
0
1
0
0
0
0
0
1
0
1
3
example 5
Comparative
Layered double hydroxide of Comparative example 3
0
0
0
0
0
0
0
0
0
0
0
example 6
Comparative
Layered double hydroxide of Comparative example 4
0
0
0
0
0
0
0
0
0
0
0
example 7
[0000]
TABLE 5
Evaluators
Males
Females
Total
Layered double hydroxide used
1
2
3
4
5
1
2
3
4
5
score
Example 72
Layered double hydroxide of Example 26
1
1
1
1
0
1
1
1
1
1
9
Example 73
Layered double hydroxide of Example 27
1
0
1
1
1
1
1
1
1
1
9
Example 74
Layered double hydroxide of Example 28
1
0
1
1
1
1
1
1
1
1
9
Example 75
Layered double hydroxide of Example 29
1
1
1
1
1
1
1
1
1
1
10
Example 76
Layered double hydroxide of Example 30
1
1
1
1
1
1
1
1
1
1
10
Example 77
Layered double hydroxide of Example 31
1
1
1
1
1
1
1
1
1
1
10
Example 78
Layered double hydroxide of Example 32
1
1
1
1
1
1
1
1
1
1
10
Example 79
Layered double hydroxide of Example 33
1
1
1
1
1
1
1
1
1
1
10
Example 80
Layered double hydroxide of Example 34
1
1
1
1
1
1
1
1
1
1
10
Example 81
Layered double hydroxide of Example 35
1
1
1
0
1
1
1
1
1
1
9
Example 82
Layered double hydroxide of Example 36
1
1
1
1
1
1
1
1
1
0
9
Example 83
Layered double hydroxide of Example 37
1
1
1
1
1
1
1
0
1
1
9
Example 84
Layered double hydroxide of Example 38
1
1
1
1
0
1
1
1
1
1
9
Example 85
Layered double hydroxide of Example 39
0
1
1
1
1
1
1
1
1
1
9
Example 86
Layered double hydroxide of Example 40
1
1
0
1
1
1
1
1
1
1
9
Example 87
Layered double hydroxide of Example 41
1
1
1
0
1
1
1
1
1
1
9
Example 88
Layered double hydroxide of Example 42
0
1
1
1
1
1
1
1
1
1
9
Example 89
Layered double hydroxide of Example 43
1
1
1
1
1
0
1
1
1
1
9
Example 90
Layered double hydroxide of Example 44
1
1
1
1
0
1
1
1
1
1
9
Example 91
Layered double hydroxide of Example 45
1
1
1
0
1
1
1
1
1
1
9
Example 92
Layered double hydroxide of Example 46
1
1
1
1
1
1
1
1
1
1
10
[0134] The results in Table 4 and Table 5 indicate that the cosmetics of Examples 47 to 92 produced using the layered double hydroxides of Examples 1 to 46 do not cause shine in most of the evaluators and selective adsorbability to unsaturated fatty acids (in particular, oleic acid) is also provided in the form of cosmetics.
[0135] In contrast, the layered double hydroxides of Comparative examples 2 to 4 have low adsorbability to unsaturated fatty acids (oleic acid) and, as a result, cannot effectively prevent occurrence of shine in the form of cosmetics (Comparative examples 5 to 7).
[0136] As described above, regarding a layered double hydroxide according to the present invention and a cosmetic produced using this layered double hydroxide, a layered double hydroxide can be provided which has a neutral pH value (i.e., a weakly acidic to weakly alkaline pH value) upon being dispersed in water, has selective adsorbability to specific unsaturated fatty acids such as oleic acid, and does not have odor such as acetic acid odor.
INDUSTRIAL APPLICABILITY
[0137] A layered double hydroxide according to the present invention can be used for producing a cosmetic and, in particular, can be used for selective adsorption to unsaturated fatty acids such as oleic acid. | The layered double hydroxide is characterized by comprising base layers each comprising a metal double hydroxide represented by the formula: M(II)1-XM(III)X(OH)2 (wherein M(II) represents one or two bivalent metal atoms; M(III) represents a trivalent metal atom; and x represents 0.2 to 0.33), and an intermediate layer and interlayer water each intercalated between the base layers, wherein the intermediate layer comprises a compound represented by the formula: R1-COOH or R2-SO3H (wherein R1 and R2 independently represent at least one substituent selected from an aliphatic hydrocarbon group, a substituted aliphatic hydrocarbon group, an aromatic hydrocarbon group, a substituted aromatic hydrocarbon group, a heterocyclic group and a substituted heterocyclic group). | 0 |
NOTICE OF INTENT TO RESERVE COPYRIGHT OR MAST WORK RIGHTS
[0001] Not Applicable
CROSS-REFERENCE TO RELATED APPLICATIONS
[0002] Not Applicable
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0003] Not Applicable
REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTING COMPACT DISC APPENDIX
[0004] Not Applicable
BACKGROUND OF THE INVENTION
[0005] When transporting a bicycle on a vehicle bike carrier, the motion of the vehicle causes issues with bicycles on an external carrier. The free wheel (i.e., that without the friction of the chain and gear system) may rotate as the vehicle accelerates and decelerates. The turning can cause damage to the bike, or the transport vehicle. The movement can also be a distraction for the driver. Drivers who ‘tune out’ or ignore this movement as seen in mirrors or as reflections of vehicle surfaces can cause a driver to unintentionally miss other roadway hazards they mistakenly believe to be the bike's movement.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 illustrates a perspective view of a Free Wheel Lock in accordance with an exemplary embodiment of the invention.
[0007] FIG. 2A illustrates a frontal view of a Free Wheel Lock in accordance with an exemplary embodiment of the invention.
[0008] FIG. 2B illustrates a side view of a Free Wheel Lock.
[0009] FIG. 2C illustrates a cross sectional view of a Free Wheel Lock in accordance with an exemplary embodiment of the invention.
[0010] FIG. 3A illustrates a side view of a Free Wheel Lock in an opened position.
[0011] FIG. 3B shows a cross sectional view of a Free Wheel Lock in an opened position in accordance with an exemplary embodiment of the invention.
[0012] FIG. 4 shows an alternative assembly of a Free Wheel Lock in a rotated position in accordance with an exemplary embodiment of the invention.
[0013] FIG. 5A shows a detailed view of the preferred latching mechanism of a Free Wheel Lock in a locked position.
[0014] FIG. 5B shows a detailed view of the preferred latching mechanism of a Free Wheel Lock in an unlocked position.
[0015] FIG. 6A shows a close-up front view of an alternative latching mechanism of a Free Wheel Lock in an opened position in accordance with an exemplary embodiment of the invention.
[0016] FIG. 6B shows a close-up side view of an alternative latching mechanism of a Free Wheel Lock in an opened position in accordance with an exemplary embodiment of the invention.
[0017] FIG. 7 shows a bicycle with two exemplary placements for a Free Wheel Lock in accordance with an exemplary embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] Described herein is a free wheel lock for a bicycle for use during transportation of the bicycle on a carrier. The primary purpose of the free wheel lock is to prevent the free wheel from rotating during transportation. Additionally, some versions of the device may be equipped with a keyed locking mechanism which provides anti-theft security is well.
[0019] The device is assembled in two similar halves which mate through a locking rod permanently affixed to one half, and removable affixed to the other half. The distal ends form curved hooks which grasp the wheel rim or the tubular of the bike frame to secure the wheel from rotating.
[0020] In the preferred embodiment, the locking, rod has teeth on a plurality of sides to allow the two halves to be rotated around the rod's central axis in relation to each other so that the hooks may orient in independent directions to each other, allowing multiple configurations to satisfy different application needs of the user.
[0021] The preferred embodiment is constructed of a metal frame, to provide strength, encased in a molded plastic to prevent scratching or corrosion of the bicycle. In alternative embodiments, the frame may be made of a durable plastic which is encased in a rubberized plastic or left in the non-encased state. In alternative embodiments the device may be constructed with fiber glass, carbon fiber, resin, or other materials for durability and wear resistance.
[0022] In the preferred embodiment, the inner surface of the hooks are further lined with padding or cushioning. This prevents bending of frame structures, or crushing of cables. The hooks are sized and curved to fit standard tubular structures. Alternative embodiment may comprise different sized hooks for different bicycle sizes. Alternative embodiments may comprise different shaped hooks for mating with different bicycle parts.
[0023] In the preferred embodiment, the two halves are substantially similar in size and shape. In alternative embodiment, the division between the two hooks may be oriented more toward one hook rather than being positioned near the middle of the body. In such a configuration, the locking d would be permanently affixed to the shorter side, and extend into a cavity on the longer side. The longer side comprises a latching mechanism for securing the rod at a plurality of locations upon its length.
[0024] The two halves of the preferred embodiment are joined by a locking rod which is permanently affixed to one side, and nest in a locking cavity in the other side. The locking cavity has a latching mechanism which engages the locking rod as it is inserted into the locking cavity, while not preventing further insertion into the cavity. However, the latching mechanism prevents the locking rod from sliding back out of the cavity unless it is disengaged. Disengaging the latching mechanism may require a key or combination which disengages a lock, or it may he a lever which requires simple force to overcome a biasing spring urging the lever to a locked position.
[0025] In another embodiment, the latching mechanism may comprise a friction hold Where a clasp secures the locking rod between a plurality of body parts on the other half to secure the two halves from separating. In an exemplary embodiment, the clasping may be a screw with a nut providing compression against the screw head.
[0026] In another embodiment, the two halves comprise at least one, but preferable a plurality of guide bars which nest into mating cavities on the opposing half, having a spring or other elastic member extended between the two halves. The two halves are pulled apart by a force overcoming the joining force of the spring, and then positioned as desired. Releasing the two halves allows the elastic member to urge the two halves back together with the guide bars, ensuring alignment when mated.
[0027] FIG. 1 illustrates a perspective view of a Free Wheel Lock in accordance with an exemplary embodiment of the invention. The wheel lock ( 100 ) comprises two hooks, ( 120 and 110 ) each lined with foam padding ( 115 and 125 ). The two hooks are joined to distal ends of a body ( 130 ) which divides at an expansion joint ( 140 ) creating two halves ( 145 & 147 ). For purposes of this discussion, the upper half ( 147 ) is illustrated with a hook ( 120 ) which flares more than the hook ( 110 ) of the lower half ( 145 ); however, the two hooks could be substantially similar.
[0028] In the illustration, the upper half ( 147 ) comprises the locking cavity (not visible) Which accepts the locking bar (not visible) and includes the release lever ( 135 ), which optionally contains a lock ( 190 ) secured with a key ( 195 ).
[0029] FIG. 2A illustrates a frontal view of a Free Wheel Lock in accordance with an exemplary embodiment of the invention. The wheel lock ( 100 ) is illustrated in a closed position where the upper half ( 147 ) with the flared hook ( 120 ) and the lower half ( 145 ) with the non-flared hook ( 110 ) are mated at the expansion joint ( 140 ) of the body ( 130 ).
[0030] FIG. 2B illustrates a side view of a Free Wheel Lock. In the side view, the foam pad ( 125 ) is shown to line the upper hook ( 120 ) and another foam pad ( 115 ) lines the lower hook ( 110 ). Just above the expansion joint ( 140 ) of the body ( 130 ) the pivot point ( 138 ) of the latch ( 135 ) is illustrated.
[0031] FIG. 2C illustrates a cross sectional view of a Free Wheel Lock in accordance with an exemplary embodiment of the invention. In the cross sectional view, the locking bar ( 170 ) is shown to have a secured end ( 172 ) which is attached/secured permanently into the lower half ( 145 ). The projecting end ( 173 ) extends into the sleeve ( 178 ) of the upper half ( 147 ) and the teeth ( 175 ) of the locking bar ( 170 ) engage the teeth ( 139 ) of the cam ( 137 ) on the end of the release lever ( 135 ). Pulling the release lever ( 135 ) rotates it around the pivot point ( 138 ) causing, the teeth ( 139 ) to rotate up into the void ( 136 ) and disengage from the teeth ( 175 ) of the locking bar ( 170 ). This then allows the locking bar ( 170 ) to be removed from the sleeve ( 178 ) of the upper half, ( 145 ) extending the distance between the two hooks ( 110 and 120 ).
[0032] FIG. 3A illustrates a side view of a Free Wheel Lock in an opened position. In the side view, the foam pad ( 125 ) is shown to line the upper hook ( 120 ) and another foam pad ( 115 ) lines the lower hook ( 110 ). The expansion joint ( 140 A and 140 B) is opened with the upper half ( 147 ) and the lower half ( 145 ) joined by the locking bar ( 170 ). The pivot point ( 138 ) of the latch ( 135 ) is illustrated on the upper half ( 147 ). The teeth ( 175 ), visible on the front and side of the locking bar ( 170 ), allow the lower half ( 145 ) to be rotated around the central axis of the locking bar ( 170 ) with respect to the upper half ( 147 ).
[0033] FIG. 3B shows a cross sectional view of a Free Wheel Lock in an opened position in accordance with an exemplary embodiment of the invention. In the cross sectional view, the locking bar ( 170 ) is shown to have a secured end ( 172 ) which is attached/secured permanently into the lower half ( 145 ). The projecting end ( 173 ) extends into the sleeve ( 178 ) of the upper half ( 147 ) and the teeth ( 175 ) of the locking bar ( 170 ) engage the teeth ( 139 ) of the cam ( 137 ) on the end of the release lever ( 135 ). Pulling the release lever ( 135 ) rotates it around the pivot point, ( 138 ) causing the teeth ( 139 ) to rotate up into the void ( 136 ) and disengage from the teeth ( 175 ) of the locking bar ( 170 ). This then allows the locking bar ( 170 ) to he removed from the sleeve ( 178 ) of the upper half ( 147 ) extending the distance between the two hooks ( 110 and 120 ). The teeth ( 175 ), located on the other sides of the locking bar ( 170 ), allow the lower half ( 145 ) to be rotated around the central axis of the locking bar ( 170 ) with respect to the upper half ( 147 ) while still presenting teeth ( 175 ) to engage the teeth ( 139 ) of the lever ( 135 ).
[0034] FIG. 4 shows an alternative assembly of a Free Wheel Lock in a rotated position in accordance with an exemplary embodiment of the invention. The lower half ( 145 ) is illustrated in a rotated position around the expansion joint ( 140 ) with respect to the upper half ( 147 ), as illustrated by the forward presentation of the latch ( 135 ) and the rear presentation of the upper hook, ( 120 ) while the lower hook ( 110 ) with its foam padding ( 115 ) is presented to the side.
[0035] FIG. 5A shows a detailed view of the preferred latching mechanism of a Free Wheel Lock in a locked position. The close up view details the pivot point ( 138 ) of the latch ( 135 ) in relation to the body ( 130 ). The cam ( 137 ) extends the teeth ( 139 ) of the latch ( 135 ) to engage the teeth ( 175 ) of the projecting end ( 173 ) of the locking bar ( 170 ) as it is inserted into the sleeve ( 178 ) of the body ( 130 ). A spring mechanism (not illustrated) urges the handle of the lever ( 135 ) against the body ( 130 ).
[0036] FIG. 5B shows a detailed view of the preferred latching mechanism of a Free Wheel Lock in an unlocked position. An opening force (not illustrated) rotates the lever ( 135 ) away from the body ( 130 ) against the urging of a spring mechanism (not illustrated). This allows the lever ( 135 ) to rotate around the pivot point, ( 138 ) moving, the teeth ( 139 ) on the cam ( 137 ) into the void ( 136 ) of the body ( 130 ) and disengaging the teeth ( 175 ) of the locking bar ( 170 ), allowing it to be removed from the ( 178 ).
[0037] FIG. 6A shows a close-up front view of an alternative latching mechanism of a Free Wheel Lock in an opened position in accordance with an exemplary embodiment of the invention. FIG. 6B shows a close-up side view of an alternative latching mechanism of a Free Wheel Lock in an opened position in accordance with an exemplary embodiment of the invention. In this embodiment, the upper and lower halves ( 145 and 147 ) remain joined by a catch end, ( 184 ) enclosing the end of a slotted opening ( 182 ) of the locking lever ( 180 ). The body ( 130 ) is notched to allow the locking lever ( 180 ) to be sandwiched in between the two notch halves. A screw ( 186 ) passes through the notched body perpendicular to the notch. The screw ( 186 ) also passes through the slotted opening ( 182 ) of the locking lever ( 180 ). A nut ( 188 ) with a handle ( 189 ) affixed thereto can he secured to the screw, ( 186 ) placing pressure through the body ( 130 ) and the locking lever ( 180 ) against the screw head ( 187 ) to produce a fiction force holding the two halves ( 145 and 147 ) in relation to one another.
[0038] FIG. 7 shows a bicycle with two exemplary placements for a Free Wheel Lock in accordance with an exemplary embodiment of the invention. The bicycle's ( 40 ) front forks ( 55 ) have a wheel lock ( 100 ) passing across and securing to them. This stops the wheel ( 45 ) from rotating. In an alternative application, a wheel lock ( 100 ) secures the tire ( 45 ) by placing pressure against the inside of the tire ( 45 ) frame and the down tube ( 50 ) of the bicycle ( 40 ) frame. This alternative application prevents the wheel for rotating, and additionally prevents the wheel from turning.
[0039] The diagrams in accordance with exemplary embodiments of the present invention are provided as examples and should not be construed to limit other embodiments within the scope of the invention. For instance, heights, widths, and thicknesses may not be to scale and should not be construed to limit the invention to the particular proportions illustrated. Additionally. some elements illustrated in the singularity may actually be implemented in a plurality. Further, some elements illustrated in the plurality could actually vary in count. Further, some elements illustrated in one Ruin could actually vary in detail. Further yet, specific numerical data values (such as specific quantities, numbers, categories, etc.) or other specific information should be interpreted as illustrative for discussing exemplary embodiments. Such specific information is not provided to limit the invention.
[0040] The above discussion is meant to be illustrative of the principles and various embodiments of the present invention. Numerous variations and modifications will become apparent to those skilled in the art once the above disclosure is filly appreciated. It is intended that the following chums be interpreted to embrace all such variations and modifications. | A method and apparatus for securing the free wheel of a bicycle to prevent rotation. Such rotation may be distracting and hazardous when a bicycle is transported on a vehicle rack. The apparatus comprises an elongated body with two curved ends, the body is separable to extend the distance between the curved ends such that they can be positioned between the wheel and/or the frame components of the bicycle to secure the wheel against rotation and turning. | 4 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional application of U.S. application Ser. No. 11/533,186, filed Sep. 19, 2006, which is incorporated herein by reference in its entirety, which claims priority to U.S. Provisional Application No. 60/718,708, filed on Sep. 20, 2005, also incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates to a ball and socket type joint of the type used in vehicular steering and/or suspension applications, and more particularly toward such a ball joint assembly for use in applications where one of the anchoring members, such as a steering knuckle or tie rod for example, is made from a relatively soft material like aluminum.
[0004] 2. Related Art
[0005] Ball joints are typically used in vehicular applications where three-dimensional movement of a wheel, and in particular a steerable wheel, is required when a vehicle is turning and the suspension is accommodating movement over rough terrain. In the normal course of operation, ball joints are subjected to very high stresses. These stresses are transmitted through the stud of a ball joint assembly into the suspension member, which may be a steering knuckle, control arm, steering link, frame member or other feature.
[0006] The recent emphasis on reducing vehicular weight is driving material selections toward lighter options. Sometimes, there is a motivation to substitute aluminum for traditional cast iron materials, even in the area of chassis and suspension components. Unfortunately, lighter materials are often softer than the heavier materials they replace, and therefore less suited to endure the localized and concentrated stresses which may arise during normal vehicular operations.
[0007] FIGS. 9 and 10 illustrate two different prior art attempts to accomplish similar functionality for ball joint assemblies, and in particular studs which are intended to be anchored in relatively soft material like aluminum. FIG. 9 , in particular, is intended to correspond to the design depicted in U.S. Pat. No. 6,527,468, the entire disclosure of which is hereby incorporated by reference. These designs are either difficult to produce on a high volume basis, or result in unacceptable attributes such as NVH issues and provide less surface-to-surface contact in the interface regions. By contrast, the subject invention as depicted in various embodiments in FIGS. 1-8 , overcomes some or all of these issues and represents a significant improvement over prior art constructions.
[0008] Accordingly, there is a need for an improved method of interconnecting a ball joint assembly to vehicular steering and suspension features to accommodate the anchor points being made from a softer material.
SUMMARY OF THE INVENTION
[0009] The subject invention comprises a ball and socket joint assembly of the type used in vehicular steering and suspension applications in which an anchoring and control member is made from relatively soft material. The assembly comprises a stud having a ball portion on one end thereof and a shank extending therefrom. The shank includes a thread form for attaching the stud to an anchoring control member made from a relatively soft material. The shank includes an adaptor interface region between the ball portion and the thread form. An annular, loose piece adaptor is slidably disposed on the shank and matingly engages the adaptor interface region in abutting surface-to-surface contact therewith. The adaptor has a frustoconical exterior surface tapering inwardly toward the thread form, and an interior surface. The interior surface of the adaptor includes a generally spheroidal female surface configuration and the adaptor interface region of the shank has a complementary-shaped generally spheroidal male surface configuration. The generally spheroidal female and male mating surfaces provide enhanced stress distributions and load carrying capabilities with less adaptor-to-shank slippage in operation.
[0010] According to another aspect of the invention, a ball and socket joint assembly is provided of the type used in vehicular steering applications in which an anchoring control member is made from relatively soft material. A stud has a ball portion on one end thereof and a shank extending therefrom. The shank includes a thread form for attaching the stud to an anchoring control member made from a relatively soft material. The shank includes an adaptor interface region between the ball portion and the thread form. An annular, loose piece adaptor is slidably disposed on the shank and matingly engages the adaptor interface region in abutting surface-to-surface contact therewith. The adaptor has a frustoconical exterior surface tapering inwardly toward the thread form, and an interior surface. The interior surface of the adaptor includes a generally cylindrical major side wall establishing a major inside diameter thereof and a generally cylindrical minor side wall, concentric with the major side wall, establishing a minor inside diameter thereof. The interior surface of the adaptor also includes at least one annular shoulder between the major and minor side walls. The adaptor interface region of the shank includes a generally cylindrical major shaft matingly received with the major side wall of the adaptor, a minor shaft matingly received within the minor side wall of the adaptor, and at least one annular shoulder between the major and minor shafts. The shoulder of the adaptor is pressed in face-to-face contact with the shoulder of the shank.
[0011] Both aspects of the invention as set forth herein overcome the shortcomings and disadvantages present in prior art designs, by providing an improved construction for interconnecting a ball joint assembly to a vehicular steering and/or suspension feature to accommodate anchor points made from a softer material.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] These and other features and advantages of the present invention will become more readily appreciated when considered in connection with the following detailed description and appended drawings, wherein:
[0013] FIG. 1 is a perspective view of an exemplary application for the subject ball and socket joint assembly wherein the steering knuckle is supported between upper and lower control arms made from a relatively soft material such as aluminum;
[0014] FIG. 2 is a cross-sectional view taken generally along lines 2 - 2 in FIG. 1 ;
[0015] FIG. 3 is a front elevation view of a stud according to the subject invention showing an annular, loose piece adaptor operatively disposed thereon and depicted in cross-section;
[0016] FIG. 4 is a perspective view of the annular, loose piece adaptor shown in quarter section;
[0017] FIG. 5 is a view as in FIG. 3 but depicting a first alternative embodiment of the geometric surface formations between the female and male mating surfaces of the stud and the adaptor;
[0018] FIG. 6 is a view as in FIG. 3 but showing a second alternative embodiment for the mating interface between the stud and adaptor;
[0019] FIG. 7 is a view as in FIG. 3 but depicting a third alternative embodiment of the adaptor interface region;
[0020] FIG. 8 is a view as in FIG. 3 but illustrating a fourth alternative embodiment of the abutting surface-to-surface contact region between the adaptor and the stud;
[0021] FIG. 9 is a depiction of a prior art style stud and adaptor configuration; and
[0022] FIG. 10 is another depiction of a prior art stud and adaptor configuration.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0023] Referring to the Figures, wherein like numerals indicate like or corresponding parts throughout the several views, a vehicular steering and suspension assembly such as used in the front, dirigible wheels of a motor vehicle is generally shown at 12 in FIG. 1 . Although the front suspension system 12 is shown here comprising upper 14 and lower 16 control arms interconnecting a steering knuckle 18 , it will be appreciated by those of skill in the art that the contemplated invention may find application in other steering and/or suspension components. For example, the invention, as will be described in multiple embodiments, may be deployed in not only steering knuckles and control arm interfaces, but also in steering linkages, frame member connections, and other articulating features.
[0024] Returning to the illustrative application depicted in FIG. 1 , a suspension system 12 is shown including a combined spring and dampening device 20 interconnecting the lower control arm 16 to interposing portions of the vehicle chassis or frame (not shown). The steering knuckle 18 includes a spindle 22 upon which a vehicular wheel assembly 24 is mounted, together with appropriate braking and bearing components as is well known to those of skill in this art. A steering arm 26 extends transversely from the steering knuckle 18 , ready to connect with an appropriate steering link (not shown). Although purely depicted for its illustrative value in FIG. 1 , the steering suspension system 12 in this example includes components made from relatively soft material such as aluminum or other light-weight materials or alloys, as compared with the traditional steel and cast iron constructions. For example, the lower control arm 16 in this example is made from aluminum or an aluminum alloy having material properties and characteristics which are softer and more ductile than traditional iron and steel constructions. The suspension system 12 includes, in this example, a pair of ball joint assemblies, generally indicated at 28 , interconnecting the upper 14 and lower 16 control arms to the steering knuckle 18 , respectively.
[0025] FIG. 2 represents a cross-sectional view of the ball joint assembly 28 as taken through the lower control arm 16 . Here, the ball joint assembly 28 is shown including a stud, generally indicated at 30 , having a ball portion 32 at one end thereof. A shank 34 extends from the ball portion 32 , and includes a thread form 36 for attaching the stud 30 to an anchoring control member made from a relatively soft material, which in this case is the lower control arm 16 . A washer 38 and nut 40 are advanced onto the thread form 36 for establishing the requisite tensile stress through the stud 30 to maintain a secure connection to the lower control arm 16 in use.
[0026] A housing cap 42 surrounds the ball portion 32 of the stud 30 for providing an articulating interface therewith. The housing cap 42 , while shown in but one purely exemplary configuration in FIG. 2 , is seated via a press fit operation into a corresponding receiving pocket in the steering knuckle 18 . A polymer liner 44 may, in some circumstances, be interposed between the housing cap 42 and the ball portion 32 as a bearing surface. A resilient dust boot 46 is shown extending between the housing cap 42 and the shank 34 for preventing contaminant infiltration into the articulating interface. Of course, many other constructions and designs of the housing cap 42 and other components such as the dust boot 46 may be implemented in conjunction with the novel features of this invention. It is necessary only that the housing cap 42 complement the ball portion 32 and thereby provide a full articulating joint which facilitates the three-dimensional movement necessary to accommodate wheel turning, suspension travel, and other mechanical linkage movements.
[0027] Referring now to FIGS. 3 and 4 , the stud 30 portion of the ball joint assembly 28 is shown including an adaptor interface region 48 between the ball portion 32 and the thread form 36 . An imaginary central axis A is shown as a center-line for the various surface features formed as a body of revolution. The adaptor interface region 48 includes numerous surface features and contours including a generally cylindrical collar 50 which, among other functions, may serve to receive the clamped lower end of the dust boot 46 , as depicted in FIG. 2 . In addition, the adaptor interface region 48 includes a generally spheroidal male surface configuration 52 formed in the concave direction. Thus, the spheroidal male surface configuration 52 takes the appearance of an enlarged fillet transitioning the collar 50 down toward the thread form 36 .
[0028] The adaptor interface region 48 of the shank 34 is designed to receive an annular, loose piece adaptor, generally indicated at 54 . The adaptor 54 is slidably disposed over the shank 34 and matingly engages the adaptor interface region 48 in abutting surface-to-surface contact therewith. The adaptor 54 has a frustoconical exterior surface 56 tapering inwardly toward the thread form 36 . Thus, as shown in FIG. 2 , the frustoconical exterior surface 56 of the adaptor 54 seats within a complementary shaped flare 58 in the lower control arm 16 . The relatively shallow taper presented by the frustoconical exterior surface 56 of the adaptor 54 accommodates a distribution of loading stresses over a wider area of the lower control arm 16 . This thereby reduces the pressure applied to the anchoring lower control arm 16 via the tightened nut 40 . By reducing the contact pressure in this manner, the use of softer material such as aluminum and alloys thereof for the lower control arm 16 , or other suspension member or linkage, can be enabled.
[0029] The adaptor 54 also includes an interior surface, opposite the frustoconical exterior surface 56 , which is characterized in this embodiment by a generally spheroidal female surface configuration 60 . The spheroidal female configuration 60 complements the spheroidal male configuration 52 of the shank 34 and establishes an abutting surface-to-surface contact therewith. The spheroidal female configuration 60 is shown in the convex direction, and cooperates together with the mating male surface to provide enhanced stress distributions and load carrying capabilities for the ball joint assembly 28 . The spherical or spheroidal surface curvatures also facilitate less adaptor-to-shank slippage in operation. The surface configurations are conducive to manufacturability, and also provide other benefits such as enhanced NVH characteristics and the like. The interior surface of the adaptor 54 further includes a generally cylindrical side wall 62 adjacent its generally spheroidal female surface configuration 60 . The side wall 62 matingly receives a lower portion of the collar 50 of the shank 34 , and provides enhanced seating and radial stress distributions between the two components.
[0030] Referring now to FIG. 5 , a first alternative embodiment of the subject invention is depicted, wherein like or corresponding parts are depicted using the same reference characters with the prefix “1.” In this embodiment, the adaptor 154 is identical in every respect to that described previously in connection with the preferred embodiment, but the side wall 62 is omitted. In this case, the spheroidal female configuration 60 receives 100% of the axial and radial loading vectors between the adaptor 154 and the stud 30 . In some applications, this design may be preferred.
[0031] Turning now to FIG. 6 , a second alternative embodiment of the subject invention is depicted, wherein like or corresponding parts to those described above are indicated using the same reference numerals together with the prefix “2.” In the embodiment of FIG. 6 , the interior surface of the adaptor 254 is characterized by the generally spheroidal female surface configuration 260 having a generally concave formation, whereas the mating, generally spheroidal, male surface configuration 252 on the adaptor interface region 248 has a generally convex formation. Thus, it can be seen that FIG. 6 represents a mere reversal of concave and convex features in the surface contact regions between the adaptor 254 and the adaptor interface region 248 . Accordingly, similar performance characteristics can be expected.
[0032] In FIG. 7 , a third alternative embodiment of the subject invention is depicted. In this example, like or corresponding parts to those previously presented are shown with like reference numerals preceded by the prefix “3.” In this example, generally spheroidal interface surfaces between the adaptor 354 and the adaptor interface region 348 are substituted with one or more step configurations. A single step configuration is illustrated in FIG. 7 , wherein the interior surface of the adaptor 354 includes a generally cylindrical major side wall 362 establishing a major inside diameter. A generally cylindrical minor side wall 364 , concentric with the major side wall 362 , establishes a minor inside diameter of the adaptor 354 . At least one annular shoulder 366 extends between the major 362 and minor 364 side walls, thereby providing a ledge generally perpendicular to the central axis A. The shoulder 366 therefore establishes a contact surface through which all axially vectored stresses are transferred between the adaptor 354 and the stud 30 . The adaptor interface region 348 of the shank 334 includes a generally cylindrical major shaft corresponding to the collar 350 . This major shaft is matingly received within the major side wall 362 of the adaptor 354 . The adaptor interface region 348 also includes a minor shaft 368 that is matingly received within the minor side wall 364 of the adaptor 354 . An annular shoulder 370 extends between the major 350 and minor 368 shafts to establish a generally transverse ledge, relative to the central axis A. The shoulder 370 is adapted to seat in face-to-face contact with the shoulder 366 of the adaptor 354 .
[0033] FIG. 8 depicts a fourth alternative embodiment of the subject invention wherein like or corresponding parts to those described above are reiterated but with the prefix “4” for convenience. In this example, a pair of progressively sized steps are machined or otherwise formed on the adaptor interface region 448 , with complementary receiving shapes formed on the inner surface of the adaptor 454 . More specifically, the interior surface of the adaptor 454 is shown herein including a generally cylindrical intermediate side wall 472 that is concentrically disposed relative to the major side wall 462 and thereby establishing an intermediate sized diameter. The intermediate side wall 472 bisects the shoulder 466 into plural segments. The adaptor interface region 448 of the shank 434 likewise includes a generally cylindrical intermediate shaft bisecting the shoulder 470 into plural segments. The intermediate shaft 474 matingly engages the intermediate side wall 472 of the adaptor 454 . Thus, as can be seen upon consideration of FIG. 8 , the multi-stepped configuration of the mating surfaces increases the integrity of fit between the adaptor 454 and the stud 430 . Of course, additional steps can be incorporated into the design, as can combinations of steps together with the spheroidal curvatures depicted in FIGS. 2-6 .
[0034] Obviously, many modifications and variations of the present invention are possible in light of the above teachings. For example, more steps can be formed in the interface portion, and the step configuration can be combined with spheroidal curvatures. It is, therefore, to be understood that the invention may be practiced otherwise than as specifically described. | A ball joint assembly for a vehicular steering or suspension application includes a cap-like housing in which is captured the articulating ball portion of a stud. A shank extends from the ball portion, outwardly from the housing cap, to provide a connection and anchoring interface for the suspension member or other anchoring component. The connection interface with the anchoring suspension member is characterized by a specially designed surface which is convenient to machine, provides increased surface-to-surface contact area, and provides additional advantages such as improved stress distribution and NVH benefits. A washer-like cone adaptor mates with a specially formed adaptor interface region on the stud. On its outer surface, the adaptor has a broad tapering feature designed to seat in a complementary-shaped receiving flare in the anchoring suspension member. The mating contact region between the adaptor and the stud is formed with spherical or spheroidal curvatures, or by single or multiple step configurations. | 5 |
FIELD OF THE INVENTION
[0001] The present invention relates to folding solid wood blockboard.
BACKGROUND OF THE INVENTION
[0002] Curved wood panels are used in backrests for wooden chairs, casket lids, boat shells, and wood furniture, cabinet doors and drawers, to only give some examples. Some curved wood panels, such as the backrests of chairs, are folded on the length of the grain, i.e. longitudinally arched. We can say that other curved wood panels such as casket lids, have boards parallel to the axis of the vault, i.e. are transversely arched.
[0003] The production of longitudinally arched wood panels implies folding, or curving, the wood. Curving or folding wood is a delicate operation which requires to master the process and to have a good knowledge of the solid wood properties. The green wood, that is wood freshly cut, is generally easier to curve then the wood which was dried in an oven. The wood can be exposed to vapor, or be immersed in the water, before it is curved to reduce the probability of checking or cracking. Curving the wood can be made by different ways, for example using a custom jig or using a press.
[0004] The production of longitudinally arched wood panels implied, until this day, assembling several parts previously curved side by side, by any way, to form a panel. For the transversely curved panels, the machining of at least one edge of each of the wood boards is necessary to give it an angle to assemble the boards, and to assemble them to give them a transversely shaped curve. The radius of the vault is thus predetermined by the angle at which the edges of the wood parts are machined.
[0005] Curving or folding solid wood by vapor has allowed so far the use of parts of wood of a single cut, that is, unique parts, which have to have at the onset the wished final dimension. This thus limits the dimension of the possible curved parts and often causes a lot of wood loss.
[0006] The known processes of production to obtain curved solid wood panels were satisfactory to a certain extent. However, there is still place for improvement.
SUMMARY
[0007] It is possible to obtain a curved panel, using a flat panel composed of boards rectified on their edges and transforming it, by pressing, into a bent panel.
[0008] We can also use a bent wood panel fabrication method starting from a flat panel formed of boards glued edge on edge to transform it from a flat panel into a panel bent transversely, longitudinally or bothwise.
[0009] We can use a bent wood panel fabrication method starting from a flat panel formed of boards glued edge on edge using a glue resisting to the vapor; this method will allow the use of warm vapor which will increase the flexibility of the wood boards and facilitate the folding of the panel.
[0010] We can use a bent wood panel fabrication method starting from a flat panel formed of boards glued edge on edge which have between 8 and 30% of hygroscopic humidity and which are glued using a glue resisting to the vapor, then steaming them during 2 to 60 minutes. This technique allows to fold panels of thickness of ⅛″ to 1⅞″ and to have a radius larger than 2 inches.
[0011] We will be able to bend the panel longitudinally, transversely, or bothwise.
[0012] It is also possible to fold panels formed of wood boards assembled in a longitudinal way, a transverse way, or bothwise.
[0013] The wood panels can be panels of solid wood.
BRIEF DESCRIPTION OF THE FIGURES
[0014] In the appended figures:
[0015] FIG. 1 is a perspective view showing an example of paneling, i.e. a panel of flat solid wood before the folding stage;
[0016] FIG. 2 is a perspective view showing an example of a panel of wood longitudinally arched;
[0017] FIG. 3 is a perspective view showing an example of a wood panel transversely bent;
[0018] FIG. 4 is an organization chart showing an example of method to obtain a bent panel;
[0019] FIG. 5 is an organization chart showing an example of a method to obtain a longitudinally arched panel;
[0020] FIG. 6 is an organization chart showing an example of a method to obtain a panel bent transversely; and
[0021] FIG. 7 shows examples of panels of wood longitudinally and transversely arched;
DETAILED DESCRIPTION
[0022] In FIG. 1 , an example of a panel of side glued boards 10 , before it is folded, is shown. It is formed of a number of solid wood boards 12 , glued together edge on edge. This type of panel can be folded longitudinally or transversely, for example.
[0023] In FIG. 2 , an example of a panel 110 bent longitudinally is shown. The panel 110 is formed of 6 full boards 112 , 114 , 116 , 118 , 120 , 122 of solid wood, which are assembled edge on edge. These boards 112 , 114 , 116 , 118 , 120 , 122 are folded on their length, around the axis 124 , and we can then say that the bent panel 110 is folded longitudinally. This type of panel can be used to make a chair back, for example.
[0024] In FIG. 3 , an example of a panel 210 bent transversely is shown. It is made of a number of boards 212 in solid wood glued in parallel and oriented along the axis 218 . We can thus say that the panel is <<transversely folded>>. This type of panel can be used to make a coffin lid, for example.
[0025] In FIG. 4 , we find an organization chart which illustrates the simplified process used to make a panel of boards which will be bent longitudinally, transversely, or obliquely. As illustrated, the stage of folding is performed after the stage of the panelling. During the stage of the panelling, a number of boards is used to assemble the panel by diverse techniques, but it is necessary to make sure that joints are well glued by using an appropriate glue.
[0026] In FIG. 5 , we find an organization chart which illustrates the detailed process used to make a panel of boards of solid wood, bent longitudinally.
[0027] In FIG. 6 , we find an organization chart which illustrates the detailed process used to make a panel of boards of solid wood, bent transversely.
[0028] In FIG. 7 , examples of panels, bent longitudinally 2 and transversely 3 respectively, are shown. They are each formed of a number of boards 5 .
[0029] A set of tests was so made to validate the principle of the longitudinally folding and of the transverse folding. For each of the tests, panels were curved using a similar process. Each of the tests was realized according to the processes illustrated in FIG. 5 or 6 , depending if it is a longitudinal or transverse bending. Variables in the general process were brought from one test to the other one, such as represented in the following tables, to obtain the best result.
[0000]
Tests for longitudinally folding
TH %
Radius of
Type of
No. of
Wood
Species of
Steaming
Compression
the curve
press
Glue
test
Humidity
the wood
(Min.)
when folding
(inches)
used
used
1
25-30
Yellow
15
No
23
Heating
Linestar
birch
trays
4610
(Nacan)
2
25-30
Yellow
30
No
23
Heating
Pur-Feet
birch
trays
Lok
(Nacan)
3
12-16
Yellow
15
Yes
23
High
Purbond
birch
frequency
HB-222
(Nacan)
4
12-16
Yellow
15
Yes
6
Folding
MUF 400
birch
tables
(Tembec)
[0030] For the longitudinal bending, the general process used in each of the 4 tests is represented in FIG. 5 . The method includes the use of a series of boards of yellow birch, let to dry naturally in air, having a thickness of 4/4 and a variable width. The category of the boards of yellow birch is “select, SAP”, having a pale face (face free of heartwood). During each test, randomly selected boards were tested to obtain their level of hygroscopic humidity (TH %), to obtain the rate of humidity of the boards used in the making of panels for each of the 4 tests. This initial humidity is also indicated in the above Table.
[0031] During the stage of panelling, each panel is made by gluing a variable number of boards of varied widths edge on edge with the glue indicated in the above Table. It is good to note that all the panels are flat after they are glued, before being curved. The panels are glued directly in the steaming room. The heat, 85-90 degrees Celsius, in the steaming room, contributed to harden the glue during the steaming stage of 15 or 30 minutes depending on the test. A total of about ten panels were made for each test.
[0032] The panelling was followed by a panel sizing stage. Panels were trimmed at 13/16 inch and cut at a precise length to fit to the compression steel sheet when such a device is used.
[0033] Each panel was then folded in a hydraulic press on a mould. The type of press used is indicated in the above Table. When a compression steel sheet was used during the folding step, it is also indicated in the column “compression when folding” in this Table.
[0034] The folded panels were, afterward, let to dry naturally, in normal atmospheric situation (hygroscopic balance from 6 to 8%).
[0035] The folded panels were then inspected to verify the condition of the glued joints, the appearance of the panels, both on the concave and on the convex faces. The results of this inspection for each test appear in the Table presented below.
[0000]
RESULTS OF THE TEST FOR LONGITUDINALLY FOLDINGS
Quantity of
Condition of the glued
good panels
No. tests
joints after the folding
in % (note 1)
Comments
1
Approximately 30% of
0%
Some glued
joints partially gave in
joints remained
when folded
intact on all
the length
2
Approximately 50% of
0%
Some glued
the glued joints partially
joints remained
gave in when folded
intact on all
the length
3
The glued joints
85%
Use of a
remained intact on the
compression
concave face. On the
steel sheet
convex face, we find, on
the bad panels, small
openings.
4
The glued joints
70%
Use of a
remained intact on the
compression
concave face. On the
steel sheet
convex face, we find, on
the bad panels, small
openings in the center of
the curvature.
(Note 1)
A panel is considered as good when the joints of glue remained intact, without opening on the concave and convex face of this one after the folding and the final drying.
[0000]
Tests for transversally folding
TH %
Species
Radius of
No. of
Wood
of the
Steaming
Compression
the curve
Type of
Glue
test
Humidity
wood
(Min.)
when folding
(inches)
press used
used
1
25-30
Yellow
30
No
23
Heating
Linestar
birch
trays
4610
(Nacan)
2
25-30
Yellow
30
No
23
Heating
Pur-Feet
birch
trays
Lok
(Nacan)
3
25-30
Yellow
15
No
23
High
Purbond
birch
Frequency
HB-222
(Nacan)
4
12-16
Yellow
15
Yes
18
High
Purbond
birch
Frequency
HB-222
(Nacan)
[0036] For the transverse folding, the general process used in each of 4 tests is represented in FIG. 6 . The method includes the use of a series of boards of yellow birch let to dry naturally at the air, having a thickness of 4/4 and a variable width. The category of the boards of yellow birch is “select, SAP”, with a pale face (face free of heartwood). During each test, boards selected randomly were tested to obtain their level of hygroscopic humidity (TH %), to so obtain the rate of humidity of the boards used in the making of panels for each of the 4 tests. This initial humidity is also indicated in the above Table.
[0037] During the stage of panelling, each panel is made by gluing a variable number of boards of varied widths, edge on edge, with the glue indicated in the above Table. The panels are glued in a spider-type press. It is good to note that all the panels are flat after being glued, before being curved. The time it takes for the glue to dry and harden is according to the manufacturer's data sheet of the glue used. A total of about ten panels were made for each test.
[0038] The panelling is followed by a stage of panel sizing. Panels were trimmed at 13/16 inch and cut to a precise width to fit to the compression steel sheet when used.
[0039] Every panel was treated with vapor with a free steam steaming pit. This operation was made at 85-90 Celsius degrees for 15 or 30 minutes depending on the test.
[0040] Each panel was then folded in a hydraulic press on a mould. The type of press used is indicated in the above Table. When a compression steel sheet was used during the folding, it is indicated in the column “compression when folding”, also in this Table.
[0041] The folded panels were left, afterward, to dry naturally, in normal atmospheric conditions (hygroscopic balance from 6 to 8%).
[0042] The folded panels were inspected to verify the condition of the joints of glue, the appearance of panels, both on the concave face and on the convex face. The results of this inspection for every trial appear in the Table presented below.
[0000]
RESULTS OF THE TESTS FOR
TRANSVERSALLY FOLDINGS
Quantity of
Condition of the glued
good panels
No. tests
joints after the folding
in % (note 1)
Comments
1
All the glued joints
100%
remained intact on the
concave and convex
faces.
2
The majority of the
75%
glued joints remained
intact on the concave
and convex faces
3
All the glued joints
100%
remained intact on the
concave and convex
faces.
4
All the glued joints
100%
Use of a
remained intact on the
compression
concave and convex
steel sheet
faces.
(Note 1)
A panel is considered as good when the joints of glue remain intact, without opening on the concave and convex faces after the folding and the final drying steps.
[0043] A compression steel sheet has for objective to prevent the stretching of the wood fiber on the convex face of the piece of wood or the panel to bend. On both extremities of the steel sheet, we find a stop plate; the panel is then cut in a precise dimension at the exact distance between these two stop plates. In the stage of the folding, the steel sheet follows the panel in the press until the final shape.
[0044] In conclusion, the more the radius of curvature is small, the more it is recommended to use a compression steel sheet. The radius of curvature is influenced by the thickness of the wood to be folded: the greater the thickness of the wood is, the greater the radius of curvature must be. Every panel was folded with a hydraulic bending press. The folded panels were, afterward, let to dry naturally, in normal atmospheric conditions (hygroscopic balance from 6 to 8%).
[0045] The deformation produced on the bent panels, after drying, is very small. A recovery occurred on the folded panels, but no more than what is normally foreseen for a unique part, that is, without being glued. A very interesting fact is that the folding of a glued wood panel tolerates some defects that the folding of individual parts would not accept at the risk of breaking during the folding step. For example, knots and wood with an oblique thread support the effect of the folding when these parts are glued together. Given that these defects are not often found facing one another, boards exempt of defects support those who do have defects. We can thus expect a better and bigger use of wood resources.
[0046] It is normally easier to fold a panel transversely than longitudinally. During a longitudinal folding, the joints of glue are subjected to important longitudinal shears. On the other hand, during a transverse folding, the effort acts between the fibers of the wood rather than on the length of the wood fibers, and the effort on the joints of glue is mainly felt by the tension between the wood boards.
[0047] The experiments above described demonstrate that the folding of panels made of solid wood boards is doable and gives satisfactory results while allowing the recovery of the wood, transversely as well as longitudinally. These results imply that the oblique folding of the panels is as well doable because to bend obliquely is the combination of a transverse and longitudinal folding.
[0048] If we try to make a folded panel using individual boards then assembled together, the uneven recovery of each individual board will result in panels of uneven surfaces. The radius of the folding of each board can be uneven and the panel which will result will have to be worked on again to obtain a satisfactory product.
[0049] Trimming the panel flat on its thickness, before folding it, is much simpler and will require no additional operation after the folding, except a light sanding.
[0050] Folding the panel, rather than folding individual boards and assembling them afterwards, can save a considerable quantity of time and decrease a lot the wood loss, given that the glued boards can be of varied widths, even narrow. This can eliminate operations which do not contribute to added value and allows new applications. For example, chair backs, which were usually made with a unique part, can now be made with a glued panel. Panels bent of bigger dimension can also be made, because the panelling allows a lot of flexibility in the size of the finish parts, simply by assembling more or less boards together.
[0051] In the case of panels folded transversely, the folding of the panel can advantageously save the step to have to manufacture an angle on the edges of the components. In other terms, assembling a flat panel then folding it can be realized in a short time, according to a process simpler than assembling boards with angular edges and, afterward, gluing them in a mould, and leveling them respecting the target curvature.
[0052] Besides the examples above-mentioned in this document, several other alternatives can be considered.
[0053] For example, although the examples described above apply to panels folded regularly on their entire surface, it is as well possible to bend only part of the surface.
[0054] The folding of the panel can be made with other appropriate tools. For example, the use of rollers rather than a press can be suited in certain situations.
[0055] An appropriate choice of glue plays an important role to prevent the appearance of faults in the joints of glue. The glue should be able to resist heat and humidity to which the panel is exposed during the steaming, and should also be able to resist the folding operation. Adequate glue can be polyurethane glue, melamine containing some formaldehyde urea with a catalyst, a white glue of PVA type with a catalyst, to give only some examples. Certain glues must be avoided. In particular, the outside glue PVA of Lepage™, as well as the white glue PVA without catalyst is not suited, at least in some applications.
[0056] Hard wood indicated as broad-leaved trees generally give better results than conifer. Wood such as the African mahogany and the eucalyptus or lyptus is to be avoided. The wood species advisable is the wood which we use normally in panelling and industrial folding. For some applications, we can begin the process with already dry wood, dried with a dryer, rather than to use wood naturally dried in air.
[0057] After the folding, panels can finish to dry freely, at ambient air, or in an artificial dryer with controlled heat and humidity.
[0058] Panels made of solid wood boards having a hygroscopic humidity comprised between 8 and 30% and between ⅛ and 1⅞ inch of thickness, were bent after having been warmed in vapor for between 2 and 60 minutes before the folding and having a radius of curvature higher to 2 inches, for example.
[0059] This new way of making opens nice perspectives in the technical and economic point of view for the manufacturers of curved articles, such as wood sport articles, backrests of chairs or cabinet doors and drawers, in solid wood, for example. | The invention allows the realization of parts, longitudinally or transversely curved, of large dimensions, by assembling boards of solid wood side by side, with glue, and to afterward arch the resulting part. The loss of solid wood is then decreased a lot since it is thus possible to assemble several wood boards of various widths together. It allows the realization of final curved parts of almost unlimited dimension, dimension whereas dimensions are usually limited by the width of the sawing, or, in other words, by the thickness of the trees. Here, the limit is situated at the level of the capacity of equipments used to bend solid wood. | 4 |
TECHNICAL FIELD
The present invention relates generally to improving data transmission on telecommunication networks and, more particularly, to methods and devices for providing scheduling and rate control coordination accounting for interference cancellation at a mobile terminal.
BACKGROUND
3GPP Long Term Evolution (LTE) is a standard for mobile phone network technology. LTE is a set of enhancements to the Universal Mobile Telecommunications System (UMTS), and is a technology for realizing high-speed packet-based communication that can reach high data rates on both downlink and uplink channels. As illustrated in FIG. 1 , LTE transmissions are sent from base stations 102 , 110 such as Node Bs (NBs) and evolved Node Bs (eNBs) in a telecommunication network 106 , to mobile stations 104 , 108 (e.g., user equipment (UEs)). Examples of wireless UE communication devices include mobile telephones, personal digital assistants, electronic readers, portable electronic tablets, personal computers, and laptop computers. The UEs operate within serving cells 112 , 114 corresponding to base stations 102 , 110 , respectively. LTE wireless communication systems may be deployed in a number of configurations, such as, for example, a Multiple-Input, Multiple-Output (MIMO) radio system.
The LTE standard is primarily based on Orthogonal Frequency Division Multiplexing (OFDM) in the downlink, which splits the signal into multiple parallel sub-carriers in frequency. In LTE, available transmission capacity is divided within the frequency domain 206 and time domain 208 into a plurality of resource blocks (RBs). For instance, as illustrated in FIG. 2 , a frame 200 comprised of transmission resources (e.g., RBs) 202 , 204 may be transmitted in accordance with the LTE standard. Each of resources 202 , 204 may consist, for example, of twelve (12) sub-carriers in the frequency domain and 0.5 ms in the time domain.
One aspect of the LTE transmission scheme is that the time-frequency resources can be shared between users. A scheduler controls assignment of the resources among the users (for both downlink and uplink) and also determines the appropriate data rate to be used for each transmission. Due to the use of OFDM, the scheduler can allocate resources for each time and frequency region. For instance, in the example of FIG. 2 , a first user may be allocated a first group of resources (shown with hashing) that includes resource 202 while a second user is scheduled for transmission on a second group of resources (shown without hashing) that includes resource 204 . In most systems, the condition of the channel for each user is a consideration in determining the most efficient allocation of resources. For instance, a scheduler may be configured to give scheduling priority to UEs with the highest channel quality.
The quality of the signal received by a given user is dependent upon a number of factors, including the channel quality from the serving node, the level of interference from other cells and nodes, and the noise level. In order to optimize the overall capacity of the system, a scheduler will typically try to match the modulation, coding, and other signal/protocol parameters to the signal quality. For instance, when signal quality is low, a scheduler may reduce the coding rate or select a lower-order modulation scheme to increase tolerance to interference and raw bit error rates (e.g., error rates measured before decoding) or to otherwise improve robustness.
According to the LTE standard, UEs may be configured to report Channel Quality Indicators (CQIs) to assist the scheduler. These CQI reports are derived from the downlink received signal quality and are often based on measurements of the downlink reference signals (RSs). Channel Quality Indicators may be referred to as Channel State Information (CSI) in certain systems.
Despite the many advantages of existing LTE schemes and protocols, there exists a significant problem with inter-cell interference and a need to coordinate between cells in order to mitigate the negative effects of interference. The LTE standard is primarily designed to operate under the presumption that the entire spectrum is available in each cell. In other words, that the same time-frequency resources may be used in neighboring cells with limited interference. However, this is not always true in practice, particularly at the cell-edge. Transmissions intended for a first user in a first cell, are often overheard by a second, unintended user in a second cell.
In a heterogeneous network (HetNet), the impact of inter-cell interference can be much higher due to the large difference between the transmit power levels of macro and, for example, pico base stations. A HetNet deployment is illustrated in exemplary network 300 , which is shown in FIG. 3 . The striped and dotted regions 302 , 304 represent the serving area of a pico base station 306 . The dotted region 304 represents an area where the received power from the pico base station 306 is higher than that from the macro base station 308 . The striped region 302 represents an area where the path loss between UE 310 and the pico base station 306 is smaller than that to the macro base station 308 . If the pico base station 306 had the same transmit power as the macro base station 308 , the dotted region 304 would be expanded to cover the striped region 302 . However, in practice, the transmit power level of a pico base station is typically much lower than that of a macro base station, resulting in a much smaller area of the dotted region 304 shown in FIG. 3 .
The striped region 302 is often referred to as the “range-expansion zone” because, from an uplink perspective, the system 300 would still prefer that UE 310 be served by the pico base station 306 within this region. However, from the downlink perspective, terminals at the outer edge of such a range-expansion zone experience very large received power differences between the macro and pico layers. For instance, in the example of FIG. 3 , if the transmit power levels are 40 watt and 1 watt, respectively, from macro base station 308 and pico base station 306 , the power difference can be as high as 16 dB at UE 310 . Thus, if UE 310 is in the range-expansion zone and served by pico base station 306 in the downlink, while at the same time the macro base station 308 is serving UE 312 using the same radio resources, UE 310 would be subject to severe interference from the macro base station 308 .
Existing solutions to this type of interference attempt to avoid simultaneous scheduling of transmission to and from UEs at the cell-edge of neighboring cells. In order to support inter-cell interference coordination, information is communicated between nodes using, for instance, the X-2 interface, in accordance with the LTE specification. Each cell can identify the high-power resource blocks in the frequency domain (e.g. in terms of resource blocks) or time domain (e.g. in terms of sub-frames) for its neighboring cells. This allows the neighboring cells to schedule cell-edge users in a manner that avoids these high-power radio resources. Also, reduced power sub-frame approaches may be used. These mechanisms are currently employed to reduce the impact of inter-cell interference in LTE.
Scheduling coordination between cells in existing systems, however, is not coupled with rate control. The main objective of conventional inter-cell interference coordination (ICIC) schemes is to avoid reusing the radio resources that have high transmit power levels in neighboring cells. Such an approach ensures cell-edge user performance at the expense of network spectral efficiency. The reduction in network spectral efficiency can be even worse for frequency domain partitioning schemes (e.g. frequency-reuse factor greater than 1) or time domain partitioning schemes (e.g. the almost-blank sub-frame (ABS) approach considered for heterogeneous networks (HetNet)).
Some mobile terminals, known as “interference mitigation receivers,” have internal interference cancellation capabilities. There are various types of interference mitigation receivers, such as post-decoding successive interference cancellation (SIC) receivers and iterative multi-stage turbo interference cancellation (turbo-IC) receivers.
To fully take advantage of a user terminal's (UE's) interference cancellation capability, a base station should adjust the transmission data rate accordingly. This has been done in the single-user MIMO (SU-MIMO) case, which is illustrated in FIG. 4 . The serving base station 402 sends multiple data streams to the same UE 404 . The transmission rates of the multiple data streams can be adjusted to account for interference cancellation at the mobile terminal.
For example, the 1 st data stream of FIG. 4 can be decoded by UE 404 first, despite the presence of interference from the 2 nd data stream. After decoding the 1 st data stream, the received signal contributed by the 1 st data stream can be cancelled; the cleaned-up received signal is used for detecting the 2 nd data stream. The base station 402 adjusts the data rate of the 2 nd data stream assuming that the interference from the 1 st data stream will not degrade (or have little effect on degrading) the reception quality of the 2 nd data stream. Such rate adjustment may in fact take place at the mobile terminal in the process of generating the channel quality indicator (CQI) estimates for the multiple data streams. In this process, the mobile terminal accounts for reduced (or no) interference from the 1 st data stream to the 2 nd data stream. The estimated CQI's are fed back to the base station, which uses them as the basis for determining SU-MIMO transmission rates. However, as discussed above, interference remains a significant problem in the case of multiple co-channel users served by nodes in different cells or multiple user MIMO (MU-MIMO) systems when multiple users are served in the same cell.
Accordingly, there is a need for improved scheduling and rate control coordination between cells and in MU-MIMO scenarios that accounts for interference cancellation by UEs in order to maximize spectral efficiency.
SUMMARY
According to certain aspects of the present invention, scheduling efficiency is improved by considering the transmission rate, location, and/or interference cancellation capabilities of UEs in a communication network. In certain embodiments, the transmission data rate to one or more interference cancellation (IC) capable UEs may be adjusted to account for the UE's ability to cancel own-cell MU-MIMO interference or other-cell interference resulting from receipt of transmissions from multiple nodes.
Scheduling decisions may be coordinated among the neighboring cells to ensure high interference cancellation efficiency at a victim terminal, i.e., a UE receiving signals intended for another UE. The scheduling coordinator selects appropriate pairings of co-scheduled users, either in the same cell or different cells, to minimize the impact of co-channel interference. According to certain aspects, the transmission data rates to one or more co-scheduled users may be lowered to ensure good interference cancellation at the other co-scheduled users. When multiple co-scheduled terminals are capable of interference cancellation, the coordinating scheduler may mix different scheduling strategies so that all IC-capable terminals share the efficiency benefit.
For example, the scheduler may determine that in a first sub-frame (or resource block), the transmission rate to a first co-scheduled IC-capable terminal should be lowered to enable a second co-scheduled IC-capable terminal to effectively perform interference cancellation. In the subsequent sub-frame, the transmission rate to the second co-scheduled IC-capable terminal may be lowered to help the first co-scheduled IC-capable terminal perform interference cancellation. In this example, when the performance is averaged over time, both IC-capable terminals see improved user data rates.
In certain respects, certain aspects of the present invention may be characterized as a “reduced-rate radio resource,” approach. This is in contrast to existing sub-frame blanking (zero-rate) schemes, which are based on orthogonal time/frequency resource partitioning. Particular embodiments of the invention provide an improvement over reduced power sub-frame approaches. Specifically, in disclosed embodiments, transmission rates may be lowered, but transmission power need not be modified. In the case of existing reduced power sub-frame approaches, the transmission powers (and necessarily the transmission rates) to the interfering UE(s) are reduced, which, in general, causes the interfering signals to be undecodable by a victim UE. Certain embodiments of the invention enable higher overall system-wide data rates by fully utilizing the interference cancellation capability of the UE(s). The proposed reduced-rate solutions may also be applied to conventional reduced-power approaches as long as the transmission data rate to a co-scheduled terminal is reduced to account for both the reduced transmit power and the decodability at another co-scheduled IC-capable victim terminal.
In certain embodiments, both scheduling coordination and transmission data rate adjustment may be based on CQI estimates received from one or more UEs. They may also be determined by mobility measurements from one or more UEs, e.g., neighbor cell reference symbol received powers (RSRPs) reported to the network. A UE may also report CQI measurements with respect to neighboring cells in addition to reports for its serving cell.
According to certain aspects, a method for cancelling interference from data transmissions within a communication network between UEs and network nodes includes receiving, at a scheduling coordinator, reception quality indicators from a plurality of UEs that indicate, for each UE, representative link quality between the UE and one of a first network node and a second network node. The method further includes selecting a first scheduled UE from among the plurality of UEs to receive data from the first network node during a first period of time and a second scheduled UE to receive data from the second network node during at least a portion of the first period of time. A first data rate is determined for transmitting a first signal from the first network node to the first scheduled UE and a second data rate for transmitting a second signal from the second network node to the second scheduled UE. The selection of the first and second scheduled UEs and/or the determination of the first and second data rates are based on the received reception quality indicators for the first and second UEs, which enables the second scheduled user to cancel, from the second signal, interference caused by the first signal.
According to certain aspects, the received reception quality indicators include CQI information. The method may also include receiving, at the scheduling coordinator, mobility measurement information from one or both of the first and second scheduled UEs relating to one or more of common pilot channel (CPICH) received power, received signal code power (RSCP), and cell-specific reference signal (C-RS) received power (RSRP). In this case, the selection of the first and second scheduled UEs and/or the determination of the first and second data rates are further based on the received mobility measurement information.
In some embodiments, another method for cancelling interference from data transmissions within a communication network between user equipment and network nodes is provided. The method includes receiving, at a scheduling coordinator, location-based indicators from a plurality of UEs indicating, for each UE, a location between the UE and one of a first network node and a second network node. The method also includes selecting a first scheduled UE from the plurality of UEs to receive data from the first network node during a first period of time and a second scheduled UE to receive data from the second network node during at least a portion of the first period of time. A first data rate is determined for transmitting a first signal from the first network node to the first scheduled UE. A second data rate is determined for transmitting a second signal from the second network node to the second scheduled UE. The selection of the first and second scheduled UEs and/or the determination of the first and second data rates are based on the received location-based indicators for the first and second scheduled UEs to enable the second scheduled user to cancel from the second signal interference caused by the first signal.
In certain aspects of the invention, the method may include determining one or more reception quality indicators based on at least one of common pilot channel (CPICH) received power, received signal code power (RSCP), and cell-specific reference signal (C-RS) received power (RSRP).
In certain embodiments, data rate adjustments may be performed at a scheduling coordinator (such as the scheduling coordination unit 800 discussed in further detail below with respect to FIG. 8 ) that has access to the CQI, location data, and/or mobility measurement reports from UEs in one or more cells. For instance, in a High-Speed Packet Access (HSPA) system, this scheduling coordination unit may reside in or represent a radio network controller (RNC), such as RNC 514 illustrated in FIG. 5 . In alternative embodiments (e.g., networks that do not include RNCs), the scheduling coordination unit 800 may represent another type of network nodes. Alternatively, a NodeB (in the case of HSPA) or eNodeB (in the case of LTE) may be designated as the scheduling coordinator among a number of coordinating cells. The coordinating scheduler may be implemented, for instance, in the data processing 708 of a base station 502 . In certain instances, the cells that are being coordinated need to forward measurements to the scheduling coordinator. In a HetNet deployment, a macro cell may be the scheduling coordinator that coordinates its scheduling decision with the pico cells within its cell coverage area.
In certain embodiments, a method for cancelling interference from data transmissions within a communication network between UEs and a plurality of antennas includes receiving, at a scheduling coordinator, reception quality indicators from a plurality of UEs that indicate, for each UE, representative link quality between the UE and one of a first of a plurality of antennas and a second of a plurality of antennas. The method further includes selecting a first scheduled UE from among the plurality of UEs to receive data from the first antenna during a first period of time and a second scheduled UE to receive data from the second antenna during at least a portion of the first period of time. A first data rate is determined for transmitting a first signal from the first antenna to the first scheduled UE and a second data rate for transmitting a second signal from the second antenna to the second scheduled UE. The selection of the first and second scheduled UEs and/or the determination of the first and second data rates are based on the received reception quality indicators for the first and second UEs, which enables the second scheduled user to cancel, from the second signal, interference caused by the first signal. The antennas may be co-located on a base station, for instance, in a multi-user MIMO configuration.
According to particular embodiments, different cells may include a macro cell or pico cell whose coverage area overlaps with that of the macro cell. Thus, the term “inter-cell” interference or “other-cell” interference may include interference from a macro base station to a pico base station as well as interference between macro base stations or pico base stations.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated herein and form part of the specification, illustrate various embodiments of the present disclosure and, together with the description, further serve to explain the principles of the disclosure and to enable a person skilled in the pertinent art to make and use the embodiments disclosed herein. In the drawings, like reference numbers indicate identical or functionally similar elements.
FIG. 1 is an illustration of a wireless communication system.
FIG. 2 is an exemplary sub-frame of an LTE transmission.
FIG. 3 is an exemplary HetNet system.
FIG. 4 is an illustration of an exemplary SU-MIMO system.
FIG. 5 is an illustration of a communication network in accordance with exemplary embodiments of the present invention.
FIG. 6 is a block diagram of user equipment (UE) in accordance with exemplary embodiments of the present invention.
FIG. 7 is a block diagram of a node in accordance with exemplary embodiments of the present invention.
FIG. 8 is a block diagram of a scheduling coordination unit in accordance with exemplary embodiments of the present invention.
FIG. 9 is a flow chart illustrating a process for cancelling interference in accordance with exemplary embodiments of the present invention
FIG. 10 is a flow chart illustrating a process for cancelling interference in accordance with exemplary embodiments of the present invention
FIG. 11 is an illustration of a communication network in accordance with exemplary embodiments of the present invention.
FIG. 12 is an illustration of a communication network in accordance with exemplary embodiments of the present invention.
FIG. 13 is an illustration of a communication network in accordance with exemplary embodiments of the present invention.
FIG. 14 is an illustration of a communication network in accordance with exemplary embodiments of the present invention.
FIG. 15 is an illustration of a communication network in accordance with exemplary embodiments of the present invention.
FIG. 16 is an illustration of a transmission sequence in accordance with exemplary embodiments of the present invention.
DETAILED DESCRIPTION
The impact of inter-cell interference depends closely on the interfered with or “victim” terminal's ability to mitigate interference from signals not intended for the victim terminal. For example, presuming that the victim UE includes an interference mitigation receiver, the victim UE may be able to first decode the interference signal and then cancel the interference signal before decoding its desired signal. Thus, even a strong interference signal can be rendered harmless provided that it can be decoded correctly and removed by the victim UE.
Accounting for this interference mitigation capability, transmission data rates to IC-capable terminals can be higher compared to transmissions to UEs where the interference is not cancelled. If such interference can be cancelled, there is no need to avoid reusing the same radio resources when serving a cell-edge user in a neighboring cell. However, successful interference mitigation in the victim UE is dependent upon on the transmission rate of the interfering signal. This requires that the scheduler of the cell transmitting the interfering signal have an awareness regarding the victim terminal and its link quality with respect to the interference cell. If the victim terminal is served by another cell, the scheduler needs to acquire the victim UE's link quality information from its serving cell.
Particular embodiments of the present invention are directed to methods for scheduling UEs and mitigating the effects of interference in a communication network. An exemplary communication network is provided in FIG. 5 and includes a first base station 502 and a second base station 504 . Each base station has a serving cell, for instance, base station 502 serves cell 506 while base station 504 serves cell 508 . The second base station 504 may be, in this example, a pico base station located within the coverage area of macro base station of 502 . UE 1 is within cell 508 and in communication with base station 504 . UE 2 is within cell 506 and in communication with base station 502 . However, in certain instances, UE 1 receives signals intended for UE 2 , i.e., UE 1 is the victim of interference from base station 502 .
The network 500 of FIG. 5 further includes a third base station 510 , which has a serving cell indicated by 516 . Base station 510 is in communication with and serving UE 3 in this example. The base stations 510 and 502 are connected via a network 512 . A radio network controller 514 may also be connected to the network 512 and configured to communicate with base station 510 and 502 .
FIG. 6 illustrates a block diagram of an exemplary UE communication device 600 , such as UE 1 , UE 2 , and UE 3 of FIG. 5 . As shown in FIG. 6 , the UE communication device may include: one or more antennas 602 , a data processing system 606 , which may include one or more microprocessors and/or one or more circuits, such as an application specific integrated circuit (ASIC), field-programmable gate arrays (FPGAs), or the like, and a data storage or memory system 608 , which may include one or more non-volatile storage devices and/or one or more volatile storage devices (e.g., random access memory (RAM)). The antennas 602 are connected to transceiver 604 , which is configured to transmit and receive signals via the antennas 602 . The UE 600 may optionally include a separate interference cancellation receiver module, or alternatively, the interference cancellation may be implemented in one of the transceiver 604 or data processing 606 .
In embodiments where data processing system 606 includes a microprocessor, computer readable program code may be stored in a computer readable medium, such as, but not limited to, magnetic media (e.g., a hard disk), optical media (e.g., a DVD), memory devices (e.g., random access memory), and the like. In some embodiments, computer readable program code is configured such that when executed by a processor, the code causes the data processing system 606 to perform steps related to interference cancellation and/or reporting of certain values, including for instance, quality indicators and reference measurements. In other embodiments, the UE communication device 600 is configured to perform certain steps without the need for code. That is, for example, data processing system1 606 may consist of one or more ASICs. Hence, the features of the present invention described herein may be implemented in hardware and/or software. For example, in particular embodiments, the functional components of the UE communication device 1600 described above may be implemented by data processing system 606 executing computer instructions, by data processing system 606 operating independent of any computer instructions, or by any suitable combination of hardware and/or software.
FIG. 7 illustrates a block diagram of an exemplary base station, such as base station 502 shown in FIG. 5 . Base stations 504 and 510 may be implemented in a similar manner. As shown in FIG. 7 , the base station 502 may include: a data processing system 708 , which may include one or more microprocessors and/or one or more circuits, such as an application specific integrated circuit (ASIC), field-programmable gate arrays (FPGAs), and the like; a network interface 706 connected to network 512 ; and a data storage system 710 , which may include one or more non-volatile storage devices and/or one or more volatile storage devices (e.g., random access memory (RAM)). The network interface 706 is connected to transceiver 704 , which is configured to transmit and receive signals via one or more antennas 702 . According to particular embodiments, the antennas may be configured to include one or more antenna ports. For instance, antenna 702 may include a first antenna port 0 , and a second antenna port 1 , which correspond to ports 0 and 1 of the LTE specification. In an exemplary embodiment of the disclosed devices and methods, the base station 502 is a Node B or Evolved Node B. According to certain aspects, the disclosed nodes may be macro, micro, pico, and femto nodes operational in a number of cell types and sizes. Cell size and type may include, for instance, very small, small, medium, large, very large, macro, very large macro, micro, pico and femto in accordance with the LTE specification.
In embodiments where data processing system 708 includes a microprocessor, computer readable program code may be stored in a computer readable medium, such as, but not limited, to magnetic media (e.g., a hard disk), optical media (e.g., a DVD), memory devices (e.g., random access memory), and the like. In some embodiments, computer readable program code is configured such that when executed by a processor, the code causes the data processing system 708 to perform steps described below (e.g., steps described below with reference to the flow chart shown in FIGS. 9 and 10 ). In other embodiments, the base station 502 is configured to perform steps described above without the need for code. That is, for example, data processing system 708 may consist merely of one or more ASICs. Hence, the features of the present invention described above may be implemented in hardware and/or software. For example, in particular embodiments, the functional components of the base station described above may be implemented by data processing system 708 executing computer instructions, by data processing system 708 operating independent of any computer instructions, or by any suitable combination of hardware and/or software.
FIG. 8 illustrates a block diagram of a particular embodiment of a scheduling coordination unit 800 . The scheduling coordination unit 800 may represent, or be a component of, any appropriate radio access network node, such as RNC 514 shown in FIG. 5 . As shown in FIG. 8 , the scheduling coordination unit 800 may include the following representative elements: a data processing system 802 and one or more interfaces 804 and 806 . The interfaces may connect the scheduling coordination unit 800 , for instance, to additional radio network controllers, macro base stations such as base station 502 , pico base stations such as base station 504 , and underlying core networks of the communication infrastructure. These interfaces may enable communication, for instance, via communication network 512 . According to certain aspects, the data processing system 802 may include a number of constituent units, such a control section (e.g., controller 808 ), a handover unit 810 , and a combiner and splitter unit 812 in this non-limiting exemplary configuration. Note that in some cases, scheduling coordination functionality may be distributed over multiple different network nodes, so scheduling coordination unit 800 may represent multiple physical components within the relevant network.
In embodiments where data processing system 802 includes a microprocessor, computer readable program code may be stored in a computer readable medium, such as, but not limited, to magnetic media (e.g., a hard disk), optical media (e.g., a DVD), memory devices (e.g., random access memory), and the like. In some embodiments, computer readable program code is configured such that when executed by a processor, the code causes the data processing system 802 to perform steps described below (e.g., steps described below with reference to the flow chart shown in FIGS. 9 and 10 ). In other embodiments, the scheduling coordination unit is configured to perform steps described above without the need for code. That is, for example, data processing system 802 may consist merely of one or more ASICs. Hence, the features of the present invention described above may be implemented in hardware and/or software. For example, in particular embodiments, the functional components of the scheduling coordination unit described above may be implemented by data processing system 802 executing computer instructions, by data processing system 802 operating independent of any computer instructions, or by any suitable combination of hardware and/or software.
Referring now to FIG. 9 , a flow chart 900 illustrating a process for cancelling interference from data transmissions within a communication network is shown. In certain instances, the process 900 may be applied to interference cancellation and scheduling in communication network 500 .
In step 902 , a scheduling coordinator receives reception quality indicators from a plurality of UEs, such as UE 1 and UE 2 in the example of FIG. 5 . The quality indicators are representative of the link quality between the UEs and first and second network nodes 502 , 504 . According to certain aspects, the received reception quality indicators may include CQI information.
The CQI report associated with the desired link is provided to the scheduling coordinator. For instance, UE 1 reports the quality of its link with base station 504 while UE 2 reports the quality of its link with base station 502 . Further, the CQI report associated with one or more interference links may also be provided. In certain embodiments, when the CQI of the desired link is measured and reported by a victim terminal, it may be assumed that the CQI associated with the desired link is measured without any benefit of interference cancellation. However, because the victim terminals of the present example are equipped with post-decoding interference cancellation receivers, the terminals may reflect interference mitigation benefits in their CQI reports.
In step 904 , the first UE (UE 1 ) is selected and scheduled to receive data from a first network node, such as base station 504 during a first period of time. Similarly, the second UE (UE 2 ) is selected and scheduled to receive data from a second network node, such as base station 502 , during at least a portion of the first period of time. As such, the signal intended for UE 2 may interfere with the signal intended for UE 1 due to the overlap of shared radio resources.
In step 906 , a first data rate, to be applied to the first signal transmission from the first base station to the first UE, is determined. In step 908 , a second data rate, to be applied to a second signal transmission from the second base station to the second UE, is determined.
The selection of the first and second UEs and/or the determination of the first and second data rates are based on the received reception quality indicator. Specifically, the rates are selected in order to enable the UEs to cancel interference caused by the unintended signal. For instance, in the example of FIG. 5 , the data rate for the transmission from base station 502 to UE 2 may be reduced to allow UE 1 to effectively cancel the interference caused by the transmission. In certain instances, the appropriate selection of UEs may mean that reduction in data rate is not necessary in order to co-schedule the two UEs. However, in further examples, the data rate for transmission to two, or even all, UEs may need to be reduced in order for each UE to effectively cancel the interference of unintended signals. Similarly, a third and/or fourth UE may be selected rather than, or in conjunction with, UEs 1 and 2 .
Disclosed methods for the cancellation of interference from data transmissions may further include the step of communicating a transmission data rate adjustment message to the first and/or second network node that includes one or more of reduced modulation order, reduced coding rate, and reduced MIMO rank.
The processes disclosed herein are not limited to the HetNet example of FIG. 5 , and as will be discussed further, may be generally applicable to a number of configurations including interference between cells, a HetNet configuration with 3 or more UEs, and same-call multi-user MIMO cases.
Referring now to FIG. 10 , a flow chart 1000 illustrating a process for cancelling interference from data transmissions within a communication network is shown. As with the process 900 , the process 1000 may be applied to interference cancellation and scheduling in communication network 500 .
In step 1002 , a scheduling coordinator receives location-based indicators from a plurality of UEs. These location-based indicators relate to the location of the UE with respect to one of a first and a second network node.
In step 1004 , a first scheduled UE is selected from among the plurality of UEs to receive data from the first network node. The first scheduled UE is allocated spectrum resources during a first period of time. A second scheduled UE is also selected from among the plurality of UEs to receive data from the second network node. The second scheduled UE is scheduled during at least a portion of the first period of time.
In step 1006 , a first data rate for transmitting a first signal from the first network node to the first scheduled UE is determined. This may be determined, for instance, by the scheduling coordinator.
In step 1008 , a second data rate for transmitting a second signal from the second network node to the second scheduled UE is determined. As with step 1006 , this determination may be made by the scheduling coordinator.
The selection of the first and second scheduled UEs and/or the determination of the first and second data rates are based on the received location-based indicators for the first and second scheduled UEs. The scheduled UEs and/or data rates are chosen to enable the second scheduled user to cancel from the second signal interference caused by the first signal. For instance, two UEs may be selected such that given their respective locations, the first and second transmission rates do not need to be reduced in order for one or both to effectively cancel unwanted signal interference. However, their relative locations may indicate that one or both transmissions need to be at a rate lower than would typically be selected give their location with respect to the serving nodes.
FIG. 11 illustrates an exemplary configuration for application of the inventive processes in a HetNet scenario. As shown, UE 1 is located in the pico range-expansion zone 1108 , while both UE 2 and UE 3 are located in the macro coverage area 1106 . At its physical location, UE 1 is capable of receiving and decoding transmissions with rates indicated by channel quality measurements CQI P1 or CQI M1 from either the pico 1104 or macro 1102 node, respectively. Because UE 2 is located further from the macro base station, it is only capable of effective reception from the macro cell at a data rate indicated by CQI M2 , where CQI M2 <CQI M1 . For purposes of this example, it may be assumed that the higher the CQI value, the higher the transmission data rate it corresponds to. With respect to UE 3 , due to its close proximity to the macro base station, it is capable of effectively reception in the macro cell at a data rate indicated by CQI M3 , where CQI M3 >CQI M1 >CQI M2 .
According to certain aspects of the present invention, a coordinated scheduling decision may be made to schedule UE 2 in the macro cell using the transmission data rate corresponding to CQI M2 , while UE 1 is simultaneously served in the pico cell. The interference from the macro base station to UE 1 , regardless of the power level, can be cancelled by UE 1 . This is an effective scheduling and rate decision because UE 1 has a channel condition that permits it to receive the macro signal at an even higher data rate than CQI M2 (CQI M1 is greater than CQI M2 ).
In fact, there is an equal-rate contour within the macro cell corresponding to CQI M1 , which is represented by a dashed circle 1110 in FIG. 11 . Since the transmission data rate to macro users outside of such a contour will be equal to or lower than CQI M1 , scheduling and rate decisions may be location based as opposed to a CQI based, as described in certain embodiments above. According to certain aspects, the macro users outside of this contour can each be co-scheduled with UE 1 . The interference from UE 2 will have limited impact on UE 1 , since the transmission rate for UE 2 is such that the interference from UE 2 may be cancelled at UE 1 .
According to certain aspects, with respect to UEs that reside in the inner pico zone 1112 , there should be no restriction on which users in the macro cell are co-scheduled. This is due to the fact that in region 1112 , the received power from the pico is higher than from the macro. Thus, macro interference is less of a problem and need not be considered in certain instances.
In situations where there is no macro user with a CQI level equal to or lower than CQI M1 (i.e., outside of the CQI M1 equal-rate contour 1110 ), the transmission rate to a co-scheduled macro user, e.g., UE 3 in the system of FIG. 11 , may be reduced. The rate is lowered to ensure that the pico UE in the range expansion zone 1108 , e.g., UE 1 , can reliably decode the macro signal and thus cancel its interference. This approach is referred to herein as a “reduced-rate resource blocks” or “reduced-rate sub-frames (RRS)” approach.
In this scenario, the transmission data rate to a macro user may be adjusted lower when the same radio resources (resource blocks or sub-frames) are reused by a user in the pico range-expansion zone 1108 . This is advantageous in terms of spectral efficiency, particularly when compared to existing blanking (zero-rate) or reduced-power approaches.
One of ordinary skill in the art will recognize that the scenario of one macro cell coordinating with one pico cell can be extended to a scenario where one macro cell coordinates with multiple pico cells, as shown in FIG. 12 , or a scenario where multiple macro cells coordinate with one pico cell, as shown in FIG. 13 .
In FIG. 12 , the macro cell may reduce the transmission data rate from base station 1202 to its served terminal 1204 . This allows the multiple pico served terminals 1206 , 1208 to better decode the macro interference when communicating with pico nodes 1210 and 1212 , and consequently provide for an increase in their respective user data rate after interference cancellation.
In FIG. 13 , multiple macro cells may reduce the transmission data rates from base stations 1302 , 1304 to their respective served terminals 1306 , 1308 in order to enable the UE 1310 perform interference cancellation during communications with pico node 1312 .
According to certain aspects, transmission-rate reduction may be achieved by using one or more of reduced modulation order, reduced coding rate, and reduced MIMO rank. These rates are reduced in comparison to the recommended values from the intended (desired) terminal's channel quality measurement report.
According to certain aspects, scheduling decisions may be coordinated between macro and pico base stations, and the scheduling coordinator may have access to CQI reports from users in macro and pico cells. In one non-limiting embodiment, the scheduling coordinator may reside in the radio network controller (RNC) of an HSPA system. In a second non-limiting embodiment, coordinating schedulers in the base stations can exchange channel quality information via communication to and from the RNC. In a third non-limiting embodiment, the coordinating schedulers can exchange channel quality information via inter-base-station coordinating protocol(s), such as the X 2 protocol specified for LTE.
According to particular embodiments of the present invention, the disclosed processes for mitigation of interference in a HetNet inter-cell interference instance can be generalized to additional network deployments. Here the term “cell” may apply to a coordinated multi-point (CoMP) cell, where antennas at different cell sites work together to serve a user. An example of this configuration is illustrated in FIG. 14 . As shown in the example of FIG. 14 , UEs 1 and 2 are served by base stations A and B, respectively. The signals from base stations A (P A1 , P A2 ) and B (P B1 , P B2 ) cause interference to the unintended co-scheduled UE. In FIG. 14 , the desired signals are indicated by solid lines, whereas the unintended interference signals are indicated by dashed lines.
According to certain aspects, UE 1 reports to its serving base station (base station A) CQI A1 and CQI B1 , corresponding to the radio links to base stations A and B, respectively. A coordinated scheduling decision may pair UE 1 in cell A with a UE, denoted UE k , in cell B which satisfies one of the following conditions:
(i) a UE k with a receiver not capable of IC reporting CQI Bk , while CQI Bk <=CQI B1 ; or (ii) a UE k with a SIC receiver reporting CQI Bk and CQI Ak , while CQI Bk <=CQI B1 as well as CQI Ak >=CQI A1 .
Under the first condition, inter-cell interference can be removed at UE 1 . The first condition may occur when UE k and UE 1 are approximately the same distance from cell B, but the instantaneous fading condition of the B-k link (i.e. the link between base station B and UE k ) is worse than that of the B- 1 link (i.e. the link between base station B and UE 1 ). With respect to the second condition, inter-cell interference can be removed at both UE 1 and UE 2 . The second condition may occur when the fading condition for link B- 1 is much more favorable than that of link A- 1 and also the fading condition of link A-k is much more favorable than that of link B-k.
When neither of the above conditions can be met, the coordinating scheduler can adjust the data rates to the scheduled users in both cells to reap the inter-cell interference cancellation benefit, with the objective of maximizing the sum rate from the co-scheduled users in both cells. For example, the aforementioned reduced-rate approach may be used. One of the coordinating cells reduces the transmission rate to its scheduled user to help a simultaneously scheduled user in a neighboring cell better cancel inter-cell (IC) interference.
Similar scheduling considerations as above can be applied to same-cell multi-user MIMO (MU-MIMO) scenarios, such as the system illustrated in FIG. 15 . In the implementation of the disclosed scheduling coordination techniques in a same-cell MU-MIMO scenario, for example, there may be no need to exchange CQI information (and/or other measurement reports) between cells. Further, there also may be no need to coordinate scheduling decisions between multiple cells. However, one of ordinary skill will recognize that, if same-cell MU-MIMO interference as well as inter-cell interference are considered jointly, scheduling decisions will have to be coordinated between multiple cells and the CQI information (and/or other measurement reports) need to be exchanged or made available at a coordinating scheduler.
As shown in FIG. 15 , a base station 1502 uses antenna A to send one data stream to UE 1 and uses antenna B to send another data stream to UE 2 . In this example, antennas A and B may be physical antennas or virtual antennas (after precoding). For example, in the CoMP case, antennas at different sites may work together through a precoder to form a virtual antenna to serve one or more UEs.
In this example, the signals from antennas A and B cause interference to the other co-scheduled UE. In FIG. 15 , the desired signals are indicated by solid lines, whereas the interference signals are indicated by dashed lines.
If UE 1 is capable of performing post-decoding interference cancellation, a scheduling strategy may be used that schedules UE 2 with a transmission data rate that is achievable at UE 1 . In this example, a transmission rate that is achievable at a UE means that the UE has a channel condition for receiving signals with such a transmission data rate in an error-free, or near error-free, manner. A UE may be selected which has estimated CQIs that are lower than those of UE 1 .
For example, in the system of FIG. 15 , UE 1 has estimated CQIs given by CQI A1 and CQI B1 , which correspond to antennas A and B, respectively. UE 1 may, for instance, be instructed by the serving cell to estimate CQI based on the decoding order of antennas B and A, i.e. antenna B signal is detected first and antenna A signal is detected after antenna B signal is cancelled. According to certain aspects, a scheduling pairing scheme is provided that identifies another UE (UE k ) to be paired with UE 1 that meets one of the following conditions:
(i) a UE k with a receiver not capable of IC reporting CQI Bk , while CQI Bk <=CQI B1 ; (ii) a UE k with a successive interference cancellation (SIC) receiver reporting CQI Bk and CQI Ak , assuming the decoding order of antennas B and A, while CQI Bk <=CQI B1 ; or (iii) a UE k with a SIC receiver reporting CQI Bk and CQI Ak , assuming the decoding order of antennas A and B, while CQI Bk <=CQI B1 as well as CQI Ak >=CQI A1 .
These are exemplary ideal pairing conditions because both UE 1 and UE k can recover their respective desired signals error-free, provided that the CQI estimates are accurate. Also, in all of these instances, the MU-MIMO sum rate is higher those without other-user signal cancellation. The first two conditions are likely to be true when UE k is much further away from the base station site than UE 1 (P A1 >>P Ak and P B1 >>P Bk ). The third condition above is rare and it occurs mainly due to severe disparity between the fading conditions associated with the links corresponding to two transmit antennas.
In some embodiments, a UE may only report the CQI estimate corresponding to the link to the serving base station, e.g., only CQI A1 from UE 1 according FIG. 14 . Thus, base station B or the network does not know CQI B1 . Similarly, in this example, UE k is served by base station B, and thus only CQI Bk is available to base station B and the network. In this case, additional CQI information (e.g., CQI B1 and/or CQI Ak ) needs to be inferred from indirect means.
According to certain aspects, CQI B1 may be inferred from UE 1 's mobility measurement corresponding to interfering base station B. Similarly, UE k , which is served by base station B may only report CQI Bk , and thus CQI Ak may need to be inferred from its mobility measurement corresponding to base station A. The mobility measurement could be based on Common Pilot Channel (CPICH) received power, received signal code power (RSCP), or cell-specific reference signal (C-RS) RSRP.
For example, UE 1 may report mobility measurements M A1 and M B1 regarding base stations A and B, respectively. Thus, for these exemplary mobility measurements, a terminal needs to obtain measurements not only about the serving cell signal strength but also about neighboring cell signal strength. In addition, UE 1 reports channel quality indicator CQI A1 to its serving base station A. With this information, the network can infer CQI B1 as follows:
CQI B1 ≈CQI A1 +M B1 −M A1 ,
where the values are provided on a decibel scale.
According to another aspect, CQI B1 may be inferred from UE 1 's uplink (UL) signal strength or quality measured at base station B. Similarly, for any UE k served by base station B, CQI Ak may be inferred from its UL signal strength or quality measured at base station A. Furthermore adjustments to CQI A1 and CQI Bk may be made at the UE, serving base station, or scheduler, to account for imperfect inter-cell interference cancellation.
In certain embodiments of the disclosed processes for interference mitigation, the number of interfering base stations could be more than one. Moreover, the scheduler and UE may agree on, implicitly (without using special signaling) or explicitly (by using special signaling), which base stations are interfering base stations. For example, the interfering base stations may be the ones from which the UE has the highest measured CPICH or C-RS power levels. Moreover, the disclosed examples can be extended to cases where one or more base stations have multiple transmit antennas.
FIG. 16 provides a transmission sequence 1600 illustrating a number of aspects of particular embodiments of the present invention in a communication network having at least three user devices, three base stations or nodes, and a scheduling coordinator. The scheduling coordinator may be independent or a part of any of the three base stations.
In step 1602 , a first user device transmits data rate and/or CQI information. Similarly, in steps 1404 and 1606 , second and third user devices also transmit data rate and/or CQI information.
In step 1608 , a first base station receives the transmitted information from the first and second user devices. In step 1612 , a second base station receives the transmitted information from the second and third user devices. In step 1616 , a third base station receives the transmitted information from the third user device.
In steps 1610 , 1614 , and 1618 , the base stations communicate the received data rate and/or CQI information to a coordinating scheduler. According to certain aspects, the coordinating scheduler may be co-located with one of the base stations.
In step 1620 , the coordinating scheduler receives the data rate and/or CQI information from the base stations.
In step 1622 , the coordinating compares the information from the base stations. This comparison may comprise, for example, performance of the one or more of the aforementioned processes used to mitigate interference. This comparison results in the determination of data rates for the user devices. Depending on the outcome of the comparison, these data rates may be lower than the data rates typically associated with the reported transmission data rates or CQI information.
In step 1624 , the new data rates for each of the user devices are communicated to the base stations. In step 1626 , the first base station receives new data rates for the first and second user devices. In step 1628 , the second base station receives new data rates for the second and third user devices. In step 1630 , the third base station receives new data rates for the third user device. These data rates may include, for instance, coding and/or modulation rates.
While various embodiments have been described above, it should be understood that they have been presented by way of example only, and not limitation. Thus, the breadth and scope of the present disclosure should not limited by any of the above-described exemplary embodiments. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the disclosure unless otherwise indicated herein or otherwise clearly contradicted by context.
Additionally, while the processes described above and illustrated in the drawings are shown as a sequence of steps, this was done solely for the sake of illustration. Accordingly, it is contemplated that some steps may be added, some steps may be omitted, the order of the steps may be re-arranged, and some steps may be performed in parallel. | Devices and methods for scheduling and interference cancellation that consider the interference cancellation capability of user equipment (UEs) are disclosed. Using reduced-rate sub-frame (or resource block) strategies, the transmission data rate to a scheduled user in a given cell may be reduced to ensure effective interference cancellation performance at the receiver of a co-scheduled user in another cell. By taking advantage of interference mitigation at one or more terminals, a scheduler may improve network spectral efficiency compared to existing inter-cell interference cancellation schemes, including almost blank sub-frame (ABS), further enhanced inter-cell interference coordination (FeICIC), and other resource partitioning schemes, such as reduced power sub-frames or frequency domain resource partitioning. | 8 |
The present invention relates to a protection system that prevents and treats damage to the tendons, ligaments and other structures of a leg which would otherwise be caused by exercise induced strain, exercise induced hypothermia or by external striking. The invention relates in particular to a tendon and ligament support for an animal such as a horse.
BACKGROUND TO THE INVENTION
Tendon and ligament supports are well known in the field of equine medicine. They are used as a support system to prevent tendon and ligament injury and to facilitate the treatment of such tendon and ligament injury. One of the most delicate parts of a horse's anatomy is the area of the canon bone, fetlock joint and pastern regions of the lower leg beneath the knee and hock joints in particular the flexor tendons and suspensory ligaments are subject to strain injury. There are various causes of these injuries, all of which are well known to those engaged in the equine industry. The primary cause of such injury is generally over rotation of the fetlock joint for example, if a horse is excessively tired or unfit then the fetlock joint rotation can cause a dangerous level of tendon strain as it gallops at speed. It has been suggested that when tendon elongation is less than 8% of its relaxed length, there is no danger whatsoever to a horse and where the elongation exceeds 8% and progressively increases to 12% there is increasing stress until there is generally failure when the tendon elongation exceeds 12%. These figures must be taken as illustrative only because, obviously, the amount of tendon elongation will vary from horse to horse and the damage will also vary possibly depending on ambient conditions. However, these figures give some idea as to the approximate range of strain which needs to be considered.
The second major cause of equine tendon and ligament injury is over heating of the tendon material which in turn arises out of the dynamic loading experienced as a horse gallops. Recent research carried out by veterinary science institutions has concluded and published such conclusions which state that the heat generated within the superficial and deep digital flexor tendons and the suspensory and check ligaments of the horses lower leg during exercise is a significant factor in causing the onset of injury to this said anatomy. The studies show that the constant dynamic loading on these tendons and ligaments while the horse gallops causes an accumulation of heat that can reach 45° C. Collagen cells have viability only below a temperature of 42.5° C. Any temperature at or above 42.5° C. will result in irreparable necrotic damage to the collagen cells of which the tendon tissue is comprised. By reducing this build-up of temperature in the tendon and ligament group while exercising, cell necrosis is reduced and consequently the risk of injury to this anatomy can be significantly reduced.
Horse trainers frequently use existing boots and bandages for the purpose of protecting the horses legs against traumatic injuries caused by a strike impact from a hard object, most often a strike impact from another of the horse's legs. However these conventional boots or bandages, because they entirely cover the tendons while exercising, heat insulate the horses tendons and ligaments and prevent the aforementioned exercise induced heat from escaping to the outside air. FIG. 21 illustrates this problem where the heat transmits from the tendon core outward to the leg surface where it is blocked from further dissipation by the insulating effect of the conventional boot or bandage. Heat within the tendon core will then accumulate. Consequently the risk of heat injury to the tendons and ligaments is increased by the use of such heat insulating boots and bandages. The horse in nature is protected somewhat against such exercise induced heat build-up within the tendon and ligament cores, by the fact that as it gallops the cold air, passing unrestricted over the surfaces of the bare leg of the horse, takes with it a proportion of this said heat build up and thereby cools or reduces the core temperature of these tendons and ligaments. By using conventional boots and bandages this natural cooling method is lost.
A third major cause of tendon damage is when the tendons of the front leg are struck by the horse's hind leg. The horse's lower leg below the knee and hock joints, is also subject to a variety of traumatic injuries caused by a strike impact from a hard object, most often a strike impact from another of the horse's legs. These injuries include but are not limited to traumatic injury of the superficial digital flexor tendon, deep digital flexor tendon, the suspensory ligament, the check ligament, the extensor tendons, the skin, the synovial sheaths, the sesamoid bones, the coronet band and to the entire metacarpophalangeal joint area. There are in existence devices that are designed to protect the above-mentioned specific anatomy from a traumatic injury caused by a strike impact from another of the horse's legs. These conventional strike protection devices aim to shield the horse's legs from an impact and are at present constructed from one of the following materials: leather, plastics, rubber, woven fabric and non-rigid Kevlar. However it has been observed by veterinary surgeons that while these devices prevent penetration of the walls of the devices, they are not entirely effective at preventing injury. Indeed serious traumatic injuries to the aforementioned specific anatomy have continued to occur frequently despite the horses in question wearing these conventional devices at the time of injury. FIG. 28 illustrates this very problem which commonly occurs during an accidental over-reach while wearing one of the currently available devices. The hind leg can strike into the tendons of the front leg with an impact force in excess of 1000 Kg. It can be seen that the conventional strike prevention devices when struck by the hind leg at such forces, while they will prevent actual penetration of the impacting object through the wall of the device, they do not have sufficient stiffness and hardness to maintain their original shape. Consequently their shape deforms at the point of impact and the force is concentrated and effectively penetrates through to the fragile tendons and ligaments underneath. The result is inevitably a traumatic injury. The sources of impact include not only another of the horse's own legs but also can be from a fence which a horse is jumping, a polo mallet, a polo ball, the terrain or any other possible sources of external impact to which a horse could be exposed.
A further problem that occurs when a horse suffers a leg injury is that there is a high incidence of consequent tendon and ligament injury to the opposite leg as the animal takes the weight off the injured limb and places it all onto the opposite leg. Also, rotation of the fetlock joint can lead to a risk of carpal bone chip fracture.
In this specification the term “rotation” when used in relation to joints means pivoting or movement as would be the normal use of the joint and not as it is sometimes used to mean a twisting or other abnormal distortion of the joint. Thus, the terms “rotation” and “pivoting” are used interchangeably in this specification. Also the terms >“fetlock joint” and “metacarpophalangeal joint” refer to the same joint.
Many methods have been used to prevent or cure these problems and have heretofore been relatively inefficient and of limited or little use. For example, in GB-A-2,166,655 there is described and claimed a shock absorbing fetlock support of this general type, that can be best described as an auxiliary tendon support which is not in fact a full support system, even though it is described as such. It would undoubtedly absorb a certain amount of shock, but does not effectively limit rotation of the fetlock joint and hence tendon and ligament strain, which is an object of the present invention. The problem is that it does not take what is effectively the impact of the horse's hoof and the weight transmitted there through all of which is transmitted through the fetlock. This is because, in nature when the horse gallops, the hoof strikes the ground causing the fetlock joint travels downward towards the ground and while undoubtedly one of the problems is that this downward extension by the fetlock joint is transferred to the tendons and ligaments of the horse. The invention described in GB-A-2,166,655 would undoubtedly assist in protecting the fetlock joint but may not as suggested limit the strain on the tendons.
U.S. Pat. No. 5,579,627 describes a protection wrap for the horse's lower leg. In a laboratory experiment conducted by a major veterinary university in the UK to evaluate various non-rigid support systems for the equine metacarpophalangeal joint, this device was assessed as a means of supporting the metacarpophalangeal joint. It concluded that the device described by U.S. Pat. No. 5,579,627 had no significant effect in reducing tendon and ligament strain in horses. This is due to the fact that the soft materials from which it is constructed do not have sufficient strength and stiffness to cope with the immense forces of 2000-3000 Kg of tensile load on the flexor tendons as a horse exercises, whereas the invention described herein was proven to have a significant effect in reducing tendon and ligament strain in horses. U.S. Pat. Nos. 1,395,689; 3,209,517; 5,115,627; GB-A-1,153,613; GB-A-1,472,436 are representative of the prior art describing a similar form of boot used to protect a horse's foreleg from strikes by a hind leg, for example when galloping, but do not adequately prevent the fetlock and tendons being under constant stress.
GB-A-1,153,613 describes a support device with collars above and below the joint held together by an arrangement including an adjustable connecting strap at the back of the leg, but no hinge arrangement. While this provides a limited amount of support at a standstill, support during exercise is effectively not possible because the two collars will pull together under a tensile load.
U.S. Pat. No. 3,439,670 describes a brace for rigidly supporting knee and fetlock joints in animals. However, movement of a limited kind may be allowed by the provision of a spring-loaded hinge arrangement. The spring projects from brackets to the front of the horse's leg counteracting an articulated or hinted part of the brace to the sides of the horse's leg, to resist extension of the joint. However, this is an awkward arrangement because of the position of the spring to the front of the joint, which obstructs to the flexion of the joint, so that there is very little control of the degree of allowable movement, and no provision for any allowable sideways rotation at the fetlock joint. Also there may be a tendency for the upper part of the brace to slide upwards under load and lose its position, as there is nothing to hold the device in position along the back of the fetlock as the brace straightens out under load
Thus a need is identified for a tendon and ligament support that can effectively limit tendon and ligament strain as a horse exercises or rests by limiting the degree of rotation of the fetlock joint to a safe level and of which such support can be adjusted by the user.
Thus a need is identified for a tendon and ligament support applied to the horse's leg that will coot the said tendons and ligaments during exercise.
Thus a need is identified for a tendon and ligament support for the horse's leg that has the stiffness and strength to maintain its shape during the severest of strike impacts. It can therefore distribute the impact forces over a wider area and consequently significantly reduce the possibility of a strike injury. There is also identified a need for a strike impact protection device that can deflect the strike impact away from the horse's leg in the quickest possible time. This immediate deflection will further aid to protect the horse's leg.
SUMMARY OF THE PRESENT INVENTION
The present invention provides a tendon and ligament support device for a limb joint in accordance with claims which follow. The invention is ideally suited to, but not limited to, a load-bearing limb joint such as a knee or ankle joint. Most suitably, the invention is adapted for use as a tendon and ligament support device for an especially a horse's fetlock joint.
In the present invention, a connection means between two articulated limb-embracing collars is adapted to provide limited ligament and/or tendon elongation under load, and includes means arranged to the posterior side of the joint so as to exert a resistance to joint movement over a predetermined range of joint rotation. A unique function of the support of the present invention is that it resists joint extension only while allowing unrestricted flexion of the joint.
This present invention prevents injury to tendons and ligaments in a number of ways. Firstly the invention is directed towards providing such a tendon and ligament support which will have the advantage not alone of supporting the tendons and ligaments, but of effectively replacing the tendons and ligaments as it were and ensuring that all or substantially all of the downward force exerted by body mass, while exercising or standing, is directly transmitted from the flexor tendons and suspensory ligament to the front of the leg bones, for example the canon and pastern bones in an animal such as a horse. Secondly, further injury is alleviated by incorporating a built-in cooling system which effectively cools the tendons during exercise. Thirdly, the present invention aims not merely to stop an impacting object from penetrating through the walls of the device and injuring the tendons and ligaments beneath, but to prevent any of the forces of impact from reaching the said anatomy
The present invention is further directed towards providing a tendon and ligament support which can be used not alone for the prevention of tendon and ligament injury but also as an improved treatment of such injury.
In one embodiment of the invention a resistance-exerting pivot means incorporates an adjustment means to vary the amount of resistance to pivoting and therefore the range of fetlock joint rotation over which it exerts the said resistance. The advantage of this is that it allows veterinary surgeons to control the heating of the injured tendons. By means of its quick adjustment control it is possible to reduce gradually the amount of support it provides to the injured tendons as they heal. This will overcome problems associated with tendon repair caused by sudden loading on an injured leg when a cast is removed and on return to exercise. It will also overcome the problem of adhesions of the flexor tendon and suspensory ligament. This is a build-up of scar tissue that often occurs using conventional methods of tendon injury treatment. As a certain amount of mechanical loading is important for healthy healing and prevention of adhesions, this ability of the invention described here to support the limb in a controlled manner has, in clinical cases, enabled animals to be brought back into light work earlier thus reducing the convalescence period
In another embodiment of the invention, the pivot means is arranged to prevent pivoting beyond a predetermined critical amount of fetlock joint rotation. The advantage of this is that, when used as an injury prevention method, the device will not interfere with the normal movement of the horse during exercise but will only resist joint rotation if it should reach a dangerous level that would otherwise result in tendon strain.
Ideally, the pivot means is arranged to exert progressively increasing resistance to pivoting as the fetlock joint rotates under downward pressure. The advantage of this is that the more the fetlock joint rotates, the harder it becomes for the horse to rotate the actual joint, preventing any subsequent injury. This is very beneficial when a horse has already injured one leg, thus preventing any further damage to the injured leg and preventing the increase load on the uninjured legs. Here a tendon and ligament support is provided in which the pivot means is arranged to exert increasing resistance to pivoting as the fetlock joint rotates under downward pressure.
In one embodiment of the invention the pivot means is arranged to exert no resistance to pivoting until the fetlock joint rotates beyond a predetermined critical amount of fetlock joint rotation. Again, while preventing injury it does not interfere with the normal movement of the horse.
In a further embodiment of the invention the connection piece accommodates limited lateral movement between canon and pastern bone which has the advantage of allowing the invention to be used on animals with abnormal or crooked joint rotation.
In a still further embodiment of the invention the pivot means is formed by a hinge having its pivot joint concentric with the pivot point of the horse's fetlock join. The advantage of this is that the hinge of the support device moves in exact unison with the horse's own natural movement of the fetlock joint. This will ensure that the support device does not move or slip from its correct position on the horse's leg when in use. It also has the advantage of stopping the canon bone embracing collar and the pastern bone-embracing collar from being forced together under load.
Ideally there is a pair of hinges, one on either side of the fetlock joint. This provides added support to the fetlock joint, reducing the risk of dislocation from the correct position on the leg.
In a further embodiment of the invention the hinge incorporates a brake to provide desired resistance to pivoting. The brake may be adjusted to suit any individual horse's movement, which might not necessarily suit another horse as the load exerted would be individual to each animal, when affected by such factors as weight and speed.
In another embodiment of the invention the hinge incorporates a stop to prevent rotation beyond a predetermined critical amount of fetlock joint rotation. This would be advantageous in that there is no possibility that the horse would ever over-rotate the fetlock joint
In yet another embodiment, a means for locking or clamping the hinge is provided enabling the fetlock joint to be totally immobilised in the manner of a cast around the horse's leg. Thus, the tendon and ligament support of the present invention could be used to exert total resistance to joint movement in both flexion and extension when so required, for example during the early stages of injury treatment
In a further embodiment of the invention the desired resistance to pivoting is provided by an artificial tensile tendon comprising an extendable connection piece connecting the collars adjacent the back of a horse's leg. The ability to adjust the tension of the artificial tendon is beneficial in circumstances such as when the horse has already sustained a leg injury and its natural desire is to place the entire bodyweight onto the opposite leg. When the support is fitted to both legs, there is no risk of consequent strain injury to the opposite healthy leg.
In a further embodiment of the invention the artificial tensile tendon extends around the leg to embrace the sesamoid bones behind the fetlock joint.
In a still further embodiment of the invention there is a rigid connection between the hinge and the artificial tensile tendon on both sides of the leg to allow limited movement therebetween.
Ideally the connection piece comprises a piece of substantially inelastic material capable of limited flexion to provide pivot means.
Ideally the canon bone-embracing collar incorporates a rigid elongate support extending along the canon bone and the pastern bone-embracing collar incorporates a rigid elongate support extending along the pastern bone. In another embodiment of the invention the pastern bone-embracing collar extends over the hoof.
In a further embodiment of the invention the elongate support is adjacent the front leg.
In a still further embodiment of the invention each collar comprises a front panel with air intakes allowing air or fluid to penetrate through the front of the device. Connecting channels in the walls of the canon bone collar allow the coolant air or fluid that enter through the front to pass from the front of the leg around to the back of the leg where the tendons and ligaments in question are located.
In yet another embodiment of the invention, each collar may further comprise a shock absorbing foam lining, a gas permeable panel covering the tendon area at the back of the leg which allows hot or cold air or fluid to pass. This comprises materials that include but are not restricted to a gridwork of perforated foam or a gas permeable membrane such as a thin fabric. A curved composite material panel of a hard and smooth outer surface, is attached to the back of the foam lining about the position of the horse's flexor tendons and suspensory and check ligaments. A curved composite material panel of a hard and smooth outer surface, is attached externally to the front of the foam lining about the position of the horse's extensor tendons. A curved composite material panel of a hard and smooth outer surface, is attached externally to the foam lining about each side of the horse's fetlock joint.
Preferably a cushioning material is interposed between the inside surface of the collars and the horse's leg.
In another embodiment of the invention the cushioning material is of a viscoelastic foamed plastics material.
In another embodiment of the invention the canon bone embracing collar and the pastern bone-embracing collar are each opening central to the front of the leg.
In another embodiment of the invention the artificial tendon component has a central ring embracing the sesamoid bones. Anchored around the ring is an array of straps, of adjustable tension and length, which are in turn anchored to the canon bone embracing collar and the pastern bone-embracing collar.
In another embodiment of the invention the outer surfaces of the construction comprises a significantly stiffer and harder structure and shape that will retain its original shape under the severest of strike impacts and will distribute the force of this impact over a wider area. Due to its hard and smooth curved shape, it will immediately deflect the force of the impact away from the horse's leg.
DETAILED DESCRIPTION OF THE INVENTION
The invention will be more clearly understood from the following description of some embodiments thereof given by way of example only with reference to the accompanying drawings in which:
FIG. 1 is a side view of a tendon and ligament support according to the invention on a horse in standing position;
FIG. 2 is a side view of the tendon and ligament support of FIG. 1 representing the horse's fetlock joint under exercise load;
FIG. 3 is a typical vertical cross section through the tendon and fetlock support as illustrated in FIG. 1 on a horse in standing position;
FIG. 4 is a typical vertical cross section through the fetlock support as illustrated in FIG. 2 representing the horse's fetlock joint under exercise load;
FIG. 5 is a side view of an alternative construction of the tendon and ligament support;
FIG. 6 illustrates a still further construction of the tendon and ligament support;
FIG. 7 is a side view of a still further construction of the tendon and ligament support according to the invention;
FIG. 8 is a perspective view of portion of the tendon and ligament support of FIG. 7 ;
FIG. 9 is a side view of another tendon and ligament support according to the invention;
FIG. 10 is a side view of a still further tendon and ligament support according to the invention;
FIG. 11 is a side view of a still further tendon and ligament support according to the invention;
FIG. 12 a rear view of the tendon and ligament support of FIG. 11 ;
FIG. 13 is a side view of another tendon and ligament support according to the invention:
FIG. 14 is a side view of the tendon and ligament support of FIG. 13 in the loaded position;
FIG. 15 is a part sectional view of an artificial tendon according to the invention;
FIG. 16 is a side view similar to FIG. 15 of the artificial tendon in the loaded position;
FIG. 17 is a side sectional view of a still further artificial tendon according to the invention;
FIG. 18 is a side view of the artificial tendon of FIG. 17 in the loaded position;
FIG. 19 is a side view of a still further tendon and ligament support according to the invention
FIG. 20 is a cross-sectional view along the line X-X of FIG. 19 ;
FIG. 21 is a cross-sectional side view of a tendon and ligament support on a horse's leg;
FIG. 22 is a cross-sectional side view of the tendon and ligament support on a horse's leg;
FIG. 23 is a cross-sectional plan view along the line A-A of FIG. 22 ;
FIG. 24 is a perspective view of still a further tendon and ligament support according to the invention;
FIG. 25 is a further perspective view of the tendon and ligament support of FIG. 24 ;
FIG. 26 is a still further perspective view of the tendon and ligament support of FIG. 24 ;
FIG. 27 is a part development view of the tendon and ligament support of FIG. 24 ;
FIG. 28 is a cross-sectional side view of a tendon and ligament support on a horse's leg; and
FIG. 29 is a cross-sectional side view of the tendon and ligament support;
Referring to the drawings and initially to FIGS. 1 to 4 thereof, there is provided a fetlock support for a horse's leg indicated generally by the reference numeral 1 having a canon bone-embracing collar 2 and a pastern bone-embracing collar 3 connected by a connecting piece 4 formed from a non-rigid, essentially inelastic or stiff material of high tensile strength, which allows limited elongation under load. The connecting piece 4 which runs along the palmar aspect of the metacarpus and digit, effectively exerts a resistance to rotating about a pivot point 5 over a predetermined range of fetlock joint rotation. Interposed between the horse's leg and the canon bone-embracing collar 2 and the pastern bone-embracing collar 3 is a cushioning material 8 . The cushioning material 8 may be of any natural or synthetic material such as a viscoelastic foamed plastic. This material has been found to be most effective at absorbing the impact of a strike from a hind leg.
The connection piece, which can be made from any suitable inelastic and high tensile material such as unidirectional Kevlar fibre, will allow limited elongation and effectively provide a resistance to fetlock joint rotation within the connection piece by its very nature. Thus there is an inelastic support of high tensile strength provided which will prevent excessive pivoting of the fetlock joint and hence excessive tensile stress on the tendons and ligaments. The fetlock joint point of rotation is identified by the reference numeral 5 , as are the sesamoid bones by the reference numeral 6 . The hoof is identified by the reference numeral 7 .
When the horse places weight on its leg, a compression load identified by the reference letter X in FIGS. 2 and 4 is exerted on the canon bone. As it does so the cannon bone moves downwards towards the ground and this in turn causes the fetlock joint 5 to rotate. The connecting piece 4 resists this said rotation as it must now stretch under tensile load. Since the connection piece is inelastic, of a high tensile strength, and is securely anchored between the canon bone embracing collar 2 and the pastern bone-embracing collar 3 , it will resist rotation of the fetlock joint 5 . Since this rotation of the fetlock joint is the cause of tensile stress on the flexor tendons and ligaments of the horse, any reduction of this said rotation by artificial means will artificially reduce the said stress on the tendons.
Referring to FIG. 5 , there is illustrated an alternative construction of tendon and ligament support indicated generally by the reference numeral 10 in which parts similar to those described with reference to the previous drawings are identified by the same reference numerals. In this embodiment the connecting piece comprises a compression hinge 11 between the canon bone-embracing collar 2 and the pastern bone-embracing collar 3 . An artificial tensile tendon 12 is mounted between the canon bone-embracing collar 2 and the pastern bone-embracing collar 3 behind the fetlock joint 5 . This tensile tendon 12 is an inelastic connection piece and will provide support for the tendons and ligaments by exerting a resistance to the pivoting of the canon bone collar 2 about the pastern bone-embracing collar 3 in the same manner as described above. The purpose of this hinge 11 , which rotates concentrically with the pivot point of the fetlock joint 5 , is to keep separate the two collars as they are inclined to be pulled together by the artificial tensile tendon, under high load.
Referring now to FIG. 6 there is illustrated a still further construction of tendon and ligament support indicated generally by the reference numeral 20 which is substantially similar to the tendon and ligament support 10 illustrated in FIG. 5 and parts similar to those described with reference to the previous drawings are identified by the same reference numerals. In this embodiment there is provided a compression hinge 21 which, unlike the hinge of FIG. 5 , resists rotation by means of friction within the bearing surfaces of the hinge itself. The hinge can be of any suitable construction. It is envisaged that the hinge may be resistant to rotation in one or both directions.
Referring now to FIGS. 7 and 8 , there is illustrated a still further construction of tendon and ligament support indicated generally by the reference numeral 30 in which parts similar to those described with reference to FIG. 5 are identified by the same reference numerals. In this embodiment, each of the bone-embracing collars 2 and 3 incorporate a pair of rigid bars 31 in a pad 32 as can be seen clearly in FIG. 8 . The bars 31 will help to distribute the load across both the canon bone-embracing collar 2 and the pastern bone-embracing collar 3 .
Referring now to FIG. 9 , there is illustrated a still further construction of tendon and ligament support indicated generally by the reference numeral 40 in which parts similar to those described with reference to FIG. 5 are identified by the same reference numerals. In this embodiment there is provided a pastern bone-embracing collar 41 which extends over the hoof 7 providing further support.
In FIG. 10 there is illustrated an alternative construction of tendon and ligament support 50 which is substantially identical to the tendon and ligament support illustrated in FIG. 9 , except that there is provided a pastern bone-embracing collar 51 securely connected to a hoof shoe support 52 fitted beneath the hoof 7 .
Referring now to FIGS. 11 and 12 , there is illustrated an alternative construction of tendon and ligament support indicated generally by the reference numeral 60 . In this embodiment which is substantially similar to the embodiment illustrated in FIG. 5 , and in which parts similar to those described with reference to FIG. 5 are identified by the same reference numerals, there is provided an artificial tensile tendon 61 which extends around the leg to brace the sesamoid bones behind the fetlock. The advantage of this is that any weight that might be transmitted to the sesamoid bones is now transmitted over a wider area for reduced pressure on the sesamoid bones. Because of the manner in which the artificial tendon 61 is constructed, the hinge 11 cannot be clearly seen. The artificial tendon 61 effectively cups the back of the joint as it extends, as shown in FIG. 11 , and prevents any tendency for upward slide of the collar 2 .
Referring now to FIGS. 13 and 14 , there is illustrated a still further construction of tendon and ligament support indicated generally by the reference numeral 70 ; again parts similar to those described with reference to FIG. 5 are identified by the same reference numerals. In this embodiment, there is an artificial tensile tendon 71 connected by a connector piece 72 to the hinge 11 . It can be seen from FIG. 12 how the connector piece 72 protects and bears the pressure that would normally be transmitted to the sesamoid bones.
Referring now to FIGS. 15 and 16 , there is provided an alternative construction of artificial tendon, indicated generally by the reference numeral 72 which comprises a compressible member 73 mounted against a support 74 on the canon bone-embracing collar 2 , only portion of which is shown. A member engaging means 75 is provided and is connected by a rod 76 and strap 77 to the pastern bone-embracing collar, which is not illustrated. The compressible member 73 can be formed from any suitable compressible material such as rubber. It will be seen from FIG. 14 how the compressible member 73 is compressed under load.
Referring now to FIGS. 17 and 18 , there is illustrated an alternative construction of artificial tendon indicated generally by the reference numeral 80 , which comprises a cylinder 81 having a mounting hole 82 for connection to one of the canon or pastern bone embracing collars which houses a piston 83 connected by a rod 84 to a strap 85 which can be connected to the other bone-embracing collar. Housed within the cylinder 81 by the piston 83 is a compression resistant material 86 . This material could be any liquid, gas or a solid material such as a foamed plastics material or rubber. FIG. 18 illustrates how this works under a load X. The important aspect of this latter embodiment is that there is a high level of controllability. By means of altering the volumetric ratio between the compressible material and the actual container or cylinder it is possible to alter clearly the response of the artificial tendon, and thus to tailor the particular construction of artificial tendon to a specific strain curve and thus to an animal's need.
Referring now to FIGS. 19 and 20 , there is illustrated a canon bone-embracing collar indicated generally by the reference numeral 90 incorporating an elongate open-ended cooling channel 91 . The advantage of the cooling channel 91 is that it will allow water and air to pass therebetween preventing irritation and other diseases or damage to the horse's legs. These can occur if the temperature of the leg gets too high and also if any pressure is placed on the tendon surface as the horse exercises.
Referring specifically to FIGS. 21 to 23 , FIG. 21 illustrates the heat-insulating problem associated with conventional equine leg protection devices 100 . The heat, represented by white arrows, radiates from the tendon core 101 outward to the leg surface where it is blocked from further dissipation by the insulating effect of the conventional boot or bandage. Heat within the tendon core will then accumulate. Consequently the risk of heat injury to the tendons and ligaments is increased by the use of such heat insulating boots and bandages. FIGS. 22 and 23 illustrate an advantage of the invention in its ability to aid cooling of the flexor tendons and suspensory ligament during exercise. The device which utilises the high-speed, cold air 102 hitting the front of the horses leg, as it gallops, to pass through air intakes 103 at the front of the device. From there the high-speed, cold air is compressed and channelled via air channels 104 to the tendons and ligaments 105 . This air then acts as a coolant for the horse's tendons and ligaments 105 . The circulation of cold air through the structure is enabled by air exit holes 106 .
Referring now specifically to FIGS. 24 to 27 , there is illustrated a tendon and ligament support indicated generally by the reference numeral 111 , having a canon bone embracing collar 112 and a pastern bone embracing collar 113 connecting together by a compression hinge 114 and a tensile artificial tendon 115 . Both collars 112 and 113 are hinged centrally at the back and closed centrally at the front. This enables unitary construction whereby each of the collars requires only two parts. It also enables an easy method of applying the device to the horse's leg. FIG. 27 illustrates the artificial tensile tendon 115 in another embodiment where it comprises a central ring 116 embracing the sesamoid bones. Anchored around the central ring 116 is an array of straps 117 , of adjustable tension and length and made from flexible material of high tensile strength such as unidirectional Kevlar fibres. These straps 117 are in turn anchored securely to the canon bone embracing collar and the pastern bone-embracing collar. The device resists fetlock joint rotation by means of the inherent compression strength of the carbon fibre joint 114 combined with the tensile strength of the Kevlar tensile artificial tendon 115 . The amount of resistance that the system provides to fetlock joint rotation is a function of the position of an adjuster 118 , with a range of settings. The different settings change the length of the tensile artificial tendon 115 . At the lowest setting, the support element is at its longest and hence slackest length, offering the least amount of support; while at the highest setting the tensile artificial tendon 115 is shortest, offering the greatest degree of support to the fetlock joint.
Referring now specifically to FIGS. 28 and 29 , FIG. 28 illustrates the over-reach striking problem associated with conventional equine leg protection devices 100 . These devices 100 typically have an outer shell made from relatively soft materials such as leather, plastic or woven fabrics. These softer materials cannot resist the strike impact of the most severe over-reach by a hind leg. Consequently the material deforms on impact and the horse commonly gets a traumatic injury. FIG. 29 illustrates a tendon and ligament support comprising a canon bone-embracing collar 121 . This illustrates the benefits of the invention in the event of an accidental strike from a hind leg. Here a composite panel 123 externally covers the vulnerable anatomy. As can be seen the force of the impact is distributed over the entire length of the device and is immediately deflected away from the horse's tendons and suspensory ligament. The shock absorbent foam 122 underneath further increases this protective effect. This foam can for example be of a viscoelastic type foam with excellent shock-absorbing properties. The combination of the inherent stiffness of the composite panel 123 , such as but not limited to carbon fibre, and the curved outer shape into which it is moulded ensure that it will not deform in shape during the severest of impacts that can occur during equestrian activities. Also the composite panels are designed in such a way as to take advantage of the combined properties of hard resin carbon fibre. These include hardness, stiffness and low friction. These characteristics combined in turn with a curved outer shape panels with a low friction, hard surface, will aid to immediately deflect the force of the impacting object away from the fragile anatomy concerned.
The tendon and ligament support according to the present invention will be used for many different purposes. For example, when racing horses it is important that if the tendon and ligament support is used, it does not in any way interfere with or enhance whatsoever the normal movement of the horse. However, if the tendon and ligament support is arranged not to exert any resistance to rotating until the fetlock joint rotates beyond a point where damage could occur to the horse such as, for example, when a horse is over tired or unfit, then this will not be performance-enhancing as the horse will no longer be able to race effectively but would simply prevent injury. A similar situation may occur during training. Further, when a trainer is attempting to build up a horse's strength after a long lay off whether due to injury or some other reason then providing some support to the tendon and ligament joints by having a progressively increasing resistance to pivoting may be advantageous. Further, when a horse has been injured it may be necessary to provide almost complete immobility of a fetlock joint to ensure that the tendons and ligaments are not damaged should they be sound or if they are damaged, to give them sufficient time and opportunity under rest conditions to recover.
Many materials may be used in the construction of the present invention. For example composite materials are often advantageous in situations such as this. A carbon fibre material would be particularly advantageous for the manufacture of the various parts of the invention. This material can be used to give a very high level of structural stiffness and at the same time is relatively light-weight. Obviously in situations where lightness of weight is not crucial, for example when the invention is used for the treatment of injury, less expensive materials such as aluminium or steel, while heavier, may be used as they will still provide the relative degree of structural stiffness. As explained above, viscoelastic foamed plastics, glass fibre and Kevlar materials are also advantageously used.
It is envisaged that any suitable materials may be used to manufacture the support of the invention. It is further envisaged that the hinges may provide some lateral play.
In the specification the terms “comprise, comprises, comprised and comprising” or any variation thereof and the terms “include, includes, included and including” or any variation thereof are considered to be totally interchangeable and they should all be afforded the widest possible interpretation and vice versa.
The invention is not limited to the embodiments hereinbefore described which may be varied in both construction and detail. | A tendon and ligament support for a limb joint, such as an ankle joint, in particular a horse's fetlock joint. A first collar ( 1 ) is adapted to embrace the limb above the joint and a second collar ( 3 ) is adapted to embrace the limb below the joint. A connection provides articulation between and separation of the two collars, and is adapted to provide limited elongation of the ligaments and/or tendons under load, and includes a resistance-exerting pivot arrangement ( 11 ) resisting joint flexion or extension over a predetermined range of joint rotation, and an essentially inelastic part ( 12 ) for limiting joint extension across the posterior side of the joint connected to one or more points on each of the collars, and preferably adapted so as to mimic an artificial tendon or ligament arrangement. | 0 |
RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application No. 60/301,516, filed on Jun. 27, 2001, and is also a continuation-in-part of U.S. patent application Ser. No. 09/631,185, filed on Aug. 2, 2000, which claims the benefit of U.S. Provisional Application No. 60/146,737, filed on Aug. 2, 1999. The entire teachings of the above applications are incorporated herein by reference, although for the convenience of the reader, some parts may be repeated herein.
BACKGROUND OF THE INVENTION
Macromolecular x-ray crystallography is an essential aspect of modern drug discovery and molecular biology. Using x-ray crystallographic techniques, the three-dimensional structures of biological macromolecules, such as proteins, nucleic acids, and their various complexes, can be determined at practically atomic level resolution. The enormous value of three-dimensional information has led to a growing demand for innovative products in the area of protein crystallization, which is currently the major rate limiting step in x-ray structure determination.
One of the first and most important steps of the x-ray crystal structure determination of a target macromolecule is to grow large, well diffracting crystals with the macromolecule. As techniques for collecting and analyzing x-ray diffraction data have become more rapid and automated, crystal growth has become a rate limiting step in the structure determination process.
Vapor diffusion is the most widely used technique for crystallization in modern macromolecular x-ray crystallography. In this technique, a small volume of the macromolecule sample is mixed with an approximately equal volume of a crystallization solution. The resulting drop of liquid (containing macromolecule and dilute crystallization solution) is sealed in a chamber with a much larger reservoir volume of the crystallization solution. The drop is kept separate from the reservoir, either by hanging from a glass cover slip or by sitting on a tiny pedestal. Over time, the crystallization drop and the reservoir solutions equilibrate via vapor diffusion of the volatile species. Supersaturating concentrations of the macromolecule are achieved, resulting in crystallization in the drop when the appropriate reservoir solution is used.
The process of growing biological macromolecule crystals remains, however, a highly empirical process. Macromolecular crystallization is a hyperdimensional phenomena, dependent on a host of experimental parameters including pH, temperature, and the concentration of salts, macromolecules, and the particular precipitating agent (of which there are hundreds). A sampling of this hyperspace, via thousands of crystallization trials, eventually leads to the precise conditions for crystal growth. Thus, the ability to rapidly and easily generate many crystallization trials is important in determining the right conditions for crystallization. Also, since so many multidimensional data points are generated in these crystallization trials, it is imperative that the experimenter be able to accurately record and analyze the data so that promising conditions are pursued, while no further time, resources, and effort are spent on negative conditions.
Recently, an international protein structure initiative has taken shape with the goal of determining the three dimensional structures of all representative protein folds. This massive undertaking in structural biology which may some day rival the human genome sequencing project in size and scope, is estimated to require a minimum of 100,000 x-ray structure determinations of newly discovered proteins for which no structural information is currently available or predicted. For perspective, the total number of reported novel crystal structures determined to date (spanning nearly 50 years of work) is only approximately 10,000.
Using existing methods for the crystallization of proteins (random screens of conditions), the protein structure initiative will require a minimum of approximately 100 million crystallization trials. In addition, the biological information gleaned from genomic research in the protein structure initiative are expected to create even more demand for structural information. Specifically, the biotechnology and pharmaceutical industries are estimated to require upwards of ten fold more protein crystallization experiments (one billion) as a result of research and structure based drug design and the use of crystallized therapeutic proteins. This would require that each of the approximately 500 macromolecular crystallography labs worldwide be responsible for setting up approximately 2000 crystallization trials every working day of the year for five years. Currently, there is no known device available for setting up analysis macromolecular crystallization data on this scale.
SUMMARY OF THE INVENTION
The preparation of crystal growth screening solutions is a tedious and time consuming endeavor. As such, high-throughput crystal growth demands that the construction of crystallization screening solutions be fully automated. To address this issue, the inventors have developed a method and system, an embodiment of which is called a “Matrix Maker”, for creating new crystallization screening solutions in a crystallization plate (drawing from, for example, 96 different stock solutions). A variation of the invention (“Drop Maker”) is capable of setting up crystallization drops in the plate once the screening solutions have been prepared in the plate.
Another embodiment of the invention is capable of running chromatographic protein purification experiments by aspirating crude cell extracts from a sample plate and pumping them over a plurality of chromatography devices such as chromatography cartridges or columns. The chromatography devices are then washed by pumping a plurality of different elution buffers over the chromatography devices and collecting the liquids that flow through the chromatography devices into recipient containers. a single valve port serving as both inlet port and outlet port, and the connected pin being both a dispensing pin and an aspiration pin.
According to an embodiment of the present invention, a system for mixing crystallization trial matrices includes a plurality of precision pumps (such as precision syringe pumps), a distributor and a processor system, which may contain one or more computer or digital processors. Each pump draws, under the control of the processor, an associated stock solution from a stock solution source, and pumps the drawn stock solution out through an outlet. The distributor, also under the control of the processor system, directs a stock solution from a particular pump outlet to a selected solution receptacle or holder.
A multi-port distribution valve may be associated with each precision pump. Each valve, under control of the processor system, can at any time connect its associated pump to one of the inlets or outlets.
In one embodiment, individual inlets of a particular pump may be connected to different stock solutions. Each outlet of a pump may be uniquely associated with an inlet, such that a particular stock solution always enters through one of said inlets and always exits through the associated outlet. Furthermore, each pump may have an inlet connected to a water/wash source, and an outlet for disposing of waste.
In one embodiment, the distributor comprises one or more outlet manifolds which hold an array of dispensing pins that are connected to the outlet ports, and positioning means for aligning a particular pin over the desired solution receptacle. The dispensing pins may be made of stainless steel or some other suitable material. The distributor may also have an array of pins that are connected to tubing that is connected to one of the pump inlets. The pins and their associated lines may be used to aspirate or dispense liquids from solution receptacle container plates located beneath the distributor.
The positioning means may include a gantry on which the outlet manifold is supported. The processor system may control the movement of the gantry in two or three dimensions. In one embodiment, multiple gantries may be used.
Solution receptacles may be test tubes, crystallization plate wells, or other suitable containers (for example, Society for Biomolecular Screening type plasticware devices) that may be, for example, arranged in an array.
In one embodiment, the processor controls the pumps, valves and gantry according to predefined recipes that describe which solutions are to be mixed, each destination solution receptacle, and solution volumes. These recipes may be viewed and edited by a user.
In another embodiment, the processor may control the pumps, valves and gantry according to predefined protocols for purifying proteins chromatographically or for setting up crystallization plates. The protocols may be viewed and edited by a user.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other objects, features and advantages of the invention will be apparent from the following more particular description of preferred embodiments of the invention, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention.
FIG. 1 is a schematic diagram illustrating the operation of an embodiment of the invention, called a “Matrix Maker Robot.”
FIG. 2 is a schematic diagram illustrating the generation and use of matrix recipes.
FIG. 3 is an illustration of an embodiment of the matrix maker of FIG. 2 .
FIG. 4 is an illustration showing an array of stock solution containers and the tubing through which the solution passes, as employed in the embodiment of FIG. 3 .
FIG. 5 is illustration showing the pumps in the embodiment of FIG. 3 .
FIG. 6A is an illustration showing, in the embodiment of FIG. 3, the outlet manifold mounted to a gantry.
FIG. 6B is an illustration, similar to FIG. 6A, showing the gantry in a different position.
FIG. 7 is a closeup illustration of the embodiment of FIG. 3, showing the dispensing pins sticking through the outlet manifold.
FIG. 8 is a schematic diagram illustrating the operation of an embodiment of the invention, called the “Protein Maker-Drop Maker Robot.”
FIG. 9 is an illustration showing, in the embodiment of FIG. 8, the outlet manifold mounted to a gantry.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A description of preferred embodiments of the invention follows.
FIG. 1 is a schematic diagram illustrating the operation of an embodiment 2 of the invention, called a “Matrix Maker Robot.” This design has many important features.
For example, an embodiment of the present invention uses positive pressure displacement of stock solutions through independently controlled precision syringe pumps, such that no disposable pipette tips are required. Viscous stock solutions can be delivered with high accuracy and speed through stainless steel outlet pins that do not come into contact with the recipient plasticware or reservoirs solutions as they are being created.
Proven “workhorse” precision syringe pumps, such as those manufactured by Tecan Systems (formerly Cavro Scientific Instruments, Inc.), can be used, minimizing subsequent maintenance.
Different sizes of syringes can be used to meet varying accuracy and scalability needs.
More stock solutions can be added to the system as needed or demanded.
Sterility of stock solutions can be maintained by eliminating open exposure to air.
Finally, the appropriate volumes of stock solutions can be delivered directly to a crystallization plate or into sample tubes through the use of a manifold which is attached to a robotic gantry that can move in the X, Y and Z directions (e.g., lateral width, lateral depth and vertical directions). The outlet lines “shoot” stock solutions into the recipient plate (i.e., the individual solution receptacles).
Despite extensive investigation, the inventors were unable to identify a commercial liquid handling device that met these specifications.
Referring now to FIG. 1, plural (e.g., forty-eight) bottles 10 holding various stock solutions are directly connected via Teflon™ tubing 12 (of the shortest reasonable length) to the inlet ports of, for example twenty-four, individual precision syringe pumps 14 , such as Tecan Systems' Cavro XL-3001. Each pump 14 is equipped with an 8-port distribution valve 16 . In the illustrated embodiment, each pump 14 is attached through its distribution valve 16 to inlet lines 18 for two (2) different stock solutions, at valve positions 1 and 8 .
Each pump 14 has two outlet lines 20 , at valve positions 2 and 7 , one for each of the two stock solutions. These outlet lines 20 are attached via tubing 44 (with the shortest reasonable distance) to an array of stainless steel dispensing pins or nozzles 26 held by an outlet manifold 28 , which itself may be constructed from metal or some other suitable material.
Each pump 14 also has two waste outlet lines 22 , for example at valve positions 3 and 6 , through which waste is dumped into a waste container 42 . In addition, each pump 14 has two water inlet lines 24 , for example at valve positions 4 and 5 , connected to a water/wash supply 40 .
The outlet manifold 28 is mounted to a robotic gantry system 48 (see, for example, FIG. 6A) that can move the outlet manifold 28 in the X, Y, and Z directions/dimensions. The twenty-four pumps 14 are controlled by a controller 32 . The robotic gantry 48 is controlled by a gantry controller 34 . The pump/valve controller 32 and the gantry controller 34 shown in FIG. 1 may comprise both software components and hardware components (collectively, generally referred to as a processor system).
In one embodiment, the stock solution bottles 10 , inlet lines 12 , valves 16 , and syringe pumps 14 are comprised of chemically resistant materials such as Teflon™, polyetheretherketone (also known as PEEK™), glass, and stainless steel, such that the entire liquid path can withstand extreme pHs, high ionic strengths, and organic solvents. In this embodiment, the entire liquid path can be sterilized with chemical reagents such as ethanol, followed by extensive water washing and priming with filter sterilized stock solutions.
Solution receptacles, into which the various solutions are delivered, may be placed on a platform below the outlet manifold 28 . For example, the solution receptacles may be wells arranged in an array on a crystallization plate 36 , or tubes held in a tube rack 38 . Multiple plates and/or tube racks may be positioned on the platform, and the software programmed accordingly to fill the containers of the various plates and tube racks.
In a preferred embodiment, the solution receptacles are stationary while the delivery system is positioned by the robotic gantry 48 .
Software 30 , such as Crystal Monitor™, available from Emerald BioStructures, Inc., of Bainbridge Island, Wash., provides for simple creation of a “recipe” for making a new set of screening solutions in the desired recipient crystallization plate 36 or rack 38 of tubes.
For example, the software 30 may have the ability to capture distance constraint information on plasticware and tube racks. The software can also calculate the volume of stock solutions needed to create a new crystallization screening matrix. It also has a knowledge base of the viscosity of each stock solution.
Database (DB) tables and graphical user interface (GUI) modules of software 30 may be used to perform the following: a) map stock solutions to physical positions on the invention; b) map stock solution inlet lines to valve positions on syringe pumps; c) map stock solution outlet lines to valve positions on syringe pumps; d) map stock solution outlet lines to outlet manifold pin positions on the gantry; and e) provide a knowledge base of titration curves for the final pHs achieved from mixing variable quantities of buffer stocks at 1 pH unit above and below the pKa of the buffer.
FIG. 2 is a schematic diagram illustrating the generation and use of the recipes. A user 101 may communicate with software 30 such as Crystal Monitor through a graphical user interface (GUI) driver 103 , to define the system configuration as well as crystallization trial matrix solution specifications. A calculator 105 portion of the software 30 generates the “recipes”, which may be stored, for example, in a table 107 in a database 109 . Note that the system configuration information may also be stored in a table 108 in the same or a different database. The GUI driver 103 and calculator 105 may be integral parts of, for example, the matrix manager software described in U.S. application Ser. No. 09/631,185.
Robot mixer control software 111 also contains a GUI driver 113 , which may be launched by the Crystal Monitor program 30 . The robot mixer control software 111 allows the user 101 to directly view and edit the contents of the recipe table 107 .
Crystal Monitor 30 is able to launch the robot mixer driver 115 upon an appropriate user action. Based on the configurational information 108 and the recipes 107 , the robot mixer driver 115 can generate a sequence of instructions or commands to control the matrix maker robot 200 , by driving the syringe pumps 14 , valves 16 (FIG. 1 ), and gantry 48 (see FIG. 3) in precise concert and sequence to deliver the appropriate stock solutions into the desired recipient containers.
The robot mixer driver 115 takes into account several considerations, including, but not limited to, the following:
(1) The final pH's for buffers are achieved by delivering the appropriate volumes of stock buffers which bracket the buffer pKa by +/−1 pH unit (with reference to experimentally determined titration curves);
(2) The delivery sequence for different chemical types should be optimized;
(3) Travel distances should be minimized;
(4) Scheduling of pump wash cycles should be efficient; and
(5) “Chemical compatibility” features may be provided that warn the user that chemical precipitation would occur upon mixing certain chemicals (e.g., Ca2+ and phosphate are incompatible).
The table below illustrates a few exemplary rows (recipes) as might be defined in the recipe table 107 . Although twelve columns are shown, it would be understood by one skilled in the art that other columns can be added for various purposes. However, only those columns needed to demonstrate the present invention are shown.
The “Dispensation No.” is simply an identifier to identify a particular row in the table 107 . Here, ten recipe rows are shown, having dispensation numbers from 58168 to 58177 respectively.
The matrix mixer driver 115 may be capable of controlling multiple mixer robots 200 . Therefore, the “Robot ID” column serves to identify the particular robot 200 to which the row pertains. Here, all rows pertain to robot # 2 .
A matrix may be given a name, specified in the “Matrix Name” column.
A robot may be capable of processing multiple trays simultaneously. Each tray maybe identified by a unique identifier. Here, all of the rows pertain to tray # 12 of robot # 2 .
“Reagent No.” specifies which stock solution bottle ( 10 from FIG. 1) is to be pumped, and the “Row” and “Col” columns specify the position of the receiving container that is to receive the identified stock solution. The “Vol” column indicates the volume to be dispensed, here in microliters.
So, for example, the first five rows, identified as dispensation numbers 58168 through 58172, direct that various stock solutions (from bottles numbered 19 , 45 , 11 , 13 and 1 respectively) be dispensed into the container positioned at row 1 , column 1 , for tray 12 at robot 2 , resulting in a 2-milliliter solution. The next five rows, identified as dispensation numbers 58173 through 58177 specify the solution to be mixed in the receptacle/container at row 1 , column 2 of the same tray.
The “Asp”, “Disp”, and “Drop” flags are simply flags used to indicate whether a respective particular operation has been done yet. For example, in the row for dispensation no. 58170, the Asp flag (=Yes) indicates that aspiration has been performed, that is, the reagent from bottle 11 has been drawn into the corresponding pump 14 . The Disp flag (=No) indicates that the stock solution has not yet been dispensed from the pump 14 .
After dispensation, a drop of the stock solution may be hanging from the end of the dispensing pin. To prevent this drop from falling into and contaminating the dispensed solutions when the gantry is moved, an additional “drop” operation may be performed to draw back the drop (say about 5 microliters) into the dispensing pin. The “Drop” flag indicates whether this operation has been performed.
Finally, the status flag is used to indicate current status to the Crystal Monitor software 30 (FIG. 1 ).
Dispensation
Robot
Matrix
Tray
Reagent
Asp
Disp
Drop
Status
No
ID
Name
TD
No
Row
Col
Vol
Flag
Flag
Flag
Flag
58168
2
matrix001
12
19
1
1
200
No
No
No
1
58169
2
matrix001
12
45
1
1
80
No
No
No
1
58170
2
matrix001
12
11
1
1
367.5373
Yes
No
No
1
58171
2
matrix001
12
13
1
1
32.46267
Yes
Yes
No
1
58172
2
matrix001
12
1
1
1
1320
Yes
Yes
Yes
1
58173
2
matrix001
12
19
1
2
200
Yes
Yes
Yes
1
58174
2
matrix001
12
45
1
2
80
Yes
Yes
Yes
1
58175
2
matrix001
12
11
1
2
312.7144
Yes
Yes
Yes
1
58176
2
matrix001
12
13
1
2
87.28554
Yes
Yes
Yes
1
58177
2
matrix001
12
1
1
2
1320
Yes
Yes
Yes
1
The matrix mixer driver 115 can accommodate various syringe sizes (e.g., 0.25 to 25 mL) and syringe speeds, different volume settings, etc.
FIG. 3 is an illustration of an embodiment of the matrix mixer 200 of FIG. 2 . Stock solution bottles 10 are seated along either side of the platform 60 . The stock solutions 10 are connected to the syringe pumps 14 via inlet tubing 12 . The pumps 14 and their 8-position valves 16 sit atop a housing 50 , which contains the gantry drive system for positioning the robotic gantry 48 .
The outlet manifold 28 sits on the robotic gantry 48 . Outlet tubing 44 connects the pumps 14 with the dispensing pins 26 which deliver the various solutions.
Here, the outlet manifold 28 has been positioned over a wash/waste receptacle 43 which sits on the platform or deck 60 . The wash/waste receptacle 43 shown is of sufficient size (with respect to area) such that as many as all of the syringes and outlet tubes 44 may be washed simultaneously.
FIG. 4 is an illustration showing an array of stock solution containers 10 and the Teflon tubing 12 through which the solution passes, as employed in the embodiment of FIG. 3 .
FIG. 5 is an illustration showing the pumps 14 in the embodiment of FIG. 3. A first row of pumps 14 is located on top of the housing 50 . A second row of pumps 14 is located behind the first row and is not visible in the FIG. 5 view. As can be seen from the figure, each pump 14 is attached to an associated 8-position valve 16 previously described in detail.
FIG. 6A is an illustration showing, in the embodiment of FIG. 3, the outlet manifold 28 mounted to the gantry 48 . Tubing 44 from the pump valve outlets 20 (FIG. 1) is brought to the outlet manifold 28 , and is connected to an array of dispensing pins 26 . A wash/waste receptacle 42 is located on a stable platform next to a tube rack 38 .
FIG. 6B is an illustration similar to FIG. 6A showing the gantry 48 in a different position with respect to tube rack 38 and wash/waste receptacle 42 .
The tube rack 38 may be positioned to the platform/deck 60 via mounting pins (not shown) that allow the tube rack to be accurately positioned yet easily removed as an entire unit. This worktable mounting pin system provides the flexibility to utilize various racks containing different quantities of test tubes or different size test tubes, micro-plates, etc.
FIG. 7 is a closeup illustration of the embodiment of FIG. 3, showing the dispensing pins 26 sticking through the outlet manifold 28 . Here, one solution 54 is being delivered to a receiving test tube 52 , located in the test tube rack 38 . It should be understood that multiple solutions may be delivered or dispensed to multiple receiving containers simultaneously.
In an alternate embodiment, several syringe pistons may be attached to a common drive, as for example, on the Cavro XL-3000-8. Thus, when one syringe piston is moving to deliver liquid, the other seven syringe pistons also move with the exact same stroke. However, the switch valves at the top end of each syringe are independently operated. Hence, when the XL-3000-8 performs a single liquid delivery cycle, the switch valve for the desired stock solution is the only one switched to the output position. The other stock solutions are pumped back into the stock bottles.
In this embodiment, the stock solutions can be arranged such that they are attached to the 8-position syringe drivers in an order that provides minimal chance that a given syringe pump would have to operate through more than one cycle during the construction of a single crystallization solution. For example, stock solutions which have similar chemicals may be attached to the same 8-port precision syringe pump. Then, following recipes of table 107 , the matrix mixer driver 115 controls mixer robots 200 to pump/dispense through a subject syringe pump 14 once per cycle accordingly.
FIG. 8 is a schematic diagram illustrating the operation of another embodiment 800 of the invention, called a “Protein Maker-Drop Maker Robot.” Solution inlet lines 801 are attached to an array of stainless steel pins or nozzles 26 held by a manifold 802 . The manifold 802 is mounted to a robotic gantry system 48 (see, for example, FIG. 6 A), which is controlled by software 804 via a gantry controller 34 . The gantry controller 34 can control the movement of the manifold 802 in these orthogonal directions or dimensions. In this way, the pins 26 can be moved into sample plates 803 that contain desired solutions, which may be, for example, crude cell extracts containing protein, solutions containing purified protein, or chemical stock solutions. The pins, tubing and pumps involved are normally washed between aspiring different solutions to prevent contamination.
Alternatively, some pins could be offset from the rest and used individually without interference by the other pins.
Specified volumes of the solutions can be drawn into the inlet lines 801 , by the appropriate specified valve 16 (see, for example, FIG. 1) and pump 14 movements under the control of software 804 via the pump controller 32 . The solutions can be drawn into the syringe pumps 14 , and then pumped through chromatography cartridges 807 , via outlet lines 809 , after the valves 16 change position to connect the pump 16 contents to the outlet lines 809 .
The chromatography cartridges 807 are attached to an array of stainless steel dispensing pins or nozzles 26 held by the manifold 802 . The solutions that flow through the chromatography cartridges 807 can be collected in collection plates 811 , by software 804 controlled gantry movements of the manifold 802 . Using specified pump 14 and valve 16 movements, the chromatography cartridges 807 can be washed with a plurality of different solutions (for example, wash buffer, equilibration buffer, elution buffers), which are attached to designated inlet valve 16 positions via additional inlet lines 813 . The solutions that flow through the chromatography cartridges 807 can be collected in collection plates 811 , by software 804 controlled gantry movements of the manifold 802 .
Solutions from collection plates 811 , protein sample plates 815 , plates 817 containing detergents, plates 819 containing a set of ligands, and/or plates 821 containing crystallization screening solutions prepared from stock solutions by, for example, the matrix maker 200 , can be sequentially aspirated into solution inlet lines 801 and dispensed into crystallization plates 823 from the solution inlet lines 801 by the appropriate software 804 controlled pump 14 , valve 16 , and gantry 48 movements. The inlet lines 801 can be flushed with water between each aspiration and dispensing cycle. The water flush can be captured in the tip washer station 43 by the appropriate software 804 controlled pump 14 , valve 16 , and gantry 48 movements.
It should be apparent to one skilled in the art that the Matrix Maker Robot 200 and the Protein Maker-Drop Maker Robot 800 embodiments enable scientists to prepare new crystallization screening solutions from stock solutions, purify proteins from crude cell extracts, and set up crystallization plates by drawing from solutions in plates that were produced by the same embodiments.
FIG. 9 is a closeup illustration of the embodiment of FIG. 8, showing the dispensing pins 26 sticking through the outlet manifold 802 . Here, twenty four chromatography cartridges 807 are mounted onto the manifold 802 and attached to outlet lines 809 . Also shown are twenty-four inlet lines 801 that are attached to the manifold 802 . The gantry 48 is shown directing the movement of inlet pins 26 into a sample plate 803 . A collection plate 811 is also shown.
While this invention has been particularly shown and described with references to preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the scope of the invention encompassed by the appended claims. | A matrix mixing robot includes a plurality of precision pumps (such as precision syringe pumps), a distributor and a processor system. Each pump, under the control of the processor system, draws an associated stock solution from a stock solution source, and pumps the drawn stock solution out through an outlet. The distributor, also under the control of the processor system, directs a stock solution from a particular pump outlet to a selected solution receptacle. A multi-port distribution valve may be associated with each precision pump. Each valve, under control of the processor system, can connect its associated pump to one the pump's inlets or outlets. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a hook-and-loop fastener otherwise known as a surface fastener comprising two layers of fabric which are releasably engageable with each other. One of the fabric layers carries hook-shaped or male elements engageable with loop or female elements on the other fabric layer. The present invention is more specifically concerned with a warp-knit support tape for such hook-and-loop fasteners carrying thereon a multiplicity of pile-loop elements and engageable with a mating hook-carrying tape.
2. Description of the Related Art
There have been proposed many different forms of hook-and-loop fastener tapes, one such tape being disclosed in Japanese Utility Model Application No. 60-162742 (corresponding to U. S. Pat. No. 4,709,567 issued Dec. 1, 1987) to which the present invention is interrelated. The disclosed hook-and-loop fastener tape, as shown in FIG. 4 of the accompanying drawings, comprises a foundation web consisting two-needle stitches and laid-in weft threads, and a multiplicity of pile loops, in which the sinker loops of the two needle stitches are arranged to urge and hold the leg portions of the pile loops criss-cross against the foundation web, while the laid-in weft threads fill up in between the sinker loops and the pile loops, thus anchoring the pile loops stably in place against displacement or dislocation. The sinker loops of the two-needle stitches and the laid-in weft threads are further arranged to bear against the foundation loops which form the wales, so that the fastener tape as a whole is rendered highly resistant to stretch in either direction.
While the above-mentioned prior art device is satisfactory in its resistance to displacement or dislocation of the piles, it has been found somewhat defective in the ability of engaging with hook elements on the mating counterpart on account of the fact that the pile loops alternating on the right and the left side of the wales are prone to tilt down flat on the tape surface in opposite directions.
SUMMARY OF THE INVENTION
It is therefore the primary object of the present invention to provide a warp-knit female tape for a hook-and-loop fastener which will eliminate the foregoing drawbacks, of the prior art and which is highly resistant to pile displacement or dislocation and free from pile tilting so as to ensure a maximum of opportunity of engagement with a mating male tape.
A warp-knit tape for hook-and-loop fasteners includes a pile portion and selvage portions on opposite sides thereof, the pile portion including pile-loops arranged to extend longitudinally in a zig-zag or meandering fashion to prevent the same from tilting down flat on the surface of the tape.
The above object and other features of the invention will be better understood from the following detailed description taken with reference to the accompanying drawings, in which like reference numerals refer to like or corresponding parts throughout the several views.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 schematically illustrates the construction of a warp-knit tape embodying the invention for use as a loop or female part of a hook-and-loop fastener;
FIG. 2a-2d, inclusive, each are schematic representations of the constituent stitches for the tape of FIG. 1;
FIG. 3 is a schematic diagram on enlarged scale of a portion of the tape of FIG. 1; and
FIG. 4 is a view similar to FIG. 3 but showing a related art counterpart.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings and FIG. 1 in particular, there is shown a preferred form of warp-knit support tape 10 to be used as a loop or female part of a hook-and-loop fastener. The support tape 10 consists of a pile portion 11 and selvage portions 12 and 13 extending warpwise on opposite sides of the pile portion 11. The pile portion 11 of the tape 10 is constructed with two needle stitches 14, laid-in weft threads 15, both of which are laced together to make up a foundation of the tape 10, and pile-forming threads 16 of a multifilament which form a multiplicity of pile-loops 17 (FIG. 3). As shown in FIG. 2a, the pile-forming stitch 16 is represented by Link No. 2-1/1-1/1-0/1-1, and threads therefor are positively overfed beyond the normal rate of feed of threads for the remaining stitches and formed by sinker looping into pile-loops 17 (FIG. 3) extending over every other course in overlapping relation to the knitting needles.
The pile-loops 17 are arranged, as shown in FIG. 3, to extend longitudinally in a zig-zag or meandering fashion such that they may be free from tilting as in the case of the related art shown in FIG. 4, the arrangement being that the pile-loops 17 give themselves more opportunity to engage the hooks on the mating tape, not shown, regardless of the orientation of the latter.
A modified form of pile-loop 17a is shown in FIG. 2d which is represented by stitch Link No. 3-2/2-2/2-1/2-2 formed by threads 16a lapping on every other adjacent needles over every other course. The height of the pile-loops 17, (17a) may be adjusted by the number of needles to be skipped in the weft-wise direction and the number of courses to be skipped in the warp-wise direction.
The foundation of the support tape 10 is formed by two needle stitches 14 of Link No. 0-2/2-0 as shown in FIG. 2b and laid-in weft threads 15 of Link No. 0-0/4-4. As shown in FIG. 3, the sinker loops 14a, 14b of two needle stitches 14 are arranged to urge and hold the leg portions of pile-loops 17 criss-cross against the foundation web of the tape 10, while the laid-in weft threads 15 fill up in between the sinker loops 14a, 14b and the pile-loops 17, thus anchoring the pile-loops 17 stably in place against displacement or dislocation.
As better shown in FIG. 3, the sinker loops 14a, 14b of two needle stitches 14 are laced in a manner to bear against the foundation loops 19 that form the wales 18, and the weft threads 15 that are laid in densely between the foundation loops 19 and the sinker loops 14, 14b are held in place by the latter loops, whereby the tape system as a whole is rendered highly resistant to stretch in either direction. This will in turn serve to reduce the amount of resinous coatings required to make the knit tape firm and prevent the pile-loops from falling off and further to provide a tape product which is physically soft.
The selvages 12 and 13 interconnect a plurality of pile portions 11 in parallel and can be cut to provide individual tape lengths conveniently on use, and are constructed only with the two needle stitches 14 and laid-in weft threads 15 to provide relatively wide wale-grooves so as to facilitate sewing of the tape 10 onto a garment article.
Although various minor modifications may be suggested by those versed in the art, it should be understood that we wish to embody within the scope of the patent warranted hereon, all such embodiments as reasonably and properly come within the scope of our contribution to the art. | A warp-knit tape is disclosed for use in hook-and-loop fasteners, which tape comprises a pile portion and selvage portions on opposite sides thereof, the pile portion including pile-loops arranged to extend longitudinally in a meandering fashion to prevent the same from tilting down flat on the surface of the tape. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is the U.S. National stage filing of International Application No. PCT/EP2013/071010, filed 9 Oct. 2013, and claims priority of German application number 10 2012 218 378.7, filed 9 Oct. 2012, the entireties of which applications are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The invention relates to processes for the production of moldings or sheet materials comprising latent heat accumulators, to the moldings or sheet materials obtainable therefrom, and to use thereof by way of example in the construction industry for the coating of ceilings.
BACKGROUND OF THE INVENTION
[0003] Latent heat accumulators are materials which at certain temperatures undergo reversible thermodynamic state changes, for example solid/liquid phase transitions, and extract the associated enthalpy of phase change from the environment and, respectively, release said enthalpy into the environment. Latent heat accumulators can therefore prevent, or at least mitigate, temperature variations in the region of their thermodynamic state change, for example their melting point or freezing point. Examples of commonly used materials that accumulate latent heat are paraffin oils, fatty acids, and fatty waxes. Latent heat accumulators are used in a wide variety of applications: US 2001000517 describes the coating of textiles with materials of this type. U.S. Pat. No. 5,565,132 describes processes in which compositions comprising latent-heat-accumulating material, polymers, and silica particles are processed by way of a melt to give sheets, pellets, or fibers.
[0004] However, when latent heat accumulators are present in the liquid phase they are easily released into the environment. A frequent recommendation intended to prevent this is that latent-heat-accumulating material be sheathed with a higher-melting-point material, as described by way of example in US 2011169179A. WO 99/24525 teaches microcapsules in which a capsule wall made of highly crosslinked methacrylic ester polymers surrounds the latent-heat-accumulating material. US 2006272281, U.S. Pat. No. 8,070,876, WO11071402, and US 2011108241A describe the use of microcapsules of that type in construction applications. Another challenge consists in the further processing of these microcapsules to give marketable products, as discussed by way of example in EP1484378. The plastics technology sector makes very wide use of thermoplastic processes. However, a problem arising during the thermoplastic processing of the microcapsules is that a considerable proportion of the microcapsules is easily damaged, with the consequence that when the latent-heat-accumulating material undergoes transition to the liquid phase it can be released from the microcapsules into the environment, with resultant loss of the advantage of the microcapsules. Problems of this type arise by way of example during the thermoplastic processing of compositions which comprise polyurethane casting resins alongside the microcapsules.
SUMMARY OF THE INVENTION
[0005] Against this background it was an object to develop novel approaches that permit processing of microcapsules comprising latent heat accumulators to give moldings or sheet materials. A further intention was thus to provide access to moldings or sheet materials which comprise the greatest possible proportion of the microcapsules mentioned. The shape of the moldings or sheet materials, for example layer thicknesses, should be amenable to variation as desired within a wide range.
[0006] Surprisingly, when microcapsules comprising latent heat accumulators were processed thermoplastically together with polymers based on ethylenically unsaturated monomers said object was achieved.
[0007] The invention provides processes for the production of moldings or sheet materials comprising latent heat accumulators, characterized in that mixtures comprising one or more microcapsules and one or more polymers based on one or more ethylenically unsaturated monomers selected from the group comprising vinyl esters, (meth)acrylic esters, vinylaromatics, olefins, 1,3-dienes, and vinyl halides, where said microcapsules comprise one or more latent heat accumulators, are processed by means of thermoplastic forming techniques.
[0008] The invention further provides moldings or sheet materials comprising latent heat accumulators, said moldings or sheet materials being obtainable via thermoplastic forming of mixtures comprising one or more microcapsules, and
[0009] one or more polymers based on one or more ethylenically unsaturated monomers selected from the group comprising vinyl esters, (meth)acrylic esters, vinylaromatics, olefins, 1,3-dienes, and vinyl halides, where said microcapsules comprise one or more latent heat accumulators.
DETAILED DESCRIPTION OF THE INVENTION
[0010] Examples of suitable vinyl esters are those of carboxylic acids having from 1 to 22 C atoms, in particular from 1 to 12 C atoms. Preference is given to vinyl acetate, vinyl propionate, vinyl butyrate, vinyl-2-ethylhexanoate, vinyl laurate, vinyl myristate, vinyl palmitate, vinyl stearate, vinyl arachinate, 1-methylvinyl acetate, vinyl pivalate, and vinyl esters of α-branched monocarboxylic acids having from 9 to 11 C atoms, for example VeoVa9 R or VeoVa10 R (trademarks from Resolution). Particular preference is given to vinyl acetate.
[0011] Examples of suitable acrylic esters or methacrylic esters are esters of unbranched or branched alcohols having from 1 to 22 C atoms, in particular from 1 to 15 C atoms. Preferred methacrylic esters or acrylic esters are methyl acrylate, methyl methacrylate, ethyl acrylate, ethyl methacrylate, propyl acrylate, propyl methacrylate, n-butyl acrylate, n-butyl methacrylate, tert-butyl acrylate, tert-butyl methacrylate, 2-ethylhexyl acrylate, lauryl acrylate, myristyl acrylate, stearyl acrylate, palmityl acrylate, lauryl methacrylate, myristyl methacrylate, stearyl methacrylate, and palmityl methacrylate. Particular preference is given to methyl acrylate, methyl methacrylate, n-butyl acrylate, tert-butyl acrylate, and 2-ethylhexyl acrylate.
[0012] Preferred vinyl aromatics are styrene, methylstyrene, and vinyltoluene. Preferred vinyl halide is vinyl chloride. The preferred olefins are ethylene and propylene, and the preferred dienes are 1,3-butadiene and isoprene.
[0013] It is also optionally possible to copolymerize from 0.1 to 10% by weight, based on the total weight of the monomer mixture, of ancillary monomers. It is preferable to use from 0.5 to 5% by weight of ancillary monomers. Examples of ancillary monomers are ethylenically unsaturated mono- and dicarboxylic acids, preferably acrylic acid, methacrylic acid, fumaric acid, and maleic acid; ethylenically unsaturated carboxamides and the corresponding nitriles, preferably acrylamide and acrylonitrile; mono- and diesters of fumaric acid and maleic acid, for example the diethyl and diisopropyl esters, and maleic anhydride, ethylenically unsaturated sulfonic acids and salts thereof, preferably vinylsulfonic acid and 2-acrylamido-2-methylpropanesulfonic acid. Other examples are silicon-functional comonomers, for example acryloxypropyltri(alkoxy)-, and methacryloxypropyltri(alkoxy)silanes, vinyltrialkoxysilanes, and vinylmethyldialkoxysilanes, where alkoxy groups present can by way of example be ethoxy and ethoxy propylene glycol ether moieties. Mention may also be made of monomers having hydroxy or CO groups, for example hydroxyalkyl esters of methacrylic acid and of acrylic acid, examples being hydroxyethyl, hydroxypropyl, and hydroxybutyl acrylate and methacrylate, and compounds such as diacetone-acrylamide and acetylacetoxyethyl acrylate and methacrylate.
[0014] It is preferable that the ethylenically unsaturated monomers comprise only one ethylenically unsaturated group.
[0015] Preference is given to homo- or copolymers which comprise one or more monomers from the group comprising vinyl acetate, vinyl esters of α-branched monocarboxylic acids having from 9 to 11 C atoms, vinyl chloride, ethylene, methyl acrylate, methyl methacrylate, ethyl acrylate, ethyl methacrylate, propyl acrylate, propyl methacrylate, n-butyl acrylate, n-butyl methacrylate, 2-ethylhexyl acrylate, styrene.
[0016] More preference is given to copolymers using vinyl acetate and ethylene; using vinyl acetate, ethylene, and a vinyl ester of α-branched monocarboxylic acids having from 9 to 11 C atoms; copolymers using vinyl acetate and one or more (meth)acrylic esters of unbranched or branched alcohols having from 1 to 15 C atoms, in particular methyl acrylate, ethyl acrylate, propyl acrylate, n-butyl acrylate, 2-ethylhexyl acrylate, and optionally ethylene; copolymers using one or more vinyl esters, ethylene, and one or more vinyl halides; copolymers using one or more (meth)acrylic esters of unbranched or branched alcohols having from 1 to 15 C atoms, for example n-butyl acrylate and 2-ethylhexyl acrylate, and/or methyl methacrylate; copolymers using styrene and one or more monomers from the group of methyl acrylate, ethyl acrylate, propyl acrylate, n-butyl acrylate, 2-ethylhexyl acrylate; copolymers using 1,3-butadiene and styrene, and/or methyl methacrylate, and optionally other acrylic esters; these mixtures mentioned can optionally also comprise one or more of the abovementioned ancillary monomers.
[0017] Particular preference is given to copolymers of one or more vinyl esters with from 1 to 50% by weight of ethylene; copolymers of vinyl acetate with from 1 to 50% by weight of ethylene and from 1 to 50% by weight of one or more other comonomers from the group of vinyl esters having from 1 to 12 C atoms in the carboxylic acid moiety, for example vinyl propionate, vinyl laurate, vinyl esters of alpha-branched carboxylic acids having from 9 to 13 C atoms, for example VeoVa9, VeoVa10, VeoVa11; copolymers of one or more vinyl esters, from 1 to 50% by weight of ethylene, and preferably from 1 to 60% by weight of (meth)acrylic esters of unbranched or branched alcohols having from 1 to 15 C atoms, in particular n-butyl acrylate or 2-ethylhexyl acrylate; and copolymers using from 30 to 75% by weight of vinyl acetate, from 1 to 30% by weight of vinyl laurate, or vinyl ester of an alpha-branched carboxylic acid having from 9 to 11 C atoms, and from 1 to 30% by weight of (meth)acrylic esters of unbranched or branched alcohols having from 1 to 15 C atoms, in particular n-butyl acrylate or 2-ethylhexyl acrylate, where these also comprise from 1 to 40% by weight of ethylene; copolymers using one or more vinyl esters, from 1 to 50% by weight of ethylene, and from 1 to 60% by weight of vinyl chloride; these polymers can also comprise the quantities mentioned of the ancillary monomers mentioned, and the data in % by weight here always give a total of 100% by weight.
[0018] Particular preference is also given to (meth)acrylic ester polymers such as copolymers of n-butyl acrylate or 2-ethylhexyl acrylate, or copolymers of methyl methacrylate using n-butyl acrylate and/or 2-ethylhexyl acrylate; styrene-acrylic ester copolymers using one or more monomers from the group of methyl acrylate, ethyl acrylate, propyl acrylate, n-butyl acrylate, 2-ethylhexyl acrylate; vinyl acetate-acrylic ester copolymers using one or more monomers from the group of methyl acrylate, ethyl acrylate, propyl acrylate, n-butyl acrylate, 2-ethylhexyl acrylate, and optionally ethylene; styrene-1,3-butadiene copolymers; these polymers can also comprise the quantities mentioned of ancillary monomers, and the data in % by weight here always give a total of 100% by weight.
[0019] Most preference is given to copolymers using vinyl acetate and from 5 to 50% by weight of ethylene; and copolymers using vinyl acetate, from 1 to 50% by weight of ethylene, and from 1 to 50% by weight of a vinyl ester of α-branched monocarboxylic acids having from 9 to 11 C atoms; and copolymers using from 30 to 75% by weight of vinyl acetate, from 1 to 30% by weight of vinyl laurate, or vinyl ester of an alpha-branched carboxylic acid having from 9 to 11 C atoms, and from 1 to 30% by weight of (meth)acrylic esters of unbranched or branched alcohols having from 1 to 15 C atoms, where these also comprise from 1 to 40% by weight of ethylene; and copolymers using vinyl acetate, from 5 to 50% by weight of ethylene, and from 1 to 60% by weight of vinyl chloride.
[0020] The method here for the selection of the monomers and, respectively, the selection of the proportions by weight of the comonomers is such that the resultant glass transition temperature Tg is generally ≦120° C., preferably from −50° C. to +60° C., still more preferably from −30° C. to +40° C., and most preferably from −15° C. to +20° C. The glass transition temperature Tg of the polymers can be determined in a known manner by means of differential scanning calorimetry (DSC). Tg can also be approximated by means of the Fox equation. According to Fox T. G., Bull. Am. Physics Soc. 1, 3, page 123 (1956), the relationship is: 1/Tg=x1/Tg1+x2/Tg2+. . . +xn/Tgn, where xn is the mass fraction (% by weight/100) of the monomer n, and Tgn is the glass transition temperature in Kelvin of the homopolymer of the monomer n. Tg values for homopolymers are listed in Polymer Handbook 2nd edition, J. Wiley & Sons, New York (1975).
[0021] The polymers are produced in a known manner by way of example by the emulsion polymerization process or by the suspension polymerization process in the presence of emulsifiers or preferably of protective colloids, preferably by the emulsion polymerization process, where the polymerization temperature is generally from 20° C. to 100° C., preferably from 60° C. to 90° C., and in the case of copolymerization of gaseous comonomers such as ethylene operations can preferably be carried out under pressure, generally at from 5 bar to 100 bar. The polymerization is initiated by the water-soluble or monomer-soluble initiators or redox-initiator combinations commonly used for emulsion polymerization or suspension polymerization. Regulating substances can be used to control molecular weight during the polymerization. Protective colloids can be used for stabilization, optionally in combination with emulsifiers. The polymers preferably take the form of aqueous protective-colloid-stabilized dispersions.
[0022] Examples of protective colloids commonly used to stabilize the polymerization mixture are partially hydrolyzed or fully hydrolyzed polyvinyl alcohols; polyvinylpyrrolidones; polyvinylacetals; poly-saccharides in water-soluble form, for example starches (amylose and amylopectin), celluloses and carboxymethyl, methyl, hydroxyethyl, and hydroxypropyl derivatives thereof; proteins such as casein or caseinate, soya protein, gelatins; lignosulfonates; synthetic polymers such as poly(meth)acrylic acid, copolymers of (meth)acrylates having carboxy-functional comonomer units, poly(meth)acrylamide, polyvinyl-sulfonic acids, and water-soluble copolymers thereof; melamine-formaldehydesulfonates, naphthalene-form-aldehydesulfonates, styrene-maleic acid copolymers and vinyl ether-maleic acid copolymers. Preference is given to partially hydrolyzed or fully hydrolyzed polyvinyl alcohols. Particular preference is given to partially hydrolyzed polyvinyl alcohols with a degree of hydrolysis of from 80 to 95 mol % and with a Höppler viscosity of from 1 to 30 mPas in 4% aqueous solution (Höppler method at 20° C., DIN 53015).
[0023] Examples of suitable emulsifiers are anionic, cationic, or nonionic emulsifiers, for example anionic surfactants, such as alkyl sulfates having a chain length of from 8 to 18 C atoms, alkyl or alkylaryl ether sulfates having from 8 to 18 C atoms in the hydrophobic moiety and up to 40 ethylene oxide or propylene oxide units, alkyl- or alkylarylsulfonates having from 8 to 18 C atoms, esters and hemiesters of sulfosuccinic acid with monohydric alcohols or alkylphenols, and nonionic surfactants such as alkyl polyglycol ethers or alkylaryl polyglycol ethers having from 8 to 40 ethylene oxide units. The quantity of emulsifiers generally used is from 1 to 5% by weight, based on the total weight of the monomers. It is preferable to carry out polymerization without addition of emulsifiers.
[0024] The solids content of the resultant aqueous dispersions is preferably from 30 to 75% by weight, particularly preferably from 50 to 60% by weight.
[0025] In order to convert the polymers into water-redispersible polymer powders, the dispersions can, optionally after addition of other protective colloids as drying aid, be dried, for example by means of fluidized-bed drying, freeze drying or spray drying. It is preferable that the dispersions are spray dried. The spray drying here can take place in conventional spray drying systems, where the atomization can be achieved by means of single-, double-, or multiple-fluid nozzles, or by using a rotating disk. The selected discharge temperature is generally in the range from 45° C. to 120° C., preferably from 60° C. to 90° C., depending on system, resin Tg, and desired degree of drying. The viscosity of the feed to the nozzles is adjusted by way of the solids content in such a way so as to give a value <500 mPas (Brookfield viscosity at 20 revolutions and 23° C.), preferably <250 mPas. The solids content of the dispersion to be supplied to the nozzles is >35%, preferably >40%.
[0026] The total quantity generally used of the drying aid is from 0.5 to 30% by weight, based on the polymeric constituents of the dispersion. This means that the total quantity of protective colloid before the drying procedure is preferably to be at least from 1 to 30% by weight, based on polymer content; it is particularly preferable to use a total of from 5 to 20% by weight of protective colloid, based on the polymeric constituents of the dispersion. Examples of suitable drying aids are the abovementioned protective colloids.
[0027] A content of up to 1.5% by weight of antifoam, based on the main polymer in the material supplied to the nozzles, has often proven to be advantageous. The resultant powder can be modified with an antiblocking agent (anticaking agent) in order to increase capability for storage by improving resistance to blocking, in particular in the case of powders with low glass transition temperature, a preferred quantity being from 1 to 30% by weight, based on the total weight of polymeric constituents. Examples of antiblocking agents are Ca carbonate, Mg carbonate, talc, gypsum, silica, kaolins such as metakaolin, and silicates with particle sizes preferably in the range from 10 nm to 10 μm.
[0028] It is preferable to use the polymers in the form of protective-colloid-stabilized aqueous dispersions, or particularly preferably in the form of protective-colloid-stabilized water-redispersible polymer powders.
[0029] The latent heat accumulators are present in microcapsules, having been incorporated or included or embedded therein. Microcapsules are generally core-shell structures. The expression core-shell structure is known to the person skilled in the art and denotes structures in which a substance or a composition (core) is encapsulated by another substance or composition (shell). The production of corresponding latent-heat-accumulating microcapsules is known by way of example from WO99/24525.
[0030] The core usually comprises the latent-heat-accumulating materials. The core preferably comprises at least 50% by weight, particularly at least 70% by weight, and most preferably at least 80% by weight, of latent-heat-accumulating materials, based on the total weight of the core of a microcapsule. The latent-heat-accumulating materials preferably have a solid/liquid phase transition in the temperature range from −20 to 120° C., particularly from 0 to 60° C., and most preferably from 0 to 30° C.
[0031] Examples of latent-heat-accumulating materials are aliphatic hydrocarbon compounds, such as saturated or unsaturated C 10 to C 40 -hydrocarbons, which are branched or preferably linear, for example n-tetradecane, n-pentadecane, n-hexadecane, n-heptadecane, n-octadecane, n-nonadecane, n-eicosane, n-heneicosane, n-docosane, n-tricosane, n-tetracosane, n-pentacosane, n-hexacosane, n-heptacosane, n-octacosane and cyclic hydrocarbons, for example cyclohexane, cyclooctane, cyclodecane; aromatic hydrocarbon compounds such as benzene, naphthalene, biphenyl, o- and m-terphenyl, C 1 to C 40 - alkyl-substituted aromatic hydrocarbons, such as dodecylbenzene, tetradecylbenzene, hexadecylbenzene, hexylnaphthalene, and decylnaphthalene; saturated or unsaturated C 6 to C 30 -fatty acids, such as lauric, stearic, myristic, palmitic, oleic, or behenic acid;
[0032] fatty alcohols, such as lauryl, stearyl, oleyl, myristyl, and cetyl alcohol, or coconut fatty alcohol; C 6 to C 30 -fatty amines, such as decylamine, dodecylamine, tetradecylamine, or hexadecylamine; esters such as C 1 to C 10 -alkyl esters of fatty acids, for example propyl palmitate, methyl stearate, and methyl palmitate, and methyl cinnamate; natural and synthetic waxes such as montanic acid waxes, montanic ester waxes, carnauba wax, polyethylene wax, oxidized waxes, polyvinyl ether wax, ethylene-vinyl acetate wax, and hard waxes from Fischer-Tropsch processes; halogenated hydrocarbons, such as chloroparaffin, bromooctadecane, bromopentadecane, bromononadecane, bromoeicosane, and bromodocosane.
[0033] The shell of the microcapsules is usually composed of polymers. The shell polymers are generally based on one or more of the abovementioned ethylenically unsaturated monomers, and usually on one or more polyfunctional monomers.
[0034] Examples of polyfunctional monomers are esters or ethers of diols or of polyols with acrylic acid or methacrylic acid, and also the diallyl and divinyl ethers of these diols. Preference is given to trimethylolpropane triacrylate and trimethylolpropane trimethacrylate, triallyl ether of pentaerythritol, pentaerythrityl tetraacrylate, ethanediol diacrylate, divinylbenzene, ethylene glycol dimethacrylate, butylene 1,3-glycol dimethacrylate, methallylmethacrylamide, allyl methacrylate, and in particular propanediol diacrylate, butanediol diacrylate, pentanediol diacrylate, and hexanediol diacrylate, and the corresponding methacrylates.
[0035] The proportion of the polyfunctional monomers is usually up to 80% by weight, preferably from 5 to 60% by weight, and particularly preferably from 10 to 50% by weight, based on the total weight of the monomers that form the shell of the microcapsules.
[0036] The particle sizes of the microcapsules are preferably from 1 to 35 μm, and particularly preferably from 3 to 10 μm (determined by means of statistical light scattering by using TGV-Coulter LS 13320 equipment).
[0037] The ratio by weight of the polymers based on one or more ethylenically unsaturated monomers to the microcapsules comprising one or more latent heat accumulators in the mixtures for the thermoplastic forming techniques is preferably from 4:1 to 1:4, particularly preferably from 3:1 to 1:3, still more preferably from 2:1 to 1:2, and most preferably 1:1.
[0038] The mixtures for the thermoplastic forming techniques are based on preferably from 10 to 90% by weight, particularly preferably from 30 to 70% by weight, and most preferably from 40 to 60% by weight, of polymers based on one or more ethylenically unsaturated monomers; and/or preferably from 10 to 90% by weight, particularly preferably from 30 to 70% by weight, and most preferably from 40 to 60% by weight, of microcapsules which comprise one or more latent heat accumulators, based in each case on the dry weight of the mixtures.
[0039] The quantities of alternative polymers, such as polyurethanes, present in the mixtures are preferably less than 20% by weight, particularly preferably less than 10% by weight, and even more preferably less than 5% by weight, based in each case on the dry weight of the mixtures. It is most preferable that the mixtures comprise no polyurethane.
[0040] Other materials that can optionally be used in the production of the moldings or sheet material comprising latent heat accumulators are additional substances such as lubricants, for example calcium stearate or zinc stearate, commonly used flame retardants, plasticizers, antioxidants, UV stabilizers, antistatic agents, adhesion promoters, antiblocking agents, dyes, pigments, fillers, processing aids, and peroxides such as peroxodicarbonate for postcrosslinking. Preference is given here to lubricants and flame retardants. By way of example, from 3 to 10% by weight of flame retardants can be present, based on the dry weight of the mixtures.
[0041] The mixtures can moreover comprise one or more fillers, such as organic fillers, based by way of example on wood, leather, cork, or coconut material, or inorganic fillers, such as gypsum, lime, chalk, talc, silicas, kaolins, silicates, or titanium dioxide. It is preferable that the quantities of fillers present in the mixtures for the thermoplastic forming techniques are less than 30% by weight, particularly less than 15% by weight, and more preferably less than 5% by weight, based in each case on the dry weight of the respective mixture. It is most preferable that the mixtures comprise no fillers.
[0042] The individual constituents of the mixtures are mixed, and are then processed by means of the conventional thermoplastic forming techniques to give moldings or sheet materials comprising latent heat accumulators. Preference is given to dry mixtures here. However, it is also possible by way of example to use mixtures in aqueous form.
[0043] The mixing can by way of example be achieved in a heatable/coolable mixer, or else by way of direct granulation, for example in an extruder, Palltruder, or agglomerator. It is preferable that the mixing is achieved in a multiscrew extruder, planetary-gear extruder, and particularly in a twin-screw extruder, in particular in a contrarotating twin-screw extruder.
[0044] Examples of suitable thermoplastic forming techniques are extrusion, injection molding, pressing, granulation, and calendering. Preference is given to extrusion, and in particular to pressing.
[0045] It is preferable to begin by using thermoplastic forming techniques to produce granulates, pellets or pulverulent compound materials, which are then further processed by using further thermoplastic forming techniques. The particle sizes of the granulates or pellets are preferably from 2 to 10 mm.
[0046] The processing temperature during the mixing process is generally from 0° C. to 120° C., preferably from 20° C. to 100° C., and particularly preferably from 40° C. to 100° C. The processing temperature during the thermoplastic processing is generally from 80° C. to 250° C., preferably from 100° C. to 180° C. The temperature ranges mentioned are particularly advantageous for providing intimate mixing of the polymers, in particular the polymers in the form of water-redispersible polymer powders, and of the other components, and for developing the binder effect of the polymers. Higher temperatures can lead to formation of degraded products.
[0047] The procedure of the invention is suitable for the production of a very wide variety of moldings or sheet materials, for example sheets, foils, webs, or any other roll product. The moldings or sheet materials can be processed with other materials to give composite materials, for example via adhesive bonding onto timber boards with woodworking glue. Corresponding products are used by way of example in the construction industry, in particular in the construction of parts of buildings or of constituents of buildings, for example ceilings, walls, or floors. Other application sectors are the shoe industry, apparel industry, sports industry, leisure industry, and in particular the furniture industry.
[0048] Surprisingly, the proportions of the microcapsules that are damaged during the procedure of the invention, despite the thermoplastic processing, are preferably less than 3% by weight, particularly preferably less than 2% by weight, and most preferably less than 1% by weight; the meaning of “damaged” here is that the heat-accumulating material can escape from the microcapsules as a consequence of the thermoplastic processing.
[0049] In particular the copolymers comprising ethylene units are particularly advantageous for the processability of the mixtures of the invention. The polymer glass transition temperatures Tg of the invention are also useful for the processability of the mixtures. Copolymers comprising units of vinyl acetate and ethylene are particularly advantageous for the further processing of the moldings or sheet materials, for example by means of adhesive bonding, for example with woodworking glue.
[0050] The moldings or sheet materials produced in the invention feature high mechanical strength values, even when proportions of microcapsules or other constituents are very high. It is possible to introduce surprisingly large quantities of latent-heat-accumulating microcapsules into the moldings or sheet materials, i.e. to achieve high fill levels. The shape, and in particular the layer thickness, of the products of the invention can also be varied within a relatively wide range. Sheet materials with homogeneous surface are moreover obtainable. It is pleasing to note that no, or very little, foaming occurs during the conduct of the process of the invention, in contrast to the casting-resin process, for example using polyurethane casting resins. The moldings or sheet materials produced are markedly more compact and have fewer air inclusions. It is possible to achieve “continuous” production of sheet materials in different thicknesses. Surfaces produced are smooth and pore-free, and can be passed directly on for further processing.
[0051] The examples below serve for further explanation of the invention:
[0052] The following materials were used:
[0053] Vinnex A, B, and C:
[0054] Polyvinyl-alcohol-stabilized copolymers in the form of water-redispersible polymer powders with the following glass transition temperatures Tg:
Vinnex A: Tg 16° C.; Vinnex B: Tg −14° C.; Vinnex C: Tg −7° C.
[0058] Micronal DS 5040 X:
[0059] Microcapsules which comprise paraffin (phase transition temperature 23° C.) as heat-accumulating material and having a shell composed of a high crosslinked polymethyl methacrylate.
[0060] Process: Production of the sheet materials by means of pressing (examples 2 to 4):
[0061] The materials mentioned in the table were mixed in the quantitative proportions mentioned in the table for 5 min at 130° C. on a roll mill. The resultant milled sheet was then processed in a static press at a temperature of 150° C. and at a pressure of 5 N/mm 2 with a press time of 5 min to give pressed sheets of thickness 2 mm.
[0062] Process: Production of the sheet materials by means of extrusion (example 1):
[0063] The materials mentioned in the table were mixed in the quantitative proportions mentioned in the table for 5 min in a cooling mixer. The mixture was then processed in a Weber DS85 twin-screw extruder with EMO sheet die to give sheet materials of thickness 8 mm.
[0000]
TABLE
Ex. 1
Ex. 2
Ex. 3
Ex. 4
Process
Extrusion
Pressing
Pressing
Pressing
Micronal DS 5040 X
50
50
50
50
[pts. by wt.]
Vinnex A [pts. by wt.]
50
50
Vinnex B [pts. by wt.]
50
Vinnex C [pts. by wt.]
50
Shore A
90.3
65.6
77.4
91.7
Shore D
31.6
10.6
16.4
30.1
Tensile stress [MPa]
4.31
1.74
2.33
5.58
Tensile strain [%]
87.86
331.9
261.6
126.9
Tensile modulus of elasticity
378.02
DSC measurement [Jg{circumflex over ( )}−1]
47.99
44.09
43.46
46.02
[0064] Testing:
[0065] Shore A hardness, and also Shore D hardness, was determined on the pressed sheets in accordance with DIN 53505.
[0066] The mechanical strength of the pressed sheets was determined in the tensile test by determining tensile stress and tensile strain at break, and tensile modulus of elasticity was determined in accordance with DIN EN ISO 527 1-3 and, respectively, DIN 53504.
[0067] DSC measurement:
[0068] The heat-accumulation capacity of the sheet materials was determined by using DSC Mettler Toledo DSC1.306 equipment with the following temperature program: the respective sheet material was heated in each case at a rate of 1 K/min from 0.0° C. to 35° C., then cooled to −30° C., and finally again heated to 35° C.
[0069] The table lists the test results.
[0070] The theoretically achievable result for the heat-accumulation capacity of the sheet materials is 50 J/g. Examples 1 to 4 come very close to that value. From this it is clear that only a very small number of the microcapsules has been damaged during thermoplastic processing. | The invention provides methods for producing sheetlike structures or shaped articles that comprise latent heat storage media, characterized in that mixtures comprising one or more microcapsules which contain one or more latent heat storage media, and one or more polymers based on one or more ethylenically unsaturated monomers selected from the group consisting of vinyl esters, (meth)acrylic esters, vinylaromatics, olefins, 1,3-dienes and vinyl halides, are processed by means of thermoplastic shaping techniques. | 2 |
This is a divisional of copending application Ser. No. 08/522,810 filed on Sep. 1, 1995.
BACKGROUND OF THE INVENTION
This invention deals with an apparatus for removing and stacking trousers after they have been processed through a separate apparatus for crease permanency or pressing, or the like.
There exists in the industry a need for processing trousers with crease permanency and this need has encouraged those who service that industry to provide the means for such permanent creasing.
One such method and apparatus is disclosed in U.S. Pat. No. 4,607,589, issued Aug. 26, 1986 to Gibson, in which an apparatus for the application of crease setting compositions to trousers involves a vertical arrangement which consists of a form, over which the trousers are placed, a means of withdrawing the trousers from the form, and a means for placing crease setting compositions in the crease as the trousers are removed.
The apparatus of that invention is usually employed together with a cooperating mechanism capable of lowering the trousers onto the apparatus of the invention and removing them after the crease setting agent has been applied. The apparatus of the patent may be provided in pairs so that both trouser legs can be treated simultaneously. The trousers are conveniently conveyed hanging down from a conveyor supported by the bottoms of the legs, and are then lowered on to and removed upwardly from the apparatus, before passing to a subsequent treating or packing station. Such a mechanism is suggested in that patent, but details of such an apparatus are not disclosed, except to state that it may be a conveyor so that a continuous stream of trousers can be treated.
In actual practice, the device from the '589 patent is in use today and operates such that an operator places trousers over two vertical sets of arms which expand pulling the creases taut at the cuffs. A pair of grippers are lowered on a chain which is controlled by an electric motor. The trousers are grasped at the cuffs and removed by pulling them up. When the trousers have been removed, the cuffs are approximately ten feet in the air. A second set of grippers are waiting for the trousers at the top of the machine. They are mounted on a rodless cylinder which after the second set of grippers are activated, and the first are released, the trousers are carried horizontally to a stacking station which is approximately eight feet in the air. This stacking station is also mounted on a rodless cylinder. When the stacking station is filled, it is lowered by the second rodless cylinder so that the operator can remove the trousers.
A second type of apparatus for permanently setting a pre-formed crease in a pair of trousers comprises that disclosed in U.S. Pat. No. 4,763,600, issued Aug. 16, 1988 to Saunders, et al.
This patent is incorporated herein by reference for what it teaches about such an apparatus and its use and as part of the combination of a system described and claimed herein for permanently creasing trousers and removal and stacking of such trousers.
The Saunders, et al patent describes an apparatus which can consist of a horizontal apparatus having a support member and lower and upper crease blades pivoted on the support member. The free ends of the crease blades extend away from the support member and include applicator nozzles that are directed upward for the upper crease blades and downward for the lower crease blades. When the apparatus has received a pair of pre-creased trousers over the crease blades and the lower crease blades are pivoted downward, the trousers are pulled taut at the hems between the pre-formed creases and as the trousers are pulled off of the crease blades, a pumping mechanism supplies a flowable, curable setting material such as silicone rubber to the applicator nozzles, which applies a coating of setting material to the inside surfaces of the trousers along the creases.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a full front view of an apparatus of this invention.
FIG. 2 is a full side view of an apparatus used for placing the crease setting material in the crease of trousers.
FIG. 3 is a full view of the apparatii of FIG. 1 and FIG. 2 with regard to their combined working relationship.
FIG. 4 is a near end view of the apparatus of FIG. 1.
FIG. 5 is a distal end view of the apparatus of FIG. 1.
FIG. 6 is a distal end view of the apparatus of FIG. 1, in which the grippers are turned at a 90° angle from the resting position.
FIG. 7 is a full view of the combined apparatii of FIG. 3, showing the beginning of the removal of the trousers from the permanent crease setting apparatus.
FIG. 8 is a full side view of the combined apparatii of FIG. 3, showing the upward stroke of the trouser stacker and the 90° turn of the grippers.
FIG. 9 is a full top view of a device of U.S. Pat. No. 4,763,600.
THE INVENTION
Thus, what is disclosed is a device for removing and stacking creased trousers from an apparatus used for applying a flowable, curable setting material to the inside crease surface of the trousers, or an apparatus for pressing the trousers. The device comprises a supporting frame comprised of two end segments, one such end segment being a near end segment, and the other end segment being a distal end segment.
Each end segment is comprised of a C-shaped frame having a vertical post, each said vertical post having a top and a bottom, a top arm, having a near end and a distal end, said top arm being attached to the vertical post at the near end thereof, and the top arm extending perpendicular to the vertical post and, a bottom arm, having a near end and a distal end, the bottom arm being attached to the vertical post at the near end thereof, and the bottom arm extending perpendicular to the vertical post and, a set of two cross braces to support the end segments, each of the braces attached near the top of one vertical post and near the bottom of the other vertical post and each cross brace having a midpoint wherein the braces cross each other.
There is a rodless cylinder, the rodless cylinder being located between, and detachedly fixed to the distal ends of the top arms, and having a reciprocatable block contained therein. There is a trolley, and the trolley has a near end and a distal end, said trolley being attached to the reciprocatable block and moving therewith, said trolley having vertical support hangers fixedly attached on the near end the distal end of the trolley.
There is also a rotary actuator located between the vertical support hangers and supported therein, the rotary actuator having a drive end wherein the drive end extends through the distal end vertical support hanger and attaches to a gripper support block. The gripper support block has mounted thereon, a set of two movable grippers, said support block having a resting position and a working position, said rotary actuator being capable of rotating the gripper support block at least 90° from the resting position to a working position and returning to the resting position. And finally, there is a stacking starter. The stacking starter is comprised of a stacking starter support, wherein the support is attached to the distal end of the bottom arm of the distal end segment. It also includes at least one driving apparatus and, a stacking starter plate, wherein the stacking starter plate is attached to the driving apparatus such that the stacking starter plate can be driven in an up and down motion.
There is also disclosed a system for providing permanently creased trousers. The system comprises in combination, the device just described above, and an apparatus for permanently setting pre-formed creases in a pair of trousers. The apparatus for permanently setting pre-formed creases in a pair of trousers comprises a stanchion member; a pair of spaced-apart substantially parallel support members each having one end fixed to said stanchion member and a free end extending substantially horizontally from said stanchion member, and, a pair of substantially horizontal first crease blades each aligned with and positioned above an individual one of said support members and fixed to said individual support member, each of said first crease blades having a free end extending away from said stanchion member, and said free end of each of said first crease blades including an upper applicator nozzle directed substantially upward; a pair of second crease blades each aligned with an individual one of said support members, each of said second crease blades having one end pivotally connected to said individual support member and a free end extending away from said stanchion member, and said free end of each of said second crease blades including a lower applicator nozzle directed substantially downward; a means for pivoting the free ends of said second crease blades away from said free ends of said first crease blades; and, a means for supplying a flowable, curable setting material to said upper and lower applicator nozzles.
There is further provided a method of removing and stacking trousers, the method comprising providing trousers to be removed and stacked; using the removing and stacking device described above to remove and stack the trousers.
There is also provided a method of permanently creasing trousers, the method comprises providing trousers which are pre-creased; aligning the trousers on an apparatus used for permanently creasing trousers such that the creases are essentially straight; applying a flowable, curable setting material to the pre-creases in the trousers; removing and stacking the trousers from the apparatus by utilizing the device of this invention; allowing the trousers to remain stacked until the flowable, curable setting material has cured, whereby the trousers are permanently creased.
Even still, there is disclosed a device for removing and stacking creased trousers from a trouser pressing apparatus, said device comprising the removing and stacking device disclosed and claimed herein in conjunction with a pressing apparatus comprising essentially of an apparatus as set forth and described in U.S. Pat. No. 3,713,567.
A system for providing pressed trousers, said system comprising in combination the removing and stacking device disclosed and claimed herein and an apparatus for pressing the trousers.
DETAILED DESCRIPTION OF THE INVENTION
Turning now to the detailed description of the various embodiments of the invention, and with reference to FIG. 1, there is shown an apparatus 1 of the instant invention which is a trousers removal and stacking device. The device 1 is comprised of a frame which has a near end 2 and a distal end 3, cross braces 4 and 5 which have a mutual cross point 6, along with a rodless cylinder 25 which will be disclosed in detail infra, as the supporting frame of the invention.
With reference to FIG. 4, it can be observed that the near end 2 of the frame has a C-shaped configuration, as does the distal end 3 of the frame. The C-shape comprises a vertical post 7, a horizontal lower arm 8 which is affixed by its near end 9 to the vertical post 7 at its lower end 10.
The C-shape near end 2 also has a horizontal upper arm 11, which is affixed by its near end 12 to the vertical post 7 at its upper end 13.
Likewise, the distal end 3 has a C-shaped configuration. The C-shape comprises a vertical post 14, a horizontal upper arm 15 which is affixed by its near end 16 to the vertical post 14 at its upper end 17 and a lower horizontal arm 18 which is affixed by its near end 19 to the vertical post 14 at its lower end 20.
Returning with reference to FIG. 1, there is shown a completion of the support frame by the inclusion of a rodless cylinder 25, which is affixed to and between the respective upper arms 11 and 15 at their distal ends 21 and 22, respectively, to essentially complete the frame of the apparatus.
The two ends 2 and 3 of the frame are stabilized by cross braces 4 an 5, and the cross brace 4, for purposes of illustration is affixed near the upper end of the vertical post 7 and at the back thereof. The opposite end of brace 4 is fastened to the lower end 20 of the vertical post 14 and on the back thereof. The other cross brace 5 is fastened near the upper end 13 of the vertical post 14 and the opposite end is fastened near the lower end 10 of vertical post 7, and the braces 4 and 5 cross and are fastened at point 6. The cross brace 4 and the cross brace 5 cooperate to the extent that a second brace, that is, a support 24 for a clothes rod 23 is affixed to the inside surfaces of the respective cross braces 4 and 5 in a vertical alignment. The clothes rod 23 is affixed to the lower end 26 of the clothes rod 23 such that it is perpendicular to the support 24, the purpose of such a clothes rod 23 being to hold, in cooperation with a second clothes rod 27, stacked trousers from the device 1, the essentials of which are described infra.
With regard to the distal end 3 of the frame, and specifically with respect to the lower arm 18 on vertical post 14, there is located a stacker support 28 which is fixed to the distal end 29 of the lower arm 18. Surmounting the stacker support 28 is a stacker support bar 30, which has activatable drive means 31 detachedly mounted thereon. Each of the drive means 31 have a drive end 32 which is detachedly attached to the back surface 33 of a trouser stacker 34. When the drive means 31 is activated, the drive means 31 moves in a reciprocal vertical motion, and carries with it the trouser stacker 34.
Slidably mounted in the interior of the rodless cylinder 25 is a reciprocatable block 35 (which is shown in phantom in FIG. 1) which moves in response to air pressured into the rodless cylinder 25 through ports 36 and 37. The movement of the rodless cylinder 25 is controlled by magnetic switches 77, or some similar means. Also shown are air pressure hoses 38 and 39 used for that purpose. Not shown in the air source, and neither the hoses or the air source form any part of this invention.
Mounted to the underside of the block 35 is a trolley 40, which trolley 40 moves simultaneously with the block 35 when the block 35 is activated.
The trolley 40 has mounted on its near end 41 and its distal end 42, vertical support hangers 43 and 44, respectively. There is a rotary actuator 45 located between the vertical support hangers 43 and 44. The rotary actuator 45 has a drive end 46 which extends through the distal end 42 vertical support hanger 44 and is attached to a gripper support block 47.
The gripper support block 47 has mounted on it at least one set of movable grippers 48, and in this illustration, there are shown two such grippers 48, which are separated and mounted towards the near outside end 49 and distal outside end 50 of the gripper support block 47.
With regard to FIG. 4, there is shown a near end view of the device 1 of this invention in which there is shown the vertical post 7, cross braces 4 and 5, upper arm 11, fastened to the vertical post 7 at the top 13 of the vertical post 7. At the distal end 21 of the upper arm 11 there is shown the rodless cylinder 25, the control value 51 for the rodless cylinder 25, the air hose 38, trolley 40, the vertical support hanger 43, the clothes rod 23, the second clothes rod 27, the lower arm 8, the lower arm 18, stacker support 28, stacker support bar 30, drive means 31, drive end 32, trouser stacker 34, and distal end 29 of lower arm 18.
Viewing the device 1 of the instant invention from the opposite end, i.e. the distal end 3, and with reference to FIG. 5, there is shown the vertical post 14, the cross braces 4 and 5, the upper arm 15, attached to the upper end 17 of vertical post 14, the control valve 52 for the rodless cylinder 25, the air hose 39, the trolley 40, the vertical support hanger 44, the gripper support block 47, two sets of movable grippers 48, clothes rod 23, the second clothes rod 27, the lower 8, the lower arm 18, stacker support 28, the stacker support bar 30, drive means 31, drive end 32, trouser stacker 34, and distal end 29 of lower arm 18.
With further reference to FIG. 5, it should be noted that the gripper support block 47 is in the resting position, that is, the gripper support block 47 is horizontally positioned.
With reference to FIG. 6, there is shown essentially the view of FIG. 5, but the gripper support block 47 is turned an angle of 90° from the resting position, i.e. to the working position. It should be noted that the drive end 32 of the drive means 31 has been activated for purposes of illustration, and that the trouser stacker 34 is in an elevated position with regard to its normal resting position on the upper end 53 of the drive means 31.
The significance of the resting position and working position, and the position of the trouser stacker 34, will be clearer from the discussion of the operation of the device of this invention set forth infra.
Turning now to FIG. 2, there is shown a device 55 of U.S. Pat. No. 4,763,600, which is a device that is compatible with the device of this invention. The device 1 of this invention can be used in conjunction with the device of the '600 patent such that the instant invention device 1 will remove trousers from the '600 device and stack them.
Thus, the applicant has invented a combination of devices that include the device of the '600 patent and with regard to FIG. 2, there is shown the device 55 which includes a stanchion 59 extending vertically upward from a base portion 60 and a pair of spaced-apart substantially parallel support members 61 extending substantially horizontally from stanchion member 59.
The device 55 includes means for supporting each trouser leg of a pair of trousers along the inside surfaces of a pair of preformed creases in each trouser leg. As embodied in that device and herein, the supporting means includes pair of fixed substantially horizontal upper crease blade 56, each of which is aligned with and positioned above one of support members 57. Each upper crease blade 56 includes free end 58 extending away from stanchion member 59. Upper crease blades 56 are connected to their respective support members 61 by crease blade connectors 62. Preferably, upper crease blades 56 have a small radius top edge 54 to facilitate the alignment of the pre-formed creases of the trouser legs with the upper crease blades 56.
Device 55 includes means for pulling each trouser leg taut between the trouser leg's pair of creases. As embodied therein, the pulling means includes a pair of lower crease blades 63 each of which is pivotally connected to an individual support member 61 by pin 64. Free end 66 of each lower crease blade 63 extends in a direction away from stanchion member 59. The bottom edges 67 of crease blades 63 preferably are of a small radius.
Device 55 includes means for pivoting the free ends 66 of lower crease blades 63 away from free ends 57 of upper crease blades 56. As embodied in the '600 patent and herein, and as shown in FIG. 2, the pivoting means includes an air cylinder 65 mounted on the outside of stanchion 59.
Device 55 also includes means for applying a coating of a flowable, curable setting material along the inside surface of each crease of the trouser legs simultaneously as the trouser legs are slidably removed from the crease blades in a direction toward free ends 58 and 66. It should be noted that the trousers are generally removed by hand by an operator. The means for applying a coating herein is constituted by a supply source 68 for the flowable coating, a pump 69 to move the flowable coating, a transfer line 78 for the flowable coating, and a control 70 for applying the correct amount of the flowable coating to the crease in the trousers.
Turning to FIG. 9, there is shown a full top view of the device 55 of U.S. Pat. No. 4,763,600 which device is fully incorporated herein by reference as part of the combination of devices set forth in the claims.
For orientation purposes, there is shown the upper crease blades 56, the stanchion 59, the flow control valve 70 for each of the transfer lines 69, the support means 57 for the crease blades 56, the 68, the air cylinder 65, and base 60. This Figure also includes a photoelectric cell 71, a receptor 72 for the photoelectric cell 71 whose function in combination with the device 1 of the invention will be described infra, an air flow control valve 73, and a solenoid valve 74.
Turning now to the overall operation of the invention device of this invention and its use in combination with an apparatus for dispensing flowable material into creases of pre-formed trousers, and with reference to FIGS. 7 and 8, and firstly with FIG. 7, there is shown a device 1 of this invention, in combination and alignment with a device 55 of the '600 patent.
It should be understood by those skilled in the art that the activators for the entire system are coordinated to allow the two devices to accommodate each other and to work cooperatively with each other.
Thus, there is shown the device 1, the apparatus 55, the rodless cylinder 25, the rotary actuator 45, the movable grippers 48, a pair of trousers 75, which are aligned on the crease blades 56 and 63 by the pre-formed creases in the trousers 75. In this Figure, the trolley 40, along with the supports 43 and 44, and the rotary actuator 40, the gripper support block 47, and the movable grippers 48, all of which move simultaneously, are positioned at the distal end 3 of the frame of the device 1, although, the normal resting position for this movable assembly of the device 1 is at the near end 2, i.e. the right end in the FIG. 7, and with the grippers 48 in a vertical position.
There is shown an operator foot switch 76, which activates the entire system. The operator aligns the trousers 75 on the device 55, presses the foot switch 76 causing the air cylinder in device 55 to open, spreading the creases taut at the hems, while the actuator 45 is turning the grippers 90° and sending the moveable assembly described just above with regard to the grippers 48 to the distal end, i.e. the left end of the frame, and the grippers 48 grip the bottom edge of the trousers 75.
At this point in the overall operation, the pump 77 is activated, as are the controls for the rodless cylinder 25. The trousers 75 are drawn in essentially a straight line from the device 55, and as the trousers 75 are withdrawn at a controlled rate, the flowable material is deposited in all of the creases of the pre-creased trousers 75. When the trousers 75 have been removed from the device 55 to the extent that the crotch of the trousers 75 has passed the photoelectric cell 71, the legs of the trousers 75 no longer impede the transfer of a light beam from the photoelectric cell 71 to the receptor 72, and the photoelectric cell 71 transmits a light beam to the receptor 72 which automatically and simultaneously shuts down the flow of the flowable material to the creases, switches off the air cylinder in device 55 removing the tension in the trousers, activates the drive means 31 of the trouser stacker 34, which causes the trouser stacker 34 to be driven upwardly by the drive ends 32, which trouser stacker 34 contacts the uppers of the trousers 75, and flips the uppers of the trousers 75 inwardly towards the frame of the device 1, while at the same time, the rotary actuator 45 turns the gripper support block 47 inwardly towards the frame in a full 90° turn, which causes the grippers 48 to turn in the same direction, i.e. the "working" position, and turn the legs of the trousers 75 in an inwardly direction towards the frame. At or near the end of the rotation of the rotary actuator 45, the grippers 48 release the bottom edge of the trousers 75, and the above described entire operation causes the trousers 75 to be turned 90° and laid essentially flat, where they are released to drop by gravity to the clothes rod 23 and clothes rod 27. Processed trousers 79 are shown in FIG. 8, lying on the clothes rods.
It is also contemplated within the scope of this invention not to use the clothes rods 23 and 27, but to align a movable cart under the frame, in essentially the same position as the rods, and allow the trousers 75 to drop directly on the cart.
Upon the release of the trousers 75, the trouser stacker 34 returns to its resting position on the surface of the drive means 31, and the movable assembly containing the grippers 48 etcetera, automatically move back along the rodless cylinder 25 to the near end of the frame to be ready for the next cycle.
FIG. 8 represents the combination of equipment as shown in FIG. 7, but it should be noted that the trolley 40 has moved to the near end 2 of the frame and that the trousers 75 have been removed from the device 55, and that the trouser stacker 34 is at its highest point and has flipped the upper half of the trousers 75 inwardly towards the frame to start the stacking mode of the device 1.
It should be noted by those skilled in the art that there are various switches, activators, wires, hoses, cords, and the like that are used to electrically, pneumatically, and mechanically connect the devices 1 and 55 together, which are not shown in the drawings in order to help clarify the specification. | This invention disclosed herein deals with an apparatus for removing and stacking trousers after they have been processed through a separate apparatus for crease permanency or pressing. | 3 |
TECHNICAL FIELD
[0001] The present invention relates to a method for preparing primer used for determining PDS gene mutation of large vestibular aqueduct syndrome in vitro. Particularly, the present invention provides a method for preparing primer used for determining the IVS7-2A→G mutation within PDS gene of large vestibular aqueduct syndrome. The present invention further provides a primer prepared according to the method and the kit comprising the primer, and the use of the primer or the kit for determining the IVS7-2A→G mutation within the PDS gene of large vestibular aqueduct syndrome in vitro.
BACKGROUND
[0002] The incidence of congenital hearing loss of newborn is 1-3/1000. There are many factors leading to hearing loss. More than half of children patients with hearing loss are diagnosed hereditary hearing loss (Wang, Jinling, “Large Vestibular Aqueduct Syndrome and Fluctuating Heating Loss”, Journal of Audiology and Speech Pathology, 2003, 11(2): 81-84). The large vestibular aqueduct syndrome caused by PDS gene (Pendred's syndrome gene) mutation is an important type. In 1978, Valvassori and Clemis found 50 vestibular aqueduct cases by conducting tomography scan in 3700 temporal bones continuously, and named them as large vestibular aqueduct. The clinical symptoms associated with sensorineural hearing loss and large vestibular aqueduct were named as “larged vestibular aqueduct syndrome” (LVAS). The patients had normal hearing when they were born, or accompanied with light to medium hearing loss. The children suffering from the disease had excellent linguistic capacity at the early stage. Then they lost their hearing gradually. Most of the precipitating factors of hearing loss are head trauma, intracranial hypertension, and catch cold, etc. Since falling from bed, infant games or lightly collision in physical exercises can bring about apparent hearing loss, the diagnosis of the disease at the early stage will prevent occurrence and deterioration of it efficaciously, which enable the disease preventable (Wang, Jibao, “Large Vestibular Aquduct Syndrome”, Chinese Journal of Otorhinolaryngology Head and Neck Surgery, 2002, 37: 398-400). Recently, many foreign researchers have found that there are close correlations between the large vestibular aqueduct syndrome and the PDS gene mutation (Campbell C, Cucci R A, Green G E, et al. Pendred Syndrome, DFNB4 and PDS—identification for eight novel mutations and phenotype-genotype correlations. Human mutation, 2001, 17:403-411; Scott D A, Wang R, Kreman, et al. Functional differences of the PDS gene product are associated with phenotypic variation in patients with Pendred syndrome and non-syndromic hearing loss (DFNB4). (Human Molecular Genetics, 2000, 9:1709-1715). PDS gene (SLC26A4) (Solute carrier family) is composed of 21 exons. The open reading frame of PDS is 2343 bp in length, encoding a protein “Pendrin” which consists of 780 amino acids. Pendrin mainly consists of hydrophobic amino acids, belonging to ionic transport family. Studies suggested that the main functions of it is the transportation of iodine/chloride ions. Almost all of the hereditary patterns of PDS gene mutations which lead to hearing loss belong to autosomal recessive heredity. That is to say, parents are carriers, and ¼ of the offsprings have the disease because they inherit two mutated PDS gene mutations from their parents (homozygote), 2/4 of the offsprings are carriers because they inherit only one mutated PDS gene mutation from their father or mother (heterozygote without disease), and the other ¼ of the offsprings are wild type individuals for PDS gene because they inherit the two normal PDS alleles from their parents.
[0003] We have found 26 patients carrying different PDS mutations with enlarged vestibular aqueduct among 29 Chinese patients under our investigation, 19 patients of which carrying IVS7-2 A→G mutation, indicating that the IVS7-2 A→G mutation is a important causation leading to large vestibular aqueduct syndrome. We have found five IVS7-2 A→G homozygous mutants, four IVS7-2 A→G heterozygous mutants among the PDS gene detection of 63 deaf-mute pupils from Chifeng city of Mongolia, China, the mutation rate is 14.28%. We have found one heterozygous mutant for IVS7-2 A→G among 100 Chinese normal hearing individuals, the estimated carrier rate of this mutation in ordinary Chinese population is about 1%.
[0004] We have demonstrated for the first time that the IVS7-2 A→G mutation is the most hot mutation spot of the Chinese patients of large vestibular aqueduct, and the incidence of this disease is at a high level. But no suitable restriction sites of IVS7-2 site in the native sequences of PDS gene were found for identify IVS7-2 A→G mutation and wild type sequences. Conventional method could identify the mutations occurred in this region through sequence analysis only. Although sequence analysis is a standardized method for gene diagnosis, the method is not suitable for screening and popularization because it needs expensive equipment, complex operation, highly skilled persons. It is a time and labor consuming method.
[0005] Therefore, a method suitable for wide screening and rapid diagnosis of the IVS7-2 A→G mutation in the PDS gene among hearing loss population is needed.
SUMMARY OF THE INVENTION
[0006] The present invention was carried out based upon the following principles: distinct primers was designed by using the mutated site (i.e. IVS7-2 A→G at position 252 of SEQ ID NO:1) within the mutated PDS gene related to large vestibular aqueduct syndrome, with or without bio-software. We introduced a new restriction site including the IVS7-2 site in the PDS gene through PCR method artificially, and obtained the accurate results of the IVS7-2 A→G mutation in the PDS gene of large vestibular aqueduct syndrome through analyzing the restriction results of PCR products being tested.
[0007] Therefore, according to one aspect of the present invention, a method for preparing primers suitable for determining the IVS7-2A→G site mutation of large vestibular aqueduct syndrome in vitro was provided. It is composed of primer used for amplifying the IVS7-2 site of PDS gene and with or without bio-software based upon the IVS7-2 A→G mutation site of PDS gene (the inframe of intron 7 is the PDS IVS7-2 site which is the position 252 in SEQ ID NO:1, the PDS IVS 7-2 A-G mutation is the result of the base A which was substituted by base G at this site, the mutation is a splicing site mutation, which will result in the loss of exon 8 during transcription). The primer may introduce a base substitutive mutation in the region of 1-13 bases between upstream and downstream including the A→G mutation at IVS7-2 site, so as to obtain a new restriction site that may be used for distinguishing IVS7-2 wild type (A site) and mutant (G).
[0008] As the well-known commercial shortest restriction endonuclease recognition site including 4 bases (e.g. CviJI, recognition site RGCY), the longest restriction endonuclease recognition site including 13 to 14 bases (e.g. Sfi I including 13 bases, StySQI including 14 bases), the primers which may introduce a base substitutive the mutation in the region of 1 to 13 bases between upstream and downstream including the A→G mutation at IVS7-2 site are all useful for the present invention. Accordingly, the length of said region of 1-13 bases between upstream and downstream is preferably 1 to 10 bases, more preferably 1 to 8 bases, even more preferably 2 to 6 bases, most preferably 2-4 bases.
[0009] In another aspect, the present invention provides a method used for designing the primer through computer aided primer design software program. The software program used in the invention including, but not limited to Genetool Lite program (a software available from Biotools company, USA), Vector NTI, Oligo, Genestar, DNAMAN, DNASTAR, DNAtool, proteintool, Enzyme, pDRAW, Primer3, Primer5, Seq Convertor, and DNAassist, etc.
[0010] In another aspect, the present invention provides primers prepared according to the method mentioned above, including forward primers (F1) and reverse primers (R1). Wherein, the length of the said primers are in the range of 10 to 40 bp, preferably 15 to 35 bp, more preferably 18 to 32 bp.
[0011] In another aspect, the present invention provides a particular primer sequence prepared according to the method mentioned above. The Said primer sequence including: the forward primer sequence of 30 bp in length (SEQ ID NO:3), 5′TGGAGTTTTTAACATCTTTTGTTTTATTCC 3′, wherein, introducing a T-C artificial mutation at the second position of 3′ end; and the reverse primer sequence of 20 bp in length (SEQ ID NO:4), 5′CCCTTGGGATGGATTTAACA 3′.
[0012] In another aspect, the present invention provides kit or identical product which comprising said primers, and can be used for determining the PDS mutated gene of large vestibular aqueduct syndrome in vitro, comprising: PCR amplification reactants, mixture of said forward primer and reverse primer mixed at a ratio of 1:1, novel restriction endonuclease and it's corresponding buffer, positive specimen control, negative specimen control, and operation instruction. Wherein, the primary function of said kit or identical product is that each reagent may be contained in a small box, so that the amplification of nucleic acid fragments, the restriction and identification could be accomplished with the reagents provided in the said kit or identical product sequentially.
[0013] The said kit or identical product further comprises kit or reagents used for isolating DNA from blood sample, except for the reagents used for isolating DNA from blood sample, other components in those kit or reagents are identical. Type I kit or reagent comprises solution I of DNA lysis buffer which was used for isolating DNA from plantar blood sample, the principal component is Chelex (5% Chelex, 0.1% SDS, 1% NP40, 1% Tween 20, product from ABI company); Type II kit or reagent comprising kit (Watson Biotechnologies, Inc) was used for isolating DNA from peripheral blood sample.
[0014] In another aspect, the present invention provides a kit used for the newly introduced restriction site HpaII, comprising:
[0015] 1. Optionally comprising reagent or kit used for isolating DNA from plantar blood or peripheral blood sample;
[0016] 2. PCR amplification reactants, comprising dNTP, 10×PCR buffer, Mg++, triple distilled water, Taq enzyme;
[0017] 3. Mixture of the said forward primer (SEQ ID NO:3) and reverse primer (SEQ ID NO:4) mixed at a ratio of 1:1;
[0018] 4. Restriction enzyme HpaII and its corresponding buffer;
[0019] 5. Positive specimen control, negative specimen control, and
[0020] 6. Operation instruction.
[0021] In another aspect, the present invention provides a method for determining the IVS7-2 A→G mutation in the PDS gene of large vestibular aqueduct syndrome in vitro, and the method comprises the steps of: Designing primer used for amplify the IVS7-2 site of PDS gene through the method for preparing primers mentioned above, wherein, a base substitutive mutation may be introduced into the said primer in the region of 1 to 13 bases between upstream and downstream including the A→G mutation at IVS7-2 site, so as to obtain a new restriction site which may be used for distinguishing IVS7-2 wild type (A site) and mutant (G); or use the primer prepared through said method directly, or use the said kit/identical product directly, amplify the samples to be detected utilizing said primer, there was a site-directed mutation of a single base between the region near 3′ end of the forward primer and amplification template, but it does not affect the efficiency of the PCR of the forward primer and reverse primer, therefore, the amplification products of same length may be obtained with wild type sample or mutant sample; Restriction analysis was carried out on the amplification products with the said novel restriction endonuclease, wherein, the amplification fragments of wild type sample can not be restricted by the said novel restriction endonuclease as it comprises no mutated novel restriction site, and the amplification products of mutant sample can be restricted by the said novel restriction endonuclease as it comprises mutated novel restriction site, so as to and they can identify the sample with IVS7-2 site A-G mutation within the PDS gene. In the method mentioned above, the length of the said region of 1 to 13 bases between upstream and downstream is preferably 1 to 10 bases, more preferably 1 to 8 bases, even more preferably 2 to 6 bases, most preferably 2 to 4 bases.
[0022] In the method mentioned above, it further comprises a step of designing the said primers with computer primer design software program. The software programs, which were used, including, but not limited to: Genetool Liteprogram (a software available from Bio-tools company, USA), Vector NTI, Oligo, Genestar, DNAMAN, DNAtool, Proteintool, Enzyme, pDRAW, Primer3, Primer5, Seq Convertor, and DNAassist, etc.
[0023] In another aspect, the present invention provides a method for introducing a new restriction endonuclease HpaII site into the PDS gene, the method comprises the steps of: designing a primer pair used for amplifying IVS7-2 site of the PDS gene (SEQ ID NO:3, 4), wherein, a bases substitutive mutation may be introduced into the region of 2 to 4 bases between upstream and downstream including the IVS7-2 site (A→G), so as to obtain a new restriction site HapII which may be used for distinguishing IVS7-2 wild type (A site) and mutant (G); isolating the DNA of the sample to be detected, and obtaining amplification templates as needed; PCR amplification was carried out with amplification templates using the said primer pair (SEQ ID NO:3, 4); amplification fragments of 114 bp in length may be produced through amplification with both wild type and PDS IVS7-2 A→G mutant samples, a bright band of more than 100 bp in length was found in the actual PCR products in agarose electrophoresis, which confirmed the mismatch between the second base at 3′ end of forward primer (SEQ ID NO:3) 3′ and the template does not affect the efficiency of PCR; Restricting the PCR products with HpaII, wherein, the PCR products comprising a PDS IVS7-2 site, if the template is a IVS7-2 A→G mutant molecule, then a HpaII restriction site exists in the amplification products of 114 bp in length, and two sets of bands of 83 to 85 bp and 29 to 31 bp in length were obtained after restricted with HpaII. If the template is a PDS IVS7-2 wild type molecule, then no HpaII restriction site exists in the amplification products of 114 bp in length, and it can not be restricted by HpaII. The band of 114 bp maintains intact after restriction; Determining whether a IVS7-2 A→G mutation in the PDS gene of large vestibular aqueduct syndrome is existing in the sample to be detected according to the results of restriction electrophoresis or not.
[0024] In the method for determining new restriction endonuclease HpaII site, wherein the designing of primer pair may be accomplished by computer primer design software, such as Genetool Liteprogram (a software available from Biotools company, USA), Vector NTI, Oligo, Genestar, DNAMAN, DNAtool, Proteintool, Enzyme, pDRAW, Primer3, Primer5, Seq Convertor, and DNAassist, etc.
[0025] In the method for determining new restriction endonuclease HpaII site, wherein the extraction, PCR amplification, and restriction of sample DNA may be accomplished with kits or reagents comprising the said primer pair (SEQ ID NO:3 or 4) and new restriction endonuclease HpaII site.
[0026] The method for determining PDS gene IVS7-2 A→G mutation of the present invention provides the following advantages comparing with currently available methods (sequencing method):
[0027] The operation steps of the restriction method with restriction endonuclease of the present invention were simple, and can be completed within 4 hours; the reagents involved are common biochemical reagents, and low cost; the PCR apparatus and electrophoresis devices are basic equipment of biology laboratories and examination laboratories. These characteristics are advantage to the screening of PDS gene IVS7-2 A→G mutation nationwide, and can prevent large vestibular aqueduct syndrome, thereby reducing the possibility of deafness of large vestibular aqueduct syndromic individual fundamentally. The sequence analysis method needs sequencer, and the technical operation is complex. It takes 3 to 7 days to finish one complete analysis.
DESCRIPTION OF THE FIGURES
[0028] FIG. 1 dispicts the electrophoretic pattern for identifying the IVS7-2 A→G mutation of HpaII which restricted PDS gene on 2.5% agarose gel, lane b, c: individual's heterozygous for the IVS7-2 A→G mutation in the PDS gene; lane f, o: individual's homozygous for the IVS7-2 A→G mutation in the PDS gene; lane a, x: markers (interval was 100 bp); the rest lanes: normal wild type individuals.
[0029] FIG. 2 dispicts the results of sequence analysis which confirmed the accuracy of restriction results. Left: keep intact after restriction, no IVS7-2A-G mutation appeared in sequencing (eg. lane d); middle: two bands appeared after restriction, sequence analysis confirmed that it was heterozygous for the IVS7-2A-G mutation (lane b, c); right: all of the bands were restricted after restriction or the brightness of smaller bands were stronger than that bigger ones, sequence analysis confirmed that it was homozygous for the IVS7-2A-G mutation (lane f, o).
DETAILED DESCRIPTION
[0030] Now, the present invention will be described in more detail in referred to the following nonlimited embodiments. It should be understood that, the following embodiments are merely exemplary, and is in no way intended to limit the present invention. Unless otherwise stated, the embodiments of the present invention utilizing conventional molecular biology, cell biology, PCR amplification and mutagenesis technologies, etc., which is well known to the skilled in the art, and described in a number of literatures in detail. See, for example, Sambrook and Russell “Molecular Cloning: A Laboratory Manual” (2001); Cloning: A Practical Approach, “Volumes I and II (D. N. Glover, ed., 1985)”; T. A Brown “Genome” BIOS Scientific Publishers Limited.
Example 1 The Determination of the IVS7-2 Mutation in the PDS Gene of Deaf-Mute Population
1. Examination of Specimen
[0031] 66 deaf-mutes (all from School for deaf-mutes of Chifeng, China), 100 individuals with normal hearing were selected, with DNA isolated from peripheral whole blood of all subjects by the method provided in the kit (Watson Biotechnologies, Inc), Then the specimens are examined. The deaf-mutes were confirmed to be severe or profound hearing loss by pure-tone audiometry.
2. Primer Design
[0032] The guiding ideology of primer design is introducing a base substitution in the region of 2 to 4 bases around the PDS IVS7-2 site (i.e. Position 252 in SEQ ID NO:1), so as to obtain a new restriction site which may be used for distinguishing IVS7-2 wild type (A) and mutant (G). The GenetoolLite program was used in primer design, the length of forward primer is 30 bp, a T-C mutation was introduced into the PDS IVS7-4 site, the length of reverse primer is 20 bp, complementing with the wild type PDS gene forward sequence completely. The forward primer sequence (SEQ ID NO:3) is 5′TGGAGTTTTTAACATCTTTTGTTTTATTCC 3′, The reverse primer sequence (SEQ ID NO:4) is 5′CCCTTGGGATGGATTTAACA 3′. The amplification fragment of 114 bp can be produced by amplification both with wild type specimen and PDS IVS7-2 A→G mutation specimen. The PCR products comprise the PDS IVS7-2 site. If the template is a IVS7-2 A→G mutant molecule, there is a HpaII restriction site in the amplification products of 114 bp in length, and two sets of bands of 83 to 85 bp and 29 to 31 bp were obtained after HpaII restriction; If the template is a PDS IVS7-2 wild type molecule, there is no HpaII restriction site in the amplification products of 114 bp in length, and it can not be restricted by HpaII, the band of 114 bp maintaining intact after restriction.
3. PCR Amplification Reaction
[0033] Forward primers F and reverse primer R were obtained through artificial synthesis (synthesized with automatic nucleic acid synthesizer using given sequences) based upon said designed forward and reverse primer sequences, and said DNA isolated from detected peripheral blood was used as templates for PCR amplification reactions:
[0034] Reaction System:
[0000]
Templates
50
ng
Primers F1, R1
each 50
ng
10 × dNTP
5
μl
10 × Buffer
5
μl
Final concentration of Mg ++
1.5
mmol/L
Taq enzyme
1.0
u
Add triple distilled water to
50
μl.
Reaction Conditions:
[0035] Denaturating for 5 minutes at 95° C., then denaturating for 30 seconds at 94° C., annealing 30 seconds at 55° C., extension 30 seconds at 72° C., 30 circles together, extension 7 minutes at 72° C. finally.
[0036] The products were analyzed through 2.5% agarose gel electrophoresis. A bright and defined band bigger than the band of 100 bp was obtained after PCR amplification with F1R1, and indicate that the mismatch between the second base at 3′ end of the forward primer and the templates does not affect the efficiency of PCR.
4. HpaII Restriction Analysis
[0037] The PCR products comprise the PDS gene IVS7-2 site. If the template is a IVS7-2 A→G mutant molecule, there is a HpaII restriction site in the amplification products of 114 bp in length, and two sets of bands of 83 to 85 bp and 29 to 31 bp were obtained after HpaII restriction (only one band of 83 to 85 bp appearing on the gel); If the template is a mt IVS7-2 wild type molecule, there is no HpaII restriction site in the amplification products of 114 bp in length, and it can not be restricted by HpaII, the band of 114 bp maintains intact after restriction.
[0038] Analyzing the IVS7-2A→G mutation of the PCR amplification products from specimen is detected under the following conditions.
Restriction Reaction System:
[0039]
[0000]
PCR products
12-18
μl
10 × Buffer
3
μl
HpaII restriction enzyme
5-10
u
BSA
0.3
μl
[0040] Adding triple distilled water to 30 μl, incubated for one hour at 37° C. Analyzing the restricted reactants with 2.5% agarose gel.
5. Results
[0041] During the gel electrophoretic analysis after restriction, only one band bigger than 100 bp was found in 57 cases among the selected 66 deaf-mutes, indicated that no IVS7-2A→G mutation existed; a band bigger than 100 bp and a band smaller than 100 bp were found in 4 cases, the brightness of the bigger band was stronger than the smaller one, indicated that they are heterozygous for IVS7-2 A→G mutation; a band smaller than 100 bp was found in the rest 5 cases, indicated that they are homozygous for IVS7-2 A→G mutation (see FIG. 1 for some data);
6. The Assay for Reliability of HpaII Restriction Method
[0042] Analyzing the sequences of exon 7 and 8 of the restricted DNA samples from 5 cases which were confirmed comprising homozygous mutation for IVS 7-2 A→G of PDS gene directly, indicated that homozygous A→G substitution was existed for IVS 7-2 site; Analyzing the sequences of exon 7 and 8 of the restricted DNA samples from 4 cases which were confirmed comprising heterozygous mutation for IVS 7-2 A→G of PDS gene directly, indicated that heterozygous A→G substitution was existed for IVS 7-2 site; Analyzing the sequences of exon 7 and 8 of the restricted DNA samples from 11 cases which were confirmed comprising no mutation for IVS 7-2 A→G of PDS gene directly, indicated that the IVS 7-2 site was normal ( FIG. 2 ). Dilated vestibular aqueduct were found in the 9 cases of IVS 7-2 A→G mutation individuals (homozygous or heterozygous) through temporal bone CT scan analysis, no abnormity was found in the negative individual (table 1).
[0000]
TABLE 1
Comparison for the results of IVS 7-2A→G kit detection,
sequence analysis and temporal bone CT scan analysis
Method provided in
sequence
mutant type
the IVS 7-2A→ G kit
analysis
temporal bone CT
homozygous
5 cases
5 cases
5 cases with dilated
vestibular aqueduct
heterozygous
4 cases
4 cases
4 cases dilated
vestibular aqueduct
negative
11 cases
11 cases
11 cases with no
abnormity
Example 2 The Determination of the IVS7-2 Mutation in the PDS Gene of the DNA Extracted from Dried Plantar Blood Spot Collected on Filter Paper
1. A Type of Kit Useful for Dried Plantar Blood Spot Collected on Filter Paper (Suitable for 100 Persons) Comprises the Following Components
[0043] (1) Solution I (the principal component is 5% Chelex) 25 ml;
[0044] (2) PCR reagents (comprising 8 mM dNTP 150 μl, 10×PCR buffer 1 ml, 25 mM Mg ++ solution 1 ml, triple distilled water 1 ml×4 tubes, 5 u/μl Taq enzyme, 25 μl);
[0045] (3) Forward primers F1; Reverse primers R1 (the same as in example 1), forward and reverse primers mixed at a ratio of 1:1 (concentration was 10 nM for each), total 150 μl;
[0046] (4) Restriction enzyme HpaII, 20 u/μl, 110 μl and the corresponding 10× buffer, 1 ml;
[0047] (5) Positive control specimen 125 μl, negative control specimen 125 μl;
[0048] (6) Operation instruction.
2. Subjects Analyzed
[0049] One patient who has been confirmed to be large vestibular aqueduct syndrome by CT examination and carried the PDS gene homozygous IVS7-2 A→G mutation, the parents with normal hearing (they are carriers of heterozygous mutation), and two individuals with normal hearing and without IVS7-2 A→G mutation in the PDS gene were chosen for analysis.
3. Analyzing Methods and Results
[0050] According to the operation instruction provided in the kits, isolating DNA from dried plantar blood spot collected on filter paper of said subjects with solution I (The principal component is 5% Chelex), and taking 50 ng DNA used as templates, adding 100 ng of primers mixture, 10×dNTP 5 μl, 10× buffer 5 μl, the final concentration of Mg ++ is 1.5 mmol/L, adding triple distilled water to 50 μl, then 1.0 u Taq enzyme was added, Denaturating for 5 minutes at 95° C., then denaturating for 30 seconds at 94° C., annealing 30 seconds at 55° C., extending 30 seconds at 72° C., 30 circles together, extending 7 minutes at 72° C. finally. PCR reaction were carried out under the same PCR reaction conditions, both the positive template and negative template of PDS gene with IVS7-2 A→G heterozygous mutation provided in the kit were used as positive and negative controls, and PCR blank control tubes without template were provided, analyzing the amplification products through 2.5% agarose gel electrophoresis after reaction, as a result, no amplification products were found in the control without templates, the patient, his/her parents, individuals with normal hearing, the PCR products of positive and negative control specimen are 114 bp in length. Analyzing the PCR products restricted with HpaII, the volume of restriction reaction system is 30 μl, and comprising:
[0000]
10× buffer
3
μl
100 BSA
0.3
μl
HpaII
20
u
PCR products
12-18
μl
[0051] Made up the volume with triple distilled water, incubated at 37° C. for 1 hour. Analyzing the restricted reactants through 2.5% agarose gel electrophoresis, a band of 83-85 bp was found in the restricted products from said one patient with large vestibular aqueduct syndrome, indicated that homozygous IVS7-2 A→G mutation was existed in the PDS gene; a band of 83-85 bp and a band of 114 bp were found both in the restricted products from the parents of the patient with large vestibular aqueduct syndrome and the restricted products from the positive control, indicated that heterozygous IVS7-2 A→G mutation existed in the PDS gene; only one 114 bp band was found in said two individuals with normal hearing and the negative control, indicated that no IVS7-2 A→G mutation existed in the PDS gene. Sequence analysis showed that the patient is homozygous for the IVS7-2 A→G mutation, and the parents are heterozygous for the IVS7-2 A→G mutation representing their carrier condition. Said two individuals with normal hearing do not carry such IVS7-2 A→G mutations.
Example 3 Two Type of Kits for Determining IVS7-2 Mutation in the PDS Gene In Vitro and the Use of it
[0052] The subjects chosen for analyzing were identical to that of example 2. Except that the specimen tested was peripheral blood, the extractant used for isolating blood DNA is commercialized kit used for isolating DNA from peripheral blood, and use the kit in isolating DNA from peripheral blood, the rest components comprised in the kit and the analyzing method were the same as in example 2. The results were the same as in example 2. That is, a band of 83-85 bp was found in the restricted products from said one patient with large vestibular aqueduct syndrome, indicated that homozygous IVS7-2 A→G mutation was existed in the PDS gene; a band of 83-85 bp and a band of 114 bp were found both in the restricted products from the parents of the patient with large vestibular aqueduct syndrome and the restricted products from the positive control, indicated that heterozygous IVS7-2 A→G mutation existed in the PDS gene; only one 114 bp band was found in said two individuals with normal hearing and the negative control, indicated that no IVS7-2 A→G mutation existed in the PDS gene.
Example 4 Three Types of Kits for Determining IVS7-2 Mutation in the PDS Gene In Vitro and the Use of it
[0053] The subjects chosen for analyzing were identical to that of example 2. Except that the specimen tested was DNA which was isolated from peripheral blood, and the kit do not comprise the extractants used for isolating blood DNA. The rest components comprised in the kit and the analyzing method were the same as in example 2. The results were the same as in example 2 as well.
INDUSTRIAL APPLICABILITY
[0054] The present invention is composed of primers or kits used for determining the PDS gene mutation of large vestibular aqueduct syndrome in vitro, which may be used in the rapid screen, the rapid diagnosis and the prevention of large vestibular aqueduct syndrome caused by the IVS7-2 A→G mutation could reduce the possibility of hearing loss occurred in the large vestibular aqueduct syndrome individuals. | The present invention relates to a method of preparing a primer used for determining the IVS7-2A→G site mutation involved in the large vestibular aqueduct syndrome. The method comprises the steps of: designing a primer pair which may introduce any base substitutive mutation in the region of 1-13 bases between upstream and downstream including the IVS7-2 mutation site (A→G) based upon the IVS7-2 A→G mutation site in the PDS gene, so as to obtain a new restriction site which may be used for distinguishing IVS7-2 wild type A site and mutant G site in the amplification products. The present invention further relates to the primers prepared according to this method, the kit or reagent or identical product comprising the primers, and a method for determining the IVS7-2A→G site mutation of large vestibular aqueduct syndrome with said primers in vitro. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to bicycle tools and more particularly to bicycle cleaning tools.
2. Description of the Prior Art
A bicycle by its very nature collects dirt. The various components of a bicycle that are susceptible to dirt include the free wheel, the front and rear derailleurs, idler and jockey wheels, the chain, sprockets, chain rings, caliper rings, hubs, rims, peddles, and the tire tread. In particular, dirt and grit may hinder the chain from riding directly on the sprockets, thereby increasing the chances for chain slippage.
A bicycle is susceptible to dirt regardless of the type of biking pursued. An urban bicyclist encounters the dirt produced by cars, trucks, buses and other city vehicles. An over-the-road bicyclist, biking daily for months on end, pursues his sport through rain or snow and gravel roads. A triathlete may compete at distances up to 150 miles and may train over 500 miles a week, constantly punishing his bike. Mountain bicyclists or dirt bike competitors, maneuvering their bikes up and down steep inclines, depend on their bike's components to operate on boulders, gravel, and dirt. Even a training bike for a young child is susceptible to dirt.
A bicyclist is his or her own power source. Therefore, he or she restricts the weight of the gear to be carried. Moreover, the bicyclist prefers compact gear because of the limited areas to which gear can be affixed to a bicycle.
SUMMARY OF THE INVENTION
A feature of the present invention is a bicycle tool having a removable brush with a curved face. The brush is affixed to one end of a rigid bar.
A curved notched prong extends from an opposite end of the rigid bar. The curved prong conforms to a component of the bicycle such as individual cogs of the free wheel. The notches or teeth are disposed on a concave edge of the curved prong to bite into dirt adhering to the free wheel or other component of the bike.
The toothed prong tapers from the rigid bar to form a distal pointed end. While the notches are disposed on the concave edge of the prong, a convex edge of the prong is smooth to allow penetration of the prong into a bicycle.
The notched prong of the bicycle tool is flexible, resilient, and somewhat narrow. A brush receptacle affixing the brush to the bar is rigid and has a greater thickness than the narrow, notched prong.
The brush receptacle includes a pair of ledges extending from a pair of side faces of the rigid bar. The ledges form a base for clamps for the brush and are useful for scraping dirt from the bike.
In operation, if the free wheel is to be cleaned, the curved notched prong is placed over or between the individual cogs of the free wheel. The free wheel is then rotated by spinning the rear wheel or rotating the peddles. The notches or teeth may displace a majority of the dirt clinging to or between the individual cogs. After the dirt has been displaced or loosened, the brush is placed over or between the cogs to further displace dirt therefrom. Since the brush has a greater thickness than the notched prong, the brush may overlap into an adjacent cog, thereby contacting more surfaces within the free wheel than the notched end.
In other operations, the prong may be inserted into areas inaccessible to fingers. The rigid bar and brush receptacle may be utilized to knock hard clumps of dirt from the frame or other bicycle components. The ledges or base of the brush receptacle may be used to scrap mud or dirt from the bicycle or components thereof.
An advantage of the present invention is a bicycle tool having a number of cleaning features.
Another advantage of the present invention is that the cleaning tool is light in mass and compact. The tool readily fits within a bicycle bag connected to the handle bars.
Still another advantage of the present invention is the structure and disposition of the notches on the curved prong. The sharp, pointed notches or teeth dislodge the bulk of the dirt about the free wheel. The degree of curvature of the curved prong corresponds to the sprocket having the largest radius, but the pointed teeth are sufficiently small in size so that the curved prong operates on the smaller sprockets.
Still another advantage of the present invention is that the thicker brush may complete the cleaning of the free wheel after the narrow prong has been utilized and displace the dirt particulates that would otherwise serve as foundations on which even more dirt would cling.
Still another advantage of the present invention is that the tapered prong penetrates into generally inaccessible areas of the bicycle.
Still another advantage of the present invention is that the rigid bar and rigid brush receptacle may be utilized to knock clumps of dirt from the frame and wheels.
Still another advantage of the present invention is that the teeth and brush extend in the same direction from the rigid bar. Hence, when utilizing the brush, the teeth form a gripping handle for the fingers of a hand while the thumb presses on an edge of the rigid bar to bring pressure to bear on the brush. Conversely, when using the tooth prong, the brush forms a comfortable handle for the fingers or palm of the hand while the thumb presses on the edge of the rigid bar to bring pressure to bear on the teeth.
Still another advantage of the present invention is that the face of the brush is curved so that the brush conforms to curvature of various bicycle components.
Still another advantage of the present invention is that the brush is removable from its brush receptacle to allow its replacement with a new brush or a brush having a different face configuration for cleaning different components of the bicycle.
Still another advantage of the present invention is that the brush receptacle has a set of four inwardly biased clamps. Although the brush is removable, it is sufficiently secure in the brush receptacle so that the brush remains secure even when bicycle components are rotating at high speeds.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a perspective view of the bicycle cleaning tool.
FIG. 2 is a bottom plan view of the tool shown in FIG. 1.
FIG. 3 is a partial elevational view of the rear sprockets of a bicycle and the tool shown in FIG. 1.
FIG. 4 is a rear view of the sprockets shown in FIG. 3.
FIG. 5 is an end plan view of the tool from lines 5--5 of FIG. 1.
FIG. 6 is a sectional view of the tool at lines 6--6 of FIG. 1.
FIG. 7 is an elevational view of a bicycle.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
As shown in FIGS. 1 and 2, a plastic bicycle cleaning tool 10 has a rigid, elongate bar 11 with a pair of opposing, respective prong and brush bar ends 12 and 13. The bar 11 has a pair of opposing, planar, bar side faces 14 and 15 substantially parallel to each other and a pair of opposing, respective long and short, substantially parallel, linear, bar edges 16 and 17.
A curved, tapering, toothed prong 18 is integrally connected to the prong end 12 of the bar 11. The prong 18 has a pair of substantially parallel, planar side faces 19 and 20. The distance between the prong faces 19 and 20 is less than the distance between the bar side faces 14 and 15 so that the prong 18 is narrower and more flexible than the rigid and thicker bar 11. A curved ridge 21 is formed where the prong 18 is integrally connected to end 12 of bar 11.
The prong 18 has a pair of respective convex and concave, tapering edges 22 and 23 tapering away from bar end 12. Convex edge 22 is smooth. Concave edge 23 has a plurality of sharp, pointed teeth 24 tapering away from smooth edge 22. The tapering edges 22 and 23 form a distal pointed end 25 for penetrating into and prying dirt from generally inaccessible areas of a bicycle. A proximal prong end 26 forms a flat prong edge 27 lying flush with and substantially parallel to bar edge 17. The distal pointed end 25 lies substantially in line with edges 17 and 27. The prong 18 curves so as to form an arc on the side or edge 16 of bar 11.
As shown in FIGS. 1, 2, 5, and 6, a brush receptacle 28 is integrally connected obliquely to brush end 13. The receptacle 28 is disposed obliquely with respect to bar edges 16 and 17 so that long bar edge 16 has a greater length than short bar edge 17. The brush receptacle 28 has a base 29 and a set of four clamp extensions 30, 31, 32, and 33 integrally connected to and extending from the base 29. Opposing and longitudinally spaced clamp extensions 30 and 31 have a thickness similar to the thickness of the rigid bar 11 of the width of the bar edge 17. Opposing, elongate clamp extensions 32 and 33 are disposed between clamp extensions 30 and 31 and are biased inwardly and toward each other.
A brush 34 is clamped in brush receptacle 28 by clamp extensions 32 and 33. Clamp extensions 30 and 31 limit longitudinal movement of the brush 34. The individual bristles of the brush 34 are clinched by a brush clasp 35. The bristles of the brush 34 are wrapped about a shaft 36 inside the clasp 35. Clasp 35 and brush 34 are removably clamped in brush receptacle 28. The brush 34 and teeth 24 extend in the same direction from rigid bar 11.
Brush 34 has a curved brush face 37 with a proximal brush end 38 and a distal brush end 39. The curved brush face 37 has a decreasing slope from the distal end 39 to the proximal end 38. The changing curvature of the brush face 37 allows the brush 34 to conform to a variety of surfaces on a bicycle. The thickness of the brush face 34 is greater than the thickness of prong 18 or distance between prong faces 19 and 20.
The thickness of the base 29 is greater than the thickness of rigid bar 11 to form a pair of ledges 40 and 41 extending from the respective faces 14 and 15. The ledges 40 and 41 are disposed obliquely in relation to the parallel bar edges 16 and 17. The ledges 40 and 41 cooperate with edge 16 to scrape dirt and grit from surfaces of a bicycle. The ledges 40 and 41 and edge 16 apply different angular forces on a given clump of dirt to readily scrape especially hardened dirt from a bicycle surface.
The cleaning tool 10 performs a number of cleaning operations on a bicycle. For example, as shown in FIGS. 3, 4, and 7, the toothed prong 18 not only fits over a cog 50 of a freewheel 49, but also slides readily between the individual cog 50 and a second cog 51. When placed over a cog 50 or 51, the teeth 24 of the prong 18 bite into and dig out dirt on top of and between the teeth 52 of the cog 50. When placed into a space 53 formed by cogs 50 and 51, the teeth 24 dig out and bite into dirt and grit caught in space 53. To facilitate cleaning of the freewheel 49, the rear wheel 54 or the pedals 55 may be rotated to thereby rotate the freewheel 49 and cogs 50 and 51 while the cleaning tool 10 is held stationary. This operation continues until the teeth 24 contact and clean dirt from a ratchet cover 56.
After the teeth 24 have contacted the ratchet cover 56 and dug out as much dirt as possible from between the cogs 50 and 51, the brush 34 is utilized. The thickness of the brush face 37 is greater than the thickness of the toothed prong 18 and may be greater than the lateral distance of space 53 between cogs 50 and 51 to brush a maximum surface area of the freewheel 49. For instance, since the thickness of brush face 37 is typically greater than the lateral distance of space 53 between cogs 50 and 51, a pair of opposing inner faces 57 and 58 of cogs 50 and 51 are cleaned simultaneously as the freewheel 49 is rotated. Moreover, individual bristles of the brush 34 may be bent over and thereby clean teeth 52 of the cogs 50 and 51 as the freewheel 49 is rotated.
The slope of the curved brush face 37 changes from the distal brush end 39 to the proximal brush end 38. The difference in curvature allows the brush face 37 to conform not only to the curved ratchet cover 56 but also for instance a curved ratchet cover 59 of a lesser diameter.
The distal pointed end 25 of the flexible prong 18 is utilized to pry dirt from generally inaccessible areas such as into a front derailleur 60, a rear derailleur 61 and the chain 62. The tapered smooth edge 22 allows an easy entry and exit into the generally inaccessible areas.
The rigid bar 11 is utilized to knock clumps of dirt and small stones from the components of a bicycle such as a front caliper brake 63 and a rear caliper brake 64. The rigid bar 11 may also knock dirt from the cleats of a bicycle shoe. The tool 10 may be grasped around the toothed prong 18 for the knocking operation since the teeth 24, although pointed, provide a sufficient surface area so as to not pierce one's skin. | The present invention is a bicycle cleaning tool having a rigid bar, a flexible toothed tapered curved prong with a pointed end, and a brush with a curved brush face. The rigid bar knocks clumps of dirt from a bicycle component. The toothed prong pries into generally inaccessible areas to bite into and dig out dirt. The brush end brushes away minute particles and conforms to a number of curved surfaces on a bicycle. | 0 |
FIELD OF THE INVENTION
[0001] The present invention relates to a solid phase assay device comprising a timer function, and to a method of using the device.
BACKGROUND OF THE INVENTION
[0002] A type of solid phase assay devices comprises a plate-shaped flow matrix of bibulous material, usually a membrane strip, such as of cellulose nitrate or glass fiber, in which liquid can be transported laterally (i.e. in the plane of the strip) by capillary forces in the membrane. The membrane usually has a sample application zone, and a detection zone downstream of the sample application zone. In the detection zone, usually a capturing reagent for the analyte is immobilized. To conduct an assay, the application zone is contacted with the liquid sample to be assayed for the analyte of interest. The device is maintained under conditions sufficient to allow capillary action of liquid to transport the analyte of interest, if present in the sample, through the membrane strip to the detection zone where the analyte is captured. The capillary liquid flow is usually insured by an absorbing pad or the like at the downstream end of the strip. A detection reagent, usually labelled, is then added upstream of the detection zone and interacts with captured analyte in the detection zone, and the amount of captured analyte is measured. Often, the detection reagent is pre-deposited in or on the membrane strip, e.g. in the form of diffusively movable particles containing fluorophoric or chromogenic groups, either upstream of the sample application zone or between the sample application zone and the detection zone.
[0003] Since it takes some time for the sample and the assay liquids to be transported through the detection zone such that the result of the assay can be read, it has been proposed to provide a timing control, such as a “timer” substance or substance combination on the strip which indicates when flow through the flow matrix has occurred or that enough time has elapsed from the time that a fluid sample was applied to the membrane strip for the reading to give a correct value.
[0004] EP-A-915 336 discloses a chromatographic assay device wherein the chromatographic medium includes a resolubilizable visible dye in an area between the detection zone and the end of the chromatographic medium, e.g. applied in the absorbing pad. During the performance of the assay, the dye in the dye area is resolubilized and migrates from the dye area to a dye viewing area which gives a visual indication that flow through the chromatographic medium has occurred, such that the assay result can be read and interpreted. The resolubilizable dye may be bound to a first member of a specific binding pair, and a second member of the specific binding pair may be immobilized in the dye viewing area to capture the dye therein. The timing control of EP-A-915 336, however, only indicates that flow through the flow matrix has taken place and does not provide for any adjustment of the time elapsed from the start of the assay until the colour is visible in the viewing area.
[0005] This shortcoming is to some extent overcome by the chemical timer disclosed in EP-A-826 777. The chemical timer, which is used in a visible test strip for measuring the concentration of an analyte in a biological fluid that is applied to the strip, measures a predetermined interval chemically and comprises a dry coating of (i) a coloured indicator composition, (ii) a reagent that, when hydrated, is capable of reacting with glucose to change the colour of the indicator, (iii) an inhibitor to inhibit the change in colour of the indicator, and (iv) glucose, in which the inhibitor and glucose concentrations in the dry coating are selected so that the glucose, over a predetermined time after the biological fluid sample is applied to the strip, reacts with the reagent to change the colour of the indicator. When a sample is applied to the strip, hydration of the timer segment composition permits the colour-forming reaction to proceed. The time it takes for the timer segment to change colour is determined by the temperature and by characteristics of the testing reagent, particularly the inhibitor concentration, the amount of glucose, and the hydration and oxygen diffusion rates. The timer also serves as a quality control function, by making it apparent when a test strip has been contaminated by exposure to moisture. Migration of indicators having such a tendency may be prevented by including an ion pairing agent in the matrix.
[0006] While the time to colour-change of the chemical timer described in EP-A-826 777 may be varied, this is not readily done, requiring inter alia a different composition of the timer segment for each desired colour-change time. Since the time when the assay result may be reliably read varies between different assay formats depending inter alia on the number of the assay liquids used, there is therefore a need for a test strip having a more flexible timer that can easily be adjusted to a desired indication time to suit the requirements of a particular assay.
SUMMARY OF THE INVENTION
[0007] In accordance with the present invention, there is provided an assay device which includes a timer that exhibits a visible colour change when a predetermined time has elapsed from the time that assay liquid, e.g. sample, was applied to the flow matrix, and wherein this predetermined time by simple means may be varied to be adapted to a particular assay format. According to the present invention, this may be accomplished by applying a time indicator on, or in contact with, the absorbing or wicking member at the end of the membrane strip, and in a position along the wicking member that corresponds to a desired value of the time period elapsed from the start of the assay until colour change of the indicator.
[0008] In one aspect, the present invention therefore provides an assay device for determining an analyte in an aqueous sample comprising:
[0009] (i) a flow matrix having an upstream end and a downstream end and allowing lateral transport of fluid therebetween by capillary action, wherein said matrix comprises a liquid application zone and downstream thereof, a detection zone having an immobilized capture agent capable of directly or indirectly binding to said analyte,
[0010] (ii) a wicking member placed at the downstream end of the flow matrix and having an upstream end and a downstream end, and
[0011] (iii) a time indicator placed downstream of the detection zone for indicating when liquid applied in the liquid application zone has reached the time indicator, wherein the time indicator comprises an indicator substance or substance combination which is capable of exhibiting a visible colour change when hydrated by the liquid. The device is characterized in that the time indicator is arranged in contact with the wicking member at a variable position between the upstream and downstream ends thereof, thereby permitting variation of the time elapsing from the application of the liquid until the time that the indicator substance or substance combination changes colour.
[0012] In a second aspect of the invention, there is provided a method of performing an assay for determining an analyte in a sample, which method comprises the steps of:
[0013] (i) providing an assay device as defined above, wherein the time indicator is placed in a selected position between the upstream end and the downstream end of the wicking member adapted to the assay to be performed,
[0014] (ii) flowing sample and assay liquid(s) through the flow matrix of the device such that they reach the detection zone in a predetermined sequence, and
[0015] (iii) when the time indicator has changed colour indicating that a predetermined time has elapsed from the application of liquid to the liquid application zone, reading the result of the assay in the detection zone.
[0016] The flow matrix is preferably substantially planar, typically rectangular, such as a membrane strip, and allows lateral liquid flow therethrough. Usually, the flow matrix is a chromatographic medium suitable for thin layer chromatography. Exemplary materials are nitrocellulose, nylon, rayon, cellulose, paper or silica. A presently preferred material is nitrocellulose. The flow matrix material can be pretreated or modified as needed.
[0017] The wicking member, or absorber, can be made of a bibulous material that will hold a liquid sufficiently so that liquid can be drawn through the flow matrix and accumulate in the wicking member. The size and shape of the wicking member can be chosen according to the volume of liquid used in the assay. Usually, the wicking member is a parallelepipedic pad or the like. Typical materials for the wicking member include, but are not limited to, cellulose and filter paper.
[0018] The time indicator may comprise any substance or combination of substances that gives a colour change when hydrated, i.e. when contacted with an aqueous liquid. The term “colour change” includes a change between two distinct colours as well as two different nuances of a single colour. In the present context, also colourless or white is to be understood as representing a colour. The colour change may be caused by the chemical reaction between two, or more, chemical compounds (other than water) or by a pH change. Preferably, however, the indicator substance is a single chemical compound that changes colour when hydrated. In a preferred embodiment, such a chemical indicator is a substance that changes colour depending on the amount of crystal water therein. Thus, the substance may have a first colour when dried, and a second colour when it has taken up crystal water. An exemplary such indicator substance is cobalt dichloride hexahydrate which is bright blue when dehydrated, and pale rose when hydrated.
[0019] The indicator substance should be capable of remaining in place when hydrated, at least for a substantial time. If an indicator substance per se has a tendency to migrate, it may be necessary to immobilize or otherwise restrict the mobility of the indicator substance. This may be accomplished by various means well known in the art, e.g. chemical immobilization, bioaffinity-based immobilization etc. The indicator substance may also be allowed to diffuse a small distance before being retarded, e.g. immobilized or captured. An exemplary such indicator substance is patent blue (El131) powder mixed with a filler substance, such as Sephadex®. In dry condition, the mixture is essentially white, whereas the mixture turns blue when the patent blue dye is dissolved and migrates into the Sephadex® gel formed where its migration is retarded. The dry powder mixture may be affixed to the surface of the wicking member by a transparent tape. Alternatively, the patent blue powder may be enclosed by a non-transparent but porous tape, e.g. nonwowen cellulose or a nitrocellulose filter, in which case the patent blue dissolved by the transported fluid will turn the tape blue.
[0020] Indicator substances capable of hydration, such as the cobalt dichloride hexahydrate mentioned above, if necessary together with a hygroscopic substance, may also serve as a test that the assay device is viable, since in case of leakage of moisture into the device, which reduces the shelf-life of the device, the indicator substance will change colour. Another example of a time indicator that also will indicate leakage of moisture within the device or from exposure to the exterior is a dry powder mixture consisting of (i) an easily soluble coloured substance, such as the patent blue mentioned above, (ii) a white filler substance in a proportion that gives the powder a white appearance, and (iii) a hygroscopic salt such as calcium chloride dihydrate (CaCl 2 .2H 2 O). The white powder may be affixed to the surface of the wicking member by a transparent and permeable tape. If the tape is of white non-transparent material while still porous and permeable to water vapour, the filler substance may be omitted. Adjustment of the mixture in different ways will make it possible to make the indicator indicate moisture exposure with different stringency. An indicator of this type is non-reversible and will therefore indicate total exposure to moisture in contrast to the above-mentioned cobalt dichloride hexahydrate indicator which is reversible.
[0021] The time indicator may be the indicator substance or substance mixture per se, or may be included in or applied to a carrier or other support such as a gel, filter paper strip etc. The application of the time indicator to the assay device may be obtained by various means.
[0022] In one embodiment, the indicator substance or substance combination is applied directly to the wicking member, such as by deposition or coating thereon or fixing by tape as mentioned above, for example. In another embodiment, the indicator substance is impregnated or coated to a support, such as a thin filter paper strip, that in turn is applied to the wicking member. Alternatively, if the assay device comprises a housing or cover, the support may be mounted to the inner wall part of the housing that faces the wicking member such that the support contacts the wicking member at a desired position on the surface thereof. The time indicator should, of course, be sufficiently small compared with the extension of the wicking member to permit the time indicator to be placed at a number of different positions in the flow direction of the wicking member.
[0023] The time that it takes for an aqueous sample to be transported from the liquid application zone or area of the flow matrix to the time indicator in a given assay device, such that the indicator changes colour, is determined, on the one hand, by the liquid migration rate in the flow matrix and the liquid volume that must pass through the flow matrix, and, on the other hand, by the position of the indicator on the wicking member. By varying the position of the indicator on the wicking member in the flow direction of the assay device, the time elapsing from the liquid application to the indicator change may be shortened or prolonged as desired such that the colour change of the indicator substance takes place only when sufficient time has passed for the analyte measurement or determination in the detection zone to be reliable. A common assay device structure may therefore be provided for use in different assays by placing the indicator strip or reading window at a selected position on the wicking member according to the particular assay to be performed.
[0024] The time elapsing until the colour change is also influenced by variation of the thickness, i.e. height, of the wicking member, and this may, if desired, be used to further change the time elapsing until the colour change, e.g. by adding an additional wicking material layer on top of the original wicking member.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] [0025]FIG. 1 is a perspective view of an embodiment of a device according to the present invention.
[0026] [0026]FIG. 2 is a sectional side view of the device in FIG. 1.
[0027] [0027]FIG. 3 is an exploded view corresponding to the side view in FIG. 2.
DETAILED DESCRIPTION OF THE INVENTION
[0028] The assay device according to the present invention is provided with a time indicator that exhibits a colour change when the applied sample or other assay liquid reaches a defined position on a wicking member placed at the end of the flow matrix. In the following, the invention is illustrated applied to an assay device described in our co-pending Swedish patent application No. 9904175-8.
[0029] As best shown in FIG. 1, the device illustrated in FIGS. 1 to 3 comprises an upper housing part 1 and lower housing part 2 of a material which is inert with respect to the sample and any reagents used in the assays to be conducted with the device, e.g. polystyrene or polypropylene. The upper housing part 1 has a sample well aperture 3 (here conical) and a detection window 4 . Also shown in FIG. 1 is a removable separation means 5 to be described below.
[0030] With reference now to FIGS. 2 and 3, the lower housing part 2 has mounted therein a membrane strip 6 of bibulous material (i.e. a porous material susceptible to traversal of an aqueous medium due to capillary action), e.g. nitrocellulose on a polyester backing. Near the upstream end of the strip 6 (to the left in FIGS. 2 and 3), a filter piece 7 , containing a diffusively movable detection reagent, is placed on the strip. Such a detection reagent may, for example, be a conjugate between a label particle and a reactant capable of binding to the analyte. Further downstream, and placed below and within the detection window 4 , there is a reaction zone 8 on the strip which contains an immobilized reactant capable of binding an analyte to be tested for. In the illustrated case, there is also a calibrator zone 9 containing a predetermined amount of immobilized calibrator substance, for example analyte. Also depicted on the membrane strip 6 is a flow barrier 10 , here specifically a piece of a film element, which covers the filter piece 7 and extends towards the opening 3 in the housing part 1 . The function of the flow barrier film 10 will be described further on.
[0031] The upper housing part 1 contains at the upstream end of the membrane strip 6 , a pad 11 of liquid absorbing material intended to serve as a container for flow liquid, or buffer. The opening 3 in housing part 1 (see FIG. 1) is intended for introducing sample to the membrane 6 . In the illustrated case, a filter element 12 (which optionally may consist of two or more separate filters), is provided below the opening 3 for assays where the sample liquid needs to be filtered, e.g. when the sample is whole blood and blood cells are to be separated off. The buffer pad 11 thus forms a buffer liquid container, below referred to as buffer pad, and the room defined by the sample opening 3 and the filter element 12 forms a sample well, or sample container.
[0032] At the downstream end of the membrane strip 6 , a wicking element 13 is placed, here in the form of a pad of absorbent material, such as cellulose, the purpose of which is to assist in maintaining a capillary flow of assay liquids through the membrane strip 6 . A thin strip 14 of absorbent material, e.g. filter paper, is mounted in contact with the top of pad 13 , e.g. attached to the pad 13 as shown in FIG. 3, or attached to the opposed inner surface area of the housing part 1 . The strip 14 contains a substance that changes colour when hydrated, e.g. dehydrated cobalt dichloride hexahydrate. This substance may be applied to the strip by soaking the strip in a solution of the substance and then drying the strip. As will be described below, the strip 14 serves as a chemical time indicator, or chemical timer. At least the portion of the housing part 1 that covers the pad 13 is transparent or translucent or has an opening to permit the colour change of the strip 14 to be observed visually through the cover.
[0033] The above-mentioned separation element 5 , here a liquid-tight pull-out film, is mounted at the upstream part of the membrane strip 6 to prevent contact between the membrane strip 6 and the bottom parts of the buffer pad 11 and sample filter 12 , respectively. The film 5 is arranged to be manually removed by pulling it away from the device to thereby expose the top face of the membrane strip 6 to the buffer pad 11 (except the part of the membrane strip covered by the flow barrier film 10 ) and the sample filter 12 , respectively, such that the membrane strip 6 is brought into simultaneous or close to simultaneous liquid receiving contact with the buffer pad 11 and the filter 12 in the sample well 3 . The upper housing part 1 has a recess 15 for the buffer pad 11 designed to press the pad against the pull-out film 5 , and thereby against the membrane strip 6 and flow barrier film 10 when the pull-out film 5 is removed. To insure a liquid-tight enclosure of the pad 11 in the recess 15 , the pull out film is tightly sealed against the edges of the recess, e.g. by welding. While in the illustrated case above, the pull-out film 5 is intended to be removed completely from the device, it is, of course, sufficient that the film 5 is withdrawn from the membrane strip 6 to such an extent that the membrane strip surface parts in question are exposed to the sample and buffer liquids, respectively.
[0034] An assay for an analyte in a sample may be performed with the device described above as follows.
[0035] The device is usually provided ready for use with the buffer pad 11 soaked with buffer solution (flow liquid), with the detection reagent pre-deposited in the filter 7 , and with the respective appropriate capture reagents immobilized in the reaction (or detection) zone 8 and the calibration zone 9 , respectively. If the analyte to be tested for is, say, an antigen, the detection reagent in the filter 7 may, for example, be an antibody to the antigen coupled to a fluorogen-labelled particle, the immobilized reactant in the reaction zone 8 may be an antibody to the antigen, and the calibrator in the calibration zone 9 may be the analyte or an analyte analogue.
[0036] A predetermined amount of sample is added through the opening 3 in the housing part 1 . All the necessary assay liquids, i.e. in this case sample liquid and buffer liquid, are then present in the device, the pull-out film 5 , however, effectively preventing contact between the respective liquids and the membrane strip 6 . The assay is then started by the operator removing the pull-out film 5 to thereby put the membrane strip 6 in simultaneous liquid receiving contact with the buffer pad 11 and the sample liquid in the sample well 3 .
[0037] Buffer liquid from the pad 11 will now penetrate into the membrane strip 6 via the far upstream end part thereof which is in direct contact with the pad 11 (see FIG. 3) and be transported downstream the membrane strip 6 by capillary force. Simultaneously, sample liquid will penetrate into the membrane strip 6 and be transported in the downstream direction of the strip. There will thus be a flow of sample liquid directly followed by a (first) flow pulse of buffer liquid. However, the detection reagent filter 7 and a major part of the buffer pad 11 are separated from the membrane strip 6 by the flow barrier film 10 . Buffer liquid that has been transported into the membrane strip 6 will penetrate into and be transported through the filter 7 and bring the detection reagent deposited therein with it, thereby forming a detection reagent flow pulse. This detection reagent flow pulse will follow in sequence after the sample flow and the buffer flow pulse. Buffer that is transported in the membrane strip 6 after the detection reagent has been removed from the filter 7 will form a second buffer flow pulse following after the detection reagent flow pulse.
[0038] The above-mentioned different liquid flows will be transported along the membrane strip 6 in the indicated sequence, i.e. sample flow, first buffer flow, detection reagent flow, and second buffer flow, and will eventually reach the calibrator zone 9 and the reaction zone 8 . In the reaction zone 8 , analyte present in the sample will be captured by the reagent immobilized in the membrane. The analyte/capture reagent complex formed will be washed by the following first buffer flow, and the analyte-reagent complex will then react with detection reagent contained in the detection reagent flow to form a detectable detection reagent/capture reagent complex. The latter will finally be washed by the second buffer flow. In the calibration zone 9 , the pre-determined amount of analyte therein will react with the detection reagent in the detection reagent flow to form a detectable detection reagent/analyte complex. The flow liquid from the buffer pad 11 will thus in sequence wash, dissolve and transport detection reagent, and wash.
[0039] When the aqueous sample has reached the indicator strip 14 contacting the wicking pad 13 , the indicator substance deposited therein changes its colour which can be seen through the transparent or translucent cover or opening therein. The position of the strip 14 has been selected to ensure that all the assay liquids have passed the reaction zone 8 when the liquid front reaches the strip 14 and the colour change takes place. The colour change of the time indicator signals that the assay result may be read. By then measuring, through the detection window formed by the opening 4 in the housing part 1 , the signal intensity from the detection reagent captured in the reaction zone 8 and correlating it with that obtained in the calibration zone 9 , the amount of analyte in the sample may be determined.
[0040] As apparent from the above, an assay with the described device is easy and convenient to perform and provides for simultaneous initiation of the different assay liquid flows. Thus, once the sample has been added to the sample well, the pull-out film may be removed. The liquid in the buffer pad and the sample will thereby be brought into contact with the membrane strip and the desired sequential transport of the different liquid flows will start. The chemical timer then indicates when the assay is completed and it is reliable to read the result of the assay.
[0041] In the reaction (or detection) zone described above, a reactant capable of specifically binding the analyte is immobilized (by covalent binding, via physical adsorption, via biospecific affinity, via immobilized particles to which the reactant is covalently bound, etc.). However, instead an agent capable of reacting with the reactant may be immobilized in the membrane, and the reactant may then be added together with the sample, or be pre-deposited in the membrane in an area or zone upstream of the reaction zone. Such an immobilized agent may be one member of a specific binding pair (sbp) and the reactant is then coupled or conjugated to the other member of the spb. Exemplary specific binding pairs include immunological binding pairs, such as antigen-antibody and hapten-antibody, biotin-avidin or -streptavidin, lectin-sugar, hormone-hormone receptor, nucleic acid duplex. For example, the reaction zone may have streptavidin immobilized therein and the capture reactant for the analyte may be biotinylated.
[0042] Similarly, the calibration zone may contain a binder for the calibrator substance rather than the calibrator substance per se. The binder is usually a member of a specific binding pair, such as one of those mentioned above, whereas the other member of the specific binding pair is coupled or conjugated to the calibrator substance, which may in turn be added with the sample or pre-deposited upstream of the calibrator zone. Streptavidin, for example, may be immobilized in the calibrator zone while the calibrator substance is biotinylated.
[0043] For further details on assay devices of the type contemplated herein, and particularly regarding flow matrixes, sequential assays, calibrator systems and detection reagents, it may be referred to our published PCT applications WO 99/36776, WO 99/36777 and WO 99/36780, for example.
[0044] Analytes to be determined using the present device are readily apparent to the skilled person. Usually, however, the analyte is a biospecific affinity reactant, e.g. an antibody or other protein, hapten, nucleic acid or polynucleotide, such as a DNA sequence. In the latter case the reaction zone may contain streptavidin and the DNA sequence to which the analyte sequence is to hybridize may be biotinylated.
[0045] The present device permits convenient pretreatment of the sample before starting the assay.
[0046] The present device may also be adapted for performing assays of the type described in our published PCT application WO 99/60402 where the flow matrix contains a chromatographic separation zone upstream of the reaction (detection) zone to separate sample components which would otherwise disturb or influence the determination of the analyte.
[0047] In the following will be described an experiment demonstrating with an assay device described above how the time elapsing from the start of an assay to the colour change varies depending on the position of the chemical timer strip 14 along the wicking pad 13 in the flow direction of the membrane strip 6 .
Experiment
Time of Colour Change vs Position of Time Indicator along the Wicking Pad
[0048] A device as shown in FIGS. 1 to 3 was used. The membrane strip 6 was a 5×45 mm nitrocellulose membrane (Whatman, porosity 8 μm) on a polyester backing, the sample filter 12 was a Primecare blood cell/plasma separation membrane, and the buffer pad 11 was a PVA containing 150 μl of buffer (0.1 M Na-phosphate, pH 7.5, 3% BSA, 10% sucrose, 0.15 M NaCl, 0.05% bovine gammaglobulin, 0.05% NaN 3 ). The wicking pad 13 was a double Whatman WF 1.5 filter.
[0049] To the inner surface of the upper housing part 1 , opposite the wicking pad 13 and visible through the transparent housing, were attached by two-sided adhesive tape four filter paper strips 14 , each of 1 mm length and 8 mm width, with an interspace of 1 mm at 0, 2, and 6 mm, respectively, from the adjacent edge of the detection window 4 . The four filter strips 14 contacted the underlying wicking pad 13 , 0 mm being at the upstream edge of the wicking pad 13 . The filter paper had previously been soaked with a saturated solution of cobalt dichloride hexahydrate [COCl 2 (H 2 O) 6 ], and dried for about 15 minutes at 120° C. 80 μl of whole blood were added to the device, and after 20 seconds the pull-out film 5 was pulled off to bring the sample filter 12 and the buffer pad 11 in contact with nitrocellulose strip 6 . The time was counted from the removal of the pull-out film until (i) the colour change started, and (ii) half the indicator strip had changed colour. The change of the indicator was from bright blue to pale rose, and after a longer time the colour was washed away. The results are shown in Table 1 below as the average of 4 tests for each strip.
TABLE 1 Distance from Time to start Time to colour fore edge of colour of change of half wicking filter (mm) change (min.) indicator strip (min.) 0 11.7 13.7 2 15.0 18.0 4 19.4 22.5 6 24.6 27.8
[0050] As appears from the table, the time of the colour change of the indicator strip was proportional to the distance of the indicator strip from the upstream edge of the wicking pad, and varied from about 12 minutes to 25 minutes depending on the position of the indicator strip. This demonstrates that a desired time of colour change can be set by attaching the indicator strip at an appropriate position on the upper housing of the device, or on the wicking pad.
[0051] While the invention has been described and pointed out with reference to operative embodiments thereof, it will be understood by those skilled in the art that various changes, modifications, substitutions and omissions can be made without departing from the spirit of the invention. It is intended therefore that the invention embraces those equivalents within the scope of the claims which follow. | An assay device for determining an analyte in an aqueous sample comprises: (i) an elongate flow matrix ( 6 ) allowing lateral transport of fluid therethrough by capillary action, wherein the matrix comprises a liquid application zone ( 3 ) and downstream thereof, a detection zone ( 8 ) having an immobilized capture agent capable of directly or indirectly binding to said analyte, (ii) a wicking member ( 13 ) placed at the downstream end of the flow matrix and having an upstream end and a downstream end, and (iii) a time indicator ( 14 ) placed downstream of the detection zone ( 8 ) for indicating when liquid applied to the liquid application zone has reached the time indicator. The time indicator comprises an indicator substance or substance combination which is capable of exhibiting a visible color change when hydrated by the aqueous sample. The assay device is characterized in that the time indicator ( 14 ) is arranged in contact with the wicking member ( 13 ) at a variable position between the upstream and downstream ends thereof to thereby permit variation of the time elapsing from the application of the liquid until the indicator substance changes color. A method of performing an assay for determining an analyte in a sample, comprises the steps of flowing sample and assay liquid(s) through the flow matrix of the device such that they reach the detection zone in a predetermined sequence, and when the time indicator has changed color, reading the result of the assay in the detection zone. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to a door stop and more particularly to a door stop having an associated spring biased, releasable-latching mechanism.
2. Description of the Prior Art
Various problems and difficulties are encountered in providing suitable means to prevent doors from opening too wide and abutting against the adjacent walls, and at the same time providing a device that can be employed as a latching device to hold the door in an open position.
Several types of door stops have been tried and used, and some of these also include self-latching devices in combination therewith. However, the known devices have features that restrict their use and placement with respect to the doors and surrounding areas. Further, most known devices are too complicated to operate and/or are too expensive to install and maintain, especially when a building would require large amounts of hardware for such a purpose.
Many doors are provided with self-closing devices that are not compatible with known door-stop and latching mechanisms.
As examples of the various devices that are known in the art, one may refer to the following U.S. Pat. Nos.: 905,804; 1,309,310; 1,896,363; 1,694,023; and 1,126,836.
One answer to the above problems of the prior art is presented in the pending application Ser. No. 928,721 which is about to issue to the present applicant, this application being an improvement thereover for operational and constructive simplicity.
SUMMARY OF THE INVENTION
The present invention comprises a door stop that includes an automatic self-releasing latching mechanism, whereby a door can be opened to its fullest open position and be releasably secured in the open position by a latching-keeper member and door stop provided with a latching mechanism, the keeper being mounted to the door with the door stop being mounted to the adjacent wall or floor so as to be engageably disposed and aligned to each other.
The door stop includes a spring-biased, slidable, bumper member which--when engaged by the keeper member--allows a latching lever of the latching mechanism to arcuately rise above the door-stop body so as to release the keeper from the latching lever.
A latching tongue formed on the latching lever is so arranged as to be engageable with the keeper member, to allow the tongue to latch behind the head of the keeper member for the purpose of holding the associated door in an open position.
However, by simply forcing the door against the bumper, the latching lever will automatically be raised to permit the keeper to separate therefrom, allowing the door to again close.
OBJECTS AND ADVANTAGES OF THE INVENTION
The present invention has for an important object a provision wherein a door can be latched in an open position, and released from the open position back to a closed position, merely by movement of the door, the present device being designed to become automatically latched or unlatched by means of a keeper mounted to the door.
It is another object of the invention to provide one embodiment that will be mounted to a fixed wall, and a second embodiment that is adapted to be mounted on the floor and positioned thereon to engage a keeper mounted to the door.
It is still another object of the invention to provide a combination door stop and latching device that includes relatively few operating parts.
It is a further object of the invention to provide a combination door stop and latching device that is relatively inexpensive to manufacture.
It is still a further object of the present invention to provide a device of this character that is simple yet strong in construction.
The characteristics and advantages of the invention are further sufficiently referred to in connection with the accompanying drawings, which represent one embodiment. After considering this example, skilled persons will understand that variations may be made without departing from the principles disclosed; and I contemplate the employment of any structures, arrangements or modes of operation that are properly within the scope of the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring more particularly to the accompanying drawings, which are for illustrative purposes only:
FIG. 1 is a side-elevational view of the present invention showing the door stop mounted to the floor, and the keeper member secured to the door and latched to the door stop;
FIG. 2 is a top plan view thereof;
FIG. 3 is a cross-sectional view taken substantially along line 3--3 of FIG. 2, showing the latched mode thereof;
FIG. 4 is a cross-sectional view similar to that of FIG. 3, wherein the latch is in an unlocked mode;
FIG. 5 is a perspective view of the keeper member;
FIG. 6 is a front-elevational view of the door stop mechanism;
FIG. 7 is a side-elevational view of an alternative arrangement of the door-stop mechanism designed to be mounted to a wall;
FIG. 8 is a top-plan view of an alternative arrangement of the floor-mounted device;
FIG. 9 is a cross-sectional view taken substantially along line 9--9 of FIG. 8, showing the alternative arrangement of the latching lever and keeper member;
FIG. 10 is a cross-sectional view similar to FIG. 9, wherein the latching lever is shown disengaged from the keeper member;
FIG. 11 is a side-elevational view of the door-stop mechanism designed to be mounted to a wall structure;
FIG. 12 is a perspective view of one embodiment of the keeper member having an annular leading head member; and
FIG. 13 is a top-plan schematic view of a door locked in an open mode when the wall mounted door stoop is used.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring more particularly to FIG. 1, there is shown a door 10, whereon there is mounted a keeper member 12 which is positioned to engage the door-stop device, generally indicated at 14. A latching mechanism, designated at 16, is shown as being included as a member of the door stop having an enlarged latching tongue member 18 engaging an opposing head member 20 of keeper 12.
Accordingly, the keeper member 12 comprises the enlarged leading head member 20 formed on the free end of the outwardly extending arm member 22 which is further provided with a rear-mounting plate 24, as seen in FIG. 5. The rear-mounting plate is adapted to be secured to door 10 in any suitable conventional manner such as by screws 25 that are received through a pair of openings 26.
The door-stop device comprises a main body 28 having a mounting means defined by a plate 30 integrally formed at the lower rear portion of the main body 28, wherein plate 30 includes a plurality of holes through which screws 32 are received.
In the embodiment as seen in FIGS. 1 through 4, the main body 28 is defined by a horizontally disposed housing 34 and a rearwardly depending support base 35 on which is formed plate 30, whereby this designed embodiment is secured to a floor structure 36 so as to be in abutting and engaging alignment with keeper 12 mounted to door 10. Housing 34 also defines a first compartment or bore 38 and a second adjacent compartment 40. Bore 38 can be formed cross-sectionally, either as a square or a circular tubular sleeve member 41 adapted slidably receive thereon a bumper cover 42. Bumper cover 42 would, therefore include a bore 44 of the same configuration as tubular member 41 so as to be readily received thereover, as shown in FIG. 3. Cover 42 is provided with a closed-end bumper wall 45 which is adapted to engage head 20 and further provide an inwardly extending longitudinal cam-pin actuator 46 which projects inwardly of bore 38 and passes through hole 48 disposed in partition 50, said actuator extending further into compartment 40, as illustrated in FIGS. 3 and 4.
Thus, it can be seen that bores 38 and 40 are arranged to receive a biasing means defined by a coil spring 52 which forceably reacts against partition 50 and opposing bumper wall 45, whereby cover 42 is generally fully extended outwardly. However, the extended position is determined by stop means 54 affixed adjacent the free end of cam pin 46, the stop means being herein shown as a fixed annular washer.
Referring now to the latching mechanism 16, said latching mechanism comprises a latching lever 55 which includes latching tongue 18 formed at the leading end thereof having a pair of bifurcated side arms 58, wherein the rearward ends thereof are pivotally connected to the rearward portion of housing 34. That is, the bifurcated side arms 58 are provided with a laterally extended shaft 60 which is rotatably supported through compartment 40, whereby arms 58 together with tongue 18 can rotate about an arc, as indicated in FIG. 4. Shaft 60 is also formed with a centrally disposed cam-abutment member 62 which is positioned within compartment 40 so as to be engaged by cam pin 46 when cover 42 is forceably moved by head 20 of keeper 12.
Accordingly, as door 10 is opened, the outer arcuate surface of head 20 of keeper 12 engages to similar arcuate front surface of latching lever 55 over head 20. Tongue 18 then drops behind head 20, as seen in FIGS. 1 and 3. It should be noted that latching tongue 18 is formed having an inner concaved surface 64, and the inner surface of head 20 is convexed--thereby providing a positive engagement therebetween and locking door 10 in an open mode.
At the time door 10 is to be released, said door is moved so that head 20 engages bumper wall 45 of cover 42, thus moving bumper cover 42 inwardly along tubular member 41 against the force of spring 52, as seen in FIG. 4. Actuator pin 46 moves rearwardly, thus engaging cam-abutment member 62 and causing latching lever to rotate with shaft 60 in an upward rotation. This then frees latching tongue 18 from keeper head 20, allowing door 10 to close and head 20 to disengage from bumper 45 before lever 55 returns to a normal horizontal position, which is effected by spring 52, thus forcing bumper cover 42 back to a fully extended position whereby stop washer 54 rests against partition 50.
FIG. 7 illustrates the above-described device wherein an alternative arrangement of body 28a has been made. That is, body 28a does not include a depending support base as previously described. This embodiment is designed to be affixed to a vertical wall or partition wherein the mounting plate 30a is integrally formed with housing 34a. However, latching mechanism 16 is the same as hereinbefore described having latching lever 55 and bumper cover 42.
Referring to FIGS. 8 through 13, there are shown two additional alternative embodiments which basically function as in the above description for FIGS. 1 through 7. That is, the door-stop mechanism, as shown in FIGS. 8 through 11, comprises a main body member 28b on which latching member 16b is rotatably mounted. In the arrangement illustrated in FIGS. 8, 9 and 10, body member 28b has a lower rear portion on which mounting plate 30b is integrally formed, said plate being so positioned as to be secured to a floor structure by suitable screws 32b. Thus, main body 28b is defined by a horizontally disposed housing 34b having a rearwardly depending support base 35b on which plate 30b is provided.
Housing 34b is provided with an extending cylindrical sleeve member 41b having a bore 38b. Sleeve 41b is adapted to slidably receive thereon a bumper cover 42b, the bumper cover 42b having a cylindrical bore 44b of the same configuration as sleeve 41b so as to be readily received thereover, as shown in FIGS. 9 and 10. Cover 42b is provided with a closed-end bumper wall 45b, the wall having a convexed dome configuration on which an inwardly projecting longitudinal cam-pin actuator 46b is integrally formed. Actuator 46b extends within a secondary compartment 40b defined by partition 50b which is disposed between the first and second compartments 38b and 40b, respectively, whereby actuator 46b passes through hole 48b formed in partition 50b, and is slidably mounted thereto by stop means 54b.
Positioned with bores 38b and 40b is a biasing spring 52b which forceably reacts between partition 50b and bumper wall 45b, cover 42b being normally in an extended position as seen in FIG. 9. The extended position of cover 42b is determined by the location of stop means 54b, shown as a fixed washer.
Latching mechanism 16b comprises a latching lever 55b which is provided with tongue 18b, located at the leading end thereof, having a pair of bifurcated side arms 58b--whereby the rearward ends thereof are pivotally mounted to the rearward portion of housing 34b. That is, bifurcated side arms 58b are integrally connected to each other by a laterally positioned shaft 60b which is rotatably mounted through compartment 40b, thus allowing arms 58b together with tongue 18b to rotate about an arc. Formed on shaft 60b is a centrally disposed cam-abutment member 62b which is located within compartment 40b so that it will be engaged by cam pin 46b when cover 42 is forceably moved inwardly against spring 52b, as seen in FIG. 10. Shaft 60b is held in place by a bottom plate 61b which is secured to housing 28b at 29b.
Accordingly, there is provided a keeper member 12 which is secured to door 10 by mounting plate 24b, whereby a rounded cylindrical head member 20b of keeper 12b is positioned to engage the arcuate-faced surface 19b of tongue 18b. That is, as door 10 is opened to contact the door stop, head 20b of keeper 12b engages arcuate surface 19b, at which time latch lever 55b is raised over head 20b--thus allowing head 20b to be locked behind tongue 18b against the inner concaved surface of tongue 18b. This position is shown in FIG. 9.
It is very important to note the configuration of both tongue 18b, with its outer arcuate surface 19b, and the cylindrical arrangement of head 20b. With the combination of the two elements, head 20b is capable of engaging and locking with tongue 18b, regardless of the angle of engagement therebetween. An as example, FIG. 13 shows latching mechanism 16b of the wall support type illustrated in FIG. 11 as being mounted to wall structure 70, with keeper 12b secured to door 10. Depending upon the arrangement between wall 70 and door 10, angle "A" will vary--and so will the engagement angle of latch 16b and keeper 12b. With the indicated configuration of tongue 18b and head 20b, head 20b will readily engage and lift latch 16b at any angle of engagement of head 20b with arcuate surface 19b, and will further lock at any angle when head 20b is positioned within the inner concaved surface 64b.
The invention and its attendant advantages will be understood from the foregoing description; and it will be apparent that various changes may be made in the form, construction and arrangement of the parts of the invention without departing from the spirit and scope thereof or sacrificing its material advantages, the arrangement hereinbefore described being merely by way of example; and I do not wish to be restricted to the specific form shown or uses mentioned, except as defined in the accompanying claims. | The combination door stop and releasable latching device, which includes a keeper member generally mounted to a conventional door and positioned thereon to engage a stationary door stop having a latching mechanism coupled therewith, wherein the door stop comprises a main supporting body which is mounted in a fixed location relative to the keeper member for locking engagement therewith, the fixed body having a slidable bumper cover which is spring-biased in an outward direction for operational engagement with the keeper member, and wherein a free-falling latching lever is pivotally mounted to the fixed body and arranged to be actuated to an open mode by a cam-pin actuator secured to the bumper cover and releasably latchable over the head of the keeper when the door is positioned in an open mode. | 8 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a divisional of and claims priority benefit of an application Ser. No. 12/218,855, filed on Jul. 17, 2008, now pending. The entirety of the above-mentioned patent application is hereby incorporated by reference herein and made a part of this specification.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates to a channel-type mesoporous silica material with an elliptical pore section and to a method of preparing the same.
[0004] 2. Description of the Related Art
[0005] Ordered mesoporous silica materials having pore sizes between 2 nm and 50 nm were disclosed in the early 1990's, exhibiting tunable pore size, high surface area and pore volume, ease of surface functionalization and controllable morphology. Since the initial reports, considerable scientific efforts have been focused on the preparation, characterization and use of ordered mesoporous silicas. Potential applications widely include catalysis, separation, selective sorption, pollutant removal, drug delivery and release, optics, electronics, and many others.
[0006] It has become increasingly evident that any design of functional mesoporous materials requires high level of understanding of the factors governing supramolecular assembly at the mesoscale, particularly the formation and growth of hybrid inorganic-organic mesophases, and precise knowledge on the relationship between structure and properties. Detailed control of the structural and textural characteristics such as pore topology, pore diameter, and pore connectivity is desirable to reach the ultimate goals of industrial and commercial applications.
[0007] According to the pore topology, the ordered mesoporous silica materials can be classified into three categories. The first type thereof has channel-type mesopores, and the examples include MCM-41 and SBA-15 silica with 2D-hexagonal p6mm symmetry and MCM-48 and KIT-6 with Ia3d symmetry. The second type has cage-like mesopores interconnecting by narrow pore entrances, and the examples include SBA-16 with Im3m pore structure and KIT-5 with Fm3m pore structure. The third type is the layered mesoporous silica materials, which are however not useful because the layered pore structure collapses after the removal of the organic templates.
[0008] For most of the channel-type mesoporous silica materials reported in literatures, the pore section are circular because the supermolecular templating micellar structure of a surfactant is symmetrical in shape and is either spherical or rod-like. Due to the symmetrical and spherical pore geometry, the deposition of guest molecules or species into the channel-type mesopores is always equally possible at all positions inside the mesopores. For advanced applications of mesoporous silica materials, it would be highly interesting if the channel-type mesopores are somehow asymmetric and spatially defined deposition of functional groups or guest species is then possible.
SUMMARY OF THE INVENTION
[0009] Accordingly, this invention provides a method of preparing a channel-type mesoporous material with an elliptical pore section, which allows the pore-section ellipticity and the unit cell dimensions of the mesoporous material to be tuned.
[0010] This invention further provides a channel-type mesoporous material with an elliptical pore section that is prepared with the method of this invention.
[0011] The method of preparing a channel-type mesoporous material with an elliptical pore section of this invention is described as follows. An alkaline solution containing two surfactants different in the electronic properties of their hydrophilic groups is prepared. A silica precursor is added to form a stack of rod-like micelles each having an elliptical section with the silica precursor between the rod-like micelles. The silica precursor is reacted into a silica framework. The rod-like micelles are removed from the silica framework.
[0012] In an embodiment, the above method further include selecting at least one of the combination and the molar ratio of the two surfactants so as to control the pore shape and unit cell dimensions of the channel-type mesoporous material of this invention.
[0013] The channel-type mesoporous material with an elliptical pore section of this invention has a 2D-rectangular pore arrangement, includes silica and has a unit cell ratio a/b satisfying the inequality of √{square root over (3)}<a/b≦2.85.
[0014] The synthesis procedure can be easily applied to prepare functional mesoporous silica materials, and examples given in this application are the syntheses of cyanoethyl-functionalized and mercaptopropyl-functionalized mesoporous materials with a c2mm symmetry. The mesoporous materials of this invention have great potential for various advanced applications in the fields of catalysis, selective adsorption, controlled drug delivery and release, and many others.
[0015] In addition, the mesoporous material of this invention may contain one or more heteroatoms in the framework. Suitable heteroatoms include Ti and Al, and exemplary heteroatom sources include titanium isopropoxide and aluminum isopropoxide etc.
[0016] It is to be understood that both the foregoing general description and the following detailed description are exemplary, and are intended to provide further explanation of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a flow chart showing a method of preparing a channel-type mesoporous silica material with c2mm structure according to an embodiment of this invention.
[0018] FIG. 2 shows a unit cell (enclosed by the dash line) and the unit cell ratio a/b of a channel-type mesoporous silica material with an elliptical pore section according to this invention.
[0019] FIG. 3 shows the PXRD patterns of the c2mm mesoporous silica materials synthesized in different surfactant ratios in the example of this invention.
[0020] FIG. 4 is the transmission electron micrograph of the mesoporous silica material with c2mm structure obtained in the example of this invention, which clearly shows the elliptical pore section.
[0021] FIG. 5 shows the powder X-ray diffraction patterns of (a) the cyanoethyl-functionalized and (b) the mercaptopropyl-functionalized mesoporous materials with c2mm structure obtained in another example of this invention.
[0022] FIG. 6 shows the PXRD patterns of two c2mm mesoporous silica materials containing Ti as framework heteroatom (HUA-22-1/2, Ti in a molar percentage of 10%/5% relative to the total of Si and Ti) obtained in yet another example of this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0023] FIG. 1 is a flow chart showing a method of preparing a channel-type mesoporous silica material with c2mm structure according to an embodiment of this invention.
[0024] As shown in FIG. 1 , two surfactants different in the electronic properties of their hydrophilic groups and a base are mixed in water to prepare an alkaline solution containing the two surfactants (step 102 ), wherein the base may be added after the two surfactants are added. The two surfactants may include a cationic surfactant and a non-ionic surfactant that can form micelles together. The base may be selected from the group consisting of NaOH, NH 3 , KOH, CsOH, LiOH and so forth. Before the preparation step 102 , at least one of the combination and the molar ratio of the two surfactants may be selected so as to control the pore shape and the unit cell dimensions of the channel-type mesoporous material obtained. The effects of change in the molar ratio of the two surfactants to the pore shape and the unit cell dimensions can be seen from FIG. 3 , as described later in details.
[0025] It is possible that the cationic surfactant is a quarternary ammonium salt and the non-ionic surfactant is an alkyleneoxide adduct of a fatty alcohol. For example, the quarternary ammonium is selected from the group consisting of R 1 3 R 2 N + , R 1 2 R 2 N + —R 3 —N + R 2 R 1 2 and R 1 2 R 2 N + —R 3 —N + R 1 3 , and the alkyleneoxide adduct of the fatty alcohol has a formula of R 4 (OA) x OH. Each R 1 is independently an alkyl group of C 1 -C 3 , R 2 is an alkyl, alkenyl or aryl group of C 12 -C 22 , R 3 is an alkyl group of C 2 -C 5 , R 4 is an alkyl, alkenyl or aryl group of C 10 -C 18 , A is an alkylene group of C 2 -C 4 , and x is within the range of 2-20.
[0026] Then, in proper synthesis conditions, which may include a temperature of 15-60° C., a pH value of 9-13 and a total surfactant concentration of 2-50 mM, a silica precursor is added to cause a stack of rod-like micelles to form with the silica precursor between the rod-like micelles (step 104 ) and trigger the micro-segregation of the surfactant to deform the spherical rod-like micelles to be elliptical micellar rods. The silica precursor may be selected from the group consisting of silicon tetraalkoxides, sodium silicate, silica sol (e.g., Ludox series) and so on. A silica precursor as a silicon tetraalkoxide compound may have a formula of Si(OR) 4 , wherein R is an alkyl group of C 1 -C 4 , such as methyl or ethyl.
[0027] In the above synthesis process, it is preferred that when the added amount of the silica precursor is 1-16 molar parts, that of the two surfactants in combination is 0.6-2.0 molar parts, that of the base is 0.15-5.5 molar parts and that of water is 800-20000 molar parts. As for the two surfactants, the molar ratio of the cationic surfactant to the non-ionic surfactant may range from 0.5:0.5 to 0.85:0.15.
[0028] Then, the silica precursor is reacted into a silica framework (step 106 ). As the silica precursor is selected from the above group, the silica precursor can be reacted into the silica framework through hydrolysis and condensation at 15-60° C., which usually continued for 1-24 hours. After the reaction, the synthesis mixture may be aged at 25-100° C. for 1-7 days.
[0029] After that, the rod-like micelles are removed from the silica framework (step 108 ), through thermal calcination or solvent extraction. The thermal calcination may be conducted at a temperature of 300-600° C. The solvent may be an acidified organic solvent like ethanol, methanol or acetone.
[0030] FIG. 2 shows a unit cell (enclosed by the dash line) and the unit cell ratio a/b of a channel-type mesoporous silica material with an elliptical pore section according to this invention. The unit cell ratio a/b is greater than √{square root over (3)}, and the diameter ratio x/y of each pore is greater than one. In addition, the unit cell ratio a/b is no more than 2.85. This upper limit is reasonably deduced from the experiment result shown in FIG. 3 , as explained later. It is noted that in a conventional hexagonal porous structure with a circular pore section, the unit cell a/b is equal to √{square root over (3)} and the diameter ratio x/y of each pore is equal to one.
EXAMPLE
[0031] In the example, cetyltrimethyl ammonium bromide (C 16 H 33 N(CH 3 ) 3 Br, CTAB) and C 12 H 25 (OC 2 H 4 ) 4 OH (C 12 EO 4 ) were used as the two surfactants different in the electronic properties of their hydrophilic groups, silicon tetraethoxide (tetraethyl orthosilicate, i.e., TEOS) was used as the silica precursor and NaOH was used as a base. At first, 0.91 g of CTAB and 0.3 g of C 12 EO 4 , which corresponds to a molar percentage (f n ) of 0.25 in the C 12 EO 4 -CTAB mixture, were dissolved in 570 ml of water, and the solution was stirred until all the surfactants dissolved. Thereafter, 21.62 g of 0.4M aqueous NaOH solution was added in the above solution. Then, 5.56 g of TEOS was added in the solution, and the solution was stirred for 2 hours to form white precipitate. After that, the solution was further aged at 90° C. for 2 days. After the white precipitate was separated with filtration and then washed, it was calcined at 540° C. to remove the rod-like micelles.
[0032] Additional samples with f n -values (molar percentage of C 12 EO 4 in the C 12 EO 4 -CTAB Mixture) of 0.00, 0.10, 0.15, 0.17, 0.20 and 0.35 respectively were also prepared through the above process flow with the total mole of C 12 EO 4 and CTAB kept constant, wherein the molar ratio of the reaction composition at a given f n -value was 8:f n :(1−f n ):2.56:9840 (TEOS:C 12 EO 4 :CTAB:NaOH:H 2 O). It is particularly noted that the sample of f n =0.00 is a conventional channel-type mesoporous material with a circular pore section.
[0033] FIG. 3 shows the PXRD patterns of the c2mm mesoporous silica materials synthesized in different surfactant ratios in the above example of this invention, which are direct evidences of the formation of such a unique mesoporous structure. It is noted that when f n is larger than 0.15, the structure starts to change to c2mm symmetry from p6mm symmetry and five reflections are well resolved to be clearly indexed to the two-dimensional rectangular c2mm plane group. When f n is equal to 0.35, the ratio a/b is equal to 2.73. It is apparent from FIG. 3 that the pore shape and the unit cell dimensions of the channel-type mesoporous silica material can be adjusted by changing the molar ratio of the two surfactants.
[0034] Moreover, for the last sample with a/b=2.81 (labeled with *) in FIG. 3 , the molar ratio of the reaction composition is 8:0.25:0.75:1.95:9840 (f n =0.25), and its only difference from the sixth sample of f n =0.25 was that the amount of NaOH used in synthesis. Specifically, the amount of 0.4M NaOH solution for preparing the last sample was 16.49 g instead of 21.62 g. It is further expected that an a/b-ratio up to 2.85 can be achieved by fine tuning the synthesis conditions.
[0035] Meanwhile, direct visualization of the elliptical pore section was provided by the transmission electron microscopy (TEM), and the corresponding image of the material is shown in FIG. 4 .
[0036] Moreover, the elliptical pore section of the materials disclosed in this invention can find potential applications in various advanced field.
[0037] For example, functionalized mesoporous silica materials with the same pore structure and c2mm symmetry can be prepared with a modified synthesis process. The modified synthesis is different from the above synthesis of the pure-silica mesoporous material in that a functional silane having the functional group to be included is premixed with the silica precursor. Examples of the functional silane include, but are not limited to, cyanoethyltriethoxysilane, mercaptopropyltriethoxysilane, vinyltriethoxy-silane, allyltrimethoxysilane, phenyltriethoxysilane, octyltriethoxysilane, aminopropyl-triethoxysilane, methacrylpropyltrimethoxysilane, imidazolyltriethoxysilane, chloropropyltriethoxysilane, iodopropyltriethoxysilane and methyltriethoxysilane. Examples of the functionalized mesoporous silica materials include the cyanoethyl-functionalized ones and mercaptopropyl-functionalized ones. The X-ray diffraction patterns of a cyanoethyl-functionalized mesoporous silica material (a) and a mercaptopropyl-functionalized one (b) obtained in another example of this invention are shown in FIG. 5 . In this example, the functional silane premixed with TEOS was NCC 2 H 4 Si(OEt) 3 or HSC 3 H 6 Si(OEt) 3 , and the ratio of the functional silane to TEOS is 0.1:0.9.
[0038] Besides, mesoporous silica materials containing one or more heteroatoms in the framework and having the same pore structure and c2mm symmetry can be prepared with another modified synthesis process. The modified synthesis is different from the above synthesis of the pure-silica mesoporous material in that a heteroatom source is premixed with the silica precursor. Examples of the heteroatoms include, but are not limited to, aluminum, titanium, iron, gallium, germanium, zirconium, boron and tin, etc. Examples of the heteroatom source include metal alkoxide and metal salt.
[0039] FIG. 6 shows the PXRD patterns of two c2mm mesoporous silica materials containing Ti as a heteroatom obtained in yet another example of the invention, wherein the sample HUA-22-1 contains Ti in a molar percentage of 10% relative to the total of Si and Ti and HUA-22-2 contains Ti in a molar percentage of 5% relative to the same. It is apparent from FIG. 6 that the two mesoporous silica materials containing Ti in the framework still have c2mm symmetry.
[0040] This invention has been disclosed above in the preferred embodiments, but is not limited to those. It is known to persons skilled in the art that some modifications and innovations may be made without departing from the spirit and scope of this invention. Hence, the scope of this invention should be defined by the following claims. | A channel-type mesoporous material with an elliptical pore section has a 2D-rectangular pore arrangement. Besides, the channel-type mesoporous material includes silica and has a unit cell ratio a/b satisfying the inequality of √{square root over (3)}<a/b≦2.85. The synthesis procedure can be easily applied to prepare functional mesoporous silica materials, and examples given in this application are the syntheses of cyanoethyl-functionalized and mercaptopropyl-functionalized mesoporous materials with a c2mm symmetry. The mesoporous materials discussed herein have great potential for various advanced applications in the fields of catalysis, selective adsorption, controlled drug delivery and release, and many of other applications. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of International Patent Application No. PCT/CN2012/071757 with an international filing date of Feb. 29, 2012, designating the United States, now pending, and further claims priority benefits to Chinese Patent Application No. 201110143385.3 filed May 31, 2011. The contents of all of the aforementioned applications, including any intervening amendments thereto, are incorporated herein by reference. Inquiries from the public to applicants or assignees concerning this document or the related applications should be directed to: Matthias Scholl P. C., Attn.: Dr. Matthias Scholl Esq., 14781 Memorial Drive, Suite 1319, Houston, Tex. 77079.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a subgroup B recombinant human adenovirus vectors Ad11-5EP and Ad11-5ETel-GFP and methods for constructing and for using the same.
2. Description of the Related Art
Adenovirus 11 (Ad11) is a serotype of the subgroup B human adenovirus and is obviously superior to Ad 5 in oncolytic virotherapy. Ad11 is able to combine other cell surface receptor X besides the CD46 receptor. Tuve has reported that Ad11 is the only virus in the B subgroup adenovirus that is able to combine CD46 as well as the surface receptor X, which indicated that Ad11 is capable of infecting a much wider spectrum of tumor cells, thereby solving the problem of low infection rate in the application of Ad5 due to downregulation of virus acceptor. Ad11 is also superior to Ad5 in that the content of neutralizing antibodies of Ad11 is relatively low, being 10-31%, compared with 45-90% of that of Ad5, and the neutralizing antibodies of Ad11 have no cross-reactivity. When Ad11 is intravenously injected to transgenic mice expressing CD46, no obvious intrahepatic transduction or hepatotoxicity occurs. Furthermore, Ad11 is able to effectively transduce dendritic cells, allows tumor-specific antigens to express, and enhances the immune response to benefit the cancer therapy.
Studies on other adenovirus serotypes except Ad5 used as a vaccine or gene conversion vector have been reported, but the use of the adenovirus serotype used as an oncolytic virus has been rarely conducted. In vitro and in vivo studies from Sandberg indicated that transduction, replication, and lysis of Ad11 effectively undergo in prostate cancer cell line PC-3, but the comparison between Ad5 was not conducted by Sandberg. Shashakova et al. have compared oncolytic efficacy among Ad5, Ad6, Ad11, and Ad35 based on in vitro studies on human tumor cell lines and in vivo studies on human prostate cancer cell lines DC 145, and found that Ad5, Ad6, and Ad11 have similar antitumoral efficacy whereas Ad35 has no antitumoral efficacy. The most important is that only Ad5 has hepatotoxicity. After that, chimeric oncolytic Ad5 (by substituting cilium of Ad5 by that of the B subgroup adenovirus) was constructed for allowing the chimeric oncolytic Ad5 to combine with membrane receptor CD46 to improve the antitumoral efficacy. However, compared with a whole B subgroup adenovirus, this method is not able to overcome the neutralizing ability of hexon antigen of Ad5.
The number of circulating tumor cells (CTCs) is in relation to the clinical stage, treatment effect, and short survival rate. CTCs level in peripheral blood in tumor patient is taken as the basis for monitoring, adjusting the treatment, and anticipating the results. Thus, a specific and sensitive method for detecting these cells is necessitated. In recent years, immune cells counting analysis and quantitative PCR have been applied by which a small amount of CTCs were detected, however, the application of these methods were restricted because of a high testing cost and the lack of specific biological markers.
Replication-selective oncolytic adenovirus is a new kind of medicine for treating tumors. To be noted, it has been reported recently that the replication-selective oncolytic adenovirus expressing GFP has been used to detect CTCs among more than hundred million of peripheral blood cells. However, genetic variation of tumor cells is a very important factor affecting the infection ability of adenovirus. A low expression of CAR in tumor cells significantly decreases the infection ability of Ad5, which further influences the positive rate of tumor cells. Besides the known influence mechanism of the low expression of CAR, it has also been found that other tumor related genes like CEACAM6 influences Ad5 from entering the nuclear, thereby decreasing the infection ability of Ad5 on tumor cells. These data indicate that methods for testing CTCs using Ad5 have a low sensitivity in some tumor cells.
SUMMARY OF THE INVENTION
In view of the above-described problems, it is one objective of the invention to provide an adenovirus vector Ad11-5EP that is more effective in cancer therapy, and to provide a subgroup B recombinant human adenovirus vector Ad11-5ETel-GFP for treating tumor or detecting tumor cells in circulating blood.
Inventors have first compared the anti-tumor potencies of Ad11 and Ad5 in human cancer cell lines in vitro, and found that only 9 among 25 cell lines being tested are Ad11-sensitive, in which, PC-3 is insensitive to Ad5 and sensitive to Ad11. Compared with Ad5, Ad11 obviously inhibits the growth of subcutaneous tumors of PC-3 cells in vivo, and further improves the survival of tumor-bearing animals. When the above experiment is conducted on Ad5-sensitive and Ad11-insensitive MIAPaCa-2 cell line, the antitumoral efficacy of Ad11 is obviously reduced.
Although Ad11 receptors are often highly expressed within human tumor cells, the wild-type Ad11 is not able to effectively kill the tumor cells. The inventors have conducted extensive studies and proved that more Ad11 than Ad5 are attached to the membrane of tumor cells by using two different methods. The attached Ad11 virus particles are capable of entering the nucleus, which means a relatively high level of Ad11 exists in the nucleus in early stage of the virus infection compared with Ad5. The inventors have studied expressions of two viruses in early stage of tumor cells infection, and levels of mRNA of E1A are tested by using specific primers for quantitative PCR. After 2 hours of virus infection in all cell lines, it was found that in cell lines that had a high level of Ad11, E1AmRNA was highly expressed. Expression of E1AmRNA of Ad11 in Ad11-insensitive cell lines (MIAPaCa-2 and LNCaP) after 2 hours of the infection is obviously decreased. Ad11-sensitive Capan-2 and PC-3 cells have a high level of Ad11E1AmRNA. Ad11E1AmRNA directly influences the replication of virus, so that the decrease of the level of Ad11E1AmRNA in MIAPaCa-2 and LNCaP cell lines will decrease the replication level of the virus, and correspondingly decrease the synthesis of hexon protein. Such result is in accordance with the production of low level of Ad11 virus particles and the cytotoxicity from the initial observation. These results indicate that the replication and cell killing of Ad11 have no relationship with its infectivity, but are associated with the activity of the enhancer and the promoter of early gene E1A.
To solve the above problem, one objective of the invention is to construct a tumor targeting adenoviral vector (Ad11-5EP) where the original enhancer and promoter of Ad11 E1A gene was replaced by the counterpart of Ad5. Experiments indicate that Ad11-5EP is a very useful backbone vector capable of developing replication-selective oncolytic adenovirus for treating a wider spectrum of human cancers.
To explore the application of the new adenovirus vector and improve the sensitivity to detect circulating tumor cells in the blood using replication-selective adenovirus, the Ad5 promoter of Ad11-5EP is substituted by a promoter of human telomerase gene, a reporter gene GFP was inserted into E3gp18.5 K of Ad11, and a replication-selective adenovirus (Ad11-5ETel-GFP) capable of expressing reporter genes was created by homologous recombination. As telomerase is highly expressed in 95% of human tumor cells, Ad11-5ETel-GFP selectively replicates and expresses GFP in tumor cells but has no activity in normal epithelial cells.
To achieve the above objective, in accordance with one embodiment of the invention, there is provided a method for constructing a subgroup B recombinant human adenovirus vector Ad11-5EP (SEQ ID NO: 1) comprises substituting a 365 bp fragment comprising an enhancer and a promoter of an upstream coding sequence of Ad5 E1A (SEQ ID NO: 2)for a corresponding region of a serotype Ad11 (SEQ ID NO: 3) of the subgroup B human adenovirus vector by homologous recombination to construct the subgroup B recombinant human adenovirus vector Ad11-5EP.
In a class of this embodiment, the homologous recombination comprises: amplifying a 329 bp fragment in the front of the Ad11 genome as a left arm sequence, providing a fragment formed by ligating a 195-559 bp fragment of Ad5 E1A comprising the enhancer and the promoter and a 568-1125 bp fragment of Ad11 E1A (SEQ ID NO: 4) as a right arm sequence, and ligating the left arm sequence and the right arm sequence to multi-cloning sites arranged on two sides of pSS-ChI (SEQ ID NO: 12), respectively, to construct a shuttle vector pSS-A1A7 (SEQ ID NO: 5); digesting and purifying the pSS-A1A7 by PmeI while performing homologous recombination between a PmeI digested segment and pAd11 (SEQ ID NO: 6) plasmid within BJ5183 cells, and screening positive clones using agar plates comprising ampicillin and chloramphenicol; and digesting the positive clones by SwaI, and deleting a chloramphenicol-resistance gene expression cassette to yield pAd11-Ad5EP (SEQ ID NO: 7), digesting and linearizing the pAd11-Ad5EP by NotI, and transfecting 293 cells to yield the adenovirus vector Ad11-5EP.
In a class of this embodiment, the concentrations of ampicillin and chloramphenicol are 100 mg/mL and 25 mg/mL, respectively.
A method for reconstructing replication-selective oncolytic adenovirus using the subgroup B recombinant human adenovirus vector Ad11-5EP, the method comprises one of the following steps:
1) deleting E1A CR2 gene (SEQ ID NO: 8) and/or anti-apoptotic gene E1B 21K (SEQ ID NO: 9) that are necessary for viability of the adenovirus in normal cells but not necessary in tumor cells;
2) inserting a tumor-specific promoter to drive the expression of E1A gene;
3) re-directing a cellular tropism of Ad11-5EP according to receptors on a tumor cell surface; or
4) allowing adenovirus to selectively replicate in tumor cells combining with MicroRNA technology.
A method for constructing a subgroup B recombinant human adenovirus vector Ad11-5ETel-GFP (SEQ ID NO: 10), the method comprises:
1) constructing vectors pSS-ChI and pSS-kna (SEQ ID NO: 13) by using two different antibiotics-resistance cassettes, introducing SwaI restriction sites to two flanks of a chloramphenicol-resistance gene sequence cassette, and introducing sbfI restriction sites to two flanks of a kanamycin-resistance gene sequence cassette;
2) cloning an initiation sequence for replication of pBR322 (SEQ ID NO: 14) by pUC18, (SEQ ID NO: 15) ligating a first synthetic nucleotide sequence comprising multi-cloning sites to the chloramphenicol-resistance gene sequence cassette to yield pSS-ChI, homologously recombining an upstream of a left arm sequence and a downstream of a right arm sequence of the chloramphenicol-resistance gene sequence cassette, and inserting the upstream of the left arm sequence of the chloramphenicol-resistance gene sequence cassette and the downstream of the right arm sequence of the chloramphenicol-resistance gene sequence cassette into the multi-cloning sites on two sides of pSS-ChI by blunt end insertion or cohesive end insertion, respectively, to construct a shuttle vector pSSENTel (SEQ ID NO: 16) for recombination;
3) cloning an initiation sequence for replication of pBR322 by pUC18, ligating a second synthetic nucleotide sequence comprising multi-cloning sites to the kanamycin-resistance gene sequence cassette to yield pSS-kna, homologously recombining an upstream of a left arm sequence and a downstream of a right arm sequence of the kanamycin-resistance gene sequence cassette, and inserting the upstream of the left arm sequence of the kanamycin-resistance gene sequence cassette and the downstream of the right arm sequence of the kanamycin-resistance gene sequence cassette into the multi-cloning sites on two sides of pSS-kna by blunt end insertion or cohesive end insertion, respectively, to construct a shuttle vector pSSGFP (SEQ ID NO: 17) for recombination;
4) constructing pSSENTe comprising: amplifying a 329 bp in the front of Ad11 genome as a left arm sequence, providing a fragment formed by ligating 195-378 bp of Ad5 E1A enhancer, −714-0 bp of human TERT promoter, and 568-1125 bp of Ad11 E1A in order as a right arm sequence, introducing two restriction enzyme sites XbaI and NcoI to two sides of the human TERT promoter, and inserting the left arm sequence and the right arm sequence into SnabI and EcoRV arranged on two sides of pSS-ChI, respectively, by blunt end insertion, to yield pSSENTel;
5) constructing pSSGFP comprising: providing a left arm being a product by ligating 27301-27837 bp of DNA segment of Ad11 genome with EGFP gene via NcoI, and introducing a SnaBI site to 3′ terminal of EGFP; providing a right arm being 28337-28920 bp of DNA segment of Ad11 genome; and inserting the left arm and the right arm into SnabI and EcoRV sites arranged on two sides of pSS-kna by blunt end insertion, to yield pSSGFP; and
6) digesting and purifying the pSSENTel and pSSGFP by PmeI, to yield two PmeI digested segments, performing homogenous recombination synchronously between the two PmeI digested segments and pAd11 plasmid, respectively, in BJ5183 cells; screening positive clones using agar plates comprising ampicillin, kanamycin, and chloramphenicol; digesting the positive clones by SwaI and SbfI, and deleting chloramphenicol-resistance gene expression cassette and kanamycin-resistance gene expression cassette to yield pAd11-5ETel-GFP (SEQ ID NO: 11); and digesting and linearizing the pAd11-5ETel-GFP by NotI, and transfecting 293 cells to produce adenovirs vector Ad11-5ETel-GFP.
In a class of this embodiment, the concentrations of ampicillin, kanamycin, and chloramphenicol are 100 mg/mL, 50 μg/mL, and 25 mg/mL, respectively.
In a class of this embodiment, Tel sequence of pSSENTel is substitutable by promoters of other tumor specific genes to yield a tumor-specific oncolytic adenovirus; and GFP sequence of pSSGFP is substitutable by a signal gene or therapeutic gene.
In a class of this embodiment, Ad11 18.5 K gene promoter of pSSGFP is substitutable by a tumor-specific promoter.
A method for treatment of tumor comprises applying a subgroup B recombinant human adenovirus vector Ad11-5EP.
A method for treatment of tumor or detection of tumor cells in circulating blood comprises applying a subgroup B adenovirus vector Ad11-5ETel-GFP.
Advantages of the invention are as follows:
1) The tumor targeting adenovirus vector Ad11-5EP is acquired by substituting the enhancer and the promoter of E1A by the enhancer and the promoter of Ad5E1A based on the wild type Ad11. Such a vector has stronger oncolytic efficacy than the wild type Ad11, thereby enhancing the potency on the tumor cells.
2) The tumor targeting adenovirus vector Ad11-5EP has tumor targeting and antitumoral efficacy. Experiments from oncolytic potency have indicated that Ad11-5EP has stronger potency on tumor cells than Ad5 and stronger cell toxicity than Ad11. Measurements of tumor growth and tumor clearance indicate that Ad11-5EP significantly reduces the tumor growth, and the non-tumor ratio of the tumor-bearing mice is significantly better than Ad11.
3) The tumor targeting adenovirus vector Ad11-5EP can be used as a tumor-targeting genetic engineering drug for treating cancer, thereby producing social and economic benefits.
4) The method for constructing subgroup B human recombinant adenovirus vector Ad11-5ETel-GFP of the invention features that homogeneous recombination is performed synchronously between Ad11-5EP genome and shutter vectors of pSSENTel and pSSGFP to produce recombinant virus vector Ad11-5ETel-GFP. Ad11-5ETel-GFP can be used in cancer therapy or detection of cancer cells in circulating blood. Expression tests of GFP of Ad11-5ETel-GFP in human normal epithelial cells and cancer cells and CTCs tests demonstrated that Ad11-5ETel-GFP is very sensitive to cancer cells and is capable of infecting a wide spectrum of cancer cells, thereby being specific, sensitive, and economic to apply in cancer cells detection in circulating blood.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram showing a method of construction of a subgroup B recombinant human adenovirus vector Ad11-5EP;
FIG. 2 is a diagram showing oncolytic potency of Ad5, Ad11 and Ad11-5EP in human cancer cells sensitive to Ad11;
FIG. 3 is a diagram showing oncolytic potency of Ad5, Ad11 and Ad11-5EP in human cancer cells less sensitive to Ad11; in FIGS. 2 and 3 , white columns represent Ad5, black columns represents Ad11, grid columns represent Ad11-5EP;
FIG. 4 is a curve chart showing mean tumor volume after treatment of Ad5, Ad11, and Ad11-5EP in MIAPaCa-2 subcutaneous xenograft model;
FIG. 5 is a chart showing percentage of progression-free mice after treatment with Ad5, Ad11, and Ad11-5EP in MIAPaCa-2 subcutaneous xenograft model; in FIGS. 4-5, 1 represents PBS, 2 represents Ad11, 3 represents Ad11-5EP, and 4 represents Ad5;
FIG. 6 is a procedure diagram of construction of shutter vectors pSSENTel and pSSGFP and replication-selective oncolytic adenovirus plasmid pAd11-5ETel-GFP;
FIG. 7 is a comparison chart of GFP expression after Ad11-5ETel-GFP infection in human normal epithelial cells and cancer cells;
FIG. 8 is a histogram of detected tumor cells in blood by Ad11-5ETel-GFP in number; and
FIG. 9 is a fluorescent image showing detected tumor cells in blood by Ad11-5ETel-GFP in fluorescent image.
DETAILED DESCRIPTION OF THE EMBODIMENTS
The invention is further described by the following embodiments but not to limit the protection scope of the invention. It will be obvious to those skilled in the art that changes and modifications may be made without departing from the invention in its broader aspects, and therefore, the aim in the appended claims is to cover all such changes and modifications as fall within the true spirit and scope of the invention.
Example 1
Method for Constructing a Subgroup B Recombinant Human Adenovirus vector Ad11-5EP
A 365 bp fragment comprising an enhancer and a promoter of an upstream coding sequence of Ad5 E1A was substituted for a corresponding region of a serotype Ad11 of the subgroup B human adenovirus vector by homologous recombination to construct the subgroup B recombinant human adenovirus vector Ad11-5EP.
A 329 bp fragment in the front of the Ad11 genome was provided as a left arm sequence, and a fragment formed by ligating a 195-559 bp fragment of Ad5 E1A comprising the enhancer and the promoter and a 568-1125 bp fragment of Ad11 E1A was provided as a right arm sequence. The left arm sequence and the right arm sequence were connected to multi-cloning sites arranged on two sides of pSS-ChI, respectively, to construct a shuttle vector pSS-A1A7. The pSS-A1A7 was digested and purified by PmeI while performing homologous recombination between a PmeI digested segment and pAd11 plasmid within BJ5183 cells. Positive clones were screened using agar plates comprising ampicillin and chloramphenicol. The positive clones were digested by SwaI, and a chloramphenicol-resistance gene expression cassette was deleted to yield pAd11-Ad5EP. The pAd11-Ad5EP was and linearized by NotI, and 293 cells were transfected to yield the adenovirus vector Ad11-5EP (as shown in FIG. 1 ).
Example 2
Oncolytic Potencies of Ad5, Ad11, and Ad11-5EP in Ad11-Sensitive and -Insensitive Human Cancer Cell Lines
Oncolytic potencies of Ad5, Ad11, and Ad11-5EP were tested on Ad11-sensitive human tumor cell lines Capan-2, PaTu8988s, PC-3m MCF7, HT-29 and Ad11-insensitive human tumor cell lines MIAPaCa-2, MDA-MB-231, HCT116, LNCaP, and A549 in vitro. 2% of fetal bovine serum (FBS) medium was employed to prepare cell suspensions of the above 10 cell lines, respectively, and were inoculated to a 96-well plate. After 14-18 h, virus was diluted by a serious dilution. An original concentration was 1×104 pt/cell, and the viral solution was then diluted by a ten-fold series dilution. The diluted solution was added to different cell lines of the 96-well plate at an addition of 10 μl/hole, and the oncolytic potencies of Ad5, Ad11, and Ad11-5EP were tested by MTS on a 6 th day after the infection.
Results showed that: in all Ad11-sensitive cell lines, Ad11-5EP has better oncolytic potency than Ad5, and Ad11 produced stronger cytotoxicity (as shown in FIG. 2 ) whereas in Ad11-insensitive cell lines, performance of Ad11-5EP was significantly improved (as shown in FIG. 3 ). Ad11-5EP showed a high sensitivity in 90% (9/10) cell lines, which indicated that Ad5 and Ad11 has better cancer killing efficacy, and Ad11-5EP was capable of killing a wide spectrum of cancer cells.
Example 3
Antitumoral Efficacy of Ad5, Ad11, and Ad11-5EP in a MIAPaCa-2 Subcutaneous Xenograft Model
MIAPaCa-2 cells (as MIAPaCa-2 is Ad11-insensitve and Ad5-sensitive) were subcutaneously grafted to right backs of BALA/c nude mice (n=8/group), respectively, to construct subcutaneous xenograft models. When a volume of the tumor reached 180 mm 3 , PBS or viruses (Ad5, Ad11, and Ad11-5EP, 1X1010 viral particles/injection) were injected at a 1 st , 3 rd , and 5 th days, tumor growth and tumor clearance rate were observed. Results showed that Ad11-5EP was as effective as Ad5 in reducing tumor growth (as shown in FIG. 4 ), and non-tumor ratio of tumor-bearing mice was significantly better than Ad11-treated group (as shown in FIG. 5 ).
Example 4
Method for Constructing a Subgroup B Recombinant Human Adenovirus vector Ad11-5ETel-GFP
1) Vectors pSS-ChI and pSS-kna were constructed by using two different antibiotics-resistance cassettes, SwaI restriction sites were introduced to two flanks of a chloramphenicol-resistance gene sequence cassette, and sbfI restriction sites were introduced to two flanks of a kanamycin-resistance gene sequence cassette.
2) An initiation sequence for replication of pBR32 was cloned by pUC18, and a first synthetic nucleotide sequence comprising multi-cloning sites was connected to the chloramphenicol-resistance gene sequence cassette to yield pSS-ChI. Homologously recombination between an upstream of a left arm sequence and a downstream of a right arm sequence of the chloramphenicol-resistance gene sequence cassette was performed, and the upstream of the left arm sequence of the chloramphenicol-resistance gene sequence cassette and the downstream of the right arm sequence of the chloramphenicol-resistance gene sequence cassette were inserted into the multi-cloning sites on two sides of pSS-ChI by blunt end insertion or cohesive end insertion, respectively, to construct a shuttle vector pSSENTel for recombination.
3) An initiation sequence for replication of pBR32 was cloned by pUC18, and a second synthetic nucleotide sequence comprising multi-cloning sites was connected to the kanamycin-resistance gene sequence cassette to yield pSS-kna. Homologously recombination was performed between an upstream of a left arm sequence and a downstream of a right arm sequence of the kanamycin-resistance gene sequence cassette, and the upstream of the left arm sequence of the kanamycin-resistance gene sequence cassette and the downstream of the right arm sequence of the kanamycin-resistance gene sequence cassette were inserted into the multi-cloning sites on two sides of pSS-kna by blunt end insertion or cohesive end insertion, respectively, to construct a shuttle vector pSSGFP for recombination.
4) pSSENTe was constructed, and the construction of pSSENTe comprised: amplifying a 329 bp in the front of Ad11 genome as a left arm sequence, providing a fragment formed by ligating 195-378 bp of Ad5 E1A enhancer, −714-0 bp of human TERT promoter, and 568-1125 bp of Ad11 E1A in order as a right arm sequence, introducing two restriction enzyme sites XbaI and NcoI to two sides of the human TERT promoter, and inserting the left arm sequence and the right arm sequence into SnabI and EcoRV arranged on two sides of pSS-ChI, respectively, by blunt end insertion, to yield pSSENTel.
5) pSSGFP was constructed and the construction of pSSGFP comprised: providing a left arm being a product by ligating 27301-27837 bp of DNA segment of Ad11 genome with EGFP gene via NcoI, and introducing a SnaBI site to 3′ terminal of EGFP; providing a right arm being 28337-28920 bp of DNA segment of Ad11 genome; and inserting the left arm and the right arm into SnabI and EcoRV sites arranged on two sides of pSS-kna by blunt end insertion, to yield pSSGFP.
6) pSSENTel and pSSGFP were digested and purified by PmeI to yield two PmeI digested segments, homogenous recombination was synchronously performed between the two PmeI digested segments and pAd11 plasmid, respectively, in BJ5183 cells. Positive clones were screened using agar plates comprising ampicillin, kanamycin, and chloramphenicol. The positive clones were digested by SwaI and SbfI, and chloramphenicol-resistance gene expression cassette and kanamycin-resistance gene expression cassette were deleted to yield pAd11-5ETel-GFP (as shown in FIG. 6 ).
The pAd11-5ETel-GFP was and linearized by NotI, and 293 cells were transfected to produce adenovirus vector Ad11-5ETel-GFP.
Example 5
Expression of GFP of Ad11-5ETel-GFP in Human Normal Epithelial Cells and Cancer Cells
Ad11-5ETel-GFP was used to infect human pancreatic cancer cell line SUIT-2 and human normal bronchial epithelial cell line NHBE (an infection concentration of 100 pfu/cell), expression of GFP was observed under immunofluorescence microscope after 24 h. It has been found that GFP had a high expression in cancer cell line SUIT-2, and relatively low expression in normal cells NHBE (as shown in FIG. 7 ), which indicated that the cancer cell line SUIT-2 is Ad11-5ETel-GFP-sensitive.
Example 6
Circulation Tumor Cells (CTCs) Detection Using Ad11-5ETel-GFP
10, 25, 50, 100, and 200 human pancreatic cancer cell line SUIT-2 were respectively mixed with 3 mL of blood, nucleated cells were collected by centrifugation after red blood cells were lysised. Thereafter, the nucleated cells were resuspended in 900 μL of DMEM medium, added with 1×104 pfu of Ad11-5ETel-GFP, and cultured for 24 h. GFP positive cells were counted under an immunofluorescence microscope (as shown in FIG. 8 ). Peripheral blood cells were mixed with 0, 10, 100, and 1000 human pancreatic cancer cell line SUIT-2, respectively (an infection concentration of 100 pfu/cell). The samples were processed as described above. GFP positive cells were observed under the immunofluorescence microscope after 24 h of culturing and it demonstrated that the cancer cell line SUIT-2 is Ad11-5ETel-GFP-sensitive. The GFP-positive cells were correlated to the number of tumor cells mixed with the blood cells.
While particular embodiments of the invention have been shown and described, it will be obvious to those skilled in the art that changes and modifications may be made without departing from the invention in its broader aspects, and therefore, the aim in the appended claims is to cover all such changes and modifications as fall within the true spirit and scope of the invention. | A method for constructing a subgroup B recombinant human adenovirus vector Ad11-5EP. The method includes substituting a 365 bp fragment including an enhancer and a promoter of an upstream coding sequence of Ad5 E1A for a corresponding region of a serotype Ad11 of the subgroup B human adenovirus vector by homologous recombination to construct the subgroup B recombinant human adenovirus vector Ad11-5EP. A subgroup B recombinant human adenovirus vector Ad11-5EP constructed by the method and the use thereof for treatment of tumors are also provided. | 2 |
CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority to German Patent Application No. DE 10 2014 002 974.3, filed Mar. 6, 2014, the content of which is incorporated herein in its entirety by reference.
TECHNICAL FIELD
The present invention relates to a trailer for a tugger train.
BACKGROUND
Tugger trains are used for transporting materials in the scope of in-plant logistics and intralogistics. A tugger train is typically comprised of one or more towing vehicles, which tow a train of trailers that are coupled together. Each trailer can, depending on the design, receive one or more inner wagons to be transported.
With the design of the trailer for a tugger train, there is a fundamental distinction between portal trailers, with which the inner wagon to be transported can be pushed in from both sides, and frame-based trailers, which can receive an inner wagon to be transported only from one side. There, the inner wagon does not have be a wagon located completely within the trailer. The inner wagon can also extend laterally beyond the trailer, and be thusly transported with the trailer. Any load-bearing unit that is suitable for transporting on a trailer and can be moved preferably on wheels or rollers is considered as an inner wagon.
With the trailers for tugger trains, along with the distinction with regard to receiving the inner wagon, there is also the distinction of whether the inner wagon with the rollers or wheels thereof is clear of the floor during transport. Fundamentally, tugger trains are known with which the towed inner wagons themselves roll and are guided in the trailer. Alternatively, trailers are also known with which the inner wagon is raised and the wheels of the inner wagon are clear of the floor during transport such that the inner wagon is carried.
SUMMARY
With trailers having frames that can be loaded from one side, which allow transporting the inner wagon in the raised state, manufacturing has proven to be relatively complicated. This is particularly true with respect to customer-specific requests. The trailer is comprised of a frame and a central web, upon which, or on which, the inner wagon can be transported.
A trailer for a tugger train that can be easily and flexibly designed even in the case of customer-specific requirements is desirable.
The trailer according to implementations of the invention is designed and intended for a tugger train or a tow train, which are used in intralogistics. The trailer has a frame, which in the longitudinal direction relative to the tow direction thereof, has a drawbar and a coupling. The trailer can be attached to a towing vehicle using the drawbar. A towed trailer can be towed by the towing vehicle using the coupling. The reverse arrangement of the coupling and drawbar is also possible. The frame, transverse to the tow direction, has a laterally open receiving space for an inner wagon to be transported. A central web is arranged in the receiving space. According to an implementation of the invention, the frame is equipped with a first connection means in each case for the drawbar and coupling. The frame may also be equipped with second connection means for the central web. The second connection means is designed such that a releasable connection can be established between the central web and the frame. The distinction between first and second connection means relates only to the use of the connection means on the trailer, and does not imply that the first and second connection means are different from each other. Moreover, the first and second connection means can be identical in design, but be positioned at different positions of the frame.
In some designs, the connection means for the frame and central web has a screw connection and/or a bolt connection. Using a screw connection and/or bolt connection, a releasable connection can be produced between the frame and central web that, depending on the intended operation or use of the trailer, allows a central web of the desired design and configuration to be connected to a frame of the desired design and configuration.
In some designs, the connection means for the frame and central web is designed such that a form-locking, force-fitting and/or friction-fitting connection can be produced between the frame and central web. In particular, by combining different connections a sufficiently stable connection can be produced for accommodating loads.
In a further design, the connection means for the frame and the drawbar as well as the coupling are designed for producing a releasable connection. This facilitates the assembly of a trailer having the desired properties with regard to the drawbar and coupling.
The trailer according to the teachings herein may be comprised of three assemblies or components that are releasably connected together. This allows a trailer to be very flexibly configured according to customer-specific requests. Depending on the request, suitable drawbars and couplings can be connected to the frame. Likewise, a suitably designed central web can be connected to the frame.
In some designs, the frame is substantially U-shaped. Here, the limbs of the U may form the sites to which the drawbar and coupling can be attached to the frame.
In some designs, the central web is provided with an undercarriage. The undercarriage of the central web is preferably the only undercarriage of the trailer where it is present, but this is not required.
For directionally stable handling of the trailer, the central web may be designed centrally on the U-shaped frame or centrally between the coupling points of drawbar and coupling. Depending on the design of the drawbar and coupling, the coupling points of the drawbar and coupling are generally also the points at which a pivoting occurs with respect to the towed or towing vehicle.
In some designs, the frame and central web are designed as two separate components that are releasably connected together using a mounting flange serving as a connection means. It is also possible that both central web and also frame each have a mounting flange, which flanges are connected together. They may be connected together by lying them flat on top of each other and, for example, screwing them together.
In designs where the central web is fastened sunken on the frame, the frame also laterally delimits the receiving space that is delimited downward by the top side of the central web. In a feasible design, the frame has on its bottom side the mounting flange for the face-side fastening of the central web, such that the receiving space is delimited on at least three sides by the frame and downward by the central web. Alternatively or additionally, the central web can have a face-side mounting flange for fastening to the frame, wherein the receiving space is again delimited on at least three sides by the frame and downward by the central web. The height offset between the central web and the U-shaped frame is especially suited for providing a suitable flange as a connection means for a screw connection or bolt connection. This is because a mounting flange projecting in this manner has the particular advantage of an easily accessible assembly to the frame.
In some designs, a mounting flange is provided in each case on the frame in the tow direction as a connection means for the drawbar and for the coupling. Alternatively or at the same time, the drawbar and coupling can have a mounting flange at the frame-side ends thereof as a fastening means.
In some designs, the central web is equipped laterally with two ramps upon which the inner wagon to be transported can be pushed in order to be cleared of the floor. Alternatively or additionally, the central web can also be provided with a lifting apparatus that raises an inner wagon to be transported.
The advantages of the teachings herein are particularly significant for a set of trailers where the set has at least one frame and a plurality of central webs that can be releasably connected to the frame and any frame with any central web can be connected to the trailer. Here, a plurality of frames and a plurality of central webs refer to the fact that a plurality of frames may be available having a different design or a different frame type, and also the mountable central webs differ in shape, form, function and/or configuration. With this set, a trailer can be configured by a user according to user requirements without reconstruction or great effort.
In a further design, a plurality of frames may be provided with the set such that the frames differ from each other in frame strength and/or frame height. Depending on the intended use, the frames can be designed having different strength and/or height. Likewise, it is also possible to implement the central webs with or without rollers. In such cases, the frames may be correspondingly modified in the undercarriage. Fundamentally, it is also possible that the frames are equipped with different undercarriages. For example, one or more frames in the set can be equipped with four casters, preferably in the corners of the frame. The central web can be equipped, for example, with two fixed casters, or only with one centrally arranged fixed caster. The fixed casters can also be spring-mounted, for example, in order to ensure a good positioning of the trailer on the ground. In an alternative design, the rollers on the central web can also be equipped with a drive. With a three- or four-wheel undercarriage on the frame it is possible to design the central web also without rollers, wherein then the frame is equipped with steered casters. For the sets of frames and central webs, it is also possible to provide different frame lengths, which are equipped for receiving one or more inner wagons or pallets. Here, it is also possible to equip the frames with more than one central web for supporting the inner wagon.
BRIEF DESCRIPTION OF THE DRAWINGS
A design of the trailer according to implementations of the invention is explained in greater detail below with reference to the drawings in which:
FIG. 1 is a perspective view of a trailer according to the teachings herein with the inner wagon pushed in;
FIG. 2 is a perspective view of the trailer from FIG. 1 without the inner wagon pushed in;
FIG. 3 is a perspective view of an assembly of a trailer according to the teachings herein with central web to be attached and a lifting apparatus;
FIG. 4 is a perspective view of an attachment of a central web with a ramp-shaped slide-on aid laterally on the central web;
FIG. 5 is a top view of a trailer frame; and
FIG. 6 is a side perspective view of a trailer frame with flange.
DETAILED DESCRIPTION
FIG. 1 shows a trailer 10 according to embodiments of the invention described herein in which an inner wagon 12 with an accommodated pallet 14 is pushed in. The trailer 10 has a U-shape frame 16 having drawbar 18 on one side and a trailer coupling 20 on the opposing side. The drawbar 18 is comprised of a rigid drawbar arm 22 , which is designed as a rectangular hollow profile. The end of the drawbar arm 22 pointing toward the trailer has a flange plate 24 , which has a bore hole 26 in each of the corners thereof. The opposite end of the drawbar arm 22 is delimited by two limb plates 28 , 30 . The limb plates 28 , 30 have bore holes 32 , 34 aligned with each other. The drawbar 18 is fastened rigidly to the frame 16 using the flange plate 24 . For this purpose, mounting bolts can be guided through the bore hole 26 and a corresponding frame bore hole (not shown). It is also possible, alternatively or additionally, to weld the flange plate 24 to the frame 16 . As seen in FIG. 1 , the connection of the coupling 20 is substantially similar to the connection of the drawbar 22 to the frame. The coupling 20 also has a flange plate 36 , with which the coupling 20 is fastened to the frame 16 . The coupling 20 also has a continuous coupling bore hole 38 for receiving a coupling pin (not shown).
The substantially U-shaped frame 16 is comprised of three profile limbs 40 , 42 , 44 , each of which is formed having a double T-shape. Other profile shapes, such as rectangular profiles, are also possible. As shown in FIG. 2 , the limb 40 supports the drawbar 22 , the limb 42 supports the coupling 20 , and the limb 44 supports a central web 46 . The transitions between the limbs 42 and 44 as well as the limbs 40 and 44 are provided with rounded reinforced corners 48 in order guide the tractive forces acting on the frame 16 from coupling 20 to the drawbar 22 . The receiving space 52 , in which the central web 46 projects, is located between the limbs 40 and 42 . Laterally of the receiving space 52 , the limbs 42 and 40 have a chamfer 50 , which facilitates the pushing of the inner wagon 12 into the inner space 52 .
FIGS. 3 and 4 show a mounting flange 54 that is attached to the connecting limb 44 . The mounting flange 54 is substantially perpendicular to the plane spanned by the limbs 40 , 42 , 44 of the U-shaped frame 16 . Bolt ends 56 , which permit the mounting of a central web 46 a , project from the mounting flange 54 . The central web 46 a is covered by an integral metal sheet 58 . A lifting apparatus can be arranged beneath the metal sheet 58 so that an inner wagon 12 pushed into the trailer frame 16 can be raised using the lifting apparatus. FIG. 4 shows an alternative design of the trailer 10 having a central web 46 b , which has a respective ramp 60 on opposing sides thereof. Rotatably mounted roller bodies 62 project laterally from the ramps 60 . An inner wagon 12 to be transported is pushed over the ramps 60 with the roller bodies 62 thereof into a raised position, where the wagon 12 can be secured for transport.
FIGS. 5 and 6 show the frame 16 with a mounting flange 54 . The mounting flange 54 is attached centrally to the limb 44 by, for example, welding. Depending on customer requests, specific additions for the drawbar and trailer coupling, as well as for the central web, can be attached without great effort to the frames shown in FIGS. 5 and 6 . In this manner, a modular frame trailer arises that is comprised of a plurality of modules and functional groups having defined interfaces, which are pre-manufactured independently of each other and largely independent of customer orders. The central web can be equipped, for example, with rollers for light-weight goods, and manual pushing in and lifting onto the central web. In addition, chamfered roller tracks can be provided as an inclined plane for manual operation. If a lifting unit is used, a hydraulic, pneumatic or electrical lifting unit can be provided here. In addition, central webs with special slim-designed lifting units, or two divided lifting units, are also possible.
Likewise, different designs can be provided with regard to the combination of the drawbar and drawbar coupling. Thus, it is possible for example to provide a center-pivoting drawbar designed rigid with respect to moments in the vertical direction. Also, drawbars that are vertically movable and/or adjustable in height can be provided. In addition, drawbars that are particularly long and thin can be attached to the frame.
With the central web, different shapes of undercarriages are also possible. Thus, an undercarriage having nylon rollers with thin small diameter, and having Vulkollan® rollers with a large diameter can be provided. Also, depending on the inner wagons being used, undercarriages having different heights can be used. Basically, even undercarriages with springs are possible for outdoor use.
With the trailer according to the teachings herein, it is possible to pre-mount all of the aforementioned components for the central web, the undercarriage thereof, and the drawbar, to stockpile them, and to assemble them according to specific orders. | A trailer for a tugger train has a frame, which in the tow direction has a drawbar and a coupling, and which transverse to the tow direction has a laterally open receiving space for an inner wagon to be transported. A central web is arranged in the receiving space. The frame has connection means in each case for drawbar and coupling, and the frame has connection means for the central web for the releasable connection of the frame and connection means. | 1 |
RELATED APPLICATIONS
The present invention was first described in and claims the benefit of U.S. Provisional Patent Application No. 60/967,982 filed on Sep. 10, 2007, the entire disclosures of which are incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates generally to a tobacco product filtration device and, more particularly, to said device reducing second hand smoke.
BACKGROUND OF THE INVENTION
There are many situations where children require transportation on multiple passenger vehicles. Field trips and transportation to school require a school bus. Some children are transported in large multiple passenger vans. Airplanes, commercial buses, trains all create situations where children can be easily displaced or forgotten about due to other pressures on a vehicle operator. When children are overlooked in conveyances of this sort, it may have dreadful consequences. Children have died from being left in overheated vehicles. Accordingly, there exists a need for a means by which the presence of a child on a multiple passenger vehicle can be more readily and easily detected. The development of the invention herein described fulfills this need.
It is all too often that we hear on the news of a child is left behind a school bus after a school day. Most of the time, the child is found at the school bus yard storage facility and the story ends happily. However in some cases, such as in inclement weather, weekends, or when a parent thinks the child is with someone else, the event can end tragically with a child's death. The causes of such oversight are many and may include new bus drivers, substitute bus drivers, or more likely, a child that has simply fallen asleep. Even with a required walk through after the bus run, children are sometimes simply overlooked. The development of the invention herein described fulfils this need.
U.S. Pat. No. 7,151,452 issued to Shieh discloses a vehicle occupant sensing system comprising a sensing system to determine if a child is within a motor vehicle. Unfortunately, this patent does not appear to disclose an apparatus and method the uses a unique identifier card issued to school children to monitor a child's presence on a school bus nor does this patent appear to disclose the use of a plurality of sensors located in the seats of a multiple passenger vehicle that electronically communicate with a main control cabinet.
U.S. Pat. No. 7,135,983 issued to Filppov et al discloses an occupant presence detection device that is able to detect whether a person is seated and occupying a motor vehicle, restaurant seat or the like. Unfortunately, this patent does not appear to disclose a main control cabinet that is pivotally adjustable adjacent to an operator nor does it appear to disclose the use of unique identifier cards issued to passengers that are read by a reader on the main control cabinet.
U.S. Pat. No. 7,091,873 issued to Bauer et al. discloses a device and method for detecting the occupation of a seat in a motor vehicle comprising a sensor analyzer and a detector analyzer. Unfortunately, this patent does not appear to a system that utilizes unique identifier cards issued to passengers to determine their presence in an assigned seat on a vehicle nor does this patent appear to disclose a system capable of wireless control and monitoring.
U.S. Pat. No. 7,082,360 issued to Oestreicher et al discloses a method and system for determining weight and position of a vehicle seat occupant for use in controlling a restraint system in a motor vehicle. Unfortunately, this patent does not appear to disclose a disclose an apparatus and method the uses a unique identifier card issued to school children to monitor a child's presence on a school bus nor does this patent appear to disclose the use of a plurality of sensors located in the seats of a multiple passenger vehicle that electronically communicate with a main control cabinet.
U.S. Pat. No. 7,075,450 issued to Young and Nathan discloses a vehicle occupant sensing system having discrete wiring comprising a controller and at least one sensor assembly. Unfortunately, this patent does not appear to disclose an apparatus that is utilized to detect the presence of a child on a multiple passenger vehicle and that is capable of alerting responsible individuals of that situation.
U.S. Pat. No. 7,055,639 issued to Kiribaynashi discloses an occupant detection system for vehicles comprising a seat occupancy sensor that interacts with an air bag electrical control unit. Unfortunately, this patent does not appear to a system that utilizes unique identifier cards issued to passengers to determine their presence in an assigned seat on a vehicle nor does this patent appear to disclose a system capable of wireless control and monitoring.
U.S. Pat. No. 7,039,514 issued to Fortune discloses an occupant classification method based on seated weight measurement for purposes of air bag suppression. Unfortunately, this patent does not appear to disclose a sensing system for children capable of detecting the presence of a child on a multiple passenger vehicle and that further alerts individuals to the unattended child nor does it appear that this system is capable of wireless control and monitoring via an external antenna.
SUMMARY OF THE INVENTION
In view of the foregoing disadvantages inherent in the prior art, it has been observed that there is a need for a seat occupancy verification system for motor vehicles which monitors occupancy of seated children on school buses or other multi-passenger vehicles utilizing seat sensors and an electronic card system.
An object of the seat occupancy verification system is to verify that a child is not left unattended on a multi-passenger vehicle.
Another object of the seat occupancy verification system is to verify the location of a child on a multi-passenger vehicle by providing each child with an identification (ID) card that the child inserts into the main control cabinet on entry and egress of a multiple passenger vehicle, such as a school bus. Discrepancies in any child's location activate an indicator light and alarm alerting the bus operator to check a corresponding seat location.
A further object of the seat occupancy verification system is to verify that each child is in the seat assigned to that child by displaying this information to an operator on an attached display screen.
Yet a further object of the seat occupancy verification system is that the system may be used aboard multi-passenger vehicles. The system may also be used aboard other vehicles such as commercial busses, tour busses, airplanes, and ferry boats with equal benefits and results.
Yet another object of the seat occupancy verification system provides a main control cabinet that is located adjacent to an operator so that the main control cabinet is easily visible and physically accessible to the operator.
Another object of the seat occupancy verification system is that the system receives electric power from an onboard electrical system of the multi-passenger vehicle.
Yet a further object of the seat occupancy verification system is that the system comprises an external antenna connected to the main control cabinet that provides wireless remote access to the system.
Still a further object of the seat occupancy verification system is a quick-release mechanism that permits the main control cabinet to be rotationally pivoted by an operator to a desired position.
Yet still another object of the seat occupancy system is that the quick-release mechanism further permits the main control cabinet to be easily removed and placed in another vehicle or in another location if so desired.
Still another object of the seat occupancy system is that the electrical connections to the main control cabinet may be easily connected or disconnected through the use of dedicated connectors so that the main control cabinet may be easily disconnected form the system.
An aspect of the seat occupancy verification system comprises a main control cabinet, a plurality of sensors, a pedestal, interconnected cabling, power cabling, transmitter cabling, and an antenna.
Another aspect of the seat occupancy verification system comprises a main control cabinet further comprising a metallic rectangular control center; a mimic panel and a plurality of seat number labels corresponding directly to a particular arrangement of passenger seats and passenger locations; a card reader, an acknowledgement indicator light, a denial indicator light, and an alarm verifying seating eligibility upon conformation with an internal computerized database; a mounting post, and a plurality of fasteners, wherein the pedestal provides a conduit through which the power cable, transmitter cable, and interconnecting cables pass and are subsequently routed to the main control cabinet; and wherein the pedestal is supported and affixed to a floor surface adjacent to the operator of the multi-passenger vehicle.
User interface with the system is provided via a keyboard and electronic display screen. Power is routed via a power cable to a microprocessor such as a basic stamp controller, a programmable logic controller, a personal computer, or other similar device capable of executing various commands dependent upon certain inputs.
Yet another aspect of the seat occupancy verification system comprises a quick release mechanism. The quick-release mechanism comprises a plurality of fasteners, a locking pin, a release handle, a plurality of locking apertures, and a retaining spring.
A further aspect of the seat occupancy verification system comprises a power cable, a transmitter cable, interconnected cabling, an extension cable, a first connector, and a second connector. The power cable, transmitter cable, and interconnecting cabling are routed through the pedestal, being attached and combined to a first connector.
Yet another aspect of the seat occupancy verification system comprises a first connector, a second connector, and an extension cable that provide convenient electrical connection and disconnection of the main control cabinet to the system, thereby allowing removal of the control cabinet from the system.
Yet another aspect of the seat occupancy verification system comprises a plurality of seat sensors positioned on an underside portion of each passenger seat, providing indication to the main control cabinet that a person is present in a respective seat. The seat sensors preferably comprise common mechanical-type contact closure devices similar to those utilized in many automobile systems, although other types of mechanical and electronic switches and sensors may be provided such as, transducers, heat sensing, and ultrasonic, that provide equal benefit and function.
A further aspect of the seat occupancy verification system comprises sensors that provide various “closed” and “open” signals routed through the interconnecting cabling and collected by a signal shaping circuit which take said signals and convert them to a suitable resultant signal that can be used by the microprocessor. Additional input signals are provided from a keyboard to the microprocessor. In a similar manner, output signals are provided from the microprocessor to the electronic display screen. Output signals are also provided from the microprocessor to a light driver circuit which controls the application of power to the array of indicator lights. A number and arrangement of seat sensors would match that of the indicator lights for any one particular multi-passenger vehicle. An output signal is provided from the microprocessor to the acknowledgment indicator light, denial indicator light, and buzzer as well. An input signal is provided from the card reader to the microprocessor. Finally, a bi-directional communication path carries electrical signals between the microprocessor and transceiver modem.
BRIEF DESCRIPTION OF THE DRAWINGS
The advantages and features of the present invention will become better understood with reference to the following more detailed description and claims taken in conjunction with the accompanying drawings in which like elements are identified with like symbols and in which:
FIG. 1 is an overall perspective view of the seat occupancy verification system for motor vehicles 10 depicting a utilized state, according to the preferred embodiment of the present invention;
FIG. 2 is a front perspective view of a quick-release mechanism 26 , according to a preferred embodiment of the invention;
FIG. 3 is a section view of a main control cabinet portion 20 of a seat occupancy verification system for motor vehicles 10 , according to a preferred embodiment of the invention; and,
FIG. 4 is an electrical block schematic diagram that depicts the electrical components as used in the seat occupancy verification system for motor vehicles 10 , according to a preferred embodiment of the invention.
DESCRIPTIVE KEY
10
seat occupancy verification system
15
multi-passenger vehicle
20
main control cabinet
21
mounting post
22
fastener
23
locking aperture
25
pedestal
26
quick-release mechanism
27
locking pin
28
retaining spring
29
release handle
30
first connector
31
second connector
32
extension cable
35
power cable
40
transmitter cable
45
antenna
46
alarm
50
sensor
55
passenger seat
60
interconnecting cabling
65
mimic panel
70
indicator lights
75
seat number labels
80
card reader
82
identification (ID) card
85
acknowledgment indicator light
90
denial indicator light
95
ON/OFF switch
100
keyboard
105
display screen
110
mounting plate
120
battery
125
over current device
130
microprocessor
135
signal shaping circuit
140
light driver circuit
145
bi-directional communication path
150
transceiver modem
160
operator
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The best mode for carrying out the invention is presented in terms of its preferred embodiment, herein depicted within FIGS. 1 through 4 . However, the invention is not limited to the described embodiment, and a person skilled in the art will appreciate that many other embodiments of the invention are possible without deviating from the basic concept of the invention, and that any such work around will also fall under scope of this invention. It is envisioned that other styles and configurations of the present invention can be easily incorporated into the teachings of the present invention, and only one particular configuration shall be shown and described for purposes of clarity and disclosure and not by way of limitation of scope.
The terms “a” and “an” herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced items.
The present invention describes a system and method for a seat occupancy verification system for motor vehicles (herein described as the “system”) 10 , which monitors occupancy of seated children on school buses or other multi-passenger vehicles 15 by utilizing seat sensors 50 and an electronic card system 80 . Upon entering a bus 15 , each child provides an ID card 82 which is inserted thereinto a control cabinet 20 . In like manner, the ID card 82 is again inserted as the child exits the bus 15 , thereby accounting for a location of each child. Discrepancies in any child's location activates an indicator light 90 and an alarm 46 alerting the bus operator 160 to check a corresponding seat location 55 . Each sensor 50 is connected to a control cabinet 20 which provides an operator 160 , or assigned chaperone, displayed information for each seat assignment upon a display screen 105 .
Referring now to FIG. 1 , an overall perspective view of the system 10 depicting a utilized state, according to the preferred embodiment of the present invention is disclosed. The system 10 is used aboard a multi-passenger vehicle 15 , depicted here as a school bus having the roof cut away for purposes of illustration; however, it should be noted that other vehicles such as commercial busses, tour busses, airplanes, ferry boats, other multi-passenger vehicles, and the like, can be used with equal benefits and results, and as such, should not be interpreted as a limiting factor of the present invention. A main control cabinet 20 is located upon a floor-mounted pedestal 25 adjacent thereto an operator 160 of said multi-passenger vehicle 15 , thereby being easily visible and physically accessible. The main control cabinet 20 receives electric power therefrom a power cable 35 being connected thereto an onboard electrical system of the multi-passenger vehicle 15 . A transmitter cable 40 connects the control cabinet 20 to an external antenna 45 providing wireless remote access thereto the system 10 by others as needed. The system 10 comprises a plurality of seat sensors 50 on an underside portion of each passenger seat 55 . The sensors 50 are electrically interconnected to the main control cabinet 20 by a plurality of interconnecting cables 60 routed discreetly within a floor surface of the multi-passenger vehicle 15 . Said power cable 35 , transmitter cable 40 , and interconnecting cables 60 , are subsequently routed therewithin a pedestal portion 25 and thereinto the control cabinet 20 . In such a manner, each passenger seat 55 provides indication to the main control cabinet 20 that a person is present in a respective seat 55 (see FIGS. 2 and 3 ).
Referring next to FIG. 2 , a front perspective view of a main control cabinet portion 20 of the system 10 , according to a preferred embodiment of the invention, is disclosed. The main control cabinet 20 comprises a metallic rectangular control center approximately twenty-four (24) inches wide, twelve (12) inches high, and twelve (12) inches deep. The control cabinet 20 contains a forward facing mimic panel 65 comprising a plurality of indicator lights 70 and associated seat number labels 75 which correspond directly thereto a particular arrangement of passenger seats 55 and passenger locations on the multi-passenger vehicle 15 . A card reader 80 is provided on a side panel portion of the main control cabinet 20 such that an entering passenger to the multi-passenger vehicle 15 inserts a corresponding electronic ID card 82 verifying his or her identity and associated seat assignment. An acknowledgment indicator light 85 , a denial indicator light 90 , and the alarm 46 verifies seating eligibility upon conformation with an internal computerized database. Power thereto the system 10 is controlled by an ON/OFF switch 95 . Finally, user interface with the system 10 is provided via a keyboard 100 and electronic display screen 105 . As previously mentioned, the main control cabinet 20 is supported and affixed thereto a floor surface of the multi-passenger vehicle 15 by a pedestal 25 further comprising a mounting plate 110 and a plurality of common threaded anchoring fasteners 22 . The main control cabinet 20 is joined to the pedestal 25 using a quick-release mechanism 26 that allows the main control cabinet 20 to pivot as well as be moved from one multi-passenger vehicle 15 to another as needs require (see FIG. 3 ).
Referring now to FIG. 3 , a section view of a quick-release mechanism portion 26 of the system 10 , according to a preferred embodiment of the invention, is disclosed. The quick-release mechanism 26 comprises a securing assembly made using rugged machined or cast metal parts providing a mounting and orientation means thereto the control cabinet 20 as well as a detachment means therefrom the pedestal 25 . The quick-release mechanism 26 comprises a mounting post 21 , a plurality of fasteners 22 , a locking pin 27 , and a release handle 29 . The control cabinet 20 provides an attachment means thereto the mounting post 21 along a bottom horizontal surface using a plurality of common fasteners 22 such as bolts, screws, or the like. The mounting post 21 comprises a “T”-shaped cylindrical fixture having an upper supporting flange and a main vertical diameter suitable for insertion thereinto an interior diameter of the pedestal 25 . Said flange portion of the mounting post 21 provides a plurality of equally-spaced drilled holes therearound, thereby utilizing a normal threaded attachment thereto said control cabinet 20 using corresponding fasteners 22 in an expected manner. Insertion of the mounting post 21 thereinto a top opening of the pedestal 25 provides rotational positioning of the control cabinet 20 , thereby providing an operator 160 an effective selectable viewing angle. The quick-release mechanism 26 provides a means of locking said control cabinet 20 thereinto a desired orientation via a locking pin 27 , corresponding locking apertures 23 , and a release handle 29 . The locking pin 27 provides an inserting round pin which slidingly passes horizontally thereinto a drilled hole in the pedestal 25 and subsequently thereinto a particular locking aperture 23 located therein the mounting post 21 . The locking pin 27 further comprises a retaining spring 28 and an “L”-shaped handle 29 . In use, the handle 29 is manually pulled away from the pedestal 25 , thereby compressing the spring 28 and releasing the locking pin 27 therefrom a respective locking aperture 23 , thereby allowing re-orientation or if lifted in an upward direction, removal thereof the control cabinet 20 therefrom the pedestal 25 . The locking apertures 23 comprise a plurality of equally-spaced drilled holes approximately one (1) inch deep and arranged in a radial manner therearound the mounting post 21 , thereby enabling an operator 160 to select and secure a desired orientation of the control cabinet 20 .
Convenient electrical connection and disconnection of the control cabinet 20 therefrom the system 10 is also provided via a first connector 30 , a second connector 31 , and an extension cable 32 . The first connector 30 , a second connector 31 , and an extension cable 32 comprise commercially available electrical components providing a linear molding of multiple conductors and expected matching pairs of male and female plastic end fittings providing a rugged connection and disconnection means, thereby allowing removal of the control cabinet 20 therefrom the system 10 . As previously described, the power cable 35 , transmitter cable 40 , and interconnecting cabling 60 are routed therethrough the pedestal 25 , being attached and combined thereto the first connector 30 . The first connector 30 is mounted along an outer wall portion of the pedestal 25 subjacent thereto the quick-release mechanism 26 . Said first connector 30 provides a penetration means therethrough a wall portion of the pedestal 25 . The first connector 30 provides a female fitting portion along an external surface of the pedestal 25 providing standard electrical attachment thereto a proximal end portion of the extension cable 32 . Said extension cable 32 comprises an approximately eighteen (18) inch long section of multi-conductor cable having mating end fittings providing expected electrical attachment thereto the first 30 and second 31 connectors at proximal and distal end portions, respectively. The second connector 31 provides a standard panel-mount attachment means thereto a bottom surface of the control cabinet 20 (see FIG. 4 ).
Referring finally to FIG. 4 , an electrical block schematic diagram which depicts the electrical components as used in the system 10 , according to a preferred embodiment of the invention is disclosed. Main power is provided via a battery 120 portion of an electrical system of the multi-passenger vehicle 15 . Said power is then routed through an over current device 125 such as a fuse, whereupon it is be controlled by an ON/OFF switch 95 . Power is then routed via a power cable 35 thereto a microprocessor 130 such as a basic stamp controller, a programmable logic controller, a personal computer, or other similar device capable of executing various commands dependent upon certain inputs. The seat sensors 50 preferably comprise common mechanical-type contact closure devices similar to those utilized in many automobile systems; however, it is understood that other types of mechanical and electronic switches and sensors may be provided such as, but not limited to: transducers, heat sensing, ultrasonic, and the like, while providing equal benefit and function and as such should not be interpreted as a limiting factor of the invention 10 . Said sensors 50 provide various “closed” and “open” signals routed therethrough the interconnecting cabling 60 and collected by a signal shaping circuit 135 which take said signals and convert them to a suitable resultant signal that can be used by the microprocessor 130 . Additional input signals are provided therefrom a keyboard 100 to the microprocessor 130 . In a similar manner, output signals are provided from the microprocessor 130 to the electronic display screen 105 . Output signals are also provided from the microprocessor 130 to a light driver circuit 140 which controls the application of power to the array of indicator lights 70 . As noted previously, a number and arrangement of seat sensors 50 would match that of the indicator lights 70 for any one particular multi-passenger vehicle 15 . An output signal is provided from the microprocessor 130 to the acknowledgment indicator light 85 , denial indicator light 90 , and alarm 46 as well. An input signal is provided from the card reader 80 to the microprocessor 130 . Finally, a bi-directional communication path 145 carries electrical signals between the microprocessor 130 and transceiver modem 150 . The external antenna 45 is connected to the transceiver modem 150 by the transmitter cable 40 . In such a manner, the system 10 can be controlled from a remote location and/or data read, thereby verifying that all passengers are properly seated or removed from the multi-passenger vehicle 15 .
It is envisioned that other styles and configurations of the present invention can be easily incorporated into the teachings of the present invention, and only one particular configuration shall be shown and described for purposes of clarity and disclosure and not by way of limitation of scope.
The preferred embodiment of the present invention is envisioned to be installed therein a multi-passenger vehicle 15 by a skilled automotive electrical technician and can be utilized by the common user in a simple and effortless manner following normal operational training. After initial purchase or acquisition of the system 10 , it would be installed as indicated in FIG. 1 .
The method of installing the system 10 may be achieved by performing the following steps: installing the seat sensors 50 thereto each passenger seat 55 ; routing the interconnecting cabling 60 discreetly within a floor surface and through the pedestal 25 ; anchoring the pedestal 25 thereto a floor portion of the multi-passenger vehicle 15 adjacent thereto the operator 160 using the mounting plate 110 and provided fasteners 22 ; routing and connecting the power cable 35 thereto a suitable power source therewithin the existing electrical system of the multi-passenger vehicle 15 ; connecting the transmitter cable 40 thereto the external antenna 45 ; mounting the control cabinet 20 thereto the pedestal 25 by pulling the handle 29 outwardly; inserting the mounting post 21 thereinto a top opening of said pedestal 25 ; pivoting the control cabinet 20 thereto a desired viewing angle; releasing the handle 29 , thereby engaging the locking pin 27 thereinto an adjacent locking aperture 23 ; connecting the extension cable 32 thereto the first 30 and second 31 connectors; pressing the ON/OFF switch 95 to energize the system 10 .
The method of utilizing the system 10 may be achieved by performing the following steps: allowing passengers to enter the multi-passenger vehicle 15 in a normal manner; directing each passenger to insert an electronically readable ID card 82 in the card reader 80 , thereby transferring preprogrammed data including the passenger's name, address, seat assignment, and other critical information dependent on the specific application of the seat system 10 ; directing each passenger to then progress to an assigned seat 55 and sit down; responding to discrepancies in any child's location as indicated by the denial light 90 and alarm 46 alerting the bus operator 160 to check a corresponding seat location 55 ; responding also to said denial light 90 and/or alarm 46 should at any time during a trip onboard the multi-passenger vehicle 15 , a passenger gets up from his or her passenger seat 55 and exceeds an allowable time delay; responding also to said denial light 90 and/or alarm 46 such as in the case of a child being skipped over when scheduled to be dropped off; directing each passenger to insert their ID card 82 in the card reader 80 as they exit the multi-passenger vehicle 15 , thereby updating associated passenger status data; and, benefiting from securely monitored occupancy of seated children on school buses or other multi-passenger vehicles 15 using the present invention 10 .
Should electronic ID cards 82 not be used, the keyboard 100 and electronic display screen 105 can be used to manually input passenger parameter data. In the case of a school bus, the system 10 serves as a supplemental warning system, in addition to visual verification, should a sleeping child be left behind. As previously described, the system 10 can be monitored remotely through use of the external antenna 45 should it be necessary.
The foregoing descriptions of specific embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention and method of use to the precise forms disclosed. Obviously many modifications and variations are possible in light of the above teaching. The embodiment was chosen and described in order to best explain the principles of the invention and its practical application, and to thereby enable others skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated. It is understood that various omissions or substitutions of equivalents are contemplated as circumstance may suggest or render expedient, but is intended to cover the application or implementation without departing from the spirit or scope of the claims of the present invention. | A system and methodology utilizing seat sensors and an electronic card system that monitors the location of children on a bus as well as preventing children from being left behind, is herein disclosed. As the child enters the bus, the child would insert a personalized identification card, thereby recording the child's seat location and presence. Upon exiting, the child again inserts the identification card and following a prescribed time interval, a warning light and alarm would be activated if the seat remains occupied, thus alerting the bus driver to check the seat location. Every bus seat would have an integral weight sensor electrically connected to a main control panel. The system provides the bus driver, or assigned chaperone, a pushbutton selection array corresponding to each seat assignment. | 6 |
BACKGROUND OF THE INVENTION
The present invention relates generally to methods and systems of predicting fatigue life in metal alloys, and more particularly to using probabilistic models and high cycle fatigue behavior for predicting very high cycle fatigue life in aluminum and related metals. Even more particularly, the invention relates to predicting fatigue life in cast aluminum alloy objects at very high cycle fatigue levels.
The increased demand for improving fuel efficiency in automotive design includes an emphasis on reducing component mass through the use of lightweight materials in the construction of vehicle component parts, including in the powertrain and related componentry. Cast lightweight non-ferrous alloys in general, and aluminum alloys in particular are increasingly being used in, but are not limited to engine blocks, cylinder heads, pistons, intake manifolds, brackets, housings, wheels, chassis, and suspension systems. In addition to making such components lighter, the use of casting and related scalable processes helps to keep production costs low.
As many of the applications of cast aluminum and other lightweight metal alloys in vehicle components involve very high cycle (generally, more than 10 8 cycles, and often associated with between 10 9 and 10 11 cycles) loading, the fatigue properties, particularly the very high cycle fatigue (VHCF) properties, of the alloys are critical design criteria for these structural applications. Fatigue properties of cast aluminum components are strongly dependent upon discontinuities (that often initiate fatigue cracks), such as voids and related porosity, or oxide films or the like, that are produced during casting. Moreover, the probability of having a casting discontinuity in a given portion of the casting depends on many factors, including melt quality, alloy composition, casting geometry and solidification conditions. Given these factors, as well as inherent nonhomogeneities of the material, it can be appreciated that the nature of fatigue is probabilistic, where prediction of expected behavior over a range of loads is more meaningful that trying to establish a precise, reproducible fatigue value.
Despite this, there are factors that provide good indicators of fatigue behavior. For example, cracks readily initiate from large discontinuities that are located near or at the free surface of components and are subjected to cyclic loading, and the size of such cracking is important to determining the fatigue life of a component. As a general proposition, the resulting fatigue strength for a given number of cycles to failure, or life for a given load, is inversely proportional to the size of the discontinuities that initiate fatigue cracks.
One particular form of fatigue, known as high cycle fatigue (HCF), is concerned with the repeated application of cyclic stresses for a large number of times. The most commonly-cited value for such large number of times is about ten million (10 7 ). The suitability of many structural materials (for example, ferrous-based and non-ferrous based alloys) for use in components and applications where HCF is a concern is often measured by familiar means, such as from the data in well-known S-N curves, examples of which are shown in FIGS. 1 and 2A where the number of completely reversed stress cycles that the material will survive decreases with an increase in stress level. Referring with particularity to FIG. 1 , the fatigue strengths and corresponding S-N curves for many materials (for example, ferrous-based alloys) have a tendency to flatten out above a certain number of cycles at a stress known as the endurance limit. In general, the endurance limit is the maximum stress that may be applied to the material through an indefinite number of such completely reversed cycles without failure.
Unfortunately, aluminum-based alloys (also shown in FIG. 1 ) do not show a clearly-defined endurance limit, instead exhibiting successively lower levels of allowable cyclic stresses, for fatigue lives in the millions to trillions of cycles. Such alloys are considered to be generally not possessive of an endurance limit, or if possessive of one, are such that the endurance limit is not generally discernable or readily quantified. In either event, it is difficult to determine an appropriate design strength (under cyclic loading) and related material properties of cast aluminum alloys beyond either the HCF limit or those associated with very high cycle fatigue (VHCF, typically from about 10 8 to 10 11 or more cycles). Since long-term properties of components made from such alloys are critical to their success and are considered to be important design criteria for these components in structural applications, additional methods of determining strength and related properties for cast aluminum alloys in a manner generally similar to that used to predict the fatigue behavior of ferrous-based alloys are desired.
The well-known Wöhler test (the results of which can be used to produce the aforementioned S-N curve) and staircase fatigue test (the results of which are depicted in FIG. 2B ) are commonly used to characterize the fatigue properties of materials for conventional HCF (e.g. 10 7 ) life cycles. The statistical analysis of the results of these two fatigue tests is usually based on the assumption that the fatigue strength is normally distributed. As a result, the results generally agree for estimations of median fatigue strength, but show significant differences (up to, for example, a factor of two) in their standard deviation. One of the disadvantages of the staircase fatigue test is that the fatigue strength tested and calculated is restricted to a fixed number of cycles (for example, around 10 4 cycles for low cycle fatigue (LCF), and 10 7 cycles for HCF). In comparison with the staircase fatigue test, the S-N curve from the Wöhler test can offer fatigue strengths at different numbers of cycles to fracture. Whether using Wöhler or staircase testing, conventional servo-hydraulic fatigue testing systems operate at nominal frequencies of no more than a hundred or so cycles per second, making it time-wise impractical to generate S-N or related curves for VHCF applications, where 10 8 through 10 11 (or more) cycles are experienced. Accordingly, it would be desirable to be able to estimate strength and related material properties of cast aluminum alloys beyond the HCF limit, including the VHCF range.
BRIEF SUMMARY OF THE INVENTION
These desires are met by the present invention, wherein improved methods and systems that employ probabilistic approaches to estimate VHCF properties of cast aluminum and other non-ferrous alloys are disclosed. These approaches can be based on S-N and staircase fatigue data for conventional HCF (i.e., up to about 10 7 cycles) and discontinuity and microstructure constituent populations in the materials of interest.
In accordance with a first aspect of the present invention, a method is used for predicting VHCF strength for a metal alloy. The method includes selecting an alloy where at least one fatigue crack initiation site is presumed or determined to be present and where the alloy is generally not possessive of an identifiable endurance limit. The method further includes inputting a discontinuity or microstructure constituent size representative of the fatigue crack initiation site. From that, the method can be used to calculate VHCF strength and an infinite life fatigue strength based on a modified random fatigue limit (MRFL) model.
Optionally, the MRFL model includes using Eqn. 2, discussed in more detail below. In a more particular version, the size of the discontinuity or microstructure constituent that initiates fatigue cracking is introduced in the model. This extends the MRFL model to be applicable to the same material but with different discontinuity and microstructure constituent populations. In a particular form, the metal alloy comprises a cast aluminum alloy. It will be appreciated by those skilled in the art that other non-ferrous metal alloys can be used, including wrought and related non-cast alloys, as well as those of other non-ferrous metals, such as magnesium. In another option, one or more fatigue crack initiation sites are determined by at least one of direct measurement and analytical prediction, where the direct measurement is selected from one of X-ray computed tomography, single and serial sectioning metallography, fractography or related methods. In another option, the infinite life fatigue limit follows a distribution according to Eqn. 3 that is discussed in more detail below. In an even more particular option, the size of the discontinuity or microstructure constituent follows a generalized extreme value distribution according to Eqn. 4 as discussed in more detail below. The present inventors have additionally discovered that fatigue performance of a given volume element in a cast aluminum component is controlled by extremes in the discontinuity and microstructure constituent size, and as such may benefit from the use of Extreme Value Statistics (EVS) in making predictions about the fatigue life of aluminum-based alloys. In situations where the fatigue life of the alloy extends beyond conventional HCF values and into the VHCF regime (for example, at least 10 8 cycles), the applied stress is also used as a VHCF strength from Eqn. 2, discussed in more detail below.
In accordance with a second aspect of the present invention, an article of manufacture useable to predict fatigue life in metal castings is disclosed. The article of manufacture comprises a computer-usable medium having computer-executable instructions adapted to such fatigue life predictions. The computer-executable instructions comprise equations used to determine fatigue life properties based upon various constants, input conditions and nature of a fatigue-inducing condition. The article is particularly well-suited for predicting VHCF fatigue life, where an endurance limit associated with a metal casting is either not existent or not readily identifiable. In the present context, an endurance limit is considered non-existent when there is no substantially fixed maximum stress level below which a material can endure a substantially infinite number of stress cycles without failing. Likewise, the endurance limit is not readily identifiable if after a large number of stress cycles, an appropriate measure (for example, an S-N curve) does not reveal a substantially constant maximum stress level.
Optionally, the computer-readable program code portion for calculating the VHCF strength comprises using a generalized extreme value distribution in conjunction with the equations associated with the MRFL model.
In accordance with a third aspect of the present invention, an apparatus for predicting VHCF life in a metal alloy is disclosed. The apparatus includes a computing device such as discussed in the previous aspect, and may additionally include sample sensing equipment examples of which may include fatigue measuring components, as well as components capable of inducing and measuring tension, compression, impact and hardness properties of various structural materials under precisely controlled conditions. Such equipment (many examples of which are commercially available) may be operatively coupled to the computing device such that sensed data taken from the equipment can be operated upon by computer-readable software to, among other things, calculate fatigue properties of the sampled alloy. In other forms, the sample sensing equipment may be a sensor configured to identify discontinuities, cracks and related flaws that may serve as fatigue crack initiation sites. Such equipment may operate using machine vision or any other method known to those skilled in the art to detect such defects. The computing member includes program code to effect calculations of infinite life fatigue strengths based on one or more of the equations discussed below.
Optionally, the program further comprises at least one extreme value statistical algorithm to estimate an upper bound initiation site size expected to occur in the alloy. The code portion for calculating the infinite life fatigue strength comprises using the MRFL equations.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
The following detailed description of the present invention can be best understood when read in conjunction with the following figures:
FIG. 1 shows a representative S-N plot for both a ferrous alloy and an aluminum alloy;
FIG. 2A shows a plot of data for an S-N test on a cast A356 aluminum alloy;
FIG. 2B shows a plot of data and procedure for a staircase fatigue test on a cast A356 aluminum alloy;
FIG. 3 shows a generalized extreme value distribution of porosity size characterized by the pore area for a cast A356 sample;
FIG. 4 shows an estimation of VHCF for a lost foam casting of A356 aluminum alloy using a MRFL model according to an embodiment of the present invention, as well as a comparison to the S-N data of FIG. 2A ; and
FIG. 5 shows an article of manufacture incorporating an algorithm employing one or more of the equations used in the MRFL model.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring with particularity to FIG. 4 , the MRFL model is used to predict the fatigue strengths of cast aluminum components for very long lives (10 8 cycles and higher). The MRFL model proposed in this invention is based on an earlier random fatigue limit model where the finite fatigue lives can be calculated as follows:
ln( N f )= B 0 +B 1 ln( S a −S L )+ξ (1)
where ξ represents the scatter in fatigue lives, B 1 and B 1 are constants, and S L is the infinite fatigue limit of the specimen.
For a given stress state, the scatter of the fatigue lives of cast aluminum components is believed to be mainly related to the presence of discontinuities and microstructure constituents in general, and in particular to their sizes. As such, the present inventors felt that the random fatigue limit model of Eqn. 1 should be modified to incorporate the discontinuity and microstructure constituent sizes, thereby improving model accuracy and applicability to cast aluminum alloys. Eqn. 2 is a representation of how the random fatigue limit model of Eqn. 1 should be modified:
ln( a i α N f )= C 0 +C 1 ln(σ a −σ L ) (2)
where C 0 and C 1 are empirical constants, α is a constant (in the range of 1-10), σ a is the applied stress, and a i is the size of the discontinuity or microstructure constituent at which the fatigue crack nucleates. In this invention, the a i is assumed to be equal to the defect size in the case of a volume containing a defect, to the second phase particle size, or to the size of the mean free path in the aluminum matrix. As with the value S L in Eqn. 1, σ L is the infinite life fatigue limit of the specimen. The present inventors believe that the infinite life fatigue limit σ L will follow a Weibull distribution given by Eqn. (3):
P = 1 - exp ( - σ L σ 0 ) β ( 3 )
where P is the probability of failure at an infinite number of cycles, and σ 0 and β are the Weibull parameters for the infinite life fatigue limit distribution.
In comparison with the earlier random fatigue limit model of Eqn. 1, the MRFL model of Eqn. 2 is not only more physically sound, but also more accurate in life prediction. For example, while the model constants in the earlier random fatigue limit model of Eqn. 1 have to be refitted when the discontinuity and material constituents change, even for the same alloy and material, no such change is needed in the MRFL model. Specifically, the model constants do not need to change for different populations of discontinuity and microstructure constituents in the same material and alloy. This is advantageous in that the discontinuity population can vary with normal process variation, such as seasonal humidity changes that affect the amount of hydrogen dissolved in the liquid aluminum, which in turn impacts the size of pores in the solidified component.
Referring to methods to estimate the parameters of a statistical distribution from a set of data, the Maximum Likelihood (ML) method is used by the inventors because of its good statistical properties. The main advantages of the ML method are the ability to correctly treat censored data and the fact that any distribution can be used (as long as the likelihood equations are known). The likelihood equations are functions of the experimental data and the unknown parameters that define the distribution.
In a staircase fatigue test, for instance, if a specimen tested at stress amplitude σ a does not fail after, say, 10 7 cycles, it can be assumed that the fatigue strength for this specimen is certainly higher than σ a . If the specimen fails, however, then the fatigue strength should be lower than σ a . If F(σ a i {p}) is the cumulative density function for the distribution chosen to represent the fatigue strength variability in the staircase test, then the likelihood function for the staircase tests is defined as
L = ∏ i = 1 n F ( σ a i , { p } ) · ∏ j = 1 m [ 1 - F ( σ a j , { p } ) ] ( 4 )
where n corresponds to the number of failed specimens and m is the number of runouts, {p} are the parameters that define the fatigue strength distribution for the specified number of cycles. In S-N tests, the likelihood of fatigue life for a given stress amplitude σ a can be defined as follows:
L = ∏ i = 1 n f ( N F i , { p } ) · ∏ j = 1 m [ 1 - F ( N R j , { p } ) ] ( 5 )
where n corresponds to the number of failed specimens and m is the number of runouts, f(N F i , {p}) is the probability density function, F(N R j , {p}) is the cumulative density function, and {p} are the parameters that define the fatigue life distribution for a given applied stress.
Referring next to probability of the size of discontinuity and microstructure constituents (a i in Eqn. 2) in a cast aluminum object, a generalized extreme value distribution is used. It is well known that fatigue cracks initiate at the largest “weak link” feature in the volume of material exposed to cyclic stress. Therefore when choosing the scale of fatigue crack initiator candidates, the upper bound of the available population should be considered. This is accomplished by estimating the upper bound using various EVS methods, or by directly measuring crack initiation sites which are themselves representative of the upper bound of the available population in a given volume. A representation of how the size of discontinuity or microstructure constituents follows a generalized extreme value distribution (GEVD) when the measurements were made directly from the crack initiation sites is as follows:
P = exp ( - ( 1 + c ( a i - μ a 0 ) ) - 1 c ) ( 6 )
where c, a 0 and μ are the GEVD parameters that represent the shape and scale of the probabilistic distribution function of a i . The determination of three parameters, c, a 0 and μ is made by using the ML method. FIG. 3 shows an example of pore size (for example characterized as a i =√{square root over (pore area)}) using a GEVD for a cast A356 sample.
Metallographic techniques are widely utilized in practice to characterize casting flaws and microstructures in two dimensions (2D). With the conventional 2D metallographic data, the size distributions of casting flaws, inclusions and other microstructure features can be well described by EVS with a cumulative distribution function such as:
F ( x ) = exp ( - exp ( - x - λ δ ) ) ( 7 )
where x is the characteristic parameter of flaws or microstructural features, and λ and δ are referred to as the EVS location and the scale parameters (also referred to as distribution parameters), respectively. It will be appreciated by those skilled in the art that while Eqn. 7 is used in the present disclosure to produce a cumulative distribution function, it is merely exemplary of such functions, and other similar distribution functions can be used to best fit the experimental data.
Considering a population of flaws or microstructure features as an example, an estimate of the distribution parameters λ and δ can be made by different methods, where the most commonly used and convenient method is ordering/ranking statistics together with a linear regression. The characteristic flaw or microstructural feature parameters are ordered from the smallest to the largest with each assigned a probability based on its ranking j as follows:
F = j - 0.5 n ( 8 )
where n is the total number of data points. Eqn. 7 can be rearranged to a linear equation by twice taking its natural logarithm and transforming the parameters F(x) to ln(−ln F(x)) and the parameter x as follows:
-
ln
(
-
ln
(
F
(
x
)
)
)
=
1
δ
·
x
-
λ
δ
.
(
9
)
The EVS parameters λ and δ can then be calculated from ML, moment or least squares methods. When the sample size is small (for example, approximately 30 flaws or microstructure features), the ML method gives the most efficient estimates. For a large number of samples (for example, where n from Eqn. 8 is greater than about 50), the ML, moment, and least square methods give similar precision.
The characteristic flaw or microstructure feature parameters predicted by EVS depend on the volume of material for which the prediction is sought. The volume effect is accounted for by the return period T, where two such periods, T and T b , are considered. T accounts for the volume sampled compared to the volume of one part. The T return period of the maximal flaw or microstructure features in a given casting is usually determined by:
T = V V 0 ( 10 )
where V is the volume of a casting and V 0 is the volume of the specimen for flaw or microstructure features measurement.
Next, the volume effect is extrapolated to represent the population. The population is represented by a batch of N castings. The return period of the extreme flaw or microstructure features occurring once in a batch of N castings is:
T b =T*N (11)
Once the volume effects are accounted for, the characteristic flaw or microstructure feature parameters can be estimated using:
x ( T b ) = λ - δ ln [ - ln ( 1 - 1 T b ) ] ( 12 )
and three sigma (i.e., minimum theoretical 99.94%) estimates on the maximal flaw or microstructure feature characteristic parameter can be made. The standard deviation is estimated by the Cramer-Rao lower bound:
SD [ x ( T b ) ] = δ n · 0.60793 y 2 + 0.51404 y + 1.10866 ( 13 )
where y, which is shown as:
y = - ( ln ( 1 - 1 T b ) ) ( 14 )
is the reduced variate of EVS, and n is the number of analyzed flaws or microstructure features.
The three sigma standard deviation confidence interval of x(T b ) is given by
x ( T b )+3· SD[x ( T b )] (15)
and x+3σ estimates of the maximum flaw or microstructure feature characteristic parameter in certain number of castings is given by:
x
=
λ
-
δ
ln
[
-
ln
(
1
-
1
T
b
)
]
+
3
(
SD
[
x
(
T
b
)
]
)
.
(
16
)
EVS can estimate the maximum 3D characteristic dimensions, which are otherwise difficult and costly to obtain, from readily available 2D measurements. It will be appreciated that if actual 3D dimensions for any given portion of a casting sample are determined, EVS may not be needed.
Referring again to FIG. 4 , the predictions of the MRFL model compared with the experimental measurements in S-N curves show that incorporating discontinuity (such as porosity) size, calculated from Eqn. 6, in the MRFL model provides good fatigue property predictions, especially in the VHCF regime. Specifically, the predictions of the MRFL model compared with the experimental measurements in S-N curves show that incorporating second phase particle size estimated using Eqn. 6 in the MRFL model provides good fatigue property predictions.
Referring next to FIG. 5 , the MRFL model discussed above may be embodied in an algorithm that can be run on a computation device 200 . Computation device 200 (shown in the form of a desktop computer, but understood by those skilled in the art as also capable of being a mainframe, laptop, hand-held, cellular or other related microprocessor-controlled device) includes a central processing unit 210 , input 220 , output 230 and memory 240 , the latter of which may include random access memory (RAM) 240 A and read-only memory (ROM) 240 B, where the former generally refers to volatile, changeable memory and the latter to more permanent, non-alterable memory. With recent developments, such distinctions between RAM 240 A and ROM 240 B are becoming increasingly evanescent, and while either ROM 240 B or RAM 240 A could be used as a computer-readable medium upon which program code representative of some or all of the aforementioned fatigue life prediction equations can be run, it will be understood by those skilled in the art that when such program code is loaded into the computation device 200 for subsequent reading and operation upon by the central processing unit 210 , it will typically reside in RAM 240 A. Thus, in one preferable form, the algorithm can be configured as computer-readable software such that when loaded into memory 240 , it causes a computer to calculate fatigue life based on a user's input. The computer-readable medium containing the algorithm can additionally be introduced into computation device 200 through other portable means, such as compact disks, digital video disks, flash memory, floppy disks or the like. Regardless of the form, upon loading, the computer-readable medium includes the computer-executable instructions adapted to effect the decision-making process of the MRFL model. As will be appreciated by those skilled in the art, the computation device 200 may optionally include peripheral equipment. Moreover, the computation device 200 may form the basis for a system that can be used to predict fatigue life in aluminum castings. The system may additionally include measuring, testing and sampling equipment (not shown) such that fatigue data taken directly from a sample casting may be loaded into memory 240 or elsewhere for subsequent comparison to predicted data or the like.
While certain representative embodiments and details have been shown for purposes of illustrating the invention, it will be apparent to those skilled in the art that various changes may be made without departing from the scope of the invention, which is defined in the appended claims. | A system and method for predicting fatigue life in metal alloys for very high cycle fatigue applications. The system and method are especially useful for cast metal alloys, such as cast aluminum alloys, where a fatigue endurance limit is either non-existent or hard to discern. Fatigue properties, such as fatigue strength in the very high cycle fatigue region, are based on a modified random fatigue limit model, where the very high cycle fatigue strength and infinite life fatigue strength are refined to take into consideration the sizes of the discontinuities and microstructure constituents since the fatigue life scatter depends upon the presence of discontinuities and microstructure constituents. The sizes of the discontinuities and microstructure constituents that can initiate fatigue cracks can be determined with extreme value statistics, then input to the modified random fatigue limit model. | 6 |
BACKGROUND OF THE INVENTION
The present invention relates to a cast tubular structure, such as engine water inlet and outlet fittings or a turbocharged engine intake manifold, including an integral cast hose connection element having a hose sealing surface which, as cast, is concentric, smooth, and free of glue joint beads, parting lines, and vent opening dimples as well as to the method and tooling elements used in its manufacture.
THE PRIOR ART
Presently, cast structures, such as a water inlet or outlet fittings for a vehicle engine, including a hose connection element of the type disclosed herein, are produced by use of a lost foam casting process.
In such lost foam (evaporative pattern) casting process, patterns are produced by blowing expanded polystyrene beads into aluminum tooling elements which are typically vented on all surfaces. Steam is then injected into the cavity of the tooling elements to expand the beads so that they flatten against the tooling element surfaces and adhere to one another. After cooling, the foam pattern sections formed in this manner are ejected from the tooling elements.
Typically, the cast structure has been formed from two pattern half-sections, which are glued together, for example, when dealing with a curved structure, along a parting line running longitudinally adjacent the tubular passage thereof. A gate or gating system, comprising a piece of foam, may be formed as a separate structure which is glued to the joined foam pattern sections to form a path or orifice through which molten metal will be poured into the mold to be produced, filling the foam filled cavity of the mold during a later step in this process, after which it will become a "handle" for the cast structure, to be removed and discarded as scrap.
Such multi-component foam patterns, along with foam gating systems used therewith, are assembled with special contact adhesives. The pattern/gating assembly formed thereby is coated, usually by dipping into a permeable clay slurry coating, and then air dried (or oven dried) at 140° F. or less.
The coated pattern/gating assembly, the coating of which will line the final mold, is then positioned within a steel flask and unbonded sand is poured into the steel flask around the assembly while the flask is machine-vibrated to compact the sand and fill any hidden cavities. Part of the gating system of the mold is left protruding during this step.
After filling the flask with sand, the surface coating is removed from the protruding part of the gating, forming an orifice or path via which molten metal may be poured into the foam-filled interior of the mold within the coating. The molten metal is then poured into the mold, via the gate or gating system, vaporizing the foam pattern within the mold and allowing the molten metal to fill the mold cavity. The dried slurry coating around the foam pattern/gating assembly not only provides a mold surface which precisely duplicates the surface of the foam pattern but also prevents the molten metal from contacting the sand therearound.
Once the molten metal cools and solidifies, the formed casting is removed from the sand and the coating is removed therefrom with the gating system being removed and discarded. Since the molten metal was insulated from direct contact with the sand by the coating, embedding of sand particles into the casting surface is eliminated, and, with the exception of molding vent dimples and glue joint beads, the resultant casting surface is flat and smooth.
It will be understood that during the process described above, when blowing the polystyrene beads into the tooling element, it has been expedient to provide vent openings on all surfaces of the tooling element to allow the air used to blow the polystyrene beads into the tooling element to vent therethrough, so that the polystyrene beads are tightly packed into the tooling element. A drawback of using this expedient is that the beads tend to pack into the vent openings, resulting in raised dimples on the foam pattern surface in the location of each vent opening. Consequently, such raised dimples appear on the surface of the finished casting as well, forming potential leak paths therealong, particularly on the external hose sealing surface area of the hose connection element. Also, since the tooling elements used typically provide a two section pattern, seams or glue joint beads are also formed along the parting lines on opposite surfaces of the pattern after the sections are joined together, defining further potential leak paths, again significant in the hose sealing surface area of the hose connection element. Previously, to assure reliable sealing when the casting was subsequently installed on the engine and filled with water, either in an engine test cell or on the vehicle, such dimples, seams, and beads would have to be ground off the hose sealing surfaces of the casting. Exceesive grinding, however, can result in an out-of-round condition of the sealing surface and produce another potential leakage path.
SUMMARY OF THE INVENTION
As will be defined in greater detail hereinafter, the casting including the cast hose connection element of the present invention is formed in such a manner that vent opening dimples are only present on the inside surface of the hose connection element and further that the pattern for the hose connection element is molded separately as a single seamless unit, and is glued to the pattern sections which will eventually produce the rest of the casting. The completed pattern/gating assembly is then dipped into the clay slurry, dried and inserted into the flask for casting of the cast structure including the hose connection element of the present invention. As a result, the external hose sealing surface of the cast hose connection element, as cast, will be concentric, smooth, free of surface irregularities due to glue joints, beads, and vent opening dimples, thereby eliminating all potential leak paths.
According to the invention, there is provided a hose connection element which is cast integrally with a cast structure such as a water outlet conduit for a vehicle engine as a tubular structure having a circumferential hose retaining bead positioned slightly adjacent to the hose end thereof wherein the outer surface adjacent the bead is provided with an as cast hose sealing surface which is substantially flawless.
Further according to the invention, there is provided a set of three tooling elements used in creating a polystyrene lost foam casting pattern for a casting having an integral hose connection element. The tooling elements comprise first and second tooling elements used to create a first and second half-section patterns for a body forming portion of the cast structure, such as a water conduit, and a third hose connection forming tooling element. The first and second tooling elements are vented along all surfaces and including an annular recess along a peripheral edge thereof forming a female socket. The third tooling element comprises a cylindrical structure including an uninterrupted outer wall and an inner wall including vent openings thereon, the outer wall further including an annular protuberance disposed thereon adjacent one end thereof. The parting line of this third tooling element lies along the crest of the area of protuberance.
Still further according to the invention, there is provided a method for lost foam casting of a cast structure including an integral hose connection element, the method including the steps of: creating two vented tooling elements used to form half-sections of a pattern of a body portion of the cast structure, each of the tooling elements including a recess forming a semicircular socket half within each pattern half-section to be molded therein to provide a circular socket seat therein of predetermined dimension when the body pattern half-sections are joined together; creating a third tooling element which will provide a pattern for the hose connection element of the cast structure, the third tooling element including vent openings only along a surface thereof defining the inner diameter of said hose connection element; blowing polystyrene foam beads into each of the three tooling elements; injecting hot steam into the three tooling elements to produce the three pattern sections to be utilized in forming the pattern of the cast structure including an integral hose connection element; joining the foam pattern half sections for the body portion and seating the pattern for the hose connection element within the circular socket seat formed by the joined pattern half-sections to create the pattern for the cast structure including integral hose connection element; creating a gating assembly and joining same to the formed pattern in an appropriate manner; coating the pattern and most of the gating assembly with a clay slurry; allowing the clay slurry to dry around the pattern/gating assembly; placing the coated pattern/gating assembly within a casting flask; filling the flask with sand, while maintaining access to the gating assembly; pouring molten metal into the area within the coating via the gating assembly, the polystyrene pattern therewithin dissolving upon contact with the molten metal; allowing the molten metal to cool within the coating; removing the cast metal structure surrounded by coating from within the flask; removing the coating from the cast structure; and removing the gating assembly from the cast structure.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and advantages of the invention will become more apparent upon reading the detailed description thereof and upon reference to the drawings, in which:
FIG. 1 is a plan view of a cast structure, such as a water inlet or outlet conduit for use in a vehicle engine, incorporating the cast hose connection element with as-cast hose sealing surface of the present invention;
FIG. 2 is a plan view partly in section of a complete foam pattern formed from three sections used in forming the slurry mold for the cast structure, including the cast hose connection element of FIG. 1;
FIG. 3 is a section of a first tooling element used to form a first body forming section of the foam pattern of FIG. 2;
FIG. 4 is a section of a second tooling element used to form a second body forming section of the foam pattern of FIG. 2; and,
FIG. 5 is a section of a third tooling element used to form the pattern section for the hose connection element of FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, there is illustrated in FIG. 1 a cast structure 10, such as a water inlet or outlet conduit for use in a vehicle engine (not shown). The cast structure 10 incorporates a body portion 12 including a mounting flange 14 at one end 16 thereof and a hose connection element 20 at the other end 22 thereof. Although the body portion 12 is illustrated in the present embodiment as curved, other body portion shapes are feasible.
As further illustrated, the outer surface 24 of the hose connection element 20 is provided with a hose sealing surface 25 between a hose retainer bead 26 disposed on the surface 24 adjacent the end 22 thereof and a hose abutment flange 28 on the body portion 12. When manufactured in accordance with the improved method of the present invention, the hose sealing surface as cast is smooth, flawless and uninterrupted by seams or dimples. In this respect, the as-cast surface of hose connection elements formed by prior art methods include glue joint beads, seams and vent opening dimples on the outer surface thereof as discussed above. Such interruptions or flaws in the hose sealing surface as cast would cause the formation of leakage paths between such flawed sealing surface and the inner surface of a hose fitted thereover and so the prior methods result in cleaning up the surface as by grinding to eliminate the flaws. A description of the prior art method of forming such cast structures is set forth above and may be used as a foundation upon which the improved method of the invention can be based.
In accordance with the invention, in order to provide a hose connection element 20 having a hose sealing surface 25 which, as cast, has no potential leakage-path-forming interruptions thereon, the hose connection element 20 is patterned as a unitary structure, eliminating glue joint beads from the external or outer surface thereof, and the tooling element forming the hose connection pattern is provided without vent openings in the wall adjacent the external hose sealing surface 25 of the element 20 so that the casting 10, integrally including the hose connection element 20, may be cast with the surface 25 as flawless as possible, without vent opening dimples therein.
Referring now to FIG. 2, there is illustrated a polystyrene pattern 50, formed in accordance with the teachings of the present invention, which is utilized to create the cast structure 10. Unlike previous casting patterns of this type, the pattern 50 is formed from three sections, not two. The body portion of pattern 50 is formed from two mating (along line 51) curved semicylindrical body pattern sections 52 and 54, including mounting flange halves 53 and 55 respectively on one end, with a pattern section 56 for the hose connection element 20, formed as a single, seamless structure, disposed at the other end. To provide for attachment of the hose connection element pattern section 56, each of the body pattern sections 52 and 54 is provided with half of an annular recess 60 on the inner periphery 62 at the end 64 thereof to form half of a socket within which the pattern section 56 for the hose connection element 20 will seat against abutment surface 65, as shown.
The pattern sections 52 and 54 further include a distal flange 67 flaring radially outwardly from the outer surface of each pattern section 52, 54, such flange 67 eventually forming the hose abutment flange 28 of the cast structure 10.
The pattern section 56 for the hose connection element 20 is a cylinder having an outer diameter 57 equal to the inner diameter of socket 60 in patterns 52, 54 and an inner diameter 58 preferably at least as large as the inner diameter 62 of the body portion. Adjacent an end 72 thereof, the outer diameter of pattern section 56 is provided with an annular protruberance 70 defining the hose bead 26 in the finished casting 10. Between the protruberance 70 and the opposite end, the pattern section 56 is provided with a smooth uninterrupted surface 66 corresponding to the hose sealing surface 25 in the finished casting.
After the pattern sections 52, 54, and 56 have been molded as will be described hereinafter, the two body pattern sections 52 and 54 are glued together along longitudinal end edges thereof as at 51 and the pattern section 56 for the hose connection element 20 is then seated against abutment 65 within the circular socket formed by the joined recesses 60 and glued in place, thereby forming the pattern 50 for the entire cast structure 10.
Turning now to FIGS. 3-5, which are sectional views of the tooling elements, it will be understood that the tooling elements illustrated, when viewed from an engineering standpoint, are two separable mold half dies defining the "negatives" between which the pattern sections 52, 54, and 56, the engineering "positives", will be formed. In order for air to be ventable throughout the interior hollow areas between the confines of the walls of these tooling elements to permit blowing the polystyrene beads into the cavities formed therein, vent openings are provided in the walls of each of the tooling elements. For clarity purposes, the vent openings 82 are shown only in FIG. 5.
In FIG. 3, a tooling element 80 is shown which is used to create the body foam pattern section 52 defined above. As illustrated in section, the tooling element 80 comprises a pair of mold half dies 81, 83 which are provided on all mold surfaces with vent openings. The die 83 is further provided with a projection 84 which is surrounded by a flange forming recess portion 86 in the die 81 to define the flange 64 of pattern section 52.
FIG. 4 illustrates a second tooling element 88 within which will be created the body foam pattern section 54 defined above. The tooling element 88 comprises a pair of mold half dies 87, 89 which are provided on all mold surfaces with vent openings. The die 87 is further provided with a projection 90 which is surrounded by a flange forming recessed portion 91 to define the flange 64 of pattern section 54.
In FIG. 5, there is illustrated a tooling element 92 comprising mold half dies 93, 95 which are utilized to create the pattern section 56 for the hose connection element 20 defined with reference to FIG. 2. As shown, the interior surface 94 of the mold half die 93 which defines the sealing surface portion 66 of outer diameter 57 of pattern section 56 contains no vent holes and is uninterrupted. Adjacent the lower end of die 93, the interior surface 94 further contains the upper portion of an annular depression 99 defining the protruberance 70 in the pattern section 56. The lower mold half die 95 is provided with an inner-diameter-forming cylindrical core 97 having a mold surface containing vent passages 82 opening to the hollow interior portion 100 of core 97.
The parting line PL between the mold die halves 93, 95 intersects the annular depression 99 so as to be disposed on the crest 68 of hose retainer bead forming protuberance 70 extending around the circumference of the pattern section 56, thereby eliminating any potential seam line from the hose sealing surface forming portion 66 thereof, although the inner core 97 of die 95 extends past the parting line. Accordingly, the die half 95 contains the lower portion of annular depression 99 adjacent the parting line. Additional vent openings 96 may be provided on the annular depression 99 in die 95. Optionally, vent openings or a segmented ring vent 98 could be provided in the mold die half 95 along an area against which the end edge 72 of pattern section 56 would be formed.
In this manner, an uninterrupted, flawless external hose sealing surface forming portion 66 will be provided for the pattern section 56 so that when the pattern section 56 for the hose connection element 20 is created therefrom, the as cast hose sealing surface 25 of the hose connection element 20, which duplicates the surface of the pattern section 56, will be flawless, free of glue joint beads and dimples thereon, providing an essentially leak-free hose sealing surface 25 against which a hose to be connected thereover can be sealed.
After a gating (not shown) has been glued onto the assembled pattern 50, the completed pattern-gating assembly (not shown) is then ready to be dipped into a clay slurry, dried, inserted into a casting flask, and the casting process is performed according to the prior method described above.
From the foregoing description it will be apparent that the hose connection element 20, the method of forming same, and the tooling elements 80, 88 and 92 of the present invention provide a number of advantages, some of which have been described above and others of which are inherent in the invention. Also, various modifications can be made to the hose connection element 20, method, and tooling elements 80, 88 and 92 disclosed without departing from the teachings of the present invention. Accordingly the scope of the invention is only to be limited as necessitated by the accompanying claims. | A cast tubular structure including an integral hose connection element formed thereon is produced by lost foam casting wherein a circular socket seat is formed on a pattern for a body portion of the cast tubular structure and a cylindrical pattern for the integral hose connection element is formed by a mold without vent openings on the mold surface in the area of the cyclindrical pattern corresponding to the hose sealing surface of the cast tubular structure. The pattern sections are joined with the pattern section for the hose connection element sealing within the circular socket seal formed in the body portion of the cast structure. The pattern assembly is coated with a slurry and, after drying, is placed in a casting flask. Molten metal is then poured within the coated pattern assembly dissolving the foam patterns and forming the cast tubular structure. | 5 |
BACKGROUND OF THE INVENTION
The present invention relates to hydraulic apparatus in general and more particularly to a hydraulic control apparatus comprising a hydraulic master cylinder and a hydraulic slave cylinder for operating a mechanism remotely located from the master cylinder, the hydraulic control apparatus being prefilled with hydraulic fluid and pretested prior to shipment to a motor vehicle manufacturer for installation in a motor vehicle.
It is known to prefill with hydraulic fluid a motor vehicle clutch control apparatus comprising a master cylinder, a reservoir of hydraulic fluid and a slave cylinder for operating the throw out bearing of a mechanical diaphragm spring clutch. Such prefilled hydraulic control apparatus are shown, for example, in U.S. Pat. Nos. 4,407,125, 4,599,860, 4,503,678, 4,506,507, 4,959,960, and 4,993,259, all assigned to the assignee of the present invention.
As is well known, prefilling with hydraulic fluid and pretesting hydraulic apparatus for operating motor vehicle mechanisms such as mechanical clutches presents the many advantages, for the motor vehicle manufacturer, of receiving a fully assembled mechanism comprising all of the components filled with hydraulic fluid and pretested for proper operation ready to install on a motor vehicle on the assembly line without requiring that the components be installed, separately connected by way of a flexible conduit, and filled after installation with hydraulic fluid while being purged of any atmospheric air contained in the apparatus.
Fast, efficient and accurate prefilling and testing of the hydraulic apparatus is critical to the commercialization of such prefilled controlled apparatus. Various filling and testing methods are disclosed in the above-identified patents assigned to applicant's assignee.
Specifically, in U.S. Pat. No. 4,407,125, liquid is supplied through the open top of the reservoir until the liquid bleeds out of a bleed port in the slave cylinder whereupon the filling is terminated.
In U.S. Pat. Nos. 4,506,507 and 4,503,678, a port is provided in a side wall of the reservoir, vacuum is applied to the system through the port to evacuate the system, liquid is introduced into the system through the port, and the port is thereafter sealed with a plug which serves to allow flow of hydraulic fluid out of the reservoir upon excess pressure but prevents reverse flow.
In U.S. Pat. No. 4,959,960, the apparatus is filled by the use of a filling head which is fitted into the open top of the reservoir and which includes a nozzle portion having an exterior surface enclosing a volume which approximates the volume of the diaphragm so that, following filling of the apparatus, removal of the filling head, and reinsertion of the diaphragm, the apparatus is automatically placed in the totally filled condition. In U.S. Pat. No. 4,993,259, the system is closed to substantially preclude escape of hydraulic fluid from the cylinder bore through the conduit means, a predetermined force is applied to the piston to urge the piston to move in the cylinder bore, and the magnitude of the movement of the piston in the cylinder bore in response to the predetermined force is measured to determine the acceptability or unacceptability of the unit under test.
Whereas the filling and testing methods disclosed in these patents have proven to be generally satisfactory, there continues to be a need to improve the apparatus and methodology of filling and testing to provide more reliable, less expensive, and faster filling and testing.
SUMMARY OF THE INVENTION
This invention is directed to the provision of improved method and apparatus for testing the integrity of a fluid pressure apparatus.
More specifically, this invention is directed to the provision of improved method and apparatus for filling, and testing the integrity of, a fluid pressure apparatus.
Yet more specifically, this invention is directed to the provision of an improved method and apparatus for prefilling a hydraulic control apparatus.
The invention methodology relates to the testing and filling of a fluid pressure apparatus having a fluid pressure chamber. For example, the fluid pressure apparatus may comprise a hydraulic control apparatus including a slave cylinder; a conduit connected to one end of the inlet port and the slave cylinder; a master cylinder connected at its discharge port to the other end of the conduit; and a reservoir assembly associated with the master cylinder.
According to the invention, the mass of the fluid in the chamber of the fluid pressure apparatus is gradually varied; the pressure in the chamber is noted at successive times as the mass is varied, whereby to generate successive pressure reading; a signature is created from the pressure reading; and the signature is compared to a known stored signature of a satisfactory apparatus. This methodology provides a convenient means of readily determining the integrity of the apparatus under test.
According to one aspect of the invention methodology, the step of gradually varying the mass of fluid in the chamber comprises evacuating air from the chamber to gradually reduce the pressure in the chamber. This evacuation step, which precedes the filling step, is thus utilized to test the integrity of the apparatus.
According to another aspect of the invention methodology, the step of gradually varying the mass of fluid in the chamber comprises gradually filling the chamber with a fluid. According to this aspect of the invention methodology, the filling step, following the evacuating step, is utilized to provide a further determination with respect to the integrity of the apparatus.
According to a more specific aspect of the invention methodology, the step of gradually varying the mass of fluid in the chamber comprises evacuating air from the chamber to gradually reduce the pressure in the chamber, and thereafter filling the chamber with a fluid; the step of noting the pressure in the chamber at successive times comprises noting the pressure in the chamber at successive times as the chamber is evacuated and thereafter noting the pressure in the chamber at successive times as the chamber is filled; the step of creating a signature from the pressure readings comprises creating a vacuum signature as the chamber is evacuated and creating a fill signature as the chamber is thereafter filled; and the step of comparing the signature to a known storage signature comprises comparing the vacuum signature to a known stored vacuum signature and thereafter comparing the fill signature to a second known stored fill signature.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of the invention test apparatus;
FIG. 2 is a perspective somewhat diagrammatic view of the invention test apparatus;
FIGS. 3 and 4 are vacuum and pressure signatures, respectively, generated by the invention test apparatus; and
FIG. 5 is a detail view of an encoder utilized in the invention test apparatus.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The invention test apparatus 10 is intended for use in filling, and testing the integrity of, a fluid pressure apparatus having a fluid pressure chamber. For example, test apparatus 10 may be utilized to fill and test hydraulic control apparatus or assembly 12.
Hydraulic apparatus 12 includes a master cylinder 14 including a housing 16, a reservoir 18, a piston 20, and a push rod 22; a slave cylinder 24 including a housing 26, a piston 28, and a push rod 30; and a conduit 32 interconnecting the discharge end 14a of the master cylinder with the intake end 24a of the slave cylinder. Apparatus 12 may comprise, for example, a clutch control apparatus for a motor vehicle in which the apparatus is supplied to a motor vehicle manufactured in prefilled and pretested form so that the clutch control apparatus is ready for use simply by connecting the push rod 22 to the clutch pedal of the motor vehicle and associating the push rod 30 with a control lever for the clutch throw out bearing.
Test apparatus 10 includes a fixture 34, an evacuate/fill conduit 36 including a trap 36a; an evacuation system 38, a fill system 40, a scavenge system 42, and an evaluation system 44.
Fixture 34 is configured to hold the housing 16 of master cylinder 14 so as to preclude movement of the master cylinder during the test procedure.
Evacuate/fill conduit 36 includes a free or distal end 36b communicating with reservoir 18 and another end 36c.
Evacuation system 38 includes a conduit 46, a conduit 48 connecting with conduit 46 and with the other end 36c of conduit 36, a pair of solenoid valves 50 and 52 interposed serially in conduit 46, a vacuum pump 54 communicating with the distal end of conduit 46, and a trap 56 interposed between solenoid valve 52 and vacuum pump 54.
Fill system 40 includes an oil cylinder 58 including a piston 60, an air cylinder 62 including a piston 64, a connecting rod 66 connecting pistons 60 and 64, a linear incremental optical encoder 68 including a sensor 70 mounted on connecting rod 66 and a fixed optical bar 71 positioned in a gap 70a of the sensor, a conduit 72 communicating with one end of the oil cylinder, a conduit 74 extending between conduit 72 and one end of conduit 48, a solenoid valve 76 in conduit 74, a check valve 78 in conduit 48, a conduit 79 connecting with the upper end of conduit 72, and a solenoid valve 80 interposed in conduit 79.
Scavenge system 42 includes a conduit 81 connected to the other end of conduit 48, a solenoid valve 82 interposed in conduit 81, and a scavenge pump 84 connected to the distal or free end 81a of conduit 81.
Evaluation system 44 includes a transducer 86, an A/D converter 87, a clock 88, a signature generator 90, a computer 92, a comparator 94, a printer 96, and leads 98, 100, 102, 104, 106, 108, 110 and 112.
Transducer 86 may take any of several well known forms and, for example, may comprise a unit available from DCT Instruments of Columbus, Ohio, as Part No. PTG15VB. Transducer 86 includes a probe 86a communicating with test/fill conduit 36 and operative to sense the pressure in the conduit 36 at all times. Transducer 86 functions in known manner to convert the pressure signal sensed by the probe 86a to an output analog electrical signal on lead 98 having a magnitude proportioned to the magnitude of the sensed pressure signal.
A/D convertor 87 receives the analog signal on lead 98 and converts the analog signal in known manner to a corresponding digital signal for further transmission on lead 111.
Clock 88 is of known form and functions to emit a clocking or time pulsed signal at selected periodic intervals.
Signature generator 90 functions to generate a first signature 114 comprising an evacuation or vacuum signature and a second signature 116 comprising a pressure or fill signature 116.
Comparator 94 functions to store signatures corresponding to known satisfactory apparatus 12 and, specifically, stores a first vacuum signature 118 corresponding generally to signature 114 and a second fill signature 120 corresponding generally to fill signature 116. Signatures 118 and 120 are stored in computer 92 by testing a plurality of known satisfactory apparatus 12 to generate satisfactory evacuate and fill signatures.
Comparator 94 receives signatures 114/116 from generator 90 on lead 106 and signatures 118/120 from computer 92 on lead 110, compares the respective signatures and make decisions with respect to the acceptability or unacceptability of the apparatus under test based on the extent to which the signatures generated by generator 90 correspond to the stored signatures in computer 92. A light console 122 on comparator 94 includes a yellow light 122a indicating that a test is in progress, a green light 122b indicating that the unit under test is satisfactory, and a red light 122c indicating that the unit under test is unsatisfactory.
Printer 96 communicates with comparator 94 via lead 108 and functions, upon a signal from comparator 94, to print a detachable label 124 for securement to the defective apparatus. Specifically, when the comparator 94 determines that an apparatus under test is unsatisfactory it generates a signal via lead 108 for transmission to printer 96 whereupon the printer functions to print out a label 124 for securement to the failed apparatus. The information generated by comparator 94 with respect to each failed unit includes not only the fact that the unit has failed but also the specific nature of the defect causing the failure. Label 124 generated by printer 96 embodies a number or letter code identifying the specific defect of the apparatus.
OPERATION
In the operation of the invention test apparatus, control apparatus or assembly 12 is received at the test apparatus 10 following assembly of the control assembly 12 in known manner on a production line basis. As each control assembly 12 is received at the test station, the master cylinder 14 of the assembly is fixedly secured in the fixture 34, the distal end 36b of evacuate/fill conduit 36 is inserted into the reservoir of the master cylinder, and the push rod 30 of the slave cylinder is held in a contracted position by the utilization of, for example, a shipping strap 126.
With valves 76 and 82 closed and valves 50 and 52 open, vacuum pump 54 is actuated so as to begin to suck air out of the apparatus 12 via conduits 46, 48 and 36. As the air is sucked out of the pressure chambers of the apparatus 12 the pressure in the conduit drops gradually and this pressure is constantly sensed by transducer 86 so that transducer 86 generates a continuous but gradually dropping analog electrical signal on lead 98 for transmittal to A/D convertor 87 where the analog signal on line 98 is converted to a corresponding digital signal whereafter the digital signal is mixed with a clock signal on line 102 and the combined signal is fed to generator 90 to generate vacuum signature 114, best seen in FIG. 3.
In overview, signature 114 comprises a plot of pressure versus time, begins at approximately atmospheric or 14.7 psi, and gradually drops as air is exhausted from the pressure chambers of the apparatus 12, reaching a final value of approximately 0.002 psi after a time lapse of for example 12 seconds.
Critical and telltale points on the signature curve include the shape of the entry knee 114a, the location of the outgassing blip 114b (indicating the release of volatiles or air trapped in pores of the cylinders under test), the slope of the signature line in the region 114c, and the specific location of the diffusion point 114d (the point at which there is no longer enough pressure in the system to push air out). The vacuum signature is transmitted in progress by lead 106 to comparator 94 and the comparable portion of the stored vacuum signal 118 in the computer 92 is gradually and simultaneously transmitted via lead 110 to the comparator 94 so that the instantaneous and progressively developing signature from the assembly under test and the stored signature of a proper assembly are gradually and simultaneously displayed and compared.
Although a decision with respect to the acceptability or unacceptability of the assembly under test may be deferred until the full signature has been developed and compared to the full stored signature, it is preferable, in the interest of saving time and money, to compare the two signatures at a plurality of points marking the respective conclusion of local graph sections such, for example, as the graph sections A, B, C and D seen in FIG. 3.
Thus the instantaneously generated signature and the stored signature may be compared at the end of graph section A after approximately three seconds of test. If the comparison reveals a discrepancy indicative of a defect, the test is immediately aborted and the test assembly is rejected. The operator is apprised of the rejection by illumination of the red light 122c on the light console 122 and the operator is precluded from releasing the master cylinder 14 from the test fixture 34 until he has performed an act, such as pressing a button or moving a lever, to indicate that he has noticed the red light and has therefore noticed that the unit under test is defective. At the same time that the defect is noted by the comparison taking place in the comparator 94, a signal is transmitted from the comparator to the printer, indicating that a defect has been noted and indicating the precise nature of the defect, and the printer 96 thereupon prints a label 124 indicating by letter or by number the nature of the defect, which label may be detached by the operator and positioned on the defective assembly to facilitate repair of the assembly for subsequent retesting.
If the comparison of sections A of the instantaneous and stored signatures does not reveal a defect, the test is continued and proceeds through section B. At the conclusion of section B, an instantaneous and stored signature are again compared, and a decision is again made with the acceptability or unacceptability of the assembly. This section by section comparison procedure continues until the test has proceeded through all four sections whereupon, assuming that the test assembly has passed at each comparison at the end of each section, the green light 122B is illuminated to apprise the operator that the assembly has passed the vacuum test. At such time as the test assembly is determined to have a defect, the exact nature of the defect may then be ascertained utilizing a lookup table incorporated in the comparator and/or the computer.
Defects that may be identified utilizing signature section A include gross part leaks and blocked or skived tubes or connectors. Defects that may be identified utilizing signature section B include reversed seals in the master cylinder, damaged seals in the master cylinder, missing or wrong components in the master cylinder, defective or damaged pistons in the master cylinder, center feed problems, blocked or skived tubes, fine leaks in the master cylinder, or scratched bores in the master or slave cylinder. Defects that may be identified utilizing signature section C include fine leaks in the slave cylinder and damaged connector seals. Defects that may be identified utilizing signature section D include unknown abnormalities or anomalies and out of tolerance parts.
Once the vacuum test has been completed, and assuming that the test has not been aborted by the detection of a defect in the assembly under test, valves 50 and 52 are closed, valve 76 is opened, and air under pressure is delivered to air cylinder 62 via conduit 128 to move the piston 64 forwardly and thereby move the piston 60 of the oil cylinder forwardly to eject hydraulic fluid out of the oil cylinder. The oil leaving the oil cylinder flows through conduit 72, conduit 74, valve 76, conduit 48, and check valve 78 to conduit 36 and thereafter into the reservoir 18 to begin filling the pressure chambers of the assembly under test.
As the hydraulic fluid flows through conduit 36 into the unit under test, transducer 86 continues to sense the pressure in the conduit 36 and continues to generate an analog signal on lead 98 for transmittal to A/D convertor 87 and transmittal via lead 111 and 104 to generator 90. This signal is mixed with a digital signal on lead 112 from encoder 68 generated by movement of the sensor 70 with connecting rod 66 relative to fixed optical bar 71 as pistons 60 and 54 continue to move forwardly. Specifically, optical bar 71 includes a plurality of equally, linearly spaced slits 71a; sensor 70 includes a diode 70b and a light detector 70c positioned on opposite sides of gap 70a; and the digital signal on lead 112 from encoder 68 is generated every time a beam is completed across the gap 70a between diode 70b and detector 70c by virtue of alignment of the diode and detector with a slit 71a. The fill signature developed during the fill cycle is seen in FIG. 4 and comprises a plot of pressure versus pulses of the encoder, which are indicative of the position of piston 60 of fill cylinder 58.
With respect to the fill signature, the analog signal generated by transducer 86 is read periodically in response to triggering from the encoder 68. Specifically, encoder 68 triggers A/D converter 87 to take a reading from transducer 86 every time the encoder ends a unit of movement as sensed by the alignment of the diode/detector 70b, 70c of the sensor with a slit 71a in the optical bar. The plot seen in FIG. 4 therefore includes a plurality of points generated at the end of each unit of linear movement of the connecting rod 66 as determined by the movement of sensor 70 with respect to bar 71. The pressure sensed by the transducer 86 during the course of the fill cycle ranges from essentially zero pressure during the initial portion of the cycle to approximately 35 psi at the maximum pressure in the cycle.
Notable and significant points on the fill signature 116 include a flat introductory portion 116a indicating the filling of the conduits leading to the assembly under test; a blip 116b indicating filling of the reservoir of the master cylinder; a steep slope portion 116c indicating movement of the oil through the orifice extending between the reservoir and the bore of the master cylinder; a blip 116d indicating the start of the filling of the master cylinder; a dwell portion 116e indicating continued filling of the master cylinder; a blip 116f indicating the beginning of the filling of the conduit 32; a steep slope portion 116g indicating the continued filling of the conduit; a blip 116h indicating the start of the filling of the slave cylinder; a plateau portion 116i indicating continued filling of the slave cylinder; and a blip 116j indicating the end of the fill cycle, whereafter the pressure falls off sharply and returns essentially to atmospheric.
As with the vacuum signature, comparison of the stored fill signature 120 to the instantaneously generated fill signature 116 may be delayed until the fill cycle has been completed but, preferably, comparisons are made at the end of each of a plurality of signature sections A, B and C and the test is aborted at such time as any one of these comparisons indicates a defect.
At such time as the comparator identifies a defect, either at the conclusion of any one of the sections A, B, or C or at the conclusion of the entire fill cycle, the comparator sends a signal to the printer 96 (to print a label 124 bearing a letter or number identifying the nature of the defect for attachment to the defective assembly under test) and causes the illumination of red light 122C (to apprise the operator that the assembly under test has failed and require the operator to perform a predetermined manual acknowledging operation prior to release of the assembly under test by fixture 34).
Defects that may be identified utilizing fill signature section A include system integrity, improper reservoir, improper supply hose, reversed or damaged master cylinder seals, center feed problems, missing or improper master cylinder components, and blocked or skived tubes or master cylinder end connectors.
Defects that may be identified utilizing fill signature Section B include improper conduit between master cylinder and slave cylinder, blocked or skived conduits or slave cylinder end connector, and improper connectors.
Defects that may be identified utilizing fill signature section C include improper slave cylinder, reverse seal in the slave cylinder, damaged or defective seal in the slave cylinder, damaged or defective piston in the slave cylinder, and missing or improper components.
Once the fill cycle has been completed, valve 76 is closed, valves 80 and 82 are opened, scavenge pump 84 is actuated, and the pressurized air supply to air cylinder 62 via conduits 128 is reversed. Reversing of the pressurized air supply to air cylinder 62 causes piston 60 to retreat in air cylinder 58; opening of valve 80 allows make-up oil to flow through conduit 79 and 72 to fill in the oil cylinder behind the retreating piston; and the actuation of the scavenge pump in conjunction with the opening of valve 82 allows the scavenge pump to suck residual oil in the system out of the system in preparation for the next test cycle.
If a defect is noted at the end of any of the sections A, B, C or D of the vacuum signature or at the end of any of the sections A, B or C of the fill signature, the test is immediately terminated. The operator is apprised of the failure by virtue of illumination of the red light 122c, and the operator, after acknowledging recognition of the failure by a suitable manual act, releases the master cylinder from the fixture 34 and places the failed apparatus 12 on a conveyor line leading to a rebuild station.
At the rebuild station the operator notes the label on the failed unit and specifically notes the specific letter or number code on the label indicating the specific defect in the unit, whereby to aid the repair person in the repair procedure. Following repair of the unit, the unit is placed again on the main conveyor line leading to the test/fill station where the unit is again tested and filled, and hopefully, passed on for shipment.
In overview, it is intended that the initial vacuum test detect the vast majority of the defective units while the units are still in a dry and therefore reusable condition, and that the subsequent pressure test detect those few defective units that were not detected by the vacuum test so that only a small percentage of the defective units that are ultimately detected comprise wet units that must be discarded.
The invention method and apparatus will be seen to provide many important advantages. Specifically, as compared to other systems employed by the assignee of the present invention for testing and filling, the test is quicker and, in fact, reduces the total evacuate and fill time by approximately 50%; the apparatus required to perform the testing is smaller and therefore takes up less space on the floor of the manufacturing and testing facilities; the test is more accurate since it involves a double test wherein the vast majority of the defective units are detected in the vacuum test and the remaining defective units are detected in the following fill test; since the vast majority of the defective units are detected in the vacuum test before they have been filled, only a few of the defective units are detected after filling and therefore only a few of the defective units have to be discarded; the system can be used to find and eliminate problems in the overall procedure rather than to simply detect bad units and as such provides a means of refining and improving the assembly process rather than simply a means of eliminating bad units resulting from the assembly process; and the fixturing required to hold the units under test is greatly improved and specifically is smaller, simpler, lends itself to modular fixturing, and provides easier loading of the units into the fixtures.
Although a preferred embodiment of the invention has been illustrated and described in detail it will apparent that various changes may be made in the disclosed embodiment without departing from the scope or spirit of the invention. For example, although the invention has been illustrated and described for purposes of clarity utilizing an item of comparator hardware to perform the comparison between the instantaneous signatures and the stored signatures, it will be understood that in actual practice the comparison between the instantaneous signatures and the stored signatures may be accomplished in known manner utilizing software.
Further, although the invention has been described with respect to the testing of a hydraulic unit including a master cylinder, a slave cylinder, and an interconnecting conduit, the system is equally applicable to the testing of master cylinder units per se with or without a quick connect coupling as well as slave cylinder units per se with or without a quick connect coupling.
Further, although the invention has been herein described with respect to a test facility at the end of the production line for the hydraulic unit to be tested and filled, the method of the invention may also be applied to systems (such as clutch or brake systems) that have already been incorporated into a motor vehicle in a dry condition as part of the overall motor vehicle assembly process in which case the invention method is used to test and fill the dry units in situ on the vehicle.
In broad overview, the present invention is applicable to the testing and filling of any fluid pressure apparatus having a fluid pressure chamber. | A method and apparatus for testing and filling hydraulic assemblies such as a hydraulic clutch control assembly for a motor vehicle. A conduit is placed in communication with a pressure chamber of the assembly; air is sucked out of the pressure chamber through the conduit while a series of pressure readings are taken in the conduit indicative of the gradually declining pressure within the pressure chamber; the pressure readings are utilized to generate a vacuum signature; the vacuum signature is compared to a stored vacuum signature corresponding to an acceptable hydraulic assembly; the hydraulic assembly is accepted or rejected based on the match between the generated vacuum signature and the stored vacuum signature; assuming that the assembly is accepted, liquid is supplied through the conduit to gradually fill the pressure chamber of the assembly while taking a series of pressure readings indicative of the pressure in the chamber during the fill process; the fill pressure readings are utilized to generate a fill signature; the fill signature is compared to a stored fill signature corresponding to an acceptable assembly; and the assembly is rejected or accepted based on the correspondence between the generated fill signature and the stored fill signature. | 5 |
BACKGROUND OF THE INVENTION
The present invention is directed to a portable and compact camouflage blind used by hunters. An object of the present invention is to provide a hunter with adequate concealment during the fair chase of game whenever camouflage is necessary. The present invention may be utilized in many different ways. It may be used by an archer for concealment. In such an embodiment, it attaches directly to a compound bow used for archery. It is also contemplated that it may be used as a ground blind as a self standing unit in conjunction with a bow, a rifle or a shotgun depending on the particular hunting season.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an overall plan view illustrating the use of the present invention.
FIG. 2 is a perspective view of the present invention.
FIG. 3 is an alternate perspective view of the present invention.
FIG. 4 is another alternate perspective view of the present invention.
FIG. 5 is an alternate view of the present invention during use.
FIG. 6 illustrates an alternate embodiment of the present invention.
SUMMARY OF THE INVENTION
The present invention is directed to a hunting screen comprising of a generally rectangular first frame that comprises pivoting joints for folding into a flat position, a generally rectangular second frame adapted to be rigidly connected to the first frame whereby the second frame is adjustable in size and forms an opening through which a weapon may be fired, an adjustable mechanism connected to the second frame adapted to connect to and support a weapon to be fired and camouflage material attached to the first frame in such a manner that the opening is not thereby obstructed.
DETAILED DESCRIPTION OF THE INVENTION
The present invention will now be described in terms of the presently preferred embodiment thereof. Those of ordinary skill in the art will recognize that many obvious modifications may be made thereto without departing from the spirit or scope of the present invention.
The present invention is directed to a hunting screen 10 as illustrated in the appended drawings. In the presently preferred embodiment, the hunting screen 10 is contemplated to be approximately 36″ in high and 24″ in wide. The bow screen 10 comprises a frame 12 that may be covered with camouflage material 14 that is presently available to suit any hunting condition. The camouflage material 14 provides visual concealment for a hunter. The frame 12 is constructed of an ultra-light composite material which is both durable and weather resistant. The camouflage material 14 is sewn onto the frame 12 in such a manner that it stretches over the frame 12 and thereby allows for easy installation and removal. The hunting screen 10 further comprises an opening 16 through which the hunter will fire the weapon. The opening 16 is readily adjustable in size to suit the hunter's need.
As shown in FIG. 2 , the frame 12 is generally rectangular in shape. It is provided with a plurality of hinged joints 13 which allows the hunting screen 10 to be folded for easy transport as shown in FIG. 3 and FIG. 4 .
The opening 16 is formed by a second frame 17 that is generally rectangular is shape. The second frame 17 is rigidly connected to the frame 12 by means of posts 15 . The second frame 17 further comprises crossbars 19 . The crossbars 19 are adjustable and moveable so that the opening 16 is adjustable in size. The second frame 17 , as further explained below, is adapted in this embodiment to connect a compound bow 18 to the hunting screen 10 . The second frame 17 further comprises two swing arms 20 , which are used to connect to the weapon.
In the preferred embodiment, the hunting screen 10 is attached to the compound bow 18 by inserting the two swing arms 20 onto a forked fitting 22 . The forked fitting 22 is adapted to be threaded into the compound bow riser 29 . As is known to those of ordinary skill in the art, a bow stabilizer is usually installed into a bow screen.
Once the hunting screen 10 is attached to the compound bow 18 , the hunting screen 10 is ready for use by a hunter. In use, the hunting screen 10 will stand upright on its own, due to the points of contact 24 with the ground. A stabilizer rod 26 is connected from the hunting screen 10 to the compound bow 18 to ensure this position. A small fitting 28 is mounted to the compound bow 18 near the aiming site 30 to connect the bow 18 to the stabilizer rod 26 .
After use, the hunting screen 10 may be removed from the bow 18 by separating the swing arms 20 from the forked fitting 22 , and removing the stabilizer rod 20 from both the frame and the fitting attached to the bow. The swing arms 20 are then turned back toward the bow, so that they are out of the way for transportation. The stabilizer rod 20 can now be attached to the bow screen frame 14 by storage clips that are provided.
At this point, as shown in FIG. 5 , the compound bow 18 may be set down on the ground upon the forked fitting 22 , which remains affixed on the compound bow and the top portion of the compound bow (usually a wheel or cam wheel). This position of the compound bow 18 is a convenient way for the hunter to set it down on the ground so that none of the accessories attached to the bow become entangled with any ground debris.
The hunting screen 10 can now be folded in half at the hinge joints 13 installed on the frame 12 . It then may be carried over the hunter's shoulder with a strap 25 , for easy transportation. The folded bow screen 10 is now approximately 18″×24″ with a total weight of about one pound.
An alternative embodiment is illustrated in FIG. 6 . In this embodiment, the bow screen 100 may be used as a ground blind. The hunting screen 100 can be unfolded and locked into place by sliding four bushings 102 over folding fittings 104 . At this unfolded position the hunting screen measures approximately 24″×36″ and may be placed in such a manner to conceal a hunter.
It may also be used on it 36″ side in the semi-folded position to make it self standing. With a second bow screen, that can be clipped together, the ground blind can be set up in many different ways to suit the hunter's needs and to provide a larger concealment area. For example, the blinds can be arranged side to side, end to end, end to side etc.
Those of ordinary skill in the art will recognize that the embodiments just described merely illustrate the principles of the present invention. Many modifications may be made thereto without departing from the spirit or scope of invention as set forth in the following claims. | What is disclosed is a portable hunting screen. The hunting screen comprises a frame, camouflage material, and an opening through which a weapon can be fired. | 5 |
RELATED APPLICATION
This application is a continuation-in-part of my U.S. patent application Ser. No. 08/811,613, filed Mar. 5, 1997, now U.S. Pat. No. 5,810,664 which is, in turn, a continuation of my U.S. patent application Ser. No. 08/500,053, filed Jul. 10, 1995 (now U.S. Pat. No. 5,609,337 dated Mar. 11, 1997) which is, in turn, a continuation-in-part of my U.S. patent application Ser. No. 999,268, filed Nov. 16, 1992 for Electronic Gaming Apparatus and Method (now U.S. Pat. No. 5,377,975, dated Jan. 3, 1995) and which is, in turn, a continuation-in-part of my U.S. patent application Ser. No. 879,747, filed May 6, 1992 (now U.S. Pat. No. 5,348,299, dated Sep. 20, 1994 for Electronic Gaming Apparatus).
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates in general to certain new and useful improvements in a redeemable voucher and game ticket combination and an electronic apparatus operating as a technological aid used with the game ticket portion to play the sweepstakes promotional game and which thereby serves as an inducement to acquire the voucher and, more particularly, to a voucher and game ticket combination where game ticket of the voucher allows the play of a game simultaneously with the dispensing of the voucher and where the voucher may represent an item of utilitarian value or evidence of an expenditure, including a redeemable expenditure, such as prepaid telephone card.
2. Brief Description of Related Art
In recent years, the dispensing of various types of vouchers in order to obtain a specific good or service has become quite popular. These vouchers are dispensed from a dispensing apparatus when the user inserts a selected amount of money into the apparatus, and thereby acquires a prepaid voucher. These vouchers are effective for use by the recipient at a later time since they are prepaid, and may be redeemed to obtain a specific good or service at time of need without the necessity to pay any money at that the time of actual use. Moreover, these vouchers are also effective as gift items.
One of the effective types of voucher is a redeemable voucher, that is, one in which the voucher represents a prepaid expenditure which can redeemed for a further good or service. A simple example is a telephone card or so-called "phone card" often referred to as a "prepaid phone card". These phone cards are effective in enabling a user to pay a specified amount of money in order to acquire a ticket or voucher representing that pre-payment for subsequent use to acquire telephone access, e.g. long distance access, on that telephone without payment at the time of use. The user of the telephone card can dial a toll-free access telephone number and/or other numeric code as, for example, a personal identification (PIN) number on the card in order to obtain access through conventional telephones for a selected time period, e.g. a two minute telephone call. In another form, the voucher may be a ticket or card of utilitarian value as, for example, a collectible, e.g. collectible baseball cards.
Other types of prepaid card dispensers may permit accessing of goods as, for example, a prepaid gasoline card, to obtain a selected amount of gasoline with that card. Thus, if a user of a gasoline card is using an automobile in which gasoline is needed, and that user does not have available money on his or her person at the time, the gasoline card would be highly effective. In like manner, a telephone card is highly effective where a user may need to access a pay telephone when money is not available or otherwise, may wish to use another party's telephone without incurring telephone costs for that other party. Inasmuch as there is little governmental regulation on this type of voucher dispenser, and due to a high profit potential there is a substantial amount of competition among voucher dispensers.
In order to enhance the use of a particular operator's voucher dispenser, it has been proposed in accordance with the present invention to incorporate a promotional game, such as a sweepstakes promotional game, in connection with the dispensing of a voucher, such as a prepaid phone card. Sweepstakes are commonly used as a marketing approach to enhance the sales of a product or service. As a simple example, soft drink manufacturers may offer a sweepstakes in connection with the sale of a bottle of a soft drink. The purchaser of the soft drink will examine the underside of the soft drink bottle or the bottle cap for a sweepstakes number, and submit that number to the operator in order to determine if that purchaser won the sweepstakes. However, in order to assure that it is a true sweepstakes and not an illegal lottery activity, the entire available public is entitled to acquire a bottle cap or the like, also presenting a possibility of winning the sweepstakes without purchasing the soft drink itself. This is accomplished by merely contacting the company or the producer of that soft drink or otherwise the retailer offering that product, and requesting a bottle cap or game ticket or other game piece without requirement of a paid purchase.
There have also been various electronic games of chance which are considered to be pure random chance games, e.g. those using random number generation such as slot machines. There are other types of games of chance which are not considered to be random chance games, such as those used in the aid of the game of pull tab and, consequently, they are available for use with the general public. There are also certain electronic types of games which enable the dispensing of a ticket and also generate a display of icons or other information which appear on the dispensed ticket. Representation of such games is U.S. Pat. No. 4,373,726 to Churchill et al for an Automatic Gaming System. There are other apparatus which will verify indicia on a game ticket as, for example, that system described and illustrated in U.S. Pat. No. 4,669,729 to Solitt, et al, for a Bingo Verification System.
In the present invention, each voucher will bear voucher indicia such as information on how to redeem the voucher for a selected good or service, or otherwise indicia which may have utilitarian value, such as information about an entertainment personality. The game ticket portion will contain a game indicia which allows for the play of the promotional game, as well as a machine readable code such as a bar code which is imprinted on the voucher. The code is read by the voucher dispensing game apparatus and information is generated on a display screen corresponding to that game indicia which is presented on the game ticket portion of the voucher.
OBJECTS OF THE INVENTION
It is, therefore, one of the primary objects of the present invention to provide a combination voucher identifying an expenditure or having utilitarian value and game ticket combination where the game ticket portion automatically initiates the play of a game, such as a promotional sweepstakes game, upon acquisition of the voucher ticket combination.
It is another primary object of the present invention to provide a redeemable voucher dispensing apparatus which is capable of dispensing vouchers which can be redeemed to obtain specific goods or services and which vouchers also have a game ticket which enable the play of a game such as a promotional sweepstakes game.
In another object of the present to provide voucher and game ticket combination of the type stated in which a dispensed combination of voucher and game ticket contains certain game indicia used in the play of the game and a machine readable code representative of game indicia on the game ticket portion of the voucher.
It is further object of the present invention to provide a voucher participating apparatus which operates as a technological aid in the play of the sweepstakes game and in which game indicia on the game ticket of the voucher may be initially covered and which when uncovered, will reveal whether or not the receiver of the dispensed voucher won or scored in a sweepstakes game and which will also enable a display of game indicia related to that on the game ticket.
It is also an object of the present invention to provide an electronic voucher dispensing apparatus in which a voucher is dispensed upon introduction of a selected amount of money, and which voucher will contain voucher indicia enabling the user to use the voucher, e.g. redeem the voucher, for a selected good or service and a game ticket portion having game indicia which allows the user to play a sweepstakes promotional game associated with the dispensed voucher.
It is still another object of the present invention to provide an apparatus of the type stated which allows for dispensing of a voucher and in which the voucher is a prepaid phone card allowing for the accessing of a telephone line for a predetermined time period, and which also enables the play of a promotional game, such as a sweepstakes game.
It is still a further object of the present invention to provide an electronic or mechanical apparatus of the type stated which dispenses a redeemable voucher and an attached and removable game card allowing for the play of a promotional game and which functions as a technological aid in the play of the sweepstakes game, and which thereby enhances the use of the redeemable voucher.
It is an additional object of the present invention to provide an apparatus of the type stated which is highly attractive in that the user obtains the advantage of a play of a game in addition to obtaining a prepaid voucher.
It is another salient object of the present invention to provide a voucher which contains first indicia enabling the acquisition of a specific good or service and which also contains second indicia enabling the play of a game on the technological aid apparatus, as well as a machine readable code which enables a generation of a display of certain second indicia on a game ticket portion of the dispensed voucher by the same apparatus.
It is still a further object of the present invention to provide a method of enabling the dispensing of a voucher which also enables the play of a game, such as a sweepstakes game.
It is another salient object of the present invention to provide both a method of providing a voucher and a voucher dispensing apparatus of the type stated which can be constructed at a relatively low cost, and which is highly adaptable for the playing of a number of games in connection with the enabling of the use of a redeemable prepaid voucher.
With the above and other objects in view, my invention resides in the novel features of form, construction, arrangement and combinations of parts presently described and pointed out in the claims.
BRIEF SUMMARY OF THE INVENTION
The present invention relates in a broad aspect to a combination of a voucher having a game ticket portion which allows the automatic play of a sweepstakes promotional game upon acquisition thereof. Although the ticket portion of the voucher may be severable from the voucher as hereinafter described, it may also be integral therewith. Thus, the term "voucher" will also include the voucher and game ticket combination.
As indicated previously, the voucher may adopt the form of a coupon, or a ticket, or the like which may represent a prepaid expenditure and, therefore, gives rise to evidence of an expenditure. Thus, the voucher may adopt the form of a prepaid card or ticket, such as a prepaid phone card, which allows use of a public telephone without payment at time of use. The term "voucher" is used in a broad sense to therefore encompass coupons and ticket or the like which evidence this expenditure for a ticket which represents a prepayment for a good or service, or otherwise, for an item which has utilitarian value.
Accordingly, the term "voucher" I used herein in a broad sense to encompass any type of redeemable ticket of the type stated, as well as tickets of utilitarian value, such as substrates bearing indicia of value which adopt the form of, for example, information about popular entertainment figures, athletic figures or the like. In addition, since a redeemable coupon or the like has utilitarian value, the term "utilitarian value" is also used in a broad sense to encompass vouchers having redemption value and vouchers having intrinsic value or extrinsic value to a holder.
In one aspect of the present invention, the voucher and game ticket combination may be dispensed from a dispensing apparatus upon introduction of payment into that apparatus. In another embodiment of the invention, the voucher and game ticket combination can be purchased at a specific place of purchase as, for example, from personnel who receive payment for the voucher and personally dispense same or otherwise from a separate dispensing apparatus and where the game ticket portion may be used in a separate game playing apparatus and, upon introduction of the game ticket, will automatically play a sweepstakes game.
As indicated previously, the voucher can be effective for redemption against any of a variety of goods or services which are provided on that voucher. In each case, the voucher is specific to a specific good or service for which it may be redeemed. Otherwise, the voucher may not be redeemable and may represent the actual value for which the money is paid. As a simple example, the voucher may exist in the form of a prepaid phone card and therefore is redeemable for telephone access without depositing money into a telephone.
When a user deposits a specific sum of money into a dispenser in accordance with the present invention, that user will receive a dispensed voucher. In the case where the voucher represents the item of value, such a utilitarian item, it is not redeemable. However, where the dispensed voucher represents prepayment for a later acquired good or service, it may be redeemed at a subsequent time for the good or service. Thus, and in a preferred embodiment, the voucher may represent a prepaid phone card. This will allow the user to access a telephone for a specified amount of time in accordance with the amount of money paid. Thus, as an example, the user may pay a $1.00 amount and receive a telephone card allowing access to any telephone for, e.g., a two minute time period.
The vouchers in accordance with the present invention usually contain two parts, and the first of which is that portion of the voucher allowing the voucher to be used for acquiring a specific good or a specific service as, for example, telephone access or otherwise access to a sporting event, etc. The second part of the voucher is that of the game ticket for playing a promotional game. In effect, the promotional game is available to the purchaser of the voucher without any additional cost, as, for example, in a conventional sweepstakes. In the particular case, the general public is also entitled to acquire a game ticket without the voucher at no cost in order to engage in the play of the sweepstakes game. Nevertheless, inasmuch as the user of the voucher can automatically acquire the game ticket, this combination voucher and game ticket and the automatic play of a game when dispensed is a highly effective promotional activity which is used to entice the user to acquire that particular redeemable voucher.
The present invention provides, in a broad sense, a system which includes both a dispenser and the vouchers issued by that dispenser, as well as a dispenser, per se, and as well as the vouchers, per se. Also in a broad sense, and in another embodiment, the present invention provides two separate apparatus and one of which may function as a voucher dispenser and the second of which may be remote to the first and function as a technological aid for playing the sweepstakes promotional game. Although the vouchers may have two major components, they preferably exist on a single substrate. That substrate may or may not be severable so as to allow the game ticket portion of the voucher to be separable from the voucher portion. For this purpose, the voucher may have a score line or like line allowing separation of the two portions.
Each of the vouchers will contain two types of indicia, including a first indicia, frequently referred to as "voucher indicia", and which provides information to the user as to the means for potentially redeeming that voucher. This indicia may also provide information to the redeeming party, such as a retail store outlet, as to the value of the voucher, etc. The game ticket portion of the voucher will further contain second indicia, often referred to as "game indicia", which allows the user to play a sweepstakes promotional game in accordance with the present invention.
The use of the promotional game, such as a sweepstakes game, has been found to be highly effective in enticing potential purchasers to select a particular voucher from a dispenser available in accordance with the present invention. This dispenser also operates as a technological aid in the play of the sweepstakes game, and therefore greatly enhances the interest and excitement obtained when selecting a redeemable voucher. As indicated previously, a separate dispenser may be employed which may adopt the form of a human counterpart in place of an electronic dispensing apparatus, and a second game apparatus may be used. In this case, the player may pay for a voucher at a first dispensing apparatus and take the voucher or at least the game ticket portion of that voucher to a separate game apparatus to engage in the play of the game. In the latter case, the user inserts the game ticket into the game apparatus which will automatically inform the user as to whether or not he or she has won or otherwise scored in a sweepstakes promotional game.
Each of the game tickets or the vouchers which are dispensed in accordance with the present invention will also contain a machine-readable code, that is, a code which is not readily decipherable by visual examination. Typically, this machine-readable code exists in the form of a bar code. The bar code is related to the game indicia, and as a dispenser dispenses a voucher, a reading mechanism in the dispenser, as hereinafter described. The bar code may be one which is encrypted but nevertheless cannot be read by visual examination. Nevertheless, the apparatus will automatically read the bar code and generate a display of indicia directly related to that game indicia on the dispensed voucher and thereby aid in the play of the game.
The game indicia on the game ticket of the voucher is usually covered by a removable cover strip when the voucher is initially dispensed. Thus, when the player or receiver of the voucher removes this removable cover strip, the game indicia will inform the recipient whether or not he or she won or at least scored in the sweepstakes promotional game. Although a cover strip is not necessary, it is usually desirable. Moreover, the cover strip also provides an indication as to whether or not the voucher may have been tampered with or if someone previously attempted to remove that cover strip.
In order to conform to many governmental regulations, and particularly the regulations of certain states, the game tickets bearing the game indicia may be available without any redemption value by merely requesting, usually in writing, one of these game tickets from the provider of the sweepstakes as, for example, the operator of a prepaid phone card dispenser. In this latter case, however, the party acquiring the free game ticket will obviously not receive the voucher having prepaid value for ultimate redemption of a good or service and will otherwise not receive a voucher portion having separate utilitarian value.
Vouchers in the nature of prepaid phone cards of this type are effective in emergency situations where a user does not have the availability of a portable telephone and may not have the proper amount of coins in which to use a pay telephone. Thus, prepaid phone cards are effective in enabling the player to use any conventional telephone by merely dialing a special code available on the prepaid phone card.
In one embodiment, the dispensing apparatus contains a primary strip which can be subdivided into individual segments and where each segment contains both the voucher indicia and the game indicia thereon. However, the game ticket portion of the voucher may be separable from the remaining portion of the voucher, as indicated previously. This strip of segments may be in the form of a roll containing the segments and where each segment is capable of being separated from the roll and dispensed. The voucher containing strip also comprises a duplicate or secondary strip covering the indicia such that the indicia is not viewable until the cover strip is removed.
The apparatus further comprises means for severing a segment of the primary strip, e.g., a prepaid phone card, and dispensing the same upon actuation of the apparatus. In addition, a separate means for dispensing is provided which dispenses the substrate segment or voucher.
In order to obtain a voucher from a dispenser in accordance with the invention, the user is required to deposit the necessary amount of money in order to actuate the apparatus and receive the voucher. At no additional cost and as a promotion, the user can also play the game associated therewith. For this purpose, the dispenser is provided with a money-receiving mechanism which will read the money and permit actuation of the apparatus when a proper amount has been so deposited. The money mechanism may be in the form of a conventional coin mechanism or in the form of a bill reading and accepting mechanism used with paper currency.
The dispensing apparatus of the present invention also includes a display means for displaying the game indicia which appears on the ticket, as aforesaid. Moreover, the game indicia can be in the form of a single icon or otherwise, in the form of a group of icons, or, for that matter, the game indicia may be other types of indicia. In addition, the game indicia can be displayed on a monitor in precisely the same location and arrangement as it appears on the dispensed voucher, and in this way the apparatus further serves as the technological aid.
As also indicated previously, one embodiment of the apparatus operates with pre-cut individual vouchers. In this case, the vouchers are dispensed from a hopper containing a stack of the vouchers. Again, those vouchers having winning game indicia, if any, would be randomly distributed throughout this stack of vouchers. Upon actuation of the dispensing apparatus, an individual voucher is released from the hopper containing the vouchers and moved to a conveyor where it is then deposited in a dispensing tray. In this case, the individual voucher is also preferably provided with a removable cover sheet. If the cover sheet is removed prior to use by a player, that is an indication that someone improperly or unauthorizedly examined that particular voucher or at least the game ticket portion of the voucher. Moreover, it precludes anyone from stacking the vouchers to know the location of those vouchers containing the winning or scoring game indicia.
In still another embodiment of the invention as indicated above, a first voucher dispenser may be employed which dispenses a particular voucher and game ticket combination. The voucher or the game ticket may then be taken to a second separate apparatus which is a game playing apparatus for playing the sweepstakes promotional game. The purchaser of the voucher will insert at least the game ticket portion of the voucher into that apparatus in order to play the sweepstakes promotional game. Beyond this, the two apparatus are essentially identical in operation and function.
In another aspect of the invention, an indicia control means forms part of the apparatus and is associated with the processing means for causing the displayed indicia to be moved across the display means and selectively stopped at selected positions, so that the player of the game of chance observes an image of indicia correlated to that on the dispensed voucher.
The present invention thereby provides a unique and novel voucher and game ticket combination as well as an apparatus which serves as a technological aid and, more specifically, as an electronic aid and allows for the automatic play of the game with the game ticket of that voucher and which satisfies and fulfills all of the above-identified objects and other objects which will become more fully apparent from a consideration of the forms in which the voucher and the apparatus may be embodied. One of these forms is more fully illustrated in the accompanying drawings and described in the following detailed description of the invention. However, it should be understood that the accompanying drawings and the detailed description are set forth only for purposes of illustrating the general principles of the invention and are not to be taken in a limiting sense.
BRIEF DESCRIPTION OF THE DRAWINGS
Having thus described the invention, reference will now be made to the accompanying drawings (six sheets) in which:
FIG. 1 is a perspective view of an apparatus constructed in accordance with and embodying the present invention;
FIG. 2 is a fragmentary perspective view, partially broken away and in section, and showing the major interior components forming part of the apparatus of the invention for severing and dispensing a voucher;
FIG. 3 is a schematic side elevational view showing a portion of the voucher dispensing mechanism forming part of the apparatus of the invention;
FIG. 4 is a perspective view showing a modified form of voucher dispensing mechanism;
FIG. 5 is a perspective view of the primary and juxtaposed secondary strips;
FIG. 6 is a fragmentary perspective view of a modified form of apparatus which is capable of dispensing individual vouchers from the apparatus upon actuation thereof;
FIG. 7 is a front elevational view of one form of voucher used in the apparatus of FIG. 6;
FIG. 8 is a rear elevational view of the voucher used in the apparatus of FIG. 6;
FIG. 9 is a fragmentary elevational view showing a mechanism for using spinning wheels in the display of the present invention;
FIG. 10 is a front elevational view of an apparatus in accordance with the present invention which uses a raster pattern display member;
FIG. 11 is a schematic electrical circuit forming part of the apparatus of the present invention; and
FIG. 12 is a front elevational view of a modified form of system using a dispensing apparatus and a separate game playing apparatus in accordance with the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring now in more detail and by reference characters to the drawings which illustrate practical embodiments of the present invention, A designates one embodiment of an electronic apparatus and the associated method used therewith and which operates with voucher-ticket combinations of the invention. In particular, this embodiment of the apparatus operates in a form of a dispenser which automatically dispenses tickets and simultaneously acts as an aid in the play of a sweepstakes game in connection therewith. For this purpose, the apparatus A is often referred to as a dispensing apparatus.
The dispensing apparatus A of the invention, at least for purposes of illustration and description, is a prepaid phone card dispensing apparatus. This phone card dispensing apparatus or so-called "dispenser", will issue a redeemable voucher or coupon, which may be a phone card, allowing accessing of a telephone for a predetermined time period. Moreover, that phone card will contain the game indicia as heretofore described and as hereinafter described, for allowing the play of a promotional game, such as a promotional sweepstakes game. Although the invention is described in terms of a phone card, it should be understood that the invention is by no means so limited, and is applicable to any type of redeemable voucher which also allows for the play of a promotional sweepstakes game.
The voucher dispensing apparatus and method will be illustrated and described as a prepaid phone card dispenser and method. However, it should be understood that this apparatus and method is effective for dispensing any of the combination vouchers and game cards in accordance with the present invention. This apparatus comprises an upstanding housing 10 having a front face 12 with a display screen 14 capable of generating a display of indicia, such as numbers or symbols on vouchers having voucher substrates, as hereinafter described. The first described embodiment of the invention uses a roll or an elongate strip of the vouchers which are severed therefrom. This embodiment of the apparatus A also uses a raster pattern display screen for generating the indicia thereon.
The housing 10 can also be provided with one or more manually actuable keys 16 which enable a user to actuate the apparatus, as hereinafter described. These keys, however, are not necessary in the present invention. The keys can possibly represent various functions which the user may select and operate the keys according to the denomination of prepaid phone ticket selected, or to select a game from a multiplicity thereof.
The dispensing apparatus housing 10 is also provided with a money or currency receiver 18, which may be in the form of a coin exchanger for operating the apparatus with coins or in the form of a bill or paper currency reader. When the proper amount of money is introduced into the money receiver 18 the apparatus will be actuated to enable an actuation of the push button switches 16 and dispensing of a prepaid phone ticket.
The money receiver 18 may be either coin operated or paper currency operated, as aforesaid. In either case, these receivers are conventional in construction and therefore neither illustrated nor described in any further detail herein. However, it should be understood that the money receiver 18 is connected to a microprocessor (as hereinafter described) which primarily serves to interpret the play of the sweepstakes game and effectively operates as a communication link between the player and the apparatus. Thus, and in this case, when an appropriate amount of money has been received, an initiation signal will be sent to the microprocessor and the microprocessor will initiate an actuation signal permitting the apparatus to be operated.
The housing 10 is also provided with a discharge chute 20 for dispensing of the voucher, such as the phone cards. The phone cards which are dispensed, may be of a single denomination as for example, a one dollar denomination providing, e.g., two minutes of telephone time. In this case, the user of the apparatus will pay a total sum of one dollar. Otherwise, the apparatus could be operated so as to provide tickets of different amounts of denomination, e.g., one dollar cards, three dollar cards, five dollar cards, etc., with those tickets of increasing value providing increasing amounts of telephone time.
It should be understood that the telephone cards are only one form of voucher, as aforesaid. It should also be recognized that the term "cards" as used herein does not necessarily imply that the vouchers are limited to cardboard type stock, plastic stock, or the like. In effect, the voucher, whether or not it adopts a form of a telephone card or otherwise, can be formed of any substrate material, including paper materials, paperboard materials, thin plastic materials, and the like.
By reference to FIG. 2, it can be observed that a voucher dispensing mechanism which forms part of the apparatus is more fully illustrated. In the preferred embodiment of the invention, it is only necessary to employ one complete voucher dispensing mechanism, as hereinafter described. However, it should be understood that a plurality of side-by-side separately actuable voucher dispensing mechanisms could be provided and adapted for either sequential operation or for simultaneous operation. These other voucher dispensing mechanisms would be designed to dispense vouchers of different amounts of money value and hence, different amounts of, e.g., telephone access time.
Referring again to FIG. 2, it can be observed that the major portions of the operating mechanism 24 of this apparatus are more fully illustrated. The apparatus comprises a supply spool 26 suitably mounted on a supply spool spindle 28. The supply spool 26 is provided with a primary strip 30 (see FIG. 5) in the form of a roll, and which may be dispensed from the supply spool. The primary strip 30 is formed of a substrate material which is usually a paper or thin paper-board material, but may effectively adopt any type of rollable or bendable material such as a thin plastic strip, plasticized paper strip, or the like, as aforesaid.
The front face of the primary strip is disposed in facewise engagement with a marginally registered secondary strip 32 or so-called cover strip as shown in FIGS. 3 and 5. The supply spool 26 in the preferred embodiment is not power driven, as such. Rather, a leader strip 34 of the sequentially formed tickets unwound from the roll is driven through a drive roller 36 and an idler roller 38 which are mounted on oppositely disposed face plates 39 forming part of a dispenser mechanism housing 40. The drive roller 36 is provided at one end with a sprocket 42 and is driven by means of a drive belt 44 trained around a drive sprocket 45 on a synchronous motor 46, all as best shown in FIGS. 2 and 3 of the drawings. In this way, the strip of sequential vouchers is driven through the dispenser mechanism.
It should also be understood in accordance with the present invention that the spool 26 could also be driven and cause movement of a leader strip 34 of the individually severable vouchers, such as telephone cards. In either case, and particularly in the embodiment as shown in FIGS. 2 and 3, the motor 45 would be actuated upon proper insertion of the selected amount of money and if required according to apparatus construction, actuation of any one of the manually actuable switches 16.
The microprocessor 18 is connected to the money receiver so as to initiate a proper energization or actuation signal, when the proper amount of money has been received in the apparatus. This type of construction in which a money receiver is connected to a microprocessor to initiate actuation of an apparatus is well known.
The primary strip 30 is imprinted on its front or covered face with a plurality of first indicia, such as indicia 52, referred to as "voucher indicia", which is usually preprinted information about use of the voucher, such as the prepaid phone card, as, for example, the money denominations, a telephone number to initiate, a potential security code, e.g., PIN code, or the like. This information is provided in a relatively simple form to enable a user to initiate a telephone call which may be, for example, a long distance telephone call, without depositing any money into a pay telephone station.
The front face of the primary strip 30 is also imprinted with a plurality of second indicia 50, which may be in the form of numbers, letters, graphic symbols, or the like, and is referred to herein as "game indicia". By reference to FIG. 5, it can be seen that the first indicia 52, and the second indicia 50, for each particular voucher are each located in the individual discrete locations 54 on the primary strip 30. These discrete locations, sometimes referred to as "indicia locations", actually constitute individual voucher locations, which are ultimately severed from the primary strip and constitute the prepaid phone card or other voucher which is dispensed to the player of the apparatus.
In the embodiment as illustrated, each location 54 on the primary strip 30 is separated from the next adjacent indicia location by a pair of upper and lower horizontal lines 58. In actuality, it is not necessary for these lines to be printed on the substrate itself.
As indicated previously, one of the unique facets of the prepaid phone card dispensing apparatus or other form of voucher dispensing apparatus of the present invention is the fact that it also simultaneously enables the play of a promotional game. In this particular case, the game may adopt the form of a sweepstakes game. The indicia 50, which is the "game indicia", may be simply a sweepstakes number and in accordance with the play of this particular sweepstakes game, could potentially represent a winning or scoring number. Thus, as an example, in the sweepstakes game which is played, a number may be randomly selected corresponding to each sweepstakes voucher which has been issued and the holder of that correct number will be a winner of the sweepstakes or otherwise score in the sweepstakes.
The game which may be played in accordance with the present invention, and for that matter even the sweepstakes game, may also have other types of indicia 50, as shown in FIG. 5, for example, which may be in the nature of individual letters, graphic symbols, or the like. These indicia as shown in FIG. 5 may also adopt the form of icons, as specifically shown. Thus, these icons could represent winning combinations in a sweepstakes game or otherwise they could be used in the play of other games. It should also be understood that the voucher dispensing apparatus could be adapted for a variety of games. Thus, the user could potentially play one or more individual games along with the actuation of the apparatus and during the dispensing of a prepaid phone card or other voucher.
In the embodiment of the invention, as illustrated, each strip segment or card is shown as being separated from the next adjacent strip segment on the strip by means of the black horizontal lines 58. In actuality, there may also be score lines at the location of each of these black upper and lower lines 58 which are printed on the substrate. Further, score lines are not necessarily required and do not have to exist as true perforations since the strip itself will be cut into the individual cards or substrate sections in a manner to be hereinafter described in more detail. The primary strip 30 and the juxtaposed cover strip 32 lie in facewise contact with one another where the indicia on the front surface of the primary strip are in facewise contact with the cover strip 32. In this way, when the two strips are in such facewise contact, the game indicia in each game indicia location is essentially hidden from view.
The primary strip 30 and juxtaposed cover strip 32 are passed beneath a scanner housing 64 before entry between the drive roller 36 and the idler roller 38. In this particular arrangement, the rear face, that is, the exposed face of the primary strip 30, or otherwise the exposed face of the cover strip is disposed upwardly.
The scanner housing 64 is constructed to contain a conventional scanning element 68, such as a charge-coupled diode. However, essentially any conventional scanning element may be employed. In like manner, if desired, a light source 70 could also be located in association with the scanner housing 64 for illuminating the exposed surface of the primary strip 30 or secondary strip 32. As best shown in FIG. 4, the combined facewise disposed primary strips and secondary strips are then introduced into a cutting mechanism 72, as hereinafter described in more detail.
The rear surface of either the primary strip 30 or secondary strip 32 contains a bar code in each of the discrete separate locations, as shown in FIG. 5. In this particular case, the bar code or other machine readable code is located on the exposed surface of the secondary strip. This bar code is an identical representation of the second indicia or so-called "game indicia" 50 on each individual prepaid phone ticket. In accordance with this arrangement, the rear face of the secondary strip 32, and hence the bar code 60 thereon, will be in readable position with respect to the scanner housing 64 and particularly the charge-couple diode 69. This bar code is not readily discernable or capable of being read by visual examination. However, when properly read and converted to corresponding indicia through the microprocessor 18, that bar code is converted to indicia in a form which can be displayed. Thus, either the primary strip segment or secondary strip segment constituting each voucher will have its own individual bar code 60 corresponding to the game indicia printed on the covered surface of the primary strip 30.
The relationship between the indicia and the bar code may be recorded in a storage mechanism and which storage mechanism can form part of the microprocessor or can be connected to and accessible by the microprocessor. In any event, the microprocessor, upon recognizing the bar code, will determine the proper indicia for display. Thereafter, the game indicia is displayed on the monitor 14. In this way, the user of the apparatus will receive a prepaid phone card or other voucher as hereinafter described, and will also be able to observe on the display screen 14 the second indicia 50 contained on that ticket.
The cutting mechanism 72 can possibly be a conventional cutting mechanism of the type which is capable of severing a plastic or like sheet strip into individual segments. In the preferred embodiment of the invention, the cutting mechanism comprises a roller 73 having a pair of oppositely disposed cutting blades 74 and which are curved and angularly disposed relative to the central axis of the roller 73. Each blade 73 will initiate one complete cut of a ticket from the strip and thereafter the roller 73 will rotate to be in position for the next cutting operation by the oppositely disposed blade 74. Each of the blades 74 will bear against an anvil 75.
The cutting mechanism must be electrically operable so that it can be actuated under the control of the microprocessor to sever the strip at a proper location which constitutes an upper or lower margin of each strip segment location.
Upon energization of the cutting mechanism as, for example, by a solenoid (not shown), the roller 73 will be rotated and the blade will force the leader strip 34 into contact with the underside of the anvil 75 and thereby literally severe a strip segment or card from the remaining portion of the leader strip and thereby form a dispensable voucher. Therefore, upon receipt of a proper signal initiated through the microprocessor, the cutting mechanism 72 will be operated by the solenoid and sever the primary strip 30 into the individual strip segments or tickets. However, the microprocessor could be operated to initiate a severing or cutting signal to the cutting mechanism 72 upon the reading of a complete bar code on a particular voucher, as hereinafter described. The prepaid phone cards are thereupon allowed to deposit in the discharge chute 20 where they may be picked up by the player of the apparatus.
Depending upon the particular play of the game, the game ticket portion of the phone card having the game indicia may be mailed to the offerer of the sweepstakes for purposes of claiming the prize or the winnings of that sweepstakes. Otherwise, if the voucher is used in another form of a game, the game ticket portion of the voucher can be taken to a cashier or like individual for purposes of collecting money or other prize, if any of the game ticket portions of the vouchers carries a winning or scoring indicia thereon.
The front face of the primary strip 30 which contains the first and second indicia will actually be disposed in intimate facewise contact with the forward face of the cover strip 32. Thus, at least the second indicia, or game indicia on the primary strip will not be initially observable until the user separates the cover strip from the primary strip. The rear and exposed face of the primary strip will contain the bar code 56, as aforesaid, and this bar code is only machine readable, that is, it cannot be intelligibly read by a user or observer of the apparatus. The secondary indicia, therefore, will not be intelligible to the player or observer until the apparatus dispenses the voucher or displays the symbols corresponding to the bar code, or the user removes the cover strip from the primary strip, or both.
FIG. 4 illustrates a slightly modified form of voucher dispensing mechanism which is similar in construction and operation to the ticket dispensing mechanism illustrated in FIG. 2. In this embodiment of the invention, the only difference between the voucher dispensing mechanism of FIG. 4 is that the position of the scanner is reversed with respect to that shown in FIG. 2. In the embodiment as shown in FIG. 4, the scanner is located immediately adjacent to, but before the cutter 72 with respect to the path of movement of the vouchers. In this position, the scanner will only read the dispensed vouchers at the last possible moment before dispensing.
FIG. 6 illustrates a slightly modified form of electronic dispensing apparatus B and which is used for the dispensing of discrete, pre-cut vouchers 76, the latter of which is best illustrated in FIGS. 7 and 8 of the drawings. The apparatus B is similar in construction to the apparatus A, except that the apparatus B utilizes a hopper 78 containing the discrete vouchers 76. In this case, the hopper 78 would be provided with means for maintaining the discrete vouchers 76 in a stack such as that shown. The lower end of the hopper 78 is provided with a discharge mechanism 80 and which operates by either an electrical signal or by means of a mechanical coupling, such as the rod 82, as shown in FIG. 6. The rod 82 or otherwise an electrical signal operating in conjunction with a solenoid (not shown) would operate a discharge plate 84 in the discharge mechanism 80 to allow a discharge of a discrete voucher 76.
Each discrete voucher 76 is deposited on a conveyor belt 88 trained about drums 90 and one of which is a powered drum for rotation. The conveyor belt 88 terminates at a discharge tray 92 in which the discrete voucher 76 is dropped for collecting by a user of the dispensing apparatus.
Each of the discrete vouchers 76 is more fully illustrated in FIGS. 7 and 8, as aforesaid, and comprises a front face 94 on the primary strip 30. The front face includes the telephone indicia 52 and the game indicia 50 thereon, as shown in FIG. 7. Moreover, the indicia is covered by a removable cover 98. The removable cover 98 is designed so that once removed, it is not readily replaceable and is capable of being discarded.
The rear or exposed face 96 of the cover strip on the discrete vouchers 76 is provided with a bar code 60, as best shown in FIG. 8. It should be understood that this bar code could actually be included on the front face 94, or for that matter on the rear face of the primary cover strip, if desired. However, it has been found to be preferable to provide the bar code on the rear face of the cover strip. Furthermore, the reading mechanism in this case could be located immediately at the lower end of the discharge mechanism 80 so as to read the bar code on the discrete voucher 76.
FIG. 9 illustrates one form of display mechanism 102 of the present invention. This display mechanism 102 uses a plurality of rotating wheels 104 in which the indicia is printed on an annular peripheral face thereof, as shown. Each of these rotating wheels 104 are rotatable with respect to a shaft 106. In this case, the shaft 106 could actually constitute a plurality of concentric shafts with each disk or rotating reel 104 mounted on a separate one of the shafts. The shaft 106 or otherwise the shaft arrangement 106 is operated by a drive mechanism 108. This drive mechanism is conventional and therefore neither illustrated nor described in any detail herein.
FIG. 10 illustrates an embodiment of the invention using a raster pattern display screen 110. In this case, three rows of indicia are shown. Generally, the display will cause the various columns 112 of the indicia to rotate as, for example, in the direction as shown by the arrows in FIG. 10. In other words, the indicia are moved upwardly across the screen from the lower edge thereof to the upper edge, and in such manner as to generate an appearance of a rotating reel. Each of these columns of indicia will stop moving so that a selected row of indicia on the game ticket will be shown at the position designated as 114, usually a row midway between the upper and lower edges of the display screen 110. All three columns of indicia will have the selected second indicia within this defined row location 114.
Also in accordance with the present invention, the first or left-hand row of indicia will first start to rotate, followed by the middle column of indicia and then followed by the right-hand column of indicia. Thereafter, the first column of indicia will stop, followed shortly thereafter by the second column of indicia, and then followed shortly thereafter by the third column of indicia. This will create an illusion as though there are actually spinning wheels behind the display member.
The present invention is provided with an indicia control means which is associated with or forms part of a microprocessor used for generating the display. In this respect, the electronic switch which is involved in generating the display is quite simple. The electronics are more fully illustrated in FIG. 11. The initial determination of whether a voucher constitutes a winning or scoring voucher, whether or not it is a discrete voucher or separated from a large strip, is performed by a scanner, such as the conventional scanning element 68. This scanner 68 is capable of reading the bar code or other type of code which may be imprinted on the game ticket portion of the voucher or a secondary strip associated with the voucher, as aforesaid. For the purposes of this invention, when a code is described as being imprinted on the voucher, it will also be understood that it may as well be on the secondary strip associated with that voucher.
In any event, after the code is read by the scanner 68, the code is introduced into a microprocessor 120 which is effectively the heart of the electronic control system of the invention. This microprocessor 120 operates the voucher dispensing mechanism represented in this FIG. 11 as 122. However, it should be understood that the term "voucher dispensing mechanism" will constitute those portions of the apparatus which cause the strip to be moved and a segment severed from the strip and dispensed, if the voucher is derived from a strip of the vouchers. In like manner, the voucher dispensing mechanism may constitute that mechanism for dispensing precut individual vouchers, as previously described.
The microprocessor operates in conjunction with a read-only memory 124 which may contain the predetermined results and the actual correct winning indicia. This read-only memory 124 would operate in conjunction with a comparator 126 in order to interpret the ticket which is dispensed as a winning or scoring ticket. A response system 128 can also be caused to operate, if desired, by generating sounds or lights.
In accordance with the present invention, the bar code which exists on each voucher is read twice. In this way, the microprocessor forming part of the dispensing apparatus will determine whether or not a complete bar code has been read. If a complete bar code has not been read, then the microprocessor will cause the apparatus to stop operation. Otherwise the microprocessor could take other action, such as causing the severing of a voucher in a center portion thereof so that it immediately becomes an invalid voucher. Contrariwise, if the full bar code has been read, then the microprocessor will recognize that this is a valid bar code and a complete voucher will be dispensed.
The actual reading of the bar code occurs in two separate scanning segments. In the first scan segment, the bar code is read to determine the content for generation of indicia to be displayed on the screen. In the second scan segment, the bar code is read in order to determine whether or not it is a valid bar code and a complete voucher.
The scanning occurs in a single sweep of the voucher past the scanning head. Actually, given the time for the voucher to literally move past the scanning head, numerous scan segments can take place. When two successive scan segments have been made and find a valid bar code, the voucher is then dispensed. However, if the microprocessor does not recognize a valid bar code or otherwise, if it does not recognize a full bar code, the microprocessor will cause a cessation of movement of the vouchers and the apparatus will effectively stop operating, as aforesaid. In this way, no invalid voucher will be dispensed.
The microprocessor 120 also operates an indicia control means 130 which may form part of the microprocessor 120, or it may be operated under control of the microprocessor 120. The indicia control means causes a display of indicia on a display member 132 which may constitute either the spinning reels or the display screen. In this case, the display member 132 represents a raster pattern display screen. The indicia control means 130 will cause the monitor, such as the display screen 132, to generate images, such as the icons or other indicia, scrolling across the display screen, much in the same manner as they appear on spinning reels or disks. Again, this indicia control means will cause the display to generate this pattern under the control of the microprocessor 124.
FIG. 11 also alternatively illustrates the operation of a plurality of individual disks or wheels, such as those disks 104. However, each of the individual disks are mounted on a shaft assembly 134 which is under the control of one or more synchronous electric motors 136. Again, the connection of the shaft assembly 134 to the synchronous motor or motors 136 is only schematically illustrated, inasmuch as the exact construction is conventional and is therefore neither illustrated nor described in any further detail herein. Nevertheless, the synchronous motor or motors 136 would cause the reels or disks to rotate, much in the same manner as the wheels or disks would rotate in a conventional slot machine gaming apparatus.
It should be understood in connection with the present invention that it is not necessary to duplicate on the monitor of the apparatus, those icons or other indicia which appear on the face of the voucher after the cover strip is removed. Thus, other information in some way related to the gaming indicia could be displayed. As a simple example, the word "winner" or other information could be presented on the screen of the monitor.
The voucher dispensing apparatus and method of the present invention are highly effective, as aforesaid. In this case, the player removes the opaque cover sheet on the game ticket portion of the voucher so that he or she can examine the indicia to thereby determine if that player was or was not a winner. No player, or any other party operating the machine or anyone else, for that matter, will know what game indicia is contained on the voucher dispensed to the player until that indicia is either displayed or read from the voucher, or both.
FIG. 12 illustrates a modified form of apparatus and dispenser combination. In this case, FIG. 12 shows a separate dispenser 140 having a money mechanism 142 and a dispensing chute 144 which receives a dispensed voucher. In this case, the dispensing portion of this dispenser 140 is essentially the same as that used in the previously described embodiment of the apparatus.
A separate apparatus 146 operating as a technological aid to the play of a sweepstakes game is also provided and includes a display screen 148 similar to the screen 14 previously described. In this case, a game ticket insertion slot 150 is provided in the game apparatus 146 and is designed to receive a ticket dispensed from the separate dispenser 140. Beyond this, the two components operate in a manner similar to that previously described. Thus, the player will take the dispensed voucher, which may be in the nature of a prepaid phone card, and use the game ticket portion thereof for play of the game in the game apparatus 146.
Thus, there has been illustrated and described a unique and novel voucher and ticket combination as well as an apparatus and a method of use therefor which fulfills all of the objects and advantages which have been sought. It should be understood that many changes, modifications, variations and other uses and applications will become apparent to those skilled in the art after considering this specification and the accompanying drawings. Therefore, any and all such changes, modifications, variations and other uses and applications which do not depart from the spirit and scope of the invention are deemed to be covered by the invention. | Electronic and mechanical apparatus utilizing a voucher and game ticket combination used in the play of a sweepstakes promotional game. The voucher may represent any document, receipt, stamp, or the like which evidences an expenditure or otherwise has utilitarian value and includes a game ticket. This sweepstakes game is used as a marketing inducement to sell the voucher or coupon. Preferably, the apparatus is a dispenser which dispenses the voucher and the game ticket combination and, in so dispensing, automatically allows the play of a sweepstake game. The game ticket and the game apparatus function as an effective marketing inducement for a purchaser to acquire a particular voucher as, for example, a prepaid telephone card. In this way, the user will be able to access a telephone service. The voucher portion contains information on the use of the voucher and the game ticket portion of the voucher contains indicia relating to a play of the sweepstakes promotional game. The promotional game indicia appears on the attached game ticket and may represent a winning or scoring indicia. In addition, a bar code is present on the game ticket and as the voucher and game ticket is dispensed, the bar code is read by the apparatus and displays indicia corresponding to the sweepstakes promotional indicia on the game ticket. | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] None
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable
THE NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT
[0003] Not applicable
INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC
[0004] Not applicable
BACKGROUND OF THE INVENTION
[0005] The present invention relates generally to those surface mounted devices providing a means to releaseably secure items against a surface.
[0006] A common problem faced when attempting to store bulky or heavy items against a vertical surface such as a wall by leaning is the tendency of these items to fall forward and away from the wall if not leant at a sufficient angle. Inevitably, this means that valuable floor space is wasted trying to get the item to “stay” against the wall. Most people don't have unlimited floor space to accommodate such waste. A typical example is the case of a ladder or bicycle leant against a garage wall. One solution has been to hang the item from a peg or hook mounted on the wall. However some of these items can be too bulky or heavy for many people to lift; this is especially the case with elderly or infirm persons.
[0007] U.S. Pat. No. 3,664,163 to Foote, describes a base plate and tether for the securing of firearms, but the base plate has no swiveling capability.
[0008] U.S. Pat. No. 4,826,193 to Davis, describes a base plate, bracket and straps as a wheelchair restraint, but the straps have no swiveling capability.
[0009] U.S. Pat. No. 5,174,543 to Corson et al. describes a tip-over protection apparatus with wall mounted bracket and cord, but has no swiveling capability.
[0010] U.S. Pat. No. 6,220,562 to Konkle, describes a furniture tipping restraint with wall mounted bracket and cord, but has no swiveling capability.
[0011] U.S. Pat. No. 6,318,941 to Guenther, describes a fastening anchor assembly for fastening an object to a hollow wall, but provides a clamp as the object fastening means which limits the size and shapes of the objects to be retained.
BRIEF SUMMARY OF THE INVENTION
[0012] The present invention is a surface mountable retention system to releasably secure large, irregularly shaped or bulky items against a multiple surface types; for example drywall, masonry or wood as well as others. It enables a person to secure items tightly against a surface such as a wall or crate without having to lean the item, thus saving floor space and creating a safer environment.
[0013] In one embodiment, the device consists of a single rotatable flanged face plate with a centered aperture through which a fastener such as a wood screw or hollow wall anchor is placed to affix the plate to a surface such as a wall or crate.
[0014] The preferred as well as alternate embodiments share the common element of a rotatable flanged plate having at least two winged flanges opposing each other, each flange punctuated by a slit aperture. Once installed, a flexible strap of shear resistant material with a fastening means at its terminal ends such as male and female buckles, is threaded through the slit aperture such that the terminal ends may encircle an item and fasten together thus securing the item to the surface.
[0015] In the preferred embodiment, the invention is an assembly of two principal plates, one having winged flanges, and another that is primarily flat having a centered aperture and a formed sleeve encircling the centered aperture. The two plates are held in place by a hub which is a flanged T-shaped bushing whereby both plates are independently rotatable about the axis provided by the bushing prior to being installed on a surface.
[0016] In another embodiment, the second plate is generally planar having no raised sleeve, and the hub is a common cylindrical bushing press fit into place forming a lip at each end of the bushing sufficient to hold the two plates together yet allowing the plates to rotate independently around a common axis provided by the bushing.
[0017] In yet another embodiment, the base plate has a resilient fastener formed into the body in place of the bushing and formed sleeve of the preferred embodiment so that the two plates may be pressed together and releasably reatained in position by the resilient fastener which allows the plates to rotate independently of each other. It is envisioned that the base plate of this embodiment will be secured to a surface by an adhesive such as 3M™ Foam Tapes. Thus the means to affix this embodiment differs from the other embodiments because no screw or drywall fastener is required.
[0018] With the exception of the embodiment of the previous paragraph, the steps to install the surface mountable retention system are as follows:
[0000] If affixing to a stud, or a wood surface, the assembled present invention is placed against the surface and a wood screw of sufficient length is placed through the centered aperture and screwed into the wooden surface thus holding the retention system in place. The plate assembly should fit snug against the wall while allowing the top plate to rotate 360 degrees. One unbuckled end of the flexible strap is then threaded through the slit apertures of the top plate, and an either a male or female buckle is cinched to the strap which is then joined to its mating portion being snapped around the item to be secured.
[0019] If affixing to drywall with a typical hollow wall anchor, the expandable sleeve element of a hollow wall anchor is fitted first into the wall, followed by the plate assembly and then a threaded bolt element is passed through the centered aperture of the plate assembly and into the expandable sleeve element of the wall anchor. The plate assembly should fit snuggly against the wall while allowing the top plate to rotate 360 degrees. One unbuckled end of the flexible strap is then threaded through the slit apertures of the top plate, and an either a male or female buckle is cinched to the strap which is then joined to its mating portion being snapped around the item to be secured.
[0020] If affixing to drywall with a toggle bolt, the bolt element of the toggle bolt is first passed through the centered aperture of the plate assembly and the toggle element affixed to its terminal end. The toggle element is them placed through a pre-drilled hole in the drywall and the bolt is tightened in the customary way. The plate assembly should fit snuggly against the wall while allowing the top plate to rotate 360 degrees. One unbuckled end of the flexible strap is then threaded through the slit apertures of the top plate, and an either a male or female buckle is cinched to the strap which is then joined to its mating portion being snapped around the item to be secured.
[0021] One object of the present invention is to provide an easy means for the releasable retention of heavy or bulky items against a surface without the need to lift or hoist the item.
[0022] Another object of the present invention is to provide an easy means for the releasable retention of irregularly shaped items by providing 360 degrees of attachment.
[0023] A further object of the present invention is to provide a means to releaseably retain large items securely against a vertical surface such as a wall minimizing the required floor space.
[0024] The applicant is not aware of any previously described art having the features and advantages of the present invention.
[0025] Other objects and advantages of the present invention will become apparent from the following descriptions, taken in connection with the accompanying drawings, wherein by way of illustration and example, a preferred embodiment of the present invention is disclosed.
BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS
[0026] FIG. 1 is perspective view of one embodiment of the present invention with rotatable flanged face plate;
[0027] FIG. 2 is an exploded view of the preferred embodiment showing T-shaped bushing and base plate element;
[0028] FIG. 3 is a partial cut-away view of the stacked plate assembly of one alternate embodiment of the present invention;
[0029] FIG. 4 is perspective view of the non-flanged bushing;
[0030] FIG. 5 is perspective view of a non-flanged base plate;
[0031] FIG. 6 is an edge view of the alternate embodiment of FIG. 3 fastened to a hollow wall by a toggle bolt and the flexible belt and buckle elements;
[0032] FIG. 7 is an edge view of the assembled preferred embodiment of FIG. 2 fastened to a stud by a wood screw and the flexible belt and buckle elements;
[0033] FIG. 8 is an exploded view of an alternate embodiment of present invention;
[0034] FIG. 9 is an edge view of the assembled alternate embodiment of FIG. 8 and fastened to a surface by way of an adhesive strip;
[0035] FIG. 10 plan view of the base plate of FIG. 8 with molded resilient bullet fastener
DETAILED DESCRIPTION OF THE INVENTION
[0036] FIG. 1 shows an exploded view of one embodiment of the present invention with a flanged face plate 10 having two winged flanges, each having a rectangular slit 20 , and a centered aperture 17 , and typical fastening means; in this case, a hollow wall anchor with a sleeve element 9 and screw 8 . In this embodiment, the flanged face plate 10 rotates 360 degrees once the entire assembly is affixed to a surface. Fastening straps with buckling means as shown in ( FIG. 6 ) are passed through the rectangular slits 20 , to encircle the object to be retained.
[0037] FIG. 2 Shows an exploded view of the preferred embodiment of the present invention that uses a T-shaped bushing having an aperture 17 a there through, a capped flange 15 , a beveled countersunk recess 19 to accept the beveled head of a typical wood screw 8 . Assembly requires the area 14 below the capped flange 15 is seated into the aperture 17 b , and the integrally formed sleeve 17 c of base plate 12 is interiorly seated within the body of the T-shaped bushing. Once assembled, the T-shaped bushing acts as a hub around which the flanged face plate 10 and base plate 12 are seated and whereby the two plates may rotate 360 degrees relative to each other prior to the affixing of the present invention to a surface, after which, the flanged face plate 10 is rotatable and the base plate 12 is fixed against a surface and immobilized.
[0038] FIG. 3 shows a partial cut away view of an alternate embodiment of the present invention where a planar base plate 12 a and flanged face plate 10 are held together by a non-flanged bushing that is situated within apertures of equal diameter 17 e , 17 d of the flanged face plate and the planar base respectively, which is press fitted during assembly so that a lip is formed at either end of the bushing to retain both plates together about a common axis. The flanged face plate rotates 360 degrees once the entire assembly is affixed to a surface. Fastening straps with buckling means as shown in ( FIG. 6 ) are passed through the rectangular slits 20 , and encircle an object to be retained.
[0039] FIG. 4 shows the non-flanged bushing 21 of the embodiment of ( FIG. 3 ).
[0040] FIG. 5 shows the planar base plate 12 a of the embodiment of ( FIG. 3 ).
[0041] FIG. 6 is an edge view illustrating the alternate embodiment of ( FIG. 3 ) in typical use being affixed to a hollow wall surface. Visible is the strap 23 having at the respective ends a male and female buckle portion 24 , where the strap is meant to encircle a retained article. Although the edge view shows the flanged wings of the face plate 10 , it should be understood that flanged face plate 10 is fully rotatable about the axis provided by the press fit bushing 21 .
[0042] FIG. 7 is an edge view illustrating the preferred embodiment of ( FIG. 2 ) in typical use being affixed to a hollow wall surface. Shown is strap 23 having at each terminal end a male or female buckle portion, where the strap is meant to encircle a retained article. Although the edge view shows the flanged wings of the face plate 10 , it should be understood that face plate 10 is rotatable about the axis provided by the T-shaped bushing 15 . It should also be understood that while the male and female buckle pairs are are illustrated here, other types of fasteners such as Velcro™, or buckle and cinch loops, are suitable.
[0043] FIG. 8 is an exploded view illustrating an alternate embodiment of the present invention that substitutes a resilient fastener 26 formed into base plate 12 b as a substitute for the bushing elements of the other embodiments. The base plate with resilient fastener are of a thermoplastic material such as polystyrene or fiber reinforced thermoplastic. Assembly requires that the flanged face plate 10 b be pressed against the base plate 12 b aligning the aperture 17 with the head of the resilient fastener having a generally bullet shaped profile and which is partially divided into four sections so that the head of the fastener may contract to allow force fitting through an aperture upon which the sections resume their position, thus releasably securing the two plates together. The completed assembly is attached to a surface by means of double sided adhesive such as 3M™ Foam Tapes. Alternately, it is possible to separate the two plates and simply use the device in the manner described in ( FIG. 1 ) thus omitting the base plate.
[0044] FIG. 9 is an edge view illustrating the alternate embodiment of ( FIG. 8 ) in typical use being affixed to a hollow wall surface. Shown is a layer of foam tape 27 of the same circumference as base plate 12 b . Visible is the strap 23 b having at each terminal end a hook or loop fastener portion so that the straps may be fastened together, so the strap can encircle a retained article. Although the edge view shows the flanged wings of the face plate 10 , it should be understood that face plate 10 is rotatable about the axis provided by the resilient fastener 26 .
[0045] FIG. 10 is an plan view illustrating the base plate of ( FIGS. 8 , 9 ) with the sections partially bisection the bullet shaped head of the resilient fastener 26 .
[0046] While the invention has been described in connection with only two principal embodiments, it is not intended to limit the scope of the invention to the particular form set forth, but on the contrary, it is intended to cover such alternatives, modifications, and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims. | A device for the retention and release of heavy, bulky or irregularly shaped items to a surface that includes a rotatable winged flanged plate with strap admitting slots through which a strap and coupling means are passed, and a surface affixing means providing for the releasable retention of large or irregularly shaped items against a wall or other surface. | 5 |
BACKGROUND OF THE INVENTION
This invention relates to masonry blocks and, more specifically, to masonry blocks which decrease thermal conductivity by utilization of non-masonry core materials.
Traditional concrete blocks have been of unitary construction with cross members and face members all formed of the same material, namely, concrete. An important consideration in masonry blocks is thermal resistence. The thermal resistence of a particular material is a relative measure of how quickly the material, block or assembly will allow heat to pass through it. In building and engineering terms, thermal resistence is referred to in terms of R-value. The more slowly the heat is allowed to pass through a material, the higher that material's thermal resistence is and, correspondingly, the higher the R-value which will be assigned to that particular material.
Traditional concrete blocks have spaces between cross members which may be filled with insulating material to increase the R-value of a wall or other structure constructed with the blocks. Such installation applications, however, have no affect on the thermal resistance of the concrete cross members in traditional masonry blocks. Adaptations of traditional concrete masonry blocks have been made to facilitate insertion of foam or other insulation material still utilizing a traditional block structure. It is also known to utilize light-weight concrete forms and non-masonry connecting members for these forms, into which concrete is poured to form a central concrete core. Other approaches have utilized exterior insulation on existing support concrete walls with insulation materials which adhere to the outside of the concrete support wall. Variations on this include a decorative, protective “skin.” The prior art, however, does not disclose a block of traditional concrete size and load-bearing capability, attached to and separated by a uniform, solid insulating core which is manufactured and then delivered and installed as a one-piece unit.
While much of the prior art has been directed toward the construction of masonry walls using concrete blocks, with a goal of providing an ultimate wall of significantly increased R-value, the examples of prior art do not address the improvements of the present invention.
Traditional cement masonry building blocks generally contain rectangular face elements which, when utilized in construction of walls, are generally laid end to end and on top of each other in an essentially vertical plane to maintain structural and load-bearing support. Additionally, there are concrete cross members which hold the face elements of the block together at the desired interval. These are not essential elements, however, for load-bearing stability once the blocks are in place.
Examples of other attempts to address this problem include U.S. Pat. No. 5,697,189, to Millar et al, which discloses a monolithically poured concrete wall panel. U.S. Pat. No. 5,209,037, to Kennedy et al, for a building block insert, discloses a substantially serpentine integral insert and two outer supportive parts. U.S. Pat. No. 4,745,720, to Taylor, discloses an insulated cinder block split into two portions. U.S. Pat. No. 4,802,318, to Snitoviski, discloses an insulated block unit comprised of two building blocks strapped about an insulating core.
Any masonry block application which will allow for greater R-factor of an overall finished wall will result in lesser insulation requirements and the balance of construction and will result in significant cost savings and commercial advantage to the builder or, likewise, in the event that additional insulation is not added, in greater savings in cooling and/or heating costs to the owner of any completed structure.
Accordingly, irrespective of the prior art, a need continues to exist for an insulated masonry block which does not require separate assembly; which does not sacrifice vertical load-bearing capacity; yet which continues to provide a traditional two-sided exterior masonry surface which allows an overall uniform thermal resistence of the interior wall significantly greater than concrete.
Specifically, what is needed is an assembled masonry block having traditional load-bearing side elements, which may be stored, and utilized in construction in the same manner as traditional concrete blocks.
SUMMARY OF THE INVENTION
This invention is directed to the provision of a unitary masonry block wall which may be assembled in the same manner and which will provide the same appearance as a standard traditional concrete masonry block and wall but which will provide significant advantages with regard to uniform thermal resistence.
More specifically, the present invention is directed to the provision of a concrete masonry block and a wall constructed of concrete masonry blocks which provide standard, traditional rectangular outer concrete surfaces which provide the same appearance and surface integrity as traditional concrete blocks and provide the same structural and load-bearing capacity as well, but which blocks have a completely unitary rigid insulating core, lighter in weight than traditional concrete, but which is sufficient, with the use of adhesive, to hold the block together for shipping, storage and assembly within a wall.
The present invention will provide a masonry block, and completed masonry wall, with a high thermal resistence rating (R-factor) between the external surface faces of the block.
According to another important feature of the present invention, the insulating core of the block may be formed of apertures or grooves to facilitate the insertion of reinforcing rod, or other structural supports, to provide further vertical and horizontal integrity to a finished wall.
According to a further feature of the invention, the cavities provided for utilization of reinforcing rod, may be further utilized for fill with concrete material for further stability, or with insulation material for further thermal resistence.
The above and additional features of the invention may be considered and will become apparent in conjunction with the drawings in particular, and the detailed description which follows:
BRIEF DESCRIPTION OF THE DRAWINGS
The following detailed description is best understood by reference to the following drawings, in which:
FIG. 1 is a perspective view of an insulated masonry block device, additionally depicting the greater depth of the surface indentation in an alternative preferred embodiment;
FIG. 2 is an end view of an alternative preferred embodiment of an insulated masonry block device showing the slot defined by the upper surface of the rigid insulation core and the protrusion on the base of said core;
FIG. 3 is a top view of the insulated masonry block device;
FIG. 4 is a perspective view of the insulated masonry block device with hidden lines showing the vertical apertures defined by the insulating core member;
FIG. 5 is a perspective view of the insulated corner block embodiment of the invention, showing a rigid support member in exploded relationship to the corner block;
FIG. 6 is a cut-away view of a section of an insulated masonry block wall assembly showing a vertical and horizontal support rod within said assembly and further showing mortar being poured within said assembly to complete the vertical and horizontal support members;
FIG. 7 is an exploded perspective view of an insulated masonry block device;
FIG. 8 is a top view of an insulated masonry block device having a single vertical aperture;
FIG. 9 is a perspective view of an insulated masonry block device, showing the same, in relationship with a pair of vertical support members, and adjoining masonry blocks in two courses of a masonry block wall assembly;
FIG. 10 is top view of an adjusting insulated masonry block device;
FIG. 11 is a perspective view of an adjusting insulated masonry block device showing alternative depths of the indentation in the surface of the insulating core member;
FIG. 12 is a cut-away view of a section of an insulated masonry block wall assembly showing horizontal and vertical support members comprised of a combination of poured mortar and rigid support rods;
FIG. 13 is a top view of an alternative embodiment of an insulated masonry corner block device;
FIG. 14 is a top view of an alternative embodiment of an insulated masonry corner block device forming a corner in conjunction with a pair of standard insulating masonry blocks and a rigid support member within the surface indentation on all of said blocks.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The invention insulated masonry block, broadly considered, includes a block 10 and an insulated block wall assembly 80 .
Block 10 includes a first masonry facing member 11 , a second masonry facing member 12 and a core member 13 . Facing members 11 and 12 are formed of concrete in the preferred embodiment. Core member 13 is comprised of a rigid insulating material which, in the preferred embodiment, may be polystyrene or a similar substance.
Each of the facing members 11 and 12 , is substantially rectangular in three dimensions as shown in the exploded view of FIG. 7 . Each of the facing members 11 and 12 has a substantially flat or planar surface, 11 a and 12 a , respectively, and a substantially flat or planar inner surface 11 b and 12 b , respectively which define a width dimension A, the inner surfaces, 11 b and 12 b , opposing each other; the facing members 11 and 12 additionally each have an upper substantially flat or planar surface 11 c and 12 c , respectively, and a lower substantially flat or planar surface 11 d and 12 d , respectively, which define a height dimension B, and a first end substantially flat or planar surface 11 e and 12 e , respectively, and a second end substantially flat or planar surface 11 f and 12 f , respectively, defining a length dimension C. As is inherent in a three dimensionally rectangular figure, the planar surfaces 11 c , 11 d , 11 e and 11 f and 12 c , 12 d , 12 e and 12 f , respectively, are at substantially right angles to the planar surfaces 11 a and 11 b and 12 a and 12 b , respectively.
Core member 13 is also three dimensionally rectangular, with a first outer surface 14 and a second outer surface 15 , an upper surface 16 , a lower surface 17 , a first end surface 18 and a second end surface 19 . Core member 13 is shaped and configured to extend between the opposing inner surfaces 11 b and 12 b of facing members 11 and 12 which are aligned in parallel. The first and second outer surfaces 14 and 15 of core member 13 contact and correspond with the respective inner surfaces 11 b and 12 b . An adhesive means 20 is utilized to affix surfaces 14 and 15 to surfaces 11 b and 12 b , respectively. In the preferred embodiment of the invention, the adhesive means 20 may be an epoxy bonding agent or other means. While the facing members 11 and 12 are formed of concrete in the preferred embodiment, other material may be substituted.
In the preferred embodiment of the invention, as is shown in FIG. 2, the upper planar surface of the core member 13 , and the plane defined by it, extends a distance “E” above the plane defined by the parallel upper surfaces 11 c and 12 c.
The core element 13 additionally contains one or more cavities or apertures 21 defined by the core member 13 and running between and through its upper surface 16 and lower surface 17 substantially parallel to surfaces 11 a and 12 a of facing members 11 and 12 .
The block 10 will optimally have a pair of such apertures 21 , but different embodiments may have none as shown in FIG. 1, one as shown in FIG. 8, or any other number.
In the preferred embodiment, one aperture 21 is centered approximately on line a—a longitudinally bisecting the upper surface of core member 13 , at a point 22 a located equidistant between the first end surface 18 and a point equidistant between surface 18 and a point 22 equidistant between surfaces 18 and 19 , and another aperture 21 is centered approximately on line a—a at a point 22 b equidistant between second end surface 19 and said point 22 . Stated otherwise, one aperture 21 is located at a point 22 a at a distance from surface 18 equal to one quarter of the distance from end 18 to end 19 and a second aperture 21 is located at a point 22 b at a distance from surface 19 equal to one quarter of the distance from end 18 to end 19 as shown in FIG 3 .
Another feature of the invention as particularly demonstrated in cross section in FIG. 2 includes a linear groove or indentation 30 having a defined depth “D” in the upper surface of core element 13 running through and between end surfaces 18 and 19 . In the preferred embodiment of the invention, this indentation 30 is approximately centered linearly between the facing members 11 and 12 , and is inwardly rectangular in shape.
The core element 13 also has a protrusion 40 of a defined height F on its lower surface 17 . In the preferred embodiment, this protrusion 40 is outwardly rectangular in configuration and is centered linearly on element 13 between facing members 11 and 12 and is equal in length to length dimension C. Protrusion 40 is configured to fit within an indentation equivalent to indentation 30 in a male-female relationship.
A further feature of the invention provides for an indentation 30 of substantially greater depth D than the height F of protrusion 40 so as to provide that when the protrusion 40 of a block 10 is filled within the indentation 30 of a like block 10 in male-female relationship, the depth D of indentation 30 beyond and the height F of the corresponding protrusion 40 of a like block 10 defines a linear aperture 41 , running between the end surfaces 18 and 19 of core element 13 of the block 10 in which the corresponding protrusion 40 is inserted this feature is demonstrated in FIG 6 .
The invention may also be optimally configured as corner block 50 , as illustrated in FIGS. 13 and 14. Corner block 50 is configured so that the first facing member 11 comprises a first rectangular element 51 and a second rectangular element 52 . Each of the rectangular elements 51 and 52 has a lower surface 11 d and an upper surface 11 c defining its height B, an outer surface 11 a and inner surface 11 b defining its width A and a first end surface 11 e and second end surface 11 f defining its length C. The width A and height B of the first element 51 and second element 52 are uniform. The upper surfaces 11 c and lower surfaces 11 d of elements 51 and 52 correspond and said second element 52 extends outwardly at right angles from the inner surface 11 b of the first element 51 such that the second end surface 11 f of the first element 51 and the outer planar surface 11 a of the second element 52 defines a unitary, singular plane 53 . The second facing member 12 of the corner block 50 , as in base block 10 , has a substantially outer planar surface 12 a , a substantially planar inner surface 12 b , a substantially planar upper surface 12 c , a substantially planar lower surface 12 d , a substantially planar first end surface 12 e and a substantially planar second end surface 12 f . In the corner block 50 embodiment of the invention, the second member 12 has a length C substantially less than the length C of the first facing member 11 , with the first end planar surfaces 11 e and 12 e defining a singular plane, the upper surfaces 11 e and 12 c defining a singular plane and the lower surfaces 11 d and 12 d defining a singular plane.
The core element 13 in corner block 50 is generally configured as in block 10 except that its second end surface 19 abuts and is affixed to the inner surface 11 b of the second element 52 of facing member 11 . Further, the linear groove or indentation 30 on the upper surface 16 of core member 13 , for corner block 50 , runs from and through end surface 18 , approximately centered linearly between the first element 51 of facing member 11 and facing member 12 to a point 54 on upper surface 16 approximately equidistant between the inner surfaces 11 b of the first member 51 and second member 52 and then at right angles parallel to the inner surface 11 b of second member 52 to and through the second outer surface 15 of core element 13 . It is additionally desirable to provide a linear protrusion 40 of defined depth D on corner block 50 essentially as provided for base block 10 except that protrusion 40 on block 50 shall be configured to fit within the linear indentation 30 of a like corner block 50 in a male-female relationship. Additionally, desirable features specifically provided for base block 10 , include, but are not limited to, such innovations as extending the height of core element 13 by E, providing for greater depth D of indentation 30 to allow formation of aperture 41 , and substitution of materials and means of affixing facing members 11 and 12 to core 13 are also applicable, and directed to block 50 in the preferred embodiment. FIGS. 13 and 14 demonstrate a top view of corner block 50 .
In a further embodiment of the invention an alternative corner block 60 is provided, as shown in FIG. 5 . Corner block 60 is comprised of a first facing member 61 and second facing member 62 . Each facing member 61 and 62 further comprises a first rectangular element 63 and second rectangular element 64 . Elements 63 and 64 each have a respective upper planar surface, 63 c and 64 c , and a respective lower planar surface, 63 d and 64 d , defining height dimension B, respective outer planar surfaces 63 a and 64 a and respective inner planar surfaces 63 b and 64 b defining width dimension “A,” and respective first end planar surfaces 63 e and 64 e and respective second end planar surfaces 63 f and 64 f , defining respective length dimension C 1 as to first rectangular element 63 of first facing member 61 , C 2 as to first rectangular element 63 of second facing member 62 , C 3 as to second rectangular element 64 of first facing member 61 , and C 4 as to second rectangular element 64 of second facing member 62 . The upper surfaces 63 c and 64 c of each facing member 61 and 62 correspond and the inner surfaces 63 b and 64 b of each facing member 61 and 62 oppose each other, respectively, for elements 63 and 64 of each facing member 61 and 62 , in parallel. The second element 64 of the first facing member 61 extends outward at right angles from the inner surface 63 b of the first element 61 such that the second end surface 63 f of first rectangular element 63 and the outer surface 64 a of the second element 64 form a singular plane, with the second element 64 of second facing member 62 extending outward at right angles from the outer surface 63 a of second rectangular element 64 , so that the second end surface 63 f of first element 63 of second facing member 62 and inner surface 64 b of second element 64 of second facing member 62 define a singular plane.
In a further embodiment of the present invention, an insulated masonry block wall assembly 80 may be constructed. A view of masonry block wall 80 is shown in FIG. 6 . The insulated masonry block wall assembly 80 comprises a series or plurality of masonry blocks 10 arranged in linear alignment as shown in FIG. 6 to form a base course 81 of masonry blocks 10 , as previously described herein, in detail, with each block 10 having a core member 13 and a uniformly planar lower surface 17 . The series of masonry blocks 10 are arranged in course 81 so that the second end surface 19 of each block 10 abuts and interfaces with, to form a common boundary 82 , with the next adjacent block 10 . The core member 13 of each block 10 in course 81 has a linear groove or indentation 30 of defined depth D as previously defined and one or more vertical apertures 21 as previously defined.
A second series of masonry blocks 10 , as defined for base course 81 , with the additional feature on each block 10 of a protrusion 40 on the lower surface 17 , as previously described in detail, is arranged substantially as course 81 , in linear alignment as shown in FIG. 6, to form a first upper course 83 . Course 83 is linearly aligned on course 81 so that the lower flat or substantially planar surfaces 11 d and 12 d of each block 10 of course 83 , oppose, approximate and interface, by forming a common boundary 84 with the flat upper surfaces 11 c and 12 c of one or more of blocks 10 of course 81 , with the linear protrusion 40 of each block 10 of course 83 configured with a portion of indentation 30 of one or more blocks 10 of course 81 in a male female relationship. In the preferred embodiment, the depth D of indentation 30 is substantially greater than the height F of protrusion 40 , so as to define a linear aperture 41 running the length 87 of each course 81 and 83 . In the preferred embodiment of insulated masonry block wall assembly 80 , each block 10 is linearly aligned in each course 81 and 83 so that the linear aperture 41 runs the entire length 87 of each course. Likewise, in the preferred embodiment, there is a plurality of sequential upper courses 88 constructed substantially as first upper course 83 with each course of the sequential courses 88 abutting and aligned linearly with the course below in substantially the same manner as the first upper course 83 abuts and is aligned with base course 81 . In the preferred embodiment, each block 10 of first upper course 83 is aligned so that its flat lower surfaces 11 d and 12 d oppose, approximate and interface with approximately equal portions 85 and 86 of the flat upper surfaces 11 c and 12 c of two adjoining blocks 10 of base course 81 . Each of the sequential upper courses 88 is similarly aligned with the course immediately below it, so that the apertures 21 of each block 10 , in each course 81 , 83 and 88 are aligned so that each aperture 21 extends in combination the entire height 89 of the insulated block wall assembly 80 . In the primary embodiment, each block 10 of each course 81 , 83 and 88 is joined to the next succeeding block in series at common boundary 82 by a concrete or mortar 90 joint and each block 10 of each course 81 , 83 and 88 is joined to a portion of two blocks 10 of the preceding course and common boundary 84 by a concrete or mortar 90 joint.
In the preferred embodiment, a rigid support member or rod 91 commonly referred to in masonry trade as re-rod, reinforcing rod, rebar and/or reinforcing bar, is inserted within aperture 41 running through length 87 of one or more of the base course 81 , first upper course 83 and sequential upper courses 88 . The balance of any aperture 41 , to the extent that said rod does not completely fill such aperture 41 , may be filled with concrete or mortar 90 for increased linear strength and stability. Likewise, a rod 41 is inserted vertically through a plurality of the aligned apertures 21 of the blocks 10 of each course through the entire height for increased vertical strength and stability. These support members or rods, as described above, in both horizontal and vertical applications, are shown in FIGS. 5, 6 , 9 and 12 .
In the preferred embodiment, the rod or member 91 is configured to fit within the entire aperture 41 or 21 , respectively, and may be entirely of concrete or mortar 90 or other pourable material, or a rod of metal or other rigid material, or a combination thereof. The invention wall assembly 80 , may also, optimally, permit angled walls by incorporating at an end of each course, a corner block 60 as shown on FIG. 5, and as described previously in detailed, or a corner block 50 as shown in FIGS. 13 and 14 and described previously in detail.
Whereas, a preferred embodiment of the invention has been illustrated and described in detail, it will be apparent that various changes may be made in the disclosed embodiment without departing from the spirit of the invention. | An insulated concrete block and wall assembly. The primary element is an insulated block which consists of two rectangular concrete facings and a rigid solid insulating core. The concrete facings are attached by adhesive to the insulating core. The insulating core has apertures within it to allow vertical reinforcing rod support in a constructed wall. The invention additionally provides an indentation along the top of each insulating core to provide for horizontal re-rod support within the wall itself. The invention provides optimal decrease in thermal conductivity coupled with simplicity of design and transport. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of and claims priority to pending U.S. application Ser. No. 13/524,509, filed Jun. 15, 2012, the contents of which are incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] This invention relates to neck support devices.
BACKGROUND
[0003] The human spine comprises several regions. The cervical region corresponds to the neck and has a natural curvature. This curvature is lordotic, meaning that it is concave dorsally. The cervical lordotic curve is also known as a “C” curve. Positioning the head in a perpendicularly to the shoulders helps maintain a healthy C curve. Bending the cervical spine, especially for prolonged periods, is considered poor posture. Poor posture can lead to negative health and wellness effects, the more minor of which may include headaches, discomfort, muscle cramps, neck pain, and shoulder pain. Maintaining proper posture is often difficult during certain activities, such as, for example, resting, reading, watching television or movies, using a computer, traveling on an airplane or in a vehicle, or remaining in a static position for a prolonged period. Though muscles can help stabilize the cervical spine, they sometimes have a reduced capacity to do so, such as during sleep or rest, or as a result of muscular conditions (e.g., atrophy). As an example, an airplane traveler may wish to sleep or rest on a long flight, but may be restricted to the seated position. In this example, the traveler may experience difficulty finding a comfortable position or may experience negative effects as a result of improper neck positioning during sleep or rest. Thus, there is a need for a device that helps maintain proper neck posture.
[0004] Currently, there are numerous neck support items available. The two primary types of neck-specific pillows include a neck collar shaped like a horseshoe and a cervical neck pillow. Each offers specific attention to the neck, while providing support in different ways. The horseshoe collar is intended for use while seated. The cervical neck pillow is intended for use while prone and provides a contoured pillow with a cradle for the head. Other neck support devices are found to be flimsy, insufficiently supportive, and uncomfortable. Thus, there is a need for a neck support device which is not flimsy, but is supportive and comfortable.
[0005] None of these neck support items is adjustable and customizable for the user's comfort and support. Instead, the items provide a one-size-fits-all solution. For example, a horseshoe collar is not adjustable for the length of the user's neck or desired position of support. Neither is the point of support adjustable; the horseshoe collar provides support principally along the jaw and base of the skull. If the user prefers to choose the location of support, the existing devices are inadequate. Thus, there is a need for an adjustable, customizable, and supportive neck support item.
[0006] Further, none of the neck support items available is easily collapsible or packable. Such a concern is especially relevant to those who use such devices while traveling. Contoured pillows often contain foams or stiff filling that resists compression. Horseshoe collars have similar problems. While some horseshoe collars comprise an inflatable bladder, such devices entail problems of their own. For example, users with a reduced lung capacity or reduced lung health may have difficulty inflating such devices. Further, the process of inflating and deflating the devices is an inconvenient step that reduces the collapsibility and packability of the device. Thus, there is a need for a portable, collapsible, or packable neck support item.
[0007] Neither horseshoe collars nor cervical neck collars provide support in the forward direction. That is, neither type of neck support item prevents the user's head from tilting forward, which may happen naturally such as during sleep while seated. Similarly, the user's head is prone to wobbling. Thus, there is a need for a neck support item that prevents the user's head from unintentionally tilting forward or wobbling.
[0008] The above problems, and others, are reduced by the invention as herein described and shown.
BRIEF SUMMARY
[0009] The above problems, and others, are reduced, according to exemplary embodiments, by the neck support device.
[0010] According to an exemplary embodiment, a neck supporting device comprises a bendable, padded disk lined on one side. Portions of the disk are incompletely separated from other portions of the disk by cuts in the material of the disk. Each portion is joined to one or more adjacent portions at edges. A user may bend the disk at the edges and may also bend the disk within each portion. The disk comprises three portions: a head portion, a neck portion, and a shoulder portion. The user bends the head portion until it is contoured to cradle the head. The user bends the shoulder portion until it is contoured to rest on the user's shoulder. The user will then position the neck portion against the side of the user's neck. The weight of the user's head will exert force upon the head portion, which weight will be translated via the neck portion to the shoulder portion, where it is in turn translated to the user's shoulder. Thus, the weight of the user's head is relieved from the user's neck, while the device facilitates proper positioning of the user's cervical spine. Multiple such neck supporting devices may be worn on opposing sides of the head, thereby translating the force exerted by the weight of the user's head to one or both of the user's shoulders.
[0011] According to an exemplary embodiment, the head portion of the neck supporting device comprises padding such as foam or discrete pads. The padding may be homogenously distributed on the head portion, may be heterogeneously distributed, or may be contoured to provide added support in particular areas. For example, additional padding may be provided to support the distal aspects of the mandibular bodies and mentum (chin), referred to as the mental protuberance (hereinafter the “MEP”). A second comfort pad may be positioned on the head portion at a location configured to support the angles of the mandible (hereinafter the “MA”). A third comfort pad may be positioned on the head portion at a location configured to support the mastoid processes (hereinafter the “MAP”) posterior to the ear. A fourth comfort pad may be positioned on the head portion at a location configured to support the skull base and, specifically, the occipital protuberance (hereinafter the “OP”) at the posterior skull base of the wearer.
[0012] An object of the invention is to provide a device to support the neck and head of a user while traveling. The device comprises an inner core which, when unbent, is flat and provides a thin profile for compact storage. When the user desires to use the device, the user can bend the inner core to a particular shape. The nature of the material of the inner core allows the user to bend the inner core with manual power alone, without the use of tools. However, it retains the shape once bent and is resistant to bending sufficiently to bear the weight of the user's head without unintentionally deforming.
[0013] Other devices, methods, and/or products according to embodiments will be or will become apparent to one of ordinary skill in the art upon review of the following drawings and further description. It is intended that all such additional devices, methods, and/or products be included within this description, be within the scope of the present invention, and be protected by the accompanying claims.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)
[0014] Having thus described the invention in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:
[0015] FIG. 1 is a perspective view of an embodiment of the present invention.
[0016] FIG. 2 is a perspective view of an aspect of the present invention.
[0017] FIG. 3 is a perspective view of an embodiment of the present invention.
[0018] FIG. 4 is a side view of an embodiment of the present invention.
DETAILED DESCRIPTION
[0019] FIG. 1 depicts a perspective view of an embodiment of the present invention. The neck support device 101 comprises a head portion 103 , a neck portion 105 , and a shoulder portion 107 . Head portion 103 and neck portion 105 join at top edge 109 . Neck portion 105 and shoulder portion 107 join at bottom edge 111 . The outer perimeter of the neck supporting device 101 may be roughly and irregularly circular or ovoid. The outer perimeter is made more irregular by cut lines 115 , which help define head portion 103 , neck portion 105 , and shoulder portion 107 . In some embodiments, the head portion 103 may directly or nearly contact the shoulder portion 107 . In other embodiments, cut lines 115 may be broad such that the head portion 103 cannot contact the shoulder portion 107 when the inner core 117 is unbent. However, the cut lines 115 transect the neck support device, but such transection is incomplete at least to the extent of the width of the neck portion 105 .
[0020] The neck support device 101 comprises an inner core 117 . The inner core 117 comprises a bendable, pliable, or flexible material, such as, for example, a soft-temper metal. Such material may be, for example, steel, steel alloy, aluminum, or aluminum alloy that is of a stiffness that requires only moderate force to bend the core into a particular shape, yet preserves that shape once assumed. The core should bend easily enough for the user to be able to do so manually and without mechanical assistance, but resistant enough to avoid unintentional deformation, such as by the weight of the user's head on the head portion 103 when the device is in use. Within this range, the exact stiffness of the core or the exact amount of force required to shape it is immaterial. Further, the stiffness of the inner core 117 may be heterogeneous, particularly among the portions and edges. For example, the neck portion 105 may be stiffer than the head portion 103 or the shoulder portion 107 . As a further example, the inner core 117 may be more or less stiff at both of or either the top edge 109 or bottom edge 111 compared to elsewhere on the inner core 117 . The inner core is bendable, moldable, or shapeable, and those terms may be used interchangeably to describe the characteristics of the inner core.
[0021] Further, mixed materials may be used throughout the inner core 117 . For example, some areas may be more frequently bent than others, in which case those frequently-bent areas may benefit more than the others from the use of material more resistant to metal fatigue. If top edge 109 or bottom edge 111 may be subject to more frequent bending than, e.g., the neck portion 105 . Other areas may benefit from stiffer, less flexible materials. Such variations in stiffness may be accomplished by variations in the type of material used, the treatment or preparation of the material used, or the thickness or amount of material used.
[0022] Around and substantially encompassing the inner core 117 is the outer sheath material 119 . The outer sheath material 119 may completely encompass and enclose the inner core 117 . Conversely, the outer sheath material 119 may partially enclose the inner core 117 , for example by leaving the edges of the inner core 117 exposed as in FIG. 1 . For an example of an embodiment with full enclosure, see FIG. 3 , FIG. 4 , and the accompanying discussion.
[0023] The outer sheath material 119 may comprise any of various types of padding, foam, cloth, fabric, or other flexible material. The outer sheath material 119 encompasses the head portion 103 , neck portion 105 , and shoulder portion 107 of the neck support device 101 . In an embodiment, the portion of the outer sheath material 119 encompassing the shoulder portion 107 comprises a gripping surface 113 . The gripping surface 113 helps prevent the neck support device 101 from slipping from the shoulder of the user when the neck support device is bent into its support shape. (See FIG. 3 , FIG. 4 , and the related discussions.)
[0024] FIG. 2 depicts a perspective view of an aspect of the present invention. In an embodiment, the invention includes a shoulder strap 201 . The shoulder strap 201 is configured to help retain the neck support device upon a user's shoulder. The shoulder strap 201 comprises a belt 205 , a paddle 211 , and a harness 213 . The belt 205 comprises a first belt portion 217 and a second belt portion 219 joined by a buckle 203 . The strap 205 is configured to encompass a user's body (not shown) with the belt 205 passing under an arm and the paddle 211 positioned upon the top of the opposite shoulder. The second belt portion 219 comprises an adjustment region 209 , which partially passes through the buckle 203 and folds back upon itself. The adjustment region 209 may be removably attachable to itself or to the second belt portion 219 . Such attachment may be accomplished by, for example, hook and loop fasteners. Varying the amount of the adjustment region 209 of the second portion 209 which is passed through the buckle 203 varies the effective overall length of the belt 205 . Different users may prefer the belt 205 to be of different lengths. For example, users with greater chest circumference measurements or greater heights may require or prefer a greater effective length for the belt 205 . Further, users may prefer a certain tightness of fit, so even users with identical body measurements may prefer different effective lengths for the belt 205 . The shoulder strap 201 is configurable to fit a variety of users dependent on the preferences and requirements of the user.
[0025] The belt 205 comprises a first belt portion 217 . The first belt portion 217 partially passes through the buckle 203 and folds back upon itself at first belt portion attachment point 207 . The first belt portion 217 , at first belt portion attachment point 207 , is secured to itself by one or more of various methods such as, for example, hook-and-Loop fasteners, sewing, adhesive, or similar methods.
[0026] The harness 213 comprises a plurality of portions removably attached to one another by the use of, for example, hook and loop fasteners. The harness 213 is configured to retain a portion of the neck support device (not shown) against the paddle 211 .
[0027] The shoulder strap 201 is utilized by positioning the paddle upon the user's shoulder, passing part of the adjustment portion 209 through the buckle 203 until the desired effective belt length is attained, ensuring the plurality of portions of the harness 213 are detached from one another, positioning the neck support device (not shown) against the paddle 211 , and attaching the plurality of portions of the harness 213 to each other, thereby removably securing the neck support device (not shown) within the harness 213 , which is positioned upon the user's shoulder.
[0028] FIG. 3 depicts a perspective view of an aspect of the present invention. A neck support device 301 is shown in a support configuration. The neck support device 301 comprises a head portion 309 , a neck portion 307 , and a shoulder portion 311 . The head portion 309 is attached to the neck portion 307 , which, in turn, is attached to the shoulder portion 311 . Thus, the head portion 309 is connected to the shoulder portion 311 via the neck portion 307 . When in use, a user positions the neck portion 307 against the side of the user's neck and the shoulder portion 311 atop the user's shoulder, with the head portion 309 being positioned to provide support to the user's head when, for example, sleeping or resting.
[0029] The neck support device 301 comprises an inner core (not shown). The inner core is of similar construction to that described in connection with FIG. 1 and FIG. 2 . However, in the embodiment shown in FIG. 3 , the inner core is not visibly depicted as it is entirely encompassed and enclosed within the outer sheath material 313 . The outer sheath may be removable from the inner core. A user may remove the outer sheath to facilitate cleaning the outer sheath or inner core, to substitute the outer sheath with a different outer sheath of different aesthetics, or to substitute the outer sheath with a different outer sheath of different material, structure, or padding distribution. Thus, the replacement outer sheath may provide additional customizability of the neck support device for the user's aesthetic preference, fit preference, comfort, or other functionality.
[0030] The shoulder portion 311 includes shoulder projections 305 , each of which is foldable and bendable to the user's preference. The shoulder portion 311 is configured to rest atop the shoulder of the user. More specifically, the shoulder portion 311 may rest primarily upon the top of the user's shoulder area, while the shoulder projections 305 may rest against the front and back of the shoulder area.
[0031] The head portion 309 includes head projections 303 , each of which is foldable and bendable to the user's preference. The head projections 303 and head portion 309 may be bent to the user's preference in order to provide sufficient support to the various areas of the user's head. Such various areas include areas such as, for example, the MEP, MA, MAP, and OP. The head projections 303 can be bent to provide additional support to prevent the user's head from drooping forward or backward, while the center of the head portion 309 prevent the user's head from drooping laterally to at least one side.
[0032] The outer sheath material 313 may comprise padding to provide support to various areas of the user's head. Further, the outer sheath material 313 at the head portion 309 may comprise circumaural padding, meaning padding which is circular, ellipsoid, or horse-shoe shaped to provide support the area of the user's head surrounding the ear, thereby removing pressure from the user's ear when the user's head is positioned upon or against the head portion 309 .
[0033] The outer sheath material 313 may comprise any of various types of padding, foam, cloth, fabric, or other flexible material. The outer sheath material 313 encompasses the head portion 309 , neck portion 307 , and shoulder portion 311 of the neck support device 301 . In an embodiment, the portion of the outer sheath material 313 encompassing the shoulder portion 311 comprises a gripping surface to help prevent the neck support device 301 from slipping from the shoulder of the user when the neck support device is bent into its support shape.
[0034] FIG. 4 depicts a side view of an aspect of the present invention. A neck support device 401 is shown in its support configuration. The neck support device 401 comprises a neck portion 413 which connects a head portion 405 to a shoulder portion 407 . The head portion 405 comprises head projections 403 . The shoulder portion 407 comprises shoulder projections 409 . The neck portion 413 is positioned against the neck of the user at a neck contact surface 411 .
[0035] The head portion 405 includes head projections 403 , each of which is foldable and bendable to the user's preference. The head projections 403 and head portion 405 may be bent to the user's preference in order to provide sufficient support to the various areas of the user's head. Such various areas include areas such as, for example, the MEP, MA, MAP, and OP. The outer sheath material 415 may comprise padding to provide support to various areas of the user's head. Further, the outer sheath material 415 at the head portion 405 may comprise circumaural padding, meaning padding which is circular, ellipsoid, or horse-shoe shaped to provide support the area of the user's head surrounding the ear, thereby removing pressure from the user's ear when the user's head is positioned upon or against the head portion 405 .
[0036] The outer sheath material 415 may comprise any of various types of padding, foam, cloth, fabric, or other flexible material. The outer sheath material 415 encompasses the head portion 405 , neck portion 413 , and shoulder portion 4070 f the neck support device 401 . In an embodiment, the portion of the outer sheath material 415 encompassing the shoulder portion 407 comprises a gripping surface to help prevent the neck support device 401 from slipping from the shoulder of the user when the neck support device is bent into its support shape.
[0037] The neck support device 401 comprises an inner core (not shown). The inner core is of similar construction to that described in connection with FIG. 1 and FIG. 2 . However, in the embodiment shown in FIG. 4 , the inner core is not visibly depicted as it is entirely encompassed and enclosed within the outer sheath material.
[0038] Multiple neck support devices may be worn. Each of these multiple neck support devices may be used in conjunction with a shoulder strap. In this case, the shoulder straps may cross the user's chest in a crisscross fashion.
[0039] Other systems, methods, and/or products according to the above embodiments will be or will become apparent to one of ordinary skill in the art upon review of the above description, the following drawings, and any further description. It is intended that all such additional systems, methods, and/or products be included within this description, be within the scope of the present invention, and be protected by the accompanying claims.
[0040] 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 or more other features, integers, steps, operations, elements, components, and/or groups thereof
[0041] The corresponding structures, materials, acts, and equivalents of all means or step plus function elements in the claims below are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. The description of the present invention has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the invention. The embodiment was chosen and described in order to best explain the principles of the invention and the practical application, and to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated. | A neck support device comprises a flat, portable device comprised of a central malleable but supportive inner core or endoskeleton covered by a comfortable padded shell. The device shapes into a structure, supporting a user's head by translating the weight of the user' head to the user's shoulder, bypassing the neck, thus allowing relaxation of the supportive structures of the neck. The neck support device comprises a flexible and bendable inner core and an outer sheath material. Portions of the device may be bent into a support position by the user to support the user's head. The device may be bent into a substantially flat configuration for storage. The device may comprise contoured padding located for support or comfort and slip-resistant materials or surfaces. The device may translate the weight of the user's head from a head portion to a shoulder portion via a neck portion. | 0 |
[0001] This application is the national stage of international patent application no. PCT/US2015/62468 filed on Nov. 24, 2015, which in turn claims priority from U.S. Provisional Patent Application Ser. No. 62/083,446 filed on Nov. 24, 2014, the disclosures of each of which are incorporated herein by reference in their entirety.
TECHNICAL FIELD
[0002] This document relates generally to a system for securing a tube positioned in a patient, and more specifically to a receiver and an applier for use in such a system.
BACKGROUND
[0003] A magnetic nasal tube bridle system has been previously described in U.S. Pat. Nos. 6,631,715 & 6,837,237. This system involves creating a loop of flexible material around the nasal septum. While the systems described in these patents are illustrative, a loop of flexible material can be positioned around a patient's nasal septum in any number of ways. The two ends of the loop are then anchored to a medical tube, whether a nasal tube or otherwise, to be retained by a clip. Existing clips are a bi-fold plastic design which clamps one or two ends of the flexible member extending around the septum and the tube together, often in a central channel. Such clips must be sized to fit the tube being retained as it must tightly adhere to the tube without slipping. In order to accommodate the multiple sized medical tubes in use, however, multiple corresponding clip sizes are manufactured and the user must select the appropriate size clip to retain a desired tube. Accordingly, there is a need for a clip which can accommodate multiple tube sizes, including non-standard tube sizes such as are commonly utilized in pediatric and neonatal applications.
[0004] Further, for neonatal and infant applications, there is need for a clip of overall smaller dimensions than existing models. In order to provide sufficient mechanical resistance against pulling of the tube, currently available clips can be difficult to close and potentially compress the lumen of the tube. Thus, an easier way to close and safely manipulate the small clip is needed.
[0005] The present invention seeks to provide a clip or receiver which accommodates multiple tube diameters and is sized appropriately for neonatal and newborn use. An applier may be included with this design to make positioning and closure of the clip easier. Retaining the clip within the applier until it is deployed, yields a safety benefit by minimizing the chance that the user will drop the clip into the patient (e.g., the patient's airway). Further, the clip may be re-opened, also using the application tool, re-loaded into the tool and re-applied to the tube as needed.
SUMMARY OF THE INVENTION
[0006] In accordance with the purposes and benefits described herein, a receiver for securing at least one tube in a patient is provided. The receiver includes a shell operable in a first position for receiving the at least one tube and a second position for securing the at least one tube, and a compressible member positioned supported by the shell for contacting the at least one tube in the second position.
[0007] In another possible embodiment, a first portion of the compressible member forms a recess for receiving the at least one tube in the first position.
[0008] In yet another possible embodiment, the first portion of the member contacts a first portion of the at least one tube through contact therewith and a second portion of the member contacts a second portion of the at least one tube in the second position.
[0009] In still another possible embodiment, the receiver further includes at least one band formed around the shell to secure the compressible member in position. In another, the at least one band includes a first band securing a distal end of the first portion of the compressible member and a second band securing a distal end of the second portion of the compressible member. In yet another, the at least one band includes first and second bands which are integrally formed with the compressible member.
[0010] In one other possible embodiment, the shell includes at least one boss.
[0011] In another possible embodiment, the shell includes a curved outer surface and first and second ends and the at least one boss includes at least a first boss extending from the first end and at least a second boss extending from the second end.
[0012] In one other possible embodiment, a system for securing at least one tube positioned in a patient includes a shell having at least one boss protruding therefrom, and an applier having at least one recess corresponding to the at least one boss for orienting the shell within the applier.
[0013] In yet another possible embodiment, the system further includes a compressible member supported by the shell for contacting the at least one tube in an engaged position.
[0014] In still another possible embodiment, the system further includes at least one band formed around the shell to secure the compressible member in position.
[0015] In another possible embodiment, the applier comprises first and second jaws. In still another, the first jaw is a moving jaw. In another, finger loops extend from the first and second jaws.
[0016] In one additional possible embodiment, the system further includes a closing member extending from the first jaw for contacting the shell and moving the shell from an open position to a closed position.
[0017] In one possible embodiment, a method of securing at least one tube positioned in a patient includes the steps of positioning a tube in a patient, placing a flexible member around the patient's nasal septum, receiving the at least one tube and at least one end of the flexible member in a shell supported by an applier, and operating the applier to move the shell from a first position for receiving the at least one tube and at least one end of the flexible member to a second position for securing the at least one tube and at least one end of the flexible member.
[0018] In another possible embodiment, the applier includes first and second jaws, and the step of operating the applier includes moving one of the first and second jaws causing contact with the receiver sufficient to move the receiver from the first position to the second position.
[0019] In still another possible embodiment, the method further includes the step of ejecting the receiver from the applier.
[0020] In yet another possible embodiment, the applier includes first and second jaws, and the step of operating the applier includes moving one of the first and second jaws from an initial position to an intermediary position such that contact between the one of the first and second jaws and the receiver during movement between the initial position and the intermediary position causes the receiver to move from the first position to the second position, and subsequently moving the one of the first and second jaws from the intermediary position to a final position such that contact between the first and second jaws during movement between the intermediary position and the final position causes the receiver to be ejected from the applier.
[0021] In one other possible embodiment, the receiver includes at least one boss and the applier includes at least one recess for receiving the boss.
[0022] In the following description, there are shown and described several possible embodiments of the receiver, system and related method of securing a tube positioned in a patient. As it should be realized, the receivers, systems and methods are capable of other, different embodiments and their several details are capable of modification in various, obvious aspects all without departing from the invention as set forth and described in the following claims. Accordingly, the drawings and descriptions should be regarded as illustrative in nature and not as restrictive.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
[0023] The accompanying drawing figures incorporated herein and forming a part of the specification, illustrate several aspects of the receiver, system and related method of securing a tube positioned in a patient, and together with the description serve to explain certain principles thereof. In the drawing figures:
[0024] FIGS. 1A and 1B are an illustrated perspective views of a receiver in a first open position;
[0025] FIG. 2 is a side elevational view of the receiver in the first open position;
[0026] FIG. 3 is a side elevational view showing the receiver in a second closed position;
[0027] FIG. 4 is an illustrated perspective view of an applier supporting the receiver in the first open position;
[0028] FIG. 5 is an illustrated perspective view of the applier supporting the receiver and a medical tube in the second closed position;
[0029] FIG. 6 is an illustrated perspective view of the applier supporting the receiver after closure of the receiver showing the flexing of the applier to allow the receiver to be ejected after closure;
[0030] FIG. 7A is a side elevational view showing the applier in a first position with the receiver in the first open position;
[0031] FIG. 7B is a side elevational view showing the applier in a second position with the receiver in the second closed position;
[0032] FIG. 7C is a side elevational view showing the applier in a third position to allow the receiver to be ejected after closure;
[0033] FIG. 8 is a side elevational view showing a first moving jaw of the applier;
[0034] FIG. 9 is a side elevational view showing a second static jaw of the applier; and
[0035] FIG. 10 is an illustrated perspective view of the second static jaw of the applier.
[0036] Reference will now be made in detail to the present described embodiments of the receivers, systems and related methods of securing a tube positioned in a patient, examples of which are illustrated in the accompanying drawing figures, wherein like numerals are used to represent like elements.
DETAILED DESCRIPTION
[0037] Broadly speaking, the described invention includes a receiver or clip 10 for securing at least one tube positioned in a patient. The at least one tube may be a temporary tube placed into the gastrointestinal or respiratory tracts of the patient or otherwise. Such tubes typically enter the patient via the nose or mouth. A system for placing securing at least one tube in a patient includes the receiver 10 and an application tool or applier 12 . Each of the receiver 10 and the applier 12 have multiple component parts and features as described below.
[0038] As shown in FIGS. 1A and 1B , the receiver 10 includes a shell 14 operable in a first position to receive at least one tube and a second position to secure the at least one tube, and a member or insert 16 supported by or positioned within the shell and contacting the at least one tube in the second position. The shell 14 further includes a hinge 18 , a locking mechanism 20 , and bosses 22 protruding from the shell to orient or locate the shell in the application tool or applier 12 . More specifically, a molded plastic shell 14 includes first and second pivotally connected parts 24 , 26 . In the described embodiment, the hinge 18 is a living hinge integrally formed with the first and second parts 24 , 26 which allows the shell 14 to move from the first to the second position.
[0039] The shell 14 is generally U-shaped in the first, or open, position, in the described embodiment, as best shown in FIG. 2 . In this position, the shell 14 is open for receiving a tube 28 and at least one end of bridle flexible members. In the second, or closed, position shown in FIG. 3 , the first and second parts 24 , 26 are further connected by the locking mechanism 20 and the tube 28 and the bridle flexible members 30 may reside centrally within the receiver 10 when in the second or closed position.
[0040] The described locking mechanism 20 , shown in FIGS. 2 and 3 , is a snap joint including a hook 32 positioned along a distal end of the first part 24 of the shell 14 and a depression 34 formed in a distal end of the second part 26 of the shell for receiving the hook in the closed position. In this position, the shell 14 is substantially cylindrical or circular in shape and the first and second parts 24 , 26 of the shell 14 form a substantially wedge shaped aperture 36 used to unlock the receiver to remove the tube and bridle flexible member(s).
[0041] The described insert 16 is made of a compressible material. In this embodiment, the compressible material is a silicone rubber in order to be inert to the human body. The geometry of the insert 16 can vary so long as the insert may be maintained in position within the shell 14 . A recess 38 in the insert 16 may be sized to fit a single tube size or a range of sizes. For example, one insert 16 will accommodate size 8 French tubes while another may accommodate 5 and 6 French tubes. Due to the compressible nature of the silicone rubber, the insert 16 may also accommodate tubes of non-standard size. An 8 French insert 16 , for example, should fit a tube having an OD just larger or just smaller than that of an 8 Fr. tube. In the described embodiment, the recess 38 is designed to accommodate a range of tube sizes. For instance, one insert 16 having recess 38 may accommodate a 5, 6, or 8 French tubes. This may be accomplished by increasing an amount of silicone behind the recess 38 .
[0042] Referring back to FIG. 2 , the insert 16 includes first and second portions 40 , 42 which substantially conform to mating surfaces on inner surfaces of the first and second parts 24 , 26 of shell 14 . Adhesives may, as well as friction due to compression, serve to keep the insert 16 in place. In the described embodiment, however, the first and second portions 40 , 42 include bands 44 formed around the shell 14 during a second molding step to secure the insert 16 in position. In an alternate embodiment, the first and second parts 24 , 26 of shell 14 and insert 16 may be integrally molded utilizing an insert molding technique.
[0043] The compressible nature of the silicone rubber used for the insert 16 allows insertion of the tube 28 and the end(s) of the flexible member 30 in any order or position within the space available for them. Further, the silicone rubber grips the tube 28 and flexible member end(s) 30 with greater friction than a harder plastic thereby providing greater resistance against the tube and/or the flexible member ends slipping out. This allows the overall size of the receiver 10 to be minimized while providing sufficient retentive force without compressing the lumen of tube 28 .
[0044] The application tool 12 is shown partially transparent in FIG. 4 with the receiver 10 retained. This is an “as supplied” configuration in the described embodiment. The described application tool 12 consists of two components including a static jaw 50 and moving jaw 52 . The static jaw 50 holds the receiver 10 in the first open position and the moving jaw 52 moves the second shell part 26 to the second closed position when the user moves the finger loops 56 closer together. Guides 58 are provided to guide or facilitate insertion of the tube 28 and the flexible member end(s) 30 into the proper location for closure of the receiver 10 . The application tool 12 also includes a wedge 60 for opening the receiver 10 . The wedge 60 fits into the substantially wedge shaped aperture 36 to unlock or disengage the locking mechanism 20 and open the receiver 10 .
[0045] As shown in FIGS. 5 and 6 , the static jaw 50 is divided into a left half 62 and a right half 64 on one end to provide a retention clamp for receiver 10 . Living hinges 66 allow the left half 62 and right half 64 to spread apart allowing for insertion or removal of the receiver 10 . The bosses 22 on the sides of the shell 14 fit into corresponding recesses 68 (best shown in FIG. 10 ) on an interior aspect of the left half 62 and the right half 64 . Ramps 70 , shown in FIG. 6 , spread the left half 62 and the right half 64 apart so that the receiver 10 may be ejected from the application tool 12 . A distal portion of the moving jaw 52 impinges upon the ramps 70 to spread the left and right halves 62 , 64 apart. Eject stop 72 provides a limit to maximum opening.
[0046] FIG. 7 illustrates three positions of the system with the static jaw 50 shown semi-transparent for illustrative purposes. More specifically, FIG. 7A shows the receiver 10 and applier 12 in an “as supplied” position. FIG. 7B shows the applier 12 after closing the receiver 10 around a tube and FIG. 7C shows the applier 12 in an ejection position where the closed receiver may be ejected from the applier.
[0047] As shown in FIGS. 4, 8, and 9 , the static jaw 50 and moving jaw 52 are connected via axle 74 . The axle 74 fits into an open recess 76 on the static jaw 50 allowing for rotational motion between the two jaws. A neck 78 of the recess 76 is slightly narrower than the axle 74 thereby maintaining the axle within the recess 76 and concentric within the larger circular apex 80 of the recess. The axle 74 is integrally molded in the moving jaw 52 . This arrangement provides easy assembly and minimizes the cost of manufacture rather than, for example, heat staking or need of a separate hinge pin part. Nonetheless, these alternate embodiments are encompassed in the broader invention. An axle stop 82 limits the rotational range of motion of the two jaws 50 , 52 relative to one another to prevent excessive closing or opening/eject. The axle stop 82 impinges on the sides of the recess 76 to limit the motion.
[0048] As shown in FIG. 8 , the moving jaw 52 includes a closing arc 84 which moves or pushes the shell 14 closed after insertion of the tube 28 and the flexible member end(s) 30 . An integrally molded indexing detent 88 is located on arcuate projection 86 . The detent 88 prevents unwanted motion of the two jaws 50 , 52 in the “as supplied” position and gives the user a definitive feedback which is palpable and audible when transitioning from open, to closed, to eject positions.
[0049] As shown in FIG. 9 , the static jaw 50 includes guides 58 to guide or facilitate insertion of the tube 28 and the flexible member end(s) 30 into the proper location for closure of the receiver 10 . The static jaw 50 further includes the recess 76 which receives the axle 74 and allows for rotational motion between the two jaws.
[0050] An interior surface 90 of the static jaw 50 is partially shown in FIG. 10 . The recesses 68 receive the bosses 22 on the sides of the shell 14 and it is of note that the recesses are at two levels. Thus, the shell 14 is removably retained in this area in the open position until the moving jaw 52 is activated. A shell retention boss 92 prevents the moving portion of the shell 14 from falling down and partially closing. The left half 62 and the right half 64 are connected distal to the static jaw living hinge 66 by connection bar 94 . A first portion 96 of the connection bar 94 serves as an index point against the arcuate projection 86 . The eject ramp 70 and stop 72 are also shown.
[0051] As indicated above, the system is supplied to the user with the receiver 10 positioned in the open position in the applier 12 . In addition to the mechanism utilizing the arcuate projection 86 and its index system, the system may also be shipped in a custom package to avoid premature closure. Prior to using the receiver 10 and the applier 12 , a bridle loop and tube have already been inserted into the patient. The user then selects an appropriately sized receiver. The only difference from one size to the next is a configuration of the insert 16 . Specifically, the diameter of the recess 38 and the thickness of the insert are sized to a specific tube size or a range of tube sizes.
[0052] The user then positions the application 12 tool such that the tube slides in between the guides 58 . Likewise, bridle flexible members are positioned using the guides 58 . When all three components are in position within the shell 14 , the user closes the receiver 10 by moving finger loops 56 of the two jaws 50 , 52 together. An audible clicking sound is heard as well as a tactile signal felt indicating that the receiver 10 has reached the closed position.
[0053] Next, the user will move the finger loops 56 apart, first back to the open position and then further motion in the same direction forces the moving jaw 52 between ramps 70 thereby spreading apart the left half 62 and the right half 64 of the static jaw 50 to an ejection position. In this ejection position, the receiver 10 is now free to exit the application tool 12 and can move out of the recesses 68 which have been holding it in place. Thus, the tube and the bridle loop flexible members are locked in place in the receiver 10 . For added security, the user may choose to tie a knot in the flexible members or may tie the flexible members together and secure only one end within the receiver 10 . Of course, redundant length of the flexible member(s) may be trimmed.
[0054] Should the user wish to open the receiver 10 , for example to reposition the tube 28 , opening wedge 60 may be used. Opening wedge 60 is inserted into the substantially wedge shaped aperture 36 used to unlock the receiver which forces the locking mechanism 20 open and the receiver 10 to return to the first or open position. The receiver may then be replaced into application tool 12 for replacement if desired. The user could also place and close the receiver 10 manually, however this is not recommended.
[0055] The foregoing has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the embodiments to the precise form disclosed. Obvious modifications and variations are possible in light of the above teachings. For example, the insert may generally take the shape of a tongue which extends outward from a main body. The tongue may be designed to wrap around the tube and at least one of the ends of the flexible member when the shell is in the closed position. The tongue may be held captive and guided by the shell to bend around the tube and flexible members by stabilizing rails during closing. All such modifications and variations are within the scope of the appended claims when interpreted in accordance with the breadth to which they are fairly, legally and equitably entitled. | A receiver for securing at least one tube in a patient includes a shell operable in a first position for receiving the tube and a second position for securing the tube, and a compressible member supported by the shell for contacting the tube in the second position. A bridle looped around the patient's septum may also be secured in the second position. A system for securing the tube includes a receiver and an applier. The applier supports the receiver in the first position and transitions the receiver from the first position to the second position after the tube is positioned within the receiver. A method of securing a tube includes positioning the tube in a patient, placing a flexible member around the patient's nasal septum, receiving the tube and flexible member in a shell supported by an applier, and operating the applier to move the shell to a closed position. | 0 |
BACKGROUND OF THE INVENTION
The invention relates to a head of a mould for the hot-top continuous casting of a metallurgical product, such as a steel bloom, billet or slab.
In the case of the continuous casting of a metallurgical product, a molten metal is poured into an upper part or head of a mould having a vertical general disposition and extracted from this mould, via the bottom, is a peripherally solidified product.
The process called “hot-top continuous casting”, which in fact constitutes an improvement of the general continuous casting process, is used in such a way that the meniscus (the free surface of the cast metal) is transferred upstream of the level where the solidification of the metal inside the head of the mould starts. In order to carry out the hot-top continuous casting process, the usual copper tubular element of the mould, cooled by internal circulation of cooling water, is surmounted, perfectly contiguously, by an uncooled feed head made of thermally insulating refractory material, serving as a reservoir of molten metal fed by the pouring jet from a tundish placed a short distance above it. By virtue of this novel type of construction of the mould head, the liquid-metal meniscus is established therein, during the casting run, within the refractory feed head, whereas the solidification of the metal starts only level with the cooled metal tubular element which, as in conventional continuous casting, calibrates the cast product in terms of shape and size. Consequently, the stirring of the liquid metal due to the pouring jet is limited within the feed head. In the solidification space defined by the copper tubular element placed below, the flow of cast metal may thus be maintained in a relatively calm hydrodynamic state, thereby making it possible in particular to even out the solidification profile of the steel in contact with the cooled copper wall all around the inner perimeter of the mould. However, in order to use such a process satisfactorily, it is necessary to avoid any premature solidification of the cast metal in the feed head so as to be able to ensure that the solidification starts lower down, precisely at the point of contact with the cold copper wall.
To do this, it has already been proposed to leave a gap of very small width (less than 1 mm and generally about 0.2 mm) between the refractory feed head and the copper tubular element and to inject, via this slot, a fluid, generally an inert gas such as argon, into the mould around its inner periphery. In order to ensure gas flow at any point in the slot, the latter is fed with pressurized gas via a distribution chamber which surrounds it.
This injection of gas has the effect of shearing the heterogeneous parasitic solidified film which could form above, against the inner wall of the refractory feed head, and thus create conditions conducive to a sharp and even onset of solidification in the cooled copper element located just below.
In the case of non-circular moulds, in other words in the case of moulds provided with a cooled tubular element quadrangular in shape (for casting slabs, blooms or billets of square cross section, for example) or more generally multiangular in shape (for casting blanks already having the shape of the desired end product), it has been observed, on the cast products after complete solidification, that there are solidification defects along the edges, such as longitudinal cracks, exfoliations, etc., defects whose origin can be identified as being a lack of solidified metal at these points already in the mould, and therefore at the very moment that the solid shell forms.
SUMMARY OF THE INVENTION
The object of the present invention is specifically to provide a solution making it possible to reduce, or even to completely eliminate, these solidification defects in the corners of the cast products obtained.
For this purpose, the subject of the invention is a mould for the hot-top continuous casting of molten metals, comprising a cooled metal tubular element of quadrangular shape, defining the shape and size of the cast product and in which the molten metal solidifies on contact with the cooled inner metal wall, the said cooled tubular element being surmounted by an uncooled feed head made of thermally insulating refractory material defining a reservoir of molten metal to be solidified, a slot for injecting a shearing fluid (especially a pressurized inert gas, preferably such as argon) around the inner periphery of the mould being provided between the cooled metal element and the refractory feed head, the said mould being characterized in that it is provided with means for reducing the flow of shearing fluid in the corners.
Preferably, these means consist of an element forming an obstacle to the flow of the gas in the injection slot, the said element being placed in each of the corners of the slot.
The invention results from the following considerations. In order to obtain a satisfactory shearing effect on the flow of gas injected at the base of the feed head, it is necessary to maintain a gas flow rate all along the slot so that there are no dead regions where undesirable solidification fragments would therefore persist. However, even if the slot is fed from a peripheral pressurized-gas manifold, and therefore ensuring that head losses are equal and, consequently, that there is a linear emerging flow with a constant flow rate over the entire length of the slot, an injected-gas flow rate equal at every point around the perimeter of the cast product is not obtained. This is because there is a greater flow rate of gas in the corners of the mould due to the fact that, since the slot is, of course, of the same rectangular shape as the mould, the inside of the latter is fed with gas in two directions in its corner regions. This greater flow rate in the corners results, in the region of the slot, and therefore in particular in the upper part of the cooled copper element located just below, in an overpressure which can cause local separation of the solidified shell from the cold copper wall at the edges of the cast product. It is these separations which, because of the collapse in the effectiveness of the product cooling in the corners which results, are responsible for solidification-disturbing phenomena of the “lack of solidified metal” type, which phenomena are then manifested, on the cast product obtained, by solidification defects in the corners along the edges.
In order to make the invention more clearly understood, a description will now be given, by way of non-limiting example and with reference to the figures appended hereto, of a mould for the hot-top continuous casting of a steel billet of square shape according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is a schematic half-view, in axial cross section, of the upper part of the mould on the plane 1 — 1 in FIG. 3 .
FIG. 2 is a schematic half-view in axial cross section of the upper part of the mould on the plane 2 — 2 in FIG. 3 .
FIG. 3 is a top view of the lower part of the mould on the plane 3 — 3 in FIG. 1 or in FIG. 2 .
FIG. 1 and FIG. 2 show the upper part of a hot-top continuous casting mould denoted overall by the reference number 1 , which has a cooled copper tubular element 6 extended upwards, and completely contiguously in order to prevent any infiltration of molten metal, by a feed head 5 made of uncooled refractory material.
The cooled metal element 6 and the refractory feed head 5 define, in their internal part, an internal casting space 3 into which a molten metal 4 , such as steel, is poured and solidifies. As may be seen in FIG. 3, the internal casting space 3 has a cross section in the form of a square with rounded corners, the radius of which has been exaggeratedly increased on purpose in order to more clearly show the characteristic elements making up the invention, which will be explained again below.
It will be noted that the cooled copper tubular element 6 forms the main element of the mould. It is this element which, being vigorously cooled by an internal circulation of water (which takes place here in a space 2 left between the element 6 and a metal jacket 8 which surrounds the latter at some distance therefrom), conventionally serves as a crystallizer, against the inner wall 11 of which the molten steel 7 solidifies, forming firstly a first shell 7 ′ as soon as the steel first comes into contact with the cold copper 11 . Next, as the cast product progresses downwards in the mould in the direction indicated by the arrow F, this shell, under the effect of the intense heat pumping due to the vigorous cooling of the copper element 6 , steadily thickens. The solidification of the cast product 7 thus progresses from the periphery towards the central axis until complete solidification, which conventionally occurs about ten metres below the mould, water sprays being provided for this purpose following the mould in order to immediately spray the surface of the cast product to be cooled.
As regards the feed head 5 , which is a specific component of so-called “hot-top” casting, its essential function is to serve as a reservoir 4 of molten metal. This metal arrives as a pouring jet 12 coming from a tundish 14 , placed a short distance above it, via a nozzle 13 mounted on the outlet orifice of the tundish. The reservoir 4 constitutes a buffer mass, which plays a key role with regard to the hydrodynamics by allowing the often violent stirring of liquid metal due to the great momentum of the steel jet 12 to freely develop therein and therefore to be damped therein. Thus, the liquid steel which then enters the crystallizer 6 , in order to solidify in it, is in a much calmer state and, above all, far from the meniscus 15 , the stirring of which is often the cause of solidification heterogeneities in the outermost shell in a conventional continuous casting mould. Beneath the reservoir 4 , the flow of the molten metal approaches “piston”-type flow, that is to say flow without a marked gradient in the velocity vector across the section, something which is extremely favourable to the proper execution of the solidification process.
As a general rule, but not shown in the figures, the feed head 5 made of refractory material has a main upper part made of a fibrous refractory material chosen for its thermal insulation properties so as to keep the reservoir of molten metal 4 in the liquid state, for example the material sold under the name A120K by the company KAPYROK, and a lower annular insert chosen to be made of a dense refractory material, such as SiAlON® in order to ensure the best mechanical integrity in the immediate vicinity of the cooled copper element 6 stressed by the onset of solidification.
It will be seen that the feed head is fastened, in a position well aligned with respect to the tubular element 6 , by means of alignment pins, not shown, and of an assembling flange 9 with a tie rod 9 ′, this flange bearing on a metal plate 5 a covering the refractory part. A box 10 made of sheet metal is advantageously provided for the passage of the tie rods and in order to stiffen the assembly.
Despite the thermal insulation properties of the refractory material used for the feed head 5 , parasitic solidified films 16 of cast metal, of greater or lesser extent, may form on the inner wall of the feed head. Even localized on the perimeter, they can be deleterious to correct solidification in the crystallizer 6 in so far as these fragments 16 may reach as far as level with the edge of the cooled element 6 where the solidification starts. In order to break, before this stage, any undesirable solidified film formed prematurely in the feed head, a shearing fluid is injected peripherally at the base of the feed head. In this regard, it would be preferable to use a gas, and even more preferably a gas which is chemically inert with respect to the cast metal, such as argon.
To this end, a narrow slot 18 , for example with a width of about 0.2 mm, is provided between the feed head 5 and the cooled copper element 6 . This slot opens freely towards the inside of the mould and emerges at its other end in a sealed annular chamber 19 provided in the feed head. This chamber 19 , which runs all along the slot 18 , serves to properly distribute the linear flow of gas that has to emerge from the slot. It is connected via a duct 20 to an external source 21 of pressurized gas. The slot 18 has an annular shape similar to the quadrangular shape of the mould, and therefore to that which the cast product 7 adopts once the shell has solidified within the copper element 6 . In particular, it therefore has an outline with four corners, as shown in FIG. 3, where the rounded part of the corners has been deliberately exaggerated for the reasons mentioned above.
Because near each of the corners 3 a , 3 b , 3 c and 3 d of the mould the shearing gas introduced into the casting space 3 is supplied from two sides of the slot 18 at right angles, the two-directional and convergent feed in the corner regions of the casting space 3 means that more gas is blown into these regions, entailing a risk of localized separation of the cast metal from the copper wall 11 at the upper edge of the latter, at the point where the outermost shell forms, and, consequently, means that there is insufficient solidified metal, compared with the rest of the perimeter, in the region of the edges of the cast product during solidification within the copper element 6 , because of the lack of effective cooling of the product at these points.
In order to prevent this excess injection of gas into the corner regions, elements for obstructing the flow of the gas are placed, according to the invention, in the corners of the slot 18 , as may be seen in FIGS. 2 and 3.
The obstructing elements 17 , placed in corners of the gap 18 , may consist of bundles of flexible fibrous refractory material which, after the feed head has been clamped against the top of the metal element 6 , locally block the passage, by flattening, from the outside towards the inside of the mould. Each of the obstructing elements 17 is then advantageously bounded towards the outside by the internal perimeter of the distribution chamber 19 , towards the inside by a corner of the casting space 3 , and laterally by two straight sides converging towards the casting space 3 and making an angle α with the perpendicular to the plane internal surface of the casting space 3 , at the corresponding end of the rounded corner 3 a (or 3 b , 3 c , 3 d , respectively) of the casting space which delimits, inwardly, the obstructing element 17 .
If the rounded corner of the casting space of the mould has a radius of about 6.5 mm, the width of the obstructing element 17 in its narrowest region, adjacent to a corner of the casting space, must preferably be between 4 and 6.5 mm. If this width is less than 4 mm, the localized excess flow of gas injected into the corner is not properly eliminated. If the width is greater than 6.5 mm, there is a region near the corner where there is no linear flow of injected gas.
Moreover, the angle a between the straight side of the obstructing element 17 and the perpendicular to the internal surface of the casting space will advantageously be between 0 and 45°. Outside these values of the inclination of the sides of the obstructing element 17 , the linear flow of injected gas, that is to say the flow per unit length of the inner perimeter of the mould level with the slot 18 , becomes zero in a region near the corners.
It has been found that a value of the angle α of about 20° makes it possible to obtain a constant linear flow around the inner perimeter of the mould in the case of the casting of products of rectangular or square shape. In certain cases, depending on whether the shape of the products to be cast is more or less complex, the two straight lateral sides of the obstructing elements 17 may make different angles α and α′ with the perpendiculars to the plane internal surface of the internal casting space 3 at the ends of the corners.
By using elements for obstructing the slot 18 which have the geometrical and dimensional characteristics given above, it is possible to obtain a linear flow of inert gas into the internal casting space, at the slot 18 , which is perfectly constant. In this way, the solidification defects observed along the edges of the cast product once it has solidified are eliminated.
The invention is not limited to the embodiment which has been described. For example, it is possible to use, as the element obstructing the slot 18 in its corner regions, materials different from refractory fibres. These elements may be completely impermeable to the gas, or else slightly porous.
It is also possible to obstruct the slot 18 in its corner regions and to eliminate the gas flow in these regions by making the feed head 5 slightly thicker in the corner regions extending over the width of the slot 18 , between the internal casting space 3 and the distribution chamber 19 . This additional thickness may be achieved by machining, for example by milling, the lower face of the feed head 5 adjacent to the element 6 . Conversely, the additional thickness in the corner may be obtained on the element 6 , that upper face of which, facing the feed head 5 , would be machined for this purpose. Preferably, the region of additional thickness will have a shape similar to the shape of the obstructing elements 17 as illustrated in FIG. 3 . This additional thickness may be preferably about 0.2 mm.
It is also possible to partially obstruct the distribution chamber 19 in regions close to its corners, so as to limit or to eliminate the injection into the corner regions of the slot 18 . The distribution chamber may be obstructed, for example, by introducing, into the corner regions of the distribution chamber, plugs penetrated by channels in the direction of flow of the gas in the distribution chamber or else plugs having a degree of porosity.
The invention applies to any multiangular mould head for the hot-top continuous casting of a metallurgical product, such as a billet, a bloom or a slab, or blanks of a shape already close to the end product, (beams, rails, various sections, etc.) provided that the head satisfies its definition given by the appended claims. Moreover, it may be applied both in the case of the continuous casting of steel and in the case of the continuous casting of non-ferrous metals. | The invention concerns an ingot mould comprising in succession, in the direction for extracting the metallic product to be cast ( 7 ): a preheater ( 5 ) made of noncooled refractory material acting as reservoir for the melting metal to be cast and a standard cooled tubular metal element ( 6 ) for solidifying the metal. A slot ( 18 ) for injecting the shearing gas (for example Ar) is arranged between the preheater ( 5 ) and the metal clement ( 6 ) so as to emerge on the ingot mold internal periphery. The injection slot comprises means ( 17 ) for reducing the gas flow in each of the ingot mold angles, preferably formed by obstructing elements. The invention enables to reduce, even eliminate, defects encountered along the edges of the solidified cast products. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 61/825,987, filed May 21, 2013 and U.S. Provisional Application No. 61/831,594, filed Jun. 5, 2013, both applications are incorporated herein by reference in their entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to a device for electronic targeting evaluation of shots fired on a shooting range and, more particularly, to a target, target system and method of use for electronic targeting evaluation of shots fired on a shooting range, which has a sensor arrangement for detecting the positions of the hits in the vicinity of the target or targets and a mobile device and receiver to provide real-time feedback of results.
DESCRIPTION OF THE RELATED ART
[0003] Various target shooting systems exist for analyzing the accuracy of a shooter's shot on a target. The means by which these target shooting systems work vary widely as demonstrated by the patents and applications identified below. Other than the standard target shooting equipment, namely a target and a means for projecting a projectile, such as a firearm, the systems disclosed in these patents and applications require some sort of additional, special equipment and lack versatility, portability, the ability to store shot information given a set of user-selected criteria (type of gun, ammo, distance, etc.) and ability to sync multiple shooters with multiple targets, all on a commonly used electronic device such as an iPad.
[0004] Cardboard or paper targets are most commonly used at firing ranges for training persons in the use of firearms. Such targets are also used at military and police firing ranges to allow soldiers and police officers to maintain and improve their marksmanship skills. Typically, shooters will shoot onto a paper target, physically walk to the target and write down the scores with a pen and notepad. Alternatively, an observer must either be stationed close to the target or be provided with an expensive spotting scope to advise the marksman of his or her progress. Such an approach subjects the shooter or observer to some danger and in the example of using an observer, requires a second dedicated person to train shooting skills.
[0005] Accordingly, there is a need for a target and/or shooting experience to eliminate the risks and time associated with physically walking to the target or observing the target to determine the accuracy of the results.
[0006] Some target ranges use a conveyer system to retrieve the target to avoid the risk of physically entering the shooting range. However, this approach does not eliminate the time to log the hits and additional time is spent waiting for the physical target to be conveyed to the shooter for evaluation.
[0007] As noted below, there are several companies that make electronic target systems using wired solutions and very basic proprietary computer systems. For example, some computer software used in such systems uses a very basic bulls-eye design or animal silhouettes and produces a score down to the tenth (e.g., 9.4 out of 10.0). Some of these computer systems are used by competitive shooters, avid hunters, military and law enforcement. There are also wireless technologies that allow an electronic target to communicate with a receiver and computer to display the shots on a target. The computer systems used in existing wireless technology consists of a prohibitively expensive, bulky, steel cased, rugged computer monitor that attaches to a Pelican Case that houses a receiver and large battery. The case is large and bulky as well. (for example, see http://www.kongsberg-ts.no/en/index.php?pageID=28&slideid=11).
[0008] In one such prior art system the target system uses acoustical measurements to determine the location of the impact of a bullet. As with other current systems, the targets are large, cumbersome and employ a special proprietary computer, not a personal mobile device.
[0009] Another one of the prior art targets uses several infrared sensors in conjunction with five microphones. The infrared sensors provide very accurate positioning in the bulls-eye area and the microphones cover the outer range.
[0010] Another company named SIUS provides an electronic scoring system such as the SA941 system or S 110 system, which provides electronic results real-time to a shooter at a shooting range. The system can accommodate multiple shooters in multiple lanes and provide results to spectators via monitors. The system uses a LON-bus based wired communication and measures the shot's impact using only microphones. Particular equipment must be used depending on the type of weapon (e.g., caliber) and ammunition. The LS10 Laserscore, a target for airguns, uses infrared laser measurement to determine the location of the strike or impact. However, target ranges must be specially equipped to provide such request real-time and such results are transmitted to specially programmed computer systems. U.S. Published Application No. 2012/0194802 describes this SIUS system, such application is hereby incorporated by reference in its entirety. The targets system is very bulky and not for portable use.
[0011] In addition to laser or acoustic determination, electronic targeting systems can detect and evaluate the holes shot in the vicinity of a target electro-optically, or detected in other ways, in order to establish the positions of the holes in relation to a target or targets. For example, U.S. Published Application No. 2002/027190 to Ulrich describes such a method, the '190 publication is hereby incorporated by reference in its entirety. As with the SIUS system, Ulrich fails to describe a portable system that can be used with standard mobile devices, such as an Android or Apple tablet, smartphone or mobile phone.
[0012] Other systems previously described are as follows:
[0013] U.S. Pat. No. 4,204,683 issued 27 May 1980, by Filippini et al. for Device and Method for Detection of the Shots on a Target from a Distance discloses a video system for capturing shots on a target based upon the point of penetration of a light field by a projectile. This system requires a specialized target. The '683 patent is hereby incorporated by reference in its entirety.
[0014] U.S. Pat. No. 4,514,621 issued to Knight et al. discloses a complex, computerized firing range including transducers located adjacent the target area for detecting airborne shock waves from supersonic projectiles. The '621 patent is hereby incorporated by reference in its entirety.
[0015] U.S. Pat. No. 4,763,903 issued 16 Aug. 1988, by Goodwin et al. for Target Scoring and Display System and Method discloses a system for capturing shots on a target based upon the point of penetration of a light field by a projectile. This system requires a specialized target. The '903 patent is hereby incorporated by reference in its entirety.
[0016] U.S. Pat. No. 4,949,972 issued 21 Aug. 1990, by Goodwin et al. for Target Scoring and Display System discloses a system for capturing shots on a target based upon the point of penetration of a light field by a projectile. This system requires a specialized target. The '972 patent is hereby incorporated by reference in its entirety.
[0017] U.S. Pat. No. 5,092,607 issued 3 Mar. 1992, by Ramsay et al. for Ballistic Impact Indicator discloses a system for alerting a shooter that a bullet has struck a target by causing a strobe light to be triggered using a vibration sensor. The patent does not provide for the location of the strike. The '607 patent is hereby incorporated by reference in its entirety.
[0018] U.S. Pat. No. 5,577,733 issued 26 Nov. 1996, by Downing for Targeting System discloses a system for capturing shots on a target based upon the point of penetration of a light field by a projectile. This system requires a specialized target. The '733 patent is hereby incorporated by reference in its entirety.
[0019] U.S. Pat. No. 5,775,699 issued 7 Jul. 1998, by Orito et al. for Apparatus with Shooting Target and Method of Scoring Target Shooting discloses an apparatus for capturing shots on a target based upon light reflected through the point of penetration of a target by a projectile. This method requires a specialized target. The '699 patent is hereby incorporated by reference in its entirety.
[0020] U.S. Pat. No. 5,924,868 issued 20 Jul. 1999, by Rod for Method and Apparatus for Training a Shooter of a Firearm discloses a video camera mounted on eyewear worn by a shooter to produce a displayed image of the target to assist the shooter in aiming the firearm. This method requires specialized eyewear integrated with a camera. The '868 patent is hereby incorporated by reference in its entirety.
[0021] U.S. Pat. No. 7,158,167 issued 2 Jan. 2007 by Yerazunis et al. for Video Recording Device for a Targetable Weapon discloses a video image recording device which is mounted on a gun to record video images before and after firing of the gun. This system requires a specialized camera mounted on and integrated with the gun. Shooting Range discloses a system for capturing shots on a target based upon the point of penetration of a light field by a projectile. The '167 patent is hereby incorporated by reference in its entirety.
[0022] US Patent Application 2002/0171924 published 21 Nov. 2002 by Varner et al. for Telescope Viewing System discloses a telescope viewing system with a camera attachable to an eyepiece of the telescope and a computer system in communication with the camera for displaying images, in particular, celestial images, recorded by the camera upon a display screen. This system provides only a telescope viewing system with a camera for capturing images. The '924 publication is hereby incorporated by reference in its entirety.
[0023] US Patent Application 2003/0180038 published 25 Sep. 2003 by Gordon for Photographic Firearm Apparatus and Method discloses a telescopic firearm scope integrated with a camera to photograph a target at the instant the target is fired upon. This method requires a specialized scope integrated with a camera for use with a firearm. The '038 publication is hereby incorporated by reference in its entirety.
[0024] US Patent Application 2004/0029642 published 12 Feb. 2004 by Akano for Target Practice Laser Transmitting/Receiving System, Target Practice Laser Transmitter, and Target Practice Laser Receiver discloses a target practice laser transmitting and receiving system to capture details of a shot fired upon a target including position, time, distance, ammunition type, weapon type and other variables of the fired shot. This system requires a specialized laser system to capture and analyze shots on a target. The '642 publication is hereby incorporated by reference in its entirety.
[0025] US Patent Application 2005/0002668 published 6 Jan. 2005 by Gordon for Photographic Firearm Apparatus and Method discloses a telescopic firearm scope integrated with a camera to photograph a target at the instant the target is fired upon. This method requires a specialized scope integrated with a camera for use with a firearm. The '668 publication is hereby incorporated by reference in its entirety.
[0026] US Patent Application 2006/0150468 published 13 Jul. 2006 by Zhao for A Method and System to Display Shooting-Target and Automatic-Identify Last Hitting Point by Digital Image Processing discloses a video-monitor system to capture and display the location of a shot fired on a target. This system requires a specialized camera. The '468 publication is hereby incorporated by reference in its entirety.
[0027] US Patent Application 2006/0201046 published 14 Sep. 2006 by Gordon for Photographic Firearm Apparatus and Method discloses a telescopic firearm scope integrated with a camera to photograph a target at the instant the target is fired upon. This method requires a specialized scope integrated with a camera for use with a firearm. The '046 publication is hereby incorporated by reference in its entirety.
[0028] US Patent Application 2008/0163536 published 10 Jul. 2008 by Koch et al. for Sighting Mechanism for Fire Arms discloses a sighting mechanism with cameras mounted on a firearm to capture shots fired on a target and to display the shots on a video screen. This system requires a specialized camera integrated with a firearm. The '536 publication is hereby incorporated by reference in its entirety.
[0029] US Patent Application 2008/0233543 published 25 Sep. 2008 by Guissin for Video Capture, Recording and Scoring in Firearms and Surveillance discloses a video camera and recording device integrated with a weapon to record shots fired; wherein the camera may be mounted either on the firearm or within the bore of the firearm. This system requires a specialized camera integrated with a firearm. The '543 publication is hereby incorporated by reference in its entirety.
[0030] U.S. Patent Application 2011/311949 published 22 Dec. 2011 to Preston et al. for Trajectory Simulation System Utilizing Dynamic Target Feedback That Provides Target Position and Movement Area but does not disclose at least a portable target system that may utilize a standard mobile device. The '949 publication is hereby incorporated by reference in its entirety.
[0031] U.S. Patent Application 2012019802 published 2 Aug. 2012 to Walti-Herter for Method For Electronically Determining The Shooting Position On A Shooting Target relates to a method for electronically determining the shooting position on a shooting target using an acoustic system. The '802 publication is hereby incorporated by reference in its entirety.
[0032] U.S. Patent Application 2012/0258432 published 11 Oct. 2012 to Weissler for Target Shooting System provides real-time visual and electronic feedback regarding hits but does not involve a reusable target and requires the use of an expensive video system. The '432 publication is hereby incorporated by reference in its entirety.
[0033] U.S. Patent Application 2012/2313324 published 13 Dec. 2012 to Frickey for Articulated Target Stand with Multiple Degrees of Adjustment discloses a target stand usable with the target disclosed herein. The '324 publication is hereby incorporated by reference in its entirety.
[0034] U.S. Patent Application 2013/0147117 published 13 Jun. 2013 by Graham et al. for an Intelligent Ballistic Target discloses a target body that detects a hit and at a certain number of hits, the target body is released. The '117 publication is not portable nor does it allow for real-time feedback to a standard mobile computing device. The '117 publication is hereby incorporated by reference in its entirety.
[0035] U.S. Patent Application 2013/0193645 published 1 Aug. 2013 by Kazakov et al. for a Projectile Target System discloses a sealed projectile target. However, the target has to face the shooter and may not be accurate with oblique shots. The target requires the setup of a target and a camera and is not an all is one system. Further, image processing may be deficient in a non-ideal environment, losing environmental flexibility.
[0036] While other target products are available, none solve the portability and ease of use problem. Accordingly, there is a need for a target system that can provide time and cost savings with real-time feedback regarding hits, that works with a variety of projectiles without changing the equipment or setup, is economical and reusable, that is easily portable such that an individual can rely upon using his or her own target for consistency, that does not require specialty set-up that may be prone to human error, increases safety for the user by eliminating the need to enter a live firing range to check targets, provides data storage of shot information, analysis and aggregation, and may be used with a standard mobile computing device such as an iOS or Android-based smartphone or tablet.
SUMMARY OF THE INVENTION
[0037] The present embodiments address the needs discussed above with a portable, wireless target system that interfaces with a personal computing device to provide real-time feedback.
[0038] One preferred embodiment is a target system with at least one target, at least one target stand, at least one transmitter, at least one receiver that is typically the base-station and not a mobile device, a plurality of sensors, and a target computer. The target is connected to the stand, preferably removably connected to the stand. In a preferred embodiment, the target removable, collapsible, storable, portable, all of these or combinations of one or more of these target aspects. The sensors are connected to the target computer such that a target strike is registered by the sensors and information detailing the strike, for example, the location and the force of the strike. Preferably, the target computer is located proximate the sensors such that the information may be conveyed wirelessly, wired, or otherwise. Alternatively, the sensors may interface directly with a mobile device application. Preferably the target computer interacts with an application programming interface (API) on the mobile device. The target system includes at least one transceiver, which can be a transmitter, which transmits data from the sensors directly or indirectly. Where transmitted indirectly, the target computer is the transmitter in a preferred embodiment. In a preferred embodiment the transceiver transmits data to a base station which is close to the shooter and will relay the strike or impact data to the shooters mobile device wirelessly, for example, via Bluetooth. Alternatively, Wi-Fi, RFID, or infrared wireless data transfer can be used.
[0039] In the preferred embodiment the transmitter is capable of communicating with more than one transceiver or receiver, base station, or mobile device. For example, the data may be conveyed to multiple base stations or multiple mobile devices for purposes of real-time monitoring of all shooters in a competition for example. Unique target identification information is conveyed to the mobile device in a preferred embodiment. The API can perform a determination regarding the whether the target identification correlates to the shooter or whether it is a target of another shooter. In one embodiment, the target ID may be scanned at the beginning of a shooting session. NFC technology could be used to scan a target ID for example, or a bar code, QR code or the like may be used.
[0040] An embodiment of the target system includes an electric motor with a wireless receiver connected with at least one target to move the target wirelessly in the X, Y, and Z axis, or any combination of directions.
[0041] In some embodiments the target comprises multiple target plates, in others the target is a single piece. The target itself is portable and reusable in the preferred embodiment such that a shooter can take the target with them to any suitable location. In some embodiments the target can fold. Alternatively, the target can be disassembled into smaller portions. In a preferred embodiment the target is manufactured of a material that renders the target reusable, such as a steel target or the like. In an embodiment, portions of the target are made of different materials. For example, one side of a steel target can be Kevlar impregnated rubber. The targets, portions thereof, or overlays of such targets can be made of other materials such as paper, cardboard, plastic, resins, and the like.
[0042] In a preferred embodiment the sensors are accelerometers. Other sensors may be used, as would be known by one of ordinary skill in the art. In a preferred embodiment more than one accelerometer is used. More preferably three accelerometers are used. Most preferably four accelerometers are used. In a preferred embodiment the accelerometers are proportionately and evenly distributed on the target. Alternatively, the sensors may be photodiodes or a mixture of accelerometers and photodiodes.
[0043] A preferred embodiment of the target system is fully battery powered for portability circumstances, meaning each component may be individually battery powered or may share portable power sources as permitted by proximity.
[0044] In the embodiments of the target system, the data related to the target and a projectile strike on the target are conveyed to the shooter real-time via a mobile device, such as a mobile telephone, personal computer, handheld device, iPad, iPhone, tablet computer, laptop, notebook, ultrabook, Android phone, video game platform or other personal computing device capable of wirelessly receiving such data. In a preferred embodiment, the mobile device uses an API to interface, receive, display and store the impact or strike data. Such data can be correlated with a number of other useful information, including location, date, and time. Information may also be stored in a cloud based database. In such cases the receiver is integrated with the mobile device. In a preferred embodiment the receiver is a standard part of the mobile device. In alternative embodiments the receiver is integrated with a detachable memory device, the transmitter is integrated with a detachable memory device, or both. In another embodiment the personal mobile device is in communication with a receiver proximate to a shooter, wherein said mobile device and said receiver are associated by wireless communication, for example, Bluetooth, RF, Wi-Fi, IR, or NFC.
[0045] The vibration sensors in some embodiments described herein use a process called trilateration or multi-lateration to determine impact information. Such a process uses at least three or more vibration sensors. In another embodiment, a process of triangulation or multi-angulation is used, where at least three vibration sensors are used. In some embodiments herein, the vibration sensors provide a unique vibration signature when impacted by a projectile.
[0046] The vibration signatures include amplitude, phase, frequency, frequency spectrum information, location, time, date, and force of impact, for example. The target impact data may also include a user-defined and assigned identifier. This identifier may be an alphanumeric.
[0047] In some embodiments, the target systems described herein further comprise a controller to receive vibration signatures corresponding to the sensed vibrations to determine where the target has been impacted by a projectile. In some embodiments long-range wireless transmitters may be coupled with the target and short-range wireless transmitters may be coupled with the personal mobile computing device configured to virtually report real-time data on a virtual target relating to the projectile impact. In other embodiments a second transmitter is unnecessary as the personal mobile computing device receives the information directly.
[0048] There is no limitation regarding the type of projectile that can be used with the embodiments herein, such as a bullet, an arrow, a paintball, a dart, or an athletic ball.
[0049] An embodiment of a mobile application used with the target system provides real-time impact information comprising the impact of the projectile on the target relative to a target design on a virtual target, wherein the mobile application optionally determines a score from the impact based on an accuracy algorithm and stored in a database.
[0050] The mobile application receives user input comprising the type of weapon used; the type of ammunition used; the distance from the weapon to the target; and weather conditions; wherein said mobile application stores the score based on at least one such input.
BRIEF DESCRIPTION OF THE DRAWING
[0051] FIG. 1 is a flow diagram describing an embodiment process.
[0052] FIG. 2 is a flow diagram describing an embodiment process.
[0053] FIG. 3 depicts a target embodiment and the target stand.
[0054] FIGS. 4 a - c depict views of a target and target stand embodiment.
[0055] FIGS. 5 a - 5 c depict views of a stowed target and target stand embodiment.
[0056] FIGS. 6 a and 6 b depict views of a stowed target and target stand embodiment.
[0057] FIG. 7 depicts an alternative target embodiment and the target stand.
[0058] FIGS. 8 a and 8 b depict views of a target embodiment and the target stand.
[0059] FIG. 9 shows a target range setup utilizing a target embodiment.
[0060] FIG. 10 shows an alternative portable target and stand embodiment.
[0061] FIG. 11 depicts a triangulation strike technique.
[0062] FIG. 12 shows signal transceivers with multiple target embodiments.
[0063] FIG. 13 shows alternative sensor position and strike determination embodiments.
[0064] FIG. 14 a shows one visual display of strike results.
[0065] FIG. 14 b shows another visual display of a target embodiment.
[0066] FIG. 14 c shows a visual display of a second target embodiment.
[0067] FIG. 14 d shows a visual display of a third target embodiment.
[0068] FIG. 15 shows a comparative display of three shooters.
[0069] FIG. 16 shows an alternative touch-screen visual display of strike results.
[0070] FIG. 17 shows an alternative target shape with wired and wireless signal options.
[0071] FIG. 18 shows an alternative matrix style signal placement.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0072] The preferred embodiments of the portable, real-time target system, including the portable target and base and method of use is disclosed herein. Other variations and features known to those of skill in the art may be used with and in conjunction with the embodiments described and disclosed herein without straying from the scope of the invention.
[0073] FIG. 1 presents a flow diagram of certain steps of the target system. Prior to 101 a user, or a shooter, sets up the target system where desired and the target system initiated by powering the system. Alternatively the target power can be designed to turn on as the target system is unfolded and setup. The portable target system, as exemplified in FIG. 3 , may be carried and set up in a number of remote environments, including any variety of shooting ranges. Desirably, the portable target system allows the user to reduce variables experienced at different ranges and use the same system, capturing relevant shooting data for honing accuracy and shooting skills. After the target is put in place, the user can locate themselves at a desired distance as determined in a number of ways, such as through a GPS transceiver on the target system. In one embodiment the user will start the application on the mobile computing device where the personal transceiver is located. After the target is impacted by the projectile in step 101 , the plurality of sensors register the impact and send the impact data to the target computer located proximate the target and sensors. Preferably at least three sensors are used on the target, more preferably four sensors. More sensors can be used and will provided greater precision, accuracy and better identification of outlier signals. After the sensors send impact data to the target computer in step 102 , in step 103 the target computer proximate the target converts the analog signal to digital, determines the coordinates of the impact location, and transmits the data package to the target transceiver, which is proximate the target computer and target. Alternatively, the coordinates may be calculated by a mobile computer device. The sensors may be hardwired or data may be transmitted electronically to the target transceiver and sent to the target computer for processing. The target transceiver wirelessly transmits the coordinates of the particular impact to the personal transceiver in step 105 proximate the shooter/user or alternatively to an observer, judge or other interested party with a transceiver configured to receive such information. In step 106 the personal transceiver sends impact data wirelessly, such as via Bluetooth, to one or more mobile computing devices, such as an iPad, smartphone, iphone, laptop, tablet, or the like. In an alternative embodiment the personal transceiver may be part of the mobile computer device. Where the personal transceiver is integrated with the mobile computing device, wireless transmission is not necessarily preferred. Multiple devices may receive the data from the personal transceiver. In an embodiment the personal transceiver is located in one mobile computing device and may transmit to other mobile computing devices enabled to receive the information. In step 107 the mobile computing device receiving the data processes the data to display information relating to the impact, including in some embodiments displaying where the impact occurred on a virtual target simulating the actual target.
[0074] FIG. 2 discusses the processing of the information received by the mobile computing device. Step 201 indicates the mobile computing device has received the impact data. In step 202 a mobile application may be used to process the data and display the location of the impact on a virtual target simulating the actual target. In an embodiment a large amount of data is also provided for each impact which may be accessed by scrolling or if a touch screen is used by touch of the impact designation on the virtual display. In an embodiment the user may customize the mobile application to embed and display the information important to the user, including a calculated measure of accuracy or a measure of skill that may consider the level of difficulty in addition to the accuracy, where the level of difficulty may be a function of a number of factors such as weather conditions such as the level of wind or visibility, the distance compared with the weapon, and other variables, including but not limited to ballistic coefficient, distance to target, weapon type and modifications, time elapsed between each shot, number of shots, ammunition type, elevation difference between target and shooter, stationary or moving target, shooter's stance (prone, kneeling, standing), shooter's support (bench rest, sling, bipod, etc.), weapon sights (magnification, windage and elevation settings, recticle (MIL versus MOA), and brand). In step 203 the mobile application may synchronize the shot performance, data and the shooter/user profile with an online database for comparative analysis and storage of the results. In step 204 the data may be saved in a database, such as a relational database for searching and data manipulation. Such may be used in a shooting series competition.
[0075] FIG. 3 shows an embodiment of the target and frame 300 . The target and frame is made to be portable and can be folded or disassembled to easily carry with the user to a variety of locations where the user may wish to use the target system. The target includes a target plate 301 that is made of a material conducive to target shooting. In one embodiment the target plate is made of AR500 steel. In another embodiment a rubberized coating may be used on target plate. In another embodiment polyethylene may be used. For targets to be functional and safe, they should be made of a material with a Brinell hardness number (BHN) of at least 500, preferably at least 550, preferably at least 600. The material must also provide sufficient strength, toughness, and impact resistance. Other materials are Heflin REM 500 steel. If the hardness is excessive the steel may be too hard and too brittle for ballistic training purposes, for example 700. Preferably, steel with a smooth, flat surface is used for the target to dissipate the projectile's energy for a longer lasting target. The base 302 is made of a mild steel in some embodiments and configured to present a streamlined or minimal face toward the shooter to avoid dangerous ricochets to minimize risk and unpredictable splatter. In an embodiment of the present invention, the target pivots with a locking mechanism, for example, a pin or spring lock. The pivot is such that the shooter may setup the target on an uneven surface but adjust the stand to present a flat face from the perspective of the shooter. Impact sensors 304 may be located in some embodiments in each corner of the target. A minimum of three sensors are needed for most purposes, four sensors are more preferable, and accuracy of the system increases as the number of sensors increase. One way the target may be locked in place after pivoting and adjusting to the preferred position is to use a removable locking pin that both allows the target face to be optimally positioned for target practice but also allows for secure storage when folded or carried. Preferably, the target may be stored flat to minimize the footprint for the target. One embodiment of the pin system is shown in FIG. 3 , at 305 . An enclosure shield 306 is included to shield the electronics from stray bullet fire or splatter. The electronics may be place in a variety of locations, a preferred location is shown as 307 on FIG. 3 behind the target plate and protected by the enclosure shield. The once set in a preferable location and orientation, the frame may be secured in place. One way to secure the frame is through use of stakes and holes in the frame such as 308 in FIG. 3 .
[0076] FIG. 4 shows various views of the target and frame with the target locked in an upright position. FIG. 5 shows various views of the target and frame in a closed position for carrying or storage. Preferably the profile and footprint of the target and frame is minimized in this position. FIG. 6 depicts the carry handle 610 that may be used to carry the target and frame when the target is in the stowed position. FIGS. 7 and 8 provide additional variations of the target. In FIG. 8 the target plate 801 is configured with a target face made of a material that is both bulletproof and transparent, such as an optically clear polycarbonate material or aluminum oxynitride (known commercially as ALON). Behind the target face material is a computer display designed to present a large number of characters, shapes, figures, fictitious images, historical images, and more. The figure depicted may move on or across the display for reactive target practice. In some embodiments, the shooter may upload any number of video files or photographs to make the experience more challenging and/or entertaining. In such an embodiment, the generated score from each impact is configured to be a factor of the situation displayed. For example, a situational simulation may be uploaded and displayed to challenge the shooter's reaction time and judgment. In other embodiments, real-life training modules may be used to simulate scenarios and score the user based on a number of factors in how to best react to the particular scenario. The user may upload and control the display from the mobile computer system which can record the simulated scenario and the user's reaction for later playback, demonstration, discussion and comparison. Alternately, the display may be projected on a target face from a forward position or a position on the target frame. In these embodiments the figure, simulation or other depiction may be transferred wirelessly from the mobile computer. Alternatively, the target computer may be programmed with such video depictions and simulations. In another embodiment the target computer has a port, such as a usb port for media interface. Preferably, a solid state memory is used with the target computer to avoid the risk of damage and data loss. The target computer in some embodiments can interface with an external computer or hard drive for backup storage. In some embodiments the target computer can backup information wirelessly to a connected mobile computer or database that is not local to the target computer, for example, through the internet. Alternatively, the database may be cloud-based storage.
[0077] FIG. 9 depicts a simplified depiction of the target system components wherein the target system includes a target 922 with a target face 926 with a target pattern displayed thereon 936 . The target plate is oriented such that a projectile will ricochet in a safe manner toward the ground or away from the shooter as depicted in 928 . In an alternate embodiment the target may be mounted on a vertical stand that is adjustable in height 924 . The stand may have a stabilized base or may be implanted into a soft surface such as in the ground. A rifle 930 or other means of conveying the projectile is used at a distant location 938 from the target. Upon impact, for example at point 983 , the sensors send impact information to the signal processing circuit or the target computer proximate thereto, which may be hardwired or wirelessly in contact with the target sensors. The transceiver 940 receives the processed data from the target computer and transmits the data to the mobile computer and the personal transceiver which further processes the data and provides a visual output of the impact information based on the circumstances and target program used.
[0078] FIG. 10 shows a perspective view of strike plate 1022 coupled to support member 1024 . Support member 1024 includes a fixed base 1044 , a pivot member 1046 coupled to fixed base 1044 , and mounts 1048 secured to a back planar surface 1050 of strike plate 1022 and to pivot member 1046 . Fixed base 1044 includes a cradle portion 1052 for loosely accommodating pivot member 1046 . Pivot member 1046 lies in cradle portion 1052 such that when planar strike surface 1026 (not shown) is struck by projectile 928 ( FIG. 9 ), strike plate 1022 is permitted to rotate about a pivot axis 1054 established by the positioning of pivot member 1046 in cradle portion 1052 of fixed base 1044 . The movement of strike plate 1022 around axis 1054 upon impact of projectile 928 ( FIG. 9 ) dampens the force of the impact to allow for a smaller ricochet proximity. This embodiment is particularly useful in less open locations where the portable target system is setup. In this embodiment, the target plate is removable from support member 1024 or removable from mounts 1048 to allow for compaction, storage and easy transportation. Alternatively, the base of the support member 1024 may be pivotally attached or removably attached to the base 1044 at hinge 1090 and contact 1092 which may be a hinge lock 1092 or where 1090 is not a hinge the support member 1024 may be locked into place with a spring-loaded latching system (not shown). The target computer and transceiver 1007 is located behind strike plate 1006 a to protect the computer and transceiver 1007 from misfire. Alternatively a back strike plate may be used to protect from ricochets and secure the target computer and transceiver in place. Alternatively a top strike plate (not shown) may be used to protect the top portion of the target computer from ricochets.
[0079] Referring to FIG. 11 in connection with FIG. 10 , FIG. 11 shows a back view of strike plate 1022 with mounts 1148 secured to back planar surface 1150 . Sensor assemblies 1174 , 1175 , 1176 and 1177 ( 1074 , 1075 , 1076 and 1077 from FIG. 10 ) are disposed on or in strike plate 1022 . Strike surface 1026 and back surface 1050 are separated by a target depth. In one embodiment configuration, first and second sensors 1174 and 1175 , respectively, extend from back surface 1050 into target 1022 and are positioned proximate first corner 1160 . Likewise, third and fourth sensors 1176 and 1177 extend from back surface 1050 into target plate 1022 proximate fourth corner 1070 . First, second, third, and fourth sensors 1174 , 1175 , 1176 , and 1177 , respectively, may be substantially equidistant from an approximate midpoint 1180 of target surface 1026 . A first baseline distance 1182 between first and second sensors 1174 and 1175 is less than a radial distance 1184 between each of first and second sensors 1174 and 1175 and midpoint 1180 . Likewise, a second baseline distance 1186 between third and fourth sensors 1176 and 1177 is less than radial distance 1184 between each of third and fourth sensors 1176 and 1177 and midpoint 1180 . In this configuration of this embodiment the sensors are equidistant from midpoint 1180 . In addition, each of the sensors are embedded at an equal depth and not fully through the target plate to prevent damage from a target strike by the projectile.
[0080] In this configuration, the sensors are located in the top portion of the target surface. The mounts 1148 and the pivot axis are in the lower portion of the target to allow for the target to lean forward. Preferably, in this embodiment, the target is angled such that the ricochet is directed downward to the ground. Dampening attachments may be used to absorb some of the impact force and limit the range of the ricochet. In such a case, the strike force of the projectile reported to the shoot must be adjusted by the absorbed force. Alternatively, if not preferable to have an impact dampening effect, the target plate may be mounted on a pivoting connection, either a full pivot to accommodate for uneven surfaces or only in the forward and back direction to position the target facing downward. Such a pivot connection preferably will have a pivot lock to lock the target into position during the firing session.
[0081] Alternately, in the embodiments shown in FIGS. 10 and 11 , the sensors may be located in other positions in the target and need not be embedded in the target face. For example, the sensors could be positioned on the back surface of the target.
[0082] FIG. 12 is a figure exemplifying the various signal paths from multiple target systems to a variety of transceivers. In some embodiments, the targets 1203 have sensors 1215 to identify impacts from individuals 1223 , 1224 , 1225 , 1226 , and 1228 . In one embodiment the signal and data from the target is transmitted to one or more transceivers that can be shared by two shooters such as 1220 and 1225 , where each shooter has individual displays 1229 and 1230 . In this embodiment two or more shooters can use the same target and by sending a signal to the target the particular individual can indicate which shooter is taking a turn for data parsing. In another embodiment a universal transceiver 1222 can be used to receive target data and signals from local target transceivers 1216 of a plurality of target systems and parse the signal to relay to the appropriate individuals, not limited to shooters. For example spectators 1228 may receive the target data to follow the results for shooters. Alternatively, an instructor or competition judges 1223 may receive target data on mobile devices or remote computers to observe or evaluate the strikes from any number of shooters. In another embodiment, a signal booster 1221 may be used to relay data from the targets. In another embodiment, a shooting range owner or competition official 1226 may utilize a transceiver to receive target data and information by frequent users of the range for purposes of providing loyalty rewards or offers to the individuals visiting such ranges. In such embodiments, the range owner or competition organizer may offer a central database 1227 for data storage where individuals may access the information associated with a particular account and can be programmed to interface with users to provide information, updates, competition information, incentive information, or the like. In a preferred embodiment the central database is accessible through a user interface, for example a personal computer or mobile device. The accessible information may include range conditions for any particular day, such as wind speed or other weather information.
[0083] FIG. 13 depicts alternative ways to orient or locate the target sensors 1315 to identify strike information.
[0084] FIG. 14 depicts a shot cluster, where the shot cluster indicates a high consistency but it not a high score regarding target accuracy. In such situations, the target system may evaluate whether a scope adjustment is appropriate and based on the shot data recommend a calibration adjustment. The calibration adjustment may also apply to compensate with weather conditions, such as wind.
[0085] FIGS. 15 and 16 are examples of display output from a personal device, such as a target system application display on a smartphone, tablet, ipad, or laptop computer, for example. The figures demonstrate a broad presentation of data relating to the particular session or as compared with historical shooting data.
[0086] The target systems herein in some embodiments are configured to measure accuracy, power and speed. Regarding speed, reaction time may be measured by using a target system with a randomized signal to fire, which may be with the application or may be integrated with the target. For example, audial or visual signal may be used. The signal in these situations is coordinated with the target such that the timing between signal and impact may be accurately measured and recorded. Preferably the signal is delivered from the mobile application which is proximate the shooter and does not require excessive volume or brightness. In some modes, the overall score may be a factor of speed, power and accuracy or any combination thereof based on the goals of the shooter.
[0087] FIG. 17 illustrates an alternative embodiment of the shooting target system 1701 according to the present invention. The target system 1701 comprises a plurality of sensors, which may be accelerometers or shock sensors 1710 a - h arranged to detect a shock wave arising and propagating in the target material upon impact of a projectile (not shown) in the target 1711 . The target system 1701 further comprises a local computer 1712 connected to each sensor 1710 a - h either wired or wirelessly and arranged to receive measurement signals there from. When a shock wave in the target material is detected by the sensors 1710 a - h , each sensor sends a signal indicating that a shock wave has been detected to the computer 1710 . Alternatively, the signal data may be transmitted via transceiver 1713 to a remote device, such as a mobile device, iPad, smartphone, tablet computer, or the like. The computer, whether local or remote, is arranged to calculate the point of impact of the projectile in the target 1711 based on the run-time difference of the shock wave between the different sensors 1710 a - h , as will be described in more detail below. In this embodiment, the target 1711 is a flat target which may be on a stand or may alternatively be a uniformly curved metal sheet. The principle of determining the point of impact of a projectile in a target described below is equally applicable to a three dimensional or two dimensional depiction. A variety of depictions or target shapes 1715 may be on the target face such that the depiction or target shape may be correlated in the target system application or program and entered into the remote application or program provide statistical accuracy and strike evaluation. For example, a deer depiction may be displayed and correlate with a program identifier such that a strike impact will be correlated with that depiction or an alternative depiction such as a human perpetrator may be correlated in the program under a different program identifier for accuracy and strike evaluation purposes relating to a differing target.
[0088] Vibrations or shock waves caused by the impact of a projectile in the target 1711 will propagate in the target material in a concentric pattern. The sensor closest to the point of impact will be the first sensor to register the shock wave. When that sensor detects the shock wave, it sends a signal to the computer which starts a timer upon reception of said signal. In the same way, the subsequently registering sensors send respective signals to the computer. When the subsequent signals are received by the computer, the value DELTA the registering time, indicative of the run time difference of the shock wave between the first sensor and subsequent sensors, is stored and used by the calculator. The same run time difference is performed between each subsequent sensor and the prior registering sensors, resulting in a plurality of timer value DELTAs indicative of the run time differences between the plurality of sensors. The “run time difference” of the shock wave between two sensors can hence also be expressed as the time-delay between the detections of the shock wave by said two sensors. That is, the value DELTA tab represents the time-delay between the detection of the shock wave by the first sensor to detect the shock wave and the second sensor to detect the shock wave, while the value DELTA tac represents the time-delay between the detections of the shock wave by the first sensor to detect it and the third sensor to detect it. By utilizing the time-delays between the detections of the shock wave by the sensors 1710 a - h as well as known parameter values, such as the speed of sound in the target material which corresponds to the velocity of shock wave propagation in the target 11 , and the shock wave propagation distances between the sensors 10 a - h , a computer 1712 , calculates the point of impact X using standard physics and well-known geometry. Shock wave propagation distance shall in this context be construed as the distance the shockwave has to propagate in the target material between two points.
[0089] Although the shooting target system 1701 in FIG. 17 comprises eight shock sensors, a person skilled in the art appreciates that three sensors are sufficient to triangulate or trilaterate the point of impact of the projectile and two shock sensors are sufficient to retrieve some information about the point of impact of the projectile. If only two shock sensors are used, an exact point of impact cannot be determined since the system is under-determined (the calculation means needs two time differences in order to determine two coordinates for the point of impact). However, a shooting target system comprising only two shock sensors (yielding one shock wave run-time difference) is able to determine a line along the target 1711 , along which line the projectile must have hit the target. This point-of-impact information may be sufficient for certain shooting applications.
[0090] The parameter values needed to calculate the point of impact except for the run-time difference of the shock wave between the sensors detecting it, such as the speed of sound in the target material and the propagation distance between the shock sensors, are preferably stored in the computer. In a preferred embodiment the computer includes a user interface for a user to change the parameter values needed to calculate the information related to the point of impact so as to allow the same calculation means 1712 to be used with different targets composed by different materials and/or shaped differently, and/or to allow repositioning of the sensors at a target so as to optimize sensor readings.
[0091] The speed of sound in an aluminum or other metal target is approximately 5000 m/sec which means that the shock wave travels approximately 10 cm in 0.02 ms. The shock sensors 1710 a - h should be separated by a distance ensuring that the electronic circuit of the calculation means 1712 can distinguish the different sensor signals from each other. The exactness of the point-of-impact determination depends on the accuracy of the timer value readings. Though three sensors could be used to triangulate the strike location, more preferably a larger number of sensors will allow for greater accuracy through data analysis and correction or by recognition of outlier signals to eliminate outlier signals from the calculation. Outlier signals may also be used to identify sensor problems and the need for maintenance of the sensor or system.
[0092] As aforementioned, shooting targets, and especially shooting targets used in military shooting exercises, often depicts fictitious enemy soldiers. A target system resolution of less than 1 cm is suitable, preferably less than 0.5 cm, more preferably less than 2.5 mm, most preferably 1 mm or less, which is fully possible to achieve with the target system according to the present invention, is thus sufficient to determine which part of the target that is hit by an incident projectile. In one embodiment the target shape is projected or displayed and coordinated with the system software such that strikes are correlated with particular location strikes on the given target and accuracy scores calculated based on the target selection. This may be achieved by associating each target coordinate or different target regions with a part of the body in a look-up table located in the signal processor 1712 or the indication means of the shooting target system.
[0093] With the portability and flexibility of the present invention a shooter may setup the target system in a number locations. Accommodation may be made to account for gusts of wind, rain or other incidental strikes. Wind gusts, hail and rain may cause vibrations in the target material which undesirably may be registered by the sensors and taken for an incident projectile by the signal processor 1712 . Such unintended readings can be prevented with use of sufficient number of sensors and an algorithm to identify outlier readings. To avoid this problem, the signal processor is preferably arranged to compare the output signals from the sensors with a predetermined threshold value and ignore signals indicative of outliers. To further minimize the risk of calculating the “point of impact” based on shock waves or vibrations that are not caused by a projectile hitting the target 1711 , the signal processor 1712 may be arranged to ignore all output signals from the sensors that are not within a predetermined amplitude interval, which interval is characteristic of shock waves caused by a projectile impact on the target. This amplitude may be adjustable to accommodate the conditions. Yet a further alternative is to analyze the variation of the sensor signal amplitude in time and only calculate the point of impact for those shock wave signals having an amplitude-time signature that matches a predetermined amplitude-time signature which is characteristic of shock waves originating from a hit by a projectile. The smart logic of the signal processor can use historic information of the target strike amplitudes to progressively increase accuracy. Other logic can be applied simultaneously. For example, the amplitude of consecutive shock waves originating from a projectile impact rapidly decrease in amplitude while the amplitudes of consecutive shock waves originating from gusts of wind most likely will fluctuate randomly. That is, the signal processor 1712 may comprise logic that, by studying the amplitude of a plurality of consecutive shock waves, is able to distinguish shock waves or vibrations originating from a projectile impact from other non-projectile generated shock waves.
[0094] FIG. 18 illustrates another embodiment of the shooting target system according to the invention. The shooting target system 1802 comprises the same components as the target system 1701 described above with similar components denoted by reference numerals having the same unit digits, with the 1700 numbers applying to FIG. 17 and 1800 numbers applying to FIG. 18 . However, the target 1821 is divided in a matrix format for the target. The target 1821 comprises a plurality of vertical dividers 1827 substantially dividing the target into a plurality of elongated target portions 1828 a - f . In this embodiment, the dividers are vertically arranged and extend from the bottom of the target 1821 to a distance from the top of the target, thereby forming a plurality of vertically elongated target portions 1828 a - f , henceforth referred to as target columns, that are held together by a horizontal “connection portion” 1830 a - h . Sensors 1820 a - f are arranged to detect impact shock waves/vibrations in the target material of each target column 1828 a - f . Preferably, the sensors 1820 a - f are disposed at or close to the ends of the target columns 1828 a - f . Horizontal sensors are similarly disposed at or close to the ends of the target rows 1830 a - h . The number of rows and columns are by example and more or less can be used depending on the sensitivity of interest.
[0095] In FIG. 1802 , the target 1821 is illustrated as a curved metal sheet which can be used to provide 3D effect. The principle of determining the point of impact in a matrix target, as will be further described below, is, however, equally applicable to a flat shooting target.
[0096] FIG. 1802 illustrates how vibrations or shock waves caused by the impact of a projectile on the matrix target 1821 are propagating in the target material. Once again, an imagined point of impact of a projectile in the target 1821 can be illustrated by placing an X on the target. When a target column (for example, target column 1828 b ) is hit by a projectile, shock waves arise and propagate in the longitudinal directions of the target column. When the outermost shock wave, i.e. the first shock wave arising in the target material due to the impact of the projectile, reaches the sensor located closest to the point of impact, which in this particular case is sensor 1820 b , the sensor transmits a signal to the signal processor 1822 whereupon a timer 1824 is started. The shockwave front propagating in the opposite direction reaches the connection portion through which the vibrations/shock waves are further spread to all target strips 1828 a - f and horizontal sensors 1830 a - h . The sensors neighboring the sensor disposed on the target cylinder hit by the projectile, in this case sensors 1820 a and 1820 c , will be the next sensors to detect the shock wave since the propagation distance from the point of impact to these sensors is shorter than the propagation distance to the other sensors (except for sensor 1820 b ). As soon as sensor 1820 a or 1820 c detects the shock wave, a signal indicating that the shock wave has been detected by a second sensor is sent to the processor 1822 whereupon the timer 1824 is stopped and a timer value DELTA t, indicating the run time difference of the shock wave between the first sensor to detect it and the second sensor to detect it, is obtained. In a similar way as described above with reference to FIG. 17 , the point of impact is then calculated by utilizing the value DELTA t and known physical and geometrical parameters, such as the speed of sound in the target material, and the shock wave propagation distance between the sensors for which the run time difference of the shock wave has been determined.
[0097] By dividing the target into a plurality of target portions by columns, the shock wave propagation path between the different shock sensors is prolonged, reducing the demands on the response time of the shock sensors and the electronic circuit processing the sensor signals. It also reduces the demands on the computational power of the calculation means since only one target coordinate needs to be calculated in order to establish the point of impact of the projectile. In, e.g., the embodiment shown in FIG. 18 the horizontal location for the point of impact is automatically given since the calculation means “knows” that the projectile must have hit the target somewhere along the vertical column on which the sensor that was the first to detect the shock wave is disposed (given that the calculation means is arranged so as to be able to distinguish signals from different sensors). Hence, a matrix shooting target eliminates one dimension from the geometrical environment of the target and the processor 1822 only needs to calculate the vertical coordinate for the point of impact based on the run time difference of the shock wave between the different sensors. The width of the columns may vary in dependence of the demand on the target system resolution. In high precision shooting exercises finely columnated targets may be used while roughly columnated targets may be sufficient for other applications. In FIG. 18 , the local computer 1822 may additionally include a transceiver 1825 which may be in contact with one or more personal transceivers located with the shooter, an observer or at a display, for example, to display results of each strike. Also, the local computer 1822 may also include a modem 1826 that can be either WiFi enabled or capable of communicating data to the internet through a suitable data transmission vehicle such as LTE, GSM, HSPA, CDMA, UMTS telecommunications, WiMax, EDGE, EV-DO, iBurst, HIPERMAN, Flash-OFDM, or the like, such that the data is uploaded to an internet based data system, such as a cloud database. In a preferred embodiment, all shot data point or a large number of data points and associated variable data can be stored in a relational database management system (DBMS), such as SQL, MySQL, DB2, Informix, Sybase Adaptive Server Enterprise, Sybase IQ, Teradata or the like. Base 36 (hexatridecimal storage) for example may be used with data for database storage in such databases, or the like. Alternatively, hierarchical databases, object databases and XML databases may be used. With this embodiment, the data can be accessed through the internet via a proprietary program or preferably with a standard internet browser. This embodiment allows observers across the world to follow the results of the shooter real-time with simple access to the internet and a web browser. Alternatively, strike information can be uploaded to the internet and processed in one or more internet-based game settings. In a preferred embodiment, the target display simulates the view of the character in a computer game and the strikes are correlated real-time with the internet-based game to provide a real-feel simulation. Such a simulation is ideal for use in police or military training.
[0098] FIG. 19 is a screen shot from a user's display, for example from the user/shooter mobile device, showing information such as the weather, distance to target, projectile device (e.g. .308 Remington), projectile, and data regarding the shot strike. The data from the shot strike includes the time of the strike, a score generated by a customized algorithm specific to the target, projectile device, distance to the target and weather conditions, for example.
[0099] FIG. 20 shows another screen shot of the user display, showing additional information about each shot, which can be displayed in a pop-up window from a touch screen or curser click. As shown, additional information can be added in a notes section. Such information can be saved and uploaded to a user data base, which may be cloud based or local.
[0100] FIG. 21 shows an alternate user display on a user computer device, such as a handheld device, portable computer, smart phone, ipad, or the like. Any device able to use a web browser may be used, though ideally the user device is a mobile device to accommodate the mobility of the target system. FIG. 21 displays a multiple user/shooter display exemplifying three shooters at the time, graphically showing the scores, ranking the shooters and indicating the accuracy of each shooter.
[0101] Although there have been described preferred embodiments of this target system, many variations and modifications are possible in light of the above teachings and may be practiced otherwise than as specifically described while within the scope of the appended claims. The embodiments described herein are not limited by the specific disclosure above, but rather should be limited only by the scope of the appended claims and their equivalents.
[0102] For example, the target system may be adapted to apply to larger weaponry target practice. | The invention relates to a shooting target and method of using the target for electronically determining the shooting position on a shooting target. Said shooting position is determined in a number of ways, including by use of a plurality of accelerometers to determine the impact area and transmit data relating to the impact to a remote receiver for real-time presentation to the shooter. Said method enables the shooting position to be determined by means of relatively economical electronic systems and said shooting target is portable such that the shooter may bring the target to a plurality of firing ranges and locations to convey the same real-time reporting and benefits to the shooter. Said shooting target may be set-up on a standard target stand to wirelessly relay shot impact information to a portable personal computing device to present real-time virtual impact data to the shooter. This data can then be stored and categorized given user-selected inputs and shared with other shooters in an online forum. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a divisional of U.S. application Ser. No. 13/157,675 entitled SHUT-OFF TRIM INCLUDING SPRING LOADED CHECK VALVE filed Jun. 10, 2011, which claims priority to U.S. Provisional Patent Application Ser. No. 61/353,589 entitled SHUT-OFF TRIM INCLUDING SPRING LOADED CHECK VALVE filed Jun. 10, 2010.
STATEMENT RE: FEDERALLY SPONSORED RESEARCH/DEVELOPMENT
[0002] Not Applicable
BACKGROUND OF THE INVENTION
[0003] 1. Technical Field of the Invention
[0004] The present invention relates generally to bi-directional valves for high pressure fluid flow and, more particularly, to a bi-directional shut-off trim for a valve which possesses the functional attributes of a pilot operated trim and a balanced trim through the integration of a spring loaded check valve into a pilot trim. In forward flow isolation, the bi-directional shut-off trim of the present invention acts as a normal pilot operated trim. In reverse flow, the check valve of the shut-off trim opens to balance the pressure on either side of the plug thereof.
[0005] 2. Description of the Related Art
[0006] There is known in the prior art valve constructions which are adapted to provide pressure balance on opposite sides of a main valve assembly during both opening and closing movements of the main valve assembly with fluid flow in either direction through the valve. One such exemplary prior art bi-directional balanced valve is disclosed in U.S. Pat. No. 3,888,280 entitled BI-DIRECTIONAL PRESSURE BALANCED VALVE issued Jun. 10, 1975.
[0007] However, currently known valve constructions or designs providing a bi-directional pressure balanced function are often subject to early failure and malfunctioning when used under severe service conditions, e.g., under high temperature and high pressure operating conditions. More particularly, the failure or malfunctioning of currently known valve designs is often attributable to the rapid erosion of deterioration of their sealing areas, as well as other critical valve components. In this regard, the available seal materials usable in conjunction with currently known bi-directional pressure balanced valve designs are often not adequate for providing required shut-off characteristics, and further frequently make the valve susceptible to early failure when the such seal materials are subjected or exposed to the intended operational environment of the valve.
[0008] The present invention is intended to represent an improvement to existing bi-directional pressure balanced valve designs by providing a valve shut-off trim which combines a pilot operated trim and a balanced trim through the addition of a spring loaded check valve within the pilot trim. As indicated above, in forward flow isolation, the shut-off trim of the present invention acts as a normal pilot operated trim, while in reverse flow, the check valve thereof opens to balance the pressure on either side of the plug of the trim. Thus, the addition of the spring loaded check valve in the shut-off trim of the present invention causes the pilot operated trim to act as a balanced plug in the reverse flow direction. These, as well as other features and advantages of the present invention, will be described in more detail below.
BRIEF SUMMARY OF THE INVENTION
[0009] In accordance with the present invention, there is provided a valve shut-off trim which includes a spring loaded check valve and is usable in applications requiring valves with bi-directional shut-off trim where the use of unbalanced trim designs is not feasible and the choice of seals is limited by temperature, and/or radiation, and/or chemistry of seal materials. The shut-off trim constructed in accordance with the present invention finds particular utility in applications requiring shut-off in a forward direction of Class V and shut-off in a reverse flow direction of Class IV, with forward flow being, for example, water at 440° F. and reverse flow being, for example, steam at 567° F.
[0010] In the present invention, to obtain Class IV shut-off in a reverse flow direction, carbon piston rings are integrated into the shut-off trim. By combining a pilot ported plug and a check valve (which allows flow in the reverse direction), the shut-off trim of the present invention allows isolation in forward and reverse directions. In the forward direction, the trim achieves leak-tight shut-off (pilot ported plug acts an unbalanced plug when in the closed position). In the reverse direction and during modulation, the shut-off trim acts as a balanced plug. Thus, when reverse pressure unseats the pilot plug, the trim acts a balanced plug as indicated above. The shut-off trim of the present invention preferably includes a spring for loading the pilot plug.
[0011] Due to its construction, which will be described with particularity below, the shut-off trim constructed in accordance with the present invention eliminates reliance on elastomeric balance seals for the forward flow direction, and allows for the use of, by way of example, carbon or metallic piston rings for the reverse direction shut-off requirements. Thus, the shut-off trim of the present invention eliminates the need for a lengthy seal qualification program and extends the qualified life of the equipment in the field with integrates the same. As a result, the shut-off trim constructed in accordance with the present invention has the capability of satisfying safety related isolation functions that have been imposed on control valves integrated or used in certain applications, such as those requiring the aforementioned Class V shut-off in a forward direction and a Class IV shut-off in a reverse direction. In many of these applications, the use of graphoil seals would not be suitable due to the number of open/close/small modulation cycles that are imposed by the application requirements. Additionally, elastomeric seals are generally unsuitable for obtaining Class V shut-off since this requirement often pushes such elastomeric seals to or beyond their documented usable limits, or undesirably shortens their qualified life due to, for example, the limited ability thereof to withstand radiation, as well as their susceptibility to hardening due to thermal aging.
[0012] The present invention is best understood in reference to the following detailed description when read in conjunction with accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] These, as well as other features of the present invention, will become more apparent upon reference to the drawings wherein:
[0014] FIG. 1 is a side-elevational, partial cross-sectional view of a shut-off trim constructed in accordance with a first embodiment of the present invention;
[0015] FIG. 2 is a side-elevational, partial cross-sectional view of a shut-off trim constructed in accordance with a second embodiment of the present invention;
[0016] FIGS. 3A-3C are side-elevational views illustrating a plug sleeve of the shut-off trim shown in FIG. 2 in differing states of actuation;
[0017] FIG. 3D is a cross-sectional view of the plug sleeve of the shut-off trim shown in FIGS. 2 and 3 A- 3 C;
[0018] FIGS. 4A-4C are side-elevational views illustrating an auxiliary plug in differing states of actuation which may be used as an alternative to the plug sleeve shown in FIGS. 2 and 3 A- 3 D in a shut-off trim constructed in accordance with a third embodiment of the present invention;
[0019] FIG. 5 is a side-elevational, partial cross-sectional view of a shut-off trim constructed in accordance with a fourth embodiment of the present invention; and
[0020] FIGS. 6A-6B are side-elevational views illustrating the check valve of the shut-off trim shown in FIG. 5 in differing states of actuation.
[0021] Common reference numerals are used throughout the drawings and detailed description to indicate like elements.
DETAILED DESCRIPTION OF THE INVENTION
[0022] Referring now to the drawings wherein the showings are for purposes of illustrating preferred embodiments of the present invention only, and not for purposes of limiting the same, FIG. 1 depicts a shut-off trim 10 constructed in accordance with a first embodiment of the present invention. It is contemplated that the trim 10 will be integrated into a valve construction wherein the valve includes a housing which defines an interior plug chamber 14 . The plug chamber 14 is partially defined by a generally cylindrical, tubular fluid energy dissipation device, such as the disc stack 16 shown in FIG. 1 . The plug chamber 14 is further partially defined by a generally cylindrical, tubular plug sleeve 18 which is coaxially aligned with the disc stack 16 , one end of the plug sleeve 18 typically being engaged to a corresponding end of the disc stack 16 .
[0023] In addition to the plug chamber 14 , the housing 12 of the valve into which the trim 10 is integrated also defines an inflow passage 20 and an outflow passage 22 which each fluidly communicate with the plug chamber 14 . The inflow and outflow passages 20 , 22 are more easily seen in those embodiments of the shut-off trim depicted in FIGS. 2 and 5 . In the valve including the trim 10 , fluid traveling through the inflow passage 20 flows radially inwardly through the disc stack 16 and into the plug chamber 14 . When the trim 10 is in an open condition or state as will be described in more detail below, fluid entering the plug chamber 14 is able to flow into the outflow passage 22 , and thereafter exit the valve including the trim 10 . Typically, the interface between the outflow passage 22 and the plug chamber 14 is defined by an annular seat ring 24 .
[0024] The trim 10 constructed in accordance with the first embodiment of the present invention comprises a main pilot plug 28 which, from the perspective shown in FIG. 1 , defines a top surface 30 , a bottom surface 32 , a side surface 34 , and a beveled sealing surface 36 which extends between the bottom and side surfaces 32 , 34 . The pilot plug 28 is not solid, but rather has a bore 38 extending axially therethrough. As is also apparent from FIG. 1 , the bore 38 is not of uniform diameter. Rather, the bore 38 defines four (4) different segments or sections, each of which is of a differing diameter. More particularly, the diameters of the bore sections defined by the bore 38 progressively decrease from the top surface 30 to the bottom surface 32 , with the lowermost bore section extending to the bottom surface 32 thus being of the smallest diameter of the four bore sections. The uppermost and upper middle bore sections are separated from each other by an annular shoulder 40 . Similarly, the upper middle and lower middle bore sections are separated by an annular shoulder 42 , with the lower middle and lowermost bore sections being separated by an annular shoulder 44 . Disposed within the shoulder 40 is a plurality of elongate grooves or channels 46 , the use of which will be described in more detail below. Additionally, disposed in the side surface 34 of that portion of the pilot plug 28 which defines the uppermost bore section is a plurality of sealing rings 48 which circumvent the pilot plug 28 and are used for reasons which will also be described in more detail below.
[0025] When the trim 10 is in a closed position within the exemplary valve including the same, the sealing surface 36 defined by the pilot plug 28 is firmly seated and sealed against the seat ring 24 . The trim 10 assumes an open position when, from the perspective shown in FIG. 1 , the pilot plug 28 is caused to move upwardly as results in the sealing surface 36 thereof effectively being separated from the seat ring 24 . Such separation allows fluid within the plug chamber 14 to flow between the sealing surface 36 and seat ring 24 into the outflow passage 22 .
[0026] In addition to the pilot plug 28 , the trim 10 includes check valve assembly comprising an auxiliary plug 50 which resides within the bore 38 of the pilot plug 28 . Like the pilot plug 28 , the auxiliary plug 50 , when viewed from the perspective shown in FIG. 1 , defines a top surface 52 , a bottom surface 54 , a side surface 56 , and a beveled sealing surface 58 which extends between the bottom and side surfaces 54 , 56 . As is apparent from FIG. 1 , the side surface 56 of the auxiliary plug 50 is not of uniform outer diameter. Rather, the side surface 56 defines four (4) side surface sections or segments which may be of differing outer diameter. Along these lines, it is contemplated that the outer diameter of the lowermost segment of the side surface 56 to which the sealing surface 58 extends will be of the greatest diameter in the auxiliary plug 50 . In the auxiliary plug 50 , the lowermost and lower middle segments of the side surface 56 are separated by an annular shoulder 60 .
[0027] In the trim 10 , the auxiliary plug 50 is operatively coupled to a collar 62 of the check valve assembly which is attached to the bottom end of the stem 64 of the valve including the trim 10 . When viewed from the perspective shown in FIG. 1 , the collar 62 defines a top surface 66 , a bottom surface 68 , and a side surface 70 . The side surface 70 is also not of uniform outer diameter, but rather includes two (2) side surface sections or segments which are of differing outer diameter. In this regard, that segment of the side surface 70 extending to the top surface 66 exceeds the outer diameter of that segment of the side surface 70 extending to the bottom surface 68 . These upper and lower segments of the side surface 70 are separated by an annular shoulder 72 .
[0028] In the trim 10 , the auxiliary plug 50 is moveably attached to the collar 62 via the receipt of a portion of the auxiliary plug 50 into a complimentary interior cavity 74 defined by the collar 62 . As seen in FIG. 1 , that portion of the auxiliary plug 50 defining the uppermost segment of the side surface 56 thereof is captured and maintained within the interior cavity 74 , as is at least a portion of the auxiliary plug 50 which defines the upper middle segment of the side surface 56 thereof. The cooperative engagement between the auxiliary plug 50 and the collar 62 allows for the reciprocal movement of the auxiliary plug 50 relative to the collar 62 in a manner either decreasing or increasing the distance separating the shoulder 60 of the auxiliary plug 50 from the bottom surface 68 of the collar 62 . In this regard, the check valve assembly of the trim 10 preferably includes a biasing spring 76 which extends between the shoulder 60 and the bottom surface 68 . The biasing spring 76 normally biases the auxiliary plug 50 away from the collar 62 , i.e., maximizes the distance separating the shoulder 60 of the auxiliary plug 50 from the bottom surface 68 of the collar 62 . As will be recognized, the movement of the auxiliary plug 50 away from the collar 62 attributable to the action of the biasing spring 76 is eventually limited by the abutment of that portion of the auxiliary plug 50 defining the uppermost segment of the side surface 56 against an inner surface portion of the collar 62 which partially defines the interior cavity 74 thereof.
[0029] As indicated above, the pilot plug 28 of the trim 10 is moveable between a closed position wherein the sealing surface 36 thereof is sealed against the seat ring 24 , and an open position wherein the sealing surface 36 of the pilot plug 28 is separated from the seat ring 24 , thus allowing fluid to flow therebetween into the outflow passage 22 . The movement of the pilot plug 28 between its closed and open positions is facilitated by the upward and downward movement or actuation of the stem 64 , and more particularly, the collar 62 attached to one end thereof. As will be recognized, the reciprocal movement of the stem 64 and collar 62 as is needed to facilitate the movement of the pilot plug 28 between its closed and open positions is facilitated by an actuator which is operatively coupled to that end of the stem 64 opposite that having the collar 62 attached thereto. The downward movement of the stem 64 when viewed from the perspective shown in FIG. 1 causes the shoulder 72 defined by the collar 62 to act against the shoulder 40 of the pilot plug 28 in a manner which forces the sealing surface 36 of the pilot plug 28 against the seat ring 24 and maintains the sealed engagement therebetween.
[0030] When the pilot plug 28 is in its closed position, the biasing force exerted against the auxiliary plug 50 by the biasing spring 76 causes the sealing surface 58 of the auxiliary plug 50 to firmly engage and establish sealed contact with a portion of the pilot plug 28 at the inner periphery of the shoulder 44 thereof, as shown in FIG. 1 . As is further shown in FIG. 1 , in the check valve assembly integrated into the trim 10 , a biasing spring 78 extends between the shoulder 42 of the pilot plug 28 and the shoulder 72 of the collar 62 . From the perspective shown in FIG. 1 , when the stem 64 is actuated to facilitate the movement of the pilot plug 28 to the closed position, the downward biasing force exerted against the pilot plug 28 by the biasing spring 78 assists in maintaining the sealed engagement between the sealing surface 36 of the pilot plug 28 and the seat ring 24 even if the shoulder 72 of the collar 62 ceases to apply force directly to the shoulder 40 of the pilot plug 28 .
[0031] When the trim 10 is in a state or condition wherein the sealing surface 36 of the pilot plug 28 is sealed against the seat ring 24 and the sealing surface 58 of the auxiliary plug 50 is sealed against the pilot plug 28 , the pressure level P 1 in the inflow passage 20 will typically exceeds the pressure level P 2 in the outflow passage 22 . The pressure level P 1 also exists in the plug chamber 14 . In this regard, when viewed from the perspective shown in FIG. 1 , the plug chamber 14 is at the pressure level P 1 both above and below the level of a plug plate 80 which is attached to the top surface 30 of the pilot plug 28 through the use of, for example, fasteners such as bolts 82 . The plug plate 80 , which is used for reasons described in more detail below, includes at least one flow opening 84 which extends between the opposed top and bottom surfaces thereof.
[0032] In the valve including the trim 10 , that portion of the plug chamber 14 located above the plug plate 80 reaches the pressure level P 1 as a result of anticipated leakage which occurs between the inner surface of the plug sleeve 18 and the sealing rings 48 disposed in the side surface 34 of the pilot plug 28 . In this regard, the sealing rings 48 facilitate the pressurization of that portion of the plug chamber 14 located above the plug plate 80 in a regulated, metered manner. As is also seen in FIG. 1 , the side surface 34 of the pilot plug 28 is not of uniform outer diameter, but rather defines an annular shoulder 84 which is disposed in relative close proximity to the sealing surface 36 . Advantageously, the fluid pressure at the pressure level P 1 within that portion of the plug chamber 14 below the plug plate 80 and in between the side surface 34 and the inner surfaces of the disc stack 16 and plug sleeve 18 is able to act against the shoulder 84 in a manner supplementing or increasing the force of the sealed engagement between the sealing surface 36 and seat ring 24 . Such sealed engagement is further supplemented by the pressure level P 1 within that portion of the plug chamber 14 disposed below the plug plate 80 acting against the shoulders 40 , 42 , 44 of the pilot plug 28 . In this regard, fluid migrating between the pilot plug 28 and plug sleeve 18 into that portion of the plug chamber 14 disposed above the plug plate 80 is able to flow into the uppermost section of the bore 38 via the at least one flow opening 84 of the plug plate 80 . Even if the shoulder 72 of the collar 62 is firmly seated against the shoulder 40 of the pilot plug 28 , fluid is also able to flow into the upper middle and lower middle sections of the bore 38 via the channels 46 in the shoulder 40 , at least portions of which extend radially beyond that segment of the side surface 70 of the collar 62 of greater diameter extending to the top surface 66 thereof. Such flow results in the upper middle and lower middle sections of the bore 38 reaching the fluid pressure level P 1 along with the uppermost section of the bore 38 . Advantageously, the pressure level P 1 in the lower middle section of the bore 38 also acts against the shoulder 60 of the auxiliary plug 50 which supplements or enhances the sealed engagement between the sealing surface 58 of the auxiliary plug 50 and the pilot plug 28 .
[0033] In the valve including the trim 10 , the movement of the pilot plug 28 from its closed position to an open position is facilitated by the upward movement of the stem 64 , and hence the collar 62 , when viewed from the perspective shown in FIG. 1 , such upward movement being facilitated by the actuator cooperatively engaged to the stem 64 . The upward movement of the stem 64 initially causes the collar 62 to act against that portion of the auxiliary plug 50 residing within the interior cavity 74 as effectively removes the sealing surface 58 from its sealed engagement to the pilot plug 28 . The movement of the auxiliary plug 50 out of sealed engagement with the pilot plug 28 creates a balanced pressure condition between the plug chamber 14 and the outflow passage 22 . In this regard, the removal of the auxiliary plug 50 from its sealed engagement to the pilot plug 28 allows for open flow between the plug chamber 14 (including that portion disposed above the plug plate 80 ) and the outflow passage 22 via the bore 38 and flow passage 84 of the plug plate 80 .
[0034] The continued upward movement of the collar 62 after the auxiliary plug 50 is unseated from the pilot plug 28 results in the top surface 66 of the collar 62 acting against the bottom surface of the plug plate 80 . By virtue of the attachment of the plug plate 80 to the pilot plug 28 , the continued upward movement of the collar 62 after the same engages the plug plate 80 results in the sealing surface 36 of the pilot plug 28 being lifted off of and thus separated from the seat ring 24 , thereby causing the trim 10 to assume an open position.
[0035] In the trim 10 constructed in accordance with the present invention, it is contemplated that in a further mode of operation, a balanced pressure condition between the plug chamber 14 and outflow passage 22 may be achieved if the pilot plug 28 is in its closed position, but the pressure level P 2 in the outflow passage 22 exceeds the pressure level P 1 in the inflow passage 20 and plug chamber 14 . In this instance, it is contemplated that the pressure level P 2 will act against the bottom surface 54 of the auxiliary plug 50 in a manner facilitating the compression of the biasing spring 76 and removal of the sealing surface 58 from its sealed engagement to the pilot plug 28 . The upward movement of the auxiliary plug 50 by virtue of the compression of the biasing spring 76 is accommodated by the clearance between that portion of the auxiliary plug 50 residing within the interior cavity 74 and those surfaces of the collar 62 defining the interior cavity 74 . Once the auxiliary plug 50 is unseated from the pilot plug 28 , fluid is able to flow into the lower middle and upper middle sections of the bore 38 , and thereafter into the uppermost section of the bore 38 via the channels 46 disposed in the shoulder 40 . Fluid flowing into the uppermost section of the bore 38 is in turn able to flow into that portion of the plug chamber 14 disposed above the plug plate 80 via the flow opening 84 within the plug plate 80 . The equalization of the pressure level in the plug chamber 14 with the pressure level in the outflow passage 22 results in the sealing surface 58 of the auxiliary plug 50 being returned to sealed engagement to the pilot plug 28 by operation of the biasing spring 76 . Similarly, the sealed engagement between the sealing surface 36 of the pilot plug 28 and the seat ring 24 is maintained by the biasing spring 78 .
[0036] The check valve assembly integrated into the trim 10 comprises the auxiliary plug 50 , collar 62 and biasing springs 76 , 78 . Importantly, the functional attributes provided to the trim 10 by the check valve assembly allow the trim to achieve a Class V shut-off when subjected to an operational condition wherein the pressure level P 1 within the inflow passage 20 and plug chamber 14 exceeds the pressure level P 2 in the outflow passage 22 . The unique structural and functional attributes of the trim 10 also allow the same to achieve a Class IV shut-off when subjected to an operational condition wherein the pressure level P 2 in the outflow passage 22 rises to the level which exceeds that of the pressure level P 1 in the inflow passage 20 and plug chamber 14 .
[0037] Referring now to FIGS. 2 and 3 A- 3 C, there is shown a shut-off trim 100 constructed in accordance with a second embodiment of the present invention. The trim 100 comprises a main pilot plug 128 which, from the perspective shown in FIG. 2 , defines a top surface 130 , a bottom surface 132 , a side surface 134 , and a sealing surface 136 which extends between the bottom and side surfaces 132 , 134 . The pilot plug 128 is not solid, but rather has a bore 138 extending axially therethrough. The bore 138 is not of uniform diameter. Rather, the bore 138 defines four (4) different segments or sections, each of which is of a differing diameter. More particularly, the bore 138 includes an uppermost section, an upper middle section, and a lower middle section which are of a progressively decreasing diameter. The bore 138 also defines a lowermost section which is of the greatest diameter, exceeding that of the uppermost section thereof. The uppermost and upper middle sections of the bore 138 are separated by a shoulder 140 . Similarly, the upper middle and lower middle sections of the bore 138 are separated by an annular shoulder 142 . Additionally, disposed in the side surface 134 of that portion of the pilot plug 128 which defines the uppermost bore section is a plurality of sealing rings 148 which circumvent the pilot plug 128 and are used for reasons which will also be described in more detail below.
[0038] When the trim 100 is in a closed position within the exemplary valve including the same, the sealing surface 136 defined by the pilot plug 128 is firmly seated and sealed against the seat ring 24 . The trim 100 assumes an open position when, from the perspective shown in FIG. 2 , the pilot plug 128 is caused to move upwardly as results in the sealing surface 136 thereof effectively being separated from the seat ring 24 . Such separation allows fluid from within the plug chamber 14 to flow between the sealing surface 136 and seat ring 24 into outflow passage 22 .
[0039] In addition to the pilot plug 128 , the trim 100 includes a check valve assembly comprising a fastener 186 which is secured to that end of the stem 64 opposite the end portion cooperatively engaged to the actuator. As best seen in FIGS. 3A-3C , the fastener 186 comprises a cylindrically configured shank portion, an enlarged head portion which is formed on one end of the shank portion, and an externally threaded attachment portion which is threadably advanced into a complimentary, internally threaded aperture disposed within the end surface of the stem 64 . As is also apparent from FIGS. 3A-3C , the end portion of the stem 64 defining the end surface having the internally threaded aperture formed therein is enlarged relative to the remainder of the stem 64 . The end surface of the stem 64 which includes the internally threaded aperture therein also includes an annular groove or channel 188 which is formed therein and effectively circumvents the internally threaded aperture. The use of the channel 188 will be described in more detail below. The advancement of the attachment portion of the fastener 186 into the complimentary, internally threaded aperture of the stem 64 is continued until such time as the shank portion of the fastener 186 abuts the end surface of the stem 64 .
[0040] In addition to the fastener 186 , the check valve assembly comprises a generally cylindrical, tubular plug sleeve 190 which is cooperatively engaged to both the fastener 186 and stem 64 , and is reciprocally movable relative thereto in a manner which will be described in more detail below. An enlarged, cross-sectional view of the plug sleeve 190 standing alone is shown in FIG. 3D . The plug sleeve 190 includes a bore 192 which extends axially therethrough. The bore 192 is also not of uniform diameter. Rather, the bore defines two (2) different segments or sections, each of which is of differing diameter. More particularly, when viewed from the perspective shown in FIGS. 3A-3D , the bore 192 defines upper and lower sections which are separated from each other by an annular wall portion 194 of the plug sleeve 190 which is integrally connected to a main body portion 196 thereof, and protrudes from the inner surface of the main body portion 196 radially inwardly into the bore 192 . The wall portion 194 defines opposed, generally annular first and second shoulders 198 , 199 , the first shoulder 198 being directed toward the upper section of the bore 192 , and the second shoulder 199 being directed toward the lower section of the bore 192 which is of a reduced diameter in comparison to the upper section thereof.
[0041] In the check valve assembly of the trim 100 , the cooperative engagement of the plug sleeve 190 to the fastener 186 and stem 64 is facilitated by advancing the end portion of the main body portion 196 disposed furthest from the wall portion 194 into the channel 188 of the stem 64 . In this regard, the channel 188 has a configuration which is complimentary to that of the end portion of the main body portion 196 which is advanced thereinto. At the same time, the enlarged head portion of the fastener 186 is received into and reciprocally moveable within the reduced diameter lower section of the bore 192 . The shank portion of the fastener 186 resides within the increased diameter upper section of the bore 192 . The check valve assembly of the trim 100 further includes a biasing spring 178 which also resides within the upper section of the bore 192 of the plug sleeve 190 , and extends between the first shoulder 198 and the end surface of the stem 64 . The biasing spring 178 normally biases the plug sleeve 190 away from the stem 64 , i.e., maximizes the distance separating the wall portion 194 from the end surface of the stem 64 . In the check valve assembly, the movement of the plug sleeve 190 away from the stem 64 attributable to the action of the biasing spring 178 is eventually limited by the abutment of the second shoulder 199 defined by the wall portion 194 against the enlarged head portion of the fastener 186 . Conversely, the movement of the plug sleeve 190 toward the stem 64 is limited by the eventual abutment or bottoming out of the main body 196 of the plug sleeve 190 against the bottom, innermost surface of the channel 188 .
[0042] As indicated above, the pilot plug 128 of the trim 100 is movable between a closed position wherein the sealing surface 136 is sealed against the seat ring 24 , and an open position wherein the sealing surface 136 is separated from the seat ring 24 , thus allowing fluid to flow therebetween into the outflow passage 22 . The movement of the pilot plug 128 between its closed and open positions is facilitated by the upward and downward movement or actuation of the stem 64 . The reciprocal movement of the stem 64 as is needed to facilitate the movement of the pilot plug 128 between its closed and open positions is facilitated by an actuator which is operatively coupled to that end of the stem 64 opposite that having the fastener 184 attached thereto. The downward movement of the stem 64 when viewed from the perspective shown in FIG. 2 causes a peripheral portion of the end surface thereof having the internally threaded aperture and channel 188 formed therein to act against the shoulder 140 of the pilot plug 128 in a manner which forces the sealing surface 136 of the pilot plug 128 against the seat ring 24 and maintains the sealed engagement therebetween.
[0043] When the pilot plug 128 is in its closed position, the biasing force exerted against the plug sleeve 190 by the biasing spring 178 causes an annular sealing surface 197 defined by the main body portion 196 of the plug sleeve 190 to firmly engage and establish sealed contact with a portion of the pilot plug 128 at the inner periphery of the shoulder 142 thereof in the manner shown in FIG. 3A . Further, when the trim 100 is in a state or condition wherein the sealing surface 136 of the pilot plug 128 is sealed against the seat ring 24 and the sealing surface 197 of the plug sleeve 190 is sealed against the pilot plug 128 , the pressure level P 1 in the inflow passage 20 will typically exceed the pressure level P 2 in the outflow passage 22 . The pressure level P 1 also exists in the plug chamber 14 . In this regard, when viewed from the perspective shown in FIG. 2 , the plug chamber 14 is at the pressure level P 1 both above and below the level of a plug plate 180 which is attached to the top surface 130 of the pilot plug 128 through the use of, for example, fasteners such as bolts 182 . The plug plate 180 includes flow openings 184 which are disposed therein and extend between the opposed top and bottom surfaces thereof.
[0044] In the valve including the trim 100 , that portion of the plug chamber 14 located above the top surface 130 of the pilot plug 128 reaches the pressure level P 1 as the result of anticipated leakage which occurs between the inner surface of the plug sleeve 18 and the sealing rings 148 disposed in the side surface 134 of the pilot plug 128 . In this regard, the sealing rings 148 facilitate the pressurization of that portion of the plug chamber 14 located above the pilot plug 128 in a regulated, metered manner. As seen in FIG. 2 , the side surface 134 of the pilot plug 128 is not of uniform outer diameter, but rather defines an annular shoulder 184 which is disposed in relative close proximity to the sealing surface 136 . Advantageously, fluid pressure at the pressure level P 1 within that portion of the plug chamber 14 below the top surface 130 and in between the side surface 134 and the inner surfaces of the disc stack 16 and plug sleeve 18 is able to act against the shoulder 184 in a manner supplementing or increasing the force of the sealed engagement between the sealing surface 136 and seat ring 24 . Such sealed engagement is further supplemented by the pressure level P 1 within that portion of the plug chamber 14 disposed above the pilot plug 128 acting against the top surface 130 thereof. The pressure level P 1 also acts against the shoulders 140 , 142 within the bore 138 of the pilot plug 128 , thus further supplementing the force of the sealed engagement to be between the sealing surface 136 and the seat ring 24 . In this regard, fluid migrating between the pilot plug 128 and plug sleeve 18 into that portion of the plug chamber 14 disposed above the pilot plug 128 is able to flow into the uppermost and upper middle sections of the bore 138 to act against the shoulders 140 , 142 via the flow openings 184 of the plug plate 180 and one or more additional flow openings 185 which are disposed in the peripheral portion of the enlarged end portion of the stem 64 having the internally threaded aperture and the channel 188 formed therein. Even if the end surface of the stem 64 is firmly seated against the shoulder 140 of the pilot plug 128 , fluid is able to flow into the upper middle section of the bore 138 via the flow openings 185 . Such flow results in the uppermost and upper middle sections of the bore 138 reaching the fluid pressure level P 1 .
[0045] Moreover, in the valve including the trim 100 , the movement of the pilot plug 128 from its closed position to its open position is facilitated by the upward movement of the stem 64 , such upward movement being facilitated by the actuator cooperatively engaged to the stem 64 . The upward movement of the stem 64 initially causes the head portion of the fastener 186 to act against the shoulder 199 defined by the wall portion 194 of the plug sleeve 190 in a manner which effectively removes the sealing surface 197 of the plug sleeve 190 from its sealed engagement to the pilot plug 128 . The movement of the plug sleeve 190 out of sealed engagement with the pilot plug 128 creates a balanced pressure condition between the plug chamber 14 and outflow passage 22 . In this regard, the removal of the plug sleeve 190 from its sealed engagement to the pilot plug 128 allows for open flow between the plug chamber 14 and the outflow passage 22 via the bore 138 , the flow passages 184 of the plug plate 180 , and the flow passages 185 within the enlarged end portion of the stem 64 .
[0046] The continued upward movement of the stem 64 after the plug sleeve 190 is unseated from the pilot plug 128 results in the enlarged end portion of the stem 64 acting against the bottom surface of the plug plate 180 . By virtue of the attachment of the plug plate 180 to the pilot plug 128 , the continued upward movement of the stem 64 after the same engages the plug plate 180 results in the sealing surface 136 of the pilot plug 128 being lifted off of and thus separated from the seat ring 24 , thereby causing the trim 100 to assume an open position.
[0047] In the trim 100 , it is contemplated that in a further mode of operation, a balanced pressure condition between the plug chamber 14 and the outflow passage 22 may be achieved if the pilot plug 128 is in its closed position, but the pressure level P 2 in the outflow passage 22 exceeds the pressure level P 1 in the inflow passage 20 and plug chamber 14 . In this instance, it is contemplated that the pressure level P 2 will act against an annular end surface 195 of the plug sleeve 190 which is defined by the main body portion 196 thereof. In this regard, the sealing surface 197 extends to the outer peripheral edge of the end surface 195 . More particularly, the pressure level P 2 reaches the end surface 195 via the lowermost and lower middle sections of the bore 138 , and acts against the end surface 195 in a manner facilitating the compression of the biasing spring 178 and removal of the sealing surface 197 from its sealed engagement to the pilot plug 128 . The upward movement of the plug sleeve 190 by virtue of the compression of the biasing spring 178 is accommodated by the clearance between that end surface of the main body portion 196 opposite the end surface 195 and the bottom of the channel 188 . Once the plug sleeve 190 is unseated from the pilot plug 128 , fluid is able to flow from the outflow passage 22 into that portion of the plug chamber 14 above the pilot plug 128 via the bore 138 and the flow passages 185 , 184 . The equalization of the pressure level in the plug chamber 14 with the pressure level in the outflow passage 22 results in the sealing surface 197 of the plug sleeve 190 being returned to sealed engagement to the pilot plug 128 by operation of the biasing spring 178 . The check valve assembly integrated to the trim 100 provides the same functional characteristics of the trim 10 described above.
[0048] Referring now to FIGS. 4A-4C , there is shown in different states of actuation a check valve assembly 200 which may be integrated into a shut-off trim constructed in accordance with a third embodiment of the present invention, the check valve assembly 200 shown in FIGS. 4A-4C being used as an alternative to the check valve assembly shown in FIGS. 3A-3D . In this regard, the check valve assembly 200 is used in conjunction with the same pilot plug 128 possessing the same structural and functional attributes as described above in relation to the trim 100 . The check valve assembly 200 is also used in conjunction with the aforementioned plug plate 180 which is attached to the pilot plug 128 in the same manner described above in relation to the trim 100 .
[0049] The check valve assembly 200 integrated to the trim constructed in accordance with the third embodiment of the present invention comprises an auxiliary plug 286 which is secured to that end of the stem 64 opposite the end portion cooperatively engaged to the actuator. The auxiliary plug 286 comprises a cylindrically configured main body portion 287 having an elongate stem portion 289 protruding therefrom. Disposed within and extending through the stem portion 289 is an elongate slot 291 . Additionally, disposed in the main body portion 287 is an annular channel 293 of a prescribed depth, the channel 293 circumventing the base of the stem portion 289 . The auxiliary plug 286 further defines an annular plan flange portion 295 which circumvents the channel 293 , and thus also circumvents the base of the stem portion 289 .
[0050] In the check valve assembly 200 , the stem portion 289 of the auxiliary plug 286 is slideably advanced into a complimentary aperture disposed within the end surface of the enlarged end portion of the stem 64 . Subsequent to the advancement of the stem portion 289 into the complimentary aperture within the stem 64 , a pin 297 is advanced through the stem 64 and through the slot 291 disposed within the stem portion 289 . As seen in FIGS. 4A-4C , the advancement of the pin 297 through the slot 291 allows for the reciprocal movement of the auxiliary plug 286 toward and away from the stem 64 , but maintains the auxiliary plug 286 in attachment to the stem 64 .
[0051] As is apparent from FIGS. 4A-4C and as indicated above, the end portion of the stem 64 defining the end surface having the aperture formed therein is enlarged relative to the remainder of the stem 64 . The end surface of the stem 64 which includes such aperture for receiving the stem portion 289 also includes an annular groove or channel 288 which is formed therein and circumvents the aforementioned aperture. The use of the channel 288 will be described in more detail below.
[0052] In the check valve assembly 200 , the cooperative engagement of the auxiliary plug 286 to the stem 64 is facilitated the advancing the stem portion 289 into the complimentary aperture in the end surface defined by the enlarged end portion of the stem 64 , and securing the auxiliary plug 286 to the stem 64 through the use of the pin 297 advanced through the slot 291 within the stem portion 289 . At the same time, the flange portion 295 of the auxiliary plug 286 is slidably advanced into the channel 288 which has a configuration complimentary to that of the flange portion 295 . As is also apparent from FIGS. 4A-4C , the check valve assembly 200 further includes a biasing spring 278 which is disposed within the channel 293 , and extends between the main body portion 287 of the auxiliary plug 286 and a portion of the end surface of the enlarged end portion of the stem 64 which circumvents the aperture therein for accommodating the stem portion 289 . The biasing spring 278 normally biases the auxiliary plug 286 away from the stem 64 . In the check valve assembly 200 , the movement of the auxiliary plug 286 away from the stem 64 attributable to the action of the biasing spring 278 is eventually limited by the abutment of the pin 297 against that end of the slot 291 disposed closest to the distal end of the stem portion 289 . Conversely, the movement of the auxiliary plug 286 toward the stem 64 is limited by the abutment of the pin 297 against the opposite end slot 291 and/or the abutment or bottoming out of the flange portion 295 of the auxiliary plug 286 against the bottom of the channel 288 within the enlarged end portion of the stem 264 .
[0053] The pilot plug 128 of the trim including the check valve assembly 200 is movable between a closed position wherein the sealing surface 136 is sealed against the seat ring 24 , and an open position wherein the sealing surface 136 is separated from the seat ring 24 , thus allowing fluid to flow therebetween into the outflow passage 22 . The movement of the pilot plug 128 between its closed and open positions is facilitated by the upward and downward movement or actuation of the stem 64 . As in the prior embodiments discussed above, the reciprocal movement of the stem 64 as is needed to facilitate the movement of the pilot plug 128 between its closed and open positions is facilitated by an actuator which is operatively coupled to that end of the stem 64 opposite that having the auxiliary plug 286 attached thereto. The downward movement of the stem 64 when viewed from the perspective shown in FIGS. 4A-4C causes a peripheral portion of the end surface thereof having the aperture and channel 288 formed therein to act against the shoulder 140 of the pilot plug 128 in a manner which forces the sealing surface 136 of the pilot plug 128 against the seat ring 24 and maintains the sealed engagement therebetween.
[0054] When the pilot plug 128 is in its closed position, the biasing force exerted against the auxiliary plug 286 by the biasing spring 278 causes an annular sealing surface 299 defined by the main body portion 287 of the auxiliary plug 286 to firmly engage and establish sealed contact with a portion of the pilot plug 128 at the inner periphery of the shoulder 142 thereof in the manner shown in FIG. 4A . Further, when the trim including the check valve assembly 200 is in a state or condition wherein the sealing surface 136 of the pilot plug 128 is sealed against the seat ring 24 and the sealing surface 299 of the auxiliary plug 286 is sealed against the pilot plug 128 , the pressure level P 1 in the inflow passage 20 will typically exceed the pressure level P 2 in the outflow passage 22 . The pressure level P 1 also exists in the plug chamber 14 . In this regard, when viewed from the perspective shown in FIGS. 4A-4C , the plug chamber 14 is at the pressure level P 1 both above and below the level of a plug plate 180 which is attached to the top surface 130 of the pilot plug 128 through the use of the bolts 182 . As indicated above, the plug plate 180 includes flow openings 184 which are disposed therein and extend between the opposed top and bottom surfaces thereof.
[0055] In the valve including the trim having the check valve assembly 200 , that portion of the plug chamber 14 located above the top surface 130 of the pilot plug 128 reaches the pressure level P 1 as the result of anticipated leakage which occurs between the inner surface of the plug sleeve 18 and the sealing rings 148 disposed in the side surface 134 of the pilot plug 128 . In this regard, the sealing rings 148 facilitate the pressurization of that portion of the plug chamber 14 located above the pilot plug 128 in a regulated, metered manner. As indicated above, the side surface 134 of the pilot plug 128 is not of uniform outer diameter, but rather defines an annular shoulder 184 which is disposed in relative close proximity to the sealing surface 136 . Advantageously, fluid pressure at the pressure level P 1 within that portion of the plug chamber 14 below the top surface 130 and in between the side surface 134 and the inner surfaces of the disc stack 16 and plug sleeve 18 is able to act against the shoulder 184 in a manner supplementing or increasing the force of the sealed engagement between the sealing surface 136 and seat ring 24 . Such sealed engagement is further supplemented by the pressure level P 1 within that portion of the plug chamber 14 disposed above the pilot plug 128 acting against the top surface 130 thereof. The pressure level P 1 also acts against the shoulders 140 , 142 within the bore 138 of the pilot plug 128 , thus further supplementing the force of the sealed engagement to be between the sealing surface 136 and the seat ring 24 . In this regard, fluid migrating between the pilot plug 128 and plug sleeve 18 into that portion of the plug chamber 14 disposed above the pilot plug 128 is able to flow into the uppermost and upper middle sections of the bore 138 to act against the shoulders 140 , 142 via the flow openings 184 of the plug plate 180 and one or more additional flow openings 285 which are disposed in the peripheral portion of the enlarged end portion of the stem 64 having the aperture and the channel 288 formed therein. Even if a portion of the end surface of the stem 64 is firmly seated against the shoulder 140 of the pilot plug 128 , fluid is able to flow into the upper middle section of the bore 138 via the flow openings 285 . Such flow results in the uppermost and upper middle sections of the bore 138 reaching the fluid pressure level P 1 .
[0056] Moreover, in the valve including the trim having the check valve assembly 200 , the movement of the pilot plug 128 from its closed position to its open position is facilitated by the upward movement of the stem 64 , such upward movement being facilitated by the actuator cooperatively engaged to the stem 64 . The upward movement of the stem 64 initially causes the pin 297 to act against the stem portion 289 of the auxiliary plug 286 in a manner which effectively removes the sealing surface 299 of the auxiliary plug 286 from its sealed engagement to the pilot plug 128 . The movement of the auxiliary plug 286 out of sealed engagement with the pilot plug 128 creates a balanced pressure condition between the plug chamber 14 and outflow passage 22 . In this regard, the removal of the auxiliary plug 286 from its sealed engagement to the pilot plug 128 allows for open flow between the plug chamber 14 and the outflow passage 22 via the bore 138 , the flow passages 184 of the plug plate 180 , and the flow passages 285 within the enlarged end portion of the stem 64 .
[0057] The continued upward movement of the stem 64 after the auxiliary plug 286 is unseated from the pilot plug 128 results in the enlarged end portion of the stem 64 acting against the bottom surface of the plug plate 180 . By virtue of the attachment of the plug plate 180 to the pilot plug 128 , the continued upward movement of the stem 64 after the same engages the plug plate 180 results in the sealing surface 136 of the pilot plug 128 being lifted off of and thus separated from the seat ring 24 , thereby causing the trim including the check valve assembly 200 to assume an open position.
[0058] In the trim of the third embodiment including the check valve assembly 200 , it is contemplated that in a further mode of operation, a balanced pressure condition between the plug chamber 14 and the outflow passage 22 may be achieved if the pilot plug 128 is in its closed position, but the pressure level P 2 in the outflow passage 22 exceeds the pressure level P 1 in the inflow passage 20 and plug chamber 14 . In this instance, it is contemplated that the pressure level P 2 will act against a circular end surface 283 of the auxiliary plug 286 which is defined by the main body portion 287 thereof. In this regard, the sealing surface 299 extends to the outer peripheral edge of the end surface 283 . More particularly, the pressure level P 2 reaches the end surface 283 via the lowermost and lower middle sections of the bore 138 , and acts against the end surface 283 in a manner facilitating the compression of the biasing spring 278 and removal of the sealing surface 299 from its sealed engagement to the pilot plug 128 . The upward movement of the auxiliary plug 286 by virtue of the compression of the biasing spring 278 is accommodated by the clearance between the flange portion 295 and the bottom of the channel 288 . Once the auxiliary plug 286 is unseated from the pilot plug 128 , fluid is able to flow from the outflow passage 22 into that portion of the plug chamber 14 above the pilot plug 128 via the bore 138 and the flow passages 285 , 184 . The equalization of the pressure level in the plug chamber 14 with the pressure level in the outflow passage 22 results in the sealing surface 299 of the auxiliary plug 286 being returned to sealed engagement to the pilot plug 128 by operation of the biasing spring 278 . The check valve assembly 200 provides the same functional characteristics of the trim 10 described above.
[0059] Referring now to FIGS. 5 and 6 A- 6 B, there is shown a shut-off trim 300 constructed in accordance with a fourth embodiment of the present invention. The trim 300 comprises a pilot plug 328 which, from the perspective shown in FIG. 5 , defines a top surface 330 , a bottom surface 332 , a side surface 334 , and a sealing surface 336 which extends between the bottom and side surfaces 332 , 334 . The pilot plug 328 is not solid, but rather has a bore 338 extending axially therethrough. The bore 338 is not of uniform diameter. Rather, the bore 338 defines three (3) different segments or sections, each of which is of a differing diameter. More particularly, the bore 338 includes an upper section and a middle section which is of a reduced diameter in comparison to the upper section. The bore 338 also defines a lower section which is of the greatest diameter, exceeding that of the upper section thereof. The upper and middle sections of the bore 338 are separated by a shoulder 340 . Disposed in the side surface 334 of that portion of the pilot plug 328 which defines the upper bore section is a plurality of sealing rings 348 which circumvent the pilot plug 328 and are used for reasons which will also be described in more detail below.
[0060] When the trim 300 is in a closed position within the exemplary valve including the same, the sealing surface 336 defined by the pilot plug 328 is firmly seated and sealed against the seat ring 24 . The trim 300 assumes an open position when, from the perspective shown in FIG. 2 , the pilot plug 328 is caused to move upwardly as results in the sealing surface 336 thereof effectively being separated from the seat ring 24 . Such separation allows fluid from within the plug chamber 14 to flow between the sealing surface 336 and seat ring 24 into outflow passage 22 .
[0061] The pilot plug 328 included in the trim 300 further includes a check valve assembly 301 which is shown with particularity in FIGS. 6A and 6B . More particularly, the check valve assembly 301 comprises a flow passage 303 which extends from the top surface 330 of the pilot plug 328 to and into fluid communication with the lower section of the bore 338 thereof in the manner best shown in FIG. 5 . The flow passage 303 is not of uniform inner diameter. Rather, when viewed from the perspective shown in FIG. 5 , the flow passage 303 includes an upper section and a lower section which are separated from each other by an annular shoulder 305 , the diameter of the upper section exceeding that of the lower section. Disposed within the upper section of the flow passage 303 is a check ball 307 . The diameter of the check ball 307 presents the same from entering into the lower section of the flow passage 303 . The check ball 307 is maintained within the upper section of the flow passage 303 by an annular cap 309 which is partially advanced into the upper section of the flow passage 303 , and extends in substantially flush relation to the top surface 330 of the pilot plug 328 . At least a portion of that surface of the pilot plug 328 defining the upper section of the flow passage 303 is internally threaded, with the outer surface of the cap 309 being externally threaded so as to provide for the threadable engagement of the cap 309 to the plug 328 .
[0062] The check valve assembly 301 further comprises a biasing spring 311 which is disposed within the upper section of the flow passage 303 . One end of the biasing spring 311 is abutted against or engaged to the check ball 307 , with the opposite end of the biasing spring 311 being abutted against that end surface of the cap 309 which is opposite the end surface extended in substantially flush relation to the top surface 330 of the pilot plug 328 . As seen in FIG. 6A , the biasing spring 311 normally biases the check ball 307 against the inner peripheral edge of the shoulder 305 , thus causing the check ball 307 to define a blockage or seal between the upper and lower sections of the flow passage 303 . By virtue of its annular configuration, the cap 309 defines a flow opening which extends axially therethrough and facilitates the fluid communication between the flow passage 303 and that portion of the plug chamber 14 disposed above the pilot plug 328 when viewed from the perspective shown in FIG. 5 .
[0063] The pilot plug 328 of the trim 300 is movable between a closed position wherein the sealing surface 336 is sealed against the seat ring 24 , and an open position wherein the sealing surface 336 is separated from the seat ring 24 , thus allowing fluid to flow therebetween into the outflow passage 22 . The movement of the pilot plug 328 between its closed and open positions is facilitated by the upward and downward movement or actuation of the stem 64 . As in the prior embodiments discussed above, the reciprocal movement of the stem 64 as is needed to facilitate the movement of the pilot plug 328 between its closed and open positions is facilitated by an actuator which is operatively coupled thereto. The downward movement of the stem 64 when viewed from the perspective shown in FIG. 5 causes a peripheral portion of the end surface thereof to act against the shoulder 340 of the pilot plug 328 in a manner which forces the sealing surface 336 of the pilot plug 328 against the seat ring 24 and maintains the sealed engagement therebetween.
[0064] When the pilot plug 328 is in its closed position, the biasing force exerted against the check ball 307 by the biasing spring 311 causes the check ball 307 to be firmly seated and sealed against the shoulder 305 , thus effectively blocking fluid communication between the outflow passage 22 and plug chamber 14 as would otherwise be provided by the flow passage 303 . Further, when the trim 300 is in a state or condition wherein the sealing surface 336 of the pilot plug 328 is sealed against the seat ring 24 and the check ball 307 is sealed against the shoulder 305 , the pressure level P 1 in the inflow passage 20 will typically exceed the pressure level P 2 in the outflow passage 22 . The pressure level P 1 also exists in the plug chamber 14 . In this regard, when viewed from the perspective shown in FIG. 5 , the plug chamber 14 is at the pressure level P 1 both above and below the level of a plug plate 380 which is attached to the top surface 330 of the pilot plug 328 through the use the bolts 382 . The plug plate 380 includes flow openings 384 which are disposed therein and extend between the opposed top and bottom surfaces thereof.
[0065] In the valve including the trim 300 , that portion of the plug chamber 14 located above the top surface 330 of the pilot plug 328 reaches the pressure level P 1 as the result of anticipated leakage which occurs between the inner surface of the plug sleeve 18 and the sealing rings 348 disposed in the side surface 334 of the pilot plug 328 . In this regard, the sealing rings 348 facilitate the pressurization of that portion of the plug chamber 14 located above the pilot plug 328 in a regulated, metered manner. The side surface 334 of the pilot plug 328 is not of uniform outer diameter, but rather defines an annular shoulder 384 which is disposed in relative close proximity to the sealing surface 336 . Advantageously, fluid pressure at the pressure level P 1 within that portion of the plug chamber 14 below the top surface 330 and in between the side surface 334 and the inner surfaces of the disc stack 16 and plug sleeve 18 is able to act against the shoulder 384 in a manner supplementing or increasing the force of the sealed engagement between the sealing surface 336 and seat ring 24 . Such sealed engagement is further supplemented by the pressure level P 1 within that portion of the plug chamber 14 disposed above the pilot plug 328 acting against the top surface 330 thereof. The pressure level P 1 also acts against the shoulder 340 within the bore 338 of the pilot plug 328 , thus further supplementing the force of the sealed engagement to be between the sealing surface 336 and the seat ring 24 . In this regard, fluid migrating between the pilot plug 128 and plug sleeve 18 into that portion of the plug chamber 14 disposed above the pilot plug 328 is able to flow into the upper section of the bore 338 to act against the shoulders 140 via the flow openings 384 of the plug plate 380 . Such flow results in the upper section of the bore 338 reaching the fluid pressure level P 1 . Fluid at the pressure level P 1 also flows from the plug chamber 14 into the upper section of the flow passage 303 via the flow opening defined by the cap 309 . Such fluid at the pressure level P 1 acts against the check ball 307 in a manner supplementing the biasing force exerted thereagainst by the biasing spring 311 , thus enhancing the sealed engagement of the check ball 307 against the shoulder 305 .
[0066] Moreover, in the valve including the trim 300 having the check valve assembly 301 , the movement of the pilot plug 328 from its closed position to its open position is facilitated by the upward movement of the stem 64 , such upward movement being facilitated by the actuator cooperatively engaged to the stem 64 . When the pilot plug 328 is in its closed position, a sealing surface defined by the enlarged end portion of the stem 64 engages and is sealed against the inner peripheral rim defined by the shoulder 340 of the pilot plug 328 , thus effectively creating a blockage or barrier between the upper and middle sections of the bore 338 . The upward movement of the stem 64 initially causes the sealing surface of the stem 64 to be removed from its sealed engagement to the pilot plug 328 , thus creating a balanced pressure condition between the plug chamber 14 and outflow passage 22 . In this regard, the removal of the sealing surface defined by the enlarged end portion of the stem 64 from its sealed engagement to the pilot plug 328 allows for open flow between the plug chamber 14 and the outflow passage 22 via the bore 338 and flow passages 384 of the plug plate 380 .
[0067] The continued upward movement of the stem 64 after the sealing surface thereof is unseated from the pilot plug 328 results in the enlarged end portion of the stem 64 acting against the bottom surface of the plug plate 380 . By virtue of the attachment of the plug plate 380 to the pilot plug 328 , the continued upward movement of the stem 64 after the same engages the plug plate 380 results in the sealing surface 336 of the pilot plug 328 being lifted off of and thus separated from the seat ring 24 , thereby causing the trim 300 to assume an open position.
[0068] In the trim 300 including the check valve assembly 301 , it is contemplated that in a further mode of operation, a balanced pressure condition between the plug chamber 14 and the outflow passage 22 may be achieved if the pilot plug 328 is in its closed position, but the pressure level P 2 in the outflow passage 22 exceeds the pressure level P 1 in the inflow passage 20 and plug chamber 14 . In this instance, it is contemplated that the pressure level P 2 will act against the check ball 307 in a manner overcoming the biasing force exerted thereagainst by the biasing spring 311 , thus effectively forcing the check ball 307 toward the cap 309 and out of its sealed engagement to the shoulder 305 . As will be recognized, since the diameter of the check ball 307 is less than that of the upper section of the flow passage 303 , the movement of the check ball 307 out of sealed engagement to the shoulder 305 effectively unblocks the flow passage 303 , thus allowing open fluid communication between the outflow passage 22 and that portion of the plug chamber 14 disposed above the pilot plug 328 . As will be recognized, the pressure level P 2 reaches the check ball 307 via the lower section of the bore 338 and the lower section of the flow passage 303 . As indicated above, once the check ball 307 is unseated from the shoulder 305 , fluid is able to flow from out outflow passage 22 into that portion of the plug chamber 14 above the pilot plug 328 via the lower section of the bore 338 and flow passage 303 . The equalization of the pressure level in the plug chamber 14 with the pressure level in the outflow passage 22 results in the check ball 307 of the check valve assembly 301 being returned to sealed engagement to the shoulder 305 by operation of the biasing spring 311 . The trim 300 including the check valve assembly 301 provides the same functional characteristics of the trim 10 described above.
[0069] This disclosure provides exemplary embodiments of the present invention only. The scope of the present invention is not limited by these exemplary embodiments. Numerous variations, whether explicitly provided for by the specification or implied by the specification, such as variations in structure, dimension, type of material and manufacturing process may be implemented by one of skill in the art in view of this disclosure. | In accordance with the present invention, there is provided a bi-directional shut-off trim for a valve which possesses the functional attributes of a pilot operated trim and a balanced trim through the integration of a spring loaded check valve into a pilot trim. In forward flow isolation, the bi-directional shut-off trim of the present invention acts as a normal pilot operated trim. In reverse flow, the check valve of the shut-off trim opens to balance the pressure on either side of the plug thereof. | 8 |
TECHNICAL FIELD
The invention described herein relates generally to semiconductor device packaging. In particular, the invention relates to a method and package for a semiconductor device that is resistant to electrostatic discharge that can be caused by various factors.
BACKGROUND
The semiconductor industry makes wide use of standard BGA (ball grid array) type semiconductor packages. Such packages generally include a BT (bismaleimide triazine) core having various metallization and solder mask layers to form the substrate. A semiconductor die is attached to the substrate and electrically connected to various electrical connections of the substrate using ball attach or wire-bonding techniques. The wire bonds and the die are typically encapsulated with a protective layer of encapsulant. Such packages and the methods of their construction are well known to persons having ordinary skill in the semiconductor packaging arts. Additionally, ball attach arrangements are provided with an underfill encapsulant to protect the bonding arrangements of the solder balls.
Commonly, the packages are then provided with a stiffener and a heat spreader to complete the packages. These completed packages are then subject to a series of tests used to qualify the packages to insure they meet all the necessary specifications prior to shipping.
One such test subjects the package to a series of electrostatic discharge (ESD) events to determine the packages robustness and resistance to these ESD events. In the present art, each of the ball pins of a ball grid array type package are tested for charge coupled electrostatic discharge failures. To alleviate this problem each die includes shunt circuitry associated with each external connection. One purpose of this shunt circuitry is to provide a level of resistance to ESD events.
Commonly, testing is done using a device specifically constructed for administering such testing. One example of such a tester is an Orion CDM Tester produced by Oryx Instruments Corporation of Fremont, Calif. Such equipment can be programmed to implement testing for compliance in accordance with a number of test standards. Typical examples being provided by the JEDEC, AEC, and ESDA standards as well as others. One particular standard being JEDEC No. JESD22-C101C.
FIG. 1 is a simplified schematic cross-section view of a portion of a standard PBGA (plastic ball grid array) package 101 arranged on a tester. Commonly, such packages 101 include a substrate 102 or core. The core is typically sandwiched between two metallization layers which also include layers of solder mask. Most commonly, the core 102 is formed of fiber material suspended in a cured a BT resin material. This core 102 is then treated to form metallization layers. Commonly, copper materials or coated copper materials are used. Other conductive materials are also used. A solder mask layer is then formed over the metallization layers. Typically, the solder mask layer is photolithographically patterned to create a solder mask that can be used to define a corresponding pattern in the metallization layers. Such substrates are commonly very thin, for example, less than about 0.60 mm thick. The methods of accomplishing this are very well known to those having ordinary skill in the art
With continued reference to FIG. 1 , the substrate 102 forms part of a semiconductor package 101 . Ball attach pads are typically formed on a backside 105 surface of the substrate 102 . Solder balls 115 are typically formed on the ball attach pads. Additionally, a semiconductor integrated circuit die 110 is mounted to the front side 106 surface of the substrate 102 . In many implementations, solder balls electrically connect the die 110 to associated electrical contact points on the substrate 101 . Vias (not shown in this simplified view) formed in and through the substrate 102 enable the electrical communication between circuitry of the die 110 and the solder balls 115 mounted on the backside 105 of the package 101 . The die and electrical connections at the interface between the die 110 and substrate 102 are commonly encapsulated in a protective layer 112 of encapsulating underfill material.
Additionally, many prior art devices include a metal stiffener 103 and a heat spreaders 104 . Such elements are known to persons having ordinary skill in the art.
With continued reference to FIG. 1 , the package 101 is typically placed upside down (solder ball side up) on a tester 120 . As shown here, the package is placed on an insulated tester board for testing. For example, the package 101 is placed on a tester chuck 12 which has a layer of insulating material 122 (e.g., FR-4 or other such materials). The tester board ( 121 , 122 ) is set at some predetermined electrical potential (e.g., 500 volts). Then a testing probe 123 descends to contact each of solder balls of the package 101 . The probe is commonly set at ground. If the package survives pre-selected test routine without damage the packaged is “qualified”.
This commonly constructed package has provided satisfactory ESD protection until recently. Now, with increasing scaling of circuit elements formed on the die, smaller less ESD resistant devices and elements are becoming more common. These devices have increased vulnerability to ESD events. Thus, the traditional package format is increasingly lacking in the ability to protect these vulnerable elements from ESD events. Accordingly, the incidence of ESD induced package failure has been rising and is expected to continue to do so as circuitry and device sizes continue to shrink.
Accordingly, what is needed is a packaging design and approach that provides increased resistance to ESD induced package failure.
SUMMARY OF THE INVENTION
In accordance with the principles of the present invention, an improved semiconductor package and methods for its fabrication are disclosed.
In general, the present invention is directed toward methods and packages that increase the package impedance of a semiconductor package thereby increasing the resistance of the overall package to ESD associated package failures.
One embodiment of the invention comprises a semiconductor integrated circuit package having a substrate with a die attached to the front side thereof. The package includes a die electrically connected with the substrate. The package further including a discharge shield configured to protect the die from electrostatic discharge events. In still another related embodiment, the ESD shield can comprise a frame and cap elements.
In a method embodiment, aspects of the invention involve a method for forming an ESD hardened semiconductor integrated circuit package. The method including providing a substrate having a semiconductor integrated circuit die mounted thereon. An electrostatic discharge shield is mounted on the substrate over the die. A thermal grease is placed between the top and die to facilitate heat flow from the die to the ESD shield.
Other aspects and advantages of the invention will become apparent from the following detailed description and accompanying drawings which illustrate, by way of example, the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The following detailed description will be more readily understood in conjunction with the accompanying drawings, in which:
FIG. 1 is a simplified schematic views of a conventional substrate and package used to package semiconductor IC chips.
FIGS. 2( a )- 2 ( b ) are simplified cross-sectional views of embodiments of the invention depicting various ESD shield embodiments formed in accordance with the principles of the invention .
It is to be understood that in the drawings like reference numerals designate like structural elements. Also, it is understood that the depictions in the Figures are not necessarily to scale.
DETAILED DESCRIPTION OF THE INVENTION
The present invention has been particularly shown and described with respect to certain embodiments and specific features thereof. The embodiments set forth hereinbelow are to be taken as illustrative rather than limiting. It should be readily apparent to those of ordinary skill in the art that various changes and modifications in form and detail may be made without departing from the spirit and scope of the invention.
In general, the present invention encompasses semiconductor package designs that include an ESD shield formed over the die in order to reduce the incidence of ESD induced devices failures. In the following detailed description, semiconductor package embodiments will be disclosed. In particular, the depicted structures show package embodiments having various ESD shield embodiments suitable for increasing package resistance to ESD induced package and device failures.
FIG. 2( a ) depicts one embodiment of a semiconductor package constructed in accordance with the principles of the invention. The depicted embodiment is view in plan view. In some ways the depicted embodiment is similar to a prior art package. However, there are several significant distinctions. The package 200 includes a substrate 202 . The substrate 202 in the depicted embodiment can be an ordinary BT substrate such a described herein above. The substrate 202 can be an ordinary two-layer PBGA substrate. Commonly, such substrates are on the order of 0.60 mm thick although substrates of any thickness can be employed. A die 210 is mounted to the substrate 202 . Such mounting is done using any of a number of different standard techniques.
In the depicted embodiment, the die 210 is electrically connected to the substrate using a set solder balls 211 that contact via structures (not shown) to electrically connect the die 210 with the backside solder balls 215 of the package. Generally, a layer of encapsulant underfill 212 material is injected between the balls 211 between the die 210 and substrate 202 . Such underfill material is of a type generally known in the art.
In order to pass the specification, a package must be able to withstand a certain level of electrostatic discharge to be properly “qualified”. Using, for example, a JEDEC standard Charged Device Model (CDM) Electrostatic Discharge specification a device constructed in accordance with the principles of the invention would be able to function properly after being subjected to a current of about 5 A for about 1 nanosecond (ns). Of course other standards exist (such as the previously referenced AEC and ESDA standards) and the inventors contemplate that a package constructed in accordance with the principles of the invention will be sufficiently robust to protect such packages from ESD related failures.
Again referring to FIG. 1 , the embodiment includes an electrostatic discharge shield 220 mounted on the substrate 202 . The shield 210 is configured to protect the die 210 from electrostatic discharge events. The electrostatic discharge shield 220 can be simply configured. In the depicted embodiment, the electrostatic discharge shield 220 is simply placed on the substrate 210 in place of the prior art stiffener 103 and heat spreader 104 . It can be affixed using a standard adhesive if desired. One example is a thermal setting epoxy. For example, MC-723 manufactured by Ablestik can be employed. Of course many other adhesive known to those having ordinary skill in the art can also be employed. Additionally, other means of affixing the shield can be employed. Mounting pegs, solder and numerous other approaches can be employed.
In one particularly useful embodiment, the shield 220 is used to replace the stiffener and the heat spreader. In such an embodiment, a thermal grease 224 is spread between the die and shield to enhance the thermal transfer between the die 210 and the shield 220 which serves as the heatspreader.
The inventors have discovered that AlSiC (aluminum silicon carbide) works well as an ESD shield 220 . This is because AlSiC has a sufficiently high resistivity enabling the shield to maximize impedance between the die and an external ESD generating source, thereby minimizing ESD current into the die. This also results in reduced capacitance between the die and the external ESD generating source. For example, AlSiC has a resistivity in the range of about 30-50 μΩ·cm (10 −6 ohm centimeters). AlSiC also provides a sufficiently high thermal conductivity to enable its effective use as a heat spreader. For example, AlSiC has a thermal conductivity in the range of about 130-200 W/mK. What makes AlSiC a surprising choice is the CTE (coefficient of thermal expansion) mismatch between AlSiC and ordinary substrate materials like BT. BT has a CTE of about 17 ppm/° C. whereas the CTE for AlSiC is in the range of about 6-9 ppm/° C. The inventors have found that under most operational conditions such a mismatch can still be functional in a package. The inventors also believe that shields comprising BeO and A 1 2 O 3 can also be employed to some good effect. The inventors further contemplate that materials having a resistivity greater than about 30 μΩ·cm and high thermal conductivity high enough to facilitate its use as a heat spreader can also be employed.
It should be noted that although the invention is described here with respect to a two-layer BGA package, the principles and methodologies described here can readily be used to construct four and six (or more) layer packages, as well as, EPBGA (enhanced plastic ball grid array) packages, leaded packages (those with leads rather than solder balls), or chip scale packages (those that are 15×15 mm 2 or smaller). The support elements can be formed on the front side and/or the backside of the substrate, depending on the amount of stiffening desired.
Another embodiment is depicted in simplified schematic sectional view in FIG. 2( b ). Again, in many ways the depicted embodiment is similar to that shown, for example, in FIG. 1 . The package 250 again includes a substrate 202 . Typically, the substrate 202 is an ordinary BT substrate such a described herein above. Again, the substrate 202 can be an ordinary two-layer PBGA substrate or alternatively a four and six (or more) layer package. Also the package can comprise EPBGA (enhanced plastic ball grid array) packages, leaded packages (those with leads rather than solder balls), or chip scale packages. The electrical connections include wire bonds 251 that connect the die 210 to the bottom solder balls 215 . A layer 253 of protective encapsulant material is used to protect and encapsulate the wires 251 . In this embodiment, the ESD shield comprises an ESD shield frame 253 that is mounted on the substrate 202 . The ESD frame 253 is formed of material having good electrical insulation properties. For example, AlSiC can be used as well as other electrically insulative materials. Such mounting can be conducted using a variety of mounting techniques known to those having ordinary skill in the art. In the depicted embodiment an adhesive layer 254 is used to adhere the frame 253 to the substrate 202 . For example, a thermal setting adhesive can be used. An ESD shield cap 255 is then attached to the top of the frame 253 . The ESD cap 255 is formed of material having good electrical insulation properties. Also, in some embodiments it is desirable that the cap 255 have a relatively high thermal conductivity enabling it to function as a heatspreader. Moreover, in embodiments where the frame 253 also demonstrates a high thermal conductivity the frame expands the capacity of the shield as a heat spreader. Therefore, AlSiC also provides an excellent cap 255 material. The cap 255 can be mounted to the frame 253 conducted using a variety of mounting techniques known to those having ordinary skill in the art. In the depicted embodiment an adhesive layer 256 is used to adhere the cap 255 to the frame 253 . Also, a thermal grease 256 can be positioned between the die and the shield to enhance the heat transfer capacity of the package 250 .
In the depicted embodiments, the shield 220 is separated from the top of the die by about 75 microns and is about 1.2 mm tall. In one embodiment of the invention the package is configured to dissipate an ESD of at least 20 Watts (W).
Some of the advantages of package embodiments described herein include manufacturability advantages related to the fact that these embodiments require no change in existing die design. Additionally, the inventors contemplate that the shunts currently employed for ESD purposes are no longer as important and in some cases may not be necessary at all. To that end, the removal of the shunts from the die, frees up more space on the die for operational circuitry thereby expanding the functionality of the die. Additionally, the introduction of the heat shield does not substantially affect package manufacturing process flow with the shield replacing existing stiffeners and heat spreaders.
The present invention has been particularly shown and described with respect to certain preferred embodiments and specific features thereof. However, it should be noted that the above-described embodiments are intended to describe the principles of the invention, not limit its scope. Therefore, as is readily apparent to those of ordinary skill in the art, various changes and modifications in form and detail may be made without departing from the spirit and scope of the invention as set forth in the appended claims. Other embodiments and variations to the depicted embodiments will be apparent to those skilled in the art and may be made without departing from the spirit and scope of the invention as defined in the following claims. In particular, it is contemplated by the inventors that support elements constructed for the purpose of increasing the rigidity of a semiconductor package can be formed on the package in any configuration. Although only two configurations are expressly disclosed herein, it should be appreciated by anyone having ordinary skill in the art that, using the teachings disclosed herein, many different package support configurations can be implemented and still fall within the scope of the claims. Further, reference in the claims to an element in the singular is not intended to mean “one and only one” unless explicitly stated, but rather, “one or more”. Furthermore, the embodiments illustratively disclosed herein can be practiced without any element which is not specifically disclosed herein. | Embodiments of the invention include a semiconductor integrated circuit package that includes a substrate having an integrated circuit die attached thereto. The package includes a ESD shield attached to the substrate. The ESD shield configured to increase the ESD hardness of the package. The ESD shield can further serve to stiffen the package to prevent warping and operate as a heat spreader. | 7 |
CROSS REFERENCE TO RELATED APPLICATION
This application claims the priority of German Application No. 197 39 187.7 filed Sep. 8, 1997, which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
This invention relates to a roll for removing material from components of a fiber processing machine, particularly a carding machine, for grinding the clothing points of the flat bars of the traveling flats or for removing dirt from the crushing rolls.
Conventionally, a grinding roll associated with the traveling flats of a carding machine is arranged for rotation about an axis parallel to the longitudinal axis of the flat bars. The circumferential surface of the grinding roll and the travelling flat bars have unlike velocities.
It is known that during operation of the carding machine the clothing points of the flat bars are exposed to slow wear, resulting in the dulling of the points. This causes a deterioration of the operation of the carding machine, and thus the quality of the fiber web produced by the carding machine is adversely affected. Accordingly, it is therefore conventional to grind the clothing points of the flat bars from time to time to restore the points to their necessary sharpness.
The conventional clothing point grinding roll and process, however, have the disadvantage that for the sharpening operation the carding machine has to be stopped, resulting in a certain down time. Further, the grinding roll and its carrier have to be very stable and must be manufactured with the utmost precision. These requirements render the grinding process expensive. Further, the points are ground to a non-uniform extent. It is still another drawback that, viewed over a longer period of time, the quality of the continuously formed web slowly decreases as the clothing points become increasingly dull and after each grinding process the web quality abruptly improves. Such a circumstance makes the manufacture of yarn of uniform properties more difficult as viewed over both short-term and long-term working periods of the carding machine.
In the known grinding process of the flat bar clothing points, rolls are used which have a grinding layer on their rigid circumferential surface. To ensure that during grinding each point of the clothing is ground in an optimal manner, that is, to ensure that from each point neither too little nor too much material is removed, very high requirements are set for the linearity of the grinding roll. To comply with such requirements involves significant expense, rendering the grinding process uneconomical. Also, it is unavoidable that from the individual points excessive or insufficient amount of material is removed because in practice the clothing points are not of uniform height.
SUMMARY OF THE INVENTION
It is an object of the invention to provide an improved material-removing roll of the above-outlined type from which the discussed disadvantages are eliminated and which, in particular, makes possible a significantly improved and uniform grinding of the clothing points of flat bars in a carding machine.
This object and others to become apparent as the specification progresses, are accomplished by the invention, according to which, briefly stated, the fiber processing machine includes a fiber processing component and a material-removing roll supported to be in contact with the fiber processing component for removing material therefrom. The material-removing roll includes a radially deformable resilient circumferential surface and a material-removing substance carried at least indirectly by the resilient surface.
By virtue of the elastic circumferential surface of the grinding roll, such surface is radially deformable and thus the grinding layer conforms to the non-uniform height of the clothing points. As an advantageous result, all points are ground and ground down to a uniform extent. It is a further advantage of the invention that the grinding roll--in contrast to conventional arrangements--is not subject to the same stringent requirements. Since the grinding roll according to the invention makes possible a grinding process during the normal operation of the carding machine, in contrast to the periodic grinding process--in which a slow deterioration of quality of the fiber web and an abrupt improvement of its quality after each grinding process occur--with the use of the invention a sustained evening of the fiber web produced by the carding machine is achieved.
The invention has the following further advantageous features:
The material-removing roll is supported on stationary bearings.
The roll support and/or the material-removing roll is adjustable.
The material-removing roll may conform to the various heights of the points of the flat bar clothing points.
The material-removing roll has a core made of a hard material, for example, steel, aluminum or plastic carrying an elastic circumferential layer.
The elastic circumferential layer is an elastic hose or the like made, for example, of foam material, rubber of cellular structure, or foamed silicone.
The elastic circumferential layer is made of a soft material.
The elastic circumferential layer contains the grinding or cleaning (polishing) substance.
The grinding or cleaning substance is applied to the surface of the elastic circumferential layer.
The grinding or cleaning material is wound on the elastic circumferential layer, for example, as a ribbon.
The material-removing roll has a circumferential speed of approximately 3-10 m/sec.
The material-removing roll is intermittently or continuously engaging the flat bar clothings.
The material-removing roll is arranged downstream of the cleaning device for the traveling flats, as viewed in the advancing direction of the flat bars.
The direction of motion of the material-removing roll coincides with or is opposite to that of the flat bars in the mutual contacting zone.
The material-removing roll engages the clothing points of the flat bars under its own weight.
The grinding or cleaning substance comprises sanding substances such as silicone, corundum, titanium carbide or sanding fibers or comprises polishing elements such as artificial leather.
The grinding or cleaning substance is applied to a textile carrier (such as a woven or knit fabric) which is mounted about the elastic circumferential layer of the material-removing roll.
The textile carrier is elastic at least in one direction.
The textile carrier has at least partially elastic yarns, such as Elastan.
The material-removing roll is cooperating with a roll cleaning device such as a cleaning roll, a scraper blade or a suction device.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic side elevational view of a carding machine incorporating the invention.
FIG. 2 is a sectional end elevational view of a material-removing roll according to the invention.
FIG. 3 is a schematic side elevational view of a crushing roll pair in which each crushing roll is associated with a cleaning roll structured according to the invention.
FIG. 4 is a schematic side elevational view of a grinding roll in contact with flat bar clothing points and cooperating with a stripping roll.
FIGS. 4a, 4b and 4c are schematic side elevational views of flat bar clothing points in a new, worn and resharpened condition, respectively.
FIG. 5 is a schematic side elevational view illustrating cleaning rolls according to the invention, cooperating with crushing rolls situated between the doffer and a sliver trumpet of a carding machine.
FIG. 6 is a schematic side elevational view of travelling flats, a grinding roll according to the invention associated therewith as well as a common drive for the travelling flats and the material-removing roll.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a carding machine CM which may be, for example, an EXACTACARD DK 803 model, manufactured by Trutzschler GmbH & Co. KG, Monchengladbach, Germany. The carding machine CM has a feed roll 1 cooperating with a feed tray 2, licker-ins 3a, 3b and 3c, a main carding cylinder 4, a doffer 5, a stripper roll 6, cooperating crushing rolls 7 and 8, a web guiding element 9, a web trumpet 10, cooperating calender rolls 11, 12, traveling flats 13 having flat bars 14, a coiler can 15 and a sliver coiling mechanism 16. The direction of rotations is indicated by curved arrows drawn into the respective rolls. Underneath the stripping roll 6 a profiled element 20 is provided which guides the fiber web into the nip defined by the cooperating crushing rolls 7, 8.
A grinding roll 17 designed according to the invention is provided for the clothings 14a of the flat bars 14. Cleaning rolls 18 and 19, also structured according to the invention, cooperate with respective crushing rolls 7 and 8. It is noted that the grinding roll 17 as well as the cleaning rolls 18 and 19 are also collectively referred to as material-removing rolls and designated at R. Arrow A designates the direction of working travel of the flat bars 14 as their clothing cooperates with the clothing of the main carding cylinder 4.
Turning to FIG. 2, the material-removing roll R is composed of a rigid core 21 which may be a tube or a rod of solid cross section made of steel and a soft-elastic jacket 22 surrounding the core 21 and made, for example, of foam material and serving as a cushion. The jacket 22, in turn, is surrounded by a circumferential layer 23 which carries a material-removing (grinding, polishing or cleaning) substance 24 such as, for example, corundum sanding grains. The layer 23 is a textile carrier made of a woven or knit textile fabric wound around the resilient jacket 22. The fabric may be a strip significantly less in width than the axial length of the roll R, in which case the fabric is helically wound on the resilient jacket 22. The textile carrier layer 23 is elastic at least in one direction of its fabric. For this purpose an elastic yarn (such as Elastan) is used. The woven or knit fabric structure of the textile carrier 23 is selected such that an elasticity of the carrier surface at least in one direction is obtained. The total elasticity of the upper face of the material-removing roll R which is composed of the elasticity of the jacket 22, the substance-carrying surface of the layer 23 and the elasticity of the carrier fabric of the layer 23 is so selected that the pressing grinding forces may be maintained within certain limits without the need of a highly precise positioning of the material-removing roll R relative to the clothing points 14a when using the material-removing roll R as the grinding roll 17. The pressing forces may be limited by providing that such forces are applied only by the roll weight; for this purpose, the roll 17 is swingably held by its supports. By virtue of the elasticity of the grinding surface the individual pins 14a of the flat bar clothing which project to a greater extent may radially inwardly deform the grinding surface to such an extent that even those pins 14a which project to a lesser extent will be in contact with the grinding surface. The grinding roll 17 may be a permanently installed part of the carding machine 1 (FIG. 1) and may be positioned normally such that it does not continuously contact the points of the clothing pins 14a. Controlled by the machine program or by manual actuation, the grinding roll 17 may be, during the carding operation, brought into contact with the clothing points of the flat bars 14 for a predetermined period, such as more than one revolution of the traveling flats. It is not necessary to bring the roll 17 into an exact grinding position (such as to the accuracy of a few hundredths of a millimeter), and therefore not all elements of the roll guide, roll holding device and abutments need be made and set with high precision. The elastic construction of the grinding roll 17 takes into account that the individual pins 14a of the flat bar clothing project or are recessed to a non-uniform extent. The soft elasticity thus results in technological and economical advantages.
When using the material-removing roll R as a cleaning roll, such as rolls 18, 19 for the crushing rolls 7 and 8, respectively, due to the elasticity of the cleaning rolls, a slight application pressure is obtained and the cleaning surface may conform to the deformations of the crushing rolls 7, 8 caused by the crushing forces. The surface of the cleaning rolls 18, 19 is selected such that a slight grinding or polishing effect is obtained. As the jacket layer 23, artificial leather, such as Alcantara or Vileda may be used.
Each cleaning roll 18, 19 is, in turn, cleaned by an additional cleaning device which, as shown in FIG. 3, comprises strippers, such as stripping blades 25, 26. The cleaning rolls 18, 19 may clean the crushing rolls 7, 8 continuously or intermittently or cyclically along the crushing roll lengths. The dirt is collected in a gathering device 27, 28 or may be directly or indirectly drawn away by a non-illustrated suction device. When using the material-removing rolls R as cleaning rolls 18, 19 for the crushing rolls 7, 8, to the cleaning rolls adhesion-repellent materials (such as talcum or other powder) are applied which prevent the slightest sticking of the cleaning rolls to the crushing rolls 7, 8. The applied material may contain sugar-dissolving enzymes, particularly for removing honeydew fro m the crushing rolls. The rotary direction of the rolls 7, 8, 18 and 19 are designated with respective arrows 7a, 8a, 18a and 19a.
In FIG. 4 the material-removing roll R is a grinding roll 17 in engagement with the points of the flexible clothing 14a of the flat bars 14. 17a designates the direction of rotation of the grinding roll 17. The grinding roll 17 cooperates with a cleaning roll 29 which may be brush roll and which is in contact with the outer circumferential surface of the grinding roll 17.
The points 14b of the flat bars 14a are shown in FIG. 4a in their new (unused) condition, in FIG. 4b they are illustrated in a worn state and in FIG. 4c in a resharpened state. The distance between the point 14b and the securing surface of the clothing 14a is designated at a.
Turning to FIG. 5, the cleaning rolls 18 and 19 are rotated by drives 30 and 31, respectively. The drives 30, 31 may be driven by a non-illustrated common prime mover such as an electric motor.
Turning to FIG. 6, the grinding roll 17 is coupled to a driving pulley 33 by means of a drive belt 32. The driving pulley 33 is mounted coaxially with a driving pulley 34 for the main carding cylinder 4 which, in turn, is coupled by a drive belt 35 to a drive, for example, an electric motor 36.
The essential feature of the material-removing roll R, whether used as a grinding roll 17 or a cleaning roll 18, 19, is the elastically yielding pressure it exerts on the components treated thereby. Such an elastically yielding pressure results in conforming the roll surface to the shape and height of the items to be ground or rubbed. In this manner, material removal is achieved accompanied by a polishing effect.
The clothings 14a and the crushing rolls 7, 8 are thus treated by grinding or rubbing, respectively. From the clothing 14 essentially metallic material and from the crushing rolls 7, 8 essentially dirt is removed by grinding (grinding roll 17) or, respectively, rubbing (cleaning roll 18, 19).
It will be understood that the above description of the present invention is susceptible to various modifications, changes and adaptations, and the same are intended to be comprehended within the meaning and range of equivalents of the appended claims. | A fiber processing machine includes a fiber processing component and a material-removing roll supported to be in contact with the fiber processing component for removing material therefrom. The material-removing roll includes a radially deformable resilient circumferential surface and a material-removing substance carried at least indirectly by the resilient surface. | 3 |
FIELD OF INVENTION
[0001] The present invention relates to a pharmaceutical composition having virucidal and spermicidal activity. More particularly, the present invention relates to Acaciaside-B [Ac-B] and one of its co-isolate which is enriched with Acaciaside-B (Ac-B-en-frn), to be used as a prophylactic contraceptive for HIV infection/AIDS. The present invention further relates to the use of Ac-B and/or Ac-B-en-frn in mixture with other natural or synthetic substances in the field of drugs and pharmaceuticals, for preparing formulations/methodology/devices for protection against human immunodeficiency virus (HIV-1) infection through invasive sexual contacts and/or control of unwanted pregnancy. The present invention also relates to the use of the seeds of Acacia auriculiformis as raw materials for isolation of Ac-B to provide an active principle for preparation of over the counter (OTC) available self-administrable, prophylactic, vaginal formulation/contraceptive with anti-HIV hallmark.
BACKGROUND OF THE INVENTION AND DESCRIPTION OF PRIOR ART
[0002] Presently available spermicidal contraceptives contain ingredients including the neutral surfactants isononyl-phenyl-polyoxyethylene (9) ether or Nonoxynol-9 (N-9), p-menthanyl-phenyl-polyoxyethylene (8,8) ether or menfegol, isooctyl-phenyl-polyoxy-ethylene (9) ether or Octoxynol-9 (0-9) [K. Furuse, et al. J Pharmacobiodyn. 6: 359, 1983; G A Digenis, et al. Pharm Dev Technol.; 4: 421, 1999], etc. Of these, the most commonly used spermicidal contraceptive in the United Kingdom and the United States is N-9 [OTC Panel. Federal Register.; 45: 1980, 82014; E. Chantler. Brit Fam Plann.; 17, 118, 1992]. Other preparations/molecules under different phases of investigation are: Oxovanadium (IV) complexes of 1,10-Phenanthroline, 2,2′-Bipyridyl, 5′-Bromo-2′-Hydroxyacetophenone and derivatives [GA Digenis, et al. Pharm Dev Technol.: 4, 1999, 421]; Aryl Phosphate Derivative of Bromo-Methoxy Zidovudine (Compound WHI-07) [O. J D'Cruz., et al, Biology of Reproduction: 62, 2000, 37]; Lipophilic Vaginal Contraceptive Gel-Microemulsion, GM-144 [O J D'Cruz, et al. AAPS Pharm Sci Tech.; 2, article 5, 2001] and sodium nimidinate, the spermicidal agent of neem oil [DE Champagne, et al; Phytochemistry, 31, 377, 1992]. N-9 is being used at concentrations of 2% to 6% in creams and gels, 12% in foams, and as high as 18% in condom lubricants and 28% in vaginal contraceptive film. Frequent use of N-9 as a vaginal contraceptive/microbicide has been associated with an increased risk of vaginal or cervical infection, irritation, or ulceration [M L Rekart. J Acquir Immune Defic Syndr.; 5: 425, 1992, R E Roddy, et al. Int J STD HIV.; 4: 165, 1993, S S Weir, et al. Genitourin Med.; 71: 78, 1995]. In addition, it alters vaginal niche of bacteria or microflora, specially Lactobacilli and lead to an increased risk of opportunistic infections [T M Hooton, et al. JAMA.; 265: 64, 1991; M K Stafford, et al. J Acquir Immune Defic Syndr Hum Retrovirol.; 17: 327, 1998; I J Rosenstein, et al. J Infect Dis.; 177, 1386, 1998]. Such infections are known to enhance the susceptibility of the ectocervical epithelium and the endocervical mucosa to sexually transmitted pathogens including human immunodeficiency virus, type 1 (HIV-1) infection [J Kreiss, et al. JAMA.; 268, 477, 1992; M H Augenbraun, et al. Infect Dis Clin North Am.; 8: 439, 1994; EG Raymond, et al. Obstetrics & Gynecology.; 103, 430, 2004]. Frequent use of spermicidal vaginal foaming tablets containing menfegol is also associated with a high incidence of genital lesions [J Goeman, et al. J Infect Dis. 171, 1611, 1995]. Moreover, N-9 is composed of multiple oligomers that vary in ethyleneoxyde chain length and in biological performance [P. T. Fowler, et al AAPS Pharm Sci Tech 2003; 4(3) Article 30; B Walter, et al. Pharm Res, 1991; 8:409].
[0003] Thus, in short Nonoxynol-9 (N-9), the effective spermicidal molecule used widely in vaginal contraceptive formulations has been shown to render the user susceptible to STDs, including AIDS. The WHO has cautioned that N-9 containing formulations should not be used by those at risk of acquiring HIV infection.
[0004] Since heterosexual transmission of HIV-1 is the predominant mode of the epidemic spread of acquired immunodeficiency syndrome (AIDS), there is a pressing need to expedite research to get a safe, effective vaginal spermicidal product lacking strong toxicity and which may offer significant clinical advantage over the currently available medications in the market. A recent statement from the Medical Advisory Panel of the IPPF recommends that N-9 should be used only in combination with a mechanical barrier method and that condoms pre-lubricated with N-9 have no added advantage in contraceptive efficacy and should no longer be distributed to women at high risk of HIV/AIDS [IPPF Medical Bulletin, 37, 1, 2003].
[0005] India is one of the 12 mega-diversity countries in the world with a vital stake in conservation and sustainable utilization of its biodiversity resources. It is rich in vegetation of medicinal plants. One of such plants, Acacia auriculiformis (English: Earleaf Acacia, and Akashmoni/Sonajhuri in Bengali and Hindi), is a loose, rounded, evergreen, roadside or wild tree. The tree is also available in other parts of the world. The use of extracts from seeds of the tree is reported from time to time. The major components of the extracts are saponins of different kinds.
[0006] Herbal saponins are in use since the early age of human civilization specially for making toiletries. Some other medicinal properties of the saponins are also noted by different workers. Acaciaside-A and Ac-B, two acylated bisglycoside saponins originally isolated from the seeds of Acacia auriculiformis (B C Pal, et al. Indian Patent No. 186738] are known to have anti-helminthic activity [N K Ghosh, et al. J Helminthol. 70, 171, 1996]. Mandal et al. [Fitoterapia, 76, 462, 2005] reported that complete inhibition of conidial germination of Aspergillus ochraceous and Curvularia lunata was recorded at 300 μg/ml or less; whereas 700 μg/ml or higher concentrations of the mixture was required to inhibit the growth of Bacillus megaterium, Salmonella typhimurium and Pseudomonas aeruginosa . The conjugated unsaturated diene system of the saponins is likely to be involved in producing their damaging effect, probably by generation of free radicals that induce membrane damage through peroxidation [S P Sinha Babu, et al. Jpn J Pharmacolm. 75, 451, 1997; B Nandi, et al. Phytother Res., 18, 191. 2004]. Some other investigations suggest that the plant may contain active antimutagenic and chemopreventive agents [K. Kaur, et al Willd. Ex Del. Drug Chem Toxicol.; 25, 39, 2002] and antifilarial effect [M, Ghosh, et al Indian J Exp Biol. 31, 604, 1993; S B Mahato Adv Exp Med Biol. 404, 173, 1996]. A mixture of Acaciaside-A and Ac-B was reported to kill in vitro 97% microfilaria of Setaria cervi in 100 min at 4 mg/ml concentration and 100% of adults in 35 min. Farnsworth et al. reported that the majority of triterpine saponins, obtained from the plants, possess spermicidal properties [Research frontiers in fertility regulation 2, 1, 1982]. Setty et al reported that saponins, isolated from Indian medicinal plants, may act as potential spermicides [B S Setty, et al. Contraception 14: 571, 1976]. A series of bioactive triterpenoid saponins were characterized by a stringent structure-activity and were reported to be potent and selective inhibitors of human immunodeficiency virus type 1 (HIV-1) replication [Yang X W; et al. J Nat Prod. 1999: 62(11):1510-3].
[0007] A mixture of two analogous triterpenoid glycosides, Acaciaside-A and Ac-B, isolated from the seeds of Acacia auriculiformis , was reported to possess strong in vitro spermicidal property on human spermatozoa [A, Pakrashi, et al., Contraception 43: 475, 1991]. But a serious disadvantage of considering the mixture for formulation is that the MEC in humans is much higher (350 μg/ml) than that of pure Ac-B (125 μg/ml) [H Ray, et al., Unpublished observation]. Moreover, one of its major constituents (i.e. Acaciaside-A) is a mutagen.
[0008] The most intriguing aspect of Ac-B, however, is that its spermicidal effects involve damage of lipid molecules of the cell membrane [H Ray, et al., Unpublished Observation]. HIV requires intact lipid rafts, highly specialized sub-regions in cell membranes, for entry into cells and budding of fully infectious particles. By virtue of its lipid dispersing effects, Ac-B is likely to disrupt the lipid rafts as well as the lipid molecules of viral envelop and therefore, theoretically appears to be a likely prophylactic candidate for HIV infection.
OBJECTS OF THE INVENTION
[0009] The main objective of the present invention is thus to provide a pharmaceutical having virucidal property, which is capable of acting as a chemical barrier against HIV-1 infection (AIDS) along with a superfluous spermicidal property.
[0010] Another object of the present invention is to provide a prophylactic formulation/contraceptive that would provide a convenient, readily available method of self protection against AIDS and/or unwanted pregnancy.
[0011] Another objective of the present invention is to provide a naturally occurring molecule to be used as a chemical barrier against HIV-1 infection during invasive sexual interaction.
[0012] Another objective of the present invention is to provide an active principle for protection against other retroviruses.
SUMMARY OF THE INVENTION
[0013] The present invention provides a novel active principle of plant origin i.e. Acaciaside-B, which is non-mutagenic and/or Ac-B-en-frn, whose mutagenic potential is yet to be explored, that possess virucidal and spermicidal properties, and may be useful as an active principle for the preparation of OTC formulations, available as emergency protection against HIV-1 infection during heterosexual invasive contact and/or vaginal contraceptive, wherein the said composition comprising the therapeutically effective amount of Ac-B, or its derivatives, or analogues, or pharmaceutically acceptable enriched mixture with other inert and/or safe materials, thereof obtained from the extract of the seeds of Acacia auriculiformis for preparation of chemical barrier against HIV infection during heterosexual interaction or as OTC available vaginal formulation/contraceptive with prophylactic action.
[0014] The in vitro dosage for the said composition for the virucidal activity is ≧1.0 μg/ml and for spermicidal activity is 125 μg/ml for human sperms wherein the in vivo contraceptive dosage would increase as per requirement (e.g. 25 mg/ml KY-jelly for rabbit). Ac-B is water soluble and can be dissolved or dispersed in a number of carriers. For example, it may be formulated for “stand alone usage” in forms which include but not limited to gels, foams, suppositories, creams, lotions, tablets, pessaries, lubricants, and the like. Any formulation which allows the delivery of Ac-B in a quantity sufficient to neutralize HIV, inactivate spermatozoa.
[0015] The formulations may further include other ingredients which are well known to those of skill in the art, including but not limited to stabilizers, colorants, preservatives, perfumes, gelling agents, antioxidants, other active ingredients and the like. The composition of matter of the present invention may contain pure Ac-B or equivalent amount in an Ac-B enriched fraction of the seed extract of Acacia auriculiformis.
[0016] The composition of matter of the present invention may also be used in conjunction with other contraceptive devices. Examples include but not limited to: addition to condoms or diaphragms to enhance their activity, or to imbibe a cervico-vaginal sponge that would act both as a mechanical and chemical barrier against HIV infection and sperm penetration into upper reproductive tract.
[0017] The present invention further provides a method of contraception in female mammals, which involves placing a contraceptively effective amount of Ac-B in the vaginal cavity of a female mammal. Those of skill in the art will recognize that a variety of means are known by which a compound may be delivered intravaginally, for example plunger-type applicators, pessaries, film, sprays, squeezable tubes, cervical rings, sponges and the like. All such means for intravaginal delivery are intended to be encompassed by the present invention.
[0018] The present invention also provides a method of topical application of Ac-B in any suitable formulation of any suitable form as protection against HIV-1 infection in organs, including vagina of mammalian female where contraception is not a primary objective and the spermicidal property of Ac-B is superfluous.
[0019] The present invention also provides a method of topical application of Ac-B in any suitable formulation of any suitable form as protection against HIV-1 infection in organs including mammalian rectum where prevention of HIV transmission is a primary objective.
[0020] Accordingly, the present invention provides the use of the compound Acaciaside-B [Ac-B], derivatives, analogues and pharmaceutically acceptable salts thereof and/or its mixture with other synthetic or natural substances as virucidal and spermicidal agents.
DETAILED DESCRIPTION OF THE INVENTION
[0021] Three isolates, (i) a mixture of two triterpenoid saponins (Acaciaside-A and Acaciaside-B), (ii) Acaciaside-B (Ac-B), and (iii) an Acaciaside-B enriched fraction (Ac-B-en-frn), were obtained from seeds of Acacia auriculiformis.
[0022] In the present invention, the compound Acaciaside-B and/or enriched fraction, its derivatives, analogues and pharmaceutically acceptable salts thereof and/or its mixture with other synthetic or natural substances are used as virucidal and spermicidal agents. The compound is isolated from the plant Acacia auriculiformis . The infectivity of HIV and motility of spermatozoa are inhibited simultaneously by the said compound. Ac-B and/or enriched fraction is utilized for the preparation of prophylactic formulations useful against HIV and as spermicidal agent.
[0023] In an embodiment, the virus is preferably human immunodeficiency virus [HIV], but may also include other retroviruses.
[0024] In another embodiment, the compound Ac-B is administered with a carrier in a water soluble form.
[0025] In another embodiment, the compound is administered via the vaginal or rectal route.
[0026] In yet another embodiment, the administrable form for the compound/s is selected from the group consisting of lubricated condoms, jelly-filled plunger-type applicators, pessaries, films, foams, squeezable tubes, cervical rings, sponges and the like.
[0027] In a further embodiment, the carriers are selected from the group consisting of proteins, carbohydrates, sugars, talc, cellulose, inorganic salts, starch-gelatin paste and pharmaceutically acceptable excipients.
[0028] In another embodiment, the MEC of the pure Ac-B is in the range of 0.5 to 2.5 microgram per ml for inactivation of HIV in vitro.
[0029] In yet another embodiment, the MEC of the pure Ac-B is in the range of 60 to 125 microgram per ml for spermicidal activity in vitro.
[0030] In another embodiment, the EC 50 of Ac-B is 22 microgram per ml for spermicidal activity in vitro for human sperm.
[0031] The said compound/s is not likely to affect the vaginal niche of Lactobacillus as it does not affect bacterial growth in culture up to a concentration of 500 milligram per ml.
[0032] The present invention also provides a pharmaceutical composition useful as a virucidal as well as a spermicidal agent comprising of therapeutically effective amount of the compound Ac-B, derivatives, analogues and pharmaceutically acceptable salts thereof along with pharmaceutically acceptable excipients.
[0033] In an embodiment, the carriers are selected from the group consisting of proteins, carbohydrates, sugars, talc, cellulose, inorganic salts, starch-gelatin paste and pharmaceutically acceptable excipients.
[0034] The present invention further provides a method for simultaneous prevention of HIV infection and unwanted pregnancy in a subject, comprising administering a therapeutically effective amount of the compound Ac-B, derivatives, analogues and pharmaceutically acceptable salts thereof optionally along with pharmaceutically acceptable excipients, to a subject in need thereof.
[0035] In an embodiment, the subject is human.
[0036] In another embodiment, the compound Ac-B is administered with a carrier in a water soluble form.
[0037] In another embodiment, the compound is administered via the vaginal route.
[0038] In yet another embodiment, the administrable form for the compound is selected from the group consisting of lubricated condoms, jelly-filled plunger-type applicators, pessaries, films, foams, squeezable tubes, cervical rings, sponges and the like.
[0000] The Tree, Acacia auriculiformis
Taxonomy:
[0039] Name: Acacia auriculiformis A. Cunningham ex Benth, Family—Fabaceae;
Common name: Auri, Darwin black wattle, Earleaf Acacia, Papuan wattle, etc
Habitat:
[0040] Acacia auriculiformis is planted either as road side tree or may grow in the wild. Quickly reaching a height of 40 feet and a spread of 25 feet, Earleaf Acacia becomes a loose, rounded, evergreen, open shade tree (FIG. 1). It is often planted for its abundance of small, beautiful, bright yellow flowers and fast growth. The flattened, curved branchlets, which look like leaves, are joined by twisted, brown, ear-shaped seed pods. Growing 6 to 8 feet per year, Earleaf Acacia quickly grows into a medium-sized shade tree. This makes it a popular tree; however, it has brittle wood and weak branch crotches, and the tree can be badly damaged during wind storms. Prune branches so there is a wide angle of attachment to help them from splitting from the tree. Also be sure to keep the major branches pruned back so they stay less than half the diameter of the trunk. These technique might increase the longevity of existing trees.
Description:
[0041] The tree: Height: 35 to 40 feet; Spread: 25 to 35 feet; Crown uniformity: irregular outline or silhouette; Crown shape: round; Crown density: moderate; Growth rate: fast; Texture: medium; Trunk and Branches: droop as the tree grows, and will require pruning for vehicular or pedestrian clearance beneath the canopy; not particularly showy; should be grown with a single leader; no thorns Pruning requirement: requires pruning to develop strong structure; Light requirement: tree grows in full sun; Soil tolerances: clay; loam; sand; acidic; occasionally wet; alkaline; well-drained; Drought tolerance: high.
[0042] Foliage: The seedlings bear normal compound leaves. As these leaves become mature, the leaflets drop off and the petioles become flattened and leaf-like. These flattened petioles are called phyllodes and appears as simple leaves. Leaf arrangement: alternate; Leaf margin: entire; Leaf shape: linear; Leaf venation: parallel; Leaf type and persistence: broadleaf evergreen; evergreen; Leaf blade length: 4 to 8 inches.
[0043] Flower: Arranged on twig tips in panicle type of inflorescence; color: yellow; Flower characteristics: showy; spring flowering.
[0044] Fruit: Fruit shape: irregular; Fruit length: 1 to 3 inches; Fruit covering: dry or hard; Fruit color: green when young and brown at ripening.
[0045] Isolation and Identification of Saponins:
[0046] The air-dried and powdered seeds of A. auriculiformis were extracted with methanol. The combined methanolic extracts were evaporated to dryness, dissolved in water and partitioned between chloroform and n-butanol. The butanol fraction was chromatographed over silica gel eluting with solvent chloroform, chloroform-methanol (4:1), chloroform-methanol (7:3) and chloroform-methanol (1:1). The combined chloroform-methanol (7:3 and 1:1) fraction was rechromatographed to yield TLC homogeneous saponins. HPLC analysis of this glycoside fraction showed to be a mixture of two compounds. Preparative HPLC of this mixture with the help of reverse phase C-18 Bondapack column with solvent system methanol-water (7:30) afforded Acaciaside-A and Acaciaside-B.
[0047] Yield: From 1 kg seeds about 190 g methanolic extract was available which on further elution (a) with n-Butanol yielded 48 g of a mixture of which 5.84% was Acaciaside-A and 11.93% was Acaciaside-B; (b) with water yielding an aqueous fraction of which 38.11% was Acaciaside-B. This fraction was termed as B-enriched fraction (Ac-B-en-frn). Pure compounds were separated from the butanolic aqueous fraction. The elution of the methanolic extract with ethyl acetate yielded about 15 g of a product which did not possess any spermicidal property.
[0048] The chemicals used for preparation of reagents were of analytical grade and purchased from Sigma Chemical Co (St Louis, Mo., USA). Purified water (Milli-Q Biocel System, Millipore Corporation) was used for experiments. Disposable plastic wares were purchased from M/s. Tarsons (India). Working spermatozoa suspension were made in glass tubes containing Briggers, Whitten, and Whittengham's medium (BWW). The serial dilutions of (a) mixture of Ac-A and Ac-B, (b) Ac-B, and (c) the Ac-B-enriched fraction, were prepared in BWW medium, in concentrations, ranging from 10 μg/ml to 500 μg/ml, at a 100 or 10 μg apart. The final concentration was determined with more close dilutions (2.5 μg apart). The positive control (Nonoxynol-9) solutions were also prepared in a similar manner. Sterilized K-Y jelly (Johnson & Johnson Ltd, India) was used as vehicle as well as placebo for in vivo testing.
Animals and Housing:
[0049] The laboratory animals used in the assay of different parameters were obtained and kept in the institutional Animal House with 22-24 degree C. room temperature, 55-60 percent relative humidity and 12:12 hour circadian rhythm. The rodents were kept in polypropylene cages with stainless steel grill-top and rabbits were kept in stainless steel cages of appropriate size. The animals were allowed sufficient space and other provisions in their cages as per recommendation of the Committee for the Purpose of Control and Supervision of Experimentation on Animals (CPCSEA), Ministry of Social Justice and Empowerment, Govt. of India. Balanced diet and purified drinking water were provided ad libitum to all animals.
[0050] In general, tests were performed with Sprague-Dawley rats, Balb/C mice and New Zealand Rabbits. The vaginal cytology of the female rats was monitored daily for at least two weeks via saline lavage to identify female rats with regular 4-5 day estrous cycle.
Human Sample:
[0051] Human semen samples and normal cervical mucus of ovulatory phase were collected from an infertility clinic, Institute of Reproductive Medicine, Kolkata, after their utilization of required volume for diagnostic purposes, and with due approval.
[0052] Medium: The composition of BWW medium used in the tests was: 95 mM NaCl, 44 μM sodium lactate, 25 mM NaHCO 3 , 20 mM Hepes, 5.6 mM D-glucose, 4.6 mM KCl, 1.7 mM CaCl 2 , 1.2 mM KH 2 PO 4 , 1.2 mM MgSO 4 , 0.27 mM sodium pyruvate, 0.3% (w/v) BSA, 5 I.U./ml penicillin, 5 μg/ml streptomycin, pH 7.4.
[0053] Collection and preparation of spermatozoa suspension: Sexually mature male mice and rats were autopsied following euthanasia by an overdose of Ketamin (≧200 mg/kg body weight; injected i.p.) and their cauda epididymis were excised. Working suspension of animal spermatozoa was prepared with the exudates obtained after careful pricking of the cauda epididymis with an injection needle (18 G) and the exudates were collected in a conical centrifuge tube.
[0054] The exudates/liquefied human semen samples were suspended in BWW medium (pre equilibrated at 37 degree C.). The spermatozoa with forward motility were separated from immotile or sluggishly motile cells by the swim-up technique and were allowed to disperse evenly within a CO 2 incubator at 37 degree C. At least five aliquots from each sample was used to prepare the working spermatozoa suspension. The swim up procedure was as follows:
[0055] Pre equilibrated BWW medium (1.25 ml) was gently layered over cauda-exudates or liquefied human semen (1 ml) in a sterile 15 ml conical-based centrifuge tube. The tube was inclined at an angle of 45 degree and incubated for 1 hour at 37 degree C. in a CO 2 -incubator. It was then gently returned to the upright position and the uppermost 1 ml medium with a turbid appearance was removed. This aliquot of motile cells was pooled from each set, then diluted with same volumes of pre equilibrated BWW medium, centrifuged at 500 g for 5 minutes and finally resuspended in 1 ml pre equilibrated BWW medium to obtain a working suspension. The sperm cells were counted in a Makler chamber (Zygotec Systems, Springfield, M A, USA) and finally a working spermatozoa suspension having concentration of 25 to 30×10 6 cells/ml was prepared.
Test for Spermicidal Activity (In Vitro):
[0056] For in vitro assay of spermicidal effect, sperms collected from proven male rats and mice, and motile spermatozoa from liquefied human semen were used.
[0057] Experiment: The assay was done following the Sander & Cramer assay method. Two hundred micro liter (200 microlitres) of working spermatozoa suspension was added to 1 ml solution of test material in BWW medium and mixed on a light vortex for 10 seconds. A wet mount was immediately prepared on a clean microscopy glass slide and examined (at ×100) under a phase contrast microscope (Leitz, Biomed). The weakest concentration that immobilized all spermatozoa within 20 seconds of mixing was recorded as MEC. At least five fields were examined for each wet mount preparation. The observation was repeated with five individual spermatozoa suspension for each concentration of test compound solution. For negative control, saponin solutions were replaced by equal volume of BWW medium, while Nonoxynol 9 was used as positive control.
Result:
[0058] The results of Sander and Cramer Test are summarized in following Table 1.
[0059] The in vitro studies showed that the mixture (Tg), Ac-B and the Ac-B-en-frn, all have spermicidal property. With an increase in the concentration of the isolates, there was a dose-dependent increase in the immobilization of sperm. The MEC for each compound was different from others. Pure Ac-B was found to be the most potent. It induced 100% immobilization at 125 microgram per ml for human spermatozoa as compared to >350 microgram per ml for Nonoxynol 9 and 170 (±5) for Ac-B-en-frn.
[0000]
TABLE 1
Comparison of MEC as per Sander and Cramer Test
(in microgram per ml)
Mixture (Tg) of
Species
Ac-A & Ac-B
Ac-B
Ac-B-en-frn
Nonoxynol 9
Human
350 (±10)
125 (±7)
170 (±5)
>350
(N = 5)
Rat
300 (±10)
60 (±2)
80 (±5)
350 (±10)
(N = 10)
Mouse
270 (±20)
60 (±2)
80 (±5)
350 (±10)
(N = 10)
Assessment of Contraceptive Efficacy of Ac-B (In Vivo):
[0060] The foregoing results of in vitro tests attest to the spermicidal potential of Ac-B. However, the overall objective was the use of developed spermicides as an effective molecule in vaginal contraceptives. It was therefore important to assess how effective the in vitro spermicidal property of Ac-B is in inducing contraceptive effects in vivo. Keeping these objective in view, an evaluation was made on the effects of Ac-B, administered in vivo on the establishment of pregnancy in rat and rabbit.
Experiment 1: Intra Uterine Application and IUI in Rat:
[0061] Female cycling rats weighing 180-200 g were obtained from the institutional Animal House. The duplex nature of the rat uterus with separate cervical canal helped us to organize both control and experimental sets in the same animal with exposure to identical physiological milieu.
[0062] On the day of pro-estrous, both horns of the uterus were exposed by mid-ventral incision of the abdomen under light anesthesia following intra peritoneal injection of Ketamin at a concentration of 100 mg/kg body weight, supported by inhalation of anesthetic-ether, during 17.00-17.30 hours of the day. IUI was performed by injecting 50 microlitres of sperm suspensions with varied concentration (25-30, 40-50, and 50-55 million sperms/ml) through a 24 G needle fitted onto a tuberculin syringe in the cervical end of the uterine lumen of each horn. The muscle in the injection site was held tightly for a while to prevent leakage through the puncture. Prior to IUI, each rat received a injection of 1.75 mg Ac-B in 50 microlitres BWW medium in the left horn and simple BWW medium in the right horn. The opened abdominal muscle and skin layers were properly sutured by suturing silk thread. The outer most skin layers were further fixed by metal clips. The wound was properly cleaned with antiseptic lotions. Each operated animal was housed individually in fresh cage for collection and counting of unfertilized oocytes, two celled embryos, and fragmented bodies. After 40 to 48 hours of IUI, each animal was killed by euthanasia. The abdomen was opened and each of the fallopian tubes was collected carefully. The content of each tube was flushed out by introducing BWW medium into each tube with the help of a 30 G hypodermic needle in a watch glass. The flushed out lavage was examined under an inverted phase contrast microscope (Leitz, Labovert, ×100) to score the number of recovered fertilized/unfertilized eggs from individual fallopian tube. The results obtained are illustrated in Table 2.
[0000]
TABLE 2
Fertilization outcome in rats following IUI with prior IU administration of Ac-B
Sperm count
Rate of fertilization as observed after flushing (38-40 hours after IUI)
(million/ml)
Treated horn (Ac-B in BWW)
Control horn (BWW medium)
used for IUI
Fertilized
Unfertilized
Total
Fertilized
Unfertilized
Total
25-30 (N = 3)
0 (0%)
17 (100%)
17
10 (62.25%)
6 (37.5%)
16
40-50 (N = 4)
0 (%)
19 (100%)
19
12 (80%)
3 (20%)
15
50-55 (N = 4)
3 (18%)
13 (82%)
16
17 (85%)
3 (15%)
20
Experiment 2: Contraceptive Efficacy of Ac-B Following Intravaginal Application in Rabbits
[0063] Healthy virgin, nulliparous female rabbits were primed with PMSG (200 i.u.; i.p.; 96 hrs prior to testing) to induce ovulation. Serial dilutions (2.5 mg/ml, 10 mg/ml, 25 mg/ml and 50 mg/ml) of Ac-B in KY-jelly was prepared to be used as test solutions and only KY-jelly was used for control group. Two ml of test/control solution was introduced 6-8 cm deep into the vagina of each rabbit with by the syringe with gavaging needle. The animal was held in supine position for about five minutes and then hand-mated by the selected proven bucks. The buck was allowed one-time mating. To ensure ovulation 100 i.u. of hCG was administered through the marginal ear vein of each participating doe. The vaginal lavage of the mated doe was examined under a microscope. The presence of spermatozoa in the lavage was considered as confirmed mating. The mated does were kept in separate cages to complete their gestation period and the number of delivered pups was recorded. The mean value of the pups was calculated to determine the contraceptive potential.
[0064] The results of intravaginal application of Ac-B have been summarized in Table 3. The result of each test group was compared with corresponding control group.
[0000]
TABLE 3
Pregnancy outcome in rabbits following intra-vaginal application of Ac-B
treated (n = 5)
Concentration of Acaciaside-B in K-Y jelly
statistical parameters
Control (n = 5)
2.5 mg/ml
10 mg/ml
25 mg/ml
50 mg/ml
Mean numbers of pups
3.6
3.4
2.2
0.2
0.0
delivered
SD
±1.14
±1.14
±0.84
±0.45
0.0
P value
NS
P = 0.058
P = 0.0003
P = as compared with control,
NS = Non significant
N = number of rabbits,
* = as compared with control,
P < 0.05 is significant
Investigations on Mechanism of Spermicidal Effect
[0065] Spermicidal potential of Ac-B in vitro has been tested in rats, mice and humans, while in vivo contraceptive efficacy has been conducted in rabbits. Subsequent investigations pertaining to mechanism of spermicidal action and related studies have been performed using human spermatozoa only.
1. Motility Revival Tests:
[0066] Experiment A: Human spermatozoa, treated with Ac-B at MEC and BWW control set were washed twice in pre-equilibrated BWW medium, re-suspended in fresh BWW medium and again incubated in a CO 2 -incubator at 37 degree C. for 30-60 minutes. At the end of the incubation, wet-preparation of spermatozoa was made from each set on a glass slide. The preparation was examined under a phase contrast microscope (at ×400) to note reversal of motility in 10 fields-of-view.
[0067] Experiment B: A modified Kremer-Test was used for assessment of cervical mucus penetrating capacity of treated sperm.
[0068] A drop of human mid-cycle cervical mucus was placed on a slide and flattened by a cover slip (22 mm×22 mm). A drop of human sperm suspension treated with the test compounds (at MEC) was deposited at the side of the cover slip and in contact with the edge, the sperm suspension moved in under the cover slip by capillary force and a clear interface was obtained between the sperm suspension and the cervical mucus. The slide preparation was placed within a CO 2 incubator at 37 degree C. for 30 minutes. Suitable control sets were prepared side by side. Each preparation was examined under a phase contrast microscope to observe the entry of spermatozoa into the cervical mucus zone.
[0069] Experiment C: Penetrak Test (bovine cervical mucus penetration test).
[0070] The bovine cervical mucus penetration test was performed using the Penetrak kit (Serono Diagnostics, Allentown, Pa.).
[0071] Working suspension of human spermatozoa, prepared as above was treated in vitro with Ac-B at MEC, washed and resuspended in pre-equilibrated BWW medium. For the negative control set, same treatment was given to the sperms in BWW medium. Flat-capillary tubes filled with periovulatory mid-cycle bovine cervical mucus, in duplicate, were thawed at room temperature for 30 minutes and snapped at the red score mark above the mucus meniscus. The cut end was placed in tube containing treated/control washed sperm suspension and placed inside a CO 2 incubator for 1 hour. The capillary tubes were then taken out, cleaned to remove superficially attached sperms, placed on a calibrated slide and examined by phase contrast microscopy (at ×400). The vanguard sperm was located and the distance (in mm) covered by it was measured to score the penetrating capacity of a sperm of the test sets.
Results:
[0072] Experiment A: At the end of the incubation at 37 degree C., no sign for revival of motility was noted in the Ac-B-treated spermatozoa.
[0073] Experiment B: At the interface, finger like projections of sperm suspension/s those penetrating into the cervical mucus was noted within a short period. In the BWW control set, a large number of spermatozoa penetrated the phalangeal canal before entering the mucus. Once in the cervical mucus, the motile spermatozoa swarmed at random. In case of Ac-B-treated spermatozoa, the sperms entered in the phalanges by capillary action and showed a Brownian movement but none of them crossed into the interface.
Experiment C: Penetrak Test:
[0074] In the BWW control set, vanguard sperm was noted at a distance of about 27(±3) mm but in Ac-B-treated set, it was found that the capillary was devoid of sperm inside the mucus column indicating irreversible loss of motility caused by exposure of sperms to Ac-B.
2. Assessment of Plasma Membrane Integrity of Ac-B Treated Human SPERMatozoa:
[0075] The foregoing results clearly demonstrated that Ac-B induces irreversible immobilization of the sperms which seems to be attributed to spermicidal effects of the molecules. The inventors therefore employed a battery of tests to assess the mode of execution of the spermicidal effects of Ac-B.
[0076] A functional membrane is important for the enzyme reactions necessary for a sperm to penetrate into the egg during fertilization. This is indicated by transport of selected molecules through the membrane. If trans-membrane transport does not occur or the membrane loses its selective permeability, it can be assumed that the membrane is chemically inactive or physically damaged and it would be unable to participate in the fertilization process.
[0077] A sperm with intact and functional plasma membrane, when placed in a hypo-osmotic environment will swell by influx of water. Its cell volume increases and become turgid (HOS test) with curling of tails into different shapes (HOS positive cells) but if the plasma membrane loses its integrity no such curling occurs (HOS negative cells). Again, the loss of this selectivity indicates that the cell is dead. The live-dead status of a treated sperm can be assessed by a dual fluorescent staining technique (live/dead staining). The mechanism of spermicidal activity of test agent was assessed here by hypo-osmotic swelling test (HOS Test), supra-vital staining and electron microscopy.
A. Live/Dead Staining of Treated Sperm
[0078] Live/dead staining kit (Invitrogen: Paisley, UK), using SYBR-14 in combination with propidium iodide (PI) was used for the purpose.
[0079] The SYBR-14 was prepared in anhydrous methyl sulfoxide (DMSO) at a concentration of 1 mg/ml. A working solution of SYBR-14 diluted 1:10 with DMSO was used for staining the sperm. The PI was dissolved in Tyrode's salt solution at 2 mg/ml.
[0080] The human sperm samples, pre-treated without (control) or with Ac-B (experimental) and Nonoxynol 9 (positive control) were incubated for 15 min at 36 degree C. before examination. When this stain combination was excited at 488 nm, the nucleus of the SYBR-14-stained normal sperm fluoresced bright green while the dead sperm nuclei exhibited red fluorescence (PI). The fluorescent staining of sperm was monitored and photographed with a Zeiss Axiophot epifluorescent microscope (Carl Zeiss Inc., Thornwood, N.Y.) equipped with a fluorescein isothiocyanate filter set (Zeiss #487909).
[0081] The results are summarized in Table 4 below.
B. Hypo-Osmotic Swelling (HOS) Test
[0082] A hypotonic solution was prepared by dissolving 0.735 g sodium citrate dehydrate and 1.351 g fructose in 100 ml distilled water (Milli Q). Aliquots of this solution kept frozen in −20 degree C. and thawed before use. For the test, 200 microlitres of working suspension of rat spermatozoa was treated with one ml of Ac-B solution (at MEC) or BWW (as control) for 20 seconds followed by washing with BWW medium and centrifugation at 1000 rpm for 5 min. Finally the sperm pellet was resuspended in 0.1 ml BWW medium. One ml of prewarmed (37 degree C.) HOS solution was added to the suspension and incubated for one hour at 37 degree C. The incubated sperms were examined under a phase contrast microscope at ×400 magnification to observe the curling of tails. Two hundred spermatozoa were examined for each sample.
Results:
[0083] The result of HOS test also agreed well with the live/dead staining findings over ≧85% control spermatozoa responded to hypo-osmotic swelling and curling of the tail while Ac-B treated spermatozoa showed no HOS reactivity (Table-4).
[0000]
TABLE 4
Effects of live/dead staining and hypo-osmotic swelling
Percentage of dead spermatozoa or
Response to HOS
Ac-B
BWW
Live/dead staining
92 (±5)%
10 (±5)%
Hypo-osmotic Swelling
0% (HOS+)
85% (HOS+)
Test (HOS)
C. Assessment of Plausible Biochemical Mechanism
[0084] The biochemical change that may initiate the spermicidal activity is likely to be peroxidation of lipid layer of the cell membrane. The effect of conjugated unsaturated diene system of the Ac-B might be involved in producing the damaging effect, probably by consequential formation of free radicals that induce membrane damage through peroxidation of lipid. Lipid peroxidation triggers the loss of membrane integrity, causing increased cell permeability, enzyme inactivation, and structural damage to DNA, and ultimately cell death Accordingly, Ac-B probably generates free radicals that induce membrane damage through peroxidation of the polyunsaturated fatty acids (pFA), present in the phospholipids of spermatozoal membrane, resulting in the formation of soluble malondialdehyde (MDA). So the MDA concentration in suspension of treated sperm was assessed using the thiobarbituric acid (TBA) method.
Assessment of Membrane Lipid Peroxidation:
[0085] Membrane lipid peroxidation was estimated by the end point generation of malondialdehyde (MDA) determined by the thiobarbituric acid (TBA) test.
[0086] Suspension of human spermatozoa was prepared using the swim up technique, as described above. A series of dilutions (10, 20, 40, 60, 80, 100 and 120 microgram per ml) of Ac-B was prepared in BWW medium. From each test (Ac-B) solution, 800 microlitres was taken out and mixed with 200 microlitres of sperm suspension with a gentle vortex for 10 seconds. After 20 seconds of mixing, the treated spermatozoa were separated from the suspending medium by centrifugation. The pellet of washed spermatozoa was resuspended in physiological saline. A control set of untreated sperm was treated similarly. Membrane lipid peroxidation was estimated by the end point generation of malondialdehyde (MDA), determined by the thiobarbituric acid (TBA) test.
[0087] Briefly, diluted spermatozoa with or without treatment (250×10 6 cells in 1 ml) were mixed with 1 ml of cold 20% (wt/vol) trichloroacetic acid (TCA) to precipitate protein. The precipitate was pelleted by centrifugation (2000 rpm for 10 minutes), and 1 ml of the supernatant was incubated with 1 ml of 0.67% (wt/vol) TBA in a boiling water bath at 100 degree C. for 30 minutes. After cooling, the absorbance was determined by a spectrophotometer (UNICAM PU 8610 Kinetics spectrophotometer; Philips, Holland) at 535 nm.
Results:
[0088] The spectrophotometric readings clearly demonstrated that there was an increase in the production of MDA (microgram per ml) along with an increase of concentration of the Ac-B. This observation extended support to the reported damaging effects of acaciasides on lipid molecules of the plasma membrane.
D. Electron Microscopy of Treated Sperm
[0089] For electron microscopy, the suspending medium was replaced with 0.1M phosphate buffer (pH 7.0). A concentrated untreated (control) and Ac-B-treated (experimental) human sperm suspension were mixed with 2% glutaraldehyde in phosphate buffer for fixation at 4 degree C. for 4 hours. After three successive washings in buffer at room temperature, post-fixation was done by 1% osmium tetroxide. Thirty minutes after post-fixation, the spermatozoa were quickly washed with phosphate buffer and end block staining was done by saturated urenyl acetate solution. Dehydration of the fixed spermatozoa was done in graded (50%, 70%, 90% and 100%) ethyl alcohol. A portion of each set of dehydrated sperms were embedded in spur and blocks were prepared for ultra-thin sectioning. Ultra-thin sections were prepared in LKB Ultramicrotome using a diamond knife. Finally the thin sections were stained with urenyl acetate and freshly prepared lead citrate. The stained sections were thoroughly examined under TECHNI G2 BIOTWEEN transmission electron microscope (at ×25000). The rest of the dehydrated sperm sets were prepared for examination under tescan scanning electron microscope.
Results:
[0090] In the control set all cells demonstrated the presence of intact plasma. The acrosomal cap was also found to be intact. But the saponin-treated sperms exhibited damaged plasma membrane of various degrees ranging from vesiculation, vacuolization to complete disintegration and their acrosomal cap was most severely damaged.
Assessment of Microbicidal Potential
[0091] a. Effect on In Vitro Culture of Lactobacillus acidophilus
[0092] The media for culture of bacteria purchased from HI-MEDIA, India and spores of Lactobacillus acidophilus were obtained from pharmaceutical capsule marketed by Infer (India) Limited.
[0093] Sterile, molten (45-50 degree C.) Lactobacilli MRS agar was poured into sterile Petri dishes with (a) 1, 10, 100, 200, 500 mg of Ac-B (Experimental) and (b) without Ac-B (Control). The plates were placed within an incubator having 37 degree C. inside temperature and 5% CO 2 in air for 72 hours. The number of colonies and their individual size were compared.
[0094] The size of colonies grown in the presence of Ac-B was comparable to that of control. Comparative evaluation demonstrated that at least up to 500 milligram per ml dose level Ac-B does not affect the growth of Lactobacillus acidophilus cultured in vitro.
[0095] The results indicated that Ac-B possibly would not have any impact on vaginal population of L. acidophilus so as to disturb the vaginal ecology.
[0000] B. Effect on In Vitro Culture of Candida albicans for 24 Hours
[0096] Candida albicans spores were grown in vitro on Potato dextrose [PD] agar plates without (control) and with Ac-B at a concentration of 125 microgram per ml. It was observed that there was no significant difference between the number of colonies grown in the presence or absence of Ac-B. However, the sizes of the individual colonies were comparatively smaller in the Ac-B exposed group. This indicated that Ac-B might have a possible anti-microbial beneficial side effect on topical use.
Screening of Mutagenic Potential of Ac-B
[0097] Ac-B was examined for its ability to produce mutations/revert mutations in a bacterial reverse mutation assay using amino acid-requiring strain of Salmonella typhimurium ( S. typhimurium ) TA100 and the result was compared with a known mutagen (Na-azide). A commercial kit (The MUTA-CHROMOPLATE) from M/s Environmental Biodetection Products Inc. Ontario, Canada, was used. Suspensions of bacterial cells were exposed to the test substance in the presence and in the absence of an exogenous metabolic activation system. After 5 days of incubation, revertant colonies were detected by the change of colour from blue to yellow on solvent control plates. All yellow, partially yellow or turbid wells were scored as positive, while all purple wells were scored as negative. Number of positive wells for each plate was recorded, their number was counted and compared to that of spontaneous revertant colonies. The “Background” (i.e. no test material added) plate was used as reference for the level of spontaneous or background mutation of the assay organism. The statistical difference was determined using a table provided with the kit. It was observed that at least up to 10 milligram per ml concentration, Ac-B showed no positive mutagenic effect.
[0098] Score of mutagenicity as per the set criteria of Muta-Chromoplate test kit. All yellow, partially yellow or turbid wells were scored as positive, all purple wells were scored as negative.
A. Blank (No. of ‘+’ wells==0) B. Background (No. of ‘+’ wells==20) C. ‘+’Control (Na-azide) (No. of ‘+’ wells==74) D. Acaciaside-B (No. of ‘+’ wells==18)
[0103] The overall results showed that Ac-B is non-mutagenic.
Test for Anti-HIV Potential
[0104] 1. Anti-HIV Screening in CEM-GFP Cells:
[0105] Human CD4+ T cell line CEM-GFP cells were infected with HIV-1 NL-4.3 virus pretreated without or with Ac-B at varying concentrations (1 hour at 37 degree C.) at a multiplicity of infection (MOI) of 0.01. The cells were then cultured in the presence or absence of Ac-B for up to 7 days post infection. Virus production was analyzed in the culture supernatant on day-7 post infection by p24 antigen capture ELISA
[0106] Cells infected with untreated virus but subsequently cultured in the presence of Ac-B (0.1 to 2.5 microgram per ml) showed only partial inhibition of viral transmission. However, complete inhibition was observed when cells were infected with Ac-B treated virus and cultured in the presence of Ac-B at concentrations greater than or equal to 1.0 microgram per ml). This observation clearly indicated inhibition of HIV-1 replication in T cells under exposure to Ac-B.
[0000] TABLE 5 Percentage inhibition of hiv growth in CEM-GFP T cell line Ac-B Concentration (microgram per Pretreatment Without ml) with Ac-B Pretreatment 0.1 70.5 0 0.2 77.8 0 0.25 92 0 0.5 90.6 36.1 1 99.73 60.5 1.5 100 100 2 100 100 2.5 100 100
B. Anti-HIV activity in P4 (Hela-CD4-LTRβ Gal) cells
[0107] P4 (Hela-CD4-LTR-β Gal) cells were infected with 0.05 MOI of NL4.3 virus pretreated without or with Ac-B at varying concentrations (1 hour at 37 degree C.) followed by incubation for 48 hours in the presence or absence of Ac-B at a concentration of 0.5 to 2.5 microgram per ml. Virus production was analyzed by ELISA of p24 antigen in the culture supernatant. Viral transmission in the transfected cells was evaluated by X-gal staining, in which an antiretroviral therapeutic drug, Azidothymidine (AZT) was used as positive control. There was no inhibition of viral transmission when the cells were infected with untreated virus and cultured in the presence of Ac-B. However, viral transmission was inhibited >95% when the cells were infected with Ac-B-treated virus, irrespective of whether subsequent culture was conducted in the presence or absence of Ac-B (greater than or equal to 1.5 microgram per ml).
[0108] As assessed by X-gal staining, anti-HIV activity offered by Ac-B at concentration 1.0 microgram per ml (0.005 micromoles) was comparable to or greater than that induced by AZT at 2 micromole concentration.
[0000]
TABLE 6
Percentage inhibition of hiv growth in p4 cell line
Ac-B Concentration
Without
(microgram per ml)
Pretreatment with Ac-B
Pretreatment
0.5
76.53
0
1
95.86
0
2
96
0
2.5
95.53
0
CONCLUDING REMARKS
[0109] Though like most of the popularly used marketed spermicides (viz. Nonoxynol-9), Ac-B is a nonionic surfactant, it differs from N-9 in following respects:
Pure Ac-B is a natural compound of herbal origin having molecular size of about three fold bigger than the synthetic molecule of N-9. This characteristic feature may favour poor absorption through vaginal epithelium and entry into systemic circulation. Its MEC for spermicidal action (125 microgram for human sperm) is much less than that of N-9 (MEC 200-500 microgram). Ac-B has no adverse impact on Lactobacillus growth in culture and therefore is expected to have no adverse impact on vaginal ecology, while Nonoxynol-9 is known to damage vaginal microflora that renders the subject susceptible to opportunistic infections including HIV. Finally, significant spermicidal as well as virucidal activities with apparently no possible mutagenic effects and adverse effects on vaginal ecology highlight the credential of Acaciaside-B as a prospective candidate molecule for future development of spermicidal microbicide, which is however, subject to proper evaluation of its safety margins.
EXAMPLES
[0114] The following examples are given by way of illustration of the present invention and therefore should not be construed to limit the present invention.
Example 1
Anti-HIV Screening in CEM-GFP Cells
[0115] Human CD4+ T cell line CEM-GFP cells were infected with HIV-1 NL-4.3 virus pretreated without or with Ac-B at varying concentrations (1 hour at 37° C.) at a multiplicity of infection (MOI) of 0.01. The cells were then cultured in the presence or absence of Ac-B for up to 7 days post infection. Virus production was analysed in the culture supernatant on day-7 post infection by p24 antigen capture ELISA (FIG. 1).
[0116] Cells infected with untreated virus but subsequently cultured in the presence of Ac-B (0.1-2.5 mcg/ml) showed only partial inhibition of viral transmission. However, complete inhibition was observed when cells were infected with Ac-B treated virus and cultured in the presence of Ac-B at concentrations (≧1.0 mcg/ml). This observation clearly indicates inhibition of HIV-1 replication in T cells under exposure to Ac-B (FIG. 2).
Example 2
Anti-HIV Activity in P4 (Hela-CD4-LTR-β Gal) Cells
[0117] P4 (Hela-CD4-LTR-β Gal) cells were infected with 0.05 MOI of NL4.3 virus pretreated without or with Ac-B at varying concentrations (1 hour at 370 C) followed by incubation for 48 hours in the presence or absence of Ac-B (0.5-2.5 μg/ml). Virus production was analyzed by ELISA of p24 antigen in the culture supernatant (FIG. 1). Viral transmission in the transfected cells was evaluated by X-gal staining, in which an antiretroviral therapeutic drug, Azidothymidine (AZT) was used as positive control (FIG. 4). There was no inhibition of viral transmission when the cells were infected with untreated virus and cultured in the presence of Ac-B. However, viral transmission was inhibited >95% when the cells were infected with Ac-B-treated virus, irrespective of whether subsequent culture was conducted in the presence or absence of Ac-B (≧1.0 mcg/ml) (FIG. 3).
[0118] As assessed by X-gal staining, anti-HIV activity offered by Ac-B at concentration 1 μg/ml (0.005 μM) was comparable to or greater than that induced by AZT at 2 μM concentration. (FIG. 4).
Example 3
Spermicidal Activity In Vitro
[0119] As evaluated by Sander-Cramer test, Ac-B is spermicidal for human, mice, rats. The MECs, however, vary between the species: the lowest (60 μg/ml) for rats/mice and highest (125 μg/ml) for human sperm. Motility revival tests proved the loss of motility to be irreversible.
Example 4
Assessment of Sperm Viability and Plasma Membrane Integrity
[0120] Viability of Ac-B-treated human spermatozoa was evaluated using a dual fluorescent live/dead staining kit (Invitrogen; Paisley, UK) consisting of SYBR 14 and propidium iodide (PI). PI cannot penetrate living cells but can bind to and stain cellular DNA in damaged cells giving them red fluorescence. On completion of staining reaction, proportionate distribution of green (live) and red (dead) stained spermatozoa was recorded using dual emission filter for SYBR14 and propidium iodide. In the control set all sperms were stained green but the Ac-B-treated spermatozoa (125 mcg/ml) were stained red. This observation clearly demonstrates that Ac-B exerts spermicidal but not spermatostatic effects.
[0121] Integrity of plasma membrane was tested by hypo-osmotic swelling (HOS) test. The curling of tails in the untreated (control) spermatozoa, caused by the turgidity due to imbibitions of water into the cell indicates intact integrity of plasma membrane around the cell. The absence of curling in the Ac-B treated spermatozoa indicates that the surrounding plasma membrane has lost its integrity.
[0122] The modus operandi of membrane damage involves increased lipid peroxidation of the plasma membrane leading to loss of integrity with consequent death of the exposed sperms. Increased lipid peroxidation was evident by Ac-B-induced dose-dependent increased generation of malondialdehyde (MDA). The electron microscopic study also confirms the membrane damaging effects of Ac-B. As observed in TEM, the damaging effect of Ac-B involves vesiculization/vacuolization of the plasma membrane leading to its disintegration. In the SEM of human sperm it has been observed that intact acrosomal cap and plasma membrane are present around the head and neck region of control sperms but the Ac-B-treated sperm shows mutilation of these regions.
Example 5
Effect on In Vitro Culture of Lactobacillus acidophilus
[0123] Comparative evaluation shows that at least up to 500 mg/ml dose level Ac-B does not affect the growth of Lactobacillus acidophilus cultured in vitro. The size of colonies grown in the presence of Ac-B is comparable to that of control.
[0124] This result indicates that Ac-B possibly would have no impact on vaginal population of L. acidophilus to disturb the vaginal ecology.
Example 6
Effect on In Vitro Culture of Candida albicans for 24 Hours
[0125] Candida albicans spores were grown in vitro on PD agar plates without (control) and with Ac-B at a concentration of 125 μg/ml. There was no significant difference between the number of colonies grown in the presence or absence of Ac-B. However, the sizes of the individual colonies were comparatively smaller in the Ac-B exposed group.
[0126] This indicates that Ac-B might have a possible anti-microbial beneficial side effect on topical use.
Example 7
Screening of Mutagenic Potential of Ac-B
[0127] Ac-B was examined for its ability to produce mutations/revert mutations in a bacterial reverse mutation assay using amino acid-requiring strain of Salmonella typhimurium ( S. typhimurium ) TA100 and the result was compared with a known mutagen (Na-azide). A commercial kit (The MUTA-CHROMOPLATE) from M/s Environmental Biodetection Products Inc. Ontario, Canada, was used. Suspensions of bacterial cells were exposed to the test substance in the presence and in the absence of an exogenous metabolic activation system. After 5 days of incubation, revertant colonies were detected by the change of color from blue to yellow on solvent control plates. All yellow, partially yellow or turbid wells were scored as positive, while all purple wells were scored as negative. Number of positive wells for each plate was recorded, their number was counted and compared to that of spontaneous revertant colonies. The “Background” (i.e. no test material added) plate was used as reference for the level of spontaneous or background mutation of the assay organism. The statistical difference was determined using a table provided with the kit.
[0128] At least up to 10 mg/ml concentration, Ac-B showed no positive mutagenic effect.
ADVANTAGES OF THE INVENTION
[0000]
Acaciaside-B has an anti-HIV property and capable to prevent HIV infection at a dose level of greater than or equal to 1.0 microgram per ml in vitro, which is perhaps well within tolerable limits (Hemolytic index: 7 microgram per ml).
MEC of Ac-B is 125 micro g/ml for spermicidal activity on human sperm which is significantly lower than that of closest prior arts (MEC for N-9:200-500 microgram per ml
Ac-B is non-mutagenic as tested in Ames Test.
Ac-B does not interfere with the growth of Lactobacillus acidophilus in laboratory culture, at least up to a concentration of 500 mg/ml.
Its molecular size is about three fold higher than N-9, which makes it likely to be absorbed weekly through vaginal route. | Acaciaside-B (Ac-B) has emerged as a prospective candidate molecule for prevention of HIV infection along with potential for use as/in vaginal contraceptive/formulation. It possesses anti-HIV property at a tolerably low concentration, is non-mutagenic and does not harm the niche of Lactobacilli . Thus Ac-B appears to be a superior ingredient for formulations of a chemical barrier against HIV-1 infection wherein its spermicidal property is superfluous. | 0 |
TECHNICAL FIELD
[0001] The present invention relates generally to methods of making nonwoven fabrics, and more particularly to a method of manufacturing a nonwoven fabric exhibiting improved physical characteristics while retaining aesthetic appeal, permitting use of the fabric in a wide variety of consumer applications.
BACKGROUND OF THE INVENTION
[0002] The production of conventional textile fabrics is known to be a complex, multi-step process. The production of fabrics from staple fibers begins with the carding process where the fibers are opened and aligned into a feed stock known as sliver. Several strands of sliver are then drawn multiple times on drawing frames to further align the fibers, blend, improve uniformity as well as reduce the diameter of the sliver. The drawn sliver is then fed into a roving frame to produce roving by further reducing its diameter as well as imparting a slight false twist. The roving is then fed into the spinning frame where it is spun into yarn. The yarns are next placed onto a winder where they are transferred into larger packages. The yarn is then ready to be used to create a fabric.
[0003] For a woven fabric, the yarns are designated for specific use as warp or fill yarns. The fill yarn packages (which run in the cross direction and are known as picks) are taken straight to the loom for weaving. The warp yarns (which run on in the machine direction and are known as ends) must be further processed. The packages of warp yarns are used to build a warp beam. Here the packages are placed onto a warper which feeds multiple yarn ends onto the beam in a parallel array. The warp beam yarns are then run through a slasher where a water soluble sizing is applied to the yarns to stiffen them and improve abrasion resistance during the remainder of the weaving process. The yarns are wound onto a loom beam as they exit the slasher, which is then mounted onto the back of the loom. Here the warp and fill yarns are interwoven in a complex process to produce yardages of cloth.
[0004] In contrast, the production of nonwoven fabrics from staple fibers is known to be more efficient than traditional textile processes as the fabrics are produced directly from the carding process.
[0005] Nonwoven fabrics are suitable for use in a wide-variety of applications where the efficiency with which the fabrics can be manufactured provides a significant economic advantage for these fabrics versus traditional textiles. However, nonwoven fabrics have commonly been disadvantaged when fabric properties are compared, particularly in terms of surface abrasion, pilling and durability in multiple-use applications. Hydroentangled fabrics have been developed with improved properties, which are a result of the entanglement of the fibers or filaments in the fabric providing improved fabric integrity. Subsequent to entanglement, fabric durability can be further enhanced by the application of binder compositions and/or by thermal stabilization of the entangled fibrous matrix. However, the use of such means to obtain fabric durability come at the cost of a stiffer and less appealing fabric.
[0006] U.S. Pat. No. 3,485,706, to Evans, hereby incorporated by reference, discloses processes for effecting hydroentanglement of nonwoven fabrics. More recently, hydroentanglement techniques have been developed which impart images or patterns to the entangled fabric by effecting hydroentanglement on three-dimensional image transfer devices. Such three-dimensional image transfer devices are disclosed in U.S. Pat. No. 5,098,764, hereby incorporated by reference, with the use of such image transfer devices being desirable for providing a fabric with enhanced physical properties as well as an aesthetically pleasing appearance.
[0007] Heretofore, attempts have been made to develop nonwoven fabrics exhibiting the necessary aesthetic and physical properties. U.S. Pat. No. 5,393,304, discloses a washable spunlaced nonwoven cloth, with this patent contemplating use of a PAE binder composition (polyamide-amine-epichorohydrin) with inclusion of cotton fiber in the fibrous matrix.
[0008] U.S. Pat. No. 3,988,343, discloses a nylon fabric treated with a mixture of acrylic polymer and latex binder with tinting pigments. U.S. Pat. No. 5,874,159 contemplates providing a spunlaced fabric structure with durability by the provision of a bonding material in the form of a thermal plastic polymer, which may be provided in the form of a net, an apertured or punctured film, or molten drop form. The bonding material acts to join layers or laminations from which the fabric is formed.
[0009] For specific applications, a nonwoven fabric must exhibit a combination of specific physical characteristics. As an example, fabrics used in apparel should be soft and drapeable, yet withstand home laundering, and be resistant to abrasion (which can result in aesthetically displeasing fabric “pills”). Fabrics used in the fabrication of apparel must also exhibit sufficient strength, tear resistance, and colorfastness to ensure a reasonable life span for the end-use article. The physical performance of a fabric in terms of liquid handling, i.e. perspiration control, is of utmost concern when apparel fabricated from such fabric is to be worn for extended lengths of time. These are among the characteristics which have been identified as being desirable for apparel applications including outerwear, workwear, footwear, and the like.
[0010] U.S. Pat. No. 5,478,635, discloses a knitted nylon fabric, necessary for abrasion resistance, being adhesively affixed to a nylon nonwoven fabric “reservoir”. The construction of this laminate structure requires the knitting of nylon yarn followed by the application of polyurethane adhesive dissolved in a highly volatile solvent such as methylene chloride. U.S. Pat. No. 4,941,884 is directed to a method of fabricating an abrasion resistant woven material having good aesthetics.
[0011] Notwithstanding various attempts in the prior art to develop a nonwoven fabric acceptable for apparel use applications, a need continues to exist for a nonwoven fabric exhibiting aesthetic appeal while obtaining requisite mechanical characteristics.
SUMMARY OF THE INVENTION
[0012] In accordance with the present invention, a method of making a nonwoven fabric embodying the present invention includes the steps of providing a precursor web comprising a fibrous matrix. While use of staple length fibers is typical, the fibrous matrix may comprise substantially continuous filaments and combinations thereof. In a particularly preferred form, the fibrous matrix is carded and cross-lapped to form a precursor web. It is also preferred that the precursor web be subjected to pre-entangling on a foraminous forming surface prior to imaging and patterning.
[0013] The present method further contemplates the provision of a three-dimensional image transfer device having a movable imaging surface. In a typical configuration, the image transfer device may comprise a drum-like apparatus that is rotatable with respect to one or more hydroentangling manifolds.
[0014] The precursor web is advanced onto the imaging surface of the image transfer device so that the web moves together with the imaging surface. Hydroentanglement of the precursor web is effected to form an imaged and patterned fabric.
[0015] Subsequent to hydroentanglement, the imaged and patterned fabric may be subjected to one or more variety of post-entanglement treatments. Such treatments include application of a pre-dyeing finish, dyeing of the fabric by conventional textile dyeing methods, and optionally, a subsequent post-dyeing finish.
[0016] A further aspect of the present invention is directed to a method of forming a durable nonwoven fabric which exhibits an enhanced degree of softness and drapeability, while providing the necessary high resistance to tearing and abrasion, to facilitate use in a wide variety of applications. The fabric exhibits a high degree of absorbency, thus permitting its use in apparel applications in which the fabric can quickly and effectively remove moisture, thus improving wearer comfort.
[0017] A method of making the present durable nonwoven fabric comprises the steps of providing a precursor web that is subjected to hydroentangling. Polyester precursor webs, in either homogeneous form or formed as a blend with other polymeric and/or natural fibers, have been found to desirably yield soft hand and good fabric drapeability. The precursor web is formed into an imaged and patterned nonwoven fabric by hydroentanglement on a three-dimensional image transfer device. The image transfer device defines three-dimensional elements against which the precursor web is forced during hydroentangling, whereby the fibrous constituents of the web are imaged and patterned by movement into regions between the three-dimensional elements of the transfer device.
[0018] In the preferred form, the precursor web is hydroentangled on a foraminous surface prior to hydroentangling on the image transfer device. This pre-entangling of the precursor web acts to partially integrate the fibrous components of the web, but does not impart imaging and patterning as can be achieved through the use of the three-dimensional image transfer device.
[0019] Subsequent to hydroentangling, the imaged and patterned nonwoven fabric is treated with a pre-dye finish to lend further integrity to the fabric structure. The polymeric binder composition is selected to enhance durability characteristics of the fabric, while maintaining the desired softness and drapeability of the patterned and imaged fabric.
[0020] Other features and advantages of the present invention will become readily apparent from the following detailed description, the accompanying drawings, and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] The invention will be more easily understood by a detailed explanation of the invention including drawings. Accordingly, drawings which are particularly suited for explaining the invention are attached herewith; however, is should be understood that such drawings are for explanation purposes only and are not necessarily to scale. The drawings are briefly described as follows:
[0022] FIG. 1 is a diagrammatic view of an apparatus for manufacturing a durable nonwoven fabric, embodying the principles of the present invention; and
[0023] FIG. 2 is a diagrammatic view of an apparatus for the application of a post-dye finish onto a nonwoven fabric, embodying the principles of the present invention; and
[0024] FIG. 3 is a fragmentary top plan view of a three-dimensional image transfer device of the type used for practicing the present invention, referred to as “mini-herringbone”, with approximate dimensions shown in millimeters;
[0025] FIG. 3 a is a cross-sectional view taken along lines A-A of FIG. 3 ; and
[0026] FIG. 4 is a fragmentary top plan view of a three-dimensional image transfer device of the type used for practicing the present invention, referred to as “octagons and squares”, with approximate dimensions shown in millimeters; and
[0027] FIG. 4 a is a cross-sectional view taken along lines A-A of FIG. 4 ; and
[0028] FIG. 4 b is a cross-sectional view taken along lines B-B of FIG. 4 ; and
[0029] FIG. 4 c is an isometric view of three-dimensional image transfer device shown in FIG. 4 .
DETAILED DESCRIPTION
[0030] While the present invention is susceptible of embodiment in various forms, there is shown in the drawings and will hereinafter be described a presently preferred embodiment of the invention, with the understanding that the present disclosure is to be considered as an exemplification of the invention, and is not intended to limit the invention to the specific embodiment illustrated.
[0031] In accordance with the present invention, a durable nonwoven fabric can be produced which can be employed in apparel applications, with the fabric exhibiting sufficient softness, drapeability, abrasion resistance, strength, and tear resistance, with colorfastness to light, crocking, and laundering. It has been difficult to develop nonwoven fabrics which achieve the desired hand, drape, and pill resistance that is inherent in woven fabrics. Typically, nonwoven fabrics in the 3.0 to 6.0 ounces per square yard range exhibit bulkiness, which in turn detracts from the hand and drapeability of the fabric.
[0032] In the case where nonwoven fabrics are produced using staple length fibers, the fabric typically has a degree of exposed surface fibers that will abrade or “pill” if not sufficiently entangled, and/or not treated with the appropriate polymer chemistries subsequent to hydroentanglement. The present invention provides a finished fabric that can be conveniently cut, sewn, and packaged for retail sale or utilized as a component in the fabrication of a more complex article. The cost associated with designing/weaving, fabric preparation, dyeing and finishing steps can be desirably reduced.
[0033] With reference to FIG. 1 , therein is illustrated an apparatus for practicing the present method for forming a nonwoven fabric. The fabric is formed from a fibrous matrix preferably comprising staple length fibers, but it is within the purview of the present invention that different types of fibers, or fiber blends, and/or continuous filaments can be employed. The fibrous matrix is preferably carded and cross-lapped to form a precursor web, designated P. In current embodiments, the precursor web comprises both 100% staple length polyester fibers and polyester/nylon staple length fiber blends.
[0034] FIG. 1 illustrates a hydroentangling apparatus for forming nonwoven fabrics in accordance with the present invention. The apparatus includes a foraminous forming surface in the form of belt 12 upon which the precursor web P is positioned for pre-entangling by entangling manifold 14 .
[0035] The entangling apparatus of FIG. 1 further includes an imaging and patterning drum 18 comprising a three-dimensional image transfer device for effecting imaging and patterning of the lightly entangled precursor web. The image transfer device includes a moveable imaging surface which moves relative to a plurality of entangling manifolds 22 which act in cooperation with three-dimensional elements defined by the imaging surface of the image transfer device to effect imaging and patterning of the fabric being formed.
[0036] Manufacture of a durable nonwoven fabric embodying the principles of the present invention is initiated by providing the precursor nonwoven web, preferably in the form of a 100% polyester or polyester blend. The use of the polyester desirably provides drape, which upon treatment with the specific binder formulation listed herein, results in a material with improved physical properties over the competitive 100% nylon material. During invention development, fibrous layer ratios varying from 100 percent polyester by weight to 50 percent polyester/50 percent nylon by weight were produced and tested. Such blending of the layers in the precursor web was also found to yield aesthetically pleasing color variations due to the differential absorption of dyes during the dyeing steps.
EXAMPLES
Example 1
[0037] Using a forming apparatus as illustrated in FIG. 1 , a nonwoven fabric was made in accordance with the present invention by providing a precursor web comprising Type 54W polyester fiber, 1.1 denier by 2.0 inch staple length, as obtained from Wellman. The web had a basis weight of 2.0 ounces per square yard (plus or minus 7%). The precursor web was 100% carded and cross-lapped, with a draft ratio of 2.5 to 1.
[0038] The precursor web then received thereupon a 1.5 oz of air-randomized Type T200 Nylon, 1.8 denier by 2.0 staple length, as obtained from Du Pont. Prior to patterning and imaging of the precursor web, the web was entangled by a series of entangling manifolds such as diagrammatically illustrated in FIG. 1 . FIG. 1 illustrates disposition of precursor web P on a foraminous forming surface in the form of belt 12 , with the web acted upon by an entangling manifolds 14 . In the present examples, each of the entangling manifolds included 3 orifice strips each having 120 micron orifices spaced at 42.3 per inch, with the manifolds successively operated at 100, 300, 800 and 800 psi, at a line speed of 50 feet per minute.
[0039] The entangling apparatus of FIG. 1 further includes an imaging and patterning drum 18 comprising a three-dimensional image transfer device for effecting imaging and patterning of the now-entangled precursor web. The entangling apparatus includes a plurality of entangling manifolds 22 that act in cooperation with the three-dimensional image transfer device of drum 18 to effect patterning of the fabric. In the present example, the three entangling manifolds 22 were operated at 1900 psi, at a line speed which was the same as that used during pre-entanglement.
[0040] The three-dimensional image transfer device of drum 24 was configured as a so-called octagon and square, as illustrated in FIGS. 4, 4 a , 4 b , and 4 c.
[0041] Subsequent to patterned hydroentanglement, the fabric was dried on three consecutive steam cans at 300° F. at 26 , then received a substantially uniform application by dip and nip saturation of a pre-dye finish composition at application station 30 . The web was then directed through a tenter apparatus 32 , operated at 300° F.
[0042] In the present example, the pre-dye finish composition was applied at a line speed of 50 feet per minute, with a nip pressure of 40 psi and percent wet pick up of approximately 120%.
[0043] The pre-dye finish formulation, by weight percent of bath, was as follows:
Water 83.4% Y30 0.1% (Y30 is a silicone-based defamer) As may be obtained from Down Corning of Michigan Hystretch V29 16.0% (Hystretch is an elastomeric ploymer emulsion) Registered to B.F. Goodrich of New York Freecat 187 0.02% (Freecat is a chemical catalyst) Registered to Freedom Textile Chemicals Co. of North Carolina Tween 20 0.2% (Tween is a wetting and dispersing agent) Registered to ICI Americas, Inc. of Delaware Cymel 303 0.24% (Cymel is a melamine cross-linking resin) Registered to American Cyanamid Co. of New York
[0044] After pre-dye finish application and curing of the finish on the imaged nonwoven fabric, the resulting fabric was dyed. Various dyeing methods commonly known in the art are applicable including nip, pad, and jet, with the use of a jet apparatus and disperse dyes, as represented by U.S. Pat. No. 5,440,771 and U.S. Pat. No. 3,966,406, both hereby incorporated by reference, being most preferred.
[0045] Subsequent to dyeing of the imaged fabric, the fabric was dried on three consecutive steam cans at 300° F. and rewound. The now dyed nonwoven fabric then received a substantially uniform application by dip and nip saturation, depicted in FIG. 2 , of a post-dye finish composition at application station 41 . The post-dye finish composition was applied at a line speed of 50 feet per minute, with a nip pressure of 40 psi and percent wet pick up of approximately 120%.
[0046] The post-dye finish composition formulation, by weight percent of bath, was as follows:
Water 97.8% RU40-350 2.0% (RU40-350 is a polycarbonate resin) As may be obtained from Stahl, USA of Massachusetts XR-2569 0.2% (XR-2569 is a carbodimide crosslinker) As may be obtained from Stahl, USA of Massachusetts
[0047] The final fabric was dried on steam cans 42 at 300° F.
Example 2
[0048] A fabric as made in the manner described in Example 1, whereby in the alternative the polyester precursor web reduced to a basis weight of 1.75 ounce, being formed by carding and air-randomization. In place of the 1.8 denier nylon fiber, an air randomized 1.1 denier by 2.0 inch staple length Type T200 Nylon at a 1.5 ounce basis weight was used.
Example 3
[0049] A fabric as made in the manner described in EXAMPLE 1, whereby in the alternative, a 100% Type 54W polyester fiber, 1.1 denier by 2.0 inch staple length, was formed into a precursor web at a basis weight of 4.0 ounces per square yard (plus or minus 7%). In the present example, the entangling manifolds 22 were operated at 4500 psi, at a line speed of 50 feet per minute.
[0050] The three-dimensional image transfer device of drum 24 was configured as a so-called mini-herringbone, as illustrated in FIGS. 3 and 3 a.
[0051] In the present example, the pre-dye finish composition was again applied at a line speed of 50 feet per minute, with a nip pressure of 40 psi and percent wet pick up of approximately 120%.
[0052] The pre-dye finish composition formulation, by weight percent of bath, was as follows:
Water 73.6% Y30 0.1% Tween 20 0.2% Rhoplex TR934HS 15.0% (TR934HS is an acrylic/copolymer emulsion) Registered to Rhom & Haas Co. of Delaware Rhoplex TR407 10.0% (TR407 is an acrylic/copolymer emulsion) Ammonia 0.1% Sancure 861 1.0% (Sancure is a water-based urethane resin) Registered to Sanncor Industries, Inc. of Massachusetts
[0053] The following benchmarks have been established in connection with nonwoven fabrics, which exhibit the desired combination of durability, softness, abrasion resistance, etc., for certain apparel and home use applications.
Fabric Strength/Elongation ASTM D5034 Absorbency - Capacity ASTM D1117 Elmendorf Tear ASTM D5734 Handle-o-meter ASTM D2923 Stiffness - Cantilever Bend ASTM D5732 Thermal Shrink Specified Below Fabric Weight ASTM D3776 Martindale Abrasion Test ASTM D4970 Colorfastness to Crocking AATCC 8-1988
[0054] Thermal shrinkage is determined by initially cutting 11 inch by 11 inch square samples of the test fabric, the samples being taken at a minimum of 4 inches from the edge of the fabric roll. Indelible reference markings are directly indicated on the sample at a 1 inch increment from each corner, a 9 inch span being centrally located on each edge of the sample resulting. The samples are then placed in an operating convention style oven of which has obtained and is maintaining a 350° F. temperature. The samples are incubated for 30 minutes. At the conclusion of the incubation period, the samples are removed and allowed to cool on a flat surface until the samples reach ambient temperature. Samples are remeasured against the said reference markings. The difference between the final measure and the initial measure is presented in the form of a percent change.
[0055] The test data in Table 1 shows that nonwoven fabrics approaching, meeting, or exceeding the various above-described benchmarks for fabric performance in general, and to commercially available products in specific, can be achieved with fabrics formed in accordance with the present invention. Fabrics having basis weights between about 2.0 ounces per square yard and 6.0 ounces per square yard are preferred, with fabrics having basis weights of about 3.0 ounces per square yard and 4.0 ounces per square yard being most preferred.
[0056] Fabrics formed in accordance with the present invention are durable and drapeable, and are suitable for apparel applications. From the foregoing, it will be observed that numerous modifications and variations can be affected without departing from the true spirit and scope of the novel concept of the present invention. It is to be understood that no limitation with respect to the specific embodiments illustrated herein is intended or should be inferred. The disclosure is intended to cover, by the appended claims, all such modifications as fall within the scope of the claims.
Commercial Material Inventive Material Cambrelle.RTM Type Sample 1 Sample 2 Sample 3 Of Camtex, Inc. Weight ounces/ 3.83 3.59 5.95 3.49 yard 2 Bulk mils 34.3 34.0 50.3 24.5 STRIP TENSILE MD lbs. 35.83 48.68 65.58 24.37 CD 28.15 33.78 47.29 24.16 Combined Tensile/gram 0.45 0.62 0.51 0.37 ELONGATION MD % 58.95 49.84 54.35 40.28 CD 94.65 71.99 78.28 39.93 GRAB TENSILE MD lbs. 72.58 92.21 123.4 62.45 CD 67.50 82.73 91.73 57.46 Combined Tensile/gram 0.98 1.31 0.97 0.92 ELONGATION MD % 59.59 49.88 49.76 40.79 CD 100.3 74.1 75.55 40.13 Absorbency CAP % 672 748 Buoyant 529 TIME sec 19 15 Buoyant 166 Absorbency/sec/gram fabric 0.25 0.37 0.02 Color Fastness WET 5 5 5 4.5 DRY 5 5 5 4.5 Handle-O-Meter MD grams 111 116 370 302 CD 52 77 172 96 Combined gram force/gram fabric 1.14 1.45 2.45 3.06 Cantilever Bend MD mg-cm 8.8 8.5 10.6 9.7 CD 5.7 6.3 7.1 6.9 Bend/bulk 0.42 0.44 0.35 0.68 Thermal Shrink MD % −3 1.7 −3 −4 (250° F. for 30 min) CD −1.5 0 −5.3 −5 Elmendorf Tear MD grams 2331 2451 3417 1084 CD 2209 3223 4269 1410 Combined gram force/gram fabric 32 42 35 19 Martindale Abrasion cycles >50,000 >50,000 >50,000 >50,000 | A method of forming abrasion resistant nonwoven fabrics by hydroentanglement includes providing a precursor web. The precursor web is subjected to hydroentanglement on a three-dimensional image transfer device to create a patterned and imaged fabric. Treatment with an initial pre-dye finish enhances the integrity of the fabric, permitting the nonwoven to exhibit desired physical characteristics, including strength, durability, softness, and drapeability. The pre-dye finish treated nonwoven may then be dyed by means applicable to conventional wovens. A post-dye finish may then be applied to further enhance the performance of the nonwoven fabric. | 3 |
BACKGROUND OF THE INVENTION
The present invention relates to processes of making compounds that inhibit 11-β-hydroxysteroid dehydrogenase type 1 enzyme (11-β HSD1).
Hydroxysteroid dehydrogenases (HSDs) regulate the occupancy and activation of steroid hormone receptors by converting steroid hormones into their inactive metabolites. For a recent review, see Nobel et al., Eur. J. Biochem. 2001, 268:4113-4125.
There exist numerous classes of HSDs. The 11-beta-hydroxysteroid dehydrogenases (11.beta.-HSDs) catalyze the interconversion of active glucocorticoids (such as cortisol and corticosterone), and their inert forms (such as cortisone and 11-dehydrocorticosterone). The isoform 11-beta-hydroxysteroid dehydrogenase type 1 (11.beta.-HSD1) is expressed in liver, adipose tissue, brain, lung and other glucocorticoid tissue and is a potential target for therapy directed at numerous disorders that may be ameliorated by reduction of glucocorticoid action, such as diabetes, obesity and age-related cognitive dysfunction. Seckl, et al., Endocrinology, 2001, 142:1371-1376.
The various isozymes of the 17-beta-hydroxysteroid dehydrogenases (17.beta.-HSDs) bind to androgen receptors or estrogen receptors and catalyze the interconversion of various sex hormones including estradiollestrone and testosterone/androstenedione. To date, six isozymes have been identified in humans and are expressed in various human tissues including endometrial tissue, breast tissue, colon tissue, and in the testes. 17-beta-Hydroxysteroid dehydrogenase type 2 (17.beta.-HSD2) is expressed in human endometrium and its activity has been reported to be linked to cervical cancer. Kitawaki et al., J. Clin. Endocrin. Metab., 2000, 85:1371-3292-3296. 17-beta-Hydroxysteroid dehydrogenase type 3 (17.beta.-HSD3) is expressed in the testes and its modulation may be useful for the treatment of androgen-related disorders.
Androgens and estrogens are active in their 17.beta.-hydroxy configurations, whereas their 17-keto derivatives do not bind to androgen and estrogen receptors and are thus inactive. The conversion between the active and inactive forms (estradiol/estrone and testosterone/androstenedione) of sex hormones is catalyzed by members of the 17.beta.-HSD family. 17.beta.-HSD1 catalyzes the formation of estradiol in breast tissue, which is important for the growth of malignant breast tumors. Labrie et al., Mol. Cell. Endocrinol. 1991, 78:C113-C118. A similar role has been suggested for 17.beta.-HSD4 in colon cancer. English et al., J. Clin. Endocrinol. Metab. 1999, 84:2080-2085. 17.beta.-HSD3 is almost exclusively expressed in the testes and converts androstenedione into testosterone. Deficiency of this enzyme during fetal development leads to male pseudohermaphroditism. Geissler et al., Nat. Genet. 1994, 7:34-39. Both 17.beta.-HSD3 and various 3.alpha.-HSD isozymes are involved in complex metabolic pathways which lead to androgen shuffles between inactive and active forms. Penning et al., Biochem. J. 2000, 351:67-77. Thus, modulation of certain HSDs can have potentially beneficial effects in the treatment of androgen- and estrogen-related disorders.
The 20-alpha-hydroxysteroid dehydrogenases (20.alpha.-HSDs) catalyze the interconversion of progestins (such as between progesterone and 20.alpha.-hydroxy progesterone). Other substrates for 20.alpha.-HSDs include 17.alpha.-hydroxypregnenolone or 17.alpha.-hydroxyprogesterone, leading to 20.alpha.-OH steroids. Several 20.alpha.-HSD isoforms have been identified and 20.alpha.-HSDs are expressed in various tissues, including the placenta, ovaries, testes and adrenals. Peltoketo, et al., J. Mol. Endocrinol. 1999, 23:1-11.
The 3-alpha-hydroxysteroid dehydrogenases (3.alpha.-HSDs) catalyze the interconversion of the androgens dihydrotestosterone (DHT) and 5.alpha.-androstane-3.alpha.,17.beta.-diol and the interconversion of the androgens DHEA and androstenedione and therefore play an important role in androgen metabolism. Ge et al., Biology of Reproduction 1999, 60:855-860.
1. Glucorticoids, Diabetes and Hepatic Glucose Production
It has been known for more than half a century that glucocorticoids have a central role in diabetes. For example, the removal of the pituitary gland or the adrenal gland from a diabetic animal alleviates the most severe symptoms of diabetes and lowers the concentration of glucose in the blood (Long, C. D. and Leukins, F. D. W. (1936) J. Exp. Med. 63: 465-490; Houssay, B. A. (1942) Endocrinology 30: 884-892). It is also well established that glucocorticoids enable the effect of glucagon on the liver.
The role of 11.beta.HSD1 as an important regulator of local glucocorticoid effect and thus of hepatic glucose production is well substantiated (see, e.g., Jamieson et al. (2000) J. Endocrinol. 165: 685-692). Hepatic insulin sensitivity was improved in healthy human volunteers treated with the non-specific 11.beta.HSD1 inhibitor carbenoxolone (Walker, B. R. et al. (1995) J. Clin. Endocrinol. Metab. 80: 3155-3159). Furthermore, the expected mechanism has been established by different experiments with mice and rats. These studies showed that the mRNA levels and activities of two key enzymes in hepatic glucose production were reduced, namely: the rate-limiting enzyme in gluconeogenesis, phosphoenolpyruvate carboxykinase (PEPCK), and glucose-6-phosphatase (G6 Pase) the enzyme catalyzing the last common step of gluconeogenesis and glycogenolysis. Finally, blood glucose levels and hepatic glucose production are reduced in mice in which the 11.beta.HSD1 gene is knocked-out. Data from this model also confirm that inhibition of 11.beta.HSD1 will not cause hypoglycemia, as predicted since the basal levels of PEPCK and G6 Pase are regulated independently of glucocorticoids (Kotelevtsev, Y. et al., (1997) Proc. Natl. Acad. Sci. USA 94: 14924-14929).
FR 2,384,498 discloses compounds having a high hypoglycemic effect. Therefore, treatment of hyperglycemia with these compounds may lead to hypoglycemia.
2. Possible Reduction of Obesity and Obesity Related Cardiovascular Risk Factors
Obesity is an important factor in syndrome X as well as in the majority (>80%) of type 2 diabetes, and omental fat appears to be of central importance. Abdominal obesity is closely associated with glucose intolerance, hyperinsulinemia, hypertriglyceridemia, and other factors of the so-called syndrome X (e.g. increased blood pressure, decreased levels of HDL and increased levels of VLDL) (Montague & O'Rahilly, Diabetes 49: 883-888, 2000). Inhibition of the 11.beta.HSD1 enzyme in pre-adipocytes (stromal cells) has been shown to decrease the rate of differentiation into adipocytes. This is predicted to result in diminished expansion (possibly reduction) of the omental fat depot, i.e., reduced central obesity (Bujalska, I. J., S. Kumar, and P. M. Stewart (1997) Lancet 349: 1210-1213).
Inhibition of 11.beta.HSD1 in mature adipocytes is expected to attenuate secretion of the plasminogen activator inhibitor 1 (PAI-1)—an independent cardiovascular risk factor (Halleux, C. M. et al. (1999) J. Clin. Endocrinol. Metab. 84: 4097-4105). Furthermore, there is a clear correlation between glucocorticoid “activity” and cardiovascular risk factor suggesting that a reduction of the glucocorticoid effects would be beneficial (Walker, B. R. et al. (1998) Hypertension 31: 891-895; Fraser, R. et al. (1999) Hypertension 33: 1364-1368).
Adrenalectomy attenuates the effect of fasting to increase both food intake and hypothalamic neuropeptide Y expression. This supports the role of glucocorticoids in promoting food intake and suggests that inhibition of 11.beta.HSD1 in the brain might increase satiety and therefore reduce food intake (Woods, S. C. et al. (1998) Science, 280: 1378-1383).
3. Possible Beneficial Effect on the Pancreas
Inhibition of 11.beta.HSD1 in isolated murine pancreatic .beta.-cells improves glucose-stimulated insulin secretion (Davani, B. et al. (2000) J. Biol. Chem. 2000 Nov. 10; 275(45): 34841-4). Glucocorticoids were previously known to reduce pancreatic insulin release in vivo (Billaudel, B. and B. C. J. Sutter (1979) Horm. Metab. Res. 11: 555-560). Thus, inhibition of 11.beta.HSD1 is predicted to yield other beneficial effects for diabetes treatment, besides the effects on liver and fat.
4. Possible Beneficial Effects on Cognition and Dementia
Stress and glucocorticoids influence cognitive function (de Quervain, D. J. F., B. Roozendaal, and J. L. McGaugh (1998) Nature 394: 787-790). The enzyme 11.beta.HSD1 controls the level of glucocorticoid action in the brain and thus contributes to neurotoxicity (Rajan, V., C. R. W. Edwards, and J. R. Seckl, J. (1996) Neuroscience 16: 65-70; Seckl, J. R., Front. (2000) Neuroendocrinol. 18: 49-99). Unpublished results indicate significant memory improvement in rats treated with a non-specific 11.beta.HSD1 inhibitor (J. Seckl, personal communication). Based the above and on the known effects of glucocorticoids in the brain, it may also be suggested that inhibiting 11.beta.HSD1 in the brain may result in reduced anxiety (Tronche, F. et al. (1999) Nature Genetics 23: 99-103). Thus, taken together, the hypothesis is that inhibition of 11.beta.HSD1 in the human brain would prevent reactivation of cortisone into cortisol and protect against deleterious glucocorticoid-mediated effects on neuronal survival and other aspects of neuronal function, including cognitive impairment, depression, and increased appetite.
5. Possible Use of Immuno-Modulation Using 11.beta.HSD1 Inhibitors
The general perception is that glucocorticoids suppress the immune system. But in fact there is a dynamic interaction between the immune system and the HPA (hypothalamo-pituitary-adrenal) axis (Rook, G. A. W. (1999) Baillier's Clin. Endocrinol. Metab. 13: 576-581). The balance between the cell-mediated response and humoral responses is modulated by glucocorticoids. A high glucocorticoid activity, such as at a state of stress, is associated with a humoral response. Thus, inhibition of the enzyme 11.beta.HSD1 has been suggested as a means of shifting the response towards a cell-based reaction.
In certain disease states, including tuberculosis, lepra and psoriasis the immune reaction is normally biased towards a humoral response when in fact the appropriate response would be cell based. Temporal inhibition of 11.beta.HSD1, local or systemic, might be used to push the immune system into the appropriate response (Mason, D. (1991) Immunology Today 12: 57-60; Rook et al., supra).
An analogous use of 11.beta.HSD1 inhibition, in this case temporal, would be to booster the immune response in association with immunization to ensure that a cell based response would be obtained, when desired.
6. Reduction of Intraocular Pressure
Recent data suggest that the levels of the glucocorticoid target receptors and the 11.beta.HSD enzymes determines the susceptibility to glaucoma (Stokes, J. et al. (2000) Invest. Ophthalmol. 41: 1629-1638). Further, inhibition of 11.beta.HSD1 was recently presented as a novel approach to lower the intraocular pressure (Walker E. A. et al, poster P3-698 at the Endocrine Society meeting Jun. 12-15, 1999, San Diego). Ingestion of carbenoxolone, a non-specific inhibitor of 11.beta.HSD1, was shown to reduce the intraocular pressure by 20% in normal subjects. In the eye, expression of 11.beta.HSD1 is confined to basal cells of the corneal epithelium and the non-pigmented epithelialium of the cornea (the site of aqueous production), to ciliary muscle and to the sphincter and dilator muscles of the iris. In contrast, the distant isoenzyme 11.beta.HSD2 is highly expressed in the non-pigmented ciliary epithelium and corneal endothelium. None of the enzymes is found at the trabecular meshwork, the site of drainage. Thus, 11.beta.HSD1 is suggested to have a role in aqueous production, rather than drainage, but it is presently unknown if this is by interfering with activation of the glucocorticoid or the mineralocorticoid receptor, or both.
7. Reduced Osteoporosis
Glucocorticoids have an essential role in skeletal development and function but are detrimental in excess. Glucocorticoid-induced bone loss is derived, at least in part, via inhibition of bone formation, which includes suppression of osteoblast proliferation and collagen synthesis (Kim, C. H., Cheng, S. L. and Kim, G. S. (1999) J. Endocrinol. 162: 371-379). The negative effect on bone nodule formation could be blocked by the non-specific inhibitor carbenoxolone suggesting an important role of 11.beta.HSD1 in the glucocorticoid effect (Bellows, C. G., Ciaccia, A. and Heersche, J. N. M. (1998) Bone 23: 119-125). Other data suggest a role of 11.beta.HSD1 in providing sufficiently high levels of active glucocorticoid in osteoclasts, and thus in augmenting bone resorption (Cooper, M. S. et al. (2000) Bone 27: 375-381). Taken together, these different data suggest that inhibition of 11.beta.HSD1 may have beneficial effects against osteoporosis by more than one mechanism working in parallel.
8. Reduction of Hypertension
Bile acids inhibit 11.beta.-hydroxysteroid dehydrogenase type 2. This results in a shift in the overall body balance in favour of cortisol over cortisone, as shown by studying the ratio of the urinary metabolites (Quattropani, C., Vogt, B., Odermatt, A., Dick, B., Frey, B. M., Frey, F. J. (2001) J Clin Invest. November; 108(9):1299-305. “Reduced activity of 11beta-hydroxysteroid dehydrogenase in patients with cholestasis”.). Reducing the activity of 11bHSD1 in the liver by a selective inhibitor is predicted to reverse this imbalance, and acutely counter the symptoms such as hypertension, while awaiting surgical treatment removing the biliary obstruction.
WO 99/65884 discloses carbon substituted aminothiazole inhibitors of cyclin dependent kinases. These compounds may, e.g., be used against cancer, inflammation and arthritis. U.S. Pat. No. 5,856,347 discloses an antibacterial preparation or bactericide comprising 2-aminothiazole derivative and/or salt thereof. Further, U.S. Pat. No. 5,403,857 discloses benzenesulfonamide derivatives having 5-lipoxygenase inhibitory activity. Additionally, tetrahydrothiazolo[5,4-c]pyridines are disclosed in: Analgesic tetrahydrothiazolo[5,4-c]pyridines. Fr. Addn. (1969), 18 pp, Addn. to Fr. 1498465. CODEN: FAXXA3; FR 94123 19690704 CAN 72:100685 AN 1970:100685 CAPLUS and 4,5,6,7-Tetrahydrothiazolo[5,4-c]pyridines. Neth. Appl. (1967), 39 pp. CODEN: NAXXAN NL 6610324 19670124 CAN 68:49593, AN 1968: 49593 CAPLUS. However, none of the above disclosures discloses processes of making the compounds according to the present invention.
9. Wound Healing
Cortisol performs a broad range of metabolic functions and other functions. The multitude of glucocorticoid action is exemplified in patients with prolonged increase in plasma glucocorticoids, so called “Cushing's syndrome.” Patients with Cushing's syndrome have prolonged increase in plasma glucocorticoids and exhibit impaired glucose tolerance, type 2 diabetes, central obesity, and osteoporosis. These patients also have impaired wound healing and brittle skin (Ganong, W. F. Review of Medical Physiology. Eighteenth edition ed. Stamford, Conn.: Appleton & Lange; 1997).
Glucocorticoids have been shown to increase risk of infection and delay healing of open wounds (Anstead, G. M. Steroids, retinoids, and wound healing. Adv Wound Care 1998; 11(6):277-85). Patients treated with glucocorticoids have 2-5-fold increased risk of complications when undergoing surgery (Diethelm, A. G. Surgical management of complications of steroid therapy. Ann Surg 1977; 185(3):251-63).
The European patent application No. EP 0902288 discloses a method for diagnosing the status of wound healing in a patient, comprising detecting cortisol levels in said wound. The authors suggest that elevated levels of cortisol in wound fluid, relative to normal plasma levels in healthy individuals, correlates with large, non-healing wounds (Hutchinson, T. C., Swaniker, H. P., Wound diagnosis by quantitating cortisol in wound fluids. European patent application No. EP 0 902 288, published Mar. 17, 1999).
In humans, the 11.beta.-HSD catalyzes the conversion of cortisol to cortisone, and vice versa. The parallel function of 11.beta.-HSD in rodents is the interconversion of corticosterone and 11-dehydrocorticosterone (Frey, F. J., Escher, G., Frey, B. M. Pharmacology of 11 beta-hydroxysteroid dehydrogenase. Steroids 1994; 59(2):74-9). Two isoenzymes of 11.beta.-HSD, 11.beta.-HSD1 and 11.beta.-HSD2, have been characterized, and differ from each other in function and tissue distribution (Albiston, A. L., Obeyesekere, V. R., Smith, R. E., Krozowski, Z. S. Cloning and tissue distribution of the human 11 beta-hydroxysteroid dehydrogenase type 2 enzyme. Mol Cell Endocrinol 1994; 105(2):R11-7). Like GR, 11.beta.-HSD1 is expressed in numerous tissues like liver, adipose tissue, adrenal cortex, gonads, lung, pituitary, brain, eye etc (Monder C, White P C. 11 beta-hydroxysteroid dehydrogenase. Vitam Horm 1993; 47:187-271; Stewart, P. M., Krozowski, Z. S. 11 beta-Hydroxysteroid dehydrogenase. Vitam Horm 1999; 57:249-324; Stokes, J., Noble, J., Brett, L., Phillips, C., Seckl, J. R., O'Brien, C., et al. Distribution of glucocorticoid and mineralocorticoid receptors and 11beta-hydroxysteroid dehydrogenases in human and rat ocular tissues. Invest Ophthalmol Vis Sci 2000; 41(7):1629-38). The function of 11.beta.-HSD1 is to fine-tune local glucocorticoid action. 11.beta.-HSD activity has been shown in the skin of humans and rodents, in human fibroblasts and in rat skin pouch tissue (Hammami, M. M., Siiteri, P. K. Regulation of 11 beta-hydroxysteroid dehydrogenase activity in human skin fibroblasts: enzymatic modulation of glucocorticoid action. J Clin Endocrinol Metab 1991; 73(2):326-34); Cooper, M. S., Moore, J., Filer, A., Buckley, C. D., Hewison, M., Stewart, P. M. 11beta-hydroxysteroid dehydrogenase in human fibroblasts: expression and regulation depends on tissue of origin. ENDO 2003 Abstracts 2003; Teelucksingh, S., Mackie, A. D., Burt, D., McIntyre, M. A., Brett, L., Edwards, C. R. Potentiation of hydrocortisone activity in skin by glycyrrhetinic acid. Lancet 1990; 335(8697):1060-3; Slight, S. H., Chilakamarri, V. K., Nasr, S., Dhalla, A. K., Ramires, F. J., Sun, Y., et al. Inhibition of tissue repair by spironolactone: role of mineralocorticoids in fibrous tissue formation. Mol Cell Biochem 1998; 189(1-2):47-54).
Wound healing consists of serial events including inflammation, fibroblast proliferation, secretion of ground substances, collagen production, angiogenesis, wound contraction and epithelialization. It can be divided in three phases; inflammatory, proliferative and remodeling phase (reviewed in Anstead et al., supra).
In surgical patients, treatment with glucocorticoids increases risk of wound infection and delay healing of open wounds. It has been shown in animal models that restraint stress slows down cutaneous wound healing and increases susceptibility to bacterial infection during wound healing. These effects were reversed by treatment with the glucocorticoid receptor antagonist RU486 (Mercado, A. M., Quan, N., Padgett, D. A., Sheridan, J. F., Marucha, P. T. Restraint stress alters the expression of interleukin-1 and keratinocyte growth factor at the wound site: an in situ hybridization study. J Neuroimmunol 2002; 129(1-2):74-83; Rojas, I. G., Padgett, D. A., Sheridan, J. F., Marucha, P. T. Stress-induced susceptibility to bacterial infection during cutaneous wound healing. Brain Behav Immun 2002; 16(1):74-84). Glucocorticoids produce these effects by suppressing inflammation, decrease wound strength, inhibit wound contracture and delay epithelialization (Anstead et al., supra). Glucocorticoids influence wound healing by interfering with production or action of cytokines and growth factors like IGF, TGF-.beta., EGF, KGF and PDGF (Beer, H. D., Fassler, R., Werner, S. Glucocorticoid-regulated gene expression during cutaneous wound repair. Vitam Horm 2000; 59:217-39; Hamon, G. A., Hunt, T. K., Spencer, E. M. In vivo effects of systemic insulin-like growth factor-I alone and complexed with insulin-like growth factor binding protein-3 on corticosteroid suppressed wounds. Growth Regul 1993; 3(1):53-6; Laato, M., Heino, J., Kahari, V. M., Niinikoski, J., Gerdin, B. Epidermal growth factor (EGF) prevents methylprednisolone-induced inhibition of wound healing. J Surg Res 1989; 47(4):354-9; Pierce, G. F., Mustoe, T. A., Lingelbach, J., Masakowski, V. R., Gramates, P., Deuel, T. F. Transforming growth factor beta reverses the glucocorticoid-induced wound-healing deficit in rats: possible regulation in macrophages by platelet-derived growth factor. Proc Natl Acad Sci USA 1989; 86(7):2229-33). It has also been shown that glucocorticoids decrease collagen synthesis in rat and mouse skin in vivo and in rat and human fibroblasts (Oishi, Y., Fu, Z. W., Ohnuki, Y., Kato, H., Noguchi, T. Molecular basis of the alteration in skin collagen metabolism in response to in vivo dexamethasone treatment: effects on the synthesis of collagen type I and III, collagenase, and tissue inhibitors of metalloproteinases. Br J Dermatol 2002; 147(5):859-68).
U.S. Patent Application Publication No. 2006/0142357 and WO 2005/116002 describe 11-β-HSD1 inhibitors of the following general structure and certain processes for making the same:
It is evident that this type of 11-β-HSD1 inhibitors is of great importance from a medicinal point of view. There is, therefore, a need for an efficient process to synthesize these compounds, particularly the optical isomers thereof in high purity, for large scale preparation suitable for commercial production.
SUMMARY OF THE INVENTION
The present invention provides in one embodiment a process for the preparation of compounds having formula I, or a tautomer, stereoisomer, geometric isomer, optical isomer, hydrate, solvate, prodrug, or pharmaceutically acceptable salt thereof:
Variable Z is S or O.
R 1 is selected from C 1-8 alkyl, C 2-8 alkenyl, C 3-10 -cycloalkyl, C 3-10 -cycloalkenyl, C 3-10 -cycloalkyl-C 1-8 -alkyl, C 3-10 -cycloalkenyl-C 1-8 -alkyl, aryl, aryl-C 1-8 -alkyl, heterocyclyl, heterocyclyl-C 1-8 -alkyl and haloalkyl. In the definition of R 1 , any aryl, cycloalkyl, or heterocyclyl residue is optionally independently substituted by one or more C 1-8 -alkyl, aryl, halogen, halo-C 1 -C 8 -alkyl, HO—C 1 -C 8 -alkyl, R 4 R 5 N—C 1 -C 8 -alkyl, C 1 -C 8 -alkyl-OR 6 , —OR 6 , (C 3 -C 10 )-cycloalkyl or C 1 -C 8 -alkyl-sulfonyl.
R 2 and R 3 are independently selected from C 1-8 -alkyl, C 1-8 -alkoxy, C 3-10 -cycloalkyl, heterocyclyl, C 3-10 -cycloalkyl-C 1-8 -alkyl, CN—C 1-8 -alkyl, aryl, aryl-C 1-8 -alkyl, heterocyclyl-C 1-8 -alkyl and haloalkyl. In the definitions for R 2 and R 3 , any aryl, cycloalkyl, or heterocyclyl residue is optionally independently substituted by one or more C 1-8 -alkyl, aryl, halogen, halo-C 1 -C 8 -alkyl, HO—C 1 -C 8 -alkyl, R 4 R 5 N—C 1 -C 8 -alkyl, C 1 -C 8 -alkyl-OR 6 , —OR 6 , (C 3 -C 10 )-cycloalkyl or C 1 -C 8 -alkyl-sulfonyl.
Wand R 5 are each independently selected from hydrogen, C 1 -C 8 alkyl, C 1 -C 8 alkoxy, —NR 6 R 6 , —S—(C 1 -C 8 )alkyl, aryl and heterocyclyl. In the definitions for R 4 and R 5 , any alkyl, alkoxy, heterocyclyl or aryl may be substituted with one to three substituents selected from -halo, unsubstituted C 1 -C 8 alkyl, unsubstituted C 1 -C 8 alkoxy, unsubstituted C 1 -C 8 thioalkoxy and unsubstituted aryl(C 1 -C 4 )alkyl.
R 6 is independently selected from hydrogen, C 1 -C 8 alkyl, aryl-C 1 -C 8 alkyl, C 1 -C 8 alkoxy, —S—(C 1 -C 8 )alkyl, heterocyclyl and aryl. In the definition for R 6 , any alkyl, heterocyclyl or aryl may be substituted with one to three substituents selected from -halo, unsubstituted C 1 -C 8 alkyl, unsubstituted C 1 -C 8 alkoxy, unsubstituted C 1 -C 8 thioalkoxy and unsubstituted aryl(C 1 -C 4 )alkyl.
The process comprises the following steps:
(a) contacting a compound of formula II with (i) a chiral base in the presence of an amine, and an alkylating agent R 3 -LG; wherein LG is a leaving group;
(b) contacting the product of (a) with an acid HB to form a salt of formula I′ wherein B is an organic or inorganic anion; and
(c) reacting the salt of formula I′ with a base to yield the compound of formula I.
In another embodiment, the invention provides another process for the preparation of a compound having formula I, or a tautomer, stereoisomer, geometric isomer, optical isomer, hydrate, solvate, prodrug, or pharmaceutically acceptable salt thereof:
The process comprises contacting a compound of formula II
with a chiral base in the presence of a deprotonating reagent and alkylating agent R 3 -LG. Z is S or O.
R 1 is selected from C 1-8 alkyl, C 2-8 alkenyl, C 3-10 -cycloalkyl, C 3-10 -cycloalkenyl, C 3-10 -cycloalkyl-C 1-8 -alkyl, C 3-10 -cycloalkenyl-C 1-8 -alkyl, aryl, aryl-C 1-8 -alkyl, heterocyclyl, heterocyclyl-C 1-8 -alkyl and haloalkyl; wherein any aryl, cycloalkyl, or heterocyclyl residue is optionally independently substituted by one or more C 1-8 -alkyl, aryl, halogen, halo-C 1 -C 8 -alkyl, HO—C 1 -C 8 -alkyl, R 4 R 5 N—C 1 -C 8 -alkyl, C 1 -C 8 -alkyl-OR 6 , —OR 6 , (C 3 -C 10 )-cycloalkyl or C 1 -C 8 -alkyl-sulfonyl.
R 2 and R 3 are independently selected from C 1-8 -alkyl, C 1-8 -alkoxy, C 3-10 -cycloalkyl, heterocyclyl, C 3-10 -cycloalkyl-C 1-8 -alkyl, CN—C 1-8 -alkyl, aryl, aryl-C 1-8 -alkyl, heterocyclyl-C 1-8 -alkyl and haloalkyl; wherein any aryl, cycloalkyl, or heterocyclyl residue is optionally independently substituted by one or more C 1-8 -alkyl, aryl, halogen, halo-C 1 -C 8 -alkyl, HO—C 1 -C 8 -alkyl, R 4 R 5 N—C 1 -C 8 -alkyl, C 1 -C 8 -alkyl-OR 6 , —OR 6 , (C 3 -C 10 )-cycloalkyl or C 1 -C 8 -alkyl-sulfonyl.
R 4 and R 5 are each independently selected from hydrogen, C 1 -C 8 alkyl, C 1 -C 8 alkoxy, —NR 6 R 6 , —S—(C 1 -C 8 )alkyl, aryl and heterocyclyl; where in the definition of R 4 and R 5 any alkyl, alkoxy, heterocyclyl or aryl may be substituted with one to three substituents selected from -halo, unsubstituted C 1 -C 8 alkyl, unsubstituted C 1 -C 8 alkoxy, unsubstituted C 1 -C 8 thioalkoxy and unsubstituted aryl(C 1 -C 4 )alkyl.
R 6 is independently selected from hydrogen, C 1 -C 8 alkyl, aryl-C 1 -C 8 alkyl, C 1 -C 8 alkoxy, —S—(C 1 -C 8 )alkyl, heterocyclyl and aryl; where in the definition of R 6 any alkyl, heterocyclyl or aryl may be substituted with one to three substituents selected from -halo, unsubstituted C 1 -C 8 alkyl, unsubstituted C 1 -C 8 alkoxy, unsubstituted C 1 -C 8 thioalkoxy and unsubstituted aryl(C 1 -C 4 )alkyl.
LG is a leaving group.
Another embodiment of the invention is a process for preparing a compound of formula III:
In one embodiment, the process comprises the following steps:
(a) contacting a compound of formula IV
with a chiral base of the formula
in the presence of N,N,N′,N′-tetrarnethylethylenediamine (TMEDA), and
(b) reacting the product of step (a) with isopropyl iodide.
In one embodiment, the process further comprises the following steps:
(c) contacting the product of step (b) with MeSO 3 H to form a mesylate salt, and
(d) reacting the mesylate salt from step (c) with NaOH to yield the compound of formula III.
In still another embodiment, the process further comprises the step of isolating the mesylate salt after step (c) and before step (d).
Another embodiment of the invention is a process for the preparation of a compound according to formula V:
The process comprises
(a) contacting a compound of formula (VI)
with a chiral base of the formula
in the presence of TMEDA; and
(b) reacting the product of step (a) with n-propyl iodide.
DETAILED DESCRIPTION
The various terms used, separately and in combinations, in the processes herein described are defined below.
The expression “comprising” means “including but not limited to.” Thus, other non-mentioned substances, additives, carriers, or steps may be present.
The term “aryl” in the present description is intended to include aromatic rings (monocyclic or bicyclic) having from 6 to 10 ring carbon atoms, such as phenyl (Ph), naphthyl, and indanyl (i. e., 2,3-dihydroindenyl). An aryl group may be substituted by C 1-6 -alkyl. Examples of substituted aryl groups are benzyl, and 2-methylphenyl.
The term “heteroaryl” is a monocyclic, bi- or tricyclic aromatic ring system (only one ring need to be aromatic) having from 5 to 14 ring atoms (mono- or bicyclic), in which one or more of the ring atoms are other than carbon, such as nitrogen, sulfur, oxygen and selenium as part of the ring system. In some embodiments, the ring has from 5 to 10 ring atoms such as 5, 6, 7, 8, 9 or 10. Examples of such heteroaryl rings are pyrrole, imidazole, thiophene, furan, thiazole, isothiazole, thiadiazole, oxazole, isoxazole, oxadiazole, pyridine, pyrazine, pyrimidine, pyridazine, pyrazole, triazole, tetrazole, chroman, isochroman, quinoline, quinoxaline, isoquinoline, phthalazine, cinnoline, quinazoline, indole, isoindole, benzothiophene, benzofuran, isobenzofuran, benzoxazole, 2,1,3-benzoxadiazole, benzopyrazole; benzothiazole, 2,1,3-benzothiazole, 2,1,3-benzoselenadiazole, benzimidazole, indazole, benzodioxane, indane, 1,5-naphthyridine, 1,8-naphthyridine, acridine, fenazine and xanthene.
The term “heterocyclic” and “heterocyclyl” relates to unsaturated as well as partially and fully saturated mono-, bi- and tricyclic rings having from 4 to 14 ring atoms having one or more heteroatoms (e.g., oxygen, sulfur, or nitrogen) as part of the ring system and the reminder being carbon, such as, for example, the heteroaryl groups mentioned above as well as the corresponding partially saturated or fully saturated heterocyclic rings. Exemplary saturated heterocyclic rings are azetidine, pyrrolidine, piperidine, piperazine, morpholine, thiomorpholine, 1,4-oxazepane, azepane, phthalimide, indoline, isoindoline, 1,2,3,4-tetrahydroquinoline, 1,2,3,4-tetrahydroisoquinoline, 3,4-dihydro-2H-1,4-benzoxazine, hexahydroazepine, 3,4-dihydro-2(1H)isoquinoline, 2,3-dihydro-1H-indole, 1,3-dihydro-2H-isoindole, azocane, 1-oxa-4-azaspiro[4.5]dec-4-ene, decahydroisoquinoline, and 1,4-diazepane. In addition, the heterocyclyl or heterocyclic moiety may optionally be substituted with one or more oxo groups.
C 1-8 -alkyl is a straight or branched alkyl group containing 1-8 carbon atoms. Exemplary alkyl groups include methyl, ethyl, n-propyl, isopropyl, n-butyl, sec-butyl, tert-butyl, pentyl, isopentyl, hexyl, isohexyl, n-heptyl, and n-octyl. For parts of the range “C 1-8 -alkyl” all subgroups thereof are contemplated such as C 1-7 -alkyl, C 1-6 -alkyl, C 1-5 -alkyl, C 1-4 -alkyl, C 2-8 -alkyl, C 2-7 -alkyl, C 2-6 -alkyl, C 2-5 -alkyl, C 3-7 -alkyl, C 4-6 -alkyl, etc.
C 1-8 -alkoxy is a straight or branched alkoxy group containing 1-8 carbon atoms. Exemplary alkoxy groups include methoxy, ethoxy, propoxy, isopropoxy, butoxy, sec-butoxy, tert-butoxy, pentyloxy, isopentyloxy, hexyloxy, isohexyloxy, n-heptyloxy, and n-octyloxy. For parts of the range “C 1-6 -alkoxy” all subgroups thereof are contemplated such as C 1-7 -alkoxy, C 1-6 -alkoxy, C 1-5 -alkoxy, C 1-4 -alkoxy, C 2-8 -alkoxy, C 2-7 -alkoxy, C 2-6 -alkoxy, C 2-5 -alkoxy, C 3-7 -alkoxy, C 4-6 -alkoxy, etc.
C 2-8 -alkenyl is a straight or branched alkenyl group containing 2-8 carbon atoms. Exemplary alkenyl groups include vinyl, 1-propenyl, 2-propenyl, isopropenyl, 1-butenyl, 2-butenyl, 1-pentenyl, 2-pentenyl, 1-hexenyl, 2-hexenyl, 1-heptenyl, and 1-octenyl. For parts of the range “C 2-8 -alkenyl” all subgroups thereof are contemplated such as C 2-7 -alkenyl, C 2-6 -alkenyl, C 2-5 -alkenyl, C 2-4 -alkenyl, C 3-8 -alkenyl, C 3-7 -alkenyl, C 3-6 -alkenyl, C 3-5 -alkenyl, C 4-7 -alkenyl, C 5-6 -alkenyl, etc.
C 3-10 -cycloalkyl is an optionally substituted monocyclic, bicyclic or tricyclic alkyl group containing between 3-10 carbon atoms. Exemplary cycloalkyl groups include cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl, cyclooctyl, cyclononyl, cyclodecyl, bicyclo[2.2.1]hept-2-yl, tricyclo[3.3.1.0˜3,7˜]non-3-yl, (1R,2R,3R,5S)-2,6,6-trimethylbicyclo[3.1.1]hept-3-yl, (1S,2S,3S,5R)-2,6,6-trimethylbicyclo[3.1.1]hept-3-yl, 1-adamantyl, noradamantyl, and 2,2,3,3-tetramethylcyclopropyl. For parts of the range “C 3-10 -cycloalkyl” all subgroups thereof are contemplated such as C 3-9 -cycloalkyl, C 3-8 -cycloalkyl, C 3-7 -cycloalkyl, C 3-6 -cycloalkyl, C 3-5 -cycloalkyl, C 4-10 cycloalkyl, C 5-10 -cycloalkyl, C 6-10 -cycloalkyl, C 7-10 -cycloalkyl, C 8-9 -cycloalkyl, etc. In addition, the cycloalkyl moiety can be substituted with one or more oxo groups.
C 3-10 -cycloalkenyl is an optionally alkyl substituted cyclic, bicyclic or tricyclic alkenyl group containing totally 3-10 carbon atoms. Exemplary cycloalkenyl groups include cyclopropenyl, cyclobutenyl, cyclopentenyl, cyclohexenyl, cycloheptenyl, cyclooctenyl, cyclononenyl, cyclodecenyl, and bicyclo[2.2.1]hept-5-en-2-yl. For parts of the range “C 3-10 -cycloalkenyl” all subgroups thereof are contemplated such as C 3-9 -cycloalkenyl, C 3-8 -cycloalkenyl, C 3-7 -cycloalkenyl, C 3-6 -cycloalkenyl, C 3-5 -cycloalkenyl, C 4-10 -cycloalkenyl, C 5-10 -cycloalkenyl, C 6-10 -cycloalkenyl, C 7-10 -cycloalkenyl, C 8-9 -cycloalkenyl, etc. In addition, the cycloalkenyl moiety may optionally be substituted with one or more oxo groups.
The terms “halogen” and “halo” in the present description is intended to include fluorine, chlorine, bromine and iodine.
The term “-hetero(C 1 -C 8 )alkyl” refers to a moiety wherein a hetero atom, selected from optionally substituted nitrogen, sulfur and oxygen, is the point of attachment to the core molecule and is attached to a C 1 -C 8 alkyl chain.
Combinations of substituents and variables envisioned by this invention are only those that result in the formation of stable compounds. The term “stable”, as used herein, refers to compounds which possess stability sufficient to allow manufacture and which maintains the integrity of the compound for a sufficient period of time to be useful for the purposes detailed herein (e.g., therapeutic administration to a subject for the treatment of disease, 11-.beta.-HSD1 inhibition, 11-.beta.-HSD1-mediated disease).
As used herein, the term “prodrug” means a derivative of a compound that can hydrolyze, oxidize, or otherwise react under biological conditions (in vitro or in vivo) to provide an active compound Examples of prodrugs include, but are not limited to, derivatives and metabolites of a compound derivative that include biohydrolyzable groups such as biohydrolyzable amides, biohydrolyzable esters, biohydrolyzable carbamates, biohydrolyzable carbonates, biohydrolyzable ureides, and biohydrolyzable phosphate analogues (e.g., monophosphate, diphosphate or triphosphate). Preferably, prodrugs of compounds with carboxyl functional groups are the lower alkyl esters of the carboxylic acid. The carboxylate esters are conveniently formed by esterifying any of the carboxylic acid moieties present on the molecule. Prodrugs can typically be prepared using well-known methods, such as those described by Burger's Medicinal Chemistry and Drug Discovery 6 th ed. (Donald J. Abraham ed., 2001, Wiley) and Design and Application of Prodrugs (H. Bundgaard ed., 1985, Harwood Academic Publishers Gmfh).
A “tautomer” is one of two or more structural isomers that exist in equilibrium and is readily converted from one isomeric form to another. In the present case, tautomers of the structures below are encompassed by the present invention.
As used herein, “hydrate” is a form of a compound wherein water molecules are combined in a certain ratio as an integral part of the crystal structure of the compound.
As used herein, “solvate” is a form of a compound where solvent molecules are combined in a certain ratio as an integral part of the crystal structure of the compound.
As used herein, the term “geometrical isomers” refers compounds that have the same molecular formula but the atoms are in different non-equivalent positions relative to one another.
As used herein, the term “optical isomers” refers to compounds with chiral atoms which have the ability to rotate plane polarized light, and are typically designated using the conventional R/S configuration. The term “optical isomer” includes enantiomers and diastereomers as well as compounds which can be distinguished one from the other by the designations of (D) and (L).
“Pharmaceutically acceptable” means in the present description being useful in preparing a pharmaceutical composition that is generally safe, non-toxic and neither biologically nor otherwise undesirable and includes being useful for veterinary use as well as human pharmaceutical use.
“Pharmaceutically acceptable salts” mean salts which are pharmaceutically acceptable, as defined above, and which possess the desired pharmacological activity. Such salts include acid addition salts formed with organic and inorganic acids, such as hydrogen chloride, hydrogen bromide, hydrogen iodide, sulfuric acid, phosphoric acid, acetic acid, glycolic acid, maleic acid, malonic acid, oxalic acid, methanesulfonic acid, trifluoroacetic acid, fumaric acid, succinic acid, tartaric acid, citric acid, benzoic acid, ascorbic acid and the like. Base addition salts may be formed with organic and inorganic bases, such as sodium, ammonia, potassium, calcium, ethanolamine, diethanolamine, N-methylglucamine, choline and the like. Included in the invention are pharmaceutically acceptable salts or compounds of any of the formulae herein.
Depending on its structure, the phrase “pharmaceutically acceptable salt,” as used herein, refers to a pharmaceutically acceptable organic or inorganic acid or base salt of a compound. Representative pharmaceutically acceptable salts include, e.g., alkali metal salts, alkali earth salts, ammonium salts, water-soluble and water-insoluble salts, such as the acetate, amsonate (4,4-diaminostilbene-2,2-disulfonate), benzenesulfonate, benzonate, bicarbonate, bisulfate, bitartrate, borate, bromide, butyrate, calcium, calcium edetate, camsylate, carbonate, chloride, citrate, clavulariate, dihydrochloride, edetate, edisylate, estolate, esylate, fiunarate, gluceptate, gluconate, glutamate, glycollylarsanilate, hexafluorophosphate, hexylresorcinate, hydrabamine, hydrobromide, hydrochloride, hydroxynaphthoate, iodide, isothionate, lactate, lactobionate, laurate, malate, maleate, mandelate, mesylate, methylbromide, methylnitrate, methylsulfate, mucate, napsylate, nitrate, N-methylglucamine ammonium salt, 3-hydroxy-2-naphthoate, oleate, oxalate, palmitate, pamoate (1,1-methene-bis-2-hydroxy-3-naphthoate, einbonate), pantothenate, phosphate/diphosphate, picrate, polygalacturonate, propionate, p-toluenesulfonate, salicylate, stearate, subacetate, succinate, sulfate, sulfosaliculate, suramate, tannate, tartrate, teoclate, tosylate, triethiodide, and valerate salts. Furthermore, a pharmaceutically acceptable salt can have more than one charged atom in its structure. In this instance the pharmaceutically acceptable salt can have multiple counterions. Hence, a pharmaceutically acceptable salt can have one or more charged atoms and/or one or more counterions.
The following abbreviations are used throughout the description and appended claims, and they have the following meanings:
“TMEDA” means N,N,N′N′-tetramethylethylenediamine.
“TMPDA” means N,N,N′N′-tetramethylpropylenediamine.
“TMBDA” means N,N,N′N′-tetramethylbutylenediamine.
“Ar” means aryl.
“Ph” means phenyl.
“de” means diastereomeric excess.
“MTBE” means methyl tertiary-butyl ether.
“IPA” means isopropyl alcohol.
“DCM” means dichloromethane.
“MSA” means methane sulfonic acid (MeSO 3 H).
“Tint” means the internal temperature of the reaction mixture.
“LCAP” means Peak Area % by HPLC
“TGA” means Thermogravimetric Analysis
The chemicals used in the synthetic routes delineated herein include, for example, solvents, reagents, and catalysts. The methods described above may also additionally include steps, either before or after the steps described specifically herein, to add or remove suitable protecting groups in order to ultimately allow synthesis of the compounds. In addition, various synthetic steps may be performed in an alternate sequence or order to give the desired compounds. Synthetic chemistry transformations and protecting group methodologies (protection and deprotection) useful in synthesizing applicable compounds are known in the art and include, for example, those described in R. Larock, Comprehensive Organic Transformations, VCH Publishers (1989); T. W. Greene and P. G. M. Wuts, Protective Groups in Organic Synthesis, 3 rd Ed., John Wiley and Sons (1999); L. Fieser and M. Fieser, Fieser and Fieser's Reagents for Organic Synthesis, John Wiley and Sons (1994); and L. Paquette, ed., Encyclopedia of Reagents for Organic Synthesis, John Wiley and Sons (1995) and subsequent editions thereof.
Some embodiments of the present invention contemplate processes of making a compound of the general formula I, as described above, via asymmetric alkylation of a compound of formula II:
The compound of formula (II) is prepared by the following general synthetic method:
If the appropriate urea, thiourea, or alpha-bromocarboxylic acid or ester is not commercially available, the appropriate starting material can be prepared in accordance with the methods described in U.S. Patent Application Publication No. 2006/0142357.
In one embodiment, Z is S, referring to thiazolinones. Variable Z also can be O, referring to oxazolinones.
In another embodiment, R 1 is selected from the group consisting of
An exemplary value for R 1 is:
In one embodiment, R 2 and R 3 are independently selected from methyl, isopropyl, and n-propyl.
In another embodiment, the chiral base is selected from the following group of bases:
In another embodiment, the chiral base is selected from
wherein:
X is selected from O, N, S, and C 1-8 -alkylene;
Y is selected from C 1-8 -alkyl, aryl, and heterocyclyl; and
M is selected from Li, Na, K, Cs, Cu, Zn, and Mg; and
Ar is aryl.
In another embodiment, the chiral base is
In some embodiments, the chiral base is selected from the group consisting of:
wherein M is as defined hereinabove.
In some embodiments, the chiral base is an ephedrine salt, i.e.:
wherein M is as defined hereinabove. Thus, in one embodiment, the chiral base is a salt of (1R,2S)-(−)-ephedrine:
In another embodiment, the chiral base is a salt of (1S,2R)-(−)-ephedrine:
An example of “M” in all of these embodiments is lithium ion.
In another embodiment, the leaving group LG in R 3 LG is selected from the group consisting of Cl, Br, I, —OS(O) 2 CH 3 , —OS(O) 2 C 4 F 9 , —OS(O) 2 CF 3 , and —OS(O) 2 (4-CH 3 -phenyl).
In another embodiment, the amine is selected from triethylamine, trimethylamine, triisopropyl amine, N,N,N′N′-tetramethylethylenediamine (TMEDA), N,N,N′N′-tetramethylpropylenediamine (TMPDA), and N,N,N′N′-tetramethylbutylenediamine (TMBDA). An exemplary amine in this regard is TMEDA.
In another embodiment, the solvent used in step (a) is selected from the group consisting of benzene, toluene, trifluorotoluene, xylene, chlorobenzene, dialkyl ethers, THF, dioxane, DMF, halogenated hydrocarbon solvents, ester solvents, and mixtures thereof. An exemplary solvent in this regard is toluene.
In one embodiment, the compound of Formula II is contacted with the chiral base first, followed by the alkylating agent R 3 -LG. In another embodiment, the compound of Formula II is contacted first with the alkylating agent R 3 -LG, followed by the chiral base.
In one embodiment, the acid in step (b) is selected from the consisting of HCl, H 2 SO 4 , CH 3 C(O)OH, CF 3 C(O)OH, MeSO 3 H, and C 6 H 5 SO 3 H.
In another embodiment, the acid in step (b) is MeSO 3 H.
In one embodiment, the base in step (c) is selected from the group consisting of LiOH, NaOH, KOH, and sodium acetate.
In another embodiment, the base in step (c) is NaOH.
In one embodiment, the diastereomeric excess (de) value of the product is at least 85%, 90%, 95%, or 98%.
In view of the foregoing considerations, and the specific examples below, those who are skilled in the art will appreciate that a given selection of chiral base, amine, solvent, acid, or base can determine the chirality of the end product, and/or the de thereof. Making such a selection is well within the ambit of the skilled artisan.
Another embodiment of the present invention is a process for the preparation of a compound of formula III
from a compound of formula IV
as described generally above.
In this embodiment, the process comprises the steps of (a) contacting compound IV with a chiral base of the following formula
in the presence of TMEDA, and then (b) reacting the product from step (a) with isopropyl iodide.
In one embodiment, the process further comprises the steps of (c) contacting the product of step (b) with MeSO 3 H to form a mesylate salt; and (d) reacting the mesylate salt from step (c) with NaOH to yield the compound of formula III.
In one embodiment, the product of step (b) is of de value at least 90%, 95%, or 98%.
In another embodiment, the product of step (d) is of de value at least 99%.
Still another embodiment of the invention is a further process for the preparation of a compound according to formula III:
In this embodiment, the process comprises (a) contacting a compound of formula (IV)
with a chiral base in the presence of a deprotonating reagent; and (b) reacting the product of step (a) with isopropyl iodide. The term “chiral base” as used hereinthroughout contemplates a chiral molecule that is a base. The term “chiral base” additionally contemplates a chiral base that results from deprotonation of a neutral or free base. Hence, a chiral base containing the ion “M” as defined hereinabove formally refers to a salt of the free base. A free base features —OH and —NH or —NH 2 groups, for instance, meaning chiral bases that are not deprotonated.
Illustrative examples of a chiral base include the following:
In some embodiments, the chiral base is
In the embodiment described above, the process can be carried out in the presence of a deprotonating agent. Many deprotonating agents are well-known to those who are skilled in the field of organic synthesis. For instance, deprotonating agents include but are not limited to metalorganics, such as alkyllithiums. Common examples of alkyllithiums are methyllithium, n-butyllithium, tert-butyllithium, and hexyllithium. Other deprotonating reagents include metal hydrides, such as, for instance, lithium hydride, sodium hydride, and potassium hydride.
The invention will now be described in reference to the following Examples. These examples are not to be regarded as limiting the scope of the present invention, but shall only serve in an illustrative manner.
EXAMPLES
Example 1
Preparation of (5S)-2-(bicyclo[2.2.1]heptan-2-ylamino)-5-methyl-5-propylthiazol-4(5H)-one (6)
Materials
MW
Amount
mMol
Eq
Other
5-Methylthiazolinone (1)
224.32
25.25
g
112.56
1
n/a
Chiral amine (2)
448.64
110.2
g
245.6
2
n/a
n-BuLi (3)
—
181
mL
488.7
4
2.7 M toluene
TMEDA (4)
116.21
37
mL
245.2
2
d = 0.775 g/mL
n-PrI (5)
169.99
88
mL
900.48
8
d = 1.742 g/mL
Toluene
—
160 + 375
mL
—
—
—
5-Methylthiazolinone (1) (25.25 g) was suspended in 500 mL of anhydrous toluene. The solvent of this slurry was distilled at 44° C. and 50 mbar reduced pressure to a total volume of 160 mL. To a jacketed 3 L reactor, equipped with a Julabo LH-50 process chiller, N 2 line, thermocouple, and overhead stirrer, was charged 110.2 g of chiral amine (2) solid. The reactor and contents were flushed with N 2 . Toluene (375 mL) was charged to the purged reactor via cannula, yielding a clear solution of chiral amine (2). This solution was cooled to −15° C. Butyllithium (3) (181 mL, 2.7 M in toluene) was transferred via cannula to a 250 mL addition funnel attached to the reactor. The butyllithium (3) was added dropwise over a period of 30 minutes, with the internal temperature (“Tint”) never rising above −9.0° C.
TMEDA (4) (37 mL) was charged to the reactor via syringe after Tint had been re-established at −15.5° C. After a 30 minute aging, the 160 mL slurry of 5-methylthiazolinone (1) in toluene was charged portion-wise via cannula, with the Tint never rising above −4.5° C. The Tint was then adjusted to 16° C. and the reaction was held for 1 hour. After this aging period, the Tint was readjusted to −15.5° C. N-propyl iodide (5) (88 mL) was charged via cannula over a period of 15 minutes, maintaining a Tint below −12° C. The Tint stabilized at −14.5° C. after completion of nPrI addition, and the mixture was stirred out for 16 hours.
After 16 hours, HPLC analysis indicated less than 5% residual starting material and a de of 34%. The reactor was equipped with a 250 mL addition funnel, to which was added 250 mL sat NH 4 Cl. A fast dropwise addition of NH 4 Cl was established and the saturated solution was added over a period of 1.5 hours, during which time the Tint never rose above −8.0° C. After completion of the quench, the reactor contents were warmed to 22° C., and the mixture was agitated. The stirring was then halted and the layers were allowed to separate for 5 minutes, after which the bottom aqueous component was drained off. A second 250 mL sat. NH 4 Cl quench was performed in the manner previously mentioned. The toluene layer was then acidified with 3×200 mL 2N AcOH and the extraction performed by agitation, phase separation, and draining of the bottom aqueous layer. A final extraction was performed with 200 mL of sat. NaHCO 3 . The toluene layer post workup was then polish filtered, yielding 800 mL of a clear solution.
The total volume of the 800 mL toluene solution was reduced to 100 mL by removing the toluene under reduced pressure (40° C., 60 mbar, rotary evaporator). This concentrated toluene solution was transferred to a 3 neck 1 L round bottom flask, followed by a 10 mL toluene wash. After heating the mixture to 60° C., heptane (400 mL) was added via a 1 L addition funnel over a period of 35 minutes. After completion of heptane addition the homogeneous solution was slowly cooled to 22° C. over 2 hours, resulting in a fine slurry. An additional 1 L of heptane was charged to the slurry, and the mixture was allowed to stir at 22° C. for 48 hours. After this time the slurry was filtered on a medium porosity 300 mL sinter funnel, washed with 50 mL of 0° C. heptane, and dried using house vacuum accompanied with an N 2 sweep for 16 hours. After this drying period the weight of the recovered solids was 20.3 g (67.7 yield), with an LCAP of >98% and a de=27%. 1 H NMR [(CD 3 ) 2 SO] δ: 9.00 (d, 1H), 3.75 (m, 1H), 2.24 (m, 1H), 2.20 (m, 1H), 1.68 (m, 3H), 1.47 (comp m, 8H), 1.12 (m, 4H), and 0.84 ppm (m, 3H).
Example 2
Preparation of (5S)-2-(bicyclo[2.2.1]hept-5-en-2-ylamino)-5-methyl-5-propylthiazol-4(5H)-one (8)
Materials
MW
Amount
mMol
Eq
Other
5-Methyl thiazolinone (7)
222.31
25.0
g
112.56
1
n/a
Chiral amine (2)
448.64
110.2
g
245.6
2
n/a
n-BuLi (3)
—
181
mL
488.7
4
2.7 M toluene
TMEDA (4)
116.21
37
mL
245.2
2
d = 0.775 g/mL
n-PrI (5)
169.99
88
mL
900.48
8
d = 1.742 g/mL
Toluene
—
160 + 375
mL
—
—
—
Procedure:
5-Methylthiazolinone (7) (25.0 g) was suspended in 480 mL of anhydrous toluene. The solvent of this slurry was distilled at 44° C. and 50 mbar reduced pressure to a total volume of 160 mL. To jacketed 3 L reactor, equipped with a Julabo LH-50 process chiller, N 2 line, thermocouple, and overhead stirrer, was charged 110.2 g of chiral amine (2) solid. The reactor and contents were flushed with N 2 . Toluene (375 mL) was charged to the purged reactor via cannula, yielding a clear solution of chiral amine (2). This solution was cooled to −15° C. Butyllithium (3)(181 mL, 2.7 M in toluene) was transferred via cannula to a 250 mL addition funnel attached to the reactor. The butyllithium was added dropwise over a period of 45 minutes, with the Tint never rising above −8.0° C. TMEDA (4) (37 mL) was charged to the reactor via syringe after the Tint had been re-established at −15.5° C. After a 20 minute aging, the 160 mL slurry of thiazalinone (7) in toluene was charged portion-wise via cannula, with the Tint never rising above −13° C. The Tint was then adjusted to 16° C. and the reaction was held for 30 minutes. After this aging period, the Tint was readjusted to −15.5° C. N-propyl iodide (5) (88 mL) was charged via cannula over a period of 20 minutes, maintaining a Tint below −12° C. The Tint stabilized at −14.5° C. after completion of nPrI addition, and was stirred out for 16 hours.
After 16 hours HPLC analysis indicated less than 1% residual starting material and a de of 41%. The reactor was equipped with a 250 mL addition funnel, to which was added 250 mL sat NH 4 Cl. A fast dropwise addition of NH 4 Cl was established and the saturated solution was added over a period of 1.5 hours, during which time the Tint never rose above −8.0° C. After completion of the quench, the reactor contents were warmed to 22° C., and the mixture was agitated. The stirring was then halted and the layers were allowed to separate for 5 minutes, after which the bottom aqueous component was drained off. A second 250 mL sat. NH 4 Cl quench was performed in the manner previously mentioned. The toluene layer was then acidified with 3×200 mL 2N AcOH and the extraction performed by agitation, phase separation, and draining of the bottom aqueous layer. A final extraction was performed with 200 mL of sat. NaHCO 3 . The toluene layer post workup was then polish filtered, yielding 775 mL of a clear solution.
The clear toluene solution was concentrated to 100 mL at 50 C and 60 mbar, after which anhydrous octane (400 mL) was charged to the flask. This mixture was concentrated at 60° C. and 80 mbar to ˜100 mL total volume, and was then diluted to 400 mL with octane. This solution was slowly cooled to 22° C., yielding a slurry that was stirred for 2 hours. The slurry was filtered on a medium porosity sinter funnel and dried under house vacuum overnight with an N 2 sweep, yielding 11.3 g of solids. The 350 mL of remaining mother liquor was concentrated down to 50 mL total volume (60° C., 70 mbar) and upon cooling to 22° C. a white solid rapidly crashed out. This solid was filtered in the same manner of the first batch, yielding 9.9 g of a white solid. Combination of both precipitates afforded 21.2 g (71.1% yield) of solids, 90% LCAP, de=43%. 1 H NMR [(CD 3 ) 2 SO] δ: 9.26 (d, 1H), 6.21 (m, 1H), 6.09 (m, 1H), 3.75 (m, 1H), 2.86 (m, 1H), 2.78 (d, 1H), 1.54 (comp m, 10H), 1.04 (m, 1H), and 0.86 ppm (m, 3H). Note: a minor isomer was also visible by 1 H NMR.
Example 3
Preparation of (S)-5-isopropyl-5-methyl-2-((S)-1-phenylethylamino)thiazol-4(5H)-one (11)
Materials
MW
Amount
mMol
Eq
Other
5-Methylthiazolinone (9)
233.31
26.3
g
112.56
1
96.9% de
Chiral amine (2)
448.64
110.2
g
245.6
2
n/a
n-BuLi (3)
—
181
mL
488.7
4
2.7 M toluene
TMEDA (4)
116.21
37
mL
245.2
2
d = 0.775 g/mL
i-PrI (10)
169.99
90
mL
900.48
8
d = 1.70 g/mL
Toluene
—
160 + 375
mL
—
—
—
Procedure:
5-Methylthiazolinone (9) (26.3 g) was suspended in 480 mL of anhydrous toluene. The solvent of this slurry was distilled at 44 C and 50 mbar reduced pressure to a total volume of 160 mL. To jacketed 3 L reactor, equipped with a Julabo LH-50 process chiller, N 2 line, thermocouple, and overhead stirrer, was charged 110.2 g of chiral amine (2) solid. The reactor and contents were flushed with N2. Toluene (375 mL) was charged to the purged reactor via cannula, yielding a clear solution of chiral amine (2). This solution was cooled to −15° C. Butyllithium (3) (181 mL, 2.7 M in toluene) was transferred via cannula to a 250 mL addition funnel attached to the reactor. The butyllithium was added dropwise over a period of 45 minutes, with the Tint never rising above −8.0° C. TMEDA (4) (37 mL) was charged to the reactor via syringe after the Tint had been re-established at −16.5° C. After a 20 minute aging, the 160 mL slurry of thiazalinone (9) in toluene was charged portionwise via cannula, with the Tint never rising above −13.° C. The Tint was then adjusted to 16° C. and the reaction was held for 30 minutes. After this aging period, the Tint was readjusted to −16.5° C. I-propyl iodide (10) (90 mL) was charged via cannula over a period of 20 minutes, maintaining a Tint below −14° C. The Tint stabilized at −14.5° C. after completion of iPrI addition, and was stirred out for 16 hours.
After 16 hours, HPLC analysis indicated less than 3% residual starting material and a de of 85.8%. The reactor was equipped with a 250 mL addition funnel, to which was added 250 mL sat NH 4 Cl. A fast dropwise addition of NH 4 Cl was established and the saturated solution was added over a period of 1.5 hours, during which time the Tint never rose above −7.0° C. After completion of the quench, the reactor contents were warmed to 22° C., and the mixture was agitated. The stirring was then halted and the layers were allowed to separate for 5 minutes, after which the bottom aqueous component was drained off. A second 250 mL sat. NH 4 Cl quench was performed in the manner previously mentioned. The toluene layer was then acidified with 3×200 mL 2N AcOH and the extraction performed by agitation, phase separation, and draining of the bottom aqueous layer. A final extraction was performed with 200 mL of sat. NaHCO 3 . The toluene layer post workup was then polish filtered, yielding 630 mL of a clear solution.
This toluene layer was concentrated under reduced pressure (50 C and 60 mbar) to a total volume of 90 mL. Octane (90 mL) was charged, and the murky mixture was concentrated to 50 mL total volume under the aforementioned conditions. This cycle of octane dilution to the mixture (90 mL each cycle) was performed until the ratio of octane to toluene was 4:1 by 1 H NMR. The mixture was heated to 65 C (clear solution), and slowly cooled to 35 C, at which point seed (50 mg) was suspended in the cloudy solution. The resulting slurry was cooled to 22° C. over a period of 2 hours and held 13 hours stirring under N2. Two additional 100 mL portions of octane were charged individually via an addition funnel, and after 2.5 hours of vigorous stirring the slurry was filtered. The solids were dried 16 hours with house vacuum under an N 2 sweep. A light brown solid was obtained (9.8 g, 54.1% yield), LCAP 99%, de of 89.1%. 1 H NMR [(CD 3 ) 2 SO] δ: 9.61 (d, 1H), 7.32 (comp m, 5H), 5.19 (m, 1H), 1.95 (m, 1H), 1.50-1.45 (comp m, 6H), 0.95-0.56 (comp m, 6H). Note: a minor isomer was also visible by 1 H NMR.
Example 4
Preparation of (S)-5-methyl-2-((S)-1-phenylethylamino)-5-propylthiazol-4(5H)-one (12)
Materials
MW
Amount
mMol
Eq
Other
5-Methylthiazolinone (9)
233.31
26.3
g
112.56
1
96.9% de
Chiral amine (2)
448.64
110.2
g
245.6
2
68628-85-2
n-BuLi (3)
—
181
mL
488.7
4
2.7 M toluene
TMEDA (4)
116.21
37
mL
245.2
2
d = 0.775 g/mL
n-PrI (5)
169.99
88
mL
900.48
8
d = 1.742 g/mL
Toluene
—
160 + 375
mL
—
—
—
Procedure:
5-Methylthiazolinone (9) (26.3 g) was suspended in 500 mL of anhydrous toluene. The solvent of this light slurry was distilled at 44 C and 50 mbar reduced pressure to a total volume of 160 mL. To jacketed 3 L reactor, equipped with a Julabo LH-50 process chiller, N 2 line, thermocouple, and overhead stirrer, was charged 110.2 g of chiral amine (2) solid. The reactor and contents were flushed with N 2 . Toluene (375 mL) was charged to the purged reactor via cannula, yielding a clear solution of chiral amine (2). This solution was cooled to −15° C. Butyllithium (3) (181 mL, 2.7 M in toluene) was transferred via cannula to a 250 mL addition funnel attached to the reactor. The butyllithium (3) was added dropwise over a period of 45 minutes, with the Tint never rising above −11.5 C. TMEDA (4) (37 mL) was charged to the reactor via syringe after the Tint had been re-established at −16.5 C. After a 10 minute aging, the 160 mL slurry of thiazalinone (9) in toluene was charged portionwise wise via cannula, with the Tint never rising above −8.5° C. The Tint was then adjusted to 16° C. and the reaction was held for 50 minutes. After this aging period, the Tint was readjusted to −17.0 C. N-propyl iodide (5) (88 mL) was charged via cannula over a period of 20 minutes, maintaining a Tint below −14 C. The Tint stabilized at −14.5° C. after completion of nPrI addition, and was stirred out for 16 hours.
After 16 hours, HPLC analysis indicated less than 0.5% residual starting material and a de of 61.2%. The reactor was equipped with a 250 mL addition funnel, to which was added 250 mL sat NH 4 Cl. A fast dropwise addition of NH 4 Cl was established and the saturated solution was added over a period of 1.5 hours, during which time the Tint never rose above −3.1° C. After completion of the quench, the reactor contents were warmed to 22° C., and the mixture was agitated. The stirring was then halted and the layers were allowed to separate for 5 minutes, after which the bottom aqueous component was drained off. A second 250 mL sat. NH 4 Cl quench was performed in the manner previously mentioned. The toluene layer was then acidified with 3×200 mL 2N AcOH and the extraction performed by agitation, phase separation, and draining of the bottom aqueous layer. A final extraction was performed with 200 mL of sat. NaHCO 3 . The toluene layer post workup was then polish filtered, yielding 750 mL of a clear solution.
This toluene layer was concentrated under reduced pressure (60° C. and 80 mbar) to a total volume of 90 mL. Octane (90 mL) was charged, and the murky mixture was concentrated to 60 mL total volume under the aforementioned conditions. This cycle of octane dilution to the mixture (90 mL each cycle) was performed until the ratio of octane to toluene was 2:1 by 1 H NMR. The toluene/octane solution (60 mL total volume) was heated to 70° C., achieving a clear solution. After achieving a Tint of 53° C., 50 mg of seed were charged. The slurry was cooled to 33° C. over a period of 20 minutes then reheated to 70° C. over 35 minutes. This mixture was then cooled to 43.5° C. over 2 hours, and octane (160 mL) was charged to the slurry in a fast dropwise addition over 30 minutes. The slurry was then cooled to 22° C. and held 16 hours stirring under N 2 . The slurry was filtered and dried under house vacuum with an N 2 sweep for 4 hours, yielding 12.5 g (64.8% yield) of light brown solids, 98% LCAP, de=85.7%. 1 H NMR [(CD 3 ) 2 SO] δ: 9.60 (d, 1H), 7.33 (comp m, 5H), 5.19 (m, 1H), 1.68 (m, 2H), 1.46-1.43 (comp m, 7H), 1.06 (m, 1H), 0.86 (comp m, 3H). Note: a minor isomer was also visible by 1 H NMR.
Example 5
Preparation of (5S)-2-(bicyclo[2.2.1]heptan-2-ylamino)-5-methyl-5-propylthiazol-4(5H)-one (6) of high diastereomeric excess
Materials
MW
Amount
mMol
Eq
Other
5-Me/nPr
266.4
20.3
g
76.0
1
n/a
Thiazalinone (6)
5-Me/nPr
362.51
10.6
g
29.2
1
n/a
Thiazalinone
MSA salt (13)
Methanesulfonic
96.11
5.2
mL
80.0
1.05
d = 1.481
Acid (14)
g/mL
IPA
—
100
mL
—
—
5X
DCM
—
100
mL
—
—
10X
NaOH aq
—
50
mL
50.0
1.75
1 M
Procedure:
To a 250 mL 1 neck round bottom flask was suspended 20.4 g of crude 5-Me/nPr thiazalinone (6) in 100 mL dry isopropanol at 22° C. To this slurry was added methanesulfonic acid (14) (5.2 mL, 1.05 eq), which upon complete addition fully dissolved the solids yielding a homogeneous solution. Heated over a period of 25 minutes to 50 C, held for 1 hour, then cooled to 22° C. and held 16 hours under N2. After this period the still homogeneous solution was transferred to a 500 mL 3 neck round bottom flask fitted with an overhead stirrer and a 500 mL addition funnel. Heptane (285 mL) was added portion wise, after which the 22° C. mixture was cooled in an ice bath. After 10 minutes (Tint=8.2 C) 100 mg of seed in a 12× slurry in heptane was added. The mixture was held for 16 hours and allowed to slowly warm to 22° C., resulting in a thick white slurry. This was filtered and dried (house vacuum/N 2 sweep) for 5 hours to yield 10.6 g of the MSA salt (13), 95.1% de, mother liquor de=−42.7%. 1 H NMR [(CD 3 ) 2 SO] δ: 1 H NMR [(CD 3 ) 2 SO] δ: 9.36 (d, 1H), 3.75 (m, 1H), 2.34 (s, 3H), 2.24 (m, 1H), 2.20 (m, 1H), 1.68 (m, 3H), 1.47 (comp m, 8H), 1.12 (m, 4H), and 0.84 ppm (m, 3H). Note: a minor isomer was also visible by 1 H NMR.
To a 250 Erlenmeyer flask was added 10.6 g of the 5-Me/nPr thiazalinone MSA salt (13). This solid was subsequently dissolved with 100 mL dry DCM, yielding a clear 10× solution. NaOH (1N, 50 mL) was charged to this solution and stirred vigorously for 20 minutes. After halting agitation the biphasic system was transferred to a 250 mL separatory funnel, and the upper aqueous layer was removed. Three water washes (75 mL each) were performed on the organic layer, the pH of the final water layer being 6.5-7.0. The DCM layer was polish filtered into a 250 mL round bottom flask (100 mL total), and concentrated down to 20 mL total volume (40° C., 60 mbar). Isopropanol (100 mL) was charged to this solution and the total volume was concentrated to 20 mL. An additional 20 mL of IPA was charged to the flask to obtain a 3.75× solution of the free base in IPA. Upon cooling this mixture from the evaporator bath temp of 40 C, a white solid precipitated. This was filtered and dried to yield 5.0 g of the product, 64.7% recovery, 99.4% LCAP and 95.9% de. 1 H NMR [(CD 3 ) 2 SO] δ: 9.00 (d, 1H), 3.75 (m, 1H), 2.24 (m, 1H), 2.10 (m, 1H), 1.68 (m, 3H), 1.47 (comp m, 8H), 1.12 (m, 4H), and 0.84 ppm (m, 3H).
Example 6
Preparation of (5S)-2-(bicyclo[2.2.1]hept-5-en-2-ylamino)-5-methyl-5-propylthiazol-4(5H)-one of high diastereomeric excess
Materials
MW
Amount
mMol
Eq
Other
5-Me/nPr
264.39
21.2
g
80.2
1
n/a
Thiazalinone (8)
5-Me/nPr
360.49
17.5
g
49.0
1
n/a
Thiazalinone
MSA salt (15)
Methanesulfonic
96.11
5.5
mL
84.2
1.05
d = 1.481
Acid (14)
g/mL
IPA
—
100
mL
—
—
5X
DCM
—
175
mL
—
—
10X
NaOH aq
—
88
mL
88.0
2.00
1 M
Procedure:
To a 250 mL 1 neck round bottom flask was suspended 20.4 g of crude 5-Me/nPr thiazalinone (8) in 100 mL dry isopropanol at 22° C. To this thick, pearl white slurry was added methanesulfonic acid (14) (5.5 mL, 1.05 eq), which upon complete addition fully dissolved the solids yielding a homogeneous solution. The mixture was heated over a period of 15 minutes to 50° C., held for 35 minutes, then cooled to 22° C. and held 16 hours under N 2 . After this period the still homogeneous solution was transferred to a 1 L 3 neck round bottom flask fitted with an overhead stirrer and a 500 mL addition funnel. Heptane (268 mL, 2× with respect 134 mL total IPA solution) was added portion wise over 15 minutes, after which the 22° C. mixture was cooled in an ice bath. After 50 minutes the mixture was warmed to 22° C., and the thick white slurry was aged for 16 hours. This was filtered and dried (house vacuum/N2 sweep) for 5 hours, affording 17.5 g of the MSA salt (15) 73.0% yield, 99.1% purity, 82.2% de. 1 H NMR [(CD 3 ) 2 SO] δ: 9.40 (d, 1H), 6.21 (m, 1H), 6.09 (m, 1H), 3.74 (m, 1H), 2.87 (m, 1H), 2.81 (m, 1H), 2.31 (s, 3H), 1.54 (comp m, 10H), 1.04 (m, 1H), and 0.86 ppm (m, 3H).
To a 500 Erlenmeyer flask was added 17.5 g of the 5-Me/nPr thiazalinone MSA salt (15). This solid was subsequently suspended in 175 mL of dry DCM to afford a slurry. Sodium hydroxide (1 M, 88 mL) was charged to the slurry and the biphasic mixture was stirred vigorously for 16 hours. After this period the biphasic mixture was transferred to a 1 L separatory funnel, allowing 5 minutes for phase separation. The basic aqueous layer was drained away from the organic phase, after which 3×130 mL H 2 O washes were performed on the DCM layer. The pH of the final aqueous was 7.0. The DCM layer was polished filtered and concentrated to 20 mL total volume. IPA (3.75×, 65 mL total) was charged and the entire mixture was concentrated to 20 mL total volume (40° C., 60 mbar). An additional 105 mL of IPA was charged and this solution was concentrated to 65 mL total volume (3.75×IPA). This mixture was then heated to 70° C., and then slowly cooled to 0 C. When the Tint was 66° C. water (52 mL) was charged portion-wise over a period of 5 minutes. When Tint=30.0 C a white slurry was achieved. This white slurry was stirred at 22° C. for 16 hours under N 2 . After this period the slurry was cooled at 0 C, filtered, and washed with 70 mL of 60:40 H 2 O:IPA solution. The solids were dried on a medium porosity frit for 4 hours under an N 2 sweep, affording 9.4 g (73% recovery) of a white solid, 89% LCAP, 93.1% de. 1 H NMR [(CD 3 ) 2 SO] δ: 9.26 (d, 1H), 6.21 (m, 1H), 6.09 (m, 1H), 3.75 (m, 1H), 2.86 (s, 1H), 2.80 (s, 1H), 1.54 (comp m, 10H), 1.04 (m, 1H), and 0.86 ppm (m, 3H). Note: a minor isomer was also visible by NMR.
Example 7
Preparation of (5S)-2-(bicyclo[2.2.1]heptan-2-ylamino)-5-isopropyl-5-methylthiazol-4(5H)-one (19) of high diastereomeric excess
Step 1:
A 20 L reactor was assembled as described in the “Equipment” section (above) and placed under a nitrogen sweep. (S)-exo-2-norbornylthiourea (16) (801.4 g) was charged to the reactor followed by 3.0 L of absolute ethanol. Agitation was initiated (142 RPM) and this was followed by addition of 2-bromopropionic acid (17) (509 mL) via graduated cylinder. The graduated cylinder was rinsed with 400 mL of absolute ethanol and the rinse was transferred to the reactor. Sodium acetate (965.7 g) was then charged and this was followed by a final charge of 1.4 L of absolute ethanol. The reaction mixture was heated to 80° C. and aged at this temperature for 3 hours, after which it was cooled to 22° C. Deionized water (13 L) was added and a small exotherm resulted. The mixture was allowed to return to 22° C. and aged for 12 h. The resulting suspension was filtered through a medium-porosity sintered glass funnel. NOTE: At this stage, crude material was combined during filtration with crude product from a parallel reaction with 234 g of thiourea. This was necessary due to the capacity limit of the 20 L reactor.
The solid remaining in the reactor was rinsed into the funnel with deionized water (2 L) and the filter cake was washed with 1 L of deionized water. The solid was air-dried on the filter for 3 hours, then transferred to drying trays and dried at 50° C. and 15 ton until TGA analysis indicated water content of less than 3.0%. The dry weight was recorded (1311 g) and the solid was transferred to a clean 20 L jacketed reactor. MTBE (5.9 L) was added and agitation was initiated (120 RPM). The slurry was heated to 50° C. and aged at this temperature for 2 h. The mixture was then cooled to 22° C. and filtered through a medium-porosity sintered glass funnel. The collected solid was washed twice with MTBE (500 mL each wash) and air-dried on the funnel for 1 h. The material was transferred to drying trays and dried at 50° C. and 15 ton until TGA analysis registered water content of less than 1.0%. The dried solid was packaged (isolated 1240 g, 91% yield, >98 A %).
Step 2: Asymmetric alkylation
A 20 L reactor was placed under a nitrogen sweep. (R,R)-chiral amine (2) (1761.2 g) was charged to the reactor. This was followed by a nitrogen sweep for 15 minutes. Anhydrous toluene (6.0 L) was then charged and agitation was initiated. The reaction mixture was allowed to stir under a nitrogen sweep for an additional 15 minutes, after which the reaction mixture was cooled to −5° C. A 3 L dropping funnel was charged with n-BuLi (3) solution (2.9 L). Once an internal temperature of −5° C. had been achieved, dropwise addition of the n-BuLi was initiated, ensuring that internal temperature did not rise above 0° C. The reaction mixture was cooled to −15° C. and aged for 30 minutes. TMEDA (4) (592 mL) was then added via cannula. 5-methylthiazolinone (18) (400 g) was slurried in anhydrous toluene (1.6 L) in a separate 5 L, 3-neck round-bottom flask under a nitrogen sweep for 15 min. The resulting slurry was charged portionwise to the reactor via cannula, adjusting addition rate and jacket temperature so as to maintain the internal temperature below 0° C. The round-bottom flask used to prepare the substrate slurry was rinsed with toluene (2×450 mL) and the washes were charged to the reactor. The reaction mixture was warmed to 22° C. and aged at this temperature for 30 min. The mixture was then re-cooled to −15° C. Isopropyl iodide (10) (1.42 L) was charged via cannula at such a rate as to maintain temperature below −12.5° C., adjusting the jacket temperature as needed to control the resulting exotherm. An analytical sample was pulled 20 min following completion of the isopropyl iodide addition (following the sample preparation protocol in the analytical section).
The reaction mixture was allowed to age at −15° C. until >93% conversion was obtained, and then quenched by dropwise addition of saturated NH 4 Cl solution, again adjusting addition rate and jacket temperature to control the resulting exotherm. The reaction mixture was warmed to room temperature and agitation was halted. Phases were allowed to separate (at least 20 min) and the lower aqueous layer was drained. 3.0 L of saturated NH 4 Cl solution was added and the mixture agitated for 20 minutes. The Phases were allowed to separate and the lower aqueous layer was drained. Acetic acid solution (2 M, 3.3 L) was charged to the reactor, and the mixture agitated for 20 minutes. The phases were allowed to separate and the lower aqueous layer was drained. This acetic acid wash was repeated.
Brine (3.3 L) was charged to the reactor, and the mixture was agitated for 20 minutes. The phases were allowed to separate and the lower aqueous phase was drained. Saturated NaHCO 3 solution (3.3 L) was charged to the reactor slowly while agitating for 20 minutes. The phases were allowed to separate (at least 20 min) and the lower aqueous phase was drained. A second NaHCO 3 (3.3 L) was performed and the lower aqueous was drained. Brine (3.3 L) was again charged to the reactor, the mixture was agitated for 20 minutes. The phases were allowed to separate and the lower aqueous phase was drained.
A 200 mL sample of the crude toluene solution was reduced via vacuum distillation to a final volume of 30 mL. The resulting suspension was then maintained at a temperature of 60° C. To the suspension was added 100 mL of heptane while maintaining the temperature above 55° C. Once the addition of heptane was completed, the suspension was cooled to 5° C. over an hour period. The batch was held at 5° C. for 90 minutes. The solid was then filtered through a medium fritted glass filter and the cake was washed with a minimum amount (15 mL) of cold heptane (5° C.). The solid was dried in a vacuum oven at 55° C. for 16 hours. Isolated 5.25 g of solid (67.7% yield).
Step 3 (MSA Salting)
A 3-neck, 2 L round bottom flask was placed under a N 2 sweep. Crude alkylation product (19) (84% de; 225 g) was then charged, followed by isopropyl alcohol (1125 mL, 5 volumes). Agitation was established and methanesulfonic acid (14) (57.5 mL) was then charged via addition funnel. The reaction mixture was heated to 50° C. and aged for 1 hour. The reactor contents were then cooled to 18-25° C. and aged for 1.5 hours. The solid was then isolated by filtration with a Buchner funnel. An additional portion of isopropyl alcohol (338 mL, 1.5 volumes) was used to rinse any remaining solid material from the 2 L round bottom flask. The wet cake was allowed to dry on the funnel for at least 1 hour. The solid material was then transferred to a drying tray and placed in a vacuum oven at 50° C. for 16 hours. Obtained 272.2 g (88.9% uncorrected yield, 95.98% de) of dry compound (20).
Step 4 (Free Basing):
To a 40 g suspension of MSA salt (20) in DCM (10×, 400 mL) in a 1000 mL, 3 neck round bottom flask, equipped with a mechanical stirrer and a nitrogen inlet, was added 5× of 1N NaOH (200 mL). The mixture was stirred for 1 hour and transferred to a separatory funnel. The layers were allowed to settle for 15 minutes and then split. The organic layer was then washed with 5 volumes of DI water until the pH of the aqueous layer was neutral. The organic layer (DCM) is filtered through a medium fitted glass filter prior to proceeding with the solvent exchange.
An atmospheric distillation was performed in order to reduce the volume of DCM to a level of 3.75× (150 mL). At this point, IPA (3.75×; 150 mL) was introduced into the flask and the atmospheric distillation was resumed until the volume of the batch reached once again 3.75× (150 mL). An additional 3.75× (150 mL) IPA was introduced to the flask and distillation was continued until the final volume of the batch was 3.75× (150 mL). The batch temperature during this stage was equivalent to the boiling point of IPA (˜82° C.). To the hot solution (75±5° C.) of product in IPA was added water (3×; 120 mL) at such a rate that the temperature is maintained above 70° C. The mixture was cooled to 5° C. over a >1 hour period and held for 75 minutes. The solids were filtered, and washed with a minimum amount (˜2×) of cold (5° C.) IPA/water mixture (40/60). The solid was dried in a vacuum oven at 55° C. for 17 hours. Isolated 27.97 g of product (19) (95.1% uncorrected yield; 99.76% de).
Example 8
Preparation of (5S)-2-(bicyclo[2.2.1]hept-5-en-2-ylamino)-5-isopropyl-5-methylthiazol-4(5H)-one (23) of high diastereomeric excess
Step 1:
A 20 L reactor was placed under a nitrogen sweep. (S)-exo-2-norbornenylthiourea (21) (587 g) was charged to the reactor followed by 2.97 L of absolute ethanol. Agitation was initiated, and this was followed by addition of 2-bromopropionic acid (17) (377 mL) via a graduated cylinder. Sodium acetate (715 g) was then charged. The reaction mixture was heated to 80° C. and aged at this temperature for 4 hours, after which it was cooled to 22° C. Deionized water (9 L) was added and a small exotherm resulted. The mixture was allowed to return to 22° C. and aged for 12 h. The resulting suspension was filtered through a medium-porosity sintered glass funnel. The solid remaining in the reactor was rinsed into the funnel with deionized water (1.5 L) and the filter cake was washed with 0.5 L of deionized water. The solid was air-dried on the filter for 3 hours, then transferred to drying trays and dried at 50° C. and 3-30 torr until TGA analysis indicated water content of less than 3.0%. The dry weight was recorded (728.9 g, 94% yield).
Step 2: Asymmetric Alkylation
A 20 L reactor was placed under a nitrogen sweep as stated. (R,R)-chiral amine (2) amine (1610 g) was charged to the reactor. This was followed by a nitrogen sweep for 50 minutes. Anhydrous toluene (5.42 L) was then charged and agitation was initiated. The reaction mixture was allowed to stir under a nitrogen sweep for an additional 10 minutes, after which the reaction mixture was cooled to −7.5° C. over 45 minutes. The dropping funnel was charged with n-BuLi (3) solution (2.66 L), and dropwise addition of the n-BuLi was initiated. During this addition, the addition rate and jacket temperature were adjusted to ensure that internal temperature did not rise above 0° C. Once the addition was complete, the dropping funnel was rinsed with anhydrous toluene (100 mL) transferred via cannula from a sure-seal bottle of toluene. The reaction mixture was cooled to −15° C., and TMEDA (4) (540 mL) was then added via cannula. 5-methylthiazolinone (22) (361.6 g) was slurried in anhydrous toluene (1.45 L) in a separate 5 L, 3-neck round-bottom flask under a nitrogen sweep for 30 minutes. The resulting slurry was charged portion wise to the reactor via cannula, adjusting addition rate and jacket temperature so as to maintain the internal temperature below 0° C. The round-bottom flask used to prepare the substrate slurry was rinsed with toluene (2×468 mL) and the washes were charged to the reactor
The reaction mixture was warmed to 15° C. over 1.5 hours, and aged at this temperature for 30 min (with chiller set at 22° C., max temp=20° C.). The mixture was then re-cooled to −15° C. over one hour. 2-Iodopropane (10) (1.3 L) was charged via cannula at such a rate as to maintain temperature below −12.5° C., adjusting the jacket temperature as needed to control the resulting exotherm.
The reaction mixture was allowed to age at −15° C. until >93% conversion was obtained, and then quenched by dropwise addition of saturated NH 4 Cl solution (3.62 L), again adjusting addition rate and jacket temperature to control the resulting exotherm. The reaction mixture was warmed to room temperature and agitation was halted. Phases were allowed to separate and the lower aqueous layer was drained. 4.82 L of saturated NH 4 Cl solution was added and the mixture agitated for 20 minutes. The phases were allowed to separate and the lower aqueous layer was drained. Acetic acid solution (2 M, 3 L) was charged to the reactor, and the mixture agitated for 30 minutes. The phases were allowed to separate and the lower aqueous layer was drained. This acetic acid wash was repeated. Saturated NaHCO 3 solution (3 L) was charged to the reactor slowly while agitating for 20 minutes. The phases were allowed to separate (at least 20 min). The lower aqueous phase was drained. Water (3 L) was charged to the reactor slowly while agitating for 20 minutes. The phases were allowed to separate and the lower aqueous phase was drained.
The toluene layer was solvent-swapped into octane, with the final ratio of solvents ˜20:1, octane:toluene. The distillation was performed with the internal temperature within the range of 19° C.-54° C., and the pressure within the range of 40-275 torr. After the desired solvent ratio was reached, with a final volume of 3.9 L, the slurry was filtered through a medium-porosity sintered glass funnel, rinsing with two portions of octane (1400 mL total). The solids were dried on the filter for 1-1.5 hours, and then transferred to a drying dish and dried in a vacuum oven at 45-55° C., 3-30 ton for 18-42 hours. Obtained 370 g of a white solid, 86% yield, 80.5% de.
Step 3 (MSA Salting):
A 5 L reactor was placed under a N 2 (g) atmosphere. Akylation product (23) (80.5% de; 303.3 g) was then charged, followed by isopropyl alcohol (1820 mL, 6 volumes). Agitation was established and methanesulfonic acid (14) (78.2 mL) was then charged via addition funnel. The reaction mixture was heated to 50° C. and aged for 1 hour. The reactor contents were then cooled to 20-24° C. and aged for 1.5 hours. The solid was then isolated by filtration through a 2 L medium-porosity sintered glass funnel. Two additional portions of isopropyl alcohol (2×303 mL, 2 volumes total) were used to rinse any remaining solid material from the 5 L reactor. The wetcake was allowed to dry on the funnel for at least 1 hour. The solid material was then transferred to a drying tray and placed in a vacuum oven at 50° C., 3-30 torr for 16 hours. Obtained 367.4 g (88.9% uncorrected yield, 96.8% de) of dry compound.
The isolated solid (367.4 g) was recharged to the reactor followed by isopropyl alcohol (1886 mL). Agitation was established and the reactor contents were heated to 50° C. over 105 minutes. The mixture was aged at this temperature for 23 hours. It was then cooled to 20-24° C. over 2 hours and aged for an additional 3 hours. The solid was isolated by filtration through an 8 L medium-porosity sintered glass funnel. An additional portion of isopropyl alcohol (2×269 mL) was used to rinse the wet cake. The solid material was allowed to dry on the funnel for at least 1 hour. It was then transferred to a drying tray and placed in a vacuum oven at 50° C. for 16 hours. Obtained 357.2 g (97.2% yield, 99.3% de) of dry compound.
Step 4 (Free Basing):
A 20 L reactor was placed under a nitrogen sweep. The reactor was charged with methanesulfonic acid salt (24) (598.6 g), and 5.73 L of dichloromethane. Agitation was initiated and 2.86 L of 1N sodium hydroxide was added to the suspension over 10 minutes, which caused a rise in temperature from 18.1° C. to 21.6° C. This mixture was agitated for one hour then stopped, and the layers were allowed to settle. The lower organic layer was drained. The upper aqueous layer was then drained (pH=14). The organic layer was returned to the reactor for water washes. The reactor was charged with 2.86 L of DI water and the biphasic mixture was stirred for 15 minutes. Agitation was then stopped and the layers were allowed to settle. The lower organic layer was drained. The upper aqueous layer was then drained (pH=10). The water wash was repeated once, resulting in a pH of 7. The final organic layer was filtered through a medium porosity sintered glass funnel and returned to a clean 20 L reactor equipped with a distillation apparatus.
A vacuum distillation was performed in order to reduce the volume from 7.8 L to 4.0 L (6.7×). The range in temperature was 11° C. to 40° C., and the range in pressure was 80-180 torn When a volume of 4.0 L was reached, 4.0 L of IPA was added and the vacuum distillation repeated until a volume of 3.0 L (6.8 volumes) was reached, and DCM levels were undetectable. At this point, the solution was warmed to 60° C. over 2 hours, and then 2420 L of DI water were added over 10 minutes, resulting in an 8° C. temperature decrease. The chiller was then ramped to 35° C., and when the internal temperature reached 41° C., an additional 580 mL DI water was added (total water=6.8 volumes, IPA: Water=1:1). Over one hour the temperature of the solution was ramped down to 0° C.-3° C., and then the solution was filtered through a 8 L M porosity sintered glass funnel. The solids were rinsed with 880 mL (2×) of a 70:30 water:IPA mixture. The resulting material was transferred to a drying tray and placed in a vacuum oven at 50° C., 3-30 ton for 16 hours. Obtained 392.3 g (89.3% yield, 99.3% de) of a white solid (23).
Example 9
Preparation of lithium (R)-propane-1,3-diylbis(((R)-1-phenyl-2-(piperidin-1-yl)ethyl)amide) (25)
Other chiral bases described herein may be prepared readily by procedures that are analogous to the method shown in scheme above.
Example 10
One-Pot Alkylation Reaction to Make (5S)-2-(bicyclo[2.2.1]heptan-2-ylamino)-5-isopropyl-5-methylthiazol-4(5H)-one
A 3-neck 250 mL round-bottom flask equipped with an overhead stirrer and thermocouple was charged with 5-methylthiazolinone (2 g, 8.92 mmol, 1 equiv)
and amine (8.8 g, 19.6 mmol, 2.2 equiv)
One neck was capped with a septum, and a needle inserted which was connected to a nitrogen and vacuum source. The flask was evacuated and back-filled with nitrogen. Toluene (40 mL, 20 volumes, Aldrich Sure-Seal) was charged via syringe to the flask. Agitation was initiated, and a needle was inserted in the septum under a positive pressure of nitrogen to purge the atmosphere. TMEDA (2.96 mL, 19.6 mmol, 2.2 equiv) was added via syringe, and the atmosphere was purged for 5 min. The solution was cooled to −15° C. (+/−5° C.), and the n-BuLi (2.6 M in toluene) (15.1 mL, 39.2 mmol, 4.4 equiv) was added via syringe over 35 minutes. The temperature did not exceed −15° C. (+/−5° C.). The reaction pot was warmed to 22° C. (+/−3° C.) over 30 min and then held for 90 min. At this point, the reaction was cooled to 0° C. (+/−3° C.) and 2-iodopropane (7.14 mL, 71.4 mmol, 8.0 equiv) was added over 15 min. A small latent exotherm of ˜4° C. was observed. The reaction was allowed to warm to 22° C. over 1-2 h, and then held at 22° C. for an additional 16 h. The reaction was quenched with saturated aqueous ammonium chloride (16 mL, 8 volumes) by adding it drop-wise via syringe over 30 min. The reaction mixture was added to a separatory funnel, and the two layers were separated. The upper organics layer was found to contain 1.86 g, 78% assay yield (uncorrected) of (5S)-2-(bicyclo[2.2.1]heptan-2-ylamino)-5-isopropyl-5-methylthiazol-4(5H)-one with a stereoselectivity of 87:13 and 110 mg, 5.5% of starting material. This reaction stream can be worked-up in the same manner as a two-pot alkylation reaction.
Example 11
One-Pot Asymmetric Alkylation Using (+)-Ephedrine HCl
A. Using 2.5 M n-Butyllithium in Hexanes
A 5 L reactor equipped with an overhead stirrer and a 5-port lid which was connected to an addition funnel, a nitrogen inlet, and a thermocouple was charged with 5-methylthiazolinone (95.5 g, 0.426 mol, 1.0 equiv)
and (1S,2R)-(+)-ephedrine HCl (103.1 g, 0.511 mol, 1.2 equiv)
The reactor was purged with nitrogen for 45 min. by blowing nitrogen into the inlet adapter and then out through an attached outlet adapter. Me-THF (573 mL, 493 g, 6 volumes) was added via cannula, and the reactor was purged for an additional 30 min. The nitrogen outlet adapter was removed so that the reactor was under a blanket of nitrogen, and then the reactor was cooled to −15° C. (+/−3° C.). 2.5 M n-butyllithium in hexanes (0.815 L, 2.04 mol, 4.8 equiv) was charged to an addition funnel via cannula. The chiller attached to the reactor was set to −30° C., and the butyllithium was added to the reactor drop-wise over 2 h such that the internal temperature did not exceed −9° C. After the addition was complete, the reactor was warmed to 22° C. (+/−3° C.) over 1 h and held at this temperature for 30 min. At this point, the addition of 2-iodopropane (341 mL, 3.41 mol, 8.0 equiv) portion-wise from an inert round-bottom flask was begun. 10 minutes into the addition, the chiller was set to 10° C. in order to absorb a small exotherm which brought the temperature to 26° C. The entire addition took 25 min., and the chiller was re-set to 22° C. This reaction mixture stirred at 22° C. for 16 h, and analysis of an aliquot by HPLC revealed >99% conversion and 77:23 dr. The chiller was set to 10° C., and sulfuric acid (1.05 M, 907 mL, 9.5 volumes) was added drop-wise via an addition funnel over 45 min. The chiller was re-set to 22° C., and this mixture was stirred for 1 h. Dichloromethane (478 mL, 5 volumes) and water (287 mL, 3 volumes) were added and stirred 10 min. After separation, the lower aqueous layer (1.4 Kg) was drained, analyzed by HPLC, and found to contain 45 g of ephedrine (53%). Sodium bisulfate monohydrate (20 w/v %, 907 mL, 9.5 volumes) was added to the reactor and the two layers were agitated for 30 min. The lower aqueous layer (1 Kg) was drained, analyzed by HPLC, and found to contain 19 g (23%) of ephedrine.
The organics, (2.2 Kg) were drained, analyzed by HPLC, and found to contain the desired (5S)-2-(bicyclo[2.2.1]heptan-2-ylamino)-5-isopropyl-5-methylthiazol-4(5H)-one (101 g, 89%, 77:23 dr) and (+)-ephedrine (2.9 g, 3%). An additional sodium bisulfate monohydrate (20 w/v %, 907 mL, 9.5 volumes) wash can be incorporated here, if needed, to remove excess ephedrine. The organics were returned to the reactor and washed with sodium bicarbonate (sat. aq.) (907 mL, 9.5 volumes), the layers drained, and the organics subjected to salting and freebasing in a manner analogous to steps 3 and 4 of Example 7 above to isolate the product.
B. Using 6.6 M n-Hexyllithium in Hexanes
A 100 mL round-bottom flask equipped with a thermocouple was charged with 5-methylthiazolinone (5 g, 22.3 mmol, 1.0 equiv)
and (1S,2R)-(+)-ephedrine HCl (5.4 g, 26.7 mmol, 1.2 equiv). A septum was added to seal the flask, and it was then evacuated and backfilled with nitrogen (g). Me-THF (30 mL, 6 volumes) was added via syringe, and the flask was cooled to −15° C. (+/−3° C.). n-hexyllithium in hexanes (6.6 M, 16.2 mL, 107 mmol, 4.8 equiv) was added drop-wise to the flask via syringe over 20 min. so that the internal temperature did not exceed −15° C. (+/−3° C.). The flask was warmed to 22° C. (+/−3° C.) over 30 minutes and held at that temperature for 45 min. 2-iodopropane (17.8 mL, 178 mmol, 8.0 equiv) was added to the flask at 22° C. (+/−3° C.) over 5 min., and a small latent exotherm to 26° C. was observed. This reaction mixture stirred at 22° C. (+/−3° C.) for 16 h, and then sulfuric acid (1.05 M, 47 mL, 9.5 volumes) was added drop-wise to the reaction mixture over 90 min. The internal temperature did not exceed 26° C. during this addition. Dichloromethane (15 mL, 3 volumes) and water (10 mL, 2 volumes) were added to the reaction mixture and stirred to dissolve precipitate. The layers were transferred to a separatory funnel and the lower aqueous layer (70 g) was drained, analyzed by HPLC, and found to contain ephedrine (3.5 g, 80%). The organic layer was washed with sodium bisulfate monohydrate (20 w/v %, 47 mL, 9.5 volumes) and the layers were allowed to separate. The lower aqueous layer (56 g) was drained, analyzed by HPLC, and found to contain ephedrine (800 mg, 18%) and (5S)-2-(bicyclo[2.2.1]heptan-2-ylamino)-5-isopropyl-5-methylthiazol-4(5H)-one and its racemate (28 mg, 0.5%).
The organic layer (89 g) was drained, analyzed by HPLC, and found to contain (5S)-2-(bicyclo[2.2.1]heptan-2-ylamino)-5-isopropyl-5-methylthiazol-4(5H)-one (5.1 g, 85%, 76:24 dr). An additional sodium bisulfate monohydrate (20 w/v %, 47 mL, 9.5 volumes) wash can be incorporated here, if needed, to remove excess ephedrine. The organics were returned to the separatory funnel and washed with sodium bicarbonate (sat. aq.) (47 mL, 9.5 volumes). The two layers were slow to separate, and additional brine (3 volumes) was added to aid the separation. Finally, the layers separated and were drained. | The present invention relates to methods of making compounds that inhibit 11-hydroxysteroid dehydrogenase type 1 enzyme (11-HSD1). One method comprises (a) contacting a compound of formula (II) sequentially with a chiral base in the presence of an amine, and an alkylating agent R3-LG, (b) contacting the product of (a) with an acid to form a salt, and (c) reacting the salt with a base to form the compound of formula (I), wherein Z, R1, R2, and R3 are defined herein. | 2 |
TECHNICAL FIELD OF THE INVENTION
[0001] The present invention relates to automotive ladders, including multi-function ladders useful for accessing an automotive bay such as a cargo bay or truck bed.
BACKGROUND
[0002] Users of trucks and similar automobiles often carry cargo such as equipment, tools, and supplies. Easy access to and from the cargo area is desirable both for a person's convenience and safety. Some automobiles, including trucks, typically have a tailgate that can be opened to help access the cargo bed, however, even when open to the horizontal position, the tailgate is frequently too high off the ground to afford the convenience and safety desired by a user. In addition, equipment such as a dolly or hand cart to ferry equipment from the vehicle to a desired location would be useful if it can be easily stored or mounted on the vehicle and easy to use.
[0003] While attempts to improve egress from cargo areas of vehicles have been made, there remains a need for improved access, particularly with equipment that can also be used for transporting cargo from the vehicle. For example, some ladders are formed as part of the tailgate, and thus cannot be removed from the tailgate or retrofit onto existing tailgates. Other conventional tailgate ladders are fixed to the inside of the tailgate. Some tailgate ladders are foldable with multiple pivot points which increase manufacturing cost. There is, therefore, a need for truck tailgate ladders that can be securely attached to any horizontal deck surface but still provide versatile and convenient use and be economical to manufacture.
SUMMARY
[0004] In one aspect, a multi-function automotive ladder is disclosed having a frame having two stringers, each stringer having upper and lower ends; a plurality of steps extending between the stringers; a pair of handles, each handle having first and second ends, the first end of each handle being attached to the upper end of a corresponding stringer.
[0005] In some embodiments, the each stringer of the ladder further comprises an upper stringer and a lower stringer, and the ladder also has two hinges, each hinge connecting an upper stringer to a lower stringer. In some embodiments, the hinges are located near a middle of the distance between the upper and lower ends of the stringers.
[0006] In some embodiments, the stringers comprise rectangular tubing. In some embodiments, the ladder also has leg extensions. In some embodiments, the ladder also has a pair of wheels connected to the leg extensions and an axle. In some embodiments, the ladder also has adjustment holes for adjusting the position of the leg extensions. In some embodiments, the position of the leg extensions are adjusted and locked using an internal spring plunger that engages the adjustment holes. In some embodiments, the position of the leg extensions are adjusted and locked using an external spring plunger that engages the adjustment holes.
[0007] In some embodiments, the ladder also has a platform removably connected to the lower ends of the stringers. In some embodiments, the platform is pivotally connected to the leg extensions so that the platform can swing between substantially parallel and substantially perpendicular orientations with the stringers.
[0008] In some embodiments, the ladder assembly has a mounting bracket releasably attached to the second ends of the handles. In some embodiments, the ladder assembly has a connecting pin that secures a disc to the second end of the handles and a cleat receiver on the mounting bracket releasably engages the connecting pin. In some embodiments, the ladder assembly has a disc attached to the second end of the handles, and a disc receiver having a cleat bar attached to the mounting bracket, the disc releasably engaging the cleat bar. In some embodiments, the mounting bracket attaches to an automotive body or horizontal deck.
[0009] In another aspect, a method of transporting cargo from an automobile includes providing an automotive ladder previously described and loading cargo onto the ladder.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a side view of a ladder assembly with extension legs and wheels.
[0011] FIG. 2 is a side view of a ladder assembly with a platform and wheels in a folded configuration.
[0012] FIG. 3 is a top view of a mounting assembly with a cleat plate and cleat receivers.
[0013] FIG. 4 is a side view of a ladder assembly and mounting assembly connected to an automobile surface.
[0014] FIG. 5 is side view of the ladder assembly of FIG. 1 .
[0015] FIG. 6 is a front view of the ladder assembly of FIG. 2 .
[0016] FIG. 7 is a side view of a cleat plate with two disc receivers mounted thereon.
[0017] FIG. 8A is a side view of a ladder assembly showing a handle with a disc and disc opening.
[0018] FIG. 8B is a side view of a ladder assembly showing a handle with a disc and disc opening.
[0019] FIG. 9 is a side view of a ladder assembly showing a handle engaged with a mounting assembly.
[0020] FIG. 10 is a side view of an extension leg with an attached wheel.
[0021] FIG. 11 is a side view of an extension leg inserted into a ladder assembly and secured with a spring plunger.
DETAILED DESCRIPTION
[0022] Reference throughout this specification to “one embodiment” or “an embodiment” means that a particular feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, the appearances of the phrases “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.
[0023] In one aspect, an automotive ladder assembly is disclosed. The assembly includes various components including a ladder with stringers, steps, a pair of handles, and a mounting assembly for connecting the ladder's handles to a horizontal deck such as a tailgate of a vehicle.
[0024] Referring to FIG. 1 , there is shown an embodiment of a ladder assembly 10 . The ladder assembly 10 includes a pair of parallel stringers 11 . In general, the stringers 11 are substantially parallel to one another. In some embodiments, each stringer may also include an upper segment 15 and a lower segment 17 . In some embodiments, the upper and lower segments can be connected through a hinging means, such as hinge assembly 16 shown in FIG. 1 . The hinge assembly enables a user to fold the ladder assembly between an extended state (such as that shown in FIG. 1 ) and a collapsed or folded state (such as that shown in FIGS. 2 and 6 ). In the folded state, the stringer segments 11 form an angle of between 120 and 180 degrees.
[0025] In some embodiments, the stringers need not be substantially parallel for their entire length relative to one another. For example, the lower segment of the stringers may be wider at their base and narrow as the lower stringers connect with the upper stringers.
[0026] The hinge assembly 16 includes a hinge block 25 mounted on a rear side of a stringer 11 , such as a bottom portion of an upper stringer 15 . The hinge block 25 is configured to have an opening 61 to receive a hinge pin, and the hinge pin also passes through a stringer 11 providing for a pivot point in the ladder assembly. The hinge assembly 16 also includes a plate 27 which can be mounted on an upper portion of the lower stringer 17 . In some embodiments, the hinge plate 27 may integral with the lower portion 17 . In other embodiments, the hinge plate 27 can be welded to a lower portion of upper stringer. In some embodiments, the hinge plate 27 may be removably connected to the upper portion of the lower stringer 17 . The hinge plate 27 may also include a locking opening 65 through which a hinge pin 63 or a cotter pin 67 or other fastening device may pass. When in a locked configuration, the fastening device (e.g. cotter pin 67 ) passes through locking opening 65 and a corresponding locking opening 69 located near the lower portion 47 of the upper stringer 15 .
[0027] Optionally, one of the upper and lower portions may have a storage opening in which the fastening device may be stored. For example in FIGS. 1 and 2 , storage opening 55 may receive a cotter pin 67 when the ladder is in a folded configuration.
[0028] In some embodiments, the parallel stringers 11 are continuous and incapable of folding.
[0029] The ladder assembly 10 also includes a plurality of steps (or rungs) 13 spanning between the stringers 11 . The steps 13 can be perpendicular to the stringers 11 and connected, for example with a metal weld. The height of the stringers 11 and width of the steps 13 may be of varying dimensions with consideration of automobile height and width. In some embodiments such as those shown in FIGS. 1 and 2 , the steps 13 are welded at their ends 30 to the stringers. In other embodiments, the parallel steps can fit into a plurality of pre-formed openings in the stringers 11 .
[0030] In some embodiments, the steps 13 can be textured such as with a plurality of raised bumps or stippling 31 . In some embodiments, the texture can take the form of parallel grooves, intersecting grooves, and the like. The texture serves the purpose of improving the friction between a user's shoes or gloves with the steps, thereby giving improved traction when climbing up and down the steps.
[0031] A pair of handles 12 having first ends 101 are mounted to the stringers at the upper portions 49 of the upper portions 15 . The handles 12 may be manipulated by a user when removing the ladder assembly 10 from an automobile or horizontal deck (not shown). The handles may include gaps 137 that facilitate a user's gripping of the handles. The handles 12 also can connect the ladder assembly 10 to a mounting assembly 71 through discs 99 mounted on the second ends 103 of the handles 12 . The discs 99 are attached to the handles with connecting pins 95 and leave a gap between the discs 99 and handles 12 .
[0032] Referring now to FIGS. 3 and 4 , a mounting assembly 71 for connecting the ladder to a vehicle surface is shown. The mounting assembly includes a cleat plate 73 . The cleat plate includes at least one or a plurality of openings 75 through which fasteners can attach the cleat plate 73 to an automobile surface 79 such as a tailgate. Fasteners include rivets, bolts, clamps, among others. In another embodiment, the cleat plate may attach to a horizontal surface with hook and pile fasteners.
[0033] In some embodiments, the cleat plate 73 includes a pair of cleat receivers 81 which are connected to cleat plate 73 . The cleat receivers 81 may be pivotally connected with hinges 83 . The cleat receivers 81 include a channel 89 that extends from a first end 91 to nearly the center of the receiver 81 . The channel 89 has a width 96 corresponding to the diameter of connecting pins 95 located on handles 12 .
[0034] In some embodiments, handles 12 connect to the cleat plate 73 by sliding the connecting pins 95 through the channel 89 to the center of the receiver 81 and alongside discs 99 . A locking strap 93 may be rotated forward about an axis of the connecting pins 95 to secure the handle connection to the plate 73 .
[0035] In some embodiments such as shown in FIGS. 5 and 10 , the lower portions 17 may include a plurality of holes 107 for aligning with extension legs 35 that fit within the lower portions 17 . The extension leg inserts may have wheels 37 (phenolic caster wheels for example) connected to a bottom end 41 of the extension leg through a wheel axle 39 . An upper end 43 of the extension leg fits within the lower portion 17 . The extension legs may be locked into the lower portion using, for example, an internal spring plunger 33 . The spring plunger 33 may be inserted into the holes 107 and a corresponding pair of holes 207 passing through the width (or a tube) of an extension leg. The spring plunger 33 may be pushed in to facilitate height adjustment. The spring plunger 33 becomes extended each time it aligns with an appropriate hole 107 .
[0036] The height of extension legs 35 may be independently adjusted such as with spring plungers 105 to hold the extension legs 35 (with or without optional wheels) at a desired height. Such options may be desirable when the ladder might abut an uneven surface. The spring plungers 105 are inserted into holes 107 in the lower portions. Other appropriate fasteners can be used.
[0037] In some embodiments such as shown in FIG. 11 , an external spring plunger 34 may be inserted into holes 107 in the lower portions of stringers 11 to hold the extension leg 35 in the stringer 11 .
[0038] Referring to FIGS. 2 and 6 , there is shown the embodiment of FIG. 1 , but with the ladder assembly 10 in a folded configuration and without connection to the mounting assembly 71 . Because the lower segments of the stringers can have insertable extension legs, a wide variety of features can be added to the bottom of the ladder. As also shown in FIGS. 2 and 6 , the platform and wheels make the ladder usable as a dolly or moving truck. Other suitable equipment may also be added to the ladder so long as that equipment is fitted with extension legs that fit within the stringers. As shown in FIG. 1 , the extension legs can be fitted with wheels. Alternatively, extension legs can simply extend the height of the ladder for use to climb other surfaces such as a wall. In such embodiments, the extension legs may also be bridged to one another with one or more steps. Also, because the extension legs are adjustable, the ladder may be used on uneven ground surfaces.
[0039] Extendable arms may also be inserted in to the top of the stringers to provide additional grasping handles. The grasping handles can enable a user to steady themselves when the assembly is used as a ladder, or to extend the assembly when used as a dolly or hand truck.
[0040] The stringers, steps, and other components of the ladder assembly may be made from a variety of materials, including metals such as steel or aluminum, or suitable, strong polymers.
[0041] In some embodiments, the stringers can be made of rectangular tubing. In some embodiments, the stringers can be made of circular tubing.
[0042] Referring to FIGS. 2 and 6 , there is shown an alternate embodiment of the ladder assembly shown in FIG. 1 where the lower ends 13 of the stringers 11 are connected to a platform assembly 131
[0043] The platform assembly includes a platform 114 situated between extension legs 113 . The extension legs are receivable into the lower portions 17 of the ladder assembly. The extension legs also adjoin struts 115 which are connected to a wheel axle 117 . The wheel axle is connected to a pair of wheels 119 , (inflatable rubber wheels, for example).
[0044] In some embodiments such as shown in FIG. 7 , a cleat plate 173 has one or more openings 175 that can be connected to a vehicle surface by fasteners 177 . Fastener 177 can be anything that secures the cleat plate 173 to a vehicle surface, for example a rivet, screw, nail, or pin. The cleat plate 173 has one or more disc receivers 190 . Disc receiver 190 has a cleat bar 180 that is configured to receive a disc opening 170 , described below. As shown in FIG. 8A and 8B , at least one disc 199 is secured to the second end 203 of handle 112 with at least one connector 150 . Connector 150 can be a bolt, nail, screw, or any suitable connector capable of securing the disc 199 to the end of the handle 112 . The disc 199 is shaped to have a disc opening 170 that is configured to engage mounting assembly 171 . The disc opening 170 may be any suitable shape that can engage the mounting assembly 171 , for example an oblong shape. The disc 199 has a locking bar 160 that is generally T-shaped, although it can be any shape that can secure the disc opening 170 to the mounting assembly 171 as described below. The locking bar 160 is configured to be in an engaging position—where the disc opening 170 is secured to the mounting assembly 171 as seen in FIG. 9 , and a releasing position—where the locking bar 160 does not secure the disc opening 170 to the mounting assembly 171 . A user moves locking bar 160 through a locking bar channel 165 to move the locking bar 160 from an engaging position to a releasing position.
[0045] Other systems, methods, features and advantages 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. The embodiments described below may be more fully understood by reading the following description in conjunction with the drawings. | An automotive ladder and mounting assembly for use to access automotive compartments such as a truck bed or a horizontal deck is disclosed. The ladder can have a variety of features including extendable legs or wheels and a dolly platform for transporting items and may be detachable from the automobiles for use as a ladder or hand truck. | 4 |
BACKGROUND
[0001] This application claims the benefit of U.S. Provisional Patent Application 60/978,913, filed Oct. 10, 2007, the entirety of which is incorporated by reference.
BACKGROUND
[0002] The invention relates to the processing of light weight, bulky cellulosic material, such as straw and other non-wood cellulosic material, to pulp. The invention particularly relates to chemical processing of such material.
[0003] Straw and other light weight, bulky cellulosic material are converted to pulp for use in paper, building materials and other pulp based products. These materials are processed by chemical and mechanical processing treatments. The chemical treatment of these materials typically involves caustic chemicals and short processing times.
[0004] Chemical treatment vessels that treat straw and other light weight, bulky cellulosic materials accommodate the severe chemical conditions and short retention times involved in the chemical processing, e.g., hydrolysis, of these materials. A conventional chemical treatment vessel includes a series of horizontal tubes arranged side-by-side and is referred to as a Pandia digester. Conduits connect the tubes and provide a flow path for material flowing from the discharge of one tube to the inlet to the next tube. The arrangement of tubes requires a relatively complex mechanical assembly to support the Pandia digester. Material undergoing treatment flows from one tube to the next.
[0005] In the tubes, the material is maintained at temperatures of 200° C. and pressures of 20 bar (about 290 pounds per square inch (psi)) with retention times of less than 30 minutes. Screws internal to each tube move the material through each tube. The screws are prone to becoming clogged with the material and require maintenance.
[0006] The multiple tubes make the Pandia digester a mechanically complex device having a large number of moving components, e.g., screws. There is a long felt need for treatment vessels having few moving components, at least as compared to the multiple screw conveyors in a Pandia digester. There is also a long felt need for chemical treatment vessel capable of processing large volumes of material, such as 400 tons per day with a four minute retention time in the vessel. Accordingly, there is a long felt need for a chemical treatment vessel having a relatively simple structure and capable of processing large volumes of straw and other light weight bulky cellulosic materials.
SUMMARY OF THE INVENTION
[0007] A single vessel has been developed for chemical treatment of light weight, bulky cellulosic material, such as straw and other non-wood cellulosic material. The vessel is preferably predominantly a cylinder having an interior treatment chamber with a sealed top and bottom to allow for pressures of at least 20 bar and preferably 40 bar and temperatures of at least 100° C. and preferably 200° C. The treatment chamber is substantially vertical, e.g., within 10 degrees of vertical, and may have a diameter of 1.5 to 4 meters and a height of 0.5 to 20 meters, depending on the desired volumetric flow rate and retention time of material in the chamber.
[0008] The material may be introduced through an upper inlet port to the vessel. Treatment liquids (if needed these liquids are preferably acidic chemicals to support hydrolysis, although treatments with ammonia are also suitable) and water may be added to promote treatment of the material in the chamber and to transport the material through a lower discharge. Anti-compression rings may be arranged in the upper elevations of the chamber and agitators may be included proximate to the anti-compression rings. The bottom discharge of the chamber may include devices to facilitate discharge of the material, such as one-dimensional sidewall transitions of the chamber to promote material flow, rotation devices to move material to the discharge, and baffles to allow for the injection of fluid in the bottom of the chamber that increases the fluid to material ratio as the material is discharged from the chamber or combinations thereof.
[0009] A method has been developed to chemically treat light weight, bulky cellulosic material including: introducing the material to an upper inlet of a substantially vertical treatment vessel; maintaining the material in the vessel at a pressure of at least 20 bar and at a temperature of at least 200° C.; treating the material with a cooking liquor in the vessel; moving the material past at least one anti-compression ring on an inside surface of the vessel, as the material moves downward through the vessel; agitating the material in the vessel, and discharging the treated material from a lower discharge port of the vessel.
[0010] A treatment vessel has been developed for chemically treating light weight, bulky cellulosic material, the vessel comprising: a generally vertical vessel having a sealed top and bottom and a sidewall extending from the top to the bottom, wherein the vessel is operated at a pressure of at least 20 bar and at a temperature of at least 200° C.; a material inlet port in an upper section of the vessel, wherein the inlet port receives the cellulosic material; a cooking liquor inlet port in the vessel or in a material feed system coupled to the material inlet port; at least one anti-compression ring on an inside surface of the sidewall; an agitator proximate to the anti-compression ring and agitating the material in the vessel, and a discharge outlet in a lower portion of the vessel.
SUMMARY OF THE DRAWINGS
[0011] A preferred embodiment and best mode of the invention is illustrated in the attached drawings that are described as follows:
[0012] FIG. 1 is a schematic diagram of a treatment vessel for chemical treatment, e.g., digesting, of light weight, bulky cellulosic material to produce, for example, pulp.
[0013] FIG. 2 is a cross-sectional diagram of an exemplary anti-compression ring for the vessel shown in FIG. 1 .
[0014] FIG. 3 is a side view of a discharge section of the vessel shown in FIG. 1 .
DETAILED DESCRIPTION
[0015] FIG. 1 schematically illustrates a chemical treatment vessel 10 that has been developed to treat light weight, bulky cellulosic materials, such as straw (“collectively referred to as light weight cellulosic material”). By way of example, light weight cellulosic material has a density of 50 to 120 kg/m3 (kilograms per meter cubed) which is less dense than conventional wood chips. In the example disclosed herein, the vessel 10 is a vertical reactor capable of processing 400 tons per day of the light weight cellulosic material and having a volumetric capacity of 14 cubic meters. The vessel 10 may be a closed vessel having a cylindrical body having a constant diameter circular cross-section and the body has sealed upper and lower ends.
[0016] In one embodiment, the cylindrical vessel 10 has a diameter of 1.5 meters and a height of 8 meters. In other embodiments, the vessel may have a diameter in a range of 1 meter to 10 meters, or a narrower range of 3 to 4 meters. The height of the vessel may be in a range of 0.5 meters to 40 meters. The diameter and height of the vessel may be selected depending on the desired volumetric rate of material to flow through the vessel and the retention time of material in the vessel.
[0017] The shape of the vessel may differ from the exemplary cylindrical vessel embodiment disclosed herein. The vessel may have a non-circular cross-sectional shape and dimensions different that are not constant, such as a conical body, a rectangular or elliptical body, and a body that has a shape more complex than a simple cylindrical, rectangular or elliptical (in cross-section) shape. A preferred characteristic of the vessel is that it be a single vessel, in contrast to the multiple tubes of prior art treatment vessels.
[0018] The vessel should be capable of operating at least at 20 bar pressure and 200° C. of temperature, and preferably at 40 bar pressure (approximately 580 psi) and 300° C. of temperature. These temperature and pressure conditions are suitable for processing light weight cellulosic material by treatments such as hydrolysis. Any liquid to be added to the vessel, such as liquor and cooling liquid to facilitate transport of the material through the discharge of the vessel, should preferably be added as water or be acidic. Organic treatment fluids may also be used, such as acetic acid, formic acid, ethanol and methanol. In one example, the vessel 10 may be used, for example, to treat non-wood lightweight cellulosic material, e.g., straw, by hydrolysis under acidic treatment conditions. In one embodiment, the retention time of the material in the vessel is preferably between 10 minutes and 120 minutes, where longer retention times may be more advantageous.
[0019] The operation of the vessel 10 may include conventional devices for controlling the flow of cellulosic material in a chemical treatment vessel, such as material level control. The control system may monitor a solids level in the vessel using, for example, a gamma gauge, and provide a feedback signal used to control the rate of material entering the vessel from the material feed system 12 and the discharge rate of pulp from the bottom discharge 20 . In addition, force sensors, e.g., strain gauges, may be included in the vessel to monitor pressures and forces in the vessel. Further, sensors may monitor the rotating speed of moving components in the system, such as a screw conveyor in the feed system 12 and the movement of the agitators.
[0020] The retention time and temperature of the cellulosic material in the vessel is preferably controlled and maintained at uniform levels. Control of the retention time and temperature assists in achieving the desired yield of products from the chemical reactions of the material and liquor in the vessel. Further, control of the retention time and temperature is needed to avoid side reactions in the vessel that may result in the loss of the desired reactions products.
[0021] The vessel 10 includes a feed system 12 for the light weight cellulosic material. The feed system may be a conventional system, such as a chip bin, chip screw conveyor with inlets for steam and liquor to facilitate transport of the material to and through the vessel. The vessel has an inlet port 14 at a top or upper section of the vessel. The feed system 12 may be used to transport the cellulosic material from a chip bin operating at atmospheric pressure to the vessel inlet 14 which is at a pressurized conditions, such as a temperature of 200° C. and a pressure of 20 bar, at which the vessel operates.
[0022] The vessel 10 is a pressurized vessel that is capable of maintaining uniform flow of the cellulosic material through the vessel. Preferably, the amount of liquor, e.g., liquids with chemicals to digest the cellulosic material to pulp, introduced to vessel is minimized to efficiently heat and maintain the temperature of the material being treated in the vessel. Heat energy 16 may be added to the vessel, such as steam, hot gases or other such hot medium.
[0023] The vessel 10 may have an inside chamber 18 having a vertical sidewall in which material flows downward to a material discharge 20 at a bottom of the vessel. Within the chamber at various locations along the sidewall, anti-compression rings 22 or other suitable rings to reduce compression of the material in the vessel. These rings facilitate movement of the cellulosic material through the vessel. The rings are arranged at various elevations in the chamber, and preferably at upper elevations of the chamber such in the upper half of the chamber.
[0024] FIG. 2 shows an exemplary anti-compression ring 22 which may be an annular ring having a generally right-sided triangular cross-sectional shape. The top 24 of the ring is attached to the inside wall 26 of the vessel and a first vertical cylindrical leg 28 attached to the inside wall 26 . The anti-compression ring may includes a sloped side wall 30 that is inclined inward to the vessel. The anti-compression ring promotes uniform compression of the flow of material throughout the height of the vessel. The rings apply a slight compression of the material moving downward along the sloped sidewall 30 of the rings. The compression applied by the rings provides support for the material in the upper elevations of the vessel and reduces the force applied to material in the lower elevations due to material in the upper elevations. As the material flows past the ring, there is a quick release of the compression force as the material flows past the bottom edge of the sidewall 30 and expands to the larger diameter of the vessel inside wall 26 . Suitable anti-compression rings are described in U.S. Pat. Nos. 6,280,569 and 5,454,490.
[0025] Agitators 32 may be included in the chamber 18 to assist the movement of material through the vessel and, particularly, past the anti-compression rings. The agitators may be positioned near and, possibly, connected to the anti-compression rings 22 . The agitator 32 may be bar or shaft connected to a surface of the vessel, e.g., sloped sidewall 30 , that applies an agitation movement, e.g., shaking, reciprocal movement and vibration. The agitation movement is applied to the cellulosic material to promote movement of the material through the vessel.
[0026] A motive force 34 is applied to agitator to impart the agitation movement. The agitator may be a conventional agitation device used to assist in the movement of the cellulosic material through a vessel. Combining the anti-compression rings and the agitators, such as applying a shaking arm(s) to the sloped sidewall 30 , may reduce the components and especially moving components in the vessel. Further, combining the agitator and anti-compression ring reduces the mechanical components in contact with the material and thus reduces the components that might disrupt the flow of material through the vessel.
[0027] FIG. 3 shows an exemplary discharge device 36 formed in a lower portion of the vessel in which the sidewall transitions from a cylindrical wall to a wall having a one dimensional convergence and side relief, such that a diamond shaped indention is formed on opposite sides of the discharge device. The discharge device 36 may comprise horizontal feed screws 38 mounted adjacent the bottom of the discharge device. A discharge device 36 in a bottom section of the vessel may be a flow promotion device such as described in U.S. Pat. Nos. 5,500,083; 5,628,873; and 5,617,975.
[0028] As an alternative to a horizontal feed screw, a rotating scraper 40 (that may be of conventional design) may be arranged in a lower section of the vessel. The scraper may push the cellulosic material to a central discharge point 42 at the bottom on the vessel.
[0029] A baffle 44 may be arranged at lower portion of the vessel which is just upstream of the discharge point 42 . The baffle sweeps material into the discharge point. Further, a dilution liquid may be introduced through conduit 44 to the baffle area. The dilution liquid flows from the baffle area to the material moving towards the discharge point. The dilution liquid increases the liquid to material ratio so as to assist in the movement of material to the discharge point.
[0030] The invention has been described in connection with the best mode now known to the applicant inventors. The invention is not to be limited to the disclosed embodiment. Rather, the invention covers all of various modifications and equivalent arrangements included within the spirit and scope of the appended claims. | A method to chemically treat light weight, bulky cellulosic material including: introducing the material to an upper inlet of a substantially vertical treatment vessel; maintaining the material in the vessel at a pressure of at least 20 bar and at a temperature of at least 200° C.; treating the material with a cooking liquor in the vessel; moving the material past at least one anti-compression ring on an inside surface of the vessel, as the material moves downward through the vessel; agitating the material in the vessel, and discharging the treated material from a lower discharge port of the vessel. | 3 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Application No. 61/768,928 filed on Feb. 25, 2013, entitled “Ergonomic Adjustable Desktop.” The above identified patent application is herein incorporated by reference in its entirety to provide continuity of disclosure.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to desks and office furniture items. More specifically, the present invention pertains to a new and novel desktop surface that can be raised and lowered from a work surface, allowing the keyboard and monitor height to be adjusted from the work surface for improved ergonomics.
[0004] Many jobs in the modern economy require an individual to spend much of their day in a seated position and in front of a computer. The computer improves worker productivity, allows for rapid communication between distant parties, and facilitates the efficient creation of data or a platform for analyzing the same without requiring the user to engage in much physical exertion. With this improvement in productivity, however, comes with it the fact that the common computer user is sedentary and in a static body position for long periods of time. This positioning of the body and inactivity may not be ideal for the human body, and can lead to physical injuries over time.
[0005] Work place ergonomics specialists and occupational health professionals analyze these types of work place environments and have developed many solutions for alleviating physical pain and for preventing common work place injuries related to office employees. These solutions include ergonomic furniture items such as specialized chairs and desks, as well as ergonomic computer equipment such as adjustable computer stands and shaped keyboards that prevent wrist injuries. These devices are varied in the art and relate to a means of adjusting the work environment or positioning the user such that physical injuries are prevented. These injuries most often include some form of back injury, wrist or shoulder injury, neck soreness or eyesight issues.
[0006] The typical workday for many people requires that they sit at a desk, remaining seated for an extended period of time. This can decrease blood flow to extremities and cause soreness throughout the day. Over time, chronic problems, particularly in the back, can develop. In order to promote increased blood flow or stretch, many people leave their desk and take a short break. Wellness programs and workplace awareness campaigns exist for addressing these office maladies, however the most direct means of combatting long term office injuries is furniture and computer peripherals that position the user in the most ergonomic and healthy body posture.
[0007] The present invention describes a height adjustable computer stand that allows a user to elevate a computer monitor and peripheral items above a work surface, thereby improving the positioning thereof with respect to the user's seated or standing position. The device comprises an L-shaped frame having an upstanding rail and a base support member. Cantilevered from the upstanding rail is a horizontal platform that is adapted to support the load of a personal computer and office articles. The platform is slidably positioned along the rail and lockable thereto using a locking means. Overall, the device allows a user to elevate their work surface or position the same such that the user can maintain an optimum arm, back, and eye level, or alternatively accommodate a standing user.
[0008] 2. Description of the Prior Art
[0009] Devices have been disclosed in the prior art that relate to work surfaces and adjustable furniture. These include devices that have been patented and published in patent application publications. The following is a list of devices deemed most relevant to the present disclosure, which are herein described for the purposes of highlighting and differentiating the unique aspects of the present invention, and further highlighting the drawbacks existing in the prior art.
[0010] One such device in the prior art is U.S. Pat. No. 5,526,756 to Watson, which discloses a desk assembly having an adjustably-supported computer keyboard and monitor platform that can be adjusted to various heights with respect to the rest of the desk surface. The platforms are adjustable by way of a motor and associated motor bracket and threaded rod assemblies attached to the platform for controlling the platform height by way of electric motor action. In this way, the user can raise and lower the platforms with respect to the desk without physical input. The Watson device, while offering a means of adjusting the vertical position of a keyboard and monitor, discloses an assembly that functions in connection with a desk furniture item and is not suited for being utilized on any generic support surface, as contemplated herein.
[0011] Another device is U.S. Pat. No. 6,062,148 to Hodge, which discloses a height adjustable support for desk top computer equipment, wherein a counterbalance mechanism is provided to assist with lifting and lowering the equipment. A drive shaft and a first and second energy storage device are utilized to provide a means of easily changing the height of a work surface supporting desk top equipment for the user. A frictional brake mechanism is also disclosed for controlling the work surface position during adjustment. While providing a counterbalance mechanism for a work surface lift, the Hodge device fails to contemplate the assembly of the present invention, which includes a simple, spring-biased platform for supporting work space equipment and peripherals.
[0012] U.S. Pat. No. 5,996,961 to Johnson discloses a height-adjustable work stand support having a pair of scissor lifts spaced apart from below the work surface for lifting or lowering its position with respect thereto. The pair of scissor lifts is synchronized and lifts a work surface above the base of the assembly by way of a threaded rod adjustment of the scissor lifts. While providing a means of lifting a surface, the Johnson device differs in functional elements and structure with respect to the present invention.
[0013] Finally, U.S. Patent Publication No. 2012/0248263 to Grotenhuis discloses a computer work desk that includes an upstanding mount having a pair of legs for support. Slidably positioned along the mount is a keyboard and mouse platform, which can further be tilted from the mount for improved ergonomics. Further disclosed are a self-leveling mechanism, an assisted adjustment system, and a braking control mechanism for controlling and repositioning the keyboard tray of the assembly. The Grotenhuis includes a complicated array of mechanical and electrical assemblies for the purposes of supporting a tray and moving it along a vertical mount. The present invention contemplates a purely mechanical device with an upstanding rail and locking mechanism for repositioning the work space platform of the assembly.
[0014] The present invention discloses a new and novel office furniture article that is supported by an existing work surface and provides a means to elevate a user's computer and work area. The device is lockable and adjustable to accommodate both a seated and standing user, wherein the device is aimed at reducing work place injuries and improving office ergonomics. It is submitted that the present invention is substantially divergent in design elements from the prior art, and consequently it is clear that there is a need in the art for an improvement to existing adjustable work surface devices. In this regard the instant invention substantially fulfills these needs.
SUMMARY OF THE INVENTION
[0015] In view of the foregoing disadvantages inherent in the known types of office furniture articles now present in the prior art, the present invention provides a new adjustable work surface device that can be utilized for providing convenience for the user when supporting a computer and desk articles in an elevated position for improved user ergonomics.
[0016] It is therefore an object of the present invention to provide a new and improved adjustable work surface device that has all of the advantages of the prior art and none of the disadvantages.
[0017] It is another object of the present invention to provide an adjustable work surface device that is deployable from an existing work surface, whereby no installation or modification thereof is required prior to deployment.
[0018] Another object of the present invention is to provide an adjustable work surface device that can support an office computer and its peripheral items, common work place items, and the user bearing down on the device without risk of collapsing the device during use.
[0019] Yet another object of the present invention is to provide an adjustable work surface device that is securely lockable in a given position with respect to the underlying work area and provides an assisted means of adjustment that requires low levels of input from the user during changes in position.
[0020] Another object of the present invention is to provide an adjustable work surface device that is of simple construction and offers a single degree of freedom, wherein the assembly can be readily fabricated from materials that permit relative economy that are commensurate with durability.
[0021] Other objects, features and advantages of the present invention will become apparent from the following detailed description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTIONS OF THE DRAWINGS
[0022] Although the characteristic features of this invention will be particularly pointed out in the claims, the invention itself and manner in which it may be made and used may be better understood after a review of the following description, taken in connection with the accompanying drawings wherein like numeral annotations are provided throughout.
[0023] FIG. 1 shows a perspective view of the present invention.
[0024] FIG. 2 shows a perspective view of the present invention, wherein its work surface platform is in its most elevated position.
[0025] FIG. 3 shows view of the work surface platform from an underside perspective, wherein the preferred locking means is illustrated.
[0026] FIG. 4 shows a cross section of the platform tongue within the rail of the frame upper portion when in a locked position.
[0027] FIG. 5 shows another view of the work surface platform from an underside perspective, wherein a second contemplated locking means is illustrated.
DETAILED DESCRIPTION OF THE INVENTION
[0028] Reference is made herein to the attached drawings. Like reference numerals are used throughout the drawings to depict like or similar elements of the adjustable work surface device. For the purposes of presenting a brief and clear description of the present invention, the preferred embodiment will be discussed as used for elevating a work area for a seated or standing user in an office environment, wherein improved ergonomics and a reduced likelihood of injury is achieved. The figures are intended for representative purposes only and should not be considered to be limiting in any respect.
[0029] Referring now to FIG. 1 , there is shown a perspective view of the adjustable work surface of the present invention. The device comprises an L-shaped frame having an upper frame portion 11 and a lower frame portion 21 . The upper frame portion 11 comprises a U-shaped assembly having a first and second upright member 12 connecting to an upper, horizontal member 13 that form an inverted “U”. The lower frame portion 21 comprises a substantially rectangular frame having side members 22 that are adapted to provide a widened base having sufficient weight to support the load of the frame and any anticipated working loads without tipping forward or rearward. Along the base of the upper frame portion 11 , the two frame portions are secured together to establish the overall L-shaped frame configuration that acts as a singular assembly when lifted and transported.
[0030] Along the upright members 12 of the upper frame portion 11 is a first and second rail 14 . The rail 14 is an elongated slot that accepts a protruding tongue from the horizontal work space platform 31 extending therefrom. The work space platform 31 is connected to both rails 14 and is cantilevered from the upper frame portion 11 . The rails 14 preferably extend partially up the lengths of the upright members 12 in order to limit the upper extent with which the work space platform can be raise. However, it is contemplated that the rails 14 can extend fully upward along the upright members 12 . The upper surface 32 thereof provides a clean work area for supporting a personal computer and its peripherals thereon. The surface 32 may also be sufficiently large enough to accommodate a writing space and support work materials thereon for the standing or seated user.
[0031] The work space platform 31 is supported below its upper surface 32 by way of a platform frame 33 . This frame 33 supports the rail tongue members that connect to the upstanding rails 14 and support the weight of the upper surface 32 , along with any articles placed thereon. The frame 33 comprises a substantially rectangular structure that is adapted to fit within the interior of the L-shaped frame lower portion 21 when the platform 31 is in its lowest position. In this way, the platform frame 33 and frame lower portion 21 share a common geometry and overlap one another to allow the platform upper surface 32 to descend as far as possible towards the underlying support surface while providing stable support therefor.
[0032] Referring now to FIGS. 1 and 2 , the internal spring mechanism 61 and the locking means 41 are illustrated. The internal spring mechanism 61 comprises an elongated spring that extends within and along each side member 22 of the frame upper portion 11 and connects to the work space platform 31 from within the member 22 . The spring biases the platform 31 away from the underlying work surface and the frame lower portion 21 , which facilitates lifting of the platform 31 and lifting of any contents thereon without straining. This is critical for those users with existing back injuries, wherein lifting and re-positioning of the platform 31 is facilitated with ease.
[0033] The spring 61 preferably connects within the side members 22 towards the upper extent thereof to provide an upward force to assist the user when elevating the platform 31 along the rails 14 . The spring rate of the springs 61 are designed to offset the weight of the platform 31 and some anticipated load thereon; however the spring rate is not such that the platform 31 will move rapidly on its own without user input, but rather an assistive device that reduces the weight of the platform when lifting the same. This prevents injuries to the user who mishandles the platform, wherein the platform 31 is not overly biased to accelerate the platform 31 on its own.
[0034] To lock the platform 31 into place along the rails 14 and to lock the spring 61 in a static position, a pair of locking means 41 are disposed under the platform 31 and adjacent to the rails 14 . The locking means 41 are preferably cam locks having a lever that clamps the platform tongue (not shown) and the base 34 of the platform against the rails 14 and against the frame upper portion 11 . The cam locks prevent the platform 31 from moving vertically along the rails 14 and allow the user to place objects thereon within fear of the platform shifting or lowering under the weight. When repositioning is desired, the locks 41 disengaged and the spring 61 assists the user lifting the platform 31 . When lowering the platform 31 , the user can place pressure on the upper surface 32 of the platform 31 to compress the spring 61 , whereafter the cam locks 41 can be re-engaged to lock the platform in a lowered position.
[0035] Referring now to FIG. 3 , there is shown a view of the cam lock 41 of the present invention, which is situated below the platform surface 32 and within the platform frame 33 . The cam lock 41 includes a pull handle 42 that controls an armature within the platform frame 33 . As shown in the cross section of FIG. 4 , the armature 18 connects to the tongue 19 of the platform, which is positioned within the rail 14 of the frame upright members 12 . The tongue 19 is drawn against the rail 14 surface by the armature 18 , which is controllably positioned by the cam lock. When in a locked position, the tongue 19 bears against the rail interior. The bearing of the tongue 19 within the frame is a frictional brake that prevents the tongue 19 from sliding within the rail 14 and sandwiches the upright member 12 between the tongue 19 and the base 34 of the platform. This prevents sliding motion (vertical motion) of the platform when the cam lock is engaged and in a locked position. When in an open position, cam lock releases the tongue 19 to slide within the interior of the rail 14 .
[0036] Referring now to FIG. 5 , there is shown an alternate embodiment of the rail 14 . This embodiment, rather than locking the platform by way of a cam locking mechanism and frictional brake, allows the tongue to freely slide within the rail 14 and is locked into position using a spring pin 51 locking means. The spring pin 51 comprises a spring-loaded pin that engages a pin hole 52 along the rail length. A plurality of pin holes 52 are disposed therealong to allow the user to precisely locate the platform along the rail 14 , wherein the pitch of the pin holes 52 can sufficiently small to allow for many predefined lockable platform positions with respect to the lower frame portion.
[0037] An alternative embodiment of the rail and tongue connection is a sliding joint attachment that includes roller bearings or rollers commonly deployed in drawered furniture items (drawer sliders). Use of roller bearings facilitates sliding motion of the platform along the frame upper portion and eliminates any binding. Overall, the connection between the work space platform and the frame upper portion is that of a translational joint, wherein the platform is free to be vertically positioned and movable in a single degree of freedom (translationally upwards or downwards).
[0038] The present assembly is adapted to provide a ready means of elevating a work station above an existing work area, thereby enabling the user to position his or her computer and work surface in the most ergonomic position possible relative to his or her proportions. The device is ideal for elevating a desk that cannot otherwise articulate, for providing a means (even temporary means) of permitting standing work by the user, and further for providing a means of changing the work area on demand with minimal exertion from the user. This enables those with work place injuries, chronic pain, or those starting to have issues with an otherwise non-ergonomic work area to correct their environment for a more healthy work station.
[0039] It is submitted that the instant invention has been shown and described in what is considered to be the most practical and preferred embodiments. It is recognized, however, that departures may be made within the scope of the invention and that obvious modifications will occur to a person skilled in the art. With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.
[0040] Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention. | A height adjustable work surface is provided, which includes an L-shaped frame supporting a cantilevered platform adapted to support computer and work space items thereon. The frame includes an upstanding rail portion and a horizontal base support, whereby the rail portion slidably supports a work surface platform above the base support. The rail portion and base support are U-shaped members, whereby a first and second rail is provided to support the work space platform. Cam locks are provided to lockably secure the platform in a given position, whereby the platform will not freely slide until unlocked and will support load thereon. An internal spring mechanism biases the platform to reduce lifting load requirements during adjustment of the platform. Overall, the device provides a means to adjust the elevation of work surface for a seated or standing user. | 0 |
PRIOR APPLICATION DATA
This application is a divisional of U.S. patent application Ser. No. 849,022, filed Nov. 7, 1977.
BACKGROUND OF THE INVENTION
The present invention concerns the generating of shocks in the ground for seismic exploration, and in particular concerns the production of shocks by the dropping of a weight on to the ground.
The weight dropping method has been known for a long time and is particularly described in the U.S. Pat. No. 2,851,121. In this known method a lorry fitted with a lifting jib is used to raise a heavy solid body to a certain height which is then allowed to fall on to the ground. In current practice, for example, a heavy mass of three tons is dropped from a height of three meters. Usually the energy released in the ground by the shock produced by the impact of the heavy mass is relatively low, and so it is advantageous to use a succession of such shocks giving rise to different, refracted or reflected waves which return through the ground to seismic detectors, and to integrate the different signals corresponding to different shocks to obtain a composite signal containing significant data.
The method of prospecting by weight dropping, described above, offers the essential advantage of being able to be carried out near houses (which is not the case with methods involving the exploding of charges); it is not in itself very effective from the seismic point of view, in the sense that it only introduces low amounts of energy into the ground; in any case, it requires the use of a heavy land vehicle, which precludes its use in hilly areas.
It is an object of the present invention to provide a new mode of seismic prospecting by weight dropping particularly involving a new heavy mass.
Another object of the present invention consists in the replacing of the land vehicle previously used by an aircraft, particularly a balloon or a helicopter. Helicopters are known to be more and more used in seismic expeditions. A priori, the use of aircraft allows the release of a heavy mass from a height much greater than usual heights and the potential energy of the heavy mass, which varies with the height of the drop, can be especially increased thereby, all things staying equal in other respects. For example, it seems advantageous, from the energy point of view, to work with a mass of 500 kgs for dropping heights comprised between 5 and 100 meters.
In a complementary way, the increase in the dropping height increasing the speed of arrival on the ground results in an appreciable enlargement of the spectrum of the seismic wave produced, which improves the seismic data obtained.
The first trials conducted by applicants consisted purely and simply in transposing the conventional technique to the release-by-aircraft situation, using a hovering helicopter equipped for transporting by sling and fitted with a system of electromagnetic release controlled by the pilot. Heavy masses, solid and rigid, of various shapes were released thus from various heights.
The results obtained proved nearly unusable for all of the following reasons:
on hard terrain and even on relatively loose terrain, the mass rebounds on its first impact with the ground and gives rise to a series of successive shocks in a random and unpredictable way; for that reason, the reflected or refracted seismic waves are not exploitable in practice: they contain parasite waves.
on very loose terrain, the mass buries itself in the ground, and there is a barely usable shock wave, and a significant deterioration in the surface of the ground.
Thus, it is apparent that the method putting into practice a weight drop from an aircraft cannot be a simple transposition of known weight dropping methods.
Essentially, for a seismic prospecting by aircraft, the applicants propose a new releasable heavy mass characterised by its structure and by its functions.
SUMMARY OF THE INVENTION
the releasable heavy mass according to the invention is essentially characterised in that its comprises very many individual heavy units connected together in a way sufficiently loose to allow the deformation of the mass without the assembly, however, losing its unity on impact. Furthermore, the mass comprises, according to the invention, means for ensuring and maintaining the inherent flatness of the area of the movable mass coming into contact with the ground. A seismic prospecting method using this mass involves releasing the mass from an aircraft which preferably is a helicopter.
In a first embodiment, the individual heavy elements can be formed by pieces of large metal shot connected by a special casing. In a second embodiment, preferred at the moment, taking into account realised experimental tests, the individual elements are formed by links connected together to form segments of chain disposed in the form of a star or in the form of a cobweb pattern, by elastically deformable, jointed structures.
The specification which follows with reference to the attached drawings will make the invention clearer, while making evident all its advantages and characteristics with reference to preferred embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 represents diagrammatically a heavy mass according to the invention in position about to be released,
FIG. 2 represents this same mass at the time of impact with the ground,
FIG. 3 represents diagrammatically a casing of this mass,
FIG. 4 represents diagrammatically the cobweb of chains forming the preferred embodiment,
FIG. 5 is a section along the section line V--V of FIG. 4,
FIG. 6 shows a way of suspending the cobweb of chains.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
First the embodiment in FIGS. 1, 2 and 3 will be described. A heavy mass 100 is formed of metal shot, particularly of iron shot, enclosed in several casings 101, 102 . . . . The individual elements of shot have, for example, a diameter of 0.5 to 3 cm. The exterior casings 101, 102 . . . must be both resistant and flexible. An alternation of resistant and flexible casings can be used. The resistant casings are advantageously formed by a metal trellis made of cables or of metal strands; preferably, metal strands made from thin flexible strips, as represented in FIG. 3, are used. The flexible casings are advantageously made of rubberized fabric. As a variant, a superposition of metal nets or trellis can be used. A single casing of rubber strengthened with wire can also give satisfaction.
In the suspended state shown in FIG. 1, the mass 100 takes, as represented, the shape of a pear. At the base of this pear, a plane framework 103 is placed, rigid enough to inherently give the base at least approximate flatness, as shown. The centre of gravity of the suspended mass is nearer the base 103 than the suspension point 110.
FIG. 2 shows impact of the mass 100 on a relatively hilly piece of ground S. The flexibility of the mass allows it to be deformed on impact to assume the shape of the ground S and to absorb, if not to suppress completely, the rebound effect. Moreover, the width of the base 103 substantially avoids penetration by the mass when it falls on to very soft ground. Finally, the inherent flatness of the base 103 ensures, at the time of an impact on relatively flat ground, the brevity of the impact, all points of the base, in practice, coming into contact with the soil together.
Of course, the suspension and release apparatuses for the mass 100 comprise means known in themselves and suitable for seismic application and thus require no further description. For detecting arrival on the ground in particular, the mass of shot incorporates a shock detector, for example of the known type in which the shock closes an electric contact; such a detector is advantageously connected by an electric cable to the release helicopter, this electric cable being, before release, wound on a roller with an automatic resilient return.
FIGS. 4 and 5 illustrate the most preferred embodiment of the invention. The mass 200 according to this preferred embodiment comprises a central metal disc 210 on which is mounted, as before, a shock detector or accelerometer 220. Around the central axis of the disc 210 extend six radial arms 230. As can be better seen in FIG. 5, each arm 230 is formed by an element of metal cable 231 fixed at one end 231a to the disc 210 and held at its other end 231b by a keeper or holding element. On each arm 230 are threaded successively a series of springs 232 and hollow metal braces 233, each brace having, as seen in the drawings, the shape of a spool. The springs 232 are put under compression and all the elements of each arm are thus maintained in radial tension under the effect of the springs. Each arm 230 thus forms a joined assembly which is deformable but which always returns to the straight position.
Chains 251, 252, 253, 254, are mounted in a structure of concentric hexagons at different distances from the central disc 210. To do this, the angle links of the chains span the different braces. Thus a flexible structure is finally obtained, with elements of individual links extending substantially in a plane according to a network of chains and deformable arms, in the form of a cobweb. In a typical example, the central disc can have a weight of the order of 100 kg for a chain weight of 350 kg and a total weight of the order of 500 kg.
It is moreover advantageous to provide an interchangeable central disc 210 in order to be able to adapt the releasable mass 210 to different conditions of use by slight variations of the distribution of the masses.
It is easily seen that the releasable mass 200 possesses, to a greater degree even than the mass 100, the properties which have appeared from experiment to be necessary for a weight drop carried out from a great height which is to be usable seismically, namely, the properties of flexibility, large base surface and inherent flatness.
Of course, other geometric arrangements than the hexagon can be realised and are included in the invention. Numerous networks of chains can be placed in a symmetrical fashion around a disc or a central weight, with resilient means tending to maintain the inherent flatness of the structure in a polygonal or circular arrangement.
For such plane structures of chains, particular precautions must be taken for suspension and release, and FIG. 6 shows a preferred mode of suspension for the mass 200 which is represented schematically by outlines. Six suspension slings 250 hold the mass 200 at the angles of its external periphery and one at its centre; these seven slings are joined at 260, another sling 264 joining their connection point 260 to the point of suspension 270 from a helicopter. It must be noted that in this suspension condition, the mass is slightly deformed, its concavity being turned upwards. On release, the springs 232 bring the mass 200 back to inherent flatness.
Again, after release, the mass must fall without the slings 250 coming between the mass and the ground. To do this, the slings are fitted with brace-sails 280 made, for example, of fabric, which are capable of creating a drag (parachute effect) to keep the point 260 absolutely above the mass 200. In all cases where it is desired that the mass 200 keep rigorously horizontal, the brace-sails 280 can also be given a size sufficient for the parachute effect to brake the drop of the mass slightly while keeping the latter horizontal.
Thus the deformable mass according to the invention enables the production of seismic shocks by weight dropping from aircraft with considerable drop heights and particularly drop heights of between 5 and 100 meters, the shock waves obtained being most often more exploitable and richer in data than those conventionally obtained.
In a simplified variant of the apparatus of FIGS. 4 and 5, the radial arms, anchored in the central disc 210, are cables exhibiting a rigidity sufficient to ensure, once the mass has been released, to restoration of the mat of chains to the plane condition. On each arm are threaded successively a series of braces whose role is to maintain the distance between the concentric hexagons of the chain.
In another variant of embodiment, the jointed arms are formed by cables on which are threaded successively cylinders of rubber or similar compressible material and round links forming part of chain elements, such as 251, 252, 253, 254.
Such cylinders of rubber are kept under compression and play the same role as the springs 232, in such a way that each elastically deformable arm is maintained in a state of radial tension while extended. | A releasable heavy mass is provided which is capable of producing by impact with the ground a shock which can be used in seismic prospecting.
This mass is characterized by the fact that it comprises very many individual heavy elements connected together in a way loose enough to allow deformation of the mass without loss of cohesion on impact, and in that its base is of considerable area relative to the surface of the whole mass and is maintained substantially plane at least after release and up to impact. The mass is, in seismic prospecting, released from a helicopter. | 8 |
BACKGROUND OF THE INVENTION
This application is a continuation-in-part of my earlier application Ser. No. 672,608 filed Apr. 1, 1976 and entitled "Dental and Medical X-Ray Apparatus", abandoned.
This invention relates generally to X-ray apparatus and techniques; more particularly, it concerns method and equipment enabling rapid X-ray examination of teeth, with substantially reduced exposure to radiation.
Present systems of X-ray examination of human teeth require up to eighteen exposures, accompanied by objectionably excessive amounts of side radiation to sensitive areas of the brain, cortex, sinus, throat, optic and auditory nerve centers. Recently, a technique has been proposed according to which an X-ray target is introduced into the mouth, and radiation is directed from the target back through the teeth to film supported outside the mouth, thereby to produce a so-called high resolution, panoramic radiograph. One problem encountered with that type equipment concerns the tendency to produce gagging of the patient, due to the necessity of locating the target sufficiently close to the throat that back teeth will be exposed to produced X-rays. Another problem has to do with the requirement that the upper and lower teeth be alternately exposed to radiation, which in turn requires that the shield associated with the target be re-arranged. This means that the target is removed from the oral cavity after the first exposure (as for example irradiation of the upper teeth, after which the target is re-introduced to enable the second exposure (of the lower teeth) which increases the risk of gagging and otherwise discomfort the patient.
SUMMARY OF THE INVENTION
It is a major object of the invention to provide improvements in technique and apparatus which will overcome the above objects and disadvantages. Another object is to provide target and shield configurations within the oral cavity whereby gagging will be eliminated, and all of the front and rear teeth will be irradiated, while flat upper and lower portions of the mouth and sensitive areas of the head will not be unintentionally exposed to X-rays.
Basically, the invention is embodied in apparatus that includes:
(a) X-ray tube means providing an electron beam,
(b) a beam target carried by said means and located axially rearwardly thereof to be received rearwardly into a patient's mouth,
(c) the target angled relative to said axis to produce a radiation pattern that extends forwardly of the target and also rearward and sidewardly of the target, the beam forming a microfocal spot on the target, and
(d) a shield extending forwardly above and below the target and also rearwardly thereof.
As will be seen, the shield projects forwardly both above and below the target to block radiation from passing to undesirable areas of the patient's head zones above the upper teeth and below the lower teeth; the shield may typically provide lateral openings to pass X-rays toward the back upper and lower teeth; the target may typically be angled rearwardly and sidewardly at one or both sides of the equipment axis so that radiation may pass through one or both of the shield side openings to provide access to the back teeth as well as front teeth; the microfocal spot is sufficiently small that the image of a tooth on X-ray film has a sharp boundary; and the radiation pattern produced by the target may be transversely shifted, as for example by sideward deflection of the beam to strike different portions of the target, or by physical rotation of the target, so that the target need not be removed from the mouth between exposures.
Another object concerns the provision of method and means to vary the size of the beam impingement spot on the target, for purposes as will appear.
These and other objects and advantages of the invention, as well as the details of illustrative embodiments, will be more fully understood from the following description and drawings, in which:
DRAWING DESCRIPTION
FIG. 1 is a perspective showing of high voltage generator equipment and X-ray tube floor mount associated with the invention;
FIG. 2 is a cross sectional view of gun and target apparatus embodying the invention;
FIG. 3 is a perspective showing of an alternative X-ray tube ceiling mounting;
FIGS. 4 and 5 are top plan views of gun and target relationships, in schematic form;
FIG. 6 is an enlarged frontal view of the target and shield;
FIG. 7 is a view like FIG. 4 in FIG. 5, but showing an alternative target; and FIG. 8 shows another target;
FIG. 9 is a diagram of X-ray interception by a tooth and film;
FIG. 10 is another diagram of X-ray generation at a microfocal spot on a target, and X-ray interception by a tooth and film, and FIG. 11 is a circuit diagram.
DETAILED DESCRIPTION
Referring first to FIG. 1, x-ray apparatus 10 includes a high voltage generator console 11 to which X-ray tube 12 is electrically connected, as via cable 13. A suitable adjustable support for the tube 12 includes upright post 14 carried by the console; an arm 15 adjustably attached at 16 to the post to rotate about a vertical axis; and a mount 17 for the tube apparatus and adjustably attached at 18 to the arm 15 to rotate or swivel about a horizontal axis.
Extending the description to FIG. 2, the tube means 12 includes a housing 19 containing the micro-focus X-ray tube 20 which produces an electron beam 21. A beam target 23 is carried by the tube means and is located axially rearwardly thereof (relative to the patient's head 22) to be inserted or received relatively rearwardly into the patient's mouth. The forward and rearward axis appears at 36. In the example shown, the target 23 is carried by the rearward end portion of a rearwardly axially elongated tubular element 24 projecting into the patient's mouth. The cable 13 is attached to the housing at 26, and passes through an insulator 27 to the gun 20a. The inner conductor of the cable is at high potential while the outer cable sheath is at ground potential and is solidly connected to the tube housing. The tube anode is also at ground potential and only the electron gun 20a is at high potential, insulated by gas or oil inside the tube housing. This provides the necessary electrically shock-proof mounting for intra-oral radiography.
An alternative ceiling mount for the tube 112 in FIG. 3 includes an upright post 114 affixed to or carried by the ceiling of a room. Elements 115-118 correspond to elements 15-18 in FIG. 1.
The target 23 may consist of tungsten embedded in a copper shield 31, the latter having upper and lower rearwardly tapering surfaces 80 and 81 which define an angle α therebetween. That angle subtends a zone which encompasses the patient's upper and lower teeth (including root areas) indicated at 32 and 33, but not including undesirably irradiated areas, the latter as well as the throat being protected from radiation impingement. In this regard, an X-ray film holder 34 is carried by the apparatus 12 to extend at the front of the patient's mouth, and to overlap his cheeks at opposite sides of the mouth. The film holder is also substantially subtended by the angle α. The target and shield are carried by the anode envelope 35 with is in turn carried by the tubular element 24. The anode envelope material is a low X-ray absorbtion material such as beryllium, titanium or aluminum, and forms the window for radiation emission. Another such window material is ceramic, as for example beryllium oxide, aluminum oxide, or combination of same with up to 20% by weight of silicon dioxide as a vitreous fluxing material.
Extending the description to FIG. 4, the tube anode 37 is shown axially rearwardly of the gun 20a. The target 23, located axially rearwardly of the anode, has surfaces 23a and 23b angled rearwardly and transversely (i.e. sidewardly) relative to the axis 36. Surfaces 23a and 23b are transversely symmetrical relative to axis 36, and taper axially forwardly, as shown, at angles β relative to an upright plane 39 normal to axis 36; angle β may for example be about 20°.
In accordance with an important aspect of the invention, means is provided to effect transverse shifting of the radiation pattern produced in response to beam incidence on the target. Such means may comprise a magnet supported to be shifted transversely to deflect the beam transversely relative to the target; for example, FIG. 4 shows the magnet 40 suitably supported at 41 by the tube at the right side of the axis 36, and rearwardly of the anode 37, the magnet acting to deflect the beam 21 transversely rightwardly so that it impinges on surface 23a. As a result, X-rays are produced to travel forwardly through the upper and lower teeth and face at the right side of the patient's mouth and to the film in holder 34, such teeth indicated at 44. Actually, radiation may extend transversely over the 180° angle indicated, and defined by the plane of surface 23a, and the shield does not interrupt such sideward radiation. See in this regard the shield openings 45 at opposite sides of the target, in FIG. 6. Accordingly, the shield has sections 31a and 31b above and below the target.
Upon completion of exposure of the right side teeth 44 to X-radiation, the magnet 40 is transversely shifted to the left side of axis 36, i.e. to a position as for example appears in FIG. 5. In that position, suitably supported at 41a by the tube, the magnet acts to deflect the beam 21 transversely leftwardly, so that it impinges on target left surface 23b. As a result, X-rays are produced to travel forwardly through the patient's upper and lower teeth and face at the left side of the mouth, and to the film in the holder 34, such teeth indicated at 44a. Here again, radiation may extend transversely over the 180° angle indicated and defined by the plane of surface 23b. The shield does not interrupt such sideward radiation, but does limit radiation in upper and lower directions, to remain within the angle α previously described.
Holders 41 and 41a may suitably releasably retain the magnet, as by detents. If desired, the magnet 40 may be rotatably carried to swing about axis 36 between the positions seen in FIGS. 4 and 5.
FIG. 7 shows an alternative means to effect transverse shifting of the X-ray pattern with a fixed target, seen in FIG. 8. In this view, the tube 12 and supported target 70 are rotatable about axis 136 between the solid line and broken line target surface positions shown in 50 and 50a. For example, in FIG. 1 the mount 17 may incorporate means to rotatably support the tube 12 to rotate about axis 136. A sidewardly projecting handle to rotate the tube 180° outside the mouth appears at 160. A tube position locking toggle appears at 161. In target position 50, the operation corresponds to that described in FIG. 4; whereas in target position 50a, the operation corresponds to that described in connection with FIG. 5. Envelope 135 and support element 124 corresponds to items 35 and 24 in FIG. 2.
FIG. 8 shows the modified tungsten target 70 supported by shield 71, the latter projecting forwardly at 71a sidewardly of the target to block X-ray sideward travel and confine same to the region 72. The latter is related to teeth 144 at one side of the mouth, as shown. Portions of the copper shield 71 not shown extend above and below the target and forwardly as in FIG. 6, so that a side opening is formed at only one side of the target. Target 70 and shield 71 rotate with the tube, as explained above.
It should be pointed out that since the X-ray intensity necessary for the required film density is proportional to the square of the focus-to-film distance, the radiation output of the X-ray source at 5cm need be only 1/25 or 4% of that required at 25cm with the conventional extra-oral X-ray tube distance.
The wide-angle radiation pattern of the present tube can expose a panoramic view of half the mouth including upper and lower teeth in one exposure, so that only two X-ray pictures are necessary instead of 18 with conventional extra-oral tubes. When this correction is included in the 4% noted above, the total reduction in radiation amounts to only 0.66% of that required with conventional dental radiography for the same visual information. This is a very significant reduction in radiation dosage which is less than 1% of the present radiation level for whole-mouth dental radiography. In addition, the integral connection of the probe shield and target enables grounding of the target and probe for shockproof use, and without need for coolant jacketing.
Referring to FIG. 9, it shows an unimproved means for generating an X-ray beam 80 at an elongated target region 81. X-rays 80a and 80b emanate from one end of region 81 to encompass the tooth 82, and X-rays 80c and 80d emanate from the opposite end of region 81 to encompass the tooth. The tooth boundary is not sharply delineated at the film 83, there being shadowy regions 84 and 85 at the film between rays 80a and 80c, and between rays 80b and 80d, respectively. The electron beam directed at the target is indicated at 86, within probe 87.
FIG. 10 shows an improved means for generating an X-ray beam 90 at a microfocal spot at target 91. The tube means, indicated at 92, includes structure (as for example focussing anode 37) to cause the electron beam 93 to converge and form the beam impingement microfocal spot, of sufficiently small size that X-radiation 90 is directed toward the tooth 94 and film 95 to produce a sharp boundary tooth image 96 on the film. The "spot" 91 may have an overall maximum cross-dimension of between about 0.05 and 0.10 millimeters, to produce the sharp boundary tooth image. Note the X-rays 90a and 90b encompassing the tooth and appearing to emanate from a point source at the target. A figure of merit for the reduction of geometric unsharpness U g is directly related to focal spot size f s and image magnification M as follows:
U.sub.g = f.sub.s (M-1)
where M = focus to film distance ÷ focus to subject distance.
The tube means 92 also typically includes a forming electrode 97 having a central opening 97a into which electron emitting filament 98 projects. The electron beam is precisely converged by the electrostatic field (see broken line 99) produced by anode 37, and resulting in a simple convergent "lens effect". A high beam "perveance" (I = V 3/2 ), i.e. electron flux up to 3 milliamperes, also results, with better image production at the film. The probe 100 may be narrow and hence less objectionable in patient's mouth due to the converging of beam 93, and also due to the absence of any need for a coolant jacket about the single wall probe. A window 101 carried by the probe may consist of ceramic material, or other material, as described above, to pass the X-ray beam 90.
FIG. 11 schematically shows circuit means to adjust the bias on the anode 37, and hence the electrostatic field strength and the size of spot 91; the power (KV) applied to the beam; and the operation of a microswitch which controls energization of the X-ray tube. For example, if push-button switch 120 is operated as for example for intra-oral mode use of the probe, the bias source 121 may energized to a level say of about -50 volts appearing on lead 122 connected to electrode 37 (whereby the size of spot 91 is then about 0.1 mm, for example); the "power" source 123 may be energized to a level say of about 50 KV applied via lead 124 to the gun; and the position control circuit 128 of microswitch 125 is completed via lead 126. The microswitch is then activated to effect power application (see power source 155) to the X-ray tube only if the probe 100 has been rotated (see arrows) so as to direct the X-ray beam toward teeth or other zones which are not "undesired", i.e. radiation is then blocked by the shielding, as described, from passing to undesired areas of the patient's head zones.
On the other hand, if push-button switch 130 is operated, as for example for extra-oral mode use of the probe to provide dental X-rays (with film then in the patient's mouth), the bias source 121a may be energized to a level say of -25 volts (whereby the size of the spot is increased to about 0.3 mm for example); the "power" source 123a may be energized to a level say of about 70-90 KV; and the position control circuit 128a of the microswitch 125 is then deactivated, so that the X-ray tube is powered in any rotary position of the probe, as during extra-oral operation. The increased size of the spot is then no problem since the probe and target are normally located at sufficient distance from the patient's face to obviate shadowing.
Microswitch 125 may be carried by the mount 17. The probe 24 may carry a button 150 to engage and displace the microswitch element 125a, on rotation of the probe to the position shown.
The push-button switches 120 and 130 may be gang connected as at 140 so that closing of switch 120 opens switch 130 to deactivate sources 121a, 123a and 128a; and closing of switch 130 opens switch 120 to deactivate sources 121, 123 and 128. See also power sources 158 and 159. The circuitry of FIG. 11 is schematic, and variations and refinements can of course be made all within the scope of the inventive intent.
It is therefore seen that provision is made to increase power to the tube and increase spot 91 size (preventing pitting or eroding of the target at high beam current densities) for exta-oral operation. | Dental X-ray apparatus characterized by very substantial reductions in radiation exposure of the patient, comprises
(a) X-ray tube means providing an electron beam,
(b) a beam target carried by said means and located axially rearwardly thereof to be received rearwardly into a patient's mouth,
(c) the target angled relative to the said axis to produce a radiation pattern that extends forwardly of the target and also rearwardly and sidewardly of the target, said X-ray tube means including structure to cause the electron beam to form a beam impingement spot on the target of sufficiently small size that radiation emanating from said spot and directed toward a tooth and film produce a sharp boundary tooth image on the film, and
(d) an X-ray absorbing shield adjacent the target rearwardly thereof and extending forwardly at the side of the target, the shield and target being integrally connected, the shield defining a probe that projects rearwardly for reception into the patient's mouth. | 7 |
CROSS-REFERENCE TO RELATED APPLICATION
This is a continuation of identically-titled U.S. patent application Ser. No. 12/905,847, filed Oct. 15, 2010, which is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is directed to methods for the treatment of human cancers, daily dosage forms for administration to cancer patients, and methods of formulating such dosage forms. More particularly, the invention is concerned with the administration of daily dosage forms (e.g., aqueous mixtures, capsules, pills, or tablets) containing from about 10-6,000 mg of each of β-sitosterol, isovanillin, and linolenic acid. Such treatment provides a marked decline and/or elimination of cancerous tumors, particularly those of the bladder, breast, liver, and lung, and a corresponding enhancement of the wellness and lifestyles of the treated patients.
2. Description of the Prior Art
Cancer is a generic term for a large group of diseases that can affect any part of the body. Other terms used are malignant tumours and neoplasms. One defining feature of cancer is the rapid creation of abnormal cells that grow beyond their usual boundaries, and which can then invade adjoining parts of the body and spread to other organs. This process is referred to as metastasis. Metastases are the major cause of death from cancer.
Cancer is a leading cause of death worldwide. The disease accounted for 7.4 million deaths (or around 13% of all deaths worldwide) in 2004. The main types of cancer leading to overall cancer mortality each year are:
lung (1.3 million deaths/year) stomach (803 000 deaths) colorectal (639 000 deaths) liver (610 000 deaths) breast (519 000 deaths).
More than 70% of all cancer deaths occurred in low- and middle-income countries. Deaths from cancer worldwide are projected to continue rising, with an estimated 12 million deaths in 2030.
The most frequent types of cancer worldwide (in order of the number of global deaths) are:
Among men—lung, stomach, liver, colorectal, oesophagus and prostate Among women—breast, lung, stomach, colorectal and cervical.
Cancer arises from one single cell. The transformation from a normal cell into a tumour cell is a multistage process, typically a progression from a pre-cancerous lesion to malignant tumours. These changes are the result of the interaction between a person's genetic factors and three categories of external agents, including:
physical carcinogens, such as ultraviolet and ionizing radiation chemical carcinogens, such as asbestos, components of tobacco smoke, aflatoxin (a food contaminant) and arsenic (a drinking water contaminant) biological carcinogens, such as infections from certain viruses, bacteria or parasites.
Some examples of infections associated with certain cancers:
Viruses: hepatitis B and liver cancer, Human Papilloma Virus (HPV) and cervical cancer, and human immunodeficiency virus (HIV) and Kaposi sarcoma. Bacteria: Helicobacter pylori and stomach cancer. Parasites: schistosomiasis and bladder cancer.
Aging is another fundamental factor for the development of cancer. The incidence of cancer rises dramatically with age, most likely due to a buildup of risks for specific cancers that increase with age. The overall risk accumulation is combined with the tendency for cellular repair mechanisms to be less effective as a person grows older.
Tobacco use, alcohol use, low fruit and vegetable intake, and chronic infections from hepatitis B (HBV), hepatitis C virus (HCV) and some types of Human Papilloma Virus (HPV) are leading risk factors for cancer in low- and middle-income countries. Cervical cancer, which is caused by HPV, is a leading cause of cancer death among women in low-income countries. In high-income countries, tobacco use, alcohol use, and being overweight or obese are major risk factors for cancer.
The most common cancer treatment modalities are surgery, chemotherapy, and radiation treatments. All of these techniques have significant drawbacks in terms of side effects and patient discomfort. For example, chemotherapy may result in significant decreases in white blood cell count (neutropenia), red blood cell count (anemia), and platelet count (thrombocytopenia). This can result in pain, diarrhea, constipation, mouth sores, hair loss, nausea, and vomiting.
Biological therapy (sometimes called immunotherapy, biotherapy, or biological response modifier therapy) is a relatively new addition to the family of cancer treatments. Biological therapies use the body's immune system, either directly or indirectly, to fight cancer or to lessen the side effects that may be caused by some cancer treatments.
The immune system is a complex network of cells and organs that work together to defend the body against attacks by “foreign” or “non-self” invaders. This network is one of the body's main defenses against infection and disease. The immune system works against diseases, including cancer, in a variety of ways. For example, the immune system may recognize the difference between healthy cells and cancer cells in the body and works to eliminate cancerous cells. However, the immune system does not always recognize cancer cells as “foreign.” Also, cancer may develop when the immune system breaks down or does not function adequately. Biological therapies are designed to repair, stimulate, or enhance the immune system's responses.
Some antibodies, cytokines, and other immune system substances can be produced in the laboratory for use in cancer treatment. These substances are often called biological response modifiers (BRMs). They alter the interaction between the body's immune defenses and cancer cells to boost, direct, or restore the body's ability to fight the disease. BRMs include interferons, interleukins, colony-stimulating factors, monoclonal antibodies, vaccines, gene therapy, and nonspecific immunomodulating agents.
Researchers continue to discover new BRMs, to learn more about how they function, and to develop ways to use them in cancer therapy. Biological therapies may be used to:
Stop, control, or suppress processes that permit cancer growth. Make cancer cells more recognizable and, therefore, more susceptible to destruction by the immune system. Boost the killing power of immune system cells, such as T cells, NK cells, and macrophages. Alter the growth patterns of cancer cells to promote behavior like that of healthy cells. Block or reverse the process that changes a normal cell or a precancerous cell into a cancerous cell. Enhance the body's ability to repair or replace normal cells damaged or destroyed by other forms of cancer treatment, such as chemotherapy or radiation. Prevent cancer cells from spreading to other parts of the body.
A variety of medicinal plants have also been employed in the treatment of human cancers. For example, plants from the hills and mountains of Israel, Palestine, and the Golan Heights have been used for many years for the treatment of many human diseases, including cancers. Among these are extracts of Arum palaestinum Boiss. See, for example, Said et al. Ethnopharmacological Survey of Medicinal Herbs in Israel, the Golan Heights and the West Bank Region . J. Ethnopharmacology. 83 (2002): 251-265.
The National Institutes of Health estimated that the total cost of cancer care in the United States in 2005 was $209.9 billion. Direct medical costs including inpatient and outpatient care, drugs, and devices accounted for $74 billion of this total, $17.5 billion was attributed to indirect morbidity costs (ie, lost productivity), and indirect mortality costs (i.e, lost productivity due to premature death) accounted for $118.4 billion. Given that cancer is largely a disease of older individuals, cancer expenditures will be of even greater concern in the future as the so-called baby boomer population swells the ranks of the US Medicare program from 42.5 million in 2005 to almost 70 million by 2030. As evidence of this demographic trend (and as evidence of unmet clinical need in oncology relative to other disease contexts), cancer recently surpassed heart disease as the number one killer of Americans younger than 85 years.
Despite the immense amount of worldwide research and efforts to stem the tide of cancer and its side effects, the disease in its many manifestations continues to be a huge problem. Therefore, any new cancer treatment having a curative affect and/or the ability to ameliorate cancer symptoms and improve the lifestyle of patients is highly significant and important.
SUMMARY OF THE INVENTION
The present invention provides an improved method for the treatment of a variety of human cancers, most especially female breast and lung cancers, by the administration to a cancer patient of a dosage form containing from about 10-6,000 mg (more preferably from about 1,000-4,000 mg, still more preferably from about 2,500-, 3500 mg, and most preferably about 3,000 mg) of each of (3-sitosterol, isovanillin, and linolenic acid. The administration is preferably carried out on a daily basis for a period of time of at least about 21 days, and more preferably until elimination of the patient's cancer, or at least the amelioration of the patient's cancer symptoms. The products of the invention can be in any dosage form, such as an aqueous dispersion, capsule, pill, and tablet. The most preferred dosage form is an aqueous dispersion.
In preferred practice, the dosage forms of the invention are prepared employing a decoction or tea using plant parts (preferably leaves and/or roots) of Arum palaestinum Boiss, or any other suitable plant parts of the genus Arum . However, such decoctions, standing alone, do not have the requisite amounts of β-sitosterol, isovanillin, and linolenic acid required in the invention. Accordingly, it is necessary to supplement or fortify the plant decoctions using amounts of β-sitosterol, isovanillin, and linolenic acid not derived from the plant decoctions. Advantageously, amounts of essentially pure β-sitosterol, isovanillin, and linolenic acid are added to the plant decoctions to achieve the foregoing amounts of these ingredients. The linolenic acid may be added in the acid form or as a salt (e.g., sodium or potassium salt).
If it is desired to administer an aqueous dispersion dosage form, the above-described fortified decoctions can be used directly without further additions or modifications. On the other hand, it is equally possible to provide solid dosage forms by the lypholization of the fortified decoctions to yield solid extracts. In any case, the goal of administration is to provide to the patient the above-noted milligram amounts of each of β-sitosterol, isovanillin, and linolenic acid on a daily basis.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In preferred forms, the invention involves the administration of a dosage form prepared using plant parts of Arum palaestinum Boiss, which grows naturally in the Middle East, and particularly in Palestine and adjoining regions. This plant is of the genus Arum , family Araceae, subfamily Aroideae, and tribe Areae, and has a Nomen No. of 4357. The name was verified on Nov. 5, 1985 by ARS Systematic Botanists. The species priority site is the Ornamental Plant Germplasm Center. The plant is also known by common names, including Black Calla and Solomon's-Lily.
Analysis of Arum palaestinum Boiss
A detailed examination designed to determine the identity of the chemical components of Arum palaestinum Boiss was undertaken using Gas Chromatography-Mass Spectroscopy (GC-MS). In particular, one gram of dried plant leaf was boiled in 100 ml of dichloromethane for approximately 30 minutes. After cooling, the liquid was filtered, followed by solvent evaporation under nitrogen to a final volume of 8 ml. This liquid extract was then analyzed using GC-MS. conducted at North Carolina State University. The instrument used was an Agilent Technologies 5975 GC-MS equipped with a DB-5 column. Sample volumes injected were typically 1 μL with spitless injection. The GC inlet was maintained at 300° C. with the initial oven temperature set at 60° C. Three minutes after injection, the oven temperature was increased at a rate of 5° per minute to a final temperature of 325° C., which was held for five minutes.
Background samples were collected and analyzed throughout the entire sample preparation procedure. Retention time comparison, EI mass spectrum interpretation, accurate mass analysis, and known standard comparisons were used in the qualitative analysis. Quantitation was accomplished by comparing the unknown concentrations to a set of standards of known concentrations. The following table sets forth the results of this study, wherein the relative amounts of chemical ingredients were normalized to the amount of hexadecanoic acid:
GCMS RESULTS Rela- tive Molecule Formula Amount hexadecanoic acid C16H32O2 1 linolenic acid C18H30O2 0.48 linoleic acid C18H32O2 0.44 oleamide C18H35NO 0.12 2-monopalmitin C19H38O4 0.17 phytol C20H40O 0.49 campesterol C28H48O 0.79 sitostenone C29H48O 0.085 stigmasterol C29H48O 0.29 isofucosterol C29H48O 0.13 5a-stigmastane-3,6-dione C29H48O2 0.038 beta-sitosterol C29H50O 1.9 cycloartenol C30H50O 0.19 dl-a-tocopherol C29H50O2 0.050 heneicosane C21H44 0.028 tricosane C23H48 0.093 pentacosane C25H52 0.29 heptacosane C27H56 0.88 nonacosane C29H60 2.1 hentriacontane C31H64 0.39 5,5,8a-Trimethyl-3,5,6,7,8,8a- C12H20O 0.15 hexahydro-2H-chromene 6-(3,3-Dimethyl-oxiran-2-ylidene)- C12H18O2 0.029 5,5-dimethyl-hex-3-en-2-one 2-butanone, 4(2,6,6-trimethyl -1,3 C13H20O 0.070 cyclohexadien -1 -yl) 2-cyclohexen-1-one, 4-(3-hydroxy-1- C13H20O2 0.042 butenyl)-3,5,5-trimethyl 2-cyclohexen-1-one, 4-(3-hydroxybutyl)- C13H22O2 0.12 3,5,5-trimethyl- 6-(3-Hydroxy-but-1-enyl)-1,5,5-trimethyl- C13H22O3 0.17 7-oxabicyclo[4.1.0]heptan-2-ol 3-Buten-2-one, 4-(4-hydroxy-2,2,6- C13H20O3 0.05 trimethyl-7-oxabicyclo[4.1.0]hept-1-yl)- isovanillin C8H8O3 0.012 cinnamic acid C9H8O2 0.018 2 methoxy 4 vinylphenol C9H10O2 0.035 2-propenal, 3-(4-hydroxy-3-methoxyphenyl) C10H10O3 0.063 docosyl hexadecanate C16H33O2-C22H44 0.081
Preparation of Fortified Aqueous Decoction of Arum palaestinum Boiss
In the preferred procedure, from about 12-18 grams (more preferably about 15 grams) each of Arum palaestinum Boiss comminuted leaves and roots were placed in a vessel containing about one gallon of water, along with fortifying amounts (from about 1-50 grams, more preferably from about 15-40 grams, and most preferably about 25 grams) of pure β-sitosterol, isovanillin, and linolenic acid obtained from Sigma-Aldrich of St. Louis, Mo. The β-sitosterol and isovanillin are in solid form, whereas the linolenic acid is a liquid. The mixture was then brought to a hard boil for approximately 10-15 minutes. Thereupon, the heat was reduced and the mixture was allowed to simmer for an additional approximately 10-15 minutes. The simmered mixture was then allowed to cool to ambient, either naturally or by placing the vessel in ice, to yield a yellowish liquid.
In the next step, the cooled and fortified mixture was filtered through a common household sieve to remove large solids. This results in an aqueous product which can be administered orally to a cancer patient. The preferred dosage is a total of 6 ounces per day, preferably with a regiment of 2 ounces, 3 times per day, with shaking or mixing of the liquid prior to ingestion. The shelf life of the product is 3-4 weeks.
If desired, the cooled and fortified mixture can be lypholized (freeze-dried) to obtain a dried extract. This extract may be then put in capsule form or may be tableted to provide solid dosage forms.
Case Histories of Cancer Patients
The following case histories exemplify actual uses of the fortified aqueous liquid dosage form of the invention, where each patient was dosed at a total of 6 ounces of the liquid per day.
1.)
Patient Age: 50
Gender: M
Cancer Type: Squamous cell carcinoma, with primary site at the base of the tongue
History: First diagnosed with squamous cell carcinoma in June, year 1. Cancer had metastasized to a lymph node in the neck with no primary cite identified. Problematic node removed by surgery as will as a complete tonsillectomy performed followed by radiation. In August, year 3, cancerous tumor found under patient tongue. Underwent radical tongue resection with forearm flap followed by radiation and chemotherapy. Base of tongue was determined to be primary cite of cancer. May of year 4, cancer again discovered in lymph nodes in neck. This was followed by another neck dissection and radiation. In March of year 5, cancer found at base of tongue, right side of neck, jaw and floor of mouth. This was followed by still another radical tongue resection with forearm flap, with neck dissection. In July of year 5, the cancer had returned to back of throat and floor of mouth. It was determined that no further surgery or radiation could safely be performed. Patient exhibited loss of appetite, loss of weight, lack of energy and generalized depression.
Prognosis: Diagnosis was terminal. Chemotherapy was given to slow the growth of tumors. PEG (stomach feeding tube) installed to allow for ingestion of nutrients once tumor had grown to the point where swallowing was impossible.
GHZ Product
History: Patient began taking GHZ-17 product in August of year 5, in conjunction with chemotherapy. Last session of chemotherapy was December, year 5. Patient continued to drink botanical product through February, year 6.
Outcome: Patient immediately showed an increase in appetite, energy level and weight gain. General attitude improved and patient began to exercise and participate in social activities. Tumors began to shrink in size and swallowing was no longer a problem. In March of year 6, scans indicated no tumors in any area of patient including the mouth, tongue, throat or any other part of the body. Patient has returned to full time work.
In July of year 6, cancer returned to throat and arm. Patient has difficulty in swallowing once again. Patient is back on chemotherapy as well as the botanical product. Upon resuming the GHZ-17 product, swallowing improved. Energy level and general attitude remain high. By October, tumors had shrunk in size and swallowing back to normal. Patient had gained 10 pounds lost during interval when swallowing was difficult and will return to work in early November. Chemotherapy is complete and patient will continue with GHZ-17 in an effort to reduce incidence of recurring tumors. In April of year 7, the cancer returned to the larynx which is not operable. Patient underwent chemo with serious side effects. Patient experienced loss of weight and depression. Patient continued with the elixir and discontinued chemo. Diagnosis was terminal and not expected to live 2 months. In August of year 7, the patient is showing signs of improvement. The elixir again improved the energy level and general disposition. Patient is not able to work but has begun to socialize. Diagnosis is for several more months of life.
2.)
Patient Age: 50
Gender: F
Cancer Type: Renal Cell Carcinoma, Stage 3
History: Patient diagnosed with Stage 3 Renal Cell Carcinoma on May 12, year 1. Tumor was 12 cm. Kidney and surrounding tissue was removed May 18, year 1. A CT scan in mid-July indicated the cancer had spread to the liver and lungs. Patient started chemotherapy (Sunitinib). Patient began to experience considerable pain, weakness, shortness of breath and lack of appetite. Patient also exhibited considerable jaundice.
Prognosis: Terminal
GHZ Product
History: Patient started taking GHZ-17 product in late August of year 1. Within 3 weeks the level of pain subsided and jaundice was visibly improved. In late September, x-rays indicated that the lung tumor had shrunk by 30%. Liver enzymes have risen to almost normal levels. Breathing has improved to the point where patient is now walking, going out to eat and shopping. Full set of MRI scans due October 16, year 1. In November, patient overall health was considerably improved and patient refused new scans. Will continue with GHZ-17 administration. In fall of year 1, patient stopped all treatment, including GHZ-17. Patient was diagnosed with kidney tumors in January of year 2.
3.)
Patient Age: 71
Gender: F
Cancer Type: Adenocarcinoma
History: Patient first diagnosed with lung cancer in August of year 1. In October of year 1, patient received a wedge resection to remove a portion of the left lung. In November of year 1, patient had a right lower lobectomy to remove the portion of her right lung that contained the largest tumor. In January of year 3, tumor appeared in the left lobe of the lung as well as observed lymph node enlargement on the mediastinum. Patient underwent radiation treatment. In February of year 3, patient was given 6 months to live. A new mass was found in the left lung and other nodes began to increase in size. All conventional treatment was stopped.
Prognosis: Terminal
GHZ-17 Product
History: Patient began taking GHZ-17 in July of year 3 for a period of 9 months.
Outcome: During the 9 months of GHZ-17 ingestion, both the small and large masses in the lung progressively shrunk to the point of disappearance. It also eliminated metastatic lesions. No new lesions or tumors have appeared. No adverse side effects observed as with traditional chemotherapy. Patient remains cancer-free in year 5.
4.)
Patient Age: 60
Gender: M
Cancer Type: Bladder Cancer
History: Patient observed blood in urine in year 1992, which was treated surgically. In 2000, the cancer returned. It was again treated with surgery and a series of BCG treatments that involve injecting live tuberculosis bacteria into the bladder to force the immune system to attack the cancer cells. For the next 6 years, patient had surgery yearly to remove new cancer growths. It was recommended that the patient receive an additional 6 BCG treatments.
Prognosis: Continued surgical and/or BCG treatments for remainder of life or unless the cancer spread to other areas of the body.
GHZ-17 Product
History: Patient began treatment with GHZ-17 in November of year 1, after the yearly surgeries. Continued treatment for 1 month.
Outcome: Patient tumors disappeared and patient has remained cancer free. There have been no further surgery or chemical treatments since year 2.
5.)
Patient Age: 49
Gender: F
Cancer Type: Breast Cancer
History: Patient observed lump in breast in August of year 1. Refused chemotherapy.
Prognosis: Without treatment, progression of cancer is inevitable.
GHZ-17 Product
History: Patient began taking GHZ-17 in August of year 1.
Outcome: Tumor size immediately shrunk. Subsequent scans have indicated no tumor in either breast. Patient remains cancer free through year 2.
6.)
Patient Age: 76
Gender: M
Cancer Type: Lung
History: Patient was diagnosed with lung cancer—Stage 4 in January of year 1. Immediately started chemotherapy and radiation. Subsequent scans indicated that cancer had spread to spine. Patient was diagnosed as terminal and all treatment stopped in May of year 1. Hospice called.
Prognosis: Terminal
GHZ-17 Product
History: Patient began taking GHZ-17 in June of year 1.
Outcome: Tumor in right lung disappeared, as did tumors in spine/back area. Patient overall health improved and patient expressed an interest in going to family outings etc. As tumors were shrinking, chemotherapy was again started. Patient experienced severe side effects including pain, difficulty in breathing, and unable to walk or stand. Patient also experienced tremors in hands. Scans of hip and spine indicated no presence of tumors that would cause this amount of pain. Chemo treatment was stopped. Patient is still taking botanical product but unknown prognosis. Patient is bed-ridden and on oxygen although, scans do not indicate cancer as the causative agent. Patient died September, year 1. Cause of death unknown.
7.)
Patient Age: 57
Gender: F
Cancer Type: Lung Cancer
History: Patient was first diagnosed with lung cancer in October of year 1. The cancer had not metastasized. Patient received both chemotherapy and radiation treatments.
Prognosis: If cancer can be contained in lung, prognosis is good.
GHZ-17 Product
History: Patient began taking GHZ-17 immediately upon diagnosis in conjunction with conventional treatments.
Outcome: Scans in December year 1 indicated significant reduction in tumor size. Scans in February year 2 indicated tumor was eradicated. No new signs of new cancer growth in any part of the body. November, year 2 the lining in patient's lung show signs of internal damage due to heavy radiation treatments. Patient diagnosed with pneumonia and put on ventilator. Patient died mid-November, year 2 of double pneumonia.
8.)
Patient Age: 63
Cancer Type: Colon Cancer
History: Patient was first diagnosed with colon cancer in October year 1. In January year 2 patient had a colon resection followed by 6 months of fulfox chemotherapy. In October of year 2, the cancer had metastases to liver. The patient underwent lever resection in January of year 3 in which the right lobe of the liver was removed. This was followed with 6 months of fulfuri chemotherapy. Liver tumors resurfaced in November of year 3. Patient underwent RFI followed by 3 months of fulfuri chemotherapy. In April of year 4, the cancer had spread and patient underwent a right lobectomy. In September of year 4, the patient had multiple inoperable tumors in both lungs and lymph node involvement.
Prognosis: Terminal
GHZ-17 Product
History: Patient began taking GHZ-17 in September of year 4.
Outcome: Progress continues to be monitored.
9.)
Gender: F
Patient Age: 22
History: Diagnosed with Maxillary Sinus cancer, squamous cell type on May 7, year 1. Patient received mixed chemotherapy (docetaxil, cisplatin and 5FU) starting June 3, year 1. Patient's white cell count dropped to dangerously low levels and the 5 FU drug was dropped from the treatment regiment. The tumor continued to grow and caused severe pain. Eye was swollen to the size of a large egg and patient was hospitalized for pain management on July 12. IMRT radiation treatments in combination with chemo (cisplatin) were started on July 13 to try and contain the size of the tumor. The tumor continued to grow in size and the 5FU chemo treatment was added back into the chemo treatment along with cetuximab or aka erbitux. There was a reduction in the tumor size during the last series of chemo. Last chemo and radiation was received on August 28. On August 20 patient experienced swelling in her lymph nodes. Biopsy indicated these growths to be moderately differentiated carcinoma. Patient went to MD Anderson for further evaluation in late August where it was determined that the cancer had spread to the T7 location of her thoracic spine. Surgery was ruled out as an option for treatment. It was also discovered at MD Anderson that the original diagnosis was incorrect and the correct cancer type is SinoMasal Undifferentiated Carcinoma. This diagnosis changed the cancer drug used to treat her cancer to carboplatim and etoiside, which was started on October 6, year 1.
Prognosis: Patient will continue to aggressively treat the disease with available chemotherapy drugs.
GHZ-17 Product
History: Patient began taking GHZ-17 in mid-August, year 1.
Outcome: Since starting GHZ-17, the tumor in her sinus has shrunk. Tumors in lymph nodes continue to grow. Her overall energy level and appetite has increased and overall pain has decreased. Patient will continue with GHZ-17 in combination with prescribed chemo/radiation therapy. In November, patient's pain was considerably lessened. Reasonable tolerance to new chemotherapy drugs. Cancer has spread to other areas in September of year 1. Patient died in October, year 1.
10.)
Gender: M
Patient Age: 16
History: Patient was diagnosed with Hodgkin's Lymphoma on January 4, in year 1. Started chemotherapy in mid-January. White cell count dropped to 0.2. Chemo resumed in March where white cell count again dropped to 1.1. In April, the patient was hospitalized due to an infected porta cath. Porta Cath was removed and replaced with a PICC line.
Prognosis: Favorable outcome expected with a combination of chemotherapy and radiation.
GHZ17 Product
History: Patient began to take GHZ17 in mid-January along with chemo treatments. White cell counts, which were depressed following chemo, quickly returned to normal ranges. Energy levels remained high and patient even participated in tennis workouts at school.
Outcome: Patient's chemo treatments were cut off as tumors PET scan indicated no trace of cancer in May of year 1. Patient expected to resume normal life.
11.)
Gender: F
Patient Age: unknown
History: Patient has history of skin cancer. Approximately 30 pre-cancerous spots appeared on skin Spots will have to be surgically removed if they progress to cancerous cells.
GHZ17 Product
History: Patient took pulp from elixir and placed on pre-cancerous spot with a band-aid each night for approximately 1 month
Outcome: Spots disappeared leaving only a small scar in their place.
12.)
Gender: M
Patient Age: 40
Cancer Type: Originally diagnosed with lymphoma but biopsy did not confirm presence of cancer cells.
History: Originally diagnosed with lymphoma in October of year 1, but biopsy did not validate the presence of cancer cells. No chemotherapy given. Condition worsened in July of year 2. Once again the biopsy did not confirm the presence of cancer cells.
Prognosis: Patient was diagnosed with severe liver disorder and told his condition would deteriorate until a liver transplant was needed. Also told that his muscle tone, energy level and general health would never return to normal.
GHZ Product
History: Patient began taking GHZ17 in November of year 1. By May of year 2, his liver function had returned to near normal. His appetite, energy level and muscle tone has returned to near normal and his doctor stated that he would no longer need a liver transplant.
Outcome: Patient has resumed normal life activities and overall health is excellent.
Synopsis
All patients taking GHZ-17 experienced an increase in appetite, weight gain and energy boost. Whether taken in combination with other conventional treatments or alone, all patients showed a marked decline and/or eradication of tumors including those in the bladder, breast, liver, and lung. In those patients who tracked liver enzymes pre- and post-GHZ-17 administration, liver enzyme levels showed a marked increase during administration of GHZ-17. No negative side effects of GHZ-17 were noted in any case, although some patients expressed a dislike of the taste of GHZ-17.
Although not wishing to be bound by any theory of operation, the inventors believe that the methods of the invention reduce and/or eliminate cancer and/or the symptoms thereof by augmenting or stimulating the patients' immune systems. In this sense, the invention is believed to be a form of biological therapy. As such, it is considered that the invention is applicable to virtually all cancers, such as the following: Acute Lymphoblastic Leukemia, Adult; Acute Lymphoblastic Leukemia, Childhood; Acute Myeloid Leukemia, Adult; Acute Myeloid Leukemia, Childhood; Adreno cortical Carcinoma; Adrenocortical Carcinoma, Childhood; Adolescents, Cancer in; AIDS-Related Cancers; AIDS-Related Lymphoma; Anal Cancer; Appendix Cancer; Astrocytomas, Childhood; Atypical Teratoid/Rhabdoid Tumor, Childhood, Central Nervous System; Basal Cell Carcinoma; Bile Duct Cancer, Extrahepatic; Bladder Cancer; Bladder Cancer, Childhood; Bone Cancer, Osteosarcoma and Malignant Fibrous Histiocytoma; Brain Stem Glioma, Childhood; Brain Tumor, Adult; Brain Tumor, Brain Stem Glioma, Childhood; Brain Tumor, Central Nervous System Atypical Teratoid/Rhabdoid Tumor, Childhood; Brain Tumor, Central Nervous System Embryonal Tumors, Childhood; Brain Tumor, Astro cytomas, Childhood; Brain Tumor, Craniopharyngioma, Childhood; Brain Tumor, Ependymoblastoma, Childhood; Brain Tumor, Ependymoma, Childhood; Brain Tumor, Medulloblastoma, Childhood; Brain Tumor, Medulloepithelioma, Childhood; Brain Tumor, Pineal Parenchymal Tumors of Intermediate Differentiation, Childhood; Brain Tumor, Supratentorial Primitive Neuro ectodermal Tumors and Pineoblastoma, Childhood; Brain and Spinal Cord Tumors, Childhood (Other); Breast Cancer; Breast Cancer and Pregnancy; Breast Cancer, Childhood; Breast Cancer, Male; Bronchial Tumors, Childhood; Burkitt Lymphoma; Carcinoid Tumor, Childhood; Carcinoid Tumor, Gastrointestinal; Carcinoma of Unknown Primary; Central Nervous System Atypical Teratoid/Rhabdoid Tumor, Childhood; Central Nervous System Embryonal Tumors, Childhood; Central Nervous System (CNS) Lymphoma, Primary; Cervical Cancer; Cervical Cancer, Childhood; Childhood Cancers; Chordoma, Childhood; Chronic Lymphocytic Leukemia; Chronic Myelogenous Leukemia; Chronic Myeloproliferative Disorders; Colon Cancer; Colorectal Cancer, Childhood; Craniopharyngioma, Childhood; Cutaneous T-Cell Lymphoma; Embryonal Tumors, Central Nervous System, Childhood; Endometrial Cancer; Ependymoblastoma, Childhood; Ependymoma, Childhood; Esophageal Cancer; Esophageal Cancer, Childhood; Esthesioneuroblastoma, Childhood; Ewing Sarcoma Family of Tumors; Extracranial Germ Cell Tumor, Childhood; Extragonadal Germ Cell Tumor; Extrahepatic Bile Duct Cancer; Eye Cancer, Intraocular Melanoma; Eye Cancer, Retinoblastoma; Gallbladder Cancer; Gastric (Stomach) Cancer; Gastric (Stomach) Cancer, Childhood; Gastrointestinal Carcinoid Tumor; Gastrointestinal Stromal Tumor (GIST); Gastrointestinal Stromal Cell Tumor, Childhood; Germ Cell Tumor, Extracranial, Childhood; Germ Cell Tumor, Extragonadal; Germ Cell Tumor, Ovarian; Gestational Trophoblastic Tumor; Glioma, Adult; Glioma, Childhood Brain Stem; Hairy Cell Leukemia; Head and Neck Cancer; Heart Cancer, Childhood; Hepatocellular (Liver) Cancer, Adult (Primary); Hepatocellular (Liver) Cancer, Childhood (Primary); Histiocytosis, Langerhans Cell; Hodgkin Lymphoma, Adult; Hodgkin Lymphoma, Childhood; Hypopharyngeal Cancer; Intraocular Melanoma; Islet Cell Tumors (Endocrine Pancreas); Kaposi Sarcoma; Kidney (Renal Cell) Cancer; Kidney Cancer, Childhood; Langerhans Cell Histiocytosis; Laryngeal Cancer; Laryngeal Cancer, Childhood; Leukemia, Acute Lymphoblastic, Adult; Leukemia, Acute Lymphoblastic, Childhood; Leukemia, Acute Myeloid, Adult; Leukemia, Acute Myeloid, Childhood; Leukemia, Chronic Lymphocytic; Leukemia, Chronic Myelogenous; Leukemia, Hairy Cell; Lip and Oral Cavity Cancer; Liver Cancer, Adult (Primary); Liver Cancer, Childhood (Primary); Lung Cancer, Non-Small Cell; Lung Cancer, Small Cell; Lymphoma, AIDS-Related; Lymphoma, Burkitt; Lymphoma, Cutaneous T-Cell; Lymphoma, Hodgkin, Adult; Lymphoma, Hodgkin, Childhood; Lymphoma, Non-Hodgkin, Adult; Lymphoma, Non-Hodgkin, Childhood; Lymphoma, Primary Central Nervous System (CNS); Macroglobulinemia, Waldenström; Malignant Fibrous Histiocytoma of Bone and Osteosarcoma; Medulloblastoma, Childhood; Medulloepithelioma, Childhood; Melanoma; Melanoma, Intraocular (Eye); Merkel Cell Carcinoma; Mesothelioma, Adult Malignant; Mesothelioma, Childhood; Metastatic Squamous Neck Cancer with Occult Primary; Mouth Cancer; Multiple Endocrine Neoplasia Syndromes, Childhood; Multiple Myeloma/Plasma Cell Neoplasm; Mycosis Fungoides; Myelodysplastic Syndromes; Myelodysplastic/Myeloproliferative Neoplasms; Myelogenous Leukemia, Chronic; Myeloid Leukemia, Adult Acute; Myeloid Leukemia, Childhood Acute; Myeloma, Multiple; Myeloproliferative Disorders, Chronic; Nasal Cavity and Paranasal Sinus Cancer; Nasopharyngeal Cancer; Nasopharyngeal Cancer, Childhood; Neuroblastoma; Non-Hodgkin Lymphoma, Adult; Non-Hodgkin Lymphoma, Childhood; Non-Small Cell Lung Cancer; Oral Cancer, Childhood; Oral Cavity Cancer, Lip and; Oropharyngeal Cancer; Osteosarcoma and Malignant Fibrous Histiocytoma of Bone; Ovarian Cancer, Childhood; Ovarian Epithelial Cancer; Ovarian Germ Cell Tumor; Ovarian Low Malignant Potential Tumor; Pancreatic Cancer; Pancreatic Cancer, Childhood; Pancreatic Cancer, Islet Cell Tumors; Papillomatosis, Childhood; Paranasal Sinus and Nasal Cavity Cancer; Parathyroid Cancer; Penile Cancer; Pharyngeal Cancer; Pineal Parenchymal Tumors of Intermediate Differentiation, Childhood; Pineoblastoma and Supratentorial Primitive Neuroectodermal Tumors, Childhood; Pituitary Tumor; Plasma Cell Neoplasm/Multiple Myeloma; Pleuropulmonary Blastoma, Childhood; Pregnancy and Breast Cancer; Primary Central Nervous System (CNS) Lymphoma; Prostate Cancer; Rectal Cancer; Renal Cell (Kidney) Cancer; Renal Pelvis and Ureter, Transitional Cell Cancer; Respiratory Tract Cancer with Chromosome 15 Changes; Retinoblastoma; Rhabdomyosarcoma, Childhood; Salivary Gland Cancer; Salivary Gland Cancer, Childhood; Sarcoma, Ewing Sarcoma Family of Tumors; Sarcoma, Kaposi; Sarcoma, Soft Tissue, Adult; Sarcoma, Soft Tissue, Childhood; Sarcoma, Uterine; Sézary Syndrome; Skin Cancer (Nonmelanoma); Skin Cancer, Childhood; Skin Cancer (Melanoma); Skin Carcinoma, Merkel Cell; Small Cell Lung Cancer; Small Intestine Cancer; Soft Tissue Sarcoma, Adult; Soft Tissue Sarcoma, Childhood; Squamous Cell Carcinoma; Squamous Neck Cancer with Occult Primary, Metastatic; Stomach (Gastric) Cancer; Stomach (Gastric) Cancer, Childhood; Supratentorial Primitive Neuroectodermal Tumors, Childhood; T-Cell Lymphoma, Cutaneous; Testicular Cancer; Testicular Cancer, Childhood; Throat Cancer; Thymoma and Thymic Carcinoma; Thymoma and Thymic Carcinoma, Childhood; Thyroid Cancer; Thyroid Cancer, Childhood; Transitional Cell Cancer of the Renal Pelvis and Ureter; Trophoblastic Tumor, Gestational; Unknown Primary Site, Carcinoma of, Adult; Unknown Primary Site, Cancer of, Childhood; Unusual Cancers of Childhood; Ureter and Renal Pelvis, Transitional Cell Cancer; Urethral Cancer; Uterine Cancer, Endometrial; Uterine Sarcoma; Vaginal Cancer; Vaginal Cancer, Childhood; Vulvar Cancer; Waldenström Macroglobulinemia; Wilms Tumor; Women's Cancers. | Methods for the treatment of human cancers, daily dosage forms for cancer patients, and methods of formulating the dosage forms are provided wherein the daily dosage form contains from about 10-6,000 mg of each of β-sitosterol, isovanillin, and linolenic acid. Preferably, the dosage forms are formulated by first creating an aqueous decoction of Arum palaestinum Boiss, followed by fortification of the decoction with additional quantities of β-sitosterol, isovanillin, and linolenic acid. | 0 |
BACKGROUND OF THE INVENTION
As an automatic sheet feeding apparatus, in which a stack of papers is separated and separated papers are fed out one by one, there is known an apparatus shown in FIG. 8.
In this apparatus, a plurality of stacked papers P are placed on a supporting plate, and a feed-in roller 1 and a friction roller 2 are rotated in a direction indicated by an arrow to feed the papers P toward a dividing belt 3. When the papers P arrive at a contact point of the dividing belt 3 and the friction roller 2, the lowermost paper is delivered out by the frictional force of the friction roller 2 because the delivering force of the friction roller 2 overcomes the retreating force of the dividing belt 3, but the second paper and upper papers are prevented from advancing by the dividing belt.
Namely, the friction roller and belt are arranged so that a relation of μ R >μ B >μ p is established among the friction coefficient μ R of the friction roller 2 to the paper, the friction coefficient μ B of the dividing belt 3 to the paper and the friction coefficient μ p of the papers to each other. By this arrangement, the lowermost paper alone is separated from the upper papers and fed out.
In this paper feeding apparatus, in order to enhance the dividing capacity in feeding a plurality of papers, it is necessary to increase the contact pressure between the dividing belt 3 and the friction roller 2. In this case, if thin papers being easy to be folded are fed, the top ends of papers are readily butted against the dividing belt and bent to cause a phenomenon of so-called paper jamming. If the contact pressure of the dividing belt 3 to the friction roller 2, is decreased, occurrence of paper jamming is prevented, but if a plurality of thick and hard papers are fed at one time, the dividing belt 3 rises from the surface of the friction roller 2 and the dividing capacity is reduced, with the result that two or more papers are sometimes fed at one time.
SUMMARY OF THE INVENTION
The present invention relates to an apparatus for dividing stacked sheets and for feeding out the sheets and more particularly relates to an apparatus in which a stack of sheets is separated from each other and the divided sheets are fed out one by one automatically toward a reading zone or printing zone in a facimile telegraphy, a copying machine, a printing machine or the like.
Any flexible sheets of material such as paper, card, etc. can be applied to the apparatus of the present invention.
It is a primary object of the present invention to provide an automatic sheet feeding apparatus in which stacked sheets can be fed out one by one separately in a stable condition irrespectively of the thickness and strength of the sheets.
The apparatus of the present invention is characterized in that two belts differing in the stretching force are arranged to have butting contact with a friction roller and the inclination angles of the respective belts to the friction roller are made different from each other, whereby the paper-dividing capacity is enhanced.
According to the present invention, two kinds of dividing belts differing in the inclination angle are contacted with the surface of the friction roller, and the loosely stretched first dividing belt and the tightly stretched second dividing belt are arranged along the paper feed-out direction. Therefore, when papers fed are thin papers of a low strength, only the lowermost paper is separated by the first dividing belt, and when papers fed are thick papers of a high strength, they are roughly divided stepwise by the first dividing belt and the lowermost paper of divided several papers is divided by the second dividing belt and fed out by the friction roller. Papers, irrespectively of the strength thereof, that is, either thin papers of a low strength or thick papers of a high strength, can smoothly be divided and fed out one by one assuredly.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional side view showing the structure of the apparatus of the present invention.
FIG. 2 is a view showing the section taken along the line II--II in FIG. 1.
FIG. 3 is a side view showing the state of contact between the first dividing belt and the friction roller.
FIG. 4 is a side view showing the state of contact between the second dividing roller and the friction belt.
FIG. 5 is a diagram illustrating the state of first deviation of papers of a high strength.
FIG. 6 is a diagram illustrating how upper papers of high strength are prevented from advancing while only the lowermost paper is separated.
FIG. 7 is a side view showing the structure of another embodiment.
FIG. 8 is a side view showing the structure of the conventional apparatus.
DETAILED DESCRIPTION OF THE INVENTION
The present invention will now be described in detail with reference to embodiments illustrated in the drawings.
Referring to FIGS. 1 and 2, a friction roller 2 is rotated in a direction indicated by an arrow, papers P stacked on a paper supporting plate 4 are fed to dividing belts 5 and 6 by a feed roller 1 and a pressing roller 14 for pressing papers by its own weight.
The first dividing belt 5 has a flat section and comprises a fiber core Y, and the second dividing belt 6 has a similar structure. The belts 5 and 6 are hung at a plurality of points on shafts 7 and shafts 8 so that they cannot be rotated. The first dividing belt is loosely stretched and arranged to have face-to-face contact with the peripheral surface of the friction roller 2, and the second dividing belt 6 is tightly stretched and arranged to have line-to-line contact with the peripheral surface of the friction roller 2.
The above-mentioned face-to-face contact and line-to-line contact are attained because each of the belts 5 and 6 has a certain width. In the plane of the side face as shown in FIG. 1, it may be said that the first dividing belt 5 has line-to-line contact and the second dividing belt 6 has point-to-point contact.
As illustrated above, the dividing belts 5 and 6 are stretched "loosely" and "tightly", respectively. By the term "loosely stretched" is meant the state where the belt 5 is pressed to and stretched on the surface of the friction roller 2 by the elasticity of the belt 5 per se as shown in FIG. 3, and the stretching force in this case is such that a paper of a low strength can be separated and passed through the belt and the tension imposed on the belt is zero.
By the term "strongly stretched" is meant the state where a certain high tension is applied to the belt 6 by a tensioning device such as a screw rod 9 as shown in FIG. 4 and the belt 6 is contacted substantially tangentially with the surface of the friction roller 2, and the pressing force of the belt 6 to the surface of the roller 2 is zero and the stretching force is such that the elastic force is imposed by bending of the paper passing through the belt 6 and only one paper of a high strength is allowed to pass through the belt 6. Furthermore, there is formed a clearance allowing a paper of a low strength to pass therethrough, or even when the belt is contacted with the friction roller 2, the degree of contact is such that even a paper of a low strength introduced into the paper-catching portion between the belt and friction roller 2 is allowed to pass through the contact portion when the belt is bent on catching of the paper.
The contact position between the loosely stretched first dividing belt 5 and the second dividing belt 6 is arranged so that when the paper is divided and fed out, the first dividing belt 5 first acts on the paper and both the belts 5 and 6 fall in contact with each other at the point where the second dividing belt 6 then acts on the paper.
If a tightly stretched dividing belt is first arranged and a loosely stretched belt is subsequently arranged, a paper of a low strength butts against the strongly stretched dividing belt to cause paper jamming, and when a plurality of papers of a high strength are first introduced into the tightly stretched dividing belt, the belt is raised up and several lower papers pass through the belt without being divided, and in the subsequent belt loosely stretched, they are not divided but allowed to pass through the belt because the pressing force of the belt is small. Accordingly, it is important that as pointed out above, the loosely stretched first dividing belt is first arranged and the strongly stretched second dividing belt is subsequently arranged.
By the term "strength" is meant a resistant force against the folding or bending action caused when an external force is applied to a plain paper in the direction of the plane thereof. Ordinarily, thin papers have a low strength and thick papers have a high strength. Namely, the strength is judged based on the weight of 1000 papers having a unit area. In this case, the papers should be composed of the same material. Accordingly, for example, the strength of 1000 papers having an area of 1 m 2 , which have a weight of 200 Kg, is higher than the strength of 1000 papers having an area of 1 m 2 , which have a weight of 10 Kg. In short, the former papers have a higher strength and are less readily bent than the latter papers.
In the instant specification, the degree of the strength is one defined as above.
In the present embodiment, a pressing roller 10 is arranged in the vicinity of the contact point between the second dividing belt 6 and friction roller 2 so that an urging force directed to the center of the friction roller 2 is applied by a spring 11. More specifically, the driving force of the friction roller 2 is applied to the paper separated by the loosely stretched first dividing belt 5 by means of the pressing roller 10, and in case of a paper of a low strength, the strength is relatively intensified when the paper is introduced in the paper-catching portion of the tightly stretched second dividing belt 6 and friction roller 2, whereby passage of the paper through the belt is facilitated. By the expression "the strength is relatively intensified" is meant the state where the paper is pressed in the vicinity of the paper end by the pressing roller 10 and fed out to the second dividing belt so that when the paper is gripped at a point far from the paper end and the paper end portion is pressed, the paper is bent with a weak force and when the paper end portion is similarly pressed while gripping the paper at a point close to the paper end, the paper is bent with a strong force, whereby occurrence of paper jamming is prevented. Accordingly, it is preferred that the position of the pressing roller 10 be intermediate between the contact point between the tightly stretched second dividing belt 6 and the friction roller 2 and the contact point between the loosely stretched first dividing belt 5 and the friction roller 2 and be closer to the contact point of the second dividing belt 6 and the friction roller 2.
The function of the paper feeding apparatus having the above-mentioned structure will now be described.
When papers of a low strength are fed, stacked papers are delivered toward the paper-catching portion 5a of the friction roller 2 and first dividing belt 5 and since the first dividing belt 5 is loosely stretched, only the lowermost paper is separated from upper papers and fed by the friction roller 2, while the upper papers are prevented from advancing by the first dividing belt 5. One separated paper is delivered between the first dividing belt 5 and friction roller 2 in a direction indicated by an arrow and is fed to a catching portion 6a of the second dividing belt 6 and friction roller 2 while the paper is pressed to the surface of the friction roller 2 by the pressing roller 10. The second dividing belt 6 is tightly stretched and contacted substantially tangentially with the surface of the friction roller 2. Accordingly, when a paper of a low strength, that is, a thin paper, is passed, bending of the paper is reduced and also the pressure applied by the tension of the belt is reduced during the passage. Thus, papers of a low strength can be separated one by one assuredly by the dividing action of the first dividing belt 5.
When papers of a high strength are fed, since the stretching force of the first dividing belt 5 is small, separation of the papers is relatively difficult, and as shown in FIG. 5, a plurality (2 to 3) of papers P1 having a high strength are intruded into the catching portion in such a manner that the belt 5 is raised up and they are delivered in the stepwise stacked state without being divided.
The 2 or 3 papers which have passed through the first dividing belt 5 arrive at the contact point between the second dividing belt 6 and friction roller 2 in the stacked state. Since the stretching force of the second dividing belt 6 is large and the second dividing belt 6 is contacted substantially tangentially with the friction roller 2, when a plurality of papers of a high strength are fed, as shown in FIG. 6, the upper papers are prevented from advancing by the belt 6 while only the lowermost paper PD is separated and fed out by the friction roller 2. In this case, since the strength of papers is high, paper jamming is not caused in papers blocked by the strongly stretched belt 6 but the papers are kept stationary. Thus, these papers can be separated from the lowermost paper.
More specifically, papers of a high strength are appropriately drawn by the first dividing belt 5 and slipped out of the stacked state stepwise (this is called "first separation" hereinafter), and 2 to 3 papers stacked stepwise are divided by the second dividing roller 6 and only the lowermost paper is fed out by the friction roller 2 and dividing belt 6 (this is called "second separation" hereinafter). When many papers of a high strength are introduced to the tightly stretched second dividing belt, the belt is raised up by the paper and several lower papers among stacked papers are passed through the belt collectively. However, in the above-mentioned apparatus, such many papers of a high strength undergo the first separation and hence, only several papers are introduced in the stacked state and introduction of many papers of a high strength into the second dividing belt 6 is prevented. Accordingly, the papers of a high strength can be divided one by one by the second separation and then passed through the belt and fed to a predetermined position by a guide plate 12 and a feed roller 13.
FIG. 7 illustrates an embodiment in which the contact position of the second dividing belt 6 and friction roller 2 is changed from the contact position in the above-mentioned embodiment. Namely, the contact position may be any position where the paper passed through the first dividing belt 5 is passed through the second dividing belt 6 and fed out, and a position suitable to the apparatus to which the present invention is applied is selected. Of course, also in this embodiment, it is preferred that the pressing roller 10 be arranged in the vicinity of the paper-catching portion of the second dividing belt 6 and that a guide plate and a guide roller be disposed in an intermediate portion between the first dividing belt 5 and the second dividing belt 6 to deliver the papers. | An automatic sheet feeding apparatus in which a stack of sheets is separated from each other and separated sheets are fed out one by one. The stacked sheets are fed to a friction roller by means of a feeding roller and they are divided by two belts differing in stretching force which are arranged to have butting contact with the friction roller. | 1 |
FIELD OF THE INVENTION
This invention relates to methods and apparatus for knitting machine control systems and, more specifically, to the sensing of the actual yarn tension and the adjusting thereof to permit proper yarn consumption.
BACKGROUND OF THE INVENTION
It is known to use control devices for knitting machines which, in order to control the length of yarn used by a knitting machine, each feeder receives yarn from a yarn feeding means which feeds yarn to it at a rate which is fixed at a value proportional to the knitting machine speed. Such yarn feeding devices commonly consist of a nip roller drive coupled to a driven part of the knitting machine and are suitable only when the required length of yarn to be knitted into each sequence of a small number of stitches is substantially constant.
When a knitting machine is fitted with needle selecting means so that the length of yarn required to be knitted into each sequence of a small number of stitches is not substantially constant the known arrangements described above are not suitable as the individual feeding devices cannot readily provide the various lengths of yarn which are required to be fed into the knitting machine at different times during the knitting. The present invention is believed to represent a solution to this problem.
According to one aspect of the present invention, there is provided a method of feeding yarn to a knitting machine having a group of yarn feeders and also having needle selecting means so that the length of yarn required to be knitted into each sequence of a small number of stitches is not constant, each individual yarn being fed to the knitting machine at an adjustable tension by one of the yarn feeders, the method including the steps of:
(1) measuring the length of an individual yarn fed to the knitting machine during each sequence of a small number of stitches;
(2) comparing the measured length to a predetermined length value which is a function of a predetermined stitch length;
(3) adjusting the tension in said individual yarn fed to the knitting machine in response to any deviation detected in comparison step (2) above; and
(4) maintaining the adjusted tension while repeating steps (1) and (2) and then repeating step (3) in response to the deviation detected during the repetition of steps (1) and (2) so as to continuously adjust the tension of said yarn fed to the knitting machine so that the actual yarn consumption in the knitting of an article is substantially equal to the predetermined yarn consumption.
Advantageously the function of said stitch length which is measured is the length of yarn being knitted.
The length of yarn being knitted can be measured in a number of ways. For example, the yarn may pass around a rotatable member and be arranged to make non-slipping contact therewith so that the length of yarn being knitted can be measured from the speed of rotation of the member. If desired, the member can be one of a pair of nip rollers.
In order to adjust the tension in the yarn fed to the knitting machine, a yarn-driven rotatable member may be employed, the tension being adjusted by controlling the resistance to rotation of the rotatable member. Again, if desired, the rotatable member may be one of a pair of nip rollers.
The tension control may be effected using a feed mechanism for the yarn which is driven by means of a tape drive. Preferably, the error detected by the comparing means is used to set a tension value and the feed mechanism is arranged to introduce the set tension into the yarn.
According to a further aspect of the present invention an apparatus for controlling the feeding of yarn to a knitting machine comprises means for measuring the stitch length of yarn which has been knitted by said machine or a function of said stitch length, means for comparing said measured stitch length or function thereof with a predetermined stitch length or comparable function thereof and means for adjusting the tension in the yarn fed to the knitting machine in response to any error detected by the comparing means.
For the purpose of carrying out the invention to control the length of yarn knitted by a knitting machine the means for determining the length of yarn LM1 being knitted by the machine may for example, be a rotating member with the circumferential surface of which the yarn makes non-slipping contact before it passes into the feeder of the knitting machine. The circumferential speed of the rotating member is thus equal to the speed of the yarn. It will be understood that the rotating member may for example conveniently be part of the adjusting means described above.
The rotation of the member as the yarn passes over it may conveniently be sensed by displacement detecting means which produces an output signal which is a measure of the length of yarn passing into the knitting machine. The displacement detecting means may conveniently be photoelectric, magnetic capacitative or pneumatic and the output signal may conveniently be in digital or analogue form and may conveniently take the form of an electrical current or voltage suitable for transmission to another location.
For the purpose of carrying out the invention to control the length of yarn being knitted by a knitting machine which has needle selecting means in operation controlled by a stored program computer, the means for producing a control signal to control the adjusting means, this control signal being related to the departure of the length of yarn knitted by the knitting machine from the required length, may be, for example, a transducer giving an output signal suitable for the control of the adjusting means in response to an electrical input signal produced by the computer. The computer may be programmed to calculate the required length to be knitted during each convenient amount of knitting displacement of the knitting machine from data supplied in the computer program. The computer may be arranged to receive the signal referred to above and to compute the departure from the required length of the length of yarn knitted by the knitting machine for each convenient amount of knitting displacement of the knitting machine and to produce the corresponding signal for the transducer which correspondingly produces the control signal for the adjusting means.
In order to control the length of yarn knitted by a knitting machine which has needle selecting means in operation controlled by electrical signals derived from a pattern data storage device, which may be for example a digitally marked film strip or a digitally encoded magnetic tape or a digitally perforated tape, the means for producing a signal to control the adjusting means is related to the departure of the length of yarn knitted by the knitting machine from the required length and may be for example a transducer giving an output signal suitable for the control of the adjusting means in response to an electrical input signal produced by for example a stored program computer provided with access to the needle selecting signals with the knitting machine. The computer may be programmed to calculate the required length of yarn to be knitted during each convenient amount of knitting displacement of the knitting machine from data supplied in the computer program. The computer may be arranged to compute the departure from the required length of the length of yarn knitted by the knitting machine for each convenient amount of knitting displacement of the knitting machine and to produce the corresponding signal for the transducer which correspondingly produces the control signal for the adjusting means.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic perspective view of one form of tensioning means for use in accordance with the present invention;
FIG. 2 is a diagrammatic perspective view of an alternative form of tensioning means;
FIG. 3 is a diagrammatic perspective view of a further alternative tensioning means;
FIG. 4 is a schematic diagram of an error-controlled brake-measuring pulley;
FIG. 5 is a diagram on an enlarged scale of a sensor for use on the hub of a pulley of the device shown in FIG. 4;
FIG. 6 is a diagrammatic cross section of an alternative error-controlled brake/measuring pulley;
FIG. 7 is a schematic block diagram illustrating the operation of the present invention;
FIG. 8 is a block diagram of an apparatus employing a comparison error-controlled brake; and
FIG. 9 is a block diagram of an apparatus for use in conjunction with a computer controlled knitting machine.
DETAILED DESCRIPTION
FIG. 1 shows one form of tensioning device which may be employed so that the actual thread length as consumed by the knitting machine equals a predetermined value. This tensioning device comprises a rotatable roller 10 pivoted at 11 to a supporting plate 12 and arranged to be rotated by a driving tape 13. The yarn Y passes through a pair of yarn guides 14 and contacts the rotatable member 10 at a nip region 15 and passes out to a feeder of an associated knitting machine via a yarn guide 16.
The yarn guides 14 and 16 are mounted on a supporting arm 17 of generally U-shape, the arm 17 being pivoted at a position not shown, about a pivot axis 20. The arm is connected via a flat spring 18 to an adjusting screw 19 mounted in the plate 12.
The yarn Y is fed to first guide 14 axially with respect to pivot axis 20 so that the tension in the yarn Y does not apply a turning moment to the arm 17. The yarn Y leaves guide 16 in a vertical path so that the tension in the yarn Y does apply a turning moment about pivot axis 20, the moment being opposed by the restoring force of spring 18.
The restoring force applied by spring 18 is set by means of the adjusting screw 19 which is set to provide a set tension in response to the error detected by the comparing means. Thus when the tension in yarn Y exceeds the set value the arm 17 is deflected about pivot axis 20 to move the yarn Y from the nip region 15 and when the tension falls below the set value the yarn Y is returned to the nip region 15 by the action of the spring 18 on the arm 17.
Such a device is suitable for adjusting the tension of the yarn being fed to a feeder of the knitting machine.
An alternative form of tensioning device is shown in FIG. 2. This device employs a similar rotatable member 21 mounted for rotation about an axis 20 and adapted to be driven by a tape 23. Mounted coaxially with the member 21 and adapted for rotation therewith is a conical capstan 24, the yarn Y being wrapped around a part of the conical surface. In order to enhance the frictional contact, the capstan may be provided with a friction surface, for example, an emery coating.
The generally U-shaped arm 25, similar to the arm 17 described in relation to FIG. 1, includes a first pair of yarn guides 26 and a yarn guide 27. The arm 25 is pivoted at 28 about a pivot axis 29 and carries a flat spring 30 which contacts the adjusting screw 31 carried by a supporting plate 32. The yarn Y extends from a yarn supply to the first yarn guide 26 in alignment with the pivot axis, passes through the second guide 26 around the surface of the capstan 24 and emerges through guide 27 to be delivered to the feeder of the knitting machine.
It will be appreciated that the rate of feed of the yarn will depend upon the circumferential surface speed of the capstan at the axial position of the yarn which in turn is determined by the position of the guides 26 and 27. Such a device is suitable for controlling the length and thus the tension of yarn supplied to a feeder of a knitting machine per unit displacement of the knitting machine.
A further alternative tensioning device is shown in FIG. 3 which comprises a similar rotatable member 34 pivoted for rotation about an axis 35 and adapted to be driven by means of a tape 36. Mounted coaxially with said rotatable member and adapted for rotation therewith is a roller 37 having a profiled rubber covering 38 and a nip roller 39 which may have a surface of a relatively hard material such as steel. The yarn guides shown in FIG. 3 are similar to those shown in FIG. 2 and similar reference numerals have been used in the drawing.
The yarn Y is delivered to the guide 26 along the pivot axis 29, passes around the profiled rubber covered roller 37, between the nip of rollers 37 and 39 and is delivered via the guide 27. As in the case of the tensioning device shown in FIG. 2, the axial position at which the yarn Y contacts the rubber covering 38 will depend upon the position of guides 26 and 27 and by suitable adjustment the value of the length and thus the tension of yarn supplied to a feeder of a knitting machine per unit displacement of the knitting machine can be controlled.
Referring to FIG. 4 a device is shown which can function both as a yarn tensioning device and as a measuring device for measuring the length of the yarn being knitted.
The device comprises a rotatable disc 40 having flanges 41 and which carries a disc 42, for example, of aluminum. The disc 40 rotates about a shaft 43 which is screw-threaded over part of its length on which is carried a magnet 46 which is prevented from rotating by a mounting 47. The shaft 43 can be rotated by the action of the coupled geared motor 45 so as to move the magnet 46 closer to the disc 40 to increase the hysteresis braking effect or vice versa. The yarn contacts the flange portion of the rotatable member 40 and control can then be applied thereto by means of hysteresis braking induced by the effect of the magnet 46 on the disc 42, the braking depending on the axial position of magnet 46 which is controlled in response to a comparison error signal derived from the desired stitch length and the measured yarn length.
In order that the device can operate also as a measuring pulley, a sensor 48 is disposed about one flange 41 of the rotatable member 40. This sensor can detect the speed of rotation of the rotatable member, and providing that the yarn is in non-slipping contact with the surface thereof, the length of yarn delivered per unit displacement of the knitting machine can be derived.
It is preferable to employ a sensor which acts on the hub 49 of the rotatable member since the diameter is preferably small to reduce the torque induced by cleaning pads which are employed. Such a sensor is shown diagrammatically in FIG. 5 of the drawings in which the hub 49 is provided with a diametrical hole 50 and a pile fabric covering 51 which serves as a cleaning pad. A photoelectric cell 52 is disposed diametrically opposite a light emitting diode 53 so that when the diametrical hole 50 is in alignment between the cell 52 and the diode 53 a pulse is produced. It will be appreciated that the device provides two pulses per revolution and the provision of the pile fabric produces a surface to provide a continuous cleaning effect between pulses.
Another form of combined error-controlled brake and measuring device is shown in FIG. 6. This utilizes a rotatable member, around which the yarn passes, in the form of a capstan 54 arranged to rotate about an axis 55. The capstan may, for example, be made from a suitable plastics material and carries a disc 56, for example, of aluminum. An electromagnetic coil 57 is mounted coaxially with said disc, the coils being wound on electromagnet 58. This arrangement functions in a manner similar to that shown in FIG. 4 with the exception that the photoelectric cell 59 and the light emitting diode 60 are disposed on each side of an apertured flange 61 and the hysteresis braking effect is adjusted by varying the electromagnet energizing current. The number of apertures in the flange 61 will of course determine the number of pulses produced per revolution of the capstan.
FIG. 7 is a block diagram showing an arrangement according to the invention connected to a knitting machine. A supply of yarn Y is fed at an off-winding tension T P to a constant tensioning device and is then passed to a yarn length sensing device at a tension T M . The yarn then passes to an adjustable yarn tensioning means and is delivered at a knitting tension T K to the feeder of a knitting machine. A signal L C representing the desired stitch length or a function thereof is derived from the knitting machine and fed to the error detector (i.e., comparator) together with a signal L K representing the actual yarn length measurement from the yarn length sensing device, and the difference or error f(L K -L C ) is supplied to the yarn tensioning means whereby the appropriate adjusted knitting tension T K is induced in the yarn fed to the knitting machine so as to correct for this error.
An alternative arrangement is shown in FIG. 8 in which case the yarn length sensing device is part of a length sensor/error-controlled brake such as that shown in FIG. 4 or 6. As can be seen the yarn Y is fed from the yarn supply package to the brake/sensor and the yarn with the appropriate tension is fed to one feeder of the group associated with the knitting machine. A needle selection signal is derived from the knitting machine and fed to an error-detector/controller in conjunction with a knitted length signal L K derived from the length sensing device and an input L C representing the desired stitch length. The comparator/controller then produces a control signal which is fed to the error-controlled brake which applies the appropriate adjusted tension to the yarn.
The comparator/controller may be of many conventional constructions, one such construction being a bridge circuit which compares voltage signals, as disclosed in U.S. Pat. No. 3,858,416, White et al, Column 4, lines 33-41.
When computer controlled knitting machines are employed then the computer may itself be used to provide an output for use in the error detector or comparator. Such an arrangement is shown in FIG. 9 where the yarn under a tension T P is fed to a constant tensioning device from which it emerges at a tension T M . A yarn length sensing device and yarn tensioning device then deliver the yarn at a knitting tension T K to the feeder of the knitting machine. Information from the knitting machine such as a needle selection signal is fed to the error detector in conjunction with computer information L C and a signal representing the measured length of yarn L K and an error signal f(L K -L C ) is fed to the yarn tensioning device so as to adjust the yarn tension whereby the measured yarn length will equal the desired yarn length.
In this invention, use may be made of the characteristic of many patterned knitted fabrics that one course is knitted by a group of feeders in such a way that each needle in a selectable set of the knitting machine is selected to knit at one and only at one feeder of the group in each widthway repeat of the pattern. In such cases the total length of yarn required to be knitted by the group of feeders for an integral number of widthway pattern repeats is substantially constant and independent of the patterning and may conveniently be calculated before knitting begins. Accordingly, the control of the length of yarn knitted by a knitting machine with the needle selecting means in operation may be accomplished, for example, by providing means for producing a signal to control the adjusting means comprising, for example, a comparator which accepts the signal which is related to the length of yarn knitted by the machine during each integral number of widthway pattern repeats at each feeder in the group and compares the sum for the feeders in the group of these signals with a predetermined value representing the required total length for the feeder group for each integral number of widthway pattern repeats and produces an output signal related to the difference between them and suitable for the control of the adjusting means in use of all the feeders in the group severally and in concert at a common setting. Means may be provided for providing a gating signal to start and stop the length measuring functions of means LM1 at the beginning and end respectively of the knitting of the required integral number of widthway pattern repeats. | A method and apparatus for feeding yarn to a knitting machine having needle selecting means so that the length of yarn required to be knitted into each sequence of a small number of stitches is not constant. The length of yarn as actually fed to the knitting machine during each sequence of a small number of stitches is measured, and a value or signal representing the actual measured length of yarn is then compared to a predetermined length value which represents or is a function of a predetermined stitch length. The tension in the yarn as fed to the knitting machine is continuously adjusted in response to deviations or differences detected by the comparison of the predetermined and measured length values. | 3 |
The present invention is directed to a warp knitting machine having at least one bar which is made of a reinforced material and is connected, via a first fastening location, with holding arms and via a second fastening location, with thread guide holders.
A warp knitting machine of this general type is disclosed in U.S. Pat. No. 2,694,302 (1954). The guide bars illustrated therein can, upon choice, be made of lightweight metals or out of reinforced synthetics. The holding arms are, rigidly affixed to the bar with screws. The thread guide holders are fixed to the bar by means of clamping screws and nuts. In this arrangement the clamping screws grip through vertical slits in the bar that open upwardly. The bar has an L-shaped cross-section, wherein the vertical slits occupy more than half of the total height of the bar. Despite this early suggestion of the use of reinforced synthetics, bars of this type of material have not heretofore seen commercial use. Use has however, been made of extruded bars of magnesium alloys which, while much lighter than steel bars, still have a comparatively high weight in comparison to reinforced synthetics. They also have the disadvantage of having a rather high thermal coefficient of expansion.
The purpose of the present invention is to provide a warp knitting machine of the foregoing type, possessing a commercially viable bar of reinforced synthetic material.
SUMMARY OF THE INVENTION
In accordance with the illustrative embodiments demonstrating features and advantage of the present invention, there is provided a guide bar assembly in a warp knitting machine having guide holders and holding arms. The guide bar assembly has a guide bar made of reinforced synthetic polymeric materials. The guide bar has along substantially its entire length a substantially hollow profile. The guide bar has surrounding walls substantially enclosing the hollow profile. The guide bar includes a first and second fastening segment. The first fastening segment is adapted to be attached to the holding arms. The second fastening segment is adapted to support the guide holders.
An improved guide bar assembly is therefore provided, preferably by employing a bar of partially hollow cross-section with the hollow opening extending the full length of the bar (i.e., the width of the machine). This hollow is surrounded by substantially closed walls. The holding arms and the thread guide units are clamped on two external fastening locations formed unitarily on the hollow-profile bar.
In this construction, the hollow-profile bar is a closed and thus very stable and particularly distortion-resistant. To this end, the bar may be reinforced through its entire length by fibers. The use of the closed, hollow-profile format permits the use of fibers running parallel to the axis of the bar. Also the fibers may run perpendicular to this bar axis or may subtend an angle to each other. The hollow bar can thus provide a higher degree of stiffness. These advantages are not negatively influenced by incorporating the fastening segments, since they could be provided externally of the hollowed sector. The fastening segments are formed unitarily with the hollowed sector. Conventional bars are coupled to holding arms on one side and thread guide holders on the other. The fastening segments thus increase the cross-sectional dimensions in one direction and can therefore further positively influence the stiffness of the device.
It is advantageous if the fastening segments are each provided with at least one pair of clamping surfaces stretching over the full length of the bar. Even if at a later time, only certain segments of the clamping surfaces are utilized, this mode simplifies production of the arrangement.
It is further advantageous if, between the clamping surfaces of such a pair, there is at least one opening formed in the fastening segment for the passage therethrough of a clamping element. Since this opening, which is important for the provision of the clamping force, may be bored at a later time or formed at the time of construction, any damage to reinforcing fibers by the boring has no substantial impact on bar strength.
In particular, the openings can be formed as a row of holes, wherein the cross-section of the holes is substantially that of the cross-section of the clamping element. This leads to a quite minimal weakening of the fastening segment. The stiffness thereof remains intact.
The opening can also be provided by a longitudinal slot, because the slot is external to the main body segment of the bar. The utilization of a longitudinal slot permits a very simple mode of production.
In a preferred embodiment, the first or upper fastening segment is provided with a longitudinal channel, extending across the entire width of the machine, into which at least one threaded element is inserted. Such element interacts with a clamping screw, wherein the outer side of the fastening segment and the corresponding inner side of the longitudinal channel just below it, provide a pair of clamping surfaces. Such a longitudinal channel is readily formed. It serves not only for the reception but also the prevention of rotation of the threaded element. Holding arms or thread guide holders can be held fast and secure on the outer clamping surfaces of the fastening segments.
In an alternate mode, the second or lower fixing segment for the guide holders provides clamping surfaces on mutually opposite and parallel sides thereof, on which a threaded element, cooperating with the clamping screw, can act. The surface of the fastening segment is angled to provide a barrier to prevent the rotation of the threaded element.
In yet a further embodiment, the lower fastening element can be provided with a slot parallel to the clamping surfaces. By tensioning the clamping screw about the slot, the guide holders are held tight in the slot. The threaded elements can be either multiedged nuts or flat strips having at least two threaded openings therein.
In yet another embodiment, the upper fastening element for the holding arms is provided with a dove-tailed cross-section onto which the holding arm having a dove-tailed cross-sectional guide, may be attached by means of a substantially horizontal clamping screw running perpendicular to the longitudinal axis of the guide.
It is preferred that the bar is produced as a layered molding. All openings, longitudinal channels, hollow spaces, and the like, can be readily formed by this method.
The bars are suitably manufactured by a process known as "pulltrusion." In this process, there is provided a hollow die having the internal dimensions corresponding to the outer dimensions of the bar. A floating plug with external dimensions corresponding to the hollow profile is positioned inside the die. In the space between the outside surface of the plug and the inside surface of the die, there are fed either fibers, woven fabric or non-woven fabric of the reinforcing material, or combinations thereof. Similarly, the synthetic material is also simultaneously fed through this space. The term "pulltrusion" is derived from the combination of forces in the system. The synthetics are pumped into the input side and the reinforced product is pulled out of the output side.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention may be illustrated by means of the preferred embodiments which are illustrated in the following figures.
FIG. 1 is a cross-sectional, side elevational view of a guide bar of the present invention.
FIG. 2 is a front elevational view with a partial cross-section of a guide bar viewed along lines 2--2 of FIG. 1.
FIG. 3 is a cross-sectional, side elevational view similar of a guide bar that is modification of that of FIG. 1.
FIG. 4 is a cross-sectional, side elevational view of yet another modification of the embodiment of FIG. 1.
FIG. 5 is a front elevational view with partial cross-section of the guide bar taken along lines 5--5 of FIG. 4.
FIG. 6 is a cross-sectional, side elevational view of a fourth modification of the bar of FIG. 1.
FIG. 7 is a tension/extension diagram for different fibers.
FIG. 8 is a perspective, partial cross-sectional view of a fifth embodiment of a bar showing fibers oriented parallel to the longitudinal axis only.
FIG. 9 is a perspective, partial cross-sectional view of the bar of FIG. 8, modified to show fibers oriented parallel and perpendicular to the longitudinal axis of the bar.
FIG. 10 is a perspective partial cross-sectional view of the bar showing fibers oriented parallel and perpendicular to the longitudinal axis of the bar and at 45° to the previous two directions.
FIG. 11 is a schematic view of a pulltrusion apparatus.
FIG. 12 is a perspective, partial cross-sectional view of the apparatus of FIG. 11 viewed along lines 12--12 of FIG. 11.
FIG. 13 is another perspective view of the apparatus of FIG. 12.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As illustrated in FIGS. 1 and 2, guide bar 1 is connected to a holding arm 3 via a first upper fastening location 2. Bar 1 carries guide holder 5 via a second lower fastening location 4. Holder 5 carries guides 6.
Guide bar 1, in the preferred embodiment, is constructed of a synthetic composition reinforced by carbon fibers. At its center, bar 1 has a hollow cross-section 7, with hollow space 8 running the length thereof. Space 8 is surrounded by closed walls 9, 10, 11 and 12. Integral therewith is an upper fastening segment 13 and a lower fastening segment 14. Segments 13 and 14 are formed during the formation of said bar.
The upper fastening segment 13 is provided with a longitudinal channel 15. Channel 15 is a hollow running the full length of the bar and defining the inside of a hollow cross-section. A threaded element in the form of a flat strip 16 is laid into channel 15. The strip has screws 22 and 23 with two threaded segments 17 and 18 fitting into two openings 19 and 20 in the uppermost segment 21 of the bar. Screw heads 24 and 25 press flanges 26 and 27 of the holding arm 3 against the upper surface of segment 21. The upper surface of segment 21 thus forms the first clamping surface 28 and its lower surface 29, the second clamping surface.
The lower fastening segment 14 similarly comprises a longitudinal channel 30 which receives four-edged nuts 31 and prevents them from rotating. These nuts operate in conjunction with clamping screws 32, whose heads 33 press guide holders 5 against the outer side of fastening segment 14. Also here, the flat surface flanking the longitudinal channel 30 operates as a first clamping surface and the inner surface of the longitudinal channel 30 proximal thereto provides the second clamping surface. The clamping screws 32 thus grip through openings 34 in the fastening segment 14.
The holes 19 and 20 are only fractionally larger than the cross-section of the clamping screws 22 and 23. The same is true for the cross-section of hole 34 with respect to the cross-section of clamping screw 32. These holes are formed after the production of the bar. Despite the cutting of fibers when these holes are bored, strip 16 together with the foot of holding arm 3 strengthens the bored area to avoid any weakening. Strip 16 in space 15, because of its cross-section, increases the bending strength, wherein the clamping screws 19 and 20 by means of the clamping force, provide the required distribution of the bending tension.
In the embodiment illustrated in FIG. 3, parts corresponding to those of FIG. 1 are incremented by 100. Only the lower fastening segment 114 is arranged in a different manner. Here, there is provided a longitudinal slot 35 for the holding guide holders 5. Clamping screw 132 lies with its head 133 against a clamping surface 36 and interacts with a four-edged nut 131 which lies on the other clamping surface 37 on the other side of segment 114. This clamping surface 37 is so oriented as to provide a barrier 38 which prevents rotation of four-edged nut 131.
In the embodiments of FIGS. 4 and 5, parts corresponding to those of FIG. 1 are incremented by 200. Bar 201 is illustrated having a lower fastening segment 214 similar to that of FIGS. 1 and 2. However, in place of individual openings 34, there is provided a longitudinal slot 234 through which the clamping screws 32 may pass.
There is a further difference in the first fastening location 202. Bar 201 at fastening segment 213 has a rib segment 39 of dove-tailed cross-section. This interacts with a dove-tailed guide 40 located in holding arm 203. Arm 203 is provided at the lower end thereof with a slot 41. In the vicinity of the slot, the portions of guide 40 can be drawn together by means of clamping screw 42 passing through guide 40 and securing onto nut 43 to provide a safe fastening thereof.
In the embodiment of FIG. 6, again the corresponding parts are incremented, this time by 300. Herein there is provided a bar 301 which is identical to that illustrated in FIG. 3. The lower fastening segment 314 lacks, however, a slit, such as slit 35. In this embodiment, guide holders 5 are clamped by head 33 of clamping screw 32 directly against the clamping surface 36 when these are pulled together by interaction with four-edged nut 31.
FIG. 7 illustrates the tension/extension diagram for different types of fibers.
The apparatus for producing bar 801 is schematically illustrated in FIG. 11, which shows the embodiment of the manufacturing process wherein reinforcing fibers are utilized. The apparatus comprises a creel carrying roving spools 850 from which are drawn the fibers 852. These fibers pass through coating bath 856 containing the synthetic material to be cured. From the bath 856 fibers 852 pass into preform 858 and the curing segment 860, which usually contains a heating element, to cooling sector 862. Extraction rollers 864 extract the finished bar 801.
The choice of synthetic polymeric material is also broad, the cured polymer however being thermosetting. Suitable polymers include unsaturated polyesters such as phenyl, isophthalic and vinyl; phenolic resins, epoxy resins and polyimide resins. It is desirable that the fiber/resin ratio be about 50-60:50-40% v/v. It is particularly advantageous if the bar is produced from a carbon fiber composition. This gives an extremely light product of density 1.45 kg./dm. 3 . The temperature coefficient of expansion is negligibly small so that even at higher operating temperatures, there is substantially no longitudinal expansion.
The placement of the floating plug is illustrated in FIG. 12, which represents the view along line 12--12, showing how plug 857 is held by plug holder 855 in preform 858 and how the threads 852 pass around plug 857. Holder 855 is an upright stanchion having a horizontal bore. Plug 857 is a wedge-like prism having an upstream rod bolted into the bore of stanchion 855. In other embodiments the outline of plug 857 and the opening in preform 858 can be altered to produce a guide bar of various cross-sections.
This sector is illustrated in yet further detail in FIG. 13, which shows not modified plug 857A. Plug 857A has two opposing, rectangular notches to produces shelves in the guide bar as illustrated in FIGS. 8-10. Again plug 857A is held by plug holder 855. Web 853 and fibers 852 and 852A are laid around the plug 857 with fibers 852 lying on the outside of said web 853 and fibers 852A on the inside of said web. The placement of said fibers in said web within bar 801 is also shown. Web 853 can be laid, in a saddle-like shape around the plug 857. Web 853 is closed on itself to enclose plug 857 in preform 858. Web 853 thereby becomes a laminate for reinforcing the guide bar.
The fibers utilized may be any non-metallic fibers. Glass, carbon and aramide are especially suitable. The fibers may be in the form of filaments, woven or nonwoven mats. The woven goods may be woven in any desired orientation. It is preferred that such mats are laid across the plug in such a manner that two edges of the mats meet at the bottom of the bar.
In Table I, there are illustrated various properties of various synthetic materials that are utilizable for the formation of the bars.
TABLE I__________________________________________________________________________DUROMER RESIN SYSTEM Unsaturated Polyester Epoxyresin Phenyl Isophthl Vinyl Phnolc Phenyl MY720 Plyimid__________________________________________________________________________Resin Mg/m.sup.3 1.10-1.46 1.23 1.15 1.30-1.33 1.15-1.35 1.15-1.25 1.35-1.45DensityTension MPa 35-92 53 73 42-63 40-140 85 75ResistanceBending MPa 80-150 103 132 77-120 60-180 80 100ResistanceCompress MPa 90-180 127 85-105 10-200 170ResistanceTension GPa 1.5-2.0 3.7 3.5 2.8-3.5 3.0-5.0 3.3ModulusTensile % 2.0-4.0 1.25 3.0-4.0 1.5-2.0 0.5-1.0 4.0-7.0 1.0-7.0LimitsThermal × 10.sup.-6 /K 53 70CoefficientOf Expansion__________________________________________________________________________ | A warp knitting machine has guide holders, holding arms, and a guide bar assembly. The assembly includes a guide bar made of reinforced synthetic polymeric materials. This guide bar has along substantially its entire length a substantially hollow profile. The guide bar has surrounding walls substantially enclosing the hollow profile. The guide bar includes a first and second segment. The first fastening segment is adapted to be attached to the holding arm. The second fastening segment is adapted to support the guide holders. | 3 |
GOVERNMENT INTEREST
This invention was made with Government support under Grant Number 1K20MH-01151 awarded by the National Institutes of Health. The Government has certain rights in the invention.
TECHNICAL FIELD
The present invention relates to electroconvulsive therapy (ECT) and more particularly an improved electroconvulsive therapy (ECT) treatment including methodology for simultaneously and accurately predicting seizure adequacy during treatment.
RELATED ART
Electroconvulsive therapy (ECT) is used to treat certain severe mental disorders such as major depression. At present, as many as 100,000 patients in the U.S.A. receive this treatment yearly and there is evidence that utilization is on the increase. In particular, this internationally used treatment modality is widely recognized on the basis of well-controlled scientific studies as being the most rapid and effective means of producing a clinical remission in episodes of major depressive disorder, a severe, debilitating, and frequently lethal illness which affects millions of Americans during their lifetime. Other such studies have shown ECT to be a relatively safe procedure, with the most widely reported side-effect being memory difficulties, which are nearly always temporary, except that some patients may continue to have difficulty recalling material from around the time period of the ECT treatments. The degree and persistence of these memory difficulties are related to a number of factors, including the extent to which the electrical stimulus intensity exceeds the patient's seizure threshold (as defined below).
In ECT two stimulus electrodes are applied to the patient's scalp. An electric current is applied between these electrodes, only a fraction of which reaches the brain, the rest being deflected by the skin and skull.
The stimulus in ECT is a brief series of electrical square pulses. The width of each pulse, pulse frequency, peak pulse current, and/or overall stimulus duration are adjustable by the physician administering the treatment.
The goal of ECT therapy is the induction of an electrical response in the neural tissue of the patient's brain. This appears on an electroencephalograph (EEG) instrument, using analog printed wavy lines, as a pattern similar to a typical epileptic grand mal seizure pattern. It is believed that the therapeutic benefit of the ECT is primarily due to a series of 4-18 such induced seizures, usually administered at a rate of three times per week.
The specific choice of stimulus parameters is generally tailored to the patient's electrical threshold for inducing this response. This threshold is influenced by factors such as gender, specific type of stimulus electrode location (e.g. stimulation of one side of the head (unilateral (UL) ECT) vs. both sides (bilateral (BL) ECT)), age, and number of prior seizures in the present series. Many physicians now estimate the seizure threshold at the time of the first treatment by using an electrical dose-titration technique that involves the use of increasing levels of stimulus intensity until a desired response is obtained. However, the value of this technique is limited by the fact that seizure threshold rises over the subsequent treatments in the series in a variable and unpredictable manner.
From the very beginnings of ECT the need for some way to assess the adequacy of individual seizures has been apparent. This is the case because there is a delay in time between when a treatment is administered and when the resulting therapeutic benefit and adverse cognitive effects become evident. Thus, there has always been a great need for some way to determine the expected degree of therapeutic response and adverse cognitive effects associated with individual treatments, i.e., to ensure that the induced seizure is "adequate" from the perspective both of therapeutic benefit and side-effects. Such a method for the prediction of the adequacy of the induced seizures would thereby allow ECT practitioners to adjust the treatments administered so that they maximize therapeutic outcome, but do not cause any unnecessary side effects thereby optimizing the administration of this treatment.
The prevailing viewpoint about what constitutes an adequate seizure has evolved since the origin of convulsive therapy. The predominant early view was that seizures were an "all-or-none" phenomenon, such that if a seizure was elicited then therapeutic adequacy was considered to be ensured. Over time the heterogeneity of seizures became apparent. In the early 1960's publications by Ottosson were misinterpreted as implying that the duration of the seizure elicited by ECT was related to the therapeutic effectiveness of the seizure. Bolstered by a 1978 publication by Maletzky, this view developed into the mistaken notion that it was possible to determine seizure adequacy on the basis of the duration of ECT seizures. Since that time a large number of studies have failed to support this conclusion but instead support the view that, while exceeding a seizure duration minimum may be necessary to ensure therapeutic adequacy, it is not sufficient.
More recent evidence suggests that there is a relationship between the beneficial effects and adverse effects associated with ECT treatments and the degree to which the stimulus intensity exceeds the seizure threshold (the amount of electrical charge necessary just barely to cause a seizure). This is termed relative stimulus intensity. Such evidence has suggested that higher relative stimulus intensity was associated with greater cognitive side effects. In addition, higher relative intensity stimuli are associated with a greater therapeutic response rate for one commonly used form of ECT, UL ECT, which is associated with fewer adverse cognitive effects than the other commonly used form of treatment, BL ECT, for which higher relative stimulus intensity is associated with a more rapid response. While this information does not constitute criteria for determining seizure adequacy it at least suggests some potential for being able to predict and thereby to alter therapeutic response and expected side-effects associated with ECT treatments.
Unfortunately, applying these results in the clinical practice of ECT is problematic. Although the use of a seizure threshold titration procedure allows dosing with respect to relative stimulus intensity at the beginning of the treatment course, as noted earlier, ECT treatments induce an uncertain rise in the seizure threshold over the ECT course rendering the relative stimulus intensity unclear. Unfortunately, it is impractical to remedy the situation by performing repeated determinations of the seizure threshold. Nor is the use of a high absolute stimulus intensity to assure the attainment of high relative stimulus intensity viable, since this practice is likely to be associated with unacceptably greater adverse cognitive effects. Thus, recent research highlights the need not only for a marker of the therapeutic potency and adverse effects of ECT seizures but also for the prediction of relative stimulus intensity as this itself would be expected to be associated with therapeutic outcome and the degree of expected adverse effects.
The applicants' invention uses the EEG data, which is routinely recorded noninvasively from the scalp during ECT treatments, for the prediction of ECT seizure adequacy in terms of relative stimulus intensity, therapeutic outcome, and adverse cognitive effects. Prior work with EEG data recorded during and immediately after ECT seizures has not developed models for the determination of seizure adequacy, nor has it provided evidence regarding the clinical utility of ictal EEG data (EEG data recorded during ECT seizures). Thus, such studies leave a lasting need for some scientifically valid way to assess the adequacy of ECT seizures.
The applicants' invention succeeds in meeting this long-felt need by developing ictal EEG models of seizure adequacy that can be implemented in the clinical setting and by demonstrating that these models have a high likelihood of success when implemented for that purpose. This invention is distinguished from prior art in that it is the first actually to develop a method whereby the treatment relative stimulus intensity, expected therapeutic response, and expected cognitive effects associated with an ECT treatment can be determined. Further, it is the first demonstration of a relationship between ECT therapeutic response and computer derived ictal EEG measures. This is particularly important because such computer derived measures can be automated so that accurate and reliable clinical implementation becomes possible. This invention is also the first use of completely automated ictal EEG indices, represents the first implementation of automatic EEG artifact detection and adjustment associated with ECT, and is the first embodiment of a multivariate ictal EEG predictive model.
In the applicants' method, models are developed using data where the treatment relative stimulus intensity, therapeutic potency, and associated adverse effects are known and these models are then used for the prediction of the relative stimulus intensity, expected therapeutic response, and associated side-effects for a given seizure.
While there are prior patents related to ictal EEG data, these patents only pertain to the measurement of seizure duration (see, for example, Somatics, Inc. U.S. Pat. Nos. 4,873,981; 5,269,302; and 4,878,498) and there are no patents known to the applicants relating specifically to seizure adequacy determination. The applicants' invention is a significant advancement in the ECT art by providing a reliable marker of seizure adequacy which has heretofore not been available. As a result, with this invention it will be possible for ECT practitioners to determine the expected beneficial and adverse effects associated with ECT treatments and thereby optimize the effectiveness and safety of this treatment modality.
SUMMARY OF THE INVENTION
The present invention provides a method in electroconvulsive therapy (ECT) to use ictal EEG data for clinical determination of the adequacy of an induced seizure in a patient. The method includes employing an ECT device to apply electricity to the patient in an electroconvulsive therapy session to induce seizure activity. The electrical brain waves (EEG data) of the patient are detected during the seizure and/or immediate post seizure time period and certain selected EEG data parameters are derived therefrom. Next, the likely adequacy of the induced seizure is computed by comparing the selected EEG data parameters of the patient to ictal EEG data parameters wherein the adequacy of the corresponding seizure or seizures is known. Finally, the computed likely therapeutic adequacy of the induced seizure is displayed.
It is therefore an object of the present invention to provide an improved ECT method wherein ictal EEG data is used as a predictor of adequacy of induced seizure activity.
Some of the objects of the invention having been stated hereinabove, other objects will become evident as the description proceeds, when taken in connection with the accompanying drawing as best described hereinbelow.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 shows a sample EEG tracing where the segments of data included in the prediction of seizure adequacy are designated.
DETAILED DESCRIPTION OF THE INVENTION
Applicants now report the development of new ictal EEG models that predict ECT therapeutic adequacy. Applicants have discovered a novel method providing the first use of a multivariate ictal EEG model to predict (1) the adequacy of ECT relative stimulus intensity, (2) therapeutic potency and (3) expected memory side effects associated with ECT treatments. This novel procedure and model represent the discovery of a much-needed clinically applicable marker of the adequacy of individual ECT treatments.
DEVELOPMENT OF MODELS WHICH CHARACTERIZE THE INVENTION
Overview
The development of quantitative multivariate models for ECT seizure adequacy can be thought of as a three stage process: (1) collection of data for model development, (2) computation of ictal EEG variables, and (3) construction and testing of multivariate models for the prediction of stimulus dosing, therapeutic potency, and adverse cognitive effects.
Collection of Data For Model Development
Subjects: Data from twenty-five patients clinically referred for unilateral nondominant ECT were used to assist in the development of the models. All data was collected during the conduction of a research protocol that was independent of the development of this invention. Subjects participating in the protocol all met standardized (DSM-III-R) criteria for major depression (ascertained by a single trained research rater using a structured interview), were strongly right motor dominant on a motor performance test, had not had ECT in the last 3 months, and were without evidence of active cerebral disease. In addition, subjects were free of antidepressant, antipsychotic, and benzodiazepine agents for at least 5 days prior to and during ECT (except for 1 subject who received three nighttime 15-mg doses of temazepam over the ECT course and 3 individuals who had shorter drug-free intervals, respectively, clomipramine 3 days, sertralien 2 days, and trifluoperazine 4 days). In terms of other medications known to affect seizures, one subject received a fixed dosage of theophylline throughout the study. Additional subject characteristics are listed in Table 1.
TABLE 1______________________________________Subject Characteristics by Treatment Group T Group 2.5T Group______________________________________Men 2 7Women 9 7Mean Age 48.8 54.0 (14.4) (10.6)Mean Methohexital Dosage 85.4 85.8(mg) (24.3) (22.7)Mean Succinylcholine Dosage 79.2 86.0(mg) (17.7) (19.7)Mean Estimated Seizure 44.3 41.1Threshold (mC) (19.6) (12.7)Mean Baseline MADRS Score 38.7 36.7 (6.4) (7.4)Mean Seizure Duration (sec) 73.8 66.7 (18.7) (24.0)______________________________________ Standard Deviations appear in parentheses
ECT Administration: All patients received bidirectional brief pulse ECT (MECTA SR1 ECT device, manufactured by Mecta Corp. of Lake Oswego, Oreg.) using right UL electrode placement. Routine pharmacologic agents used with ECT included methohexital 1 mg/kg; succinylcholine 1 mg/kg; and 100% of oxygen by mask. Estimation of seizure threshold was accomplished at treatment 1, beginning with a dose of 32 millicoulombs (mC) for females and 48 mC for males. When necessary, restimulation at the same treatment was carried out, using 50% increments, until a seizure of at least 25 seconds EEG duration had been achieved. This resulting final stimulus intensity represented the estimated seizure threshold (T) at the first treatment. Thereafter, patients were randomized to receive a stimulus intensity at subsequent treatments either at T or at a moderately suprathreshold level of 2.5 times estimated seizure threshold (2.5T) intensity for the next 4 treatments (T: N=11 patients; 2.5T: N=14 patients). If a seizure was elicited that was less than 25 seconds in duration, restimulation was delivered at a 50% increment for 2.5T subjects and 25% for individuals assigned to the T condition. Subjects and their treatment teams were both blind to group assignment. Interestingly, applicants discovered that neither seizure threshold nor seizure duration differed between the two groups (see Table 1 above).
EEG Recording: Two channels of EEG were recorded, using a MECTA SR1 ECT device, with left and right prefrontal-to-ipsilateral mastoid derivations and Ag/AgCl electrodes. To ensure a low EEG electrode-scalp impedance, the electrode sites were cleaned with alcohol and an abrasive cleaner (OMNIPREP from D. O. Weaver and Co.), and conduction gel was applied. Simultaneous recordings were made on magnetic tape by using a Vetter Corporation Model C-4 FM tape recorder for subsequent digitization (256 Hz) and analysis by a computer-based EEG acquisition and analysis system (EEGSYS available from Friends of Medical Science, Inc.) and by additional custom software written by applicants.
Therapeutic Outcome Measurement: The Clinical Global Impression Scale (CGI) was used to make a dichotomous therapeutic outcome assessment. The CGI consists of a 7-point severity subscale and a 9-point improvement component. A responder was defined as a subject who achieved at least moderate improvement on the CGI (improvement score <4) and was no more than mildly ill (severity rating ≦3). The CGI was administered by a trained rater: at baseline and 1 day after treatment 5. Baseline Montgomery-Asberg Depression Rating Scale (MADRS) ratings for the two groups appear in Table 1 and were not significantly different.
Memory Function Measurement: The degree of memory impairment associated with the ECT course was assessed via a complex figural memory test which was administered both at baseline and 1 day after treatment 5. Subjects were shown a complex figure and asked to reproduce it immediately and after a period of delay. Because the applicants have previously found that delayed complex figural memory reflected the degree of cognitive impairment associated with ECT, this variable served as the primary measure of memory function. Several test forms were used and their order of administration was counter-balanced.
Statistical analyses: All data were checked for distribution normality and were transformed as indicated to an approximate normal distribution. All measures except coherence data were normalized by a logarithmic transformation. Coherence data were normalized by the Fisher's z transform. The mean treatment number of seizures included in EEG analyses (treatments 2-5 only) did not significantly differ between the two treatment groups (3.38 for T subjects and 3.60 for 2.5T subjects). All analyses were carried out by using the SAS statistical analysis system (available from SAS Institute, Inc.) with two-tailed tests of significance, except for the implementation of adequacy models which were written in the C programming language.
Computation of Ictal EEG Variables
The digitized EEG was split into 3 frequency bands (2-5 Hz, 5.5-13 Hz, and 13.5-30 Hz) by using the fast Fourier transform. Spectral analysis was performed on 6-second (three 2-second epochs) segments of EEG data from the immediate poststimulus (early), midictal, and immediate postictal portions of the seizure (see FIG. 1). For the purposes of computation of ictal EEG variables, in the development of the models, the first 6 artifact-free seconds of data following the ECT stimulus were included in early segment analysis and the first 6 artifact-free seconds of data following seizure termination were utilized in postictal analysis (for model testing, completely automated computation is carried out, see below). The segment for midictal analysis was chosen by a computer program that automatically selected the 6-second portion with the maximum mean peak-to-peak amplitude by testing sequentially overlapping 6-second segments of artifact-free data (epochs 1-3, 2-4, 4-6, etc.). All selection of data segments to be analyzed was done blind to group assignment, treatment number, therapeutic outcome, and degree of cognitive impairment.
For each of these 3 segments, spectral amplitude and interhemispheric coherence were computed for each of the three frequency bands. Coherence was used to reflect the degree of physiologic coupling between the two EEG channels. It is analogous to the interhemispheric correlation of the EEG data in each frequency band. Coherence values varied from 0.0 to 1.0, with a value of 1.0 suggesting a strong linear relationship between the data in the two hemispheres in the frequency band being studied. An additional measure, time to onset of ictal slowing (TSLOW), defined as the first 6-second artifact-free period in which activity in the 2-5 Hz frequency band became greater in amplitude than activity in any other band, was determined through the use of a computer automated procedure.
FIG. 1 is an EEG tracing from a seizure elicited by a 2.5T stimulus. The vertical lines appear at 1 second intervals. The segments of the seizure utilized in ictal EEG analysis appear in the boxes. The ictal EEG parameters associated with this seizure are: Left Early 5.5-13 Hz Amplitude=39.3 μV, Right Early 5.5-13 Hz Amplitude=39.4 μV, Early 2-5 Hz Coherence=0.94, Left TSLOW=4 sec, Right TSLOW=4 sec, Left 2-5 Hz Midictal Amplitude=120 μV, Right 2-5 Hz Midictal Amplitude=127 μV, Left 2-5 Hz Post-ictal Amplitude=8.9 μV, Right 2-5 Hz Post-ictal Amplitude=8.6 μV.
The calculation of all of the ictal EEG indices have been completely automated so that models based on these measures could be implemented in automated fashion in the clinical ECT setting. Early spectral amplitude was automatically calculated from the EEG data recorded in the first 6 seconds post-stimulus and midictal spectral amplitude and TSLOW were automated as described above. Postictal spectral amplitude was automatically computed as the amplitude of the lowest amplitude portion of the seizure excluding the first 6 seconds of the seizure. This allowed postictal amplitude to be determined without the manual determination of the seizure endpoint.
Automation of such ictal EEG models necessitated the automatic detection and adjustment for artifacts that are sometimes present in ictal EEG data, which would otherwise diminish the accuracy of the associated predictors. This was accomplished in several ways. Firstly, the automated computation of postictal amplitude (the amplitude of the lowest amplitude portion of the seizure) decreased the likelihood of artifact contamination in the EEG data utilized in the postictal period, which tend to be higher in amplitude than the EEG signal. Also, the choice of using low frequency midictal amplitude prevents contamination by myogenic artifact, which tends to have higher frequency content.
To provide additional artifact protection, the applicants capitalized on the fact that artifacts cause a predictable effect on each of the EEG variables. All of the spectral amplitude measures are higher in amplitude in the presence of artifact, while TSLOW is made smaller by artifact. As a result, when spectral amplitude measures were below the mean value of the above data set, the influence of spectral amplitude measures on model prediction was doubled by multiplying the Z transformed spectral amplitude variables by 2 (Z transform versions of each variable are used in prediction of seizure adequacy and this transformation involves subtracting off the mean and dividing by the standard deviation of the present data set). Similarly, when TSLOW was greater than the mean of the above data set, the influence of this variable on outcome prediction was doubled. This process diminished the effect of artifact contaminated EEG variables on model performance by weighing more heavily EEG variables which were likely to be free of artifact.
The final set of steps taken to protect against artifact contamination involved the detection of artifact by looking for one of several patterns across 2 or more ictal EEG variables that characterize artifact contamination and subsequently eliminating the effects of variables suspected of being contaminated by artifact. These empirically determined patterns included when early or mid-ictal amplitude were greater than 2 standard-deviations above the mean while post-ictal amplitude was less than the mean of the above described data set. This pattern suggests artifact in the Early or mid-ictal amplitude variable studied. Similarly if TSLOW is 2 standard deviations below the mean and post-ictal amplitude is below the mean, then artifact is suspected in TSLOW. When artifact is suspected in an ictal EEG variable, its Z transformation (the Z transformed version of each variable are used in prediction of seizure adequacy) is set equal to the mean of the Z transformation of all the other ictal EEG variables in the model, that are not suspected of artifact contamination, thereby removing the influence of the artifact on adequacy prediction.
Construction and Testing of Multivariate Models
An Ictal EEG Model for Prediction of ECT Relative Stimulus Intensity: A multivariate logistic regression model was developed and tested for its ability to identify correctly T and 2.5T seizures. The model was developed by using the average of ictal EEG data from treatments 2 and 3 for each subject and was then tested on data from treatments 4 and 5.
To avoid the incorporation of intercorrelated measures, and also to reduce the number of variables in the model, principal components analysis was performed. In this case, the principal components were linear combinations of the original nine EEG variables after z transformation. Although nine potential principal components were generated by the analysis, only those principal components that individually accounted for 10% of more of the variance of the nine (9) ictal EEG variables were utilized. As shown in Table 2 below, the resulting four principal components together accounted for of the variance in the nine EEG variables.
TABLE 2______________________________________First 4 Principal Components of Ictal EEG Variables PRIN1 PRIN2 PRIN3 PRIN4______________________________________Percentage of 45. 25. 13. 10.VarianceAccounted ForLeft 5.5-13 Hz 0.337023 0.145347 0.457368 -0.330347EarlyAmplitudeConstantRight 5.5-13 Hz 0.372703 0.129997 0.387851 -0.186116EarlyAmplitudeConstantLeft 2-5 Hz 0.416869 0.184744 0.072316 0.387599MidictalAmplitudeConstantRight 2-5 Hz 0.403066 0.164246 0.125853 0.525657MidictalAmplitudeConstantLeft 2-5 Hz -0.312297 -0.275883 0.505134 0.214998Post-IctalAmplitudeConstantRight 2-5 Hz -0.28841 -0.292221 0.530298 0.259721Post-IctalAmplitudeConstantLeft TSLOW -0.275992 0.515537 0.180023 -0.247008ConstantRight TSLOW -0.270843 0.525611 0.192756 -0.084358ConstantEarly 2-5 Hz 0.284657 -0.444206 0.114569 -0.49787CoherenceConstant______________________________________ Where, for example, PRIN1 would be calculated from the Z transformed data from a given seizure as follows: PRIN1 = .337023 × Left Early Ampl. + .372703 × Right Early Ampl. + .426869 × Left Mid Ampl. + .403066 × Right Mid Ampl. .312297 × Left Postictal Ampl. - .28841 × Right Postictal Ampl. - .275992 × Left TSLOW - .270843 × Right TSLOW + .28465 × Early Coherence
Each of these four principal components was then entered into a logistic regression model for prediction of stimulus intensity group. Age, but not initial seizure threshold, was included in the model because only the former was found to be a significant covariate. The ability of the model to predict the stimulus intensity group assignment for data from treatments 4 and 5 was then assessed.
Because many ECT practitioners record only one channel of EEG data, reserving the second data channel of most ECT machines for electrocardiographic or electromyographic data, an EEG model of relative stimulus intensity based only on left hemispheric data was also developed and tested (left hemispheric intergroup differences tended to be more significant than for the right hemisphere). This single-channel model was developed by using identical methodology to that described above and included left early 5.5-13-Hz amplitude, left 2-5 Hz midictal amplitude, left 2-5 Hz postictal amplitude, and left TSLOW. The single channel ictal EEG model so developed was also implemented in completely automated form and its associated accuracy in the prediction of ECT seizure relative stimulus intensity adequacy was also tested, and a detailed description of the implementation of this model as it would be carried out in the clinical setting is described.
As outlined above, the first four principal components of the treatment 2-3 means of all nine (9) ictal EEG variables, along with age, were entered into a stepwise logistic regression analysis. Only age and principal components 1 and 4 contributed significantly to the prediction of stimulus intensity group, and therefore principal components 2 and 3 were dropped from the model. Based on the weightings of the two principal components used in the model (1 and 4), the ictal EEG variable that contributed most strongly to the model was midictal 2-5 Hz amplitude, followed by early 5.5-13 Hz amplitude, early 2-5 Hz coherence, postictal 2-5 Hz amplitude, and TSLOW.
This model correctly identified the relative stimulus intensity group for 95% (20/21) of the seizures from the set from which it was developed. This result included a 100% success rate for identifying T seizures (10/10) and a 91% success rate for identifying 2.5T seizures (10/11)--a sensitivity of 100% and specificity of 91% for identifying T seizures. To make a more realistic assessment of the performance of this model, applicants tested it on data from treatments 4 and 5. The resulting overall accuracy of 90% (26/29 correct predictions) included 80% accuracy for identifying T seizures (8/10) and a 95% success rate for identifying 2.5T seizures (18/19)--a sensitivity of 80% and specificity of 95% for identifying T seizures. Testing the model on data for all treatments after treatment 5 yielded a similar predictive accuracy: 88% overall accuracy (35/40); T accuracy 82% (9/11); 2.5T accuracy 904 (26/29).
As described above, a separate model was developed using only data from the left hemisphere. This model was composed of the first and fourth principal components of the four left-side EEG variables (none of the other principal components made a significant contribution) and age (see Table 3). This model correctly predicted the stimulus intensity group of all 22 seizures from which it was developed (100% accuracy) and was only slightly less successful in predicting relative stimulus intensity group than the two-hemisphere model described above when tested on treatment 4 and 5 data. An 88% overall success rate was found (37/42), with a T accuracy of 70% (7/10) and an accuracy of 95% (18/19) in identifying 2.5T seizures.
TABLE 3______________________________________Multivariate Logistic Regression ModelCoefficients and Significance LevelVariable *Regression coefficient (β) X.sup.2 p Value______________________________________PRIN1 0.7709 7.7 0.005PRIN4 -0.1880 3.9 0.05Age 4.7875 4.1 0.04Constant -18.3229 -- --______________________________________ *Group membership is predicted for seizure i, as follows: G(i) = PRIN1 × β.sub.PRIN1 + PRIN4 × β.sub.PRIN4 + Age × β.sub.Age + β.sub.ConStant Where for the present study G(i) < 0 indicated a T seizure and G(i) > 0 indicated a 2.5T seizure. The probability of group membership is: P(i) = 1/(1 + e.sup.-G(i)) P(i) < 0.5 indicates a T seizure and P(i) > 0.5 a 2.5T seizure
The automated version of the one channel ictal EEG model was associated with an 84% accuracy rate in prediction of the adequacy of ECT seizure relative stimulus intensity on the above described data set and an additional data set including 19 subjects. The parameters of this model differed slightly from those of the model developed for the non-automated EEG indices because postictal amplitude and early amplitude measures differ in the 2 cases.
The detailed steps involved in the calculation of the automated 1 channel UL ECT ictal EEG adequacy model are provided below. As described above, this model includes 4 ictal EEG variables: TSLOW, left 5.5-13 Hz mid-ictal spectral amplitude (LMGB2E), left 2-5 Hz mid-ictal spectral amplitude (LMGB1M), left 2-5 Hz post-ictal spectral amplitude (LMGB1P). The 4 ictal EEG indices listed above were entered into the algorithm below:
(1) Z Transformation of each ictal EEG Variable: The mean of each of the 4 variables as determined in the data set described herein was subtracted from the values obtained from the seizure under study and the difference divided by its standard deviation (determined from the above data set of 25 subjects). This resulted in 4 Z transformed variables: zTSLOW, zLMGB2E, zLMGB1M, zLMGB1P.
(2) Artifact Detection and Adjustment: The 3 Z transformed spectral amplitude variables were multiplied by 2 if their values were below the mean of the above data set (Z transforms <0), and zTSLOW was doubled if it is greater than the mean (zTSLOW >0). The 4 Z transformed variables were also examined for the typical patterns of artifact across these variables and when artifact is suspected, the Z transform of the suspected variable was set equal to the mean of the Z transforms of the remaining artifact-free variables.
(3) Calculation of Principal Components: principal components 1 and 4 of the Z-transformed ictal EEG variables were utilized as predictor EEG variables in this model and calculated as follows: PRIN1=0.63742×zLMB1M +0.53490×zLMB23-0.50420×zLMB1P-0.23099×zTSLOW PRIN4=0.76792×zLMB1M-0.48822×zLMB2E+0.35380×zLMB1P+0.21625×zTSLOW
(4) Calculation of Probability of Adequacy: Principal Components 1 and 4 were then included along with the natural logarithm of age (ln(Age)) in a logistic regression model (developed from the data collected from the 25 subjects as described above) of the probability (P) of seizure adequacy, where a probability of less than 0.5 indicates an inadequate seizure and a probability of greater than 0.5 is suggestive of adequacy:
P=1/(1+e.sup.-G)
Where G=1.8786×PRIN1-1.4439×PRIN4+57343×ln(Age)-20.9852
Together, these results prove that attributes of the ictal EEG are likely to be clinically useful as predictors of seizure adequacy. This conclusion is supported in a number of ways.
Strong evidence for the clinical utility of the ictal EEG as a marker of treatment adequacy is the applicants' discovery of an accurate multivariate ictal EEG model for prediction of relative stimulus intensity with UL ECT. This work represents the development of a clinically useful model of UL ECT seizure adequacy. The performance of the model suggests an expected sensitivity and specificity of at least 80%. Only principal components 1 and 4 contributed significantly to the model, suggesting that, among the ictal EEG variables, midictal 2-5 Hz amplitude was the strongest predictor of stimulus intensity group. Although to a lesser extent, the other three types of ictal EEG indices all also contributed to the model and had similar weightings on these two principal components.
An additional model was developed by using ictal EEG data from only the left hemisphere. This model was only slightly less accurate in prediction of group membership than the model including data from both hemispheres. The performance of this model suggests that an ictal EEG algorithm implemented by using only one channel of EEG data will still have a high rate of success in the prediction of adequate relative stimulus intensity. A completely automated version of this model of adequate stimulus intensity was also developed and described in detail. While the applicants developed a number of different automated ictal EEG models of seizure adequacy (see below) and these models were separately developed with both 1 and 2 channel EEG data, and for both UL and BL ECT data), for purposes of brevity and clarity only an automated 1 channel model of UL ECT seizure adequate relative stimulus intensity was described in detail in this application. That this model is associated with an 84% accuracy rate provides the strongest evidence that the models described herein are likely to be successful in the clinical setting for the determination of seizure adequacy. Furthermore, the performance of this single channel model likely underestimates the expected clinical performance of such models since models incorporating other improvements listed elsewhere in this application (the use of 2 channels of data, inclusion of gender, treatment number, etc.) would be expected to perform even better.
An Ictal EEG Model For the Prediction of ECT Therapeutic Outcome: This analysis involved a multivariate ictal EEG logistic regression model of CGI response after treatment 5. The treatment 2-5 means of all ictal EEG variables were entered into this analysis, along with age. Variables that did not significantly contribute to predicting variance in therapeutic response were removed in a stepwise manner. The model was tested by using the "leave-one-out" procedure in which the data for each subject were sequentially removed, a separate logistic regression model was developed with the remaining data, and the resulting model was then tested on the data from the removed subject.
Applicants' results were compatible with a higher therapeutic response rate for 2.5T (70%, 7/10) compared with T (50%, 5/10) ECT. Both right early 5.5-13 Hz ictal EEG amplitude (X 2 =6.1, P=0.01) and right 2-5 Hz postictal amplitude (X 2 =4.9, P=0.03) were significant predictors of therapeutic outcome. There was a trend toward significance for early 2-5 Hz interhemispheric coherence (X 2 =4.9, P=0.08). A logistic regression model including these variables and age correctly predicted the therapeutic outcome for 75% (15/20) of the subjects used to develop the model (resubstitution). When the "leave-one-out" technique was employed, the model had a successful prediction rate of 70% (14/20). This result is particularly remarkable given the high degree of "noise" associated with therapeutic response assessments. Because this model differs from that involved in discriminating differences in relative stimulus intensity, it is likely that it will offer additional clinically useful information to ECT practitioners.
An Ictal EEG Model for the Prediction of the Degree of ECT Associated Cognitive Impairment: A multiple regression model of delayed complex figural memory was developed with the average of treatment 2-5 ictal EEG data for all of the 9 ictal EEG parameters described above. Prior to model development, principal components analysis was carried out as described above in the development of the model of relative stimulus intensity. The resulting principal components were entered into a multiple regression model of post-treatment 5 delayed complex figural memory along with age and baseline delayed complex figural memory. Variables that did not significantly contribute to predicting variance in the treatment 5 memory measure were removed in a stepwise manner. Only principal components 6 and 7 made a significant contribution to the prediction of variance in complex figural memory (prin6: partial R 2 =0.17, F=5.9, p<0.02, prin7: partial R 2 =0.08, F=3.1, p<0.09) along with baseline figural memory (see Table 4). The overall model accounted for 58% of the variance in complex delayed figural memory (R 2 =0.58, F=5.4, p<0.006). The derived constants for calculation of principal components 6 and 7 and for the calculation of the predicted degree of memory impairment are specified in Tables 4 and 5 respectively.
TABLE 4______________________________________Principal Components 6 and 7 of Ictal EEG Variables.Ictal EEG Variable PRIN6 PRIN7______________________________________Left 5.5-13 Hz Early Amplitude 0.288709 -0.176692ConstantRight 5.5-13 Hz Early Amplitude -0.761490 0.111034ConstantLeft 2-5 Hz Midictal Amplitude 0.348384 0.259564ConstantRight 2-5 Hz Midictal Amplitude 0.076298 -0.230679ConstantLeft 2-5 Hz Postictal Amplitude -0.060397 0.293882ConstantRight 2-5 Hz Postictal Amplitude 0.107022 -0.280419ConstantLeft TSLOW Constant 0.129064 -0.502627Right TSLOW Constant 0.184060 0.627113Early 2-5 Hz Coherence Constant 0.379407 0.157987______________________________________
TABLE 5______________________________________Multiple Regression Model Coefficients and Significance levelfor Prediction of ECT Associated Memory FunctionVariable *Regression Coefficient (β)______________________________________PRIN6 7.0184PRIN7 6.5022Baseline Complex Figural Memory 0.3565Constant 10.9587______________________________________ *The prediction of complex figural memory rating associated with a treatment is as follows: Predicted Memory = PRIN6 × 7.0184 + PRIN7 × 6.5022 + Baseline Memory × 0.3565 + 10.9587
These results are especially notable since the relationship between ictal EEG variables and memory impairment has never been previously studied. This model is likely to be particularly useful for the clinician because for the first time, it allows a clinical means for assessing the degree of risk of memory dysfunction associated with a particular ECT treatment. In combination with the two previous types of models, this model will allow clinicians to perform a risk to benefit analysis involving the expected degree of side-effects and beneficial effects associated with each ECT treatment, and, thereby optimize the administration of ECT.
Alternative Embodiments of Invention
Applicants have further discovered certain alternative embodiments and additional features of the novel method described herein that are contemplated to be within the scope of the present invention as described and claimed herein. The alternative embodiments and additional features include the following:
(1) An alternative embodiment of this invention that applicants have implemented is to determine the adequacy of an ECT seizure by comparing ictal EEG indices in an individual treatment to the corresponding EEG measures derived from a previous treatment in the treatment course where the adequacy of the associated ECT seizure was known or could be assumed. This approach is particularly powerful because it eliminates ictal EEG variation between individuals, which can be an important factor affecting the accuracy of prediction of ictal EEG models of adequacy. An example of the use of this embodiment which is well suited to present ECT practice is to compare ictal EEG variables at treatment 6 with those at treatment 2 which was administered just after a seizure threshold determination procedure and as a result, the degree to which the treatment 2 stimulus exceeds the seizure threshold is known.
(2) Another alternative embodiment of this invention that applicants have implemented is to develop and apply ictal EEG models for prediction of the adequacy of bilateral (BL) ECT seizures. Such automated ictal EEG models have been developed and tested in a data set of 19 subjects and have been demonstrated to have similar predictive accuracy to the UL ECT models described herein.
(3) Another alternative embodiment of this invention that applicants have implemented is to develop and apply ictal EEG models for the prediction of seizure adequacy taking into account the treatment number of the seizure under study. Applicants have recently obtained data that suggests that earlier treatments, most notably treatment 1, are associated with higher ictal EEG amplitude and smaller immediate postictal amplitude than subsequent treatments. Including the treatment number in ictal EEG models of ECT seizure adequacy resulted in a greater predictive accuracy when treatments earlier in the course were tested, especially treatment 1.
(4) Another alternative embodiment of this invention that applicants have implemented is to develop an ictal EEG model of ECT seizure adequacy including gender as a variable in the model. In developing and testing a model of therapeutic response and adequate relative stimulus intensity with manually derived ictal EEG measures in a set of 40 subjects, applicants found a significant increase in model predictive accuracy when gender was included.
(5) Still another alternative embodiment of this invention is to utilize in an ictal EEG model of ECT seizure adequacy, the high frequency postictal amplitude as an ictal EEG measure. The applicants have recently acquired data suggesting that postictal spectral amplitude in the 13-30 Hz frequency band was a significant predictor of ECT seizure therapeutic potency.
(6) Still another alternative embodiment of this invention is to utilize wavelet analysis in an ictal EEG model of ECT seizure adequacy, to develop an ictal EEG measure. Wavelet analysis allows the frequency content of the EEG data to be reflected over time particularly effectively and is therefore a useful technique for application in an ictal EEG model of adequacy, since evidence presented herein suggests that the frequency content of the ictal EEG plays an important role in such models.
(7) Still another alternative embodiment of this invention is to utilize in an ictal EEG model of ECT seizure adequacy, the time and phase delays between EEG data in 2 EEG channels as an ictal EEG measure. These measures appear to have some promise for differentiating different forms of ECT and therefore may be useful in ictal EEG models of ECT seizure adequacy.
(8) Still another alternative embodiment of this invention is to utilize in an ictal EEG model of ECT seizure adequacy, the correlation between EEG data in 2 EEG leads as an EEG measure. This measure is the time-domain analog of coherence, which was demonstrated herein to be useful for the prediction of seizure adequacy.
(9) Still another alternative embodiment of this invention which applicants have implemented is to utilize in an ictal EEG model of ECT seizure adequacy, the time domain amplitude (where measurements of EEG amplitude are performed in the time domain as opposed to spectral amplitude measures) as an ictal EEG measure. Applicants have also developed models of therapeutic response and relative stimulus intensity on the basis of manually-derived EEG measures obtained in 40 individuals and found that time domain amplitude measurements made significant contributions to those models.
(10) Yet another alternative embodiment of this invention is to utilize in an ictal EEG model of ECT seizure adequacy, the morphologic regularity of the ictal EEG data as an ictal EEG measure. This measure reflects the degree to which the EEG activity takes on a stereotyped or predictable appearance over time. Applicants have implemented both manually-derived and computer versions of this measure and found that they have significantly contributed to models of seizure adequacy.
Applicants have determined that other ictal EEG measurements including largest Lyapunov exponent, signal variance, envelope analysis, and autoregressive models may be used in the practice of the invention described herein.
It will be understood that various details of the invention may be changed without departing from the scope of the invention. Furthermore, the foregoing description is for the purpose of illustration only, and not for the purpose of limitation--the invention being defined by the claims. | A method in electroconvulsive therapy (ECT) to use ictal EEG data for clinical determination of the adequacy of an induced seizure in a patient. The method includes employing an ECT device to apply electricity to the patient in an ECT session to induce seizure activity. The electroencephalographic (EEG) data is detected during the seizure and selected EEG data parameters are derived therefrom. Next, the likely adequacy of the induced seizure is computed by comparing the selected EEG data parameters of the patient to ictal EEG data parameters wherein the adequacy of the corresponding seizure or seizures is known, and the computed likely therapeutic adequacy of the induced seizure is displayed. | 0 |
BACKGROUND OF THE INVENTION
The present invention relates generally to an apparatus and process for producing an extruded plastic material product and, in particular, to an extrusion process for producing a thermoplastic material product having a foamed cellular core and an integral, non-porous skin.
Production of foamed thermoplastic material products by a continuous extrusion process has become increasingly popular. It has been found that the continuous extrusion process offers significant advantages of economy and versatility over the more common foam injection molding process. While commercial activities have concentrated on the lower cost thermoplastic materials such a polystyrene, polyethylene, and polyvinylchloride, there has been considerable development activity in polypropylene, acrylonitrile butadiene-styrene, polyamides and polycarbonates.
One of the most common methods of producing extruded foamed thermoplastic material is known as the free-foaming extrusion technique. This process is similar to conventional solid plastic extrusion except that the thermoplastic melt material contains a blowing agent which causes the melt material to foam and expand as the melt material emerges from an extruder die. In this process, the extruder die is constructed to produce a foamed thermoplastic material having a cross-sectional profile which is an approximation of the desired cross-sectional profile. The foamed thermoplastic material is then fed through a sizer which shapes the foamed thermoplastic material into a product having the desired cross-sectional profile. While this technique is typically capable of producing a foamed thermoplastic product having a uniform distribution of cells of the desired size, the resulting skin tends to be rather porous.
In order to obtain an extruded foamed thermoplastic material product with an outer solid or non-porous skin which surrounds an inner cellular core, a technique known as the controlled foam extrusion process is used. Examples of such a process can be found in U.S. Pat. No. 3,764,642 to Boutillier. The controlled foam extrusion process consists of extruding a foamable thermoplastic melt material uniformly containing a blowing agent through a specially designed extruder die and into a cooled shaper which is adjacent the die. The shaper is provided with a longitudinally extending cooled internal metal surface adapted to form the desired cross-sectional shape in the extruded melt material. In the shaper, the outer surface of the extruded melt material is rapidly cooled as it comes in contact with the metal surface to prevent foaming of the melt material adjacent the outer surface, thereby forming an outer integral solid skin. At the same time, the inner portion of the extruded melt material expands to form an inner cellular core.
In some instances, the extruder die can be designed to produce extruded foam products having a solid skin along one portion of the outer surface of the product and a cellular portion along the remaining portion of the outer surface. Such an arrangement is disclosed in U.S. Pat. No. 3,879,505 to Boutillier et al.
In the controlled foam extrusion process described above, the outer integral skin is formed about the inner cellular core by rapidly cooling a portion of the extruded melt material prior to the reaction of the blowing agent. Immediately after leaving the extruder die, an outer portion of the melt material contacts the cooled innner metal surface of the shaper and is pressed against this cooled surface by the expansion of the remaining inner portion of the melt. The cooled inner surface of the shaper is maintained at a temperature which enables the melt material in contact therewith to be cooled to a temperature below the blowing temperature of the melt material, thereby preventing expansion of this portion of the melt material to produce an outer, integral skin.
The thickness of the skin produced by this process corresponds to the depth in the melt material which is cooled to a temperature lower than the blowing temperature prior to the reaction of the blowing agent. Thus, in order to produce a relatively thick skin, it is necessary to maintain the temperature of the inner forming surface of the shaper substantially below the associated blowing temperature. It will also be appreciated that the inhibited blowing agent in this process remains in the skin portion ready to react if the skin is subsequently exposed to heat.
SUMMARY OF THE INVENTION
The present invention concerns an apparatus and process for producing an extruded thermoplastic material product having a foamed cellular core and a non-porous, integral skin. In the process of the present invention, a foamable thermoplastic material having a blowing agent therein is extruded through a first or core die outlet. Upon exiting the first die outlet, the blowing agent reacts to form a foamed thermoplastic material. After the formation of the foamed thermoplastic material, a skin or film of non-porous thermoplastic material which is free of all blowing agents is applied along at least one side of the extruded foamed thermoplastic material. In some instances, one or more decorative films are applied to the extruded foamed thermoplastic material prior to the application of the film or skin of non-porous thermoplastic material. Typically, the non-porous thermoplastic material is extruded through a second die outlet positioned adjacent the first die outlet. After the outer non-pourous film is applied, the extruded foamed material having the non-porous film thereon is fed through a forming die having a profile similar to the core die which shapes and seals together the foamed core material and the outer non-porous film into the desired cross-sectional shape. If desired, the forming die can be adapted to impress a predetermined texture or grain along a selected portion of the outer non-porous film.
From the forming die, the shaped plastic material enters a cooling station such as a water tank, for example. The plastic material can be pulled through the extrusion process by conventional means such as a pair of endless belts, for example.
The process according to the present invention offers several advantages over the prior art processes. For example, the extrusion process enables conventional extrusion equipment to be used to make the product. Also, the process of the present invention enables the skin thickness and location on the product substantially to be selected at random and to be more easily contolled. Furthermore, as will be discussed in more detail hereinafter, the present invention permits the use of dissimilar but compatible materials in the skin and core and several types of pigmenting and decorating options.
It has been found that the novel product manufactured according to the process of the present invention can advantageously be used, for example, as a molding and is particularly adapted for use as a protective side molding which is attached to a vehicle body.
BRIEF DESCRIPTION OF THE DRAWINGS
The above, as well as other advantages ot the present invention, will become readily apparent to one skilled in the art from reading the following detailed description in conjunction with the accompanying drawings in which:
FIG. 1 is a schematic diagram representing the extrusion process of the present invention;
FIG. 2 is a typical cross-sectional view through the novel extruded product produced by the process shown in FIG. 1; and
FIG. 3 is an elevational view taken along the line 3--3 of FIG. 1 (without, however, depicting the extruded product) illustrating the front of the forming rolls.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, there is shown a schematic diagram which illustrates an extrusion system 10 of the present invention. The system 10 includes a conventional first extrusion machine 12 having an outer housing 12a and an inner rotatable extrusion screw 12b. A foamable thermoplastic material 13 having a blowing agent blended therein is contained within the housing 12a. A profile die 14 is mounted adjacent the outlet of the extruder 12 for shaping the foamable thermoplastic material 13 which is driven through the die 14 by the screw 12b. As the foamable thermoplastic material 13 exits the die 14, the blowing agent therein reacts to expand the material into a foamed thermoplastic material 16.
A second extrusion machine 18 having an outlet die 18a positioned adjacent the profile die 14 is adapted to apply a non-pigmented or pigmented film of a non-porous thermoplastic material 20 along a portion of the surface of the foamed material 16 produced by the extruder 12. A forming die 22 consisting of power driven forming rollers 22a and 22b is located following the extruders 12 and 18 and is adapted to shape and integrally seal the extruded materials 16 and 20 into a unitary product 24 having the desired cross-sectional shape. The forming die 22 is provided with cooling means 26 for cooling the product 24 during the forming operation. A typical cross section of the extruded product 24 after it has been shaped by the forming die 22 is shown in FIG. 2, while a front view of the forming rollers utilized to produce the desired shape is shown in FIG. 3. As shown in FIG. 2, the product 24 includes an inner cellular core 24a formed from the foamed material 16 and an integral non-porous skin 24b formed from the non-porous material 20.
It will be appreciated that several pigmenting options are possible with the present invention. For example, the film of non-porous, i.e., unfoamed, thermoplastic material 20 can be clear or translucent, while the underlying foamed material 16 can be pigmented to produce the selected color. Alternatively, the non-porous thermoplastic material 20 can be opaque and pigmented to the desired color, such that the underlying foamed material 16 can be unpigmented or any random color.
In instances wherein the outer film of non-porous thermoplastic material 20 is clear or translucent, it may be desirable to apply a decorative film over the foamed material 16 prior to the application of the non-porous thermoplastic material 20. For example, in FIG. 1, a roller assembly 27 provides a supply of a decorative film 27a which can be applied along selected portions of the foamed material 16 by suitable guide means (not shown in the drawings) prior to the applicationn of the non-porous material 20. The decorative film 27a can be a colored or vacuum metalized Mylar® strip, for example. The decorative film 27a is shown in FIG. 2 as two individual portions 24c.
Additionally, a grain or texture can be formed in selected portions of the outer non-porous film 20 by means of the forming rolls 22. For example, in FIG. 3, the central portion 22c of the upper rolls 22a is provided with a textured surface corresponding to the desired texture to be formed along a central portion 24d (shown in FIG. 2) of the non-porous skin 24b.
After the extruded product 24 has been molded into the desired size and shape by the forming die 22, the extruded product 24 enters a cooling system such as a water tank 28. The extruded product 24 can be pulled through the system by conventional means such as a pair of endless belts 30 driven in synchronism with the forming rollers.
It will be appreciated that many types of thermoplastics and blowing agents can be used with the present invention. Examples of thermoplastics include homopolymeric polystyrene resinous mixtures, copolymers of styrene, acrylic polymers, homopolymers of vinyl chloride, polyolefins, polyamides, straight chain polyurethanes, straight chain polyesters, polycarbonates, polyethers, vinyl ethers, and vinyl esters. Examples of blowing agents include chemical blowing agents such as organic or inorganic bicarbonates or oxalates, azo-chemicals, hydrazides, and amine nitrates. Also, low boiling liquids which can produce gas by vaporization under low pressure conditions can be used. Examples of these blowing agents include carbon dioxide and aliphatic hydrocarbons.
Typically, the temperature in the first and second extruders 12 and 18 is maintained within a range of from 50° C. to 260° C., depending on the particular type of thermoplastic material and blowing agent utilized. The amount of blowing agent which is added to the core thermoplastic material is dependent on the desired reduction in specific gravity of the thermoplastic material and is thus a function of the specific gravity of the finished product. It has been found that, when the blowing agent and the thermoplastic material are first blended together and then pelletized to produce a homogeneous mixture, better control of the foaming operation is achieved.
An example of a product which can be produced by way of the above described process and apparatus is an automobile body side molding and utilizes a foamable thermoplastic core material consisting of a polyvinylchloride base compound and an azodicarbonamide blowing agent. The desired specific gravity of the finished product can be achieved by a reduction of thirty percent in specific gravity of the polyvinylchloride base compound by utilizing six-tenths of one percent by weight of blowing agent in the polyvinylchloride base compound. The molding is therafter satisfactorily achieved by applying a substantially non-porous thermoplastic film composed of the same polyvinylchloride base compound as used in the core but free of any blowing agent to a major surface of the core, i.e., the surface not to be adhered to and in contact with the automobile body.
The die outlet 18a of the second extruder 18 is positioned to apply the film of non-porous thermoplastic material 20 at a thickness corresponding to the desired thickness of the skin 24b. Preferably, the thickness of the skin 24b is in the range of from 0.3 to 1.0 mm. Typically, the distance between the extrusion dies 14 and 18a, and the forming die 22 is such as to maintain the desired temperatures associated with the process within acceptable limits.
In this example, the temperatures of both of the extruders 12 and 18 are controlled such that the temperature at which the materials 13 and 20 are extruded from their respective dies is approximately 182° C. In this situation, it has been found that the distance between the extruder die 14 and the forming die 22 should not exceed a distance which permits the temperature of the materials 13 and 20 entering the forming die 22 to drop below approximately 132° C. Under normal operating conditions, the distance between the extruder die 14 and the forming die 22 should not exceed nine inches. The line speed at which the belts 30 pull the product 24 can vary depending on the parameters of the system. In this example, the cooling means 26 maintains the temperature of both the top an bottom forming rolls 22a and 22b of the forming die 22 between 26° C. and 54° C.
In accordance with the provisions of the patent statutes, the principle and mode of operation of the present invention have been illustrated and described in what is considered to represent its best embodiment. However, it should be understood that the invention may be practiced otherwise than as specifically illustrated and described without departing from its spirit or scope. | The present invention concerns an apparatus and process for producing an improved extruded plastic material product which consists of an inner foamed thermoplastic cellular core and an outer non-porous thermoplastic skin extending along at least one side of the core. In the process, a foamable thermoplastic material is extruded through a first die outlet to produce a foamed thermoplastic material. After exiting the die outlet, a film of non-porous thermoplastic material is applied along at least one side of extruded foamed material. Next, the extruded foamed material and the non-porous film is fed through a forming die which shapes and seals the materials into the desired cross-sectional shape. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is bypass continuation of international patent application PCT/EP2010/068751 filed Dec. 2, 2010 designating the United States of America, the entire disclosure of which is incorporated herein by reference. Priority is claimed based on Federal Republic of Germany patent application no. 10 2009 056 511.6 filed Dec. 2, 2009.
TECHNICAL FIELD
[0002] The present invention concerns a filter element, in particular a passenger compartment air filter for motor vehicles. Moreover, a method for producing filter elements is described.
[0003] In order to filter in the automotive field fluids such as fuels, other operating media or passenger compartment air, folded or pleated nonwoven filter materials are frequently employed. In this connection, it is often required to support the fold profiles by auxiliary means so that even in case of fluid passage the shape is maintained. Moreover, it is desired to seal the filter elements at their rims relative to the filter receptacle or the respective filter housing so that no unfiltered fluid can bypass the pleated filter medium.
BACKGROUND OF THE INVENTION
[0004] In order to stabilize a zigzag-shaped filter medium with respect to the folds, in the past lateral straps of nonwoven filter material were attached to the fold profiles that, on the one hand, served for stabilization and, on the other hand, when provided with a projecting fold tab, served as a seal. Other known filter elements have been sealed by means of foam applied to the rims and the folds have been supported in this way. However, this sealing foam lip could be applied only at special locations due to manufacture-based reasons.
SUMMARY OF THE INVENTION
[0005] The present invention has the object to provide an improved filter element and manufacturing method.
[0006] Accordingly, a filter element is provided which is in particular a passenger compartment air filter for a motor vehicle. The filter element has a fold pack, a plastic frame that is molded at least partially onto the fold pack, and a plastic foam seal that is at least partially foamed onto the plastic frame.
[0007] The plastic frame that is molded onto the fold pack serves, for example, for supporting fold profiles of the fold pack. Moreover, the plastic frame that is molded onto the fold pack can serve as a lateral seal, for example, relative to a filter receptacle.
[0008] The plastic frame and the plastic foam seal are preferably generated by an injection molding process. The filter element can be produced with particularly little expenditure because the otherwise conventional adhesive connection between a separate lateral strap and the fold pack is not required. By molding the plastic frame that is sufficiently rigid so as to impart stability to the fold pack, a good and stable connection with the fold profiles by injection molding is achieved. Also, by molding the plastic foam seal, for example, by means of a reaction molding process, any shapes for frame and seal can be realized.
[0009] The zigzag-shaped edge of the folded filter material sheet is be understood as profile of the folds or fold profile. The fold profile is thus positioned between two terminal fold sections of the fold pack.
[0010] The plastic frame can be, for example, made of thermoplastic materials such as polyamide and the plastic foam seal can be comprised, for example, of polyurethane foam. Of course, other materials are conceivable such as ABS plastic materials for the plastic frame or polypropylene. Thermoplastic materials are in principle suitable for injection molding.
[0011] In one embodiment of the filter element, a first and a second fold pack are provided that are separated by at least one frame stay of the plastic frame. The fold profiles are supported by the plastic frame and/or the frame stay. The fold packs can have different sizes in this connection so that the filter element can be matched to the geometry of the mounting conditions. The frame stay that, for example, defines several frame sections causes a further reinforcement of the entire filter element.
[0012] Preferably, the plastic foam seal surrounds an outer rim of the plastic frame that encloses the filter element. The flexible plastic foam then causes a reliable sealing action of the filter element at the respective housing for the filter element.
[0013] In a further embodiment, in the plastic frame of the filter element at least one opening is provided through which the plastic foam seal extends. In this way, an improved connection between the plastic foam seal and the plastic frame is achieved. The plastic foam seal that is injection molded can then pass in the not yet solidified state through the openings of the plastic frame and locks essentially upon solidification with the frame that, on the one hand, provides a fold profile stabilization and, on the other hand, supports the flexible foam seal.
[0014] As filter materials for the fold pack, for example, cellulose-containing materials, fiberglass blended fabrics, polyester fiber-containing materials, nonwoven material, and/or laminated papers are suitable.
[0015] Furthermore, a method for producing a filter element is proposed.
[0016] In this connection, a plastic frame is initially generated partially about a fold pack in a first injection molding step. Subsequently, in a second injection molding step, on the plastic frame at least partially a plastic foam seal is produced in a second injection molding step.
[0017] In comparison to conventional manufacturing processes, the method has the advantage that injection molding can be done particularly efficiently. Since the two materials for the plastic frame and the plastic foam seal can be selected such that a fixed connection of the boundary surfaces of both materials is realized, no additional adhesive connections must be carried out. By injection molding, a well-defined shape and geometry of the entire filter element can be achieved moreover. In case of, for example, cast foamed frames without injection molding, further after-processing steps must be carried out, for example, in order to remove flashes. When injection molding, the workpiece that is removed from the respective cavity of the injection molding tool, i.e., the finished filter element comprising fold pack, plastic frame and plastic foam seal, is complete and can be shipped.
[0018] The method comprises in one variant the steps of: insertion of a fold pack into a first injection molding tool; injection molding a plastic frame at least partially about the fold pack for supporting the fold profiles; insertion of the fold pack provided with the plastic frame into a second injection molding tool; and reaction molding of a plastic foam for forming the plastic foam seal on the plastic frame.
[0019] By means of only a few processing steps, a finished filter element with excellent mechanical properties due to the rigid plastic frame and a reliable rim sealing action due to the flexible plastic foam seal are thus provided.
[0020] In a variant of the method, the first and the second injection molding tool can be integrated into a single injection molding tool. The injection molding tool then comprises several cavities for forming the plastic parts. Accordingly, also semi-finished elements that, for example, comprise only the fold pack and the plastic frame, can be produced simultaneously with the formation of the plastic foam seal on another filter element. Accordingly, the first injection molding step can be realized with the first injection molding tool or a first cavity of the injection molding tool on a first fold pack and, simultaneously, the second injection molding step can be carried out with the second injection molding tool or a second cavity of the injection molding tool on a second fold pack provided with a plastic frame.
[0021] Preferably, it is provided in the method that several fold packs are enclosed such with a plastic frame that at least one frame stay supports fold profiles of different fold packs. As already mentioned, by means of the frame stay an improved stability can be achieved and, moreover, the space in a corresponding filter housing can be beneficially utilized by means of fold packs that also have irregular geometries.
[0022] In a further method variant, an injection molding tool comprised of two injection molding tool parts is used. Then only one of the injection molding tools is moved for opening and closing the injection molding tool. This has the advantage that only one of the tool parts, which, for example, may also comprise an integrated first and second injection molding tool, must be provided with appropriate automation means for movement.
[0023] In the manufacturing process, polyamides as plastic frame material and polyurethane foam as plastic foam seal material are preferably used.
[0024] Further possible implementations of the invention comprise also combinations, not explicitly mentioned, of the features, method steps or embodiment variants disclosed above or in the following with respect to the embodiments. In this connection, a person of skill in the art will also add individual aspects as improvements or supplements to the respective basic form of the invention.
[0025] The above features and advantages and other features and advantages of the present invention are readily apparent from the following detailed description of the best modes for carrying out the invention when taken in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] The accompanying Figures, where like reference numerals refer to identical or functionally similar elements throughout the separate views and which together with the detailed description below are incorporated in and form part of the specification, serve to further illustrate various embodiments and to explain various principles and advantages all in accordance with the present invention.
[0027] Features of the present invention, which are believed to be novel, are set forth in the drawings and more particularly in the appended claims. The invention, together with the further objects and advantages thereof, may be best understood with reference to the following description, taken in conjunction with the accompanying drawings. The drawings show a form of the invention that is presently preferred; however, the invention is not limited to the precise arrangement shown in the drawings.
[0028] FIG. 1 is a schematic perspective illustration of a first embodiment of a fold pack;
[0029] FIG. 2 is a schematic perspective illustration of a fold pack that is provided with a plastic frame, consistent with the present invention;
[0030] FIG. 3A is an enlarged detail of a portion of the filter element of FIG. 2 , consistent with the present invention;
[0031] FIG. 3B is a detail view of FIG. 3A in cross-section;
[0032] FIG. 3C is a cross section of a filter element of FIG. 2 including a foam seal on the top side;
[0033] FIG. 3D is a cross section of a filter element of FIG. 2 including a foam seal on the radial side of the frame;
[0034] FIG. 4A is a schematic plan view illustration of a further development of the filter element, consistent with the present invention;
[0035] FIG. 4B is a schematic section through the filter element of FIG. 4A ; and
[0036] FIGS. 5A-5F present illustrations for explaining variants of a manufacturing process for filter elements, consistent with the present invention.
[0037] In the Figures, same or functionally similar elements are provided with the same reference characters.
[0038] Skilled artisans will appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of embodiments of the present invention.
DETAILED DESCRIPTION
[0039] Before describing in detail embodiments that are in accordance with the present invention, it should be observed that the embodiments reside primarily in combinations of apparatus components and method steps related to a filter element and a method of producing a filter element. Accordingly, the apparatus components have been represented where appropriate by conventional symbols in the drawings, showing only those specific details that are pertinent to understanding the embodiments of the present invention so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein.
[0040] In this document, relational terms such as first and second, top and bottom, and the like may be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. The terms “comprises,” “comprising,” or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. An element preceded by “comprises . . . a” does not, without more constraints, preclude the existence of additional identical elements in the process, method, article, or apparatus that comprises the element.
[0041] With the aid of FIGS. 1 , 2 and 3 A- 3 D, a first embodiment of a filter element is illustrated in simplified manufacturing stages. FIG. 1 shows in this connection a perspective illustration of a fold pack 2 . The fold pack 2 is, for example, formed of a nonwoven filter material wherein known mechanisms such as blade folding or rotation folding are used. The nonwoven filter material can be, for example, heat-treated so that an improved fixation of the fold profiles 3 is obtained. The illustration of FIG. 1 shows forward and rearward fold profiles 3 . The reference character 6 indicates a front end fold. Usually, onto the fold profiles 3 lateral straps are glued in order to impart stability to the entire fold pack 2 . This is not required in case of the proposed filter element.
[0042] FIG. 2 shows a perspective illustration of a fold pack 2 that is already provided with a molded plastic frame 4 . The fold pack 2 is secured at the fold profiles 3 by means of the molded plastic frame 4 . The plastic frame 4 is, for example, produced by an injection molding process. One can see in FIG. 2 that the forward folds extend between the forward and rearward frame part 4 . A connection between the fold profiles 3 and the plastic frame 4 that is formed of thermoplastic material is achieved by the selection of the injection molding tool. On the topside a circumferentially extending frame rim 5 is shown. The fold pack 2 is thus enclosed by the molded plastic frame 4 . In a subsequent method step, also by means of an injection molding step or by reaction molding, a plastic foam seal is produced on the circumferentially extending rim 5 .
[0043] In FIG. 3A , a detail is shown that corresponds in the orientation of FIG. 2 to the forward right corner of the finished filter element 1 . One can see that on the rim 5 of the frame 4 , in the orientation of FIG. 3A from below, a plastic foam seal 7 has been added. The shape of the plastic foam seal 7 can be predetermined by the selection of an injection molding tool. FIG. 3B shows the detail in cross-section. In this connection, the plastic frame 4 is connected with the fold profiles 3 of the fold pack 2 . The plastic frame and the edges or the fold profiles are fused with each other, for example. On the bottom side of the circumferentially extending rim 5 of the plastic frame 4 , the foam seal 7 has been applied by reaction molding. Accordingly, a filter element 1 with a fold pack, a plastic frame 4 , and a foam seal 7 is produced. The foam seal and the plastic frame are produced by an injection molding method.
[0044] FIG. 3C shows a modified variant wherein, at the topside of the circumferentially extending rim 5 of the plastic frame 4 , a foam seal 7 is provided that has been applied by reaction molding. The foam seal 7 , for example, can be pushed seal-tightly against the wall (not illustrated) of the filter receptacle. Seals whose sealing action is developed upon pressing in the direction of the fluid flow to be filtered are referred to also as axial seals.
[0045] FIG. 3D shows a further variant of a filter element wherein a foam seal 7 is attached to a plastic frame 4 . One can see that on the rim 5 of the plastic frame 4 a foam seal 7 has been added from the side. The shape of the plastic foam seal 7 can be predetermined again by the selection of an injection molding tool. Seals whose sealing action is developed upon pressing perpendicularly to the direction of the fluid flow to be filtered are referred to also as radial seals.
[0046] With the proposed foamed foam seals, radial as well as axial seals can be realized.
[0047] In FIGS. 4A and 4B a schematic illustration of a second embodiment of a filter element 10 is provided. The filter element 10 comprises in this connection two fold packs 2 A and 2 B. FIG. 4A shows in plan view that two separate fold packs 2 A, 2 B are separated by a stay 8 of the plastic frame 4 . In FIG. 4B a cross-section through the filter element 10 along the line S is illustrated. One can see that the stay 8 is arranged between the two fold packs 2 A and 2 B and therefore both fold profiles are supported. In this way, a stable plastic frame 4 results whose rim predetermines the geometry of the filter element 10 .
[0048] The plastic frame 4 or its rim 5 is provided moreover with openings or holes 9 . When injection molding the plastic foam seal 7 , the foaming plastic material can pass through these holes 9 . The plastic foam material closes off the holes 9 so that, as illustrated in cross-section of FIG. 4B , the resulting plastic foam seal or plastic foam lip 7 adheres particularly reliably to the frame 4 .
[0049] FIGS. 5A-5F show illustrations for explaining variants of a manufacturing process of a corresponding filter element. The manufacture will be explained with the aid of an injection molding tool. In FIGS. 5A-5F , a two-part injection molding tool 11 , 12 is illustrated. In this connection, the upper part 11 A, 12 A of the injection molding tool forms a first upper cavity or a hollow space and the lower part 11 B, 12 B of the injection molding tool forms a lower cavity.
[0050] In the manufacturing process, a fold pack is initially produced and made available. Subsequently, the fold pack 2 is inserted into the upper cavity 11 A, 12 A as illustrated in FIG. 5A . In this connection, the cavity or the hollow space, for example, the part 12 A, may have fixation means for the inserted folds. Subsequently, as illustrated in FIG. 5B , the injection molding tool is closed. First, only the upper part 11 A, 11 B will be considered. There are two hollow spaces 13 , 14 in the injection molding tool 11 A, 12 A, 11 B, 12 B. In the upper part of the injection molding tool 11 A, 12 A, the hollow space 14 corresponds to the shape of the plastic frame to be formed. In accordance with known injection molding processes, liquid plastic material is now introduced into the cavities 14 , i.e., injected into the injection molding tool. After cooling down, an injection-molded plastic frame 4 about the fold pack 2 is realized as illustrated in FIG. 5C . In the Figures, the fold pack 2 is hatched vertically and the plastic frame 4 is cross-hatched.
[0051] The injection molding tool is now opened. For example, only the left half 11 of the injection molding tool is moved in this connection. In this way, the apparatus expenditure for injection molding can be reduced. FIG. 5D shows the open injection molding tool 11 , 12 . The fold pack 2 provided with the plastic frame 4 can be referred to as a semi-finished filter element 15 . The semi-finished filter element 15 is now inserted into the cavity of the lower part of the injection molding tool 12 B. At the same time, into the upper part of the injection molding tool 12 A a new fold pack 16 can be inserted.
[0052] Now the injection molding tool is closed. In the lower cavity 11 B, 12 B a reaction molding process is carried out in order to produce an injection-molded foam. At the same time, the inserted fold pack 16 is provided with a plastic frame 17 in the upper cavity 11 A, 12 A. In the lower cavity, on the other hand, the plastic foam seal 7 is formed.
[0053] FIG. 5F shows again the open injection molding tool wherein the finished filter element 1 can be removed from the lower part of the injection molding tool 11 B, 12 B and can be shipped. The upper semi-finished filter element 18 is now inserted, in analogy to FIGS. 5C and 5D , into the lower part of the injection molding tool and provided with the seal.
[0054] The two-part configuration of the injection molding tool provides a particularly efficient and fast cycle timing in the production of the filter elements.
[0055] In comparison to known methods, by the proposed plastic injection molding with integrated foam seal, for example of PUR, a fast and inexpensive production of filter elements is possible. While in the conventional frames, even foamed ones, only simple geometries are possible in general, by means of reaction molding any geometry for frame and seal can be achieved. The seal can be, for example, also produced adjacent to the outer rim (axial) or about the outer rim (radial). After-processing is not required because upon injection molding or reaction molding no disturbing flashes are produced on the manufactured components. Manufacture of the filter elements is therefore possible in a particularly simple and inexpensive way.
[0056] In the foregoing specification, specific embodiments of the present invention have been described. However, one of ordinary skill in the art appreciates that various modifications and changes can be made without departing from the scope of the present invention as set forth in the claims below. Accordingly, the specification and figures are to be regarded in an illustrative rather than a restrictive sense, and all such modifications are intended to be included within the scope of the present invention. The benefits, advantages, solutions to problems, and any element(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential features or elements of any or all the claims The invention is defined solely by the appended claims including any amendments made during the pendency of this application and all equivalents of those claims as issued. | A filter element ( 1 ), for example a cabin filter for a motor vehicle, includes a pleated fold pack ( 2 ), a plastic frame ( 4 ) that is molded at least in part to the fold pack ( 2 ) supporting pleat profiles ( 3 ), and a plastic foam seal ( 7 ) that is foamed at least in part onto the plastic frame ( 4 ). In a method for producing a corresponding filter element ( 1 ), a plastic frame ( 4 ) is generated at least in part around a fold pack ( 2 ) in a first injection molding process, and subsequently a plastic foam seal ( 7 ) is generated at least in part on the plastic frame ( 4 ) in a second injection molding process. | 1 |
The present invention is related to electrical connectors for connecting to circuitry on flexible circuit substrates and means for separating such mated connectors.
BACKGROUND OF THE INVENTION
Electrical connectors designed for connecting to circuitry on flexible substrates typically have physically stronger structures than do other connectors to compensate for the lack of support normally provided by a rigid circuit board. When two mated connectors are separated, it is common practice to use a mechanism that engages the ends of the connectors and pries them apart. Since the forces holding the two connector halves together are greater in the center of the connector than at each end, there is a tendency for the ends to break loose first followed by the center. This, of course, causes the connector halves to bow during separation. This is especially the case when one of the connector halves is connected to circuitry on a flexible circuit substrate. Bowing of such connectors can damage the flexible circuit substrate or adversely affect the electrical contact between the connector contacts and the metalized circuitry on the flexible substrate. As connectors become more miniaturized and contact density increases, there tends to be less room for the connector housing, thereby making it difficult to provide the necessary rigidity to keep bowing within acceptable limits. What is needed is a connector for high density flexible circuit applications that has a mechanism for separating the connector halves while minimizing bowing of the connector to maintain the physical integrity of the flexible circuit and the electrical connection thereto.
SUMMARY OF THE INVENTION
The present invention is an electrical connector adapted to electrically interconnect to circuitry on a flexible circuit substrate. The connector includes an insulating housing and a plurality of electrical contacts in the housing having tails extending from the contacts which are adapted for electrical engagement with the circuitry. A stiffener member is provided that is attachable to the housing to prevent substantial bowing thereof. The stiffener member is attachable by means of some of the tails extended through holes in the stiffener member wherein the ends of the tails are deformed so that the flexible circuit substrate is clamped therebetween.
DESCRIPTION OF THE FIGURES
FIGS. 1 and 2 are front and side views of a connector incorporating the teachings of the present invention;
FIG. 3 is a cross-sectional view taken along the lines 3--3 in FIG. 1;
FIG. 4 is a plan view of a flexible circuit substrate;
FIGS. 5 and 6 are front and end views of the connector receptacle shown in FIG. 1;
FIGS. 7 and 8 are front and end views of the connector plug shown in FIG. 1;
FIGS. 9 and 10 are plan and end views of the stiffener shown in FIG. 1;
FIG. 11 is a partial cross-sectional view taken along the lines 11--11 in FIG. 9;
FIG. 12 is a front view of a retainer clip;
FIG. 13 is a front view of a pivotal lever shown in FIG. 1; and
FIG. 14 is an end view of the lever shown in FIG. 13.
DESCRIPTION OF THE PREFERRED EMBODIMENT
There is shown in FIGS. 1, 2, and 3 a connector assembly 10 consisting of a connector receptacle 12, a stiffener member 14, and a flexible circuit substrate 16 clamped therebetween. A connector plug 18, which mates with the receptacle 12, is attached to a major surface of a circuit board 20. This connector arrangement interconnects circuitry, not shown, on both the flexible circuit substrate 16 and the circuit board 20.
As best seen in FIG. 3 the plug 18 has an insulating housing 22 and a plurality of electrical contacts disposed therein, some of which are signal contacts 24 having tails 26 that are soldered to metalized pads 28 on the circuit board 20 and some of which are ground contacts 30 that form a ground bus that is arranged along a centerplane 32 of the connector and runs a major portion of the length of the plug 18. A similar connector is disclosed in U.S. Pat. No. 5,199,885. The ground contacts 30 have tails 34 that extend through openings in the circuit board 20. The receptacle 12 has an insulating housing 36 and a plurality of electrical contacts disposed therein, some of which are signal contacts 38 for mating with the contacts 24 and some of which are ground contacts 40 for mating with the contacts 30. The contacts 38 have tails 42 that are soldered to metalized pads 44 on the flexible circuit substrate 16, shown in FIG. 4. The ground contacts 40, on the other hand, have tails 46 that extend through openings 48 in the flexible circuit substrate 16 and through holes 50 in the stiffener member 14. The tails 46 are soldered to a common ground pad 49 (shown in phantom) of ground circuitry on the flexible circuit substrate adjacent the openings 48 preferably on the opposite surface from pads 44.
As best seen in FIGS. 3, 9, and 10, the stiffener member 14 is an elongated plate 52 having two spaced, parallel raised ribs 54 running the length of the member. The stiffener member has a major substantially flat surface 56, against which the flexible circuit substrate is clamped. The two raised ribs are equally spaced on either side of the centerplane 32 while the holes 50 are arranged in a line along the centerplane in alignment with the tails 46 of the ground contacts 40. Each hole 50 has a recess 58 formed in the surface 57 adjacent the hole. The depth of the recess is greater farther from the hole so that an angle 60 is formed between the floor of the recess and the hole 50 that is less than 90 degrees. The recesses 58 alternately extend in opposite directions away from the centerplane, as shown in FIG. 9. As is best seen in FIG. 3, the tails 46 are deformed by being bent over into the recesses 58 until they are against the floor thereby clamping the flexible circuit substrate 16 between the receptacle housing 36 and the major surface 56 of the stiffener member 14. Since the floors of the recesses 58 are slanted, the bend of the tails 46 exceeds 90 degrees thereby assuring maximum holding strength. Additionally, the extension of adjacent recesses in opposite directions requires that the tails 46 be bent, alternately, in opposite directions thereby adding to this holding strength. The stiffener member is made of a suitable material having sufficient strength to reduce bowing of the connector assembly 10, during mating and unmating, to within acceptable limits. Additionally, the stiffener member 14 is attached to the receptacle housing 36 by means of four projections 61 that extend upwardly from the housing, as best seen in FIGS. 5 and 6, and through corresponding openings 63 in the ends of the stiffener 14. The ends of the projections 61 are heat or ultrasonically staked to secure the ends of the receptacle housing 36 to the ends of the stiffener member 14, as shown in FIG. 3.
As shown in FIG. 3, a pair of strain relief member 62 are attached to the stiffener member 14 by means of several retainer clips 64, in the present example five such clips are used for each member 62. As shown in FIG. 12 each retainer clip 64 includes an enlarged head 66 and a shank 68 having barbs 70 formed thereon. The clips are made of a relatively thin sheet metal such as steel or brass. Ten equally spaced openings 72, five on each side, are formed in the stiffener member 14 near its edges, as shown in FIG. 9. These openings are formed as slots through the stiffener member and, as best seen in FIG. 11, each has an enlarged portion 74 in the surface 76 for receiving the head 66 of the retainer clip 64, thereby preventing the clip from passing completely through the slot. The strain relief members 62 have corresponding openings therein for receiving the shanks 68 and are sized so that the barbs 70 dig into the member 62 and secure it to the stiffener member. The flexible circuit substrate 16, as shown in FIG. 4, has clearance openings 80 formed therethrough in alignment with the openings 72 for passage of the shanks 68. When assembled, a portion 78 of the flexible circuit substrate adjacent the tails 42 is firmly clamped between each strain relief member 62 and the major surface 56 of the stiffener member 14. A generous radius 82 is formed on each of the adjacent corners of the strain relief men, her and the stiffener to reduce the damaging effects of bending of the flexible circuit substrate during handling. There is shown in FIG. 1 a pair of levers 90, each lever being pivotally attached to a respective extension 92 on the ends of the plug housing 22 by means of a pin 94. Details of the lever 90 are shown in FIGS. 13 and 14, while details of the plug housing 22 are shown in FIGS. 7 and 8. The lever 90 includes a projection 96 that engages a raised portion 98 on the end of the stiffener member 14. The projection 96 includes a small recess 100 that mates with the raised portion 98 so that as the levers are pivoted to their fully latched position as shown in solid lines in FIG. 1, that is the two levers are pivoted toward each other, the projections snap into place securing the connector assembly 10 to the plug 18 with the contacts 24,30 in mating engagement with the contacts 38,40 respectively. The pivoting end of the lever 90 includes a pair of spaced projections 102 that extend lateral of the lever, each having a prying surface 104 facing upwardly toward the projection 96. Each end of the receptacle housing 36 includes a pair of bearing surfaces 106, as seen in FIGS. 1, 5, and 6, that are in direct alignment with and oppose a respective pair of the prying surfaces 104. Note that with the levers in their latched position, as shown in solid lines, there is a small clearance space between the prying surfaces and the bearing surfaces. When it is desired to separate the connector assembly 10 from the connector plug 18, The two levers 90 are pivoted outwardly and away from each other to the position shown in phantom lines at 108 in FIG. 1. As the levers 90 are pivoted outwardly the prying surfaces 104 engage the bearing surfaces 106 forcing the entire connector assembly 10 to move upwardly away from the connector plug 18. The connector assembly 10 is prevented from bowing any appreciable amount due to the stiffener men,her 14 being firmly attached to the receptacle housing 36 by means of the bent over tails 46.
Each lever 90 includes a cam engaging surface 110 and a pair of stop surfaces 112 adjacent the pivotal end thereof, as best seen in FIGS. 13 and 14. Each extension 92 of the plug housing 22 includes an arcuate raised cam surface 114 and a pair of stop surfaces 116. The stop surfaces 116 oppose the stop surfaces 112 of the lever 90 so that as the levers are pivoted away from each other to their fully open position, shown in phantom lines in FIG. 1, these stop surfaces mutually abut and stop further pivotal movement in that direction. Additionally, during that pivotal movement, the cam engaging surface 110 interferingly engages the cam surface 114 thereby resisting the pivotal motion of the lever. Preferably the center for the radius of cam surface 114 is slightly offset outwardly from the center of pivot 94. As a result, as the pivoting movement of the lever continues, the resistance to the movement increases until the stop surfaces are engaged. At this point the two levers 90 are held in their full open position by this interference so that they cannot interfere with mating or unmating of the connector assembly 10 to the plug 18. This is especially useful when the connector is mounted inverted to that shown in FIG. 1.
While, in the present example, the receptacle 12 is attached to the stiffener member 14 and the plug 18 is attached to the circuit board 20, it will be understood that the receptacle may be attached to the circuit board and the plug attached to the stiffener member while advantageously practicing the teachings of the present invention. Additionally, the plug 18 is shown attached to a major surface of the circuit board 20, however, it may be attached to an edge of the circuit board in a manner described in U.S. Pat. No. 5,199,885. It will be appreciated by those skilled in the art that either the ground receptacle tails 34 or the ground plug tails 46 may be bent over in the recess 58 to secure its respective housing to the stiffener member 14.
An important advantage of the present invention is that the stiffener effectively prevents adverse bowing of the connector assembly attached to the flexible circuit substrate when separating the connector assembly from its mated connector half attached to the rigid circuit board, thereby protecting the delicate circuitry and connector contacts from damage. The use of the ground contact tails to clamp the flexible circuit substrate to the stiffener member is a simple and cost effective structure. Additionally, the increasing resistance to the pivotal motion of the levers, when moving them to their unlatched or open position, secures the levers in their open position to prevent interference by the levers when mating the connector assembly to the plug. | A high density connector (12 ) for connecting to circuitry on a flexible circuit substrate (16). The connector (12 ) includes a stiffener member (14 ) that is attached to the connector housing (36 ) so that the flexible substrate (16) is clamped therebetween. Tails (46) of ground buses (40) within the connector extend through flexible substrate (16 ) and through openings (48) in the stiffener member (14) and are bent over into recesses (58) to hold the stiffener member (14) and connector (12) firmly against the substrate (16) along the entire length of the connector. Pivotal levers (90) are provided to cooperate with the stiffener member (14) to secure connector (12 ) to a mating connector (18 ) in mating engagement when pivoted to a closed position, and to separate the connectors (12,18 ) with minimum bowing of connector (12) when pivoted to an open position. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a flow actuated valve for use in a wellbore. More particularly, the invention relates to a flow-actuated valve that is initially retained in an open position and is closeable with the application of fluid flow. More particularly still, the invention relates to a flow-actuated valve for use in float equipment to facilitate the injection of zonal isolation fluids into an annular area between a string of casing and a surrounding formation.
2. Description of the Related Art
Hydrocarbon wells are conventionally formed one section at a time. Typically, a first section of wellbore is drilled in the earth to a predetermined depth. Thereafter, that section is lined with a tubular string, or casing, to prevent cave-in. After the first section of the well is completed, another section of well is drilled and subsequently lined with its own string of tubulars, comprised of casing or liners. Each time a section of wellbore is completed and a section of tubulars is installed in the wellbore, the tubular is typically anchored into the wellbore through the use of wellbore zonal isolation fluids, i.e. cementing. Wellbore zonal isolation fluids includes, but not limited to, the injection of cement into an annular area formed between the exterior of the tubular string and the borehole in the earth therearound. Zonal isolation protects the integrity of the wellbore and is especially useful to prevent migration of hydrocarbons towards the surface of the well via the annulus.
Zonal Isolation of strings of tubulars in a wellbore is well-known in the art. Typically, the zonal isolation fluid is initially inserted in the tubular, and then forced to the bottom of the well and up the annular area toward the surface. With the use of other fluids, a column of zonal isolation fluids can be forced down the tubular string and into the annulus, resulting in a completely isolated annulus and leaving only a small amount of zonal isolation fluid at the bottom of the borehole. The cured fluid is drillable and is easily destroyed by subsequent drilling to form the next section of wellbore.
Float shoes and float collars facilitate zonal isolation procedures. In this specification, a float shoe is a valve-containing apparatus disposed at or near the lower end of the tubular string that is run into in a wellbore. A float collar is a valve-containing apparatus which is installed at some predetermined location, typically above a shoe within the tubular string. In certain cases, float collars are required rather than float shoes. However, in this specification, the term float shoe and float collar will be used interchangeably.
The main purpose of a float shoe is to facilitate the passage of zonal isolation fluids from the tubular to the annulus of the well while preventing the zonal isolation fluids from returning or “u-tubing” back into the tubular due to gravity and fluid density of the liquid zonal isolation fluids. In its most basic form, the float shoe includes a one way valve permitting fluid to flow in one direction through the valve, but preventing fluid from flowing back into the tubular from the opposite direction. The float shoes usually include a cone-shaped body to prevent binding of the tubular string during run-in.
As mentioned, wellbores are typically full of fluid to protect the drilled formation of the borehole and aid in carrying out cuttings created by a drill bit. When a new string of tubulars is inserted into the wellbore the tubulars must necessarily be filled with fluid to avoid buoyancy and equalize pressures between the inside and the outside of the tubular. For these reasons, a float shoe can be capable to temporarily permit fluid to flow inwards from the well bore as the tubular string is run into the wellbore and fills the tubular string with fluid. In one simple example, a spring loaded, normally closed, one-way valve in a float shoe is temporarily propped in an open position during run-in of the tubular by a wooden object which is thereafter destroyed and no longer affects the operation of the valve.
Other, more sophisticated solutions have been used that temporarily hold the valve in an open position and subsequently permit it to close and operate as a normally closed, one way valve. In a prior art arrangement, a valve is temporarily held in an open position during run-in and, thereafter, a weighted ball is dropped from the surface. The ball sinks to a seated position within the valve of a float collar and then, with pressure applied from the surface of the well, the valve is then enabled to shift to its normally closed position. In another prior art solution, a spring-loaded plunger is moved from an open position to a closed position utilizing hydrostatic pressure. The design utilizes an atmospheric chamber and shears screws. The number of shear screws determines the trip point of the device. As the tubular string is run deeper into a wellbore, hydrostatic pressure builds until it generates sufficient force on the shear screws to cause them to fail. The shearing action releases the plunger converting the valve to a normally closed, one-way valve.
More recently, spring loaded plunger valves in float shoes have been moved from a retained open position with the flow of fluid. The existing designs use energy from wellbore fluid that is circulated with pumps through the valve to depress the plunger and subsequently trip the device. These devices are typically comprised of some form of stop which temporarily retains the valve in an open position. Typically, wedges, tabs, balls, or knobs are mechanically lodged between the plunger and its retainer. These hold the plunger open against the spring force. When sufficient flow is established, the plunger moves downward, compressing the spring further and releasing the wedged stops.
There are problems associated with the prior art devices. Particularly, these devices are susceptible to premature release of the mechanism retaining the valve in an open position. For example, devices requiring a burst of fluid flow for de-activation can sometimes operate prematurely due to naturally occurring flow increases. Devices using an atmospheric chamber sometimes fail to operate as designed due to either design flaws or changes in well bore fluid density. If the valve releases premature, it is no longer possible to fill the tubular string with fluid from below. Because the tubular string must necessarily be filled with fluid to prevent pressure collapse and buoyancy, fluid must then be introduced from the surface of the well, thereby increasing the already high cost of completing drilled sections of wells.
SUMMARY OF THE INVENTION
The present invention generally relates to a flow-actuated valve for use in a wellbore. The invention includes a body having a closing member and a seat. The closing member and seat are separable to open and close the valve, thereby allowing the flow of fluid through the valve. The invention further includes a retainer to initially retain the valve in the open position absent a predetermined fluid flow rate in one direction for a predetermined time period. A biasing member thereafter urges the valve to the closed position, absent another fluid flow rate in one direction.
BRIEF DESCRIPTION OF THE DRAWINGS
So that the manner in which the above recited features of the present invention are attained and can be understood in detail, a 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 is a perspective view of a valve of the present invention.
FIG. 2 is an exploded view of the valve of FIG. 1 .
FIG. 3 is a section view of the valve of FIG. 1, with a retention assembly retaining the valve in an open position.
FIG. 4 is a section view of a wellbore with a valve of the present invention disposed in a tubular.
FIG. 5 is a section view of the valve of FIG. 4 as the retention assembly is being deactivated.
FIG. 6 is a section view of the valve operable as a one way, normally closed valve.
FIG. 7 is a section view of the valve operating to permit fluid to flow from its upper end to and through its lower end.
FIG. 8 is a section view showing an alternative embodiment of the valve with a retention assembly activated.
FIG. 9 is a section view of the valve of FIG. 8 with the retention assembly deactivated.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 is a perspective view of a valve 100 of the present invention. Visible in FIG. 1 is an upper housing 105 and a lower 110 housing. Also visible is an impeller 120 partially extending from the lower housing 110 . In use, the valve 100 is disposed in the interior of a tubular string (not shown) in a manner whereby all fluid passing through the tubular in either direction must flow through the valve 100 . In one example, the valve 100 is disposed at a lower end of a tubular string. In another example, the valve 100 is disposed at some location within the tubular apparatus, such as in a collar within a string of casing.
FIG. 2 is an exploded view of the valve 100 of FIG. 1 . Visible in FIG. 2 are the upper 105 and lower 110 housings. The upper housing 105 includes an aperture 107 formed therethrough with a seat (not visible) formed in an interior surface thereof. Additional components of the valve 100 are substantially housed between the upper 105 and lower 110 housings. A plunger 125 with a head portion 127 and a sealing member 130 therearound creates a sealing relationship between the plunger 125 and the valve body 105 when the valve 100 is closed. The sealing member, therefore blocks the inward flow of fluid of valve 100 as fluids attempt to enter the tubular string. The plunger 125 includes a shaft 135 . A biasing member, in this case a spring 140 , is locatable between the head 127 of the plunger 125 and a surface 142 formed in a support member 145 . The spring 140 is constructed and arranged to become compressed as the head 127 of the plunger moves away from the upper housing 105 . In this manner, valve 100 is biased in a closed position. The support member 145 also includes a fluid path therethrough with radially disposed spokes 147 extending between an inner and an outer portion. Below the support member 145 is an annular diverter 150 for diverting the flow of fluid through the valve as is illustrated in FIGS. 3-7.
The valve of the present invention also includes a retention assembly 200 . The retention assembly 200 serves to temporarily hold the valve 100 in an open position. The open position is especially useful to permit a tubular string to fill with fluid during run-in into a wellbore. The retention assembly 200 operates by holding the plunger head 127 away from the seat in the upper housing 105 until a sustained fluid flow rate is applied through the valve 100 in a forward direction. Typically, the forward direction is a downward direction. A partially threaded bolt 205 having a head 206 at an upper end is insertable into a hollow portion of the shaft 135 of the plunger 125 . A sleeve 210 is attachable to the bolt 205 and is extendable through a body of an impeller 120 , where it is retained at a bottom end thereof with a fastener 222 . The impeller 120 , as will be described, include blades 122 formed on a body thereof to urge the impeller 120 to rotate as the blades are acted upon by a fluid flow. The bolt 205 and the upper portion of sleeve 210 are held within the plunger shaft by a bushing 215 having threads on an inner and outer diameter. The release assembly 200 is designed whereby the bolt and sleeve will rotate with the impeller 120 while the bushing 215 and the plunger 125 will remain rotationally fixed. In this manner, axial movement of the impeller and bolt is transmitted by the interaction of the threads of the bolt 205 and the bushing 215 .
FIG. 3 is a section view of the valve 100 with the retention assembly 200 retaining the valve in an open position. Visible in the figure is an aperture 107 in an upper end of upper housing 105 . In the interior of the housing 105 is seat 109 providing a sealing surface for the sealing member 130 of the plunger 125 . In the retained position, the spring 140 is compressed between an annular surface 217 formed on the underside of the plunger head 127 and annular surface 142 of support member 145 . The retention assembly 200 operates to hold plunger 125 in the position of FIG. 3 through a mechanical connection between bushing 215 and bolt 205 . As illustrated, the bushing 215 is held in the lower end of the shaft 135 of plunger 125 while the bolt 205 is held within the sleeve 210 . The threaded connection between the bushing 215 and the bolt 205 determines the relative position of the plunger head 127 with respect to the seat 109 .
Impeller 120 with blades 122 is retained between an underside 220 of support member 145 and fastener 222 threaded to a lower end of the sleeve 210 . The purpose of the impeller 120 is to rotate in one of two directions depending upon the flow force of fluid past its blades 122 . Because the bolt 205 moves with the impeller 120 , rotation of the impeller 120 in either direction will cause relative axial movement between the bolt 205 and the bushing 215 .
FIG. 4 is a section view of the valve 100 illustrating the flow of fluid through the valve 100 in direction 225 . As previously described, the valve 100 is typically disposed in the bottom end of the tubular string 101 which is then run into a wellbore 102 having drilling fluid therein. One purpose of the valve 100 is to initially permit fluid to pass from a lower to an upper portion of the valve 100 as the tubular string 101 is being lowered into the wellbore 102 . Arrow 224 illustrates the movement of the tubular string 101 in relation to the wellbore 102 . Thereafter, the retention assembly 200 of the valve 100 is deactivated, and the valve 100 operates as a normally closed, one-way valve permitting fluid to pass from an upper to a lower portion.
In FIG. 4, the valve 100 is illustrated in a run-in position with the retention assembly 200 activated. As illustrated, the head 127 of plunger 125 is separated from seat 109 formed in the upper housing 105 of the valve 100 . As illustrated with arrows 225 , fluid flows from a lower end of the valve 100 through an annular area formed in the valve 100 between the plunger 125 and the upper 105 and lower 110 housing portions. Also illustrated by separate arrow 226 is a rotational force applied to the impeller 120 by fluid moving past blades 122 of impeller 120 . In the illustration of FIG. 4, the fluid flow in direction 225 acts on the impeller blades 122 urging the impeller 120 to rotate in a clockwise direction. However, due to high frictional forces, rotation is prohibited.
FIG. 5 is a section view of the valve 100 . In FIG. 5, the retention assembly 200 is being deactivated and the flow of fluid through the valve 100 is illustrated by arrows 230 . The arrows 230 illustrate fluid being pumped from an upper end of the valve 100 through an annular area defined between the outer surface of the plunger 125 and the inner surface of the upper 105 and lower 110 housings. In FIG. 5, the flow of fluid acting on the upper surface of plunger head 127 has depressed the plunger 125 and compressed the spring 140 further than it was originally compressed during run-in. The additional compression of the spring 140 and downward movement of plunger 125 has caused a corresponding downward axial movement of the impeller 120 . An under side 220 of support member 145 is shown separated from the upper surface of the impeller 120 . The result of this separation is greater freedom of the impeller 120 to rotate as the fluid moves across its blades 122 . Of course, the scope of the present invention permits a design of the valve 100 which does require the separation of the support member 145 from the impeller 120 before rotation of the impeller 120 .
In order to initiate the release of the retention assembly 200 of FIG. 5, two conditions are created simultaneously. First, the plunger 125 is depressed past its originally retained position in order to separate the impeller 120 from the lower surface 220 of support member 145 , making it easier for the impeller to rotate. Second, the impeller 120 must be rotated by fluid passing across the from an upper to a lower portion of the valve 100 . The rotation of the impeller 120 with the bolt 205 , in direction 227 , will cause the threaded portion of the bolt 205 to move downward in relation to the bushing 215 . As the impeller 120 continues to rotate, that portion of the bolt 205 which is threaded will pass through the bushing, allowing the bolt 205 to then slide freely within the bushing 215 after its threads are disengaged therefrom.
FIG. 6 is a section view of the valve 100 disposed in a tubular string 101 which is itself disposed in a wellbore 102 . FIG. 6 illustrates the valve 100 with the retention assembly 200 deactivated. As illustrated, bushing 215 is adjacent a portion of the bolt 205 having no threads on its outer diameter. Bolt 205 has slipped through the bushing to a location whereby head 206 of the bolt is retained on an upper surface of the bushing 215 . The axial movement of the bolt 205 with respect to bushing 215 has permitted the plunger 125 with its sealing member 130 to contact seat 109 formed in the underside of upper housing 105 . In this manner, the valve 100 is sealed to the flow of fluid from below, and will only permit fluid entry from above if the fluid flow is adequate to overcome the bias of spring 140 . The retention assembly 200 has thus been permanently disengaged and the valve 100 can now operate as a typical float shoe valve permitting zonal isolation fluids to flow through the valve 100 from the surface downhole, but preventing a back flow of the zonal isolation fluids into the tubular string 101 .
FIG. 7 is a section view of wellbore 102 with valve 100 in tubular string 101 . FIG. 7 illustrates the valve 100 in use with zonal isolation fluids such as cement being pumped from an upper end of the tubular, through the valve 100 , to the lower end of the wellbore 102 . The movement of the plunger 125 downward is shown with arrow 229 . The flow of fluid is illustrated with arrows 228 . As illustrated by the arrows 228 , zonal isolation fluids enters the valve 100 from an upper end and acts upon plunger head 127 to depress the plunger head 127 and to unseat sealing member 130 from seat 109 of upper housing 105 . Spring 140 is shown in a somewhat compressed position. The fluid flows through the valve and the annular area created by the inside of the upper and lower housings 105 , 110 and the outside of plunger 125 . Thereafter, the fluid is guided around diverter 150 and exits through the lower end of the valve 100 . Any effect the passing fluid may have on the blades 122 of the impeller 120 is unimportant as the impeller is free to rotate without creating any change in the valve 100 . This is because the threads of the bolt 205 have now been released from the bushing 215 . From the bottom of the tubular, the zonal isolation fluids flow upward to fill an annular area 103 formed between tubular 101 and wellbore 102 . At some predetermined point, when the annulus 103 is filled with zonal isolation fluids, the flow of zonal isolation fluids is stopped and the fluids are allowed to cure. Thereafter, the cement shoe, including the valve 100 can be drilled up and destroyed by subsequent drilling of another section of wellbore.
In use, the valve 100 of the present invention is utilized as follows:
The valve 100 is disposed either at the end or near the end of a tubular 101 , such as a casing or liner string. The tubular string 101 with the valve 100 disposed therein is run into a wellbore 102 with the retention assembly 200 of the valve holding it in an open position. In this manner, as the tubular string 101 is inserted into the wellbore 102 , wellbore fluid is free to pass from a lower to an upper end of the valve 100 , thereby permitting the tubular 101 to fill with fluid.
After the tubular string reaches a predetermined point in the well, wellbore fluid or some other fluid is pumped through the valve 100 at a predetermined flow rate 140 . The injection of fluid under pressure further depresses the plunger head 127 and further compresses the biasing spring 140 . In this manner, the impeller 120 disposed at the bottom of the valve 100 is separated from its contact with the surface of the support member 145 and is free to rotate. Simultaneously, the fluid utilized to depress the plunger urges the impeller 120 to rotate. The rotation of the impeller in direction 227 causes the threads of the bolt 205 and the bushing 215 to transmit motion of the bolt 205 in a downward direction with respect to the bushing 215 . As that portion of the bolt 205 having threads pass through the bushing 215 , a non-threaded portion of the bolt 205 permits the bolt 205 to drop to a lower position with respect to the bushing 215 and to be retained in the bushing 215 by bolt head 206 . In this position, the retention assembly 200 is deactivated and the valve 100 operates as a normally closed, spring loaded, one-way valve for cementing operations in a wellbore.
FIG. 8 is a section view illustrating an alternative embodiment of the invention. The valve 300 of FIG. 8, like the earlier embodiments includes a spring-loaded plunger 325 and an impeller 320 attached to the plunger by a threaded member. In the embodiment of FIG. 8, a bushing 315 is disposed in the interior of the impeller 320 and an interior of the plunger shaft 335 is threaded. A partially threaded bolt 305 is threaded into the plunger shaft at an upper end and is also threaded through the bushing 315 . FIG. 8 illustrates the valve 300 in an initial position in which a head 327 of the plunger 325 is biased against spring member 340 thereby opening the valve to flow therethrough. The bolt 305 also includes a lower end having additional threads 306 formed thereupon and a nut 307 retained on the threads.
In operation, the valve 300 of FIG. 8 operates as follows: During run-in of a string of tubulars into the wellbore the valve permits the tubular string to fill with fluid. Thereafter, the retention assembly 400 made up of the impeller 320 and bolt 305 is caused to deactivate by the flow of fluid on the plunger head 327 at a specific rate and for a predetermined amount of time. As with the earlier embodiment, the flow of fluid causes the plunger head 327 to move downwards against the spring 340 and permits the impeller 320 to move out of engagement with a support member 145 . With the impeller out of engagement, blades 322 formed on the impeller cause it to rotate in a counterclockwise direction and the bushing 315 and impeller 320 rotate and move axially away from the plunger shaft 335 . As the rotating threads of the bushing 315 reach a portion of the bolt which is unthreaded, the bushing and impeller drop to a second position in relation to the bolt 305 . As the impeller continues to rotate in a counterclockwise direction it becomes threadedly attached to the threads 306 at the lower portion of the bolt 305 and is prevented from additional rotation. The threaded portion at the lower end of the threaded member is designed to prevent the impeller from rotating after the retention assembly 400 is deactivated in order to prevent any damage that might come about due to the freely rotating impeller.
FIG. 9 is a section view of the valve 300 illustrating the components of the valve 300 after the retention assembly 400 has been deactivated. The plunger 325 is in its normally closed, spring biased position and the impeller 320 is threaded at a lower end of the bolt 305 , thereby preventing additional rotation of the impeller 320 .
While the valve of the present invention has been described with the use of an impeller which is rotated by the flow of fluid, it will be understood that the invention could use any type of rotatable member to deactivate the retention assembly and the invention is not limited to the use of an impeller having blades to be acted upon by a passing fluid flow. For instance, the rotatable member could be rotated by a downhole motor, a spring or anything else to translate the rotatable member along the threads of another member to deactivate a retention assembly. These variations are fully within the scope of the invention.
While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow. For example, the retention assembly 200 could be used with various valve devices including flapper valves and the invention is not limited to use with plunger-type valves. | The present invention generally relates to a flow-actuated valve for use in a wellbore. The invention includes a body having a closing member and a seat. The closing member and seat are separable to open and close the valve, thereby allowing the flow of fluid through the valve. The invention further includes a retainer to initially retain the valve in the open position absent a predetermined fluid flow rate in a first direction for a predetermined time period. A biasing member thereafter urges the valve to the closed position, absent another fluid flow rate in the first direction. | 4 |
This is a division of application Ser. No. 401,206, filed Sept. 27, 1973, now U.S. Pat. No. 3,886,732.
BACKGROUND OF THE INVENTION
1. Field of Invention
The present invention relates to internal combustion engines of the turbine type, more particularly relating to such an engine having coaxially mounted components.
2. Prior Art
Turbine-type internal combustion engines have been disclosed in the art. Generally they comprise individually mounted and operated compressors, combustion chambers, and turbines. Such engines are very expensive and complicated, lack desired efficiency and require many moving parts.
OBJECTS OF THE INVENTION
It is an object of the invention to provide an internal combustion-type engine having few moving parts. It is a further object to provide an internal combustion engine which is highly efficient to operate. It is an additional object to provide an engine which is inexpensive to build and operate. Still other objects will readily present themselves to one skilled in the art upon reference to the ensuing specification, the drawings, and the claims.
SUMMARY OF THE INVENTION
According to the present invention, an internal combustion-type engine is provided comprising a bearing support, and a rotor having a compressor, a combustion chamber and ducts, and a turbine all coaxially mounted for rotation as a single unit. The compressor and the turbine are each formed of a spiral web having radial plates mounted at each end defining a spiral chamber which serves in the compressor to compress the air and in the turbine to rotate the rotor assembly and attached power shaft to provide motive power.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings,
FIG. 1 is an axial cross-sectional view showing the internal combustion engine of the invention.
FIG. 2 is a cross-sectional view taken at the line 2--2 of FIG. 1, looking in the direction of the arrows, and
FIG. 3 is a cross-sectional view taken at the line 3--3 of FIG. 1, looking in the direction of the arrows.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1-3, the internal combustion engine 10 of the invention is shown comprising a base 11 having vertical bearing supports 12 and 13 with bearing assemblies 14 and 15 mounted at the ends thereof. An integral rotor subassembly 16 is provided with a tubular shaft 17 at one end and a solid cylindrical power transmitting shaft 18 at the other end journaled in the bearing assemblies 14 and 15, respectively.
The rotor subassembly 16 generally comprises a compressor 24 at one end and a turbine 25 at the other maintained in fixed spaced-apart relationship by direct connection to the end of a tubular housing or hub 26.
The compressor is formed of outer radial walls 27 and 28 connected together by means of a peripheral axial wall 29 to form a partially closed chamber. The outer radial wall 28 is provided with an axial aperture and is affixed to one end of the tubular hub 26. The outer radial wall 27 is provided with a central aperture and is affixed at the inward edge to the tubular shaft 17.
The compressor 24 is additionally provided with an inner radial wall 30 and a spiral partition web 31 disposed between and affixed at its edges by welding or other suitable means to the outer radial wall 27 and the inner radial wall 30, the structure cooperating to define a spiral chamber 32. The inner radial wall 30 has a central aperture to which is connected a tubular combustion housing 33 having a tapered end 34. The inner radial wall 30 cooperates with the outer radial wall 28 to define a cylindrical radial duct 35 communicating with a tubular compressed air duct 36 formed between the hub 26 and the combustion housing 33. Within the combustion housing 33 is a combustion chamber 37 communicating with the compressed air duct 36 by means of apertures 38.
The turbine 25 is formed of outer radial walls 43 and 44 affixed to the edges of a spiral partition web 45 by such means as welding. Alternatively, the structure may be affixed by means of bolts or other suitable means. The radial walls 43 and 44 and the partition web 45 cooperate to define a spiral chamber 46. The outer radial wall 43 is affixed to one end of the hub 26 by suitable means such as welding and is provided with a central port 47 and is affixed to the tapered end 34 of the combustion chamber 33 at the port 47, thereby connecting the combustion chamber 37 with the spiral chamber 46. Although the spiral webs 31 and 45 have each been shown and described as single units, two or more webs may be interwoven in each unit if desired. However, for optimum efficiency each separate web member should extend for at least 360°, that is, a full turn.
A fuel supply duct 48 is fixedly mounted on the apparatus by suitable means and extends through the central portion of the compressor 24 and into the combustion chamber 37. The supply duct 48 has a central tube 49 through which the fuel is supplied terminating in a fuel supply jet 50 through which the fuel is expelled with the proper force and configuration. Ignition wires 51 and 52 are mounted on the supply duct 48 and are terminated in an ignition gap 53 utilized to ignite the fuel injected into the combustion chamber 37. An air intake port 54 is provided intermediate the inner wall of the tubular shaft 17 and the fuel supply duct 48. A seal bearing 56 affixed to the duct 48 and having a sealant surface sealingly engaging the inner surface of the combustion housing prevents fuel and compressed air from backing into the compressor central chamber, and may be formed of any suitable heat-resistant material such as brass or bronze or any other bearing material. Power is provided by the rotor assembly through the shaft 18 which is affixed to the outer radial wall 44 by means of a flange 55.
If desired, water or steam may be injected into the internal combustion engine of the present invention in order to attain the proven advantages of such procedure, such as the reduction of nitric oxide exhaust products and increasing the combustion efficiency of the engine. A means for providing water or steam injection is shown in the drawings and comprises a tubular duct 60 contained in the main fuel supply duct 48, and connected to a collar or doughnut-type nozzle 61. The injection of water additionally offers the advantages that it assists in cooling the combustion chamber and additionally serves to cool the seal bearing 56 when the water in the tubular duct 60 passes below and in proximity with the bearing 56.
In operation, fuel such as kerosene, gasoline, diesel fuel, or any other suitable fuel, is supplied to the fuel supply duct 49 and as it passes out of the supply jet 50 it is ignited by an electrical discharge across the gap 53. Air is drawn in through the duct 54, and into the combustion chamber where it mixes with the ignited fuel and supports combustion, causing a high pressure combustion stream to travel through the port 47, through the spiral chamber 46 and out into the atmosphere through suitable exhaust means (not shown). If desired, a suitable exhaust system may be utilized, such as an annular housing around the edge of the turbine 25 for collecting and venting exhaust gases. As the expanded gas passes through the spiral chamber 46 it causes the turbine 25 to rotate, which, being affixed to the entire rotor, causes the entire rotor including the compressor 24 to rotate. As the compressor 28 rotates, air is drawn in through the air intake port 54, into the spiral chamber 32 where it is compressed as a result of the centrifugal force of the rotative movement, propelled through the duct 30, into the duct 36, and into the combustion chamber 37 through the apertures 38. The application of high pressure air causes the fuel to burn with increased efficiency, thereby providing even greater gas pressure to the turbine 25 and causing the entire rotor to rotate at high speed.
The internal combustion engine of the present invention has many advantages over prior art engines of the turbine type. Because the combustion chamber is mounted in the tubular hub and coaxially mounted with respect to both the compressor and turbine, a better mixture of fuel and compressed air is provided as a result of the continual rotation. The fuel supply duct and nozzle are stationary and the need for specialized or exotic seals is obviated since, after combustion, the gases move to exhaust the turbine. The need for costly seals has been one of the major problems attendant to turbine engines. In the present engine this problem is overcome since in the present design the highest compression of air takes place on the outer rim of the compressor. This structure also has the benefit of reducing compressor temperatures as the laminar peripheral layers of air caused by high speed rotation serves to remove heat. The continually expanding design of the compressor also permits the air molecules to be compressed both by increasing centrifugal force and by accelerating at high velocities. The high velocities of the air molecules are transformed into pressure in the turbine section.
The turbine structure is unique in its function as it converts heat energy into mechanical energy more efficiently than previously known systems. Also it eliminates seal problems because of the rotating structure. Further, because of the unique construction in both the compressor and turbine wherein a spirally oriented web is permanently affixed at its edges to two radial walls this provides a structure which can be very simply and inexpensively produced and yet provides a spiral channel which is free from leakage from one tunnel segment to the other. Moreover, in the compressor structure, a third inner radial wall is provided cooperating with one of the outer radial walls and the spiral web to provide compression, and having a radial duct intermediate the inner radial wall and the other radial wall serving as a duct whereby the compressed air may be directed to the center of the structure and discharged into an air passage located at the center. Additionally, as shown and described, water injection may be readily applied to the engine, with its well-known advantages.
It is to be understood that the invention is not to be limited to the exact details of operation or structures shown and described, as obvious modifications and equivalents will be apparent to one skilled in the art. | A turbine-type internal combustion engine comprising a support having coaxially mounted bearings, and a rotor assembly having shaft members rotatably mounted in said bearings and comprising a compressor, a combustion chamber, and a turbine all coaxially mounted and fixed with respect to each other, the compressor and the turbine each comprising a spiral web and a pair of radial plates affixed thereto, one on each side cooperating to define a spiral chamber, and a fuel supply having a fuel duct mounted at one end of said rotor and extending into said combustion chamber. | 5 |
STATEMENT OF GOVERNMENT INTEREST
The invention described herein may be manufactured and used by or for the Government of the United States for governmental purposes without the payment of royalty therefor.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the manufacture of thermocouples, in particular, high quality, small-scale thermocouples.
2. Description of the Prior Art
The prior art discloses several techniques for forming thermocouples. For example, thermocouples have been formed using welding techniques including spot, carbon arc or heliarc welding or other techniques involving heating and mechanical bonding.
There are at several limitations with these techniques. One problem is that wire breakages are common. A recent mechanical solution to this problem is discussed in an article entitled, "Method and Apparatus for Making Fine Wire Thermocouples", J. Phys. E. Sci. Instrum. 21, 52-54 (1988).
A second problem is the presence of impurities by which are created in the thermocouple by the particular process. These impurities detract from the performance and quality of the thermocouple.
A third problem is the difficulty and expense associated with mechanical bonding techniques.
At least one technique has been proposed to reduce the presence of impurities in a thermocouple. That technique uses electron beam welding. However, a high vacuum is required and the process is quite expensive. In addition, the electron beams may cause the thermocouple leads to outgas. Impurities produced during outgassing can then find their way into the thermocouple.
It is an object of this invention to produce a high quality, small-scale thermocouple that is relatively free of impurities.
A further object of this invention is to produce high quality, small-scale thermocouples using a relatively low cost process and materials.
SUMMARY OF THE INVENTION
A thermocouple is formed by applying a controlled, grounded, high frequency, high voltage source to one end of two leads which are located in a argon or helium gas atmosphere. The source causes a corona to form at the opposite end of the leads, creating a high quality thermocouple in an easily controlled process.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic of the apparatus of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, two leads of wires 2 and 4 are attached at one end to a high voltage radio frequency transformer 6. The bare leads run through a stopper 8 at one end of a glass "T" tube 10 to the opposite end of the "T" 12, where they are twisted together. Argon or helium gas is flowed through the third end of the "T" 14. When the transformer 6 applies a voltage to the wire 2 and 4, a corona 16 forms and propagates in the direction of the flow of the gas. The corona 16 also creates a junction 18 between the twisted leads. The size of the junction 18 is determined by the number of twists.
If the leads are insulated, they are wrapped to form a non-inductive coil. This prevents any electrical potential being developed along the length of the leads that might damage the insulation. Also, where long insulated leads (12" or more) are employed, the source is applied immediately below the junction through a metal clip. This clip serves both as an electrical connection and as a heat sink. Thus, it protects the lead insulation while it prevents the contamination of the junction by outgasing.
In one embodiment of the invention, the power level of the source was set to about 675 volt-amps, the oscillator frequency set to 6-8 Mhz and the junction was heated to about 1575 degrees Centigrade. The latter settings were chosen to provide a corona of sufficient size and temperature to fuse the junction in question. Under these conditions, it took about 5 seconds to form a thermocouple from chromel alumel wire 0.05 mm in diameter. The technique of the present invention has been successfully employed for thermocouple junctions as large as 1.5 mm in diameter.
The thermocouples formed using the technique described were then compared with commercial "Omega" junctions of the same type. The thermocouple junctions were immersed in a common heat source at various levels. The outputs were then observed on an "ANALOGIC Digi-Cal II" thermocouple digital readout. No significant discrepancies between the two sets of outputs were noted.
It will be obvious to one skilled in the application of high-frequency, high-voltage current that various modifications can be made to this invention without departing from the scope of the invention as defined in the following claims. | A high quality, small-scale thermocouple is formed by the corona developed at the twisted ends of two wires connected to a high voltage, radio frequency source. | 1 |
FIELD OF THE INVENTION
[0001] The present invention relates generally to synchronizing the timing of data transfer with a system clock using a delay lock loop circuit. More particularly, the present invention relates to a method and apparatus for producing a symmetrical data clock by adding to or subtracting compensating delays to the falling edge of an internal clock.
BACKGROUND OF THE INVENTION
[0002] Modern high-speed integrated circuit devices, such as synchronous dynamic random access memories (SDRAM), microprocessors, etc., rely upon clock signals to control the flow of commands, data, addresses, etc., into, through, and out of the devices. Additionally, new types of circuit architectures such as SLDRAM require individual circuits to work in unison even though such circuits may individually operate at different speeds. As a result, the ability to synchronize the operation of a circuit through the generation of local clock signals has become increasingly more important. Conventionally, data transfer operations are initiated at the edges of the local clock signals (i.e., transitions from high to low or low to high).
[0003] In synchronous systems, integrated circuits are synchronized to a common reference system clock. This synchronization often cannot be achieved simply by distributing a single system clock to each of the integrated circuits for the following reason, among others. When an integrated circuit receives a system clock, the circuit often must condition the system clock before the circuit can use the clock. For example, the circuit may buffer the incoming system clock or may convert the incoming system clock from one voltage level to another. This processing introduces its own delay and/or skew, with the result that the locally processed system clock, often will no longer be adequately synchronized with the incoming system clock. In addition, the system clock itself may have a certain amount of skew within a tolerance set by system specifications. For example, an exemplary DDR SDRAM system may allow a system clock skewed to have a duty cycle of 55%/45%. The trend towards faster system clock speeds further aggravates this problem since faster clock speeds reduce the amount of delay, or clock skew, which can be tolerated.
[0004] To remedy this problem, an additional circuit is conventionally used to synchronize the locally processed clock to the system clock. Two common circuits which are used for this purpose are the phase-locked loop (PLL) and the delay-locked loop (DLL). In the phase-locked loop (PLL), a voltage-controlled oscillator produces the local clock. The phases of the local clock and the system clock are compared by a phase-frequency detector, with the resulting error signal used to drive the voltage-controlled oscillator via a loop filter. The feedback via the loop filter phase locks the local clock to the system clock.
[0005] In contrast, the delay-locked loop (DLL) generates a synchronized local clock by delaying the incoming system clock by an integer number of periods. More specifically, the buffers, voltage level converters, etc. of the integrated circuit device, for example the input buffers of an SDRAM memory device, introduce a certain amount of delay. The delay-locked loop (DLL) then introduces an additional amount of delay such that the resulting local clock is synchronous with the incoming system clock.
[0006] In certain synchronous circuit devices, for example double data rate (DDR) dynamic random access memory (DRAM), wherein operations are initiated on both the rising and the falling edges of the clock signals, it is known to employ a delay lock loop (DLL) to synchronize the output data with the system clock (XCLK) using a phase detector. In an exemplary case, the transition of the data signal is perfectly aligned with the rising or falling edge of the XCLK. The time from the rising or falling edge of the data clock to the time when the data is available on the output data bus (tAC) is within specifications. A phase detector is conventionally used to lock the rising edge of the output data signal from the DLL (DQ) to the rising edge of the XCLK. Since the rising edge of the DQ signal is phase-locked to the rising edge of the XCLK signal, the rising edge of data being output from the device is synchronized with the system clock XCLK.
[0007] FIG. 1 depicts a DDR DRAM data synchronizing circuit using a DLL as is presently contemplated in the art. A DQ data output signal from an array is input to output buffer 23 and has its timing adjusted to be synchronized with the XCLK signal 8 . At system initialization, a phase detector 2 is activated by an initialization signal 4 . The phase detector 2 compares the phase of the CLKIN signal 6 , a processed signal derived from the XCLK signal 8 , with the OUT_MDL signal 10 , a model of the data output signal DQ. The phase detector 2 then adjusts the DLL delay elements 12 using respective ShiftR 14 and ShiftL 16 signals, to respectively decrease or increase the time delay added to the CLKIN signal 6 with respect to the OUT_MDL signal 10 .
[0008] The Output Buffer Model 19 models the delays generated by the Output Buffer 23 and the CLK Buffer Model 21 models the delays generated by the Input Buffer 7 to produce an OUT_MDL signal 10 such that alignment of the OUT_MDL signal 10 with the CLKIN signal 6 will result in alignment of the XCLK signal 8 with the DQ data output signal 24 . By adjusting the delay of the CLKIN signal 6 through the DLL delay elements 12 , the phase detector 2 can align the rising edge of the DQ output signal 24 with the rising edge of the XCLK signal 8 .
[0009] The output data signal DQ 24 is provided to a data pad 31 and is synchronized with the system clock XCLK 8 .
[0010] In addition, the FIG. 1 circuit can also be used to adjust an output toggle clock signal DQS as shown in FIG. 9 . In this case, an additional output buffer 23 a is used to generate the DQS signal at pad 31 a . The DQS signal can be used for timing purposes, such as a data strobe signal. For purposes of simplifying the discussion below, the background discussion and the discussion of the invention will be described in the context of synchronizing the data output signal DQ with the system clock XCLK 8 , but the discussions herein apply to also synchronizing a DQS signal with the system clock XCLK.
[0011] FIG. 2 is a timing diagram for the synchronizing circuitry of FIG. 1 . As shown in FIG. 2 , the rising edge 26 of the XCLK signal 9 , which is carried on the XCLK signal line 8 of FIG. 1 , is aligned with the rising edge 28 of the DQ signal 25 , which is carried on the DQ signal line 24 of FIG. 1 . As is indicated by the arrows shown in FIG. 2 , the rising edge 30 of the DLLCLK signal 33 (carried on the DLLCLK signal line 32 of FIG. 1 ) initiates the rise and fall of the DLLR signal 21 (carried on the DLLR signal line 20 of FIG. 1 ), through the Rise Fall CLK Generator 18 ( FIG. 1 ), which in turn initiates the rising edge 28 of the DQ signal 25 . Likewise, the rising edge 34 of the DLLCLK* signal 37 (carried on the DLLCLK* signal line 36 ) initiates the rise and fall of the DLLF signal 23 (carried on the DLLF signal line 22 of FIG. 1 ) which in turn initiates the falling edge 42 of the DQ signal 25 . For proper data synchronization, the rising edges of the XCLK 9 and DQ 25 should be aligned within an allowed tolerance and the duty cycle of the data output timing signal DQ 25 should be within the specifications for the system in which the synchronizing circuitry will be used.
[0012] Unfortunately, however, not all synchronizing circuitry components are ideal or even exemplary. Non-symmetrical delays can be created by the input processing of the system clock including input buffering of the system clock signal using the buffer 7 . The system clock itself may exhibit an asymmetric duty cycle, for example, up to a 55/45 duty cycle for a typical SDRAM. Variations in layout, fabrication processes, operating temperatures and voltages, and the like, result in non-symmetrical delays among the DLL Delay Elements 12 . All of these non-symmetrical delays produce output timing signals of the DLL exhibiting a difference between the duration of a high (tPHL) and low (tPLH) portion of the DLL output signal. As shown in FIG. 6 , the high and low tPHL and tPLH signal portions, respectively, refer to the amount of time between transitions of the signal. If a signal remains high for a period longer than it stays low, then that signal is said to be asymmetric. On the other hand, if a signal is high and low for equal periods of time, then that signal is said to be symmetric.
[0013] Non-symmetrical delays also result in a skewed data eye and a larger difference 46 ( FIG. 2 ) between the falling edge 44 of the XCLK signal 9 and the falling edge 42 of the DQ signal 25 . In other words, as shown in FIG. 2 , for an XCLK signal 9 having a 55/45 duty cycle, due to inconsistencies in the DLL delay elements 12 ( FIG. 1 ), the DLLCLK 33 and DLLCLK* 37 signals may have a duty cycle of 40/60. Because it is the rising edge 30 of the DLLCLK signal 33 and the rising edge 34 of the DLLCLK* signal 37 from which the rising 28 and falling 42 edges, respectively, of the DQ signal 25 result, the non-symmetrical delays may result in a non-functional system. Furthermore, because the number of DLL Delay Elements used is cycle time dependent, the skew and difference 46 are also cycle time dependent. This unpredictable skew is undesirable for reliable high speed performance.
[0014] Therefore, there is a strong desire and need for synchronizing circuitry which compensates for the lack of symmetry in a signal synchronized by a delay-locked loop circuit with a system clock, thus enabling more reliable performance at high speeds.
SUMMARY OF THE INVENTION
[0015] The present invention provides a method and apparatus to compensate for skew and asymmetry of a locally processed system clock used to synchronize an output signal (e.g., a DQ data or DQS timing output signal) from a digital circuit, for example a memory device.
[0016] In its apparatus aspects the invention provides a first phase detector, an array of DLL delay elements and accompanying circuitry to phase-lock the rising edge of an output signal (e.g., DQ or DQS signal) with the rising edge of the system clock XCLK signal. Additionally, a comparator circuit, a register delay, an array of DLL delay elements and accompanying circuitry are provided to add or subtract delay from the falling edge of the output signal in order to produce a symmetrical output signal. The symmetrical output signal provides an improved timing margin for a given cycle time.
[0017] In its method aspects, the invention compares a processed system clock with a signal representative of an output signal (e.g., DQ or DQS signal) to adjust a setting of a delay circuit to phase-lock a rising edge of the output signal to a rising edge of an unprocessed system clock signal, producing a first delayed timing signal. A second delay circuit is adjusted according to asymmetries in a duty cycle of the first delayed timing signal, producing at least a second delayed timing signal. At least the first and second delayed timing signals are used to produce a substantially symmetrical output signal.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] These and other advantages and features of the invention will be more clearly understood from the following detailed description which is provided in connection with the accompanying drawings in which:
[0019] FIG. 1 illustrates a block diagram of a portion of a conventional circuit for generating a synchronizing data output signal;
[0020] FIG. 2 illustrates a timing diagram for selected signals of FIG. 1 ;
[0021] FIG. 3 illustrates a block diagram of a portion of a circuit for generating a synchronizing data output signal in accordance with the present invention;
[0022] FIG. 4 illustrates a diagram of a portion of the circuit of FIG. 3 ;
[0023] FIG. 5 illustrates a block diagram of another portion of the circuit of FIG. 3 ;
[0024] FIG. 6 illustrates a timing diagram for selected signals of FIG. 3 ;
[0025] FIG. 7 illustrates a processor system employing a method and apparatus of the present invention;
[0026] FIG. 8 illustrates a partial block diagram of a memory system constructed in accordance with an embodiment of the invention; and
[0027] FIG. 9 illustrates a variation of the FIG. 1 circuit.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0028] For simplification, the invention will now be described with reference to synchronization of data output (DQ) from a memory device, it being understood that a memory device is not required, and that the invention applies to synchronizing the data output of any digital circuit which outputs data in a synchronized manner with reference to a system clock. In addition, the invention can also be used to produce a timing output signal DQS which is synchronized with a system clock.
[0029] FIG. 3 is a block diagram of an embodiment of a data synchronizing circuit according to the present invention. The embodiment in FIG. 3 includes a first phase detector 108 which, like phase detector 2 of FIG. 1 , detects the relative phase between the CLKIN signal 103 , a derivative of the system clock signal XCLK 102 , and the OUT_MDL signal 126 , which models the timing of the output buffer 134 which buffers and synchronizes the data output DQ signal 138 . In response to a phase difference between the CLKIN signal 103 and the OUT_MDL signal 126 , the first phase detector 108 adjusts the delay of DLL Delay Elements 106 to the CLKIN signal 103 by sending respective ShiftL 110 and ShiftR 112 signals to the DLL Delay Elements 106 to phase-lock the rising edges of the CLKIN 103 and OUT_MDL 126 signals. The Output Buffer Model 130 models the delays generated by the Output Buffer 134 and the CLK Buffer Model 128 models the delays generated by the Input Buffer 104 to produce an OUT_MDL signal 126 such that alignment of the OUT_MDL signal 126 with the CLKIN signal 103 will result in alignment of the XCLK signal 102 with the DQ signal 138 . Phase-locking the rising edges of the CLKIN 103 and OUT_MDL 126 signals respectively causes the rising edges of the XCLK 602 and DQ 624 signals ( FIG. 6 ) to align.
[0030] Once the first phase detector 108 has achieved a phase-lock, it outputs a phase-lock signal 124 to initiate operation of the comparator 148 . The comparator 148 compares the relative time durations of the high tPLH and low tPHL portions of the DLLCLK signal 118 and the DLLCLK* signal 122 , which is an inverted DLLCLK signal. In response to durational differences between tPLH and tPHL, the comparator 148 generates add and subtract signals 144 , 146 . The add and subtract signals 144 , 146 are used in the Rise Fall CLK Generator 132 to control the amount of delay added to or subtracted from the DLLCLK* signal 122 prior to generation of the DLLF signal 142 . The DLLR and DLLF signals 140 , 142 are generated in the Rise Fall CLK Generator 132 to correspond to the rising edge of the DLLCLK and (delayed) DLLCLK* signals 118 , 122 , respectively, and are used in the Output Buffer 134 to produce the output data timing signal 138 . As noted, the DLLR and DLLF signals 140 , 142 are also used in the Output Buffer Model and CLK Buffer Model blocks 130 , 128 to produce the OUT_MDL signal 126 . The output data signal DQ on line 138 has both its rising and falling edges synchronized with the system clock XCLK 102 .
[0031] FIG. 4 illustrates an exemplary embodiment of circuitry within the comparator 148 . A first converter circuit 211 is connected between a reference voltage Vref and ground and includes two serially connected enabling transistors 202 and 204 and pull-down transistors 206 . Transistor 202 is connected to Vref while transistor 206 is connected to ground. When transistor 202 is on, a capacitor 214 is connected between the reference voltage Vref and ground as shown in FIG. 4 . The upper plate of the capacitor, connected to the reference voltage Vref, is also connected to a first input (+) of a comparison circuit 220 . The gates of the enabling transistors 202 and 204 are controlled by the phase lock signal 124 . The gate of the pull-down transistor 206 is controlled by the DLLCLK signal 118 .
[0032] A second converter circuit 213 which is similar to converter circuit 211 is provided for a second input (−) of comparison circuit 220 as shown in FIG. 4 . The second converter circuit 213 is of similar construction to that of converter 211 , except its pull-down transistor 212 is controlled by the DLLCLK* signal 122 . The upper plate of the capacitor 216 in the second converter circuit 213 is connected to a second input (−) of the comparison circuit 220 . Comparison circuit 220 compares the differences between the output of the converter circuits 211 , 213 for the DLLCLK and DLLCLK* signals 118 , 122 .
[0033] When the phase lock signal 124 is low, it will precharge capacitors 214 and 216 to Vref. When the phase lock signal 124 goes high to activate the gates of the enabling transistors 204 , 210 , the DLLCLK signal 118 controls the gate of the pull-down transistor 206 to selectively permit discharge of the capacitor 214 during the high time of the DLLCLK signal 118 . Also, the DLLCLK* signal 122 controls the gate of the pull-down transistor 212 to selectively permit the discharge of the capacitor 216 during the high time of the DLLCLK*. signal 122 . Because the DLLCLK* and DLLCLK signals 122 , 118 are inverted and non-inverted versions of the same clock signal, the comparison circuit 220 is able to generate an error signal 228 corresponding to the lack of symmetry in the output of the DLL delay elements 106 .
[0034] For example, if the ratio of high tPLH to the low tPHL portion of the DLL output is 60/40, then the comparison circuit 220 may generate an error signal 228 of appropriate polarity during the cycle which reflects the duration of the asymmetry, or 10% of the clock cycle in this example.
[0035] The error signal 228 is translated in the arbiter block 222 into two signals, the add signal 144 and the subtract signal 146 . The add and subtract signals 144 , 146 represent delay that may be added or subtracted, respectively, with respect to the timing of the falling edge of an output data signal 138 in order to achieve symmetry. The timing of the output data signal is determined in the Rise Fall CLK Generator 132 ( FIG. 3 ). An example of using the add and subtract signals 144 and 146 in the Rise Fall CLK Generator 132 is illustrated in FIG. 5 .
[0036] FIG. 5 shows an exemplary Rise Fall CLK Generator 132 . Each of the signals DLLR 140 and DLLF 142 are generated by passing the internal DLL clock signals DLLCLK and DLLCLK* 118 and 122 , respectively, through a Rise One-Shot Generator 302 , 304 , which generates a high pulse of short duration when it receives a transition from low to high. The DLLR and DLLF signals 140 , 142 are used to control the rising and falling of the output data signal 138 ( FIG. 3 ).
[0037] As shown in FIG. 5 , a Register Delay 306 is used in the DLLF data path upstream of the DLLF Rise One-Shot Generator 304 . The add and subtract signals 144 , 146 control the amount of delay added to or subtracted from the DLLCLK* signal 122 before the DLLF signal 142 is generated in the DLLF Rise One-Shot Generator 304 . In this way, the DLLF signal 142 , and hence the falling edge of the output data signal 138 , can be delayed an amount necessary to make the high tPHL and low tPLH portions of the DLL output signal substantially equal or within an allowed tolerance of each other. In other words, the output data signal 138 has a substantially symmetric duty cycle.
[0038] It should be readily understood that FIG. 5 illustrates merely one example of a Rise Fall CLK Generator 132 . Use of the Register Delay 306 in the DLLF data path is not required and it should be readily understood that a different delay circuit may be used in the DLLR data path with appropriate modifications to associated circuitry to achieve the same result. Alternatively, delay circuits may be used in both the DLLF and DLLR data paths with appropriate modifications to associated circuitry to achieve the same result. Also, the use of a Register Delay 306 is not required and other circuit elements may be used for timing synchronization as is well known in the art.
[0039] As demonstrated in the exemplary timing diagram of FIG. 6 , by adjusting the delay of the DLLF signal 622 , the output data DQ 624 can be generated with a 50/50 ratio (duty cycle). For example, in FIG. 6 the system clock XCLK 602 is shown with a 60/40 ratio of high tPLH to low tPHL signal portions. Due to delays added by the DLL Delay Elements 106 , the DLLCLK and DLLCLK* signals 604 , 606 have a 65/35 ratio.
[0040] As shown in the first timing sequence 650 , prior to phase lock or any compensation using the circuitry of the invention, the DLLCLK and DLLCLK* signals 604 , 606 may produce corresponding DLLR and DLLF signals 608 , 610 , having a duty cycle not substantially equal to 50/50 and not in phase with the system clock XCLK signal 602 .
[0041] The second timing sequence 670 is produced after the phase-locking is completed by phase detector 108 , but before the operation of the comparator 148 . This second sequence 670 shows signals DLLR and DLLF signals 616 , 618 generated in phase with the rising edge of the system clock XCLK 602 , but still having the asymmetric duty cycle of the system clock and further exacerbated by the DLL Delay Elements 106 .
[0042] Finally, the third timing sequence 690 is produced using the comparator 148 and accompanying adjustment of the timing of the DLLF signal 142 . The subtract signal 620 is generated in the arbiter block 222 of the comparator 148 ( FIG. 4 ) and used to adjust the Register Delay 306 in the Rise Fall CLK Generator 132 ( FIG. 5 ), thereby adjusting the timing of the DLLF signal 622 , as shown in FIG. 6 . The resulting output data signal 624 has an acceptable ratio of high tPLH to low tPHL signal portions and thus exhibits a substantially symmetric 50/50 duty cycle,
[0043] The symmetric quality of the output data signal 624 permits improvement of the timing budget by maximizing the data eye used for synchronization of data output.
[0044] Thus, in reference to FIGS. 3-6 , to produce a symmetric data output signal DQ 138 having a rising edge aligned with the rising edge of the XCLK 102 , a phase detector 108 , comparator 148 and Rise Fall CLK Generator 132 are used to separately initiate rising and falling edges of the DQ signal 138 . When a system clock signal XCLK 102 is received, it is processed and compared with a signal representative of the timing of a DQ signal 138 . The processed system clock signal CLKIN 103 is delayed by DLL Delay Elements 106 controlled by a phase detector 108 to produce a delayed system clock signal DLLCLK 118 . The inverse of the delayed system clock signal DLLCLK* 122 is then further delayed by a Register Delay 306 under the control of a comparator 148 . In this way, the rising edge of the system clock signal XCLK 102 may be aligned (phase locked) with the rising edge of the data output signal DQ 138 and the data output signal DQ 138 may be generated so that it is symmetric.
[0045] FIG. 7 illustrates a processor system which employs logic circuits and selection methodologies in accordance with the method and apparatus of the invention.
[0046] As shown in FIG. 7 , a processor based system, such as a computer system 700 , for example, generally comprises a central processing unit (CPU) 702 , for example, a microprocessor, that communicates with one or more input/output (I/O) devices 712 , 714 , 716 over a system bus 722 . The computer system 700 also includes random access memory (RAM) 718 , a read only memory (ROM) 720 and, in the case of a computer system may include peripheral devices such as a floppy disk drive 704 , a hard drive 706 , a display 708 and a compact disk (CD) ROM drive 710 which also communicate with the processor 702 over the bus 722 . The RAM 718 is preferably constructed with delay-lock loop (DLL) circuitry for synchronizing the data output of the memory devices with a system clock using the method and apparatus of the invention described above with reference to FIGS. 3-6 . It should be noted that FIG. 7 is merely representative of many different types of processor system architectures which may employ the invention.
[0047] As illustrated in FIG. 8 , in another embodiment of the invention, a memory system 900 is provided including at least one or a plurality of memory devices 933 constructed with delay-lock loop (DLL) circuitry which can be used to synchronize the data output of the memory devices 933 with a system clock using the method and apparatus of the invention described above with reference to FIGS. 3-6 . Within the memory system 900 , some or all of the plurality of memory devices 933 may be arranged on at least one memory module 935 . In a preferred configuration, the memory system 900 would include a plurality of memory modules 935 , each containing at least one or a plurality of memory devices 933 constructed with the synchronizing circuitry as described above with reference to FIGS. 3-6 .
[0048] While the invention has been described and illustrated with reference to specific exemplary embodiments, it should be understood that many modifications and substitutions can be made without departing from the spirit and scope of the invention. Accordingly, the invention is not to be considered as limited by the foregoing description but is only limited by the scope of the appended claims. | An apparatus and method is disclosed to compensate for skew and asymmetry of a locally processed system clock used to synchronize an output signal, e.g., a data signal or a timing signal, from a logic circuit, for example a memory device. A first phase detector, array of delay lock loop (DLL) delay elements and accompanying circuitry are disclosed to phase-lock the rising edge of the output signal with the rising edge of the system clock XCLK signal. Additionally, a comparator circuit, a register delay, an array of DLL delay elements and accompanying circuitry are disclosed to add or subtract delay from the falling edge of the DQ signal in order to produce a symmetrical output of the DQ signal. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to provisional application 61/138,060, filed Dec. 16, 2008.
FIELD OF THE INVENTION
[0002] This invention relates in general to well pumps, and in particular to a well pump housing varying geometry to increase heat transfer.
BACKGROUND
[0003] Referring to FIG. 1 , a well contains a casing 10 . The casing 10 lines a wellbore (not shown) and is cemented in place. A pump 12 is located inside the casing 10 , frequently at great depths below the surface of the earth. The pump is used to pump production fluid from the depths of the well up to the surface. A shaft (not shown) connects pump 12 to motor 16 . Production fluid enters the pump inlet 17 and is pumped out through tubing 18 .
[0004] The motor tends to produce heat that must be removed to prolong the life of the motor. External devices used to decrease heat create additional costs. External cooling devices, for example, use a coolant pump above the well and coolant lines running through the wellbore to the pump. These cooling devices cool the pump by circulating the coolant through the pump and transferring the coolant back to the surface. The coolant pump, coolant lines, and coolant all create additional costs. Furthermore, the coolant lines may interfere with well operations.
[0005] The motor-pump assembly is located inside a wellbore so it is desirable to transfer heat to the production fluid that is flowing past the motor. It is common to arrange the pump and motor such that the production fluid flows past the motor on its way to the pump. Heat is transferred to the production fluid and carried away as the production fluid moves to the surface. It is desirable to increase the rate of heat transfer from the motor to the production fluid.
[0006] One method to increase the rate of heat transfer is to increase the surface area of the pump that is in contact with the production fluid. This can be done by elongating the motor housing or attaching a shroud to the pump or motor. The production fluid flows between the motor and the shroud so that heat can move from both the motor and the shroud into the production fluid. Other devices, such as fins, may be used to increase surface area of the motor. All of these methods of increasing surface area are limited by the small space available inside the wellbore. Furthermore, there is a problem with fins breaking off and creating blockages within the production fluid flow.
[0007] Fins may be used to create vortices within the production fluid. The vortices in the production fluid increase the rate of heat transfer between the motor and the production fluid. Unfortunately, the vortice-inducing fins, like fins used to increase the surface area, can break off and obstruct fluid flow. Fins also make pump manufacture and maintenance more difficult because they interfere with the assembly, disassembly, and the movement within the wellbore of the pump assembly.
[0008] Assembly is more difficult because the fins must be installed on the motor before the motor is inserted into the cylindrical shroud. The difficulty arises because the fins tend to interfere with the fit between the motor and the shroud. The height of the fins must be limited to allow for insertion, but even with a limited height they can still catch on other fins, the sides of the motor, or the wellbore. If the fin is attached to the motor, for example, there must be a gap between the outer edge of the fin and the shroud to allow clearance during assembly. Clearance issues also make it extremely difficult to attach fins to both the motor and the shroud in the same assembly because the fins interfere with each other during assembly and disassembly. Furthermore, fin clearance issues prevent the fin from spanning the entire gap between the shroud and the motor.
[0009] It is also difficult to perform maintenance on the motor when fins are attached directly to the motor housing because the fins make it more difficult to put the motor on a flat surface or hold it in a vice. In addition to increased assembly and maintenance costs, there is a cost associated with manufacturing and attaching the fins to the shroud and pump. It is desirable to increase the rate of heat transfer without incurring the disadvantages of fins.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a schematic view of prior art pump assembly in a wellbore.
[0011] FIG. 2 is a sectional view of the pump assembly of FIG. 1 with a shroud having an irregular-shaped side wall.
[0012] FIG. 3 is a sectional view of a pump assembly with a “stair-step” shroud attached.
[0013] FIG. 4 is a sectional view of a pump assembly with dimples on the shroud.
[0014] FIG. 5 is a sectional view of a pump assembly with dimples on the pump motor housing.
[0015] FIG. 6 is a sectional view of a pump assembly with a wire coil attached to the inside of the shroud.
[0016] FIG. 7 is a sectional view of a pump assembly with a wire coil attached to the motor housing.
[0017] FIG. 8 is a sectional view of a pump assembly and shroud with screws protruding from the inside of the shroud.
[0018] FIG. 9 is an orthogonal view of a clamshell shroud in which two halves of the clamshell are shown in the closed position.
[0019] FIG. 10 is an orthogonal view of one half of a two-part clamshell shroud and pins in the clamshell.
[0020] FIG. 11 is an orthogonal view of one half of a two-part clamshell shroud with fins.
DETAILED DESCRIPTION
[0021] Referring to FIG. 1 , the casing 10 is shown in a vertical orientation, but it could be inclined. A pump 12 is suspended inside casing 10 and is used to pump fluid up from the well. The pump 12 may be centrifugal or any other type of pump and may have an oil-water separator or a gas separator. The pump 12 is driven by a shaft (not shown), operably connected to a motor 16 . A seal section 14 is mounted between the motor 16 and pump 21 . The seal section reduces a pressure differential between lubricant in the motor and well fluid. The motor 16 is encased in a housing 19 . Preferably, the fluid produced by the well (“production fluid”) flows past the motor 16 , enters an intake 17 of pump 12 , and is pumped up through a tubing 18 . Preferably, the motor 16 is located below the pump 12 in the wellbore. The production fluid may enter the pump 12 at a point above the motor 16 , such that the fluid is drawn up, past the motor housing 19 of the motor 16 , and into the pump inlet 17 .
[0022] The rate of heat transfer is determined by the equation Q=h(A)(T); where Q=rate of heat transfer, h=the heat transfer coefficient, A=surface area, and T=the difference in temperature (in this case, T is the difference in temperature between the motor housing 19 and the production fluid).
[0023] Referring to FIG. 2 , a shroud 22 is mounted around motor 16 to increase the velocity of fluid flowing past the motor housing 19 . The shroud 22 has an open lower end 24 and an upper end 26 sealingly secured around pump 12 above intake 17 . The shroud 22 may be secured by other means and in other locations. The shroud 22 reduces the cross sectional area of the path of fluid flow and thus increases velocity. Increased velocity, or changing velocity, or both, will generally increase turbulence, which in turn increases the heat transfer coefficient (h) of the production fluid flow across the surface of the motor housing 19 . A device that increases turbulence in the fluid flow is referred to herein as a “turbulator.”
[0024] A turbulator may be a feature on a shroud, on the motor housing, or any other part of the motor. As shown in FIG. 2 , the turbulator comprises shroud 22 , which may have an irregular sidewall 28 shape, and thus creates pockets of increased velocity and turbulence as the production fluid flows within shroud 22 . In FIG. 2 , the sidewall 28 of the shroud 22 is formed into a pattern that is sinusoidal when viewed in cross section. The period of each rounded peak and valley may vary considerably. For example, the length of each curve could be much shorter than the length of the motor. The annular flow area varies along the length of the motor 16 as a result.
[0025] Referring to FIG. 3 , turbulence is increased by using a “stair-step” shaped shroud 23 as the turbulator. The production fluid develops a higher velocity, and thus more turbulence, as the inner diameter (“ID”) of the shroud 23 decreases. The laminar flow is further disrupted as the fluid flows past the corners 30 of the indentations in the shroud 23 . In one example embodiment, the motor housing 19 has a 7.25″ diameter and the shroud 22 has a 10.75″ diameter, leaving a 1.75″ maximum gap between the motor housing 19 and the shroud 23 . The shroud 23 could constrict to allow, for example, a 0.5″ clearance between the motor housing 19 and shroud 23 , thus increasing the velocity. The steps of the shroud 23 may be various lengths measured in the direction of the shroud 23 axis, including, for example, 0.5″ or 1″. For example, section 30 a has a smaller inner diameter and shorter axial length than section 30 b . Steps also could have a uniform, corrugated appearance such that, for example, every other step has the same inner diameter.
[0026] Another embodiment of the stair-step shroud 23 is an asymmetrical stair step (not shown) in which the inner diameter varies in one or more quadrants of the shroud 23 . This asymmetrical shape further disrupts laminar flow by creating pockets of higher and lower pressure from side-to-side across the motor housing 19 thus promoting lateral flow of the production fluid.
[0027] Referring to FIG. 4 , the turbulator comprises multiple dimples 32 on the shroud 25 . The dimples 32 are indentations or protrusions in the interior face of the shroud 25 . The size of the indentations 32 may vary and could be, for example, made from a ¼″ or ½″ diameter round punch driven to a ⅛″ depth. Dimples 32 could also have a significantly larger or smaller diameter and be driven to a greater or lesser depth. Furthermore, the dimples 32 may have different shapes such as round, oval, square, and the like. The dimples 32 may be distributed about the surface in a symmetric pattern or they may be placed randomly. The dimples 32 may be concave or convex in relation to the interior of the shroud 25 . The dimples 32 increase the turbulence of the production fluid and thus increase the rate of heat transfer from the motor housing 19 to the production fluid. The dimples give the shroud a textured surface. Other kinds of textured surfaces may also be used to increase turbulence. Furthermore, the dimples 32 are an inexpensive design modification and are not detrimental to the maintenance, handling, and installation of the motor 16 . The dimples 32 may be used alone or in combination with other devices that increase production fluid turbulence.
[0028] Referring to FIG. 5 , the turbulator comprises multiple dimples 33 on the motor housing 16 . The dimples 33 are indentations or protrusions in the exterior surface of the motor housing 27 . The size of the indentations 33 may vary and could be, for example, made from a ¼″ or ½″ diameter round punch driven to a ⅛″ depth. Dimples 33 could also have a significantly larger or smaller diameter and be driven to a greater or lesser depth. Furthermore, the dimples 33 may have different shapes such as round, oval, square, and the like. The dimples 33 may be distributed about the surface in a symmetric pattern or they may be placed randomly. The dimples 33 may be concave or convex in relation to the exterior of the motor housing 27 and may be used regardless of whether a shroud is used. The dimples 33 increase the turbulence of the production fluid and thus increase the rate of heat transfer from the motor housing 27 to the production fluid. The dimples give the housing a textured surface. Other kinds of textured surfaces may also be used to increase turbulence. Furthermore, the dimples 33 are an inexpensive design modification and are not detrimental to the maintenance, handling, and installation of the motor 16 . The dimples 33 may be used alone or in combination with other devices that increase production fluid turbulence.
[0029] Referring to FIG. 6 , a wire coil 34 may be attached to the inside of a shroud 35 to form a turbulator. The presence of the helical coil 34 serves to disrupt the laminar flow of the production fluid and thus increase the rate of heat transfer. The coil 34 can be installed in any variety of positions. For example, it could be attached to the shroud 35 in one or more places as it loops around the motor housing 19 , or it could use spacers to hold the wire in the gap between the motor housing 19 and the shroud 35 . In other embodiments, more than one wire could be attached to the inside of the shroud 35 . The wire may have, for example, twists or coils to further disrupt laminar flow. In still other embodiments, the wire may be attached in two places near the inlet such that the wire forms a “horseshoe” shape inside the shroud. The wire may be used by itself or in conjunction with other means of flow disruption such as dimples 32 ( FIG. 4 ) or irregularly shaped shrouds.
[0030] Referring to FIG. 7 , the turbulator may be a wire coil 37 attached in helical fashion to the outside surface of the motor 39 . The presence of the coil 37 serves to disrupt the laminar flow of the production fluid and thus increase the rate of heat transfer. The coil 37 can be installed in any variety of positions. For example, it could be looped around the motor 16 and attached directly to the motor housing 39 , or it could use spacers to hold the wire at a distance from the motor housing 39 . The wire may have, for example, twists or coils to further disrupt laminar flow. The wire may be used by itself without a shroud, or in conjunction with other means of flow disruption such as dimples 33 ( FIG. 5 ) or irregularly shaped shrouds.
[0031] Referring to FIG. 8 , the turbulator comprises pins or screws 36 attached to the shroud 41 and extending radially inward to disrupt flow. The pins 36 may be, for example, ¼″ diameter studs that could be installed by inserting them through holes drilled shroud 41 such that they protrude from the interior of the shroud 41 . In other embodiments, screws 36 or bolts could be installed by screwing them through threaded holes tapped in the shroud 41 . The pins or screws 36 may be held in place by a variety of means, including, for example, their own threads, bolts, welding, and the like. The pins or screws 36 may be distributed around the entire circumference and along the entire length of the shroud 41 . The pins or screws 36 may be arranged in a symmetrical or in a random pattern. Furthermore, the pins or screws 36 may be used to disrupt flow in straight cylindrical shrouds or in irregularly shaped shrouds, as shown in FIGS. 2 and 3 .
[0032] The pins or screws 36 serve to disrupt the laminar flow of the production fluid and thus increase the rate of heat transfer. In a preferred embodiment, the pins or screws 36 are inserted to a depth such that they contact or nearly contact the motor housing 19 . By contacting or nearly contacting the motor housing 19 , the pins or screws 36 create turbulence close to the motor and thus increase the rate of heat transfer. The user may insert the screws 36 or pins through the shroud 41 after the motor 16 is already installed in the shroud 41 . This embodiment allows easy insertion of the motor 16 , followed by installation of screws 36 that nearly contact the motor and the shroud 41 . The screws 36 may be removed prior to removal of the motor 16 from the shroud 41 , thus providing the heat transfer benefits of the screws 36 while still allowing for easy maintenance access. The pins or screws 36 may be used in combination with any other embodiment of invention, including irregularly shaped shrouds and dimples 32 .
[0033] Referring to FIG. 9 , the shroud 44 may be split into two or more halves or pieces 46 that may be joined together around the motor 16 in a “clamshell” configuration. The joint 48 may be any variety of joint types, including flange, tongue-and-groove, dowel pin, and the like. The pieces 46 may be held together with bolts, quick release latches, interlocking pieces, and the like. The clamshell may divide the shroud 44 into two, three, or more segments or pieces 46 . Each piece 46 may be a segment of a cylinder. One or more joints between the components may have a hinge. The clamshell design may be used to facilitate easier installation of the turbulators.
[0034] Referring to FIG. 10 , the clamshell shroud 44 overcomes the difficulty, for example, of installing and removing the motor 16 when other devices, such as pins 50 , screws, fins 52 , and the like are present between the motor and shroud 44 . Separating the clamshell segments facilitates installation of objects located between the shroud 44 and the motor 16 by giving better access to the inside surface of the shroud 44 . Furthermore, it is easier to manufacture irregularly shaped shrouds when the shroud 44 is split. It is easier, for example, because the pieces can be produced by metal-stamping rather than requiring extrusion, turning, or otherwise shaping a cylindrical object.
[0035] Referring to FIG. 11 , in one embodiment of the clamshell configuration, fins 52 may be installed on the motor housing 19 or the shroud 54 , and the fins 52 may be so long in radial dimensions that they contact both components. A fin 52 could, for example, be welded to the shroud 54 and contact or nearly contact the motor housing 19 when the motor 16 is installed. This embodiment overcomes the inherent manufacturing and maintenance difficulties associated with attaching fins 52 directly to the motor housing 19 , yet still creates turbulent flow immediately adjacent to the motor.
[0036] The fins 52 may be oriented in a variety of positions. In one embodiment, the fins 52 are attached at a 90 degree angle or normal in relation to the wall of the shroud 54 . Fins 52 may be slanted in relation to the axis of the shroud 54 , such as at a 45 degree angle. As illustrated by group 56 of fins 52 , adjacent fins 52 may incline at the same inclination relative to the axis of shroud 54 . Also, some of the adjacent fins 52 may slant at alternating angles to each other. For example, one fin 52 is slanted at a 45 degree angle in one direction, and the adjacent fin is slanted at an opposing 45 degree angle in the opposite direction, such that the bottom most edges 58 of the fins 52 are nearest each other and the fins diverge as they go up along the axis of the shroud. Other fins 52 may have the same 90 degree opposed orientation, but with the top most part 60 of the fins 52 nearest each other. The angle between opposed sets of fins 58 could be any angle. The fins 52 may be set at any variety of angles, and the fins need not be uniform in layout or in angles. In some embodiments, the fins join shroud 54 at an angle other than 90 degrees or normal relative to the surface of the shroud.
[0037] The various fin 52 configurations serve to disrupt the laminar flow of the production fluid as it flows past the motor housing 19 and shroud 54 . In some embodiments, the flow develops swirling or vortexes. The fins 52 may be various lengths, including, for example, 1 to 3 inches long. The fins 52 may be attached to the clamshell shroud 54 by, for example, welding or adhesives before the halves of the clamshell 54 are joined.
[0038] While the invention has been shown or described in only some 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. | The motor of an electrical submersible pump generates a significant amount of heat that can be removed by transferring it to the well production fluid. The motor housing may have turbulators that increase the turbulence of the production fluid to increase the rate of heat transfer. The turbulators are designed for manufacturability and maintenance. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to cutting and slicing devices for cutting food, and, in particular, to devices for cutting pastry. More particularly, the present invention relates to devices having multiple blades for cutting food.
2. Description of the Related Art
Devices for cutting food are known in the art. Some devices of the prior art have single blades and some have multiple blades.
It is important in serving food in schools, health care facilities, and other public and private institutions that flat sheets of food such as pastry be cut into precise and uniform portions to insure that the nutritional content of the portions served is uniform. Uniformity of served portions insures that each person served is provided with a required amount of food to meet prescribed nutritional requirements. The minimum prescribed nutritional value of the food served may be required by the institution serving the food, or may be required by state or federal law.
In some institutions, the food service workers utilized to cut or prepare the minimum portions of food to be served are unskilled, or physically and/or mentally disadvantaged. Such workers may encounter great difficulty in cutting uniform portions of food items such as pastry or other items cooked in large rectangular pans. The use of a knife having a single blade to cut uniform and precise portions of food in such pans is sometimes difficult for a skilled worker, particularly when many pans of food must be cut by a single individual and fatigue is encountered.
Exemplary of the cutting and slicing devices of the prior art are the following U.S. Pat. Nos. 5,343,623; 4,818,207; 4,327,489; 4,085,504; 3,545,325; 2,986,815; 2,557,539; 2,396,443; 1,805,411; 1,530,796; and 1,128,479.
SUMMARY OF THE INVENTION
In accordance with the present invention there is provided a food cutting apparatus for cutting food contained in a rectangular pan, the food cutting apparatus having a plurality of food cutting blades connected to a holder for the blades, the improvement including an elongated, generally flat rectangular blade holder for holding a plurality of food cutting blades, the blade holder having two elongated parallel edges connected by two parallel ends being aligned perpendicular to the two parallel edges, the two parallel ends being shorter in length than the two elongated parallel edges, two openings therein for receipt of the fingers of the two hands of the user, a blade holding device in at least one of the two elongated edges for receiving and holding each of the plurality of food cutting blades, and indicia adjacent to at least one of the edges for positioning the cutting blades at a selected location, and two guides connected to the blade holder for slidably contacting each of the two parallel edges of the pan.
A pan holding apparatus is also provided for holding the pan containing the food to be cut while the food is being cut with the apparatus of the invention.
The invention has the advantage of enabling unskilled employees in the food industry to be able to easily control the size of the portions on food served.
The invention has the further advantage of reducing stress on the wrist of the worker and reduces the number of steps needed to cut portions of food in a pan.
An additional advantage of the invention is that several different types of cutting blades may be employed as desired.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top plan view of the blade holder of the invention;
FIG. 2 is a side view of the blade holder of the invention taken along lines 2--2 of FIG. 1;
FIG. 3 is a cross sectional view of the blade holder of FIG. 1 taken along lines 3--3 of FIG. 1;
FIG. 4 is an elevational view of a preferred cutting blade assembly of the present invention;
FIG. 5 is an elevational view of the blade assembly of FIG. 4 taken along lines 5--5 of FIG. 4;
FIG. 6 is an elevational view, partly cut-away, of a second embodiment of a cutting blade assembly of the invention;
FIG. 7 is a partly cross-sectional view, partly cut-away, of the cutting blade assembly of FIG. 6 taken along lines 7--7 of FIG. 6;
FIG. 8 is a partly cross-sectional view, partly cut-away, of the cutting blade assembly of FIG. 6 taken along lines 8--8 of FIG. 6;
FIG. 9 is the cutting blade assembly of FIG. 8 showing the locking lever of FIG. 8 moved to the locked position;
FIG. 10 is a partly cross-sectional, partly cut-away, elevational view of the cutting blade assembly of FIGS. 4 and 5 connected to the blade holder shown in FIGS. 1-3;
FIG. 11 is a partly cut-away, elevational view of a blade holder guide of the invention;
FIG. 12 is a partly cut-away, elevational view of the blade holder guide of FIG. 11 taken along lines 12--12 of FIG. 11;
FIG. 13 is a partly cut-away, elevational view of FIG. 10 taken along lines 13--13 of FIG. 10;
FIG. 14 is an partly cut-away, elevational view of a third embodiment of a cutting blade assembly of the invention;
FIG. 15 is a plan view of the cutting blade assembly of FIG. 14 taken along lines 15--15 of FIG. 14;
FIG. 16 is a partly cut-away, perspective view of the blade holder of the invention showing the connection of the cutting blade assembly of FIGS. 14-15 connected thereto;
FIG. 17A is a partly cut-away, plan view of a first scale which may be connected to the blade holder of the invention;
FIG. 17B is a partly cut-away, plan view of a second scale which may be connected to the blade holder of the invention;
FIG. 17C is a partly cut-away, plan view of a third scale which may be connected to the blade holder of the invention;
FIG. 18 is a partly cut-away, plan view of a second embodiment of a blade of the invention;
FIG. 19 is a side view, partly cut-away, of the blade of FIG. 18 taken along 19--19 of FIG. 18;
FIG. 20 is a perspective view of the food cutter of the invention cutting a rectangular pan of food;
FIG. 21 is a partly cut-away, perspective view of removable stop shown attached to a surface upon which a pan of food may be placed; and
FIG. 22 is perspective view of the removable stop shown in FIG. 21 attached to the surface of a table having two pans of food thereon.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, in FIGS. 1-3, 16, and 20 is shown the elongated blade holder of the invention generally indicated by the numeral 10. Blade holder 10 can be seen to be generally rectangular in shape, having two parallel edges 12 and 14 and two parallel ends 16 and 18. Blade holder 10 has two outer, parallel rectangular faces 10a--10a, two outer rectangular faces 12a--12a which slope from rectangular faces 10a--10a to edges 12--12, and two outer rectangular faces 14a--14a which slope to edges 14--14. Two scales 12b--12b may be rigidly connected to each of the two outer rectangular faces 12a--12a, and two scales 14b--14b are rigidly connected by gluing or the like to each of the two outer rectangular faces 14a--14a. Each of the scales 12b--12b and 14b--14b may have indicia thereon similar to a common ruler with inches, centimeters, or the like indicated by the indicia thereon. The scales 12b--12b and 14b--14b may be color coded to assist the unskilled or inexperienced user to insure consistent and exact control of the size of the portions of food served. Preferably, rectangular faces 12a--12a and 14a--14a have commonly used scales permanently scribed thereon, and additional scales 12b--12b and 14b--14b are provided as needed.
Two finger holes or openings 20 and 22 shown in FIGS. 1, 3, 10, 13, 16, and 20 are located in blade holder 10 and extend from one rectangular face 10a to the other rectangular face 10a for receipt of the fingers 24 of the user. Holes 20 and 22 are preferably generally rectangular in shape with the longer edges 20c, 20d and 22c, 22d aligned parallel to edges 12 and 14. Holes 20 and 22 are wave-shaped on their inner edges and have four troughs 20a and 22a separated by four peaks 20b and 22b for comfortable receipt of the four fingers 24 of each hand 26 of the user. A circular hole 23 may be provided to extend from one rectangular face 10a to the other rectangular face 10a for enabling blade holder 10 to be hung vertically on a peg or nail when not in use.
Preferably a slot generally indicated by the numeral 28 is located in blade holder 10 adjacent to edge 12 and a slot 30 is located in blade holder 10 adjacent to edge 14. If desired, a single slot 28 could be formed in blade holder 10 and slot 30 could be omitted, but two slots 28 and 30 are preferred for greater versatility.
Slots 28 and 30 are preferably generally rectangular and are preferably identical in shape. Slots 28 and 30 extend along the complete length of edges 12 and 14, respectively. Each of slots 28 and 30 have two rectangular protuberances 28a, 28b and 30a, 30b, respectively, which preferably extend along the complete length of slots 28 and 30 and divide slots 28 and 30 into two rectangular portions 28c and 28d, and 30c and 30d.
In each of FIGS. 4, 5, 10, 13, and 20 is shown a preferred knife blade 32 having preferably having serrations 32a thereon to aid in cutting food. Serrations 32a may be deleted if desired. Blade 32 is rigidly connected by force fitting or any other conventional method to knife blade handle 34. Knife blade handle 34 has two parallel rectangular sides 34a--34a and two parallel rectangular sides 34b--34b. One side 34b has a triangular indicator 38 aligned with blade 32 for positioning blades 32 at a selected location relative to scale 12b as shown in FIGS. 13 and 16.
A generally rectangular cavity 36 is located in knife blade handle 34 and extends completely therethrough from one side 34a to the other side 34a. Cavity 36 has a generally rectangular top or ceiling 36a and a generally rectangular base or floor 36b parallel thereto, and two generally rectangular parallel sidewalls 36c and 36d.
As shown in FIG. 4, a cylindrical hole or channel 37 extends from base or floor 36b of handle 34 to the bottom 37a of handle 34. A generally rectangular guide member generally indicated by the numeral 40 is integrally formed with handle 34 or rigidly connected thereto and has a cylindrical channel 41 extending completely therethrough axially aligned with cylindrical channel 37. Guide member 40 has two larger rectangular parallel sidewalls 40a and 40b, connected by two smaller parallel sidewalls 40c and 40d.
A threaded bolt 44 extends through channels 37 and 41. A locking member generally indicated by the numeral 46 is rigidly connected to one end of bolt 44 and a threaded nut 48 is attached to the other end of bolt 44. Locking member 46 is generally rectangular in shape and has two larger rectangular parallel sidewalls 46a and 46b connected by two smaller parallel sidewalls 46c and 46d. The distance between sidewalls 46a and 46b must be less than the distance between adjacent, facing protuberances 28a-28b and 30a-30b for locking member 46 to be insertable therebetween. Locking member 46 has a generally rectangular tip 48 integrally formed therewith surrounding and rigidly connected to bolt 44.
Blade 32 and handle 34 are shown connected to blade holder 10 in FIG. 10. To connect blade 22 and handle 34 to blade holder 10, locking member 46 is oriented in the position shown in FIGS. 4 and 5 by turning bolt 44 relative to nut 48. Locking member 46 and guide member 40 are then inserted into the slot 28 in the open end 18 of blade holder 10, moved to the position desired on blade holder 10, and nut 48 is rotated with the fingers to lock blade 32 and handle 34 in the desired position.
A generally rectangular guide blade 49 for contacting the outer edge 50a of a pan 50 holding food is shown in FIGS. 11, 12, 13, and 20. Guide blade 49 is attached to handle 34 which has been described above. Guide blade 49 merely replaces blade 32 on the outer ends 16 and 18 of blade holder 10 as shown in FIGS. 13 and 20. Two guide blades 49--49 shown in FIG. 20 make sliding contact with two parallel edges outer edges 50a and 50b of pan 50 and guide blade holder 10 and blades 32 to make straight and uniform cuts in food 52 contained in pan 50.
An alternate handle 56 for blade 32 or guide blade 49 is shown in FIGS. 6-9. Knife blade handle 56 has two parallel rectangular sides 56a--56a and two parallel rectangular sides 56b--56b. One side 56a has a triangular indicator 38a aligned with blade 32 for positioning blades 32 at a selected location relative to scale 12b.
A generally rectangular cavity 58 is located in knife blade handle 56 and extends completely therethrough from one side 56a to the other side 56a. Cavity 58 has a generally rectangular top or ceiling 58a and a generally rectangular base or floor 58b parallel thereto, and two generally rectangular parallel sidewalls 58c and 58d.
As shown in FIGS. 6, 8, and 9, a cylindrical hole or channel 60 extends from base or floor 58a of cavity 58 to the bottom 56d of handle 56. A generally rectangular guide member generally indicated by the numeral 62 is identical to guide member 40 and is integrally formed with handle 56 or rigidly connected thereto. Guide member 62 has cylindrical channel 60 extending completely therethrough. Guide member 62 has two larger rectangular parallel sidewalls 62a and 62b, connected by two smaller parallel sidewalls 62c and 62d.
A cylindrical pin 64 extends through channel 60. A locking member generally indicated by the numeral 66 is rigidly connected to the bottom end of bolt 64 and a flat plate 68 is attached to the top end of bolt 64.
Flat plate 68 has two parallel upwardly extending end supports 72 and 74 integrally formed therewith. A horizontal cylindrical shaft 76 is rotatably received in end supports 72 and 74. Rigidly connected to the two ends of shaft 76 are cam members 78--78. Cam members 78--78 are rotatably received in cylinders 80--80 which extend through each sidewall 58c and 58b of cavity 58. A lever 82 is rigidly connected to shaft 76.
Locking member 66 is identical to locking member 46 and is generally rectangular in shape. Locking member 66 has two larger rectangular parallel sidewalls 66a and 66b connected by two smaller parallel sidewalls 66c and 66d. The distance between sidewalls 66a and 66b must be less than the distance between adjacent, facing protuberances 28a-28b and 30a-30b for locking member 66 to be insertable therebetween. Locking member 66 has a generally rectangular tip 70 integrally formed therewith surrounding and rigidly connected to pin 64.
Blade 32 and handle 56 are connected to blade holder 10 in the same manner as blade 32 and handle 34. To connect blade 32 and handle 56 to blade holder 10, locking member 66 is oriented in the position shown in FIG. 8 by moving lever 82 to the position shown in FIG. 8. Locking member 66 and guide member 62 are then inserted into the slot 28 in the open end 18 of blade holder 10, moved to the position desired on blade holder 10, and lever 82 is moved to the position shown in FIG. 9 to lock blade 32 and handle 56 in the desired position.
In each of FIGS. 14-16 is shown preferred knife blade 32 having preferably having serrations 32a thereon to aid in cutting food. Blade 32 is rigidly connected by force fitting or the like to alternate preferred knife blade handle 84. Knife blade handle 84 has two parallel rectangular sides 84a--84a and two parallel rectangular sides 84b--84b. One side 84b has a triangular indicator 38b aligned with blade 32 for positioning blades 32 at a selected location relative to scale 12b. A generally rectangular guide member generally indicated by the numeral 88 is integrally formed with handle 84 or rigidly connected thereto. Guide member 88 has two larger generally rectangular parallel sidewalls 88a and 88b, connected by two smaller parallel sidewalls 88c and 88d. Two rectangular slots 88e and 88f are formed in the approximate center of sidewalls 88a, 88b, 88c and 88d for sliding receipt of protuberances 28a and 28b. The intersection 90 of sidewalls 88a and 88d is arcuate, and the intersection 92 of sidewalls 88b and 88c is arcuate as indicated in FIG. 15.
To connect handle 84 to blade holder 10, handle 84 is inserted into slot 28 as shown in FIG. 16 as indicated by arrow 94 and triangular indicator 38a is aligned as desired relative to scale 12b. Handle 84 is then turned as indicated by arrow 96 to lock handle 84 to holder 10.
Additional scales 96, 98, and 100 are shown in FIGS. 17A, 17B, and 17C which may replace scales 12b and 14b as desired.
In FIGS. 18 and 19 is shown a roller blade mechanism which could be attached to any of the handles 34, 56, or 84 described above. Roller blade holder 102 can be rigidly connected to handles 34, 56, or 84 by force fitting or the like. Roller blade holder 102 has two fork members 102a and 102b which are rigidly connected to pin 104. Circular blade 106 is rotatably connected to pin 104. Circular blade 106 is similar to a conventional pizza cutting blade.
In FIGS. 21 and 22 is shown a pan holding apparatus generally indicated by the numeral 108 connected to table top 110 of the table generally indicated by the numeral 111. Pan holding apparatus 108 includes a C-clamp generally indicated by the numeral 112 having a rigid elongated L-shaped member generally indicated by the numeral 114 connected thereto.
C-clamp 112 includes two parallel bars 116 and 118 rigidly connected perpendicularly to bar 120 or integrally formed therewith. Bar 118 has an internally threaded cylindrical channel 122 in which is received externally threaded bolt 124. Bolt 124 has a handle 126 rigidly connected to the bottom end thereof and a circular disc 126 rotatably connected to the top end thereof for engaging the bottom side 128 of table top 110.
Elongated L-shaped member 114 has a rectangular horizontal base 130 to which rectangular stop 132 is rigidly connected. Rectangular stop 132 is perpendicular to horizontal base 130 and is preferably integrally formed therewith. Rectangular base 130 is rigidly connected to bar 116 by welding or the like.
As can be seen in FIG. 22, pan holding apparatus 108 is clamped to table top 110 and one of the two shorter ends 51 of rectangular pan 50 is placed against rectangular stop 132.
As shown in FIG. 20, the blades 32 and guides 49--49 are attached to blade holder 10, blade holder 10 is grasped by both hands of the user, guides 32 are aligned with opposite sides of pan 50, and holder 10 is drawn along the length of pan 50 by the user to make parallel cuts 150. After the cuts 150 extend the full length of pan 50, pan 50 is rotated 90°, blades 32 are reset at the desired location on holder 10, guides 49--49 are reset to contact the shorter ends 51 of pan 50, and cuts are made perpendicular to cuts 150. The cut portions are then removed from pan 50 by any conventional means and served.
Although the preferred embodiments of the invention have been described in detail above, it should be understood that the invention is in no sense limited thereby, and its scope is to be determined by that of the following claims: | A food cutting apparatus for cutting food contained in a rectangular pan, the food cutting apparatus having a plurality of food cutting blades connected to a holder for the blades, the improvement including an elongated, generally flat rectangular blade holder for holding a plurality of food cutting blades, the blade holder having two elongated parallel edges connected by two parallel ends being aligned perpendicular to the two parallel edges, the two parallel ends being shorter in length than the two elongated parallel edges, two openings therein for receipt of the fingers of the two hands of the user, a blade holding device in at least one of the two elongated edges for receiving and holding each of the plurality of food cutting blades, and indicia adjacent to at least one of the edges for positioning the cutting blades at a selected location, and two guides connected to the blade holder for slidably contacting each of the two parallel edges of the pan.
A pan holding apparatus is also provided for holding the pan containing the food to be cut while the food is being cut with the apparatus of the invention. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to mounting rings, and particularly to an elastically deformable mounting ring for detachable attachment to a cylindrical supporting object. The mounting ring will be explained in terms of its application to support a light diffusion disk on the cylindrical lens barrel of a camera, however, it should be understood that the mounting ring structure of the invention has application in other areas.
2. Description of the Prior Art
With respect to diffusion disks in general, as they apply to cameras, reference is made to U.S. Pat. No. 4,381,890 and the prior art cited therein. Reference is also made to Design Pat. No. D-270-069 directed to the design of a diffusion disk for application to cameras. Both of these patents were issued to the inventor of the instant invention.
A preliminary patentability search has not been conducted on the concept of an elastically deformable non-circular ring structure for application to cylindrical objects. Accordingly, applicant is unaware of any prior art applicable to this concept.
There are many different instances in ordinary living situations where it is necessary or desirable to attach a relatively wide lid or cover with very little depth detachably to a short section of cylindrical supporting structure. One such instance that comes to mind and which is readily understood by the public in general because of its wide use, is the means for sealing an open coffee can. After the metallic end of the can which preserves the vacuum tightness of the can is removed so as to permit access to the coffee in the can, a circular plastic lid is forced over the open end of the can to seal the can. This is accomplished by compressing a bead on the outer periphery of the can and stretching a bead on the inner periphery of a cylindrical flange formed on the circular plastic lid. The proportions of the beads and the dimensions of the can and lid are such that the bead on the plastic flange may be forced over the bead on the end of the can, thus preventing inadvertent detachment of the lid while permitting it to be pulled free of the can to have access to the coffee.
In U.S. Pat. No. 4,381,890 referred to above, diffusion disks having attachment means in the nature of threads on either the inner or outer periphery of a circular flange have been illustrated, and such attachment means in an appropriate case are very useful. However, they pose problems related to manufacture, costs and cross-threading in use.
It is an object of the present invention to provide a ring structure which is configured in such a way as to be elastically deformable from a non-circular, non-cylindrical configuration to a substantially circular or cylindrical configuration so that when applied to a cylindrical supporting object, the mounting ring will be deformed and retained thereon by the inherent elasticity of the ring and its normal tendency to return to its non-circular configuration.
Another object of the invention is the provision of a mounting ring of non-circular configuration which will accept a circular disk or filter or lens cap and retain the disk floatingly trapped in proper position while permitting elastic flexure of the ring from a non-circular configuration to a circular configuration without releasing the circular disk, filter or lens cap.
A still further object of the invention is the provision of a light diffusion assembly for mounting on the lens barrel of a camera, the assembly including a mounting ring having a flange portion that is non-circular in its relaxed configuration and which is elastically deformed into a substantially circular configuration when applied to the lens barrel of a camera.
A further object of the invention is the provision of a mounting ring including a mounting portion in the form of a flange one or both of the peripheries of which are non-circular in configuration and are elastically deformable into a substantially circular configuration.
The invention possesses other objects and features of advantage, some of which, with the foregoing, will be apparent from the following description and the drawings. It is to be understood however, that the invention is not limited to the embodiment illustrated and described, since it may be embodied in various forms within the scope of the appended claims.
SUMMARY OF THE INVENTION
In terms of broad inclusion, the ring structure incorporating a light diffusion disk for detachable attachment on the lens barrel of a camera, or for use in mounting other objects on cylindrical support structures, comprises in one aspect a ring-like body the outer periphery or the inner periphery or both peripheries of which are formed in a non-circular non-cylindrical configuration so that elastic deformation of the ring-like body to bring it into a substantially circular configuration requires the imposition of a force on the ring-like body which when mounted is exerted against the supporting structure to effectively hold the ring-like body on the support structure. In this aspect of the invention, the ring-like body may be toroidal in its configuration, having inner and outer peripheries one or both of which may be non-circular in its configuration, the inner and outer peripheries being joined by opposite front and rear faces to form a generally toroidal ring-like body possessing elastic deformability. The transverse or diametric dimension of the ring-like body in one plane is greater than the diametric dimension of the ring-like body in a second angularly disposed plane which passes through a common axis.
In the second aspect of the invention, the ring structure is formed by a circular toroidal body from which extends a generally tubular integral flange-like mounting portion, the inner or outer, or both inner and outer peripheries of the flange-like mounting portion being non-circular in configuration while the toroidal body from which the flange-like mounting portion extends is circular. In still another aspect of the invention, the ring-like mounting structure includes a main circular body portion and a tubular flange mounting portion having a non-circular exterior periphery for mounting the ring-like mounting structure on the lens of a camera. The ring structure is also provided with means for diffusing light impinging on one surface of the ring structure, with color compensation means, and with a disk for controlling the amount of light entering the camera, thus providing an effective light diffusion disk for application on the lens barrel of a camera equipped with an internal light metering system.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front elevational view of the invention embodied in a light diffusion disk for cameras.
FIG. 2 is an edge view of the structure illustrated in FIG. 1.
FIG. 3 is an elevational view illustrating the light diffusion disk mounted on a camera lens barrel.
FIG. 4 is a cross sectional view taken in the plane indicated by the line 4--4 in FIG. 1.
FIG. 5 is a fragmentary sectional view illustrating the method of attachment of the pull cord to the light diffusion disk assembly.
FIG. 6 is a fragmentary sectional view in enlarged scale illustrating the method of assembly of the parts of the light diffusion disk.
FIG. 7 is a view similar to FIG. 6, but showing the parts in final assembled position.
FIG. 8 illustrates a modified embodiment of the structure illustrated in FIGS. 6 and 7, the modification comprising the omission of the color compensation filter member.
FIG. 9 is an elevational end view of the mounting flange portion of the light diffusion disk illustrated in FIGS. 1 and 2, illustrating the method of converting the initially tubular cylindrical mounting flange into a tubular body in which the inner and outer peripheries are generally oval.
FIG. 10 is a view similar to FIG. 9 but showing the initially tubular cylindrical flange body of the light diffusion disk of FIGS. 1 and 2 modified in its configuration to provide three areas around its inner and outer peripheries which lie at greater distances from the central axis then the intervening portions.
FIG. 11 is a view similar to FIGS. 9 and 10, but illustrating an embodiment in which the initially tubular circular configuration of the mounting flange portion of the light diffusion disk of FIGS. 1 and 2 has been modified to provide four surface portions on the inner and outer peripheries of the flange which lie at different distances from the central axis than the intervening portions.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In terms of greater detail, the ring structure forming a part of a light diffusion disk and for detachably mounting a filter or light diffusion disk on a tubular cylindrical lens barrel of a camera, or incorporated into other devices for mounting such other devices on cylindrical support structures, comprises a ring structure designated generally by the numeral 2, as viewed in FIGS. 1 and 2, the ring structure including a body portion 3 and a mounting flange portion 4, integral with the body portion and initially being coaxially disposed with respect to the body portion. Both the body portion and the mounting flange portion are initially coaxially disposed about a central axis 6 and are modified, as will hereinafter be described, to provide the mounting flange portion with a non-circular exterior periphery 7, and/or a non-circular inner periphery 8 in a manner which will hereinafter be explained.
Referring to FIG. 4, it will be seen that the body portion 3 of the ring structure includes a generally cylindrical portion 9 having an outer periphery 12, conveniently knurled to facilitate digital manipulation, and on one end being provided with a radially inwardly extending flange 13, the flange 13 being integral with the cylindrical portion 9 of the body 3, and being circumscribed by a short cylindrical flange or bead 14 as illustrated, which may be considered to be a short extension of the cylindrical wall portion 9.
The radially extending flange 13 is provided with an inner peripheral surface 16, a front face 17, and a rear face 18, the rear face 18 joining the inner peripheral surface 16 and the front face 17 to define a circular aperture through which light is admitted to the lens (not shown) mounted within a lens mounting structure designated generally by the numeral 19 in FIG. 3. As illustrated in FIG. 4, the cylindrical wall portion 9 of the body portion 3 is recessed radially outwardly to provide an inner peripheral surface 21 that is substantially perpendicular to the rear face 18 of the flange 13, the inner peripheral surface 21 being generally cylindrical and circular and symmetrical about the longitudinal or central axis 6.
The inner peripheral surface 21 of the cylindrical body portion 9 is interrupted by a shoulder 22 defining an annular surface spaced from rear face 18 of flange 13, and lying substantially parallel thereto. The surface 22 is in turn interrupted by the inner peripheral surface 8 of the mounting flange 4. This inner peripheral surface 8 extends generally axially away from the flange rear surface 18, and is interrupted by a radially extending surface 23 which forms a shoulder defining the outer extremity of the inner peripheral surface 8, defined between the shoulders 22 and 23 as illustrated. The inner peripheral dimension of the shoulder 23 on mounting flange 4 is defined by the inner peripheral surface 24 of the end portion 26 of the mounting ring structure, and this inner peripheral surface 24, which is coaxially disposed about the central axis, and is circular in configuration, cooperates with the shoulder 23 in a way which will hereinafter be explained.
Additionally, it should be noted that between the circular peripheral surface 12 of the body 3, and the outer non-circular peripheral surface 7 of the mounting flange 4, there is a shoulder 27 which has the effect of reducing the diameter dimensions of the outer peripheral surface 7 to something less than the diameter of the cylindrical outer peripheral surface 12 of the main body. In like manner, the inner peripheral surface 8 of the mounting flange 4 is less in its diameter than the diameter of the inner peripheral surface 21, thus modifying the configuration of the cylindrical portion 9 of the body and the mounting flange portion 4 of the mounting ring to provide the equivalent of a "live" hinge 28 between the root of the shoulder 22 and the root of the shoulder 27. Thus, when a radially outwardly directed force is imposed on the surface 24 during assembly, the mounting flange portion 4 tends to elastically flex outwardly, with the live hinge 28 functioning as the turning or pivot point for the flange. During such flexure, which will hereinafter be explained, the mounting flange 4 assumes a substantially truncated conical configuration, with the small base in the area of the live hinge 28, and the major or large base defined by the end portion 26.
The cylindrical wall portion 9 and the non-circular mounting flange portion 7 are thus integrally formed to receive the remaining parts of the assembly, which in this instance include a circular diffusion plate or disk 31 having a front face 32 and a rear face 33 having prism-like projections 34 formed therein to disperse light striking the front face of the diffusion disk. The diffusion disk is fabricated from a suitable plastic material and is dropped into the central aperture defined by the inner peripheral surface 16 of flange 13 so that the radially outwardly projecting flange portion 36 of the diffusion disk rests on the inner surface 18 of the flange 13, while the cylindrical outer peripheral surface 37 of the diffusion disk 31 forms a snug slip fit with the surface 16 of flange 13.
Superimposed on the diffusion disk 31, so that it lies in contact with the apex ends of the prism-shaped members 34, is a color compensation disk 38, preferably fabricated from a light gauge plastic material having the appropriate formulation to filter the light that strikes the front face 32 of the diffusion disk 31, impeding excessive amount of such light as would produce an unwanted color. In this way, the amount of any color being passed to the film in the camera may be modified or not, as desired, within very close limits.
Superimposed on the color compensation filter 38 is a translucent filter plate or disk 39, circular in configuration, having a front face 41 which lies against the top surface of the color compensation filter 38 and in contiguous contact therewith, and having a rear face 42 from which light passes directly to the lens system of the camera. The translucent filter disk 39 possesses a circular outer peripheral surface 43 and a truncated conical configured peripheral surface portion 44 as illustrated.
During the assembly procedure, the ring structure 3 is supported on the bead 14 on an appropriate work surface (not shown). The terminal end 45 of the pull cord 40 is inserted through the tangentially directed aperture 47 so that the end portion lies in the recess defined by the inner peripheral surface 21, the shoulder 22 and the inner surface 18 of the flange 13. A drop of adhesive on the end 45 permanently adheres the end within the assembly, while the remainder of the pull cord 40 extends from the assembly. Next the diffusion disk 31 is dropped into place, as previously described, followed by the color compensation disk 38. Thereafter, as shown in FIG. 6, the disk 39 is placed on the ring so that the conical surface 44 engages the corner formed between circular surface 24 and the extreme end surface 48 of the mounting flange. Downward pressure is then applied in the direction of the arrows 49, resulting in a component of that pressure being exerted radially outwardly by the camming action of the conical surface 44. This causes the end portion 26 of the flange 4 to be elastically deformed radially outwardly in the direction of the arrow 50 to a greater diameter, permitting the circular peripheral face 43 of disk 39 to slip past circular peripheral surface 24. When the rear face 42 of disk 39 slips past the shoulder 23, the end portion 26 will recover its original position (FIG. 7), trapping the disk 39 behind the shoulder as shown, but accommodating radial displacement of the disk 39 in relation to the supporting flange 4.
It is the function of the translucent filter disk 39 to control the quantity of light passing through the ring structure and being admitted to the light metering system of the camera through the lens. As explained in U.S. Pat. No. 4,381,890 issued to the inventor hereof, the filter disk 39 is fabricated from an appropriate synthetic resinous material or plastic formulated to pass a predetermined amount of light that impinges on the front face 32 of the light diffusion disk structure, so that the amount of light being admitted into the camera correlates to the light metering system incorporated in most single lens reflex cameras.
To effectively retain the ring structure on the inner periphery of the lens barrel as indicated in FIG. 3, the outer peripheral surface 7 of the mounting flange 4 is formed in a non-circular configuration so that when it is applied to the circular inner periphery of the lens barrel, which includes the cylindrical mounting flange 46, the inner periphery of which is circular, the non-circular outer periphery of the mounting flange 4 of the light diffusion disk conforms itself to the circular configuration of the inner periphery of the flange 46, causing elastic deformation of the mounting flange 4, such elastic deformation effecting a radially outwardly directed force against the inner periphery of the mounting flange 46, thus snugly retaining the light diffusion disk detachably mounted on the lens barrel.
As illustrated in FIGS. 9, 10 and 11, there are several configurations of non-circular mounting flanges 4 that will function in the manner described to retain the light diffusion disk detachably mounted on the lens barrel. There follows an explanation of one method of achieving these different configurations. Referring to FIG. 9, in this embodiment of the invention, the ring structure having outer peripheral surface 7 and inner peripheral surface 8, both being initially circular and symmetrical about the central axis of the mounting ring, is mounted in a two-jaw lathe chuck as illustrated in broken lines at 51 and 52. This is done prior to the mounting in such ring structure of the diffusion plate 31, the color compensation filter 38 and the disk 39. After mounting, the chuck is closed down to impose radially inwardly directed forces against the outer peripheral surface 7 of the mounting flange portion 4, effecting about 0.010" radially inwardly directed displacement of the peripheral surfaces 7 and 8. The displacement may be more or less, depending on the application. Thus, the horizontal transverse dimension of the 15 inner and outer peripheral surfaces are diminished by 0.020" in the horizontal plane, and since the ring is elastic in its characteristic, the dimension of the ring in the vertical plane increases by 0.020", i.e., 0.010" at diametrically opposed sides of the ring, generating an oval configuration. Next, the amount by which the diametrical dimension in the vertical plane was increaded (0.020") is machined from the outer periphery 7 as illustrated by the stippled portions 53 and 53' in FIG. 9. The effect of this operation is that the oval configuration of the outer peripheral surface 7 of the ring is converted back to a substantially circular configuration because the amount of material that is cut from the outer peripheral surface of the ring is maximum at the 12 o'clock position as referenced by the numeral 54 and tapers down to zero adjacent the horizontal plane which passes through the 3 o'clock and 9 o'clock positions designated by the numerals 56 and 57 respectively. The same cut is of course made on the bottom half of the ring, the major depth of cut occuring at 58, which is equivalent to the 6 o'clock position while the thickness of the cut tapers to zero adjacent 56 and 57 as previously discussed.
It will of course be understood that while the outer peripheral surface 7 of the mounting flange 4 after these cuts are made and while still held in the chuck will be substantially circular, the inner peripheral surface 8 of the mounting flange 4 still retains its oval configuration. Accordingly, to provide for greater deformation of the mounting flange 4 so that it may accommodate a greater range of inner diameters of the mounting flange 46 of the lens barrel, another cut is made on the inner periphery 8 of the ring, the tool cutting 0.010" from the inner periphery with the thickest portions 59 and 59' of the cut being at the 3 o'clock and 9 o'clock positions, i.e., opposite reference numbers 56 and 57, respectively, with the depth of the cut tapering to zero adjacent the 12 o'clock and 6 o'clock positions.
The effect of this cut is to render the inner peripheral surface 8 of the ring substantially circular in its configuration so long as it is being held compressed by the chuck jaws. After these cuts have been made, when the ring is released from the pressure imposed by the jaws 51 and 52 of the chuck, the inherent or natural elasticity of the body will cause the ring to spring outwardly at 56 and 57 along the horizontal plane, and this will have the effect of drawing the previously distended portions of the ring at 12 o'clock and 6 o'clock inwardly toward the central axis, resulting in both the inner and outer peripheries of the mounting flange portion 4 or the ring to now be substantially oval or elliptical.
Thus, when the mounting flange 4 thus configured is applied to the inner circular periphery of the mounting flange 46 of the lens barrel, the slight amount of force that is impressed on the ring to mount it causes the mounting flange 4 to be elastically deformed into a circular configuration to conform to the inner periphery of the mounting flange 46. In so conforming to a circular configuration, the mounting flange 4, with its normally non-circular outer peripheral surface 7, is caused to push radially outwardly against the inner periphery of the mounting flange 46 to thus detachably retain the mounting ring on the lens barrel.
It will of course be understood that while I have described the formation of the non-circular configuration of the mounting flange 4 as being effected on a lathe, the configuration sought may also be achieved by injection molding of the plastic into a suitably configured mold. The end result sought is of course a non-circular configuration, whether it be the outer periphery, the inner periphery or both the inner and outer peripheries of the mounting flange portion 4 of the ring, so that when applied to the inner or outer peripheries of appropriately sized supporting cylindrical structures, the inherent elasticity of the body will cause the body when forced into a circular configuration, to snugly engage such circular configuration of the supporting body.
Referring to FIG. 10, the mounting flange 4 of the light diffusion disk assembly is illustrated as being non-circular and having three circumferentially spaced peripheral portions that are spaced from the central axis at distances greater than the distance of adjoining portions of the periphery. As before, this non-circular configuration of the outer peripheral surface 7, or the inner peripheral surface 8, or both the inner and outer surfaces 7 and 8, may be achieved by machining the ring structure in an appropriate lathe.
Thus, to achieve this 3-lobe non-circular configuration, the ring structure is mounted in a three-jaw chuck. The three jaws of the chuck are tightened on the ring to elastically deform the mounting flange 4, which is initially circular and concentric with the cylindrical wall 9 of the body 3, into a 3-lobe configuration illustrated by the full lines 61 and 62 designating the outer and inner peripheries 7 and 8, respectively. Note that the jaws of the chuck move radially inwardly approximately 0.010" at their points of contact at 63 (12 o'clock), 64 (4 o'clock) and 66 (8 o'clock). These pressure points and displaced areas are thus spaced 120° circumferentially about the peripheries 7 and 8. Since the ring structure is not compressible in the sense that the material from which the ring is fabricated will become more dense from such pressure, the application of pressure causes displacement of the peripheral areas inwardly at the pressure points, thus causing the intermediate portions 67, 68 and 69 of the mounting flange 4 to bulge outwardly between the pressure points an amount (0.010") substantially equal to the amount of inward displacement at the pressure points rather than to compress circumferentially. Circumferentially spaced undulated inner and outer peripheral surfaces are thus provided the clamped ring so long as it remains clamped in the 3-jaw chuck.
With respect to the undulated inner peripheral surface designated by the full line 62, note that opposite the pressure points 63, 64 and 66 there are arcuate portions 71, 72 and 73 of the flange 4 that are displaced inwardly approximately 0.015" at the point of maximum displacement, with the degree of displacement tapering off to zero on both sides of the point of application of the pressure. With the ring structure thus clamped within the three jaws of the chuck, a cut is made on the exterior periphery along the broken line 74, resulting in removing from the wall thickness of the mounting flange 4 the protruding intermediate portions 67, 68 and 69 shown by stippling in FIG. 10. In like manner, while the ring structure is held in deformed condition, a cut is made on the inner periphery along the broken line 76, resulting in removing from the wall thickness of the mounting flange 4 the inwardly displaced portions of the wall designated by reference numbers 71, 72 and 73. Note that these arcuate portions, shown by stippling, are oriented opposite each pressure point, while the portions 67, 68 and 69 are oriented circumferentially spaced from the portions 71, 72 and 73.
The effect of these two cuts is to convert the stressed mounting flange 4, while held in the chuck, back into a substantially circular configuration. But since this substantially circular configuration is maintained by the continued application of pressure at points 63, 64 and 66, it will be seen that when the ring structure is released from the chuck and the pressure relieved, the mounting flange 4 will revert to a non-circular configuration. The flange wall portions at 63, 64 and 66 will spring outwardly and the wall portions from which the protuberances 67, 68 and 69 were removed will move inwardly, so that undulated inner and outer peripheries will again be formed. It is important to note that the peripheral inner and outer surfaces, while being non-circular, are substantially parallel, resulting in a flange wall 4 of substantially uniform thickness but undulating circumferentially to provide three lobes on the outer periphery and the same number of lobes on the inner periphery. Note however that the lobes on the inner and outer peripheries are circumferentially angularly displaced, the lobes on the outer periphery occurring at 63, 64 and 66, while the lobes on the inner periphery occur at points opposite portions 67, 68 and 69.
When the mounting flange 4 of the ring structure, configured as in FIG. 10, is applied to the tubular cylindrical lens barrel flange 46, the outer peripheral lobes will be pressed inwardly by contact with the inner periphery of the flange 46, causing the flange 4 to be elastically strained into a circular configuration conforming to the inner periphery of the flange 46. The force required to effect the elastic deformation is the force that retains the ring structure detachably attached to the flange 46.
FIG. 11 illustrates a third embodiment of the mounting flange 4 formed into a non-circular configuration in the same manner as discussed above in connection with FIG. 10. The difference is that in FIG. 11 a four-jaw chuck is used to effect the elastic deformation, the jaws 81, 82, 83 and 84 moving inwardly, displacing the initially circular periphery to effect elastic deformation and the formation of four protuberances on each of the inner and outer peripheries as shown by the stippled areas 85, 86, 87 and 88 associated with the outer periphery illustrated by the full line 89, and the stippled areas 91, 92, 93 and 94 associated with the inner periphery illustrated by the full line 95 in FIG. 11.
As before, the protuberances on the inner and outer peripheries are machined off to render a circular configuration while held in the chuck, becoming a non-circular configuration when released by the chuck, as previously described. The mounting flange 4 will now have four radially outwardly protruding lobes that correspond in circumferential position to the positions where inward pressure was applied to effect elastic deformation. Additionally, it will have four radially inwardly protruding lobes on the inner periphery corresponding in circumferential positions to the positions of the protuberances 85, 86, 87 and 88 that were cut from the outer periphery.
While I have described the method of achieving three non-circular configurations as illustrated in FIGS. 9, 10 and 11 through use of a lathe and a machining operation, it should be understood that other methods of achieving a non-circular configuration may be used. For instance, the flange 4 may be injection molded to produce ultimate configurations as illustrated in FIGS. 9, 10 or 11.
It will thus be seen that by configuring the mounting flange to be non-circular, the very act of applying the non-circular flange into the inner periphery of the circular flange 4, causes an elastic deformation of the mounting flange, resulting in a radially directed retention force being applied between the elastically deformable non-circular mounting flange 4 and the cylindrical support structure to which it is applied. It has been found that in general, the greater the angular separation of the peripheral protuberances the greater is the elastic deformability. Thus, the two-lobe embodiment of FIG. 9 has a greater range of motion under the same radially directed force than the embodiments of either FIGS. 10 and 11, and the FIG. 10 embodiment (3-lobes) has a greater range of motion than the FIG. 11 embodiment.
Having thus described the invention, what is believed to be new and novel and sought to be protected by letters patent of the United States is as follows. | Presented is an elastically deformable ring structure useful to effect the detachable mounting of a lens cap, filter, or light diffusion disk on the cylindrical lens barrel of a camera. The ring structure is elastically deformable from a non-cylindrical or non-circular configuration to a substantially cylindrical or circular configuration whereby the inherent resilience of the ring structure when mounted on the cylindrical lens barrel retains the ring structure in proper position detachably attached to the lens barrel. | 6 |
This application claims the benefit of the Patent Korean Application No. 10-2006-0007834, filed on Jan. 25, 2006, which is hereby incorporated by reference as if fully set forth herein.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to laundry dryers, more particularly, to a laundry dryer which enables selective mounting/dismounting of a control panel on an upper or lower side of a front of the laundry dryer, as well as easy dismounting of a heater assembly out of the laundry dryer.
2. Discussion of the Related Art
In general, laundry finished with washing is moved to and dried at a drying stand, naturally. However, in a case the weather is irregular, or in a rainy season, the natural drying of the laundry is delayed, such that the busy modern people experience much inconvenience.
Consequently, an appliance for drying the laundry regardless of the weather is required, to develop the laundry dryer.
Recently, it is a trend that demands on the laundry increases rapidly for the busy modern people.
The laundry dryer generates hot air with heating means and blows the hot air toward a drum, to vaporize moisture from a drying object.
In the laundry dryer, there are a condensing type laundry dryer, and an exhaust type laundry dryer depending on a system for processing humid air.
A related art exhaust type laundry dryer will be described with reference to FIG. 1 attached hereto.
Referring to FIG. 1 , the laundry dryer is provided with a body case 10 , a drum 20 , a fan 30 , and a heater assembly 40 .
The body case 10 forms an exterior of the laundry dryer. The body case 10 has a laundry opening 11 in a front for introducing laundry into the drum 20 .
Mounted on an upper side of the body case 10 , there is a control unit 12 for controlling operation of the laundry dryer, having an inside with a circuit board 12 a connected to various electric outfits mounted thereon, and an outside mounted with operation buttons 12 b and a display window (not shown) connected to the circuit board 12 a mounted thereon.
The drum 20 is mounted in the body case 10 , with an opening aligned with the laundry opening 11 . There is a door D at one side of the laundry opening 11 for selective opening/closing of the laundry opening 11 .
Mounted under the drum 20 , there is the heater assembly 40 , and there is the fan 30 on a position different from the heater assembly 40 for blowing the hot air to an outside of the laundry dryer through an inside of the drum 20 .
However, the related art laundry dryer has the following problems.
First, in a case the circuit board 12 a that controls the laundry dryer is out of order, or the various operation buttons 12 b on the control unit 12 are broken, it has been very inconvenient in repairing or replacing the circuit board 12 a or the operation buttons 12 b.
That is, since the control unit 12 is fixedly secured to the body case 10 , the servicemen experience substantial inconvenience in repairing.
Second, at the time the heater assembly 40 under the drum 20 is out of order, in order to repair or replace the heater assembly 40 , there is difficulty of removing various components mounted above the heater assembly 40 .
SUMMARY OF THE INVENTION
Accordingly, the present invention is directed to a laundry dryer.
An object of the present invention is to provide a laundry dryer which enables selective mounting/dismounting of a control panel on an upper or lower side of a front of the laundry dryer, as well as easy dismounting of a heater assembly out of the laundry dryer without disassembly of an entire body case.
Additional advantages, objects, and features of the invention will be set forth in part in the description which follows and in part will become apparent to those having ordinary skill in the art upon examination of the following or may be learned from practice of the invention. The objectives and other advantages of the invention may be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.
To achieve these objects and other advantages and in accordance with the purpose of the invention, as embodied and broadly described herein, a laundry dryer includes a body case forming an exterior of the laundry dryer, a drum in the body case for holding a drying object, a heater assembly in the body case for heating air to supply hot air to the drum, a panel frame on a front of the body case, having an opening in communication with a space having the heater assembly mounted therein, and a control panel mounted to the panel frame selectively, having buttons for making various operation.
Preferably, the panel frame includes an upper panel frame on an upper side of the front of the body case, and a lower panel frame on a lower side of the front of the body case.
Preferably, the heater assembly is mounted in the body case at a lower portion thereof.
Preferably, the lower panel frame has an opening.
In this instance, preferably, the opening and the heater assembly are arranged on a straight line.
Preferably, the opening has a size enough to take out the heater assembly.
Preferably, the control panel can be mounted to the upper panel frame or the lower panel frame, selectively.
Preferably, the laundry dryer further includes a cover panel for covering the other panel frame if the control panel is mounted to one of the upper panel frame and the lower panel frame.
Thus, the laundry dryer of the present invention has the following advantages.
As described, since the control panel can be detachable from the body case, replacement or repair of the operation buttons and the display window on the control panel can be very convenient.
Since the control panel can be mounted to the upper side or lower side of the front of the laundry dryer selectively, the user's handling of the operation buttons on the control panel is convenient even if two or more than two laundry dryers are arranged in any type.
The opening in the panel frame permits easy taking out, and repair of the heater assembly.
It is to be understood that both the foregoing general description and the following detailed description of the present invention are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this application, illustrate embodiment(s) of the invention and together with the description serve to explain the principle of the invention. In the drawings:
FIG. 1 is a longitudinal section illustrating a related art laundry dryer.
FIG. 2 is an exploded perspective view illustrating a laundry dryer in accordance with a first preferred embodiment of the present invention.
FIG. 3 is a longitudinal section illustrating the laundry dryer in FIG. 2 in an assembled state.
FIG. 4 is a front view illustrating the laundry dryers of the present invention arranged in an up/down direction.
FIG. 5 is a front view illustrating the laundry dryers of the present invention arranged side by side.
DETAILED DESCRIPTION OF THE INVENTION
Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.
A laundry dryer in accordance with a first preferred embodiment of the present invention will be described with reference to FIGS. 2 and 3 .
Referring to FIG. 2 , the laundry dryer includes a body case 100 , a heater assembly 200 , a panel frame, and a control panel 400 .
The body case 100 , an exterior of the laundry dryer, includes a top plate 110 which is a top portion of the laundry dryer, a cabinet 120 which is opposite sides thereof, a back cover 130 which is a rear thereof, and a cover cabinet 140 which forms a portion of a front thereof.
The cover cabinet 140 has a laundry opening 150 for putting in/taking out laundry, and there is a door D at one side of the cover cabinet 140 having the laundry opening 150 formed therein for selective opening/closing of the laundry opening 150 .
It is preferable that the back cover 130 has a plurality of air inlets 131 for smooth drawing of external air.
The heater assembly 200 heats the air introduced into the body case 100 , and preferably is mounted under the drum Dr.
This is because a lower space of the body case 100 is the most suitable place for mounting the heater assembly 200 therein in view of arrangement of various components in the body case 100 .
Referring to FIG. 3 , the heater assembly 200 and the drum Dr are connected with an inlet duct Id to each other.
The inlet duct Id is a hot air passage from the heater assembly 200 to the drum Dr.
There is an outlet duct Od connected to the other side of the drum Dr. The outlet duct Od is a passage for discharging air and steam that dried the laundry from the drum.
Mounted on an inside of the outlet duct Od, there is the fan F for generating suction force for drawing external air into the drum Dr, and discharging steam from the drum Dr to an outside of the laundry dryer.
The panel frame is mounted to an upper side and a lower side of the cover cabinet 140 for mounting the control panel 400 or the cover panel 600 to be explained later, respectively.
The panel frame includes an upper panel frame 500 mounted to the upper side of the cover cabinet 140 , and a lower panel frame 300 mounted to the lower side of the cover cabinet 140 .
In the lower panel frame 300 , there is an opening 310 for taking the heater assembly 200 out of the body case 100 .
The opening 310 is in communication, and arranged on a straight with a space of the body case 100 wherein the heater assembly 200 is mounted.
The opening 310 has a size enough to take out the heater assembly 200 .
It is preferable that the opening 310 has a shape similar to an outline of the heater assembly 200 for taking out the heater assembly, easily.
In the meantime, it is preferable that the opening 310 is formed only in the lower panel frame 300 in a case the heater assembly 200 is mounted in a lower portion of the body case 100 like the first embodiment.
The control panel 400 enables the user to control operation of the laundry dryer, and has various operation buttons required for the control mounted thereon.
For this, there is a circuit board 410 on an inside of the control panel 400 having various circuitry components mounted thereon.
The control panel 400 is designed to be mounted on the upper panel frame 500 or the lower panel frame 300 , selectively.
Referring to the first embodiment of the present invention, the control panel 400 is mounted on the lower panel frame 300 of the body case 100 .
In the meantime, the circuit board 410 has a cable (not shown) exposed to the lower panel frame 300 for transmission of operation of the laundry dryer to the various components.
That is, the cable has one end connected to a connector, and the other end connected to the circuit board 410 , electrically.
Mounted on an outside surface of the control panel 400 , there are the various operation buttons 420 and the display window 430 connected to the circuit board 410 electrically.
The various operation buttons 420 controls operation of the laundry dryer and the display window 430 displays operation progress of the laundry dryer.
The control panel 400 is designed to be mounted on the lower panel frame 300 of the laundry dryer selectively.
In the meantime, the upper panel frame 500 has the cover panel 600 mounted thereon for covering the upper panel frame 500 from an outside of the laundry dryer.
The cover panel 600 is mounted to the other panel frame if the control panel 400 is mounted to one of the upper panel frame 500 and the lower panel frame 300 .
Owing to this, the laundry dryer causes no problem in view of exterior thereof even if the control panel 400 is mounted to either position.
It is preferable that the cover panel 600 has a shape identical to an outer shape of the control panel 400 so that the cover panel 600 can form a portion of a whole exterior of the laundry dryer.
A mounting structure of the cover panel 600 to the panel frame 300 or 500 is identical to a mounting structure of the control panel 400 to the panel frame 300 or 500 .
A mounting/dismounting state of the control panel to the lower panel frame of the laundry dryer, and a taking out state of the heater assembly will be described.
The upper panel frame 500 and the lower panel frame 300 are mounted to the upper side and the lower side of the cover cabinet 140 of the laundry dryer, respectively.
The opening 310 in the lower panel frame 300 is on a straight line with a position of the heater assembly 200 in the body case 100 .
Then, since the cable (not shown) connected to the various components in the body case 100 is exposed from an outside of the lower panel frame 300 , the cable connected to the circuit board 410 of the control panel 400 is electrically connected to the cable connected to the components in the body case 100 .
Then, as the control panel 400 is mounted to the lower panel frame 300 , a process for mounting the control panel 300 to the laundry dryer is finished.
Along with this, the cover panel 600 is mounted to the upper panel frame 500 by a method the same with a method of mounting the control panel 400 to the lower panel frame 300 .
In the meantime, a process for taking out the heater assembly out of the body case will be described.
At first, a process of mounting the control panel 400 to the lower panel frame 300 is progressed reversely, to dismount the control panel 400 from the lower panel frame 300 .
Then, a series of work for detaching the heater assembly 200 mounted on an inside of the body case 100 is progressed through the opening 310 of the lower panel frame 300 .
Upon finish of the work, the worker can take the heater assembly 200 out of the body case 100 through the opening 310 , easily.
A work for mounting the heater assembly 200 in the body case 100 is progressed in a process reverse to above process, of which detailed description will be omitted.
In the meantime, it is described that the control panel 400 can be mounted/dismounted to the upper side or the lower side of the cover cabinet 140 , selectively.
This is for easy operation of the operation buttons on each of the control panels even if two or more than two laundry dryers are arranged in any type.
States of the control panels arranged different from one another depending on states of two or more than two dryers arranged different from one another will be described with reference to FIGS. 4 and 5 .
FIG. 4 illustrates a state in which another dryer 2 (hereafter called as ‘a second dryer’) is stacked on a dryer 1 (hereafter called as ‘a first dryer’) supported on a floor.
In this case, it is preferable that the control panel 400 of the second dryer 2 is mounted to the lower panel frame 300 of the second dryer 2 .
This is for enabling the user to use the operation buttons 420 and the display window 430 of the control panel 400 conveniently, taking a general height of the user into account.
In this instance, the cover panel 600 is mounted to the upper panel frame 500 of the second dryer 2 .
On the other hand, FIG. 5 illustrates a state the second dryer 2 is arranged on a side (a right side) of the first dryer 1 .
In this case, it is preferable that the control panel 400 of the second dryer 2 is mounted to the upper panel frame 500 of the second dryer 2 .
Referring to FIG. 4 , it is for preventing the user from bending the body or squatting down for operation of the operation buttons 420 on the control panel 400 in a case the control panel 400 of the second dryer 2 is mounted to the lower panel frame 300 of the second dryer 2 .
By enabling to vary a position of the control panel 400 according to an arrangement of the laundry dryer, the user can handle the operation buttons on the control panel, conveniently.
eventually, at the time the operation buttons 420 or the circuit board 410 of the control panel 400 is replaced or repaired, not only the control panel 400 can be dismounted from the laundry dryer and perform an appropriate work, but also the heater assembly 200 can be taken out of through the opening 310 easily and perform an appropriate work when the heater assembly 200 is out of order.
It will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the spirit or scope of the inventions. Thus, it is intended that the present invention covers the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents. | Laundry dryer including a body case forming an exterior of the laundry dryer, a drum in the body case for holding a drying object, a heater assembly in the body case for heating air to supply hot air to the drum, a panel frame on a front of the body case, having an opening in communication with a space having the heater assembly mounted therein, and a control panel mounted to the panel frame selectively, having buttons for making various operation, thereby permitting easy handling of the operation buttons on the control panel even if two or more than two dryers are arranged in any type, and improving workability of replacement or repair of the heater assembly. | 3 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation in part of U.S. application Ser. No. 14/121,468 filed on Sep. 9, 2014 which is a continuation in part of U.S. application Ser. No. 13/998,981 filed on Dec. 30, 2013 both of which are incorporated herein in its entirety.
TECHNICAL FIELD
[0002] The present invention relates to an having an integral handle and auger for supporting an object on an adapter in an upright position in the ground.
BACKGROUND OF THE INVENTION
[0003] The portable and reusable auger of the present invention can be used in combination with an integrated loop handle which can be installed in the ground with no tools by twisting and rotating the handle screwing the auger base into the ground.
SUMMARY OF THE INVENTION
[0004] A rotary auger for supporting or mounting and removably holding a articles or devices upright on the ground. The auger includes an upright rod with a helical spiral coil having a point at the lower distal end to be fixedly and removably screwed into the ground to support the in an upright position. The auger vertical shaft forms a cork screw or a helical coil formed in the bottom end. A looped handle may be formed integrally within the upper end of the shaft or rod extending from the auger with an vertically disposed “S” shaped loop formed in the center of the for enabling the screwing of the cork screw into the ground for vertical stabilization of the stake. The bottom helical coil ends with a sharp tip for easing the installation into the ground.
[0005] A preferred embodiment of the helical auger includes an inner bend diameter of a selected size such as ¼ inch bar stock, 3/16 inch bar stock, ½ inch bar stock, ⅝ inch bar stock, and ⅜ inch bar stock; a helical pitch of 2.0 for 3.5 revolutions; a variable pitch of 3.0 for 0.25 revolutions; and a pitch diameter of 1.375 inches having a helical pitch of 2.0.
[0006] It is an object of this invention to provide a portable and reusable auger which includes a helical coil or spiral having a point at a distal end.
[0007] It is an object of this invention to provide an integral crank handle for the purpose of screwing auger portion into the ground.
[0008] It is an object of the present invention to form an integral one piece auger having a helical spiral formed of stock having a square cross-section.
[0009] A preferred embodiment of the present invention comprises or consists of a rotary auger support comprising or consisting of a selected length of bar stock having a square cross sectional area including a bottom portion bent into a spiral, a vertical straight top portion, a neck portion extending downward from the vertical straight top portion, a main body portion extending downwardly from the neck portion, the main body portion comprising a helical spiral coil extending downward therefrom a selected distance, a distal end segment comprising a half spiral extending downward from the main body portion, and the distal end segment including a point for penetration into the ground.
[0010] Other objects, features, and advantages of the invention will be apparent with the following detailed description taken in conjunction with the accompanying drawings showing a preferred embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] A better understanding of the present invention will be had upon reference to the following description in conjunction with the accompanying drawings in which like numerals refer to like parts throughout the views wherein:
[0012] FIG. 1 is a perspective view of a rotary auger spiral having a straight top portion and a main body portion comprising a spiral having a square cross-section and pointed tip;
[0013] FIG. 2 is a rear perspective view of the rotary auger support shown in FIG. 1 ;
[0014] FIG. 3 is a left perspective rear view of a rotary auger support having a rectangular, or square cross section showing the straight top portion defining a tubular adapter extending from the top for cooperative engagement with a corresponding tube or bar stock shaft of an article to be supported thereon;
[0015] FIG. 4 is a left perspective rear view of a rotary auger support having a rectangular, or square cross section showing the straight top portion defining a tubular adapter extending from the top for cooperative engagement with a corresponding tube or bar stock shaft of an article to be supported thereon;
[0016] FIG. 5 is a top end view of the rotary auger support shown in FIG. 1 ; and
[0017] FIG. 6 is a bottom end view of the rotary auger support of FIG. 1 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] In accordance with the present invention, there is provided a rotary auger having a top end defining a vertical shaft The integral handle tie down rest is located at an upper end of a shaft extending upwardly from a spiral auger wherein the handle tie down rest can be bent at a selected angle to hold the tie down in a selected position with respect to the surface of the ground.
[0019] The rotary auger support 10 includes an above ground upright rod or shaft top portion 12 having an offset neck 14 connecting to a main body portion 2 comprising a plurality of spirals 16 . A distal end segment 3 comprises a half spiral ending in a sharp point 18 . A main body portion spirals 16 is comprised of bar stock having a square cross sectional area. The corners 21 or the square bar stock form cutting edges 23 when the stock is bent or formed into a spiral. One preferred embodiment of the instant invention includes a main body portion 2 having three full spirals and a tip 3 comprising a half spiral. The neck 14 of the rotary auger support 10 is angled inwardly toward the center of the main body portion 2 in order to center the shaft top portion 12 with respect to the main body portion 2 . As best shown in FIG. 3 , the neck portion includes a spiral first segment 31 , a short straight inward angled second segment 32 , a straight angled third segment 33 , a short straight outward angled fourth segment 34 , connecting to a vertical straight top segment 12 of a desired length.
[0020] The rotary auger 10 having a bottom portion for insertion into the ground comprises a helical coil 16 having a cutting edge which functions as a plurality of flights forming an auger 10 having cutting edges with a point 18 at the lower distal end to be fixedly and removably screwed into the ground 20 to support the 10 in an upright position.
[0021] The cutting edges of the spiral enable the auger to cut through soil and debris for ease of rotation and deep ground penetration which includes the desirable features of spiral flights. Moreover, the auger of the present invention is an improvement over the flights of conventional augers in that the narrow diameter of the stock and diameter of the flights enables the auger to cut and drill through small openings in rocky soil and wedge between rocks. Moreover, the rotary auger support 10 of the present invention can be rotatably inserted into hard clay which would resist penetration by an auger having flights or a spiral auger comprising round stock.
[0022] A preferred embodiment of the helical auger includes an inner bend diameter of a selected size such as ¼ inch bar stock, 3/16 inch bar stock, ½ inch bar stock, ⅝ inch bar stock, and ⅜ inch bar stock. The ⅜ inch rotary auger support includes an effective helical pitch of 2 for every 3.5 revolutions and a variable pitch of 3.0 for every 0.25 revolutions. The pitch diameter of 1.375 inches has a helical pitch of 2.0 inches.
[0023] It is contemplated that a handle (not shown) may be integrally formed in a portion of the shaft of the auger extending above the ground. One embodiment includes an integral crank handle rest loop which includes a first portion which extends outwardly from the rod at a selected angle, for instance a right angle or 90 degree angle. A second portion extends upwardly over, spaced apart from and in alignment with the first portion forming a curved or bent portion and extends past the shaft a selected equal distance from the shaft. A third top portion extends upwardly over, spaced apart from and in alignment with the second portion forming a curved or bent portion and extends to the shaft.
[0024] The foregoing detailed description is given primarily for clearness of understanding and no unnecessary limitations are to be understood therefrom, for modification will become obvious to those skilled in the art upon reading this disclosure and may be made upon departing from the spirit of the invention and scope of the appended claims. Accordingly, this invention is not intended to be limited by the specific exemplification presented herein above. Rather, what is intended to be covered is within the spirit and scope of the appended claims. | A rotary auger support for mounting and removably holding a articles or devices upright on the ground. The includes an upright rod with a helical coil or flights forming an auger base having a point at the lower distal end to be fixedly and removably screwed into the ground to support the in an upright position. | 5 |
BACKGROUND
[0001] The present invention relates to improvements in insulated glass door and window structures and more particularly relates to an apparatus and method for eliminating or reducing condensation on the external face of such glass doors and the internal face of window structures. More particularly the present invention relates to improvements in the structure of insulated glass door/window structures such as are used in connection with insulated glazed windows (for use in both thermal and sound insulation applications) and refrigeration, and particularly in industrial and commercial refrigeration. The invention also relates to improvements in the economics of manufacture of insulated glass doors and windows. Although the invention will primarily be described with reference to its application in glass doors and particularly triple glazed doors used in such applications as refrigeration, it will be appreciated by persons skilled in the art that the invention has applications in other areas such as in windows and any structure which utilizes glass and particularly though not exclusively double or triple glazing.
PRIOR ART
[0002] In industrial and commercial refrigeration, and particularly refrigeration cabinets employed at points of sale and in a variety of establishments, double and/or triple glazed doors are used to insulate the refrigerated contents.
[0003] In some glass door structures, for example those in refrigerators, freezers, and the like, where a temperature differing substantially from that of the surrounding atmosphere is to be maintained within a storage compartment, an electrical current and metallic film is employed heating the door frame and outer glass pane in an effort to eliminate condensation and provide clear visibility to the goods contained.
[0004] Such conventional glass doors demand not only electrical heating themselves but, due to heat transfer, require additional energy in order to maintain internal refrigeration.
[0005] In addition, conventional insulated glass doors comprise parallel panes of glass affixed with spacer bars to form one complete insulated glass unit. This insulated glass unit is then enclosed within a metal or composite structural peripheral door-frame in order to complete the construction of the insulated glass door. The heating apparatuses required to maintain the door panels and door-frame at an optimum temperature add to the cost of the doors and fridge/freezer overall, complicate the construction of the door panels and door-frame, require additional circuitry, and add to the running costs of the fridge/freezer as well as the air conditioning generally employed.
[0006] There has been a long felt want in the industry to provide a more efficient and economic means to reduce or eliminate condensation in or on a fridge/freezer door and particularly on those doors having double/triple glazing.
INVENTION
[0007] The present invention provides improvements in the structure of insulated glass door structures such as are used in connection with refrigeration and particularly in industrial and commercial refrigeration wherein means are provided to reduce or eliminate condensation on glass and door-frame surfaces. Glass surfaces of such fridge/freezer doors are required to remain clear so that a consumer can inspect the contents of the fridge/freezer.
[0008] It will be appreciated by persons skilled in the art that, while the invention to be described herein is open to various variations and modifications, the illustrated embodiments set out herein are non-limiting. It should therefore be understood that the embodiments of the drawings are merely examples of implementation of the invention. There are a variety of embodiments and alternative constructions and equivalents falling within the scope of the invention.
[0009] The invention to be described below in its application to a fridge/freezer cabinet door can also be adapted in various applications wherein a door or window or the like separate a region of low temperature relatively dry air from a region having higher temperature and high relative humidity. In the latter case the panel according to the invention may be used to prevent condensation which would normally occur on an outer surface where the temperature on one side is low enough and is transmitted to the other side to cause condensation.
[0010] It is one object of the invention to provide means that reduces or eliminates condensation on glass doors of a refrigerator/freezer but without the need for electrical heating of glass surfaces and door-frame comprising the door.
[0011] It is another object of the invention to provide means that reduce/eliminate condensation on glass surfaces and door-frame of a refrigerator/freezer and which substantially reduces operating and manufacturing costs.
[0012] It is another object of the invention to provide mechanical means that reduce/eliminate condensation on glass doors of a refrigerator/freezer and obviates the need for electrical heating of glass surfaces and door-frame comprising the door.
[0013] It is a further object of the invention to provide an alternative means for insulation of double/triple glazed structures such as but not limited to windows and doors and to reduce or eliminate unwanted condensation on such structures.
[0014] It is a further object of the invention to provide mechanical means that reduce/eliminate condensation on glass surfaces and door-frames of a refrigerator/freezer but without the costs and maintenance associated with the electrical heating of glass surfaces and door-frames of fridge/freezer doors.
[0015] It is a further object of the invention to provide an alternative means for the construction of glazed fridge/freezer doors in which glazed panels are set into a prefabricated frame without the need for mounting an insulated glass unit into an enclosed metal, composite, or thermal plastics frame.
[0016] It is a further object of the invention to provide an alternative means for the construction of glazed fridge/freezer doors without the need for manufacturing an insulated glass unit.
[0017] It is a further object of the invention to provide an alternative means for the construction of glazed fridge/freezer doors without using steel fasteners and the like to fasten the door-frame.
[0018] The present invention seeks to provide a novel alternative to the known methods of reducing/eliminating condensation on glass refrigerator/freezer doors without the need for electrical heating elements.
[0019] The present invention also seeks to provide a novel alternative to the known methods of insulating and manufacturing double/triple-glazed windows.
[0020] In a broad form of an apparatus aspect the present invention provides a substantially planar insulating panel comprising:
[0021] a frame defining a periphery of the panel;
[0022] a first wall retained by the frame and a second wall opposing the first wall and together with the first wall and the frame defining an enclosed internal space of the panel;
[0023] at least one intermediate insulating wall disposed in the internal space intermediate the first and second wall members and which creates a first enclosed space in the internal space between the insulating wall and the first wall and a second enclosed space in the internal space between the insulating wall and the second wall, wherein the insulating wall insulates the first wall from the second wall;
[0024] the frame comprising an extruded profile;
[0025] the profile having a series of spaced mounting surfaces which receive and retain the walls, the mounting surfaces arranged in a cascading series such that the areas of the walls diminish sequentially in one direction from one side of the panel to the other and the walls are sequentially spaced apart from each other.
[0026] It is preferred that the frame is a unitary structure and the extruded profile of the frame is miter jointed to form a continuous profile having no mechanical start or end point. Preferably the miter joints are welded.
[0027] The frame profile in section may have at least one cavity for the retention of a moisture-absorbent desiccant material. Advantageously, the cavity may be sealed prior to the welding of the frame. Similarly, the frame profile in elevation may have perforations located between the mounting surfaces such that the cavities are in communication with the first and/or second enclosed spaces, such that the perforations allow for the absorption of moisture only from an apposing enclosed space. The frame profile in section also may have cavities adapted to provide insulation.
[0028] The walls, preferably, are affixed to the mounting surfaces using a rigid or semi-rigid adhesive which has either ultraviolet-setting or thermo-setting properties. In addition, the mounting surfaces may have one or more recesses which act as traps for any excess adhesive used in affixing the walls.
[0029] Preferably the first and/or second enclosed spaces are sealed and filled with air, argon gas, foam or another insulating material.
[0030] The frame may contain a gasket-retaining groove adapted to retain a magnetized flexible sealing gasket which provides an airtight seal between the panel and an article to which the panel is fitted. Similarly, the frame may include a keyway for insertion and mounting of a hinge.
[0031] According to a preferred embodiment the frame is formed of a thermal plastics material and the first and second walls comprise glass panes that define the internal space. The planar insulating wall member is preferably a transparent thermal plastics material mounted midway between the glass panes.
[0032] The frame may be formed of a semi-rigid thermal plastics material and the walls of glass or plastic panes such that the panes provide rigidity to the panel structure.
[0033] Utilising thermal plastics material in the frame allows the miter joints to be formed by thermal mirror welding which is a simple, quick and convenient process that results in a strong joint.
[0034] Preferably the walls are transparent and may be glass, Perspex™, thermal plastics or the like. According to one embodiment, plastic extrusions may be used to provide the frame that also acts as glass panel spacers and mounting surfaces.
[0035] In another broad form of a method aspect, the present invention provides a method for constructing a substantially planar insulating panel including a frame in which is disposed two walls defining an internal space; the internal space including at least one internal insulating wall which insulates the two outer walls thereby reducing or eliminating condensation on the outer walls and frame; the method comprising the steps of:
a) providing two walls of a predetermined size; b) providing an insulating wall member; c) constructing a frame having a series of spaced mounting surfaces which receive and retain the walls, the mounting surfaces arranged in a cascading series such that the areas of the walls diminish sequentially in one direction from one side of the panel to the other and the walls are sequentially spaced apart from each other; d) fitting the first wall to an inner mounting surface of the frame; e) fitting the insulating member to a second mounting surface on the frame in a central position relative to the outside surfaces of the frame; and f) fitting the second wall to a third mounting surface of the frame such that the walls are in opposing relationship and define the internal space housing the insulating member.
[0042] The method may comprise the further step of placing the insulating wall member at an optimum spacing and equidistant from the first and second walls.
[0043] Throughout the specification, a reference to a door may be taken as a reference to a window as the context allows, and a reference to a window may be taken to include a door as the context allows. Although the invention will be described with primary reference to a door, it will be appreciated by persons skilled in the art that the panel according to the invention may be used in a variety of applications to reduce/eliminate unwanted condensation on one or other of outer walls of the panel and door-frame.
DETAILED DESCRIPTION
[0044] The present invention will now be described in more detail according to preferred but non-limiting embodiment and with reference to the accompanying illustrations wherein:
[0045] FIG. 1 shows an exploded perspective view of a door panel according to one embodiment;
[0046] FIG. 2 shows a front elevation of a refrigeration unit having three doors according to one embodiment;
[0047] FIG. 3 is an enlarged cross sectional view of an abbreviated frame extrusion including fitted glass panels and an intermediate insulating panel;
[0048] FIG. 4 is a cross sectional diagram of a frame extrusion for an insulated glass door according to one embodiment;
[0049] FIG. 5 shows a part elevation view of a door panel frame from a front view;
[0050] FIG. 6 shows a part elevation view of a door panel frame from a rear view;
[0051] FIG. 7 shows an isometric view of a section of a panel with panes fitted according to a preferred embodiment;
[0052] FIG. 8 shows an enlarged cross sectional view of an extrusion used in a door-frame according to one embodiment; and
[0053] FIG. 9 shows a cross sectional view of a section of a panel with panes fitted.
[0054] Referring to FIG. 1 , there is shown an exploded perspective view of a door panel 1 according to one embodiment. Door panel 1 comprises a peripheral frame 2 having long sides 3 and 4 and short sides 5 and 6 . Fitted inside frame 2 are glass panels 7 and 8 which are disposed in opposing relationship and define an internal space 9 there between. Internal space 9 receives and retains therein an insulating member 10 which is preferably spaced so it is equidistant from panels 7 and 8 so that panels 7 and 8 are mutually isolated from each other. Panel 1 further comprises a magnetic gasket 11 which is fixed in a gasket groove (see FIG. 3 ).
[0055] FIG. 2 shows a front elevation of a refrigeration unit 12 having three doors 13 , 14 and 15 constructed in accordance with the panel 1 arrangement described in FIG. 1 . Fridge/freezer unit 12 is typically an industrial fridge/freezer having a cooled interior and transparent doors so that the contents of the fridge/freezer may be viewed from the outside. In the past the problem has been condensation forming on the outer surfaces of the doors as one side is exposed to refrigeration temperature and the other side is exposed to ambient room temperature. This inevitably leads to potential condensation on the outside of the glass panes and door frame thus obscuring the fridge contents. Doors 13 , 14 and 15 have an insulating member corresponding to insulation member 10 as described with reference to FIG. 1 .
[0056] FIG. 3 is an enlarged cross sectional view of an abbreviated frame 16 including an extrusion including fitted glass panels and an intermediate insulating panel. Extrusion 20 , which is manufactured from thermal plastics, comprises an outer wall 21 and inner wall 22 which define internal spaces 23 , 24 , 25 and 26 . Preferably a plastics extrusion is provided forming a panel which functions as either a window or door. The plastics frame extrusion 20 is cut and welded to suit the refrigeration unit 27 to which the door/window will be attached. Glass panes 28 and 29 are mounted on the respective mounting surfaces 30 and 31 . Also fitted to extrusion 20 via surface 32 is a clear rigid thermal plastics insulating member 33 mounted midway between glass panes 28 and 29 . Glass panes 28 and 29 and insulating member 33 are attached to their respective mounting surfaces using a rigid adhesive. Glass panels 28 and 29 and plastics insulating member 33 are spaced to provide optimum insulation with air and/or argon gas filled cavities 34 and 35 . Additional features in the plastics extrusion 20 include a hinge and torsion bar mounting point 36 and excess rigid adhesive traps 37 , 38 and 39 . A magnetised flexible gasket 44 is inserted into the gasket-retaining groove 45 providing an airtight seal between the insulated glass door and the door fascia of the refrigerator/freezer unit 27 .
[0057] FIG. 4 is a cross sectional diagram of a frame extrusion 40 for an insulated glass door according to one embodiment. The air and/or argon gas is inserted via latex valves (not shown) located in a horizontal door-frame formed by extrusion 40 . Desiccant chambers 41 and 42 , formed in the plastics extrusion 40 , are filled with desiccant moisture absorption granules in the vertical frame sections and sealed using plastic caps (see FIG. 3 ) prior to welding.
[0058] FIG. 5 shows a part elevation view of a door panel frame 50 from a front view. Panel 50 includes an upper frame member 52 and side member 53 .
[0059] FIG. 6 shows, from a rear (reverse side) view, an elevation view of the part door panel frame 50 comprising upper frame member 52 and side frame member 53 . Frame 50 , which is formed from a preferably plastics extrusion, is adapted with three shoulder regions 54 , 55 and 56 which define recesses which each receive and retain panes 57 , 58 and 59 as shown in FIG. 7 .
[0060] FIG. 7 shows an isometric view of a section of a panel with panes fitted according to a preferred embodiment. According to one embodiment of a method aspect, a typical panel may be constructed in accordance with a method to be described with reference to FIG. 7 .
[0061] Peripheral frame 50 may be constructed from a metal or plastics material. Preferably the frame material is an extruded plastics. Typically, a frame will comprise upper member 52 and lower member 53 formed from an extrusion and which includes recesses which form bearing shoulders 54 , 55 and 56 which respectively receive panes 57 , 58 and 59 .
[0062] Pane 57 forms an outer door surface and pane 59 an inner door surface which each define an internal space 60 . Pane 58 locates on shoulder 55 in inner space 60 and provides an insulation of panes 57 and 59 to prevent condensation.
[0000] The preferred method comprises the steps of:
[0000]
a) providing two panes 57 and 59 of a predetermined size;
b) providing an insulating member 58 ;
c) constructing a frame 50 from a thermal plastics extrusion having a profile so that the completed frame includes three shoulder regions 54 , 55 and 56 ;
d) the first pane 57 is fitted so that its periphery engages shoulder recess 54 , (Preferably the pane is glued peripherally to shoulder 54 );
e) next, insulating member 58 is glued to shoulder recess 55 which is disposed in a central position relative to outside surfaces of the door panel;
f) finally, pane 59 is seated on and glued to shoulder 56 to seal internal space 60 , (Pane 57 forms an outer surface of the panel 50 );
wherein the panes are arranged so that the first and second panes 57 and 59 define an internal space 60 divided by the insulating panel 58 , which is located intermediate the first and second panes. Preferably the panes are transparent glass.
[0069] FIG. 8 shows an enlarged cross sectional view of an abbreviated frame extrusion 70 used in a door-frame according to one embodiment. Frame extrusion 70 , which is preferably manufactured from thermal plastics, comprises an outer wall 71 and inner wall 72 . Inner wall 72 defines internal spaces 73 and 74 . Frame extrusion profile 70 provides an outer panel structure which may be a window, door or the like. The plastics frame extrusion 70 is cut and welded to suit its particular application and in a preferred embodiment is adapted as a fridge or freezer door. Panes 77 and 79 are preferably manufactured from glass and are mounted on the respective mounting surfaces 80 , and 82 . Also fitted to extrusion 70 via surface 81 is a clear rigid thermal plastics insulating member 78 mounted intermediate glass panes 77 and 79 . Glass panes 77 and 79 and insulating member 78 are attached to their respective mounting surfaces 80 , 82 and 81 using a suitable rigid sealing adhesive. Glass panes 77 and 79 and plastics insulating member 78 are spaced to provide optimum insulation with air and/or argon gas filled cavities 73 and 74 . Additional features in the plastics extrusion 70 include a hinge and torsion bar keyway (not shown) for mounting purposes.
[0070] FIG. 9 shows a half section of the door panel 70 of FIG. 8 constructed in accordance with the invention and with corresponding numbering. Panel 70 is shown including a magnetic flexible gasket 83 inserted into the gasket retaining groove 84 providing an airtight seal between the insulated glass door and the door fascia of the refrigerator/freezer unit 85 .
[0071] From the foregoing, it can be seen that the insulated door/window assembly of the present invention has a modern substantially all glass front appearance but increasing the efficiency and strength of conventional insulated doors and windows to which the industry has been accustomed. Since the door/window assembly requires fewer components such that it comprises a single unit, structural instability causing sag is eliminated, manufacturing costs are greatly reduced, and operational costs are substantially lowered with the removal of electrical heating.
[0072] Manufacture of a panel in accordance with the invention results in potentially a 60% parts saving and 50% labour saving by comparison with a known typically available commercial fridge or freezer door having a heating element apparatus. Panels or doors made in accordance with the invention do not require any ancillary heating elements or associated heating apparatuses, nor the associated materials and labour. The method of construction allows the panel to function so that condensation is eliminated without the use of heating elements. Consequently, since no heating elements are required, energy savings are estimated to be up to 55% in comparison to a panel or door of similar proportions requiring heating elements.
[0073] One advantage of the present invention is that it obviates the need for spacer bars previously used to space apart glass panels prior to final enclosure in a peripheral frame. In the past a panel was constructed by first setting the panes in layers and keeping them spaced apart by spacer bars which set a predetermined distance between the panels and formed an insulated glass unit. A metal frame was fitted around the insulated glass unit to complete the panel. This makes panels relatively heavy and their construction labor intensive. The panels according to the invention do not require spacer bars or the construction of an insulated glass unit and are lightweight in comparison to the known panels of a similar size. The preferred frame is manufactured from extruded plastics contributing significantly to weight and component reduction.
[0074] It will be recognized by persons skilled in the art that numerous variations and modifications may be made to the invention as broadly described herein without departing from the spirit and scope of the invention. | A panel comprising: a frame member ( 70 ) defining a periphery of said panel; a first wall ( 77 ) retained by the frame ( 70 ) and a second wall ( 79 ) opposing said first wall ( 77 ) and together with the first wall ( 77 ) defining an internal space ( 73, 74 ) of the panel; the panel further comprising at least one intermediate wall ( 78 ) disposed in said internal space intermediate the first ( 77 ) and second walls ( 79 ) and which creates a first space ( 73 ) in said internal space between said intermediate wall ( 78 ) and said first wall ( 77 ) and a second space ( 74 ) in said internal space between said intermediate wall ( 78 ) and said second wall ( 79 ); characterized in that the frame includes respective abutment surfaces ( 80, 81, 82 ) which receive and retain respective first, second and intermediate walls wherein; the intermediate wall ( 78 ) insulates said first wall ( 77 ) from said second wall ( 79 ). | 4 |
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